PDF DOWNLOAD KOMATSU PC360LC-11E0 PC360NLC-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00710

UENBM00710

HYDRAULIC EXCAVATOR

PC360LC -11E0 PC360NLC -11E0

SERIAL NUMBERS

PC360LC-11E0 ~ K75574 and up PC360NLC-11E0 ~ K75574 and up

00 INDEX AND FOREWORD

PC360LC-11E0, PC360NLC-11E0

00-1

INDEX

00 INDEX AND FOREWORD

INDEX 00 INDEX AND FOREWORD ........................................................................................................................ 00-1 ABBREVIATION LIST ........................................................................................................................... 00-21 FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-27 HOW TO READ THE SHOP MANUAL........................................................................................... 00-27 SAFETY NOTICE FOR OPERATION............................................................................................. 00-29 PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-37 ACTIONS IF FIRE OCCURS ......................................................................................................... 00-39 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-40 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-41 METHOD FOR CHECKING ENGINE TYPE .................................................................................. 00-42 PRECAUTIONS FOR DEF............................................................................................................. 00-44 STORE AdBlue/DEF ...................................................................................................................... 00-45 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-46 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-49 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-56 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-58 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-59 PRACTICAL USE OF KOMTRAX .................................................................................................. 00-60 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-61 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-65 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-69 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-70 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-72 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-73 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . ................................................................................................................................................... 00-75 HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-76 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-80 STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-83 CONVERSION TABLE ................................................................................................................... 00-90 01 SPECIFICATIONS .................................................................................................................................... 01-1 CONTENTS ............................................................................................................................................ 01-2 ABBREVIATION LIST ............................................................................................................................. 01-3 SPECIFICATIONS .................................................................................................................................. 01-9 SPECIFICATION DRAWING............................................................................................................ 01-9 WORKING RANGE DRAWINGS ....................................................................................................01-11 SPECIFICATIONS ......................................................................................................................... 01-12 WEIGHT TABLE ............................................................................................................................ 01-15 TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-17 SPECIFICATIONS - PC390HRD-11E0.................................................................................................. 01-18 SPECIFICATION DRAWING.......................................................................................................... 01-18 SPECIFICATIONS ......................................................................................................................... 01-21 WEIGHT TABLE ............................................................................................................................ 01-23 10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1 CONTENTS ............................................................................................................................................ 10-2 ABBREVIATION LIST ............................................................................................................................. 10-6 UREA SCR SYSTEM............................................................................................................................ 10-12 LAYOUT DRAWING OF UREA SCR SYSTEM .............................................................................. 10-12 UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-16 FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-17 COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-38 BOOT-UP SYSTEM .............................................................................................................................. 10-47 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-47 SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-49 BATTERY DISCONNECT SWITCH ............................................................................................... 10-51 ENGINE SYSTEM ................................................................................................................................ 10-52 00-2

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-52 ENGINE CONTROL SYSTEM ....................................................................................................... 10-54 AUTO-DECELERATION SYSTEM ................................................................................................. 10-57 ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-59 OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-61 TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-63 AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-65 COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-70 COOLING SYSTEM.............................................................................................................................. 10-86 LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-86 CONTROL SYSTEM............................................................................................................................. 10-88 LAYOUT DRAWING OF CONTROL SYSTEM ............................................................................... 10-88 MACHINE MONITOR SYSTEM ..................................................................................................... 10-91 KomVision SYSTEM ...................................................................................................................... 10-93 KOMTRAX SYSTEM...................................................................................................................... 10-97 PPC LEVERS ................................................................................................................................ 10-98 AUTOMATIC GREASE SYSTEM ..................................................................................................10-100 COMPONENT PARTS OF CONTROL SYSTEM...........................................................................10-114 SENSOR.......................................................................................................................................10-150 HYDRAULIC SYSTEM.........................................................................................................................10-162 LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-162 CLSS ............................................................................................................................................10-165 ENGINE AND PUMP COMBINED CONTROL SYSTEM...............................................................10-185 PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-191 COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-194 HYDRAULIC SYSTEM - PC390HRD-11E0 ..........................................................................................10-281 LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-281 COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-284 WORK EQUIPMENT SYSTEM ............................................................................................................10-301 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-301 STRUCTURE OF VALVE CONTROL............................................................................................10-307 ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-309 MACHINE PUSH-UP SYSTEM .....................................................................................................10-311 PPC LOCK SYSTEM ....................................................................................................................10-313 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-314 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-316 TOOL CONTROL SYSTEM ..........................................................................................................10-318 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-320 WORK EQUIPMENT SYSTEM - PC390HRD-11E0 .............................................................................10-346 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-346 SWING SYSTEM .................................................................................................................................10-350 LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-350 SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-353 COMPONENT PARTS OF SWING SYSTEM................................................................................10-357 TRAVEL SYSTEM................................................................................................................................10-371 LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-371 TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-375 COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-377 UNDERCARRIAGE AND FRAME........................................................................................................10-398 LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-398 WORK EQUIPMENT............................................................................................................................10-400 STRUCTURE OF WORK EQUIPMENT ........................................................................................10-400 FUNCTION OF WORK EQUIPMENT ...........................................................................................10-401 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-402 BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-403 CAB AND ITS ATTACHMENTS ...........................................................................................................10-404 ROPS CAB ...................................................................................................................................10-404 CAB MOUNT ................................................................................................................................10-405 PC360LC-11E0, PC360NLC-11E0

00-3

INDEX

00 INDEX AND FOREWORD

CAB TIPPING STOPPER .............................................................................................................10-406 TILTING CAB SYSTEM.................................................................................................................10-407 20 STANDARD VALUE TABLE ...................................................................................................................... 20-1 CONTENTS ............................................................................................................................................ 20-2 ABBREVIATION LIST ............................................................................................................................. 20-3 STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9 STANDARD VALUE TABLE FOR ENGINE: PC360LC-11E0, PC360NLC-11E0 ............................... 20-9 STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-14 STANDARD VALUE TABLE FOR MACHINE: PC360LC-11E0, PC360NLC-11E0 .......................... 20-14 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-28 STANDARD VALUE TABLE FOR MACHINE - PC390HRD-11E0.......................................................... 20-32 STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE................................ 20-32 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-39 STANDARD VALUE TABLE FOR ELECTRICAL ................................................................................... 20-43 STANDARD VALUE TABLE FOR ELECTRICAL ............................................................................ 20-43 30 TESTING AND ADJUSTING ..................................................................................................................... 30-1 CONTENTS ............................................................................................................................................ 30-2 ABBREVIATION LIST ............................................................................................................................. 30-6 RELATED INFORMATION ON TESTING AND ADJUSTING ................................................................ 30-12 TOOLS FOR TESTING AND ADJUSTING..................................................................................... 30-12 SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-19 ENGINE AND COOLING SYSTEM....................................................................................................... 30-21 TEST ENGINE SPEED .................................................................................................................. 30-21 TEST BOOST PRESSURE............................................................................................................ 30-25 TEST EXHAUST GAS COLOR ...................................................................................................... 30-27 TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-29 TEST COMPRESSION PRESSURE.............................................................................................. 30-32 TEST BLOWBY PRESSURE ......................................................................................................... 30-35 TEST ENGINE OIL PRESSURE .................................................................................................... 30-37 TEST EGR VALVE AND VGT OIL PRESSURE ............................................................................. 30-39 TEST FUEL PRESSURE ............................................................................................................... 30-41 TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-48 BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-55 TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-56 HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-58 HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-59 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-60 TEST FAN BELT AND ALTERNATOR BELT .................................................................................. 30-62 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-63 TEST SCR RELATED FUNCTIONS............................................................................................... 30-64 CLEAN AdBlue/DEF TANK ............................................................................................................ 30-89 TEST AUTO-TENSIONER ............................................................................................................. 30-93 POWER TRAIN..................................................................................................................................... 30-94 TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-94 UNDERCARRIAGE AND FRAME......................................................................................................... 30-95 TEST AND ADJUST TRACK TENSION......................................................................................... 30-95 HYDRAULIC SYSTEM.......................................................................................................................... 30-97 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................. 30-97 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ........ ..................................................................................................................................................30-103 TEST OIL PRESSURE OF CONTROL CIRCUIT ..........................................................................30-116 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ...................................30-118 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT....................................30-121 TEST OUTLET PRESSURE OF SOLENOID VALVE ....................................................................30-126 TEST PPC VALVE OUTPUT PRESSURE.....................................................................................30-129 ADJUST WORK EQUIPMENT AND SWING PPC VALVES ..........................................................30-131 MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE...30-132 TEST PUMP SWASH PLATE SENSOR........................................................................................30-134 00-4

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-135 TEST OIL LEAKAGE ....................................................................................................................30-137 BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-140 HYDRAULIC SYSTEM - PC390HRD-11E0 ..........................................................................................30-145 MEASURING AND ADJUSTING SWING SPEED REDUCTION VALVE .......................................30-145 MEASURING AND ADJUSTING BOOM AND BUCKET PPC REDUCTION VALVE .....................30-146 MEASURING AND ADJUSTING LINK CYLINDER FLOW CONTROL VALVE ..............................30-147 MEASURING AND ADJUSTING ARM CYLINDER FLOW CONTROL VALVE ..............................30-148 CAB AND ITS ATTACHMENTS ...........................................................................................................30-149 TEST CAB TIPPING STOPPER ...................................................................................................30-149 METHOD FOR ADJUSTING MIRRORS .......................................................................................30-150 ELECTRICAL SYSTEM .......................................................................................................................30-156 SET AND OPERATE MACHINE MONITOR..................................................................................30-156 METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-239 ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-244 ADJUST KomVision CAMERA ANGLE .........................................................................................30-247 ADJUST KomVision RELATED ITEMS .........................................................................................30-252 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-273 HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-274 TEST DIODES ..............................................................................................................................30-275 ELECTRICAL SYSTEM - PC390HRD-11E0.........................................................................................30-276 ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM .....................................30-276 Pm CLINIC...........................................................................................................................................30-290 Pm CLINIC SERVICE ...................................................................................................................30-290 WORKING RANGE INDICATOR SYSTEM ..........................................................................................30-305 WORKING RANGE INDICATOR SYSTEM LAYOUT ....................................................................30-305 METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU ......30-307 DIAGNOSTICS - WORKING RANGE INDICATOR SYSTEM........................................................30-309 REPLACING COMPONENTS - WORKING RANGE INDICATOR SYSTEM .................................30-316 CALIBRATION - WORKING RANGE INDICATOR SYSTEM.........................................................30-330 40 TROUBLESHOOTING .............................................................................................................................. 40-1 CONTENTS ............................................................................................................................................ 40-2 ABBREVIATION LIST ........................................................................................................................... 40-13 RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-19 GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-19 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-20 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-32 CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-34 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-36 TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-38 AUTOMATIC GREASE SYSTEM ................................................................................................... 40-58 PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM.................................................... 40-64 PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-74 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-77 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-81 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................................................................................................ 40-83 CONNECTOR CONTACT IDENTIFICATION ................................................................................. 40-86 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-126 FUSE LOCATION TABLE .............................................................................................................40-132 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..........................40-135 FAILURE CODE TABLE................................................................................................................40-139 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]).................................................................................................................................40-157 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-159 FAILURE CODE [879AKA]............................................................................................................40-159 FAILURE CODE [879AKB]............................................................................................................40-160 FAILURE CODE [879BKA]............................................................................................................40-161 PC360LC-11E0, PC360NLC-11E0

00-5

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [879BKB]............................................................................................................40-163 FAILURE CODE [879CKA]............................................................................................................40-165 FAILURE CODE [879CKB]............................................................................................................40-166 FAILURE CODE [879DKZ]............................................................................................................40-167 FAILURE CODE [879EMC] ...........................................................................................................40-169 FAILURE CODE [879FMC] ...........................................................................................................40-170 FAILURE CODE [879GKX] ...........................................................................................................40-171 FAILURE CODE [989L00] .............................................................................................................40-173 FAILURE CODE [989M00] ............................................................................................................40-174 FAILURE CODE [989N00] ............................................................................................................40-175 FAILURE CODE [A1U0N3] ...........................................................................................................40-176 FAILURE CODE [A1U0N4] ...........................................................................................................40-178 FAILURE CODE [A900FR]............................................................................................................40-180 FAILURE CODE [A900N6] ............................................................................................................40-181 FAILURE CODE [A900NY]............................................................................................................40-182 FAILURE CODE [AA10NX] ...........................................................................................................40-183 FAILURE CODE [AB00KE] ...........................................................................................................40-185 FAILURE CODE [AQ10N3] ...........................................................................................................40-188 FAILURE CODE [AS00N3]............................................................................................................40-190 FAILURE CODE [AS00R2]............................................................................................................40-192 FAILURE CODE [AS00R3]............................................................................................................40-193 FAILURE CODE [AS00R4]............................................................................................................40-194 FAILURE CODE [AS00R5]............................................................................................................40-195 FAILURE CODE [AS00R6]............................................................................................................40-196 FAILURE CODE [AS00ZK]............................................................................................................40-197 FAILURE CODE [AS10KM]...........................................................................................................40-198 FAILURE CODE [AS10NR] ...........................................................................................................40-199 FAILURE CODE [AS10NT] ...........................................................................................................40-200 FAILURE CODE [B@BAZG] .........................................................................................................40-201 FAILURE CODE [B@BAZK]..........................................................................................................40-202 FAILURE CODE [B@BCNS] .........................................................................................................40-204 FAILURE CODE [B@BCQA].........................................................................................................40-205 FAILURE CODE [B@BCZK] .........................................................................................................40-207 FAILURE CODE [B@HANS] .........................................................................................................40-209 FAILURE CODE [CA115] ..............................................................................................................40-210 FAILURE CODE [CA122] ..............................................................................................................40-211 FAILURE CODE [CA123] ..............................................................................................................40-213 FAILURE CODE [CA131] ..............................................................................................................40-215 FAILURE CODE [CA132] ..............................................................................................................40-217 FAILURE CODE [CA144] ..............................................................................................................40-219 FAILURE CODE [CA145] ..............................................................................................................40-221 FAILURE CODE [CA153] ..............................................................................................................40-223 FAILURE CODE [CA154] ..............................................................................................................40-226 FAILURE CODE [CA187] ..............................................................................................................40-229 FAILURE CODE [CA221] ..............................................................................................................40-231 FAILURE CODE [CA222] ..............................................................................................................40-233 FAILURE CODE [CA227] ..............................................................................................................40-235 FAILURE CODE [CA234] ..............................................................................................................40-236 FAILURE CODE [CA238] ..............................................................................................................40-237 FAILURE CODE [CA239] ..............................................................................................................40-239 FAILURE CODE [CA249] ..............................................................................................................40-241 FAILURE CODE [CA256] ..............................................................................................................40-243 FAILURE CODE [CA271] ..............................................................................................................40-245 FAILURE CODE [CA272] ..............................................................................................................40-247 FAILURE CODE [CA281] ..............................................................................................................40-249 FAILURE CODE [CA322] ..............................................................................................................40-250 FAILURE CODE [CA323] ..............................................................................................................40-252 FAILURE CODE [CA324] ..............................................................................................................40-254 00-6

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [CA325] ..............................................................................................................40-256 FAILURE CODE [CA331] ..............................................................................................................40-258 FAILURE CODE [CA332] ..............................................................................................................40-260 FAILURE CODE [CA343] ..............................................................................................................40-262 FAILURE CODE [CA351] ..............................................................................................................40-263 FAILURE CODE [CA352] ..............................................................................................................40-264 FAILURE CODE [CA356] ..............................................................................................................40-267 FAILURE CODE [CA357] ..............................................................................................................40-269 FAILURE CODE [CA386] ..............................................................................................................40-271 FAILURE CODE [CA428] ..............................................................................................................40-272 FAILURE CODE [CA429] ..............................................................................................................40-274 FAILURE CODE [CA435] ..............................................................................................................40-276 FAILURE CODE [CA441] ..............................................................................................................40-278 FAILURE CODE [CA442] ..............................................................................................................40-280 FAILURE CODE [CA449] ..............................................................................................................40-281 FAILURE CODE [CA451] ..............................................................................................................40-285 FAILURE CODE [CA452] ..............................................................................................................40-288 FAILURE CODE [CA488] ..............................................................................................................40-290 FAILURE CODE [CA515] ..............................................................................................................40-291 FAILURE CODE [CA516] ..............................................................................................................40-293 FAILURE CODE [CA553] ..............................................................................................................40-295 FAILURE CODE [CA555] ..............................................................................................................40-296 FAILURE CODE [CA556] ..............................................................................................................40-297 FAILURE CODE [CA559] ..............................................................................................................40-298 FAILURE CODE [CA595] ..............................................................................................................40-302 FAILURE CODE [CA687] ..............................................................................................................40-303 FAILURE CODE [CA689] ..............................................................................................................40-305 FAILURE CODE [CA691] ..............................................................................................................40-310 FAILURE CODE [CA692] ..............................................................................................................40-312 FAILURE CODE [CA697] ..............................................................................................................40-314 FAILURE CODE [CA698] ..............................................................................................................40-315 FAILURE CODE [CA731] ..............................................................................................................40-316 FAILURE CODE [CA778] ..............................................................................................................40-318 FAILURE CODE [CA1777] ............................................................................................................40-323 FAILURE CODE [CA1664] ............................................................................................................40-326 FAILURE CODE [CA1669] ............................................................................................................40-328 FAILURE CODE [CA1673] ............................................................................................................40-329 FAILURE CODE [CA1677] ............................................................................................................40-330 FAILURE CODE [CA1678] ............................................................................................................40-331 FAILURE CODE [CA1682] ............................................................................................................40-332 FAILURE CODE [CA1683] ............................................................................................................40-334 FAILURE CODE [CA1684] ............................................................................................................40-336 FAILURE CODE [CA1686] ............................................................................................................40-338 FAILURE CODE [CA1691] ............................................................................................................40-339 FAILURE CODE [CA1694] ............................................................................................................40-342 FAILURE CODE [CA1695] ............................................................................................................40-345 FAILURE CODE [CA1696] ............................................................................................................40-346 FAILURE CODE [CA1712] ............................................................................................................40-348 FAILURE CODE [CA1713] ............................................................................................................40-351 FAILURE CODE [CA1714] ............................................................................................................40-353 FAILURE CODE [CA1715] ............................................................................................................40-354 FAILURE CODE [CA1776] ............................................................................................................40-355 FAILURE CODE [CA1777] ............................................................................................................40-358 FAILURE CODE [CA1843] ............................................................................................................40-361 FAILURE CODE [CA1844] ............................................................................................................40-363 FAILURE CODE [CA1879] ............................................................................................................40-366 FAILURE CODE [CA1881] ............................................................................................................40-369 FAILURE CODE [CA1883] ............................................................................................................40-371 PC360LC-11E0, PC360NLC-11E0

00-7

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [CA1885] ............................................................................................................40-374 FAILURE CODE [CA1887] ............................................................................................................40-376 FAILURE CODE [CA1921] ............................................................................................................40-378 FAILURE CODE [CA1922] ............................................................................................................40-381 FAILURE CODE [CA1942] ............................................................................................................40-386 FAILURE CODE [CA1993] ............................................................................................................40-387 FAILURE CODE [CA2185] ............................................................................................................40-390 FAILURE CODE [CA2186] ............................................................................................................40-392 FAILURE CODE [CA2249] ............................................................................................................40-394 FAILURE CODE [CA2265] ............................................................................................................40-395 FAILURE CODE [CA2266] ............................................................................................................40-397 FAILURE CODE [CA2271] ............................................................................................................40-399 FAILURE CODE [CA2272] ............................................................................................................40-402 FAILURE CODE [CA2288] ............................................................................................................40-405 FAILURE CODE [CA2311] ............................................................................................................40-406 FAILURE CODE [CA2349] ............................................................................................................40-407 FAILURE CODE [CA2353] ............................................................................................................40-410 FAILURE CODE [CA2357] ............................................................................................................40-412 FAILURE CODE [CA2381] ............................................................................................................40-413 FAILURE CODE [CA2382] ............................................................................................................40-416 FAILURE CODE [CA2383] ............................................................................................................40-419 FAILURE CODE [CA2386] ............................................................................................................40-422 FAILURE CODE [CA2387] ............................................................................................................40-424 FAILURE CODE [CA2555] ............................................................................................................40-425 FAILURE CODE [CA2556] ............................................................................................................40-427 FAILURE CODE [CA2637] ............................................................................................................40-429 FAILURE CODE [CA2639] ............................................................................................................40-431 FAILURE CODE [CA2771] ............................................................................................................40-434 FAILURE CODE [CA2777] ............................................................................................................40-440 FAILURE CODE [CA2976] ............................................................................................................40-443 FAILURE CODE [CA3133] ............................................................................................................40-445 FAILURE CODE [CA3134] ............................................................................................................40-447 FAILURE CODE [CA3135] ............................................................................................................40-449 FAILURE CODE [CA3142] ............................................................................................................40-452 FAILURE CODE [CA3143] ............................................................................................................40-453 FAILURE CODE [CA3144] ............................................................................................................40-454 FAILURE CODE [CA3146] ............................................................................................................40-456 FAILURE CODE [CA3147] ............................................................................................................40-457 FAILURE CODE [CA3148] ............................................................................................................40-458 FAILURE CODE [CA3151] ............................................................................................................40-460 FAILURE CODE [CA3165] ............................................................................................................40-466 FAILURE CODE [CA3229] ............................................................................................................40-468 FAILURE CODE [CA3231] ............................................................................................................40-470 FAILURE CODE [CA3232] ............................................................................................................40-472 FAILURE CODE [CA3235] ............................................................................................................40-476 FAILURE CODE [CA3239] ............................................................................................................40-478 FAILURE CODE [CA3241] ............................................................................................................40-481 FAILURE CODE [CA3242] ............................................................................................................40-484 FAILURE CODE [CA3251] ............................................................................................................40-487 FAILURE CODE [CA3253] ............................................................................................................40-489 FAILURE CODE [CA3254] ............................................................................................................40-492 FAILURE CODE [CA3255] ............................................................................................................40-495 FAILURE CODE [CA3256] ............................................................................................................40-499 FAILURE CODE [CA3311] ............................................................................................................40-501 FAILURE CODE [CA3312] ............................................................................................................40-503 FAILURE CODE [CA3313] ............................................................................................................40-506 FAILURE CODE [CA3314] ............................................................................................................40-507 FAILURE CODE [CA3315] ............................................................................................................40-508 00-8

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [CA3316] ............................................................................................................40-510 FAILURE CODE [CA3317] ............................................................................................................40-511 FAILURE CODE [CA3318] ............................................................................................................40-512 FAILURE CODE [CA3319] ............................................................................................................40-514 FAILURE CODE [CA3321] ............................................................................................................40-515 FAILURE CODE [CA3322] ............................................................................................................40-517 FAILURE CODE [CA3419] ............................................................................................................40-519 FAILURE CODE [CA3421] ............................................................................................................40-521 FAILURE CODE [CA3497] ............................................................................................................40-523 FAILURE CODE [CA3498] ............................................................................................................40-524 FAILURE CODE [CA3543] ............................................................................................................40-525 FAILURE CODE [CA3545] ............................................................................................................40-532 FAILURE CODE [CA3547] ............................................................................................................40-534 FAILURE CODE [CA3558] ............................................................................................................40-535 FAILURE CODE [CA3559] ............................................................................................................40-537 FAILURE CODE [CA3562] ............................................................................................................40-539 FAILURE CODE [CA3563] ............................................................................................................40-541 FAILURE CODE [CA3567] ............................................................................................................40-544 FAILURE CODE [CA3568] ............................................................................................................40-547 FAILURE CODE [CA3571] ............................................................................................................40-551 FAILURE CODE [CA3572] ............................................................................................................40-553 FAILURE CODE [CA3574] ............................................................................................................40-555 FAILURE CODE [CA3575] ............................................................................................................40-557 FAILURE CODE [CA3577] ............................................................................................................40-559 FAILURE CODE [CA3578] ............................................................................................................40-561 FAILURE CODE [CA3582] ............................................................................................................40-563 FAILURE CODE [CA3583] ............................................................................................................40-569 FAILURE CODE [CA3596] ............................................................................................................40-571 FAILURE CODE [CA3649] ............................................................................................................40-573 FAILURE CODE [CA3681] ............................................................................................................40-575 FAILURE CODE [CA3682] ............................................................................................................40-580 FAILURE CODE [CA3713] ............................................................................................................40-586 FAILURE CODE [CA3717] ............................................................................................................40-589 FAILURE CODE [CA3718] ............................................................................................................40-590 FAILURE CODE [CA3725] ............................................................................................................40-591 FAILURE CODE [CA3741] ............................................................................................................40-594 FAILURE CODE [CA3748] ............................................................................................................40-595 FAILURE CODE [CA3751] ............................................................................................................40-597 FAILURE CODE [CA3755] ............................................................................................................40-599 FAILURE CODE [CA3866] ............................................................................................................40-601 FAILURE CODE [CA3867] ............................................................................................................40-605 FAILURE CODE [CA3868] ............................................................................................................40-608 FAILURE CODE [CA3899] ............................................................................................................40-612 FAILURE CODE [CA3911] ............................................................................................................40-614 FAILURE CODE [CA3912] ............................................................................................................40-618 FAILURE CODE [CA3932] ............................................................................................................40-620 FAILURE CODE [CA3933] ............................................................................................................40-622 FAILURE CODE [CA3934] ............................................................................................................40-624 FAILURE CODE [CA3935] ............................................................................................................40-627 FAILURE CODE [CA3936] ............................................................................................................40-629 FAILURE CODE [CA4151] ............................................................................................................40-631 FAILURE CODE [CA4152] ............................................................................................................40-635 FAILURE CODE [CA4155] ............................................................................................................40-639 FAILURE CODE [CA4156] ............................................................................................................40-641 FAILURE CODE [CA4157] ............................................................................................................40-643 FAILURE CODE [CA4158] ............................................................................................................40-645 FAILURE CODE [CA4159] ............................................................................................................40-646 FAILURE CODE [CA4161] ............................................................................................................40-647 PC360LC-11E0, PC360NLC-11E0

00-9

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [CA4162] ............................................................................................................40-650 FAILURE CODE [CA4163] ............................................................................................................40-653 FAILURE CODE [CA4164] ............................................................................................................40-655 FAILURE CODE [CA4165] ............................................................................................................40-657 FAILURE CODE [CA4166] ............................................................................................................40-659 FAILURE CODE [CA4168] ............................................................................................................40-661 FAILURE CODE [CA4169] ............................................................................................................40-664 FAILURE CODE [CA4171] ............................................................................................................40-666 FAILURE CODE [CA4249] ............................................................................................................40-669 FAILURE CODE [CA4251] ............................................................................................................40-671 FAILURE CODE [CA4259] ............................................................................................................40-673 FAILURE CODE [CA4261] ............................................................................................................40-676 FAILURE CODE [CA4277] ............................................................................................................40-679 FAILURE CODE [CA4281] ............................................................................................................40-683 FAILURE CODE [CA4459] ............................................................................................................40-686 FAILURE CODE [CA4461] ............................................................................................................40-689 FAILURE CODE [CA4658] ............................................................................................................40-692 FAILURE CODE [CA4731] ............................................................................................................40-696 FAILURE CODE [CA4732] ............................................................................................................40-697 FAILURE CODE [CA4739] ............................................................................................................40-698 FAILURE CODE [CA4768] ............................................................................................................40-699 FAILURE CODE [CA4769] ............................................................................................................40-701 FAILURE CODE [CA4842] ............................................................................................................40-704 FAILURE CODE [CA4952] ............................................................................................................40-708 FAILURE CODE [CA5115] ............................................................................................................40-710 FAILURE CODE [CA5179] ............................................................................................................40-713 FAILURE CODE [CA5181] ............................................................................................................40-715 FAILURE CODE [CA5383] ............................................................................................................40-717 FAILURE CODE [D110KB]............................................................................................................40-719 FAILURE CODE [D19JKZ] ............................................................................................................40-721 FAILURE CODE [D811MC] ...........................................................................................................40-724 FAILURE CODE [D862KA]............................................................................................................40-725 FAILURE CODE [D8ALKA] ...........................................................................................................40-726 FAILURE CODE [D8ALKB] ...........................................................................................................40-729 FAILURE CODE [D8AQKR] ..........................................................................................................40-731 FAILURE CODE [D8G6KT] ...........................................................................................................40-737 FAILURE CODE [DA20MC] ..........................................................................................................40-738 FAILURE CODE [DA22KK] ...........................................................................................................40-739 FAILURE CODE [DA25KP] ...........................................................................................................40-742 FAILURE CODE [DA29KQ]...........................................................................................................40-745 FAILURE CODE [DA2LKA] ...........................................................................................................40-747 FAILURE CODE [DA2LKB] ...........................................................................................................40-750 FAILURE CODE [DA2QKR] ..........................................................................................................40-752 FAILURE CODE [DA2RKR] ..........................................................................................................40-761 FAILURE CODE [DAF0KM] ..........................................................................................................40-762 FAILURE CODE [DAF0MB] ..........................................................................................................40-763 FAILURE CODE [DAF0MC] ..........................................................................................................40-764 FAILURE CODE [DAF8KB] ...........................................................................................................40-765 FAILURE CODE [DAF9KQ]...........................................................................................................40-767 FAILURE CODE [DAFGMC] .........................................................................................................40-768 FAILURE CODE [DAFLKA] ...........................................................................................................40-769 FAILURE CODE [DAFLKB] ...........................................................................................................40-772 FAILURE CODE [DAFQKR] ..........................................................................................................40-774 FAILURE CODE [DAZ9KQ]...........................................................................................................40-775 FAILURE CODE [DAZQKR] ..........................................................................................................40-776 FAILURE CODE [DBPQKR]..........................................................................................................40-783 FAILURE CODE [DBP0KM] ..........................................................................................................40-791 FAILURE CODE [DBP0KT] ...........................................................................................................40-792 00-10

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [DBP5KB]...........................................................................................................40-793 FAILURE CODE [DBP5KY]...........................................................................................................40-796 FAILURE CODE [DB2QKR] ..........................................................................................................40-799 FAILURE CODE [DB2RKR] ..........................................................................................................40-807 FAILURE CODE [DDNRKA]..........................................................................................................40-812 FAILURE CODE [DDNRKY]..........................................................................................................40-814 FAILURE CODE [DDNS00]...........................................................................................................40-816 FAILURE CODE [DFB1KZ] ...........................................................................................................40-818 FAILURE CODE [DFB2KZ] ...........................................................................................................40-820 FAILURE CODE [DFB3L8]............................................................................................................40-822 FAILURE CODE [DFB4L8]............................................................................................................40-824 FAILURE CODE [DFB5KZ] ...........................................................................................................40-826 FAILURE CODE [DFB6KZ] ...........................................................................................................40-828 FAILURE CODE [DGH2KB] ..........................................................................................................40-830 FAILURE CODE [DHA4KA]...........................................................................................................40-832 FAILURE CODE [DHAAMA]..........................................................................................................40-834 FAILURE CODE [DHACMA] .........................................................................................................40-836 FAILURE CODE [DHPAMA]..........................................................................................................40-838 FAILURE CODE [DHPBMA]..........................................................................................................40-841 FAILURE CODE [DHS3MA] ..........................................................................................................40-844 FAILURE CODE [DHS4MA] ..........................................................................................................40-847 FAILURE CODE [DHS8MA] ..........................................................................................................40-850 FAILURE CODE [DHS9MA] ..........................................................................................................40-853 FAILURE CODE [DHSAMA]..........................................................................................................40-856 FAILURE CODE [DHSBMA]..........................................................................................................40-859 FAILURE CODE [DHSCMA] .........................................................................................................40-862 FAILURE CODE [DHSDMA] .........................................................................................................40-865 FAILURE CODE [DHSFMA]..........................................................................................................40-868 FAILURE CODE [DHSGMA] .........................................................................................................40-871 FAILURE CODE [DHSHMA] .........................................................................................................40-874 FAILURE CODE [DHSJMA] ..........................................................................................................40-877 FAILURE CODE [DHZAMA]..........................................................................................................40-880 FAILURE CODE [DHZCL8] ...........................................................................................................40-884 FAILURE CODE [DKR0MA] ..........................................................................................................40-885 FAILURE CODE [DKR1MA] ..........................................................................................................40-888 FAILURE CODE [DKULKA]...........................................................................................................40-891 FAILURE CODE [DKULKB]...........................................................................................................40-893 FAILURE CODE [DKULKY]...........................................................................................................40-895 FAILURE CODE [DR10KA] ...........................................................................................................40-897 FAILURE CODE [DR12KA] ...........................................................................................................40-900 FAILURE CODE [DR20KA] ...........................................................................................................40-902 FAILURE CODE [DR21KX] ...........................................................................................................40-904 FAILURE CODE [DR30KA] ...........................................................................................................40-906 FAILURE CODE [DR31KX] ...........................................................................................................40-908 FAILURE CODE [DR40KA] ...........................................................................................................40-910 FAILURE CODE [DUMBKA]..........................................................................................................40-912 FAILURE CODE [DUMBKB]..........................................................................................................40-915 FAILURE CODE [DV00KA] ...........................................................................................................40-917 FAILURE CODE [DV00KB] ...........................................................................................................40-918 FAILURE CODE [DV20KB] ...........................................................................................................40-919 FAILURE CODE [DW43KA] ..........................................................................................................40-921 FAILURE CODE [DW43KB] ..........................................................................................................40-923 FAILURE CODE [DW43KY] ..........................................................................................................40-925 FAILURE CODE [DW45KA] ..........................................................................................................40-927 FAILURE CODE [DW45KB] ..........................................................................................................40-930 FAILURE CODE [DW45KY] ..........................................................................................................40-933 FAILURE CODE [DW4CKY]..........................................................................................................40-935 FAILURE CODE [DW91KA] ..........................................................................................................40-936 PC360LC-11E0, PC360NLC-11E0

00-11

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [DW91KB] ..........................................................................................................40-938 FAILURE CODE [DW91KY] ..........................................................................................................40-940 FAILURE CODE [DWA2KA] ..........................................................................................................40-942 FAILURE CODE [DWA2KB] ..........................................................................................................40-944 FAILURE CODE [DWA2KY] ..........................................................................................................40-946 FAILURE CODE [DWK0KA]..........................................................................................................40-948 FAILURE CODE [DWK0KB]..........................................................................................................40-950 FAILURE CODE [DWK0KY]..........................................................................................................40-952 FAILURE CODE [DWK2KA]..........................................................................................................40-954 FAILURE CODE [DWK2KB]..........................................................................................................40-956 FAILURE CODE [DWK2KY]..........................................................................................................40-958 FAILURE CODE [DWK8KA]..........................................................................................................40-960 FAILURE CODE [DWK8KB]..........................................................................................................40-962 FAILURE CODE [DWK8KY]..........................................................................................................40-964 FAILURE CODE [DWPUKA] .........................................................................................................40-966 FAILURE CODE [DWPUKB] .........................................................................................................40-968 FAILURE CODE [DWPUKY] .........................................................................................................40-970 FAILURE CODE [DXA8KA]...........................................................................................................40-972 FAILURE CODE [DXA8KB]...........................................................................................................40-975 FAILURE CODE [DXA9KA]...........................................................................................................40-977 FAILURE CODE [DXA9KB]...........................................................................................................40-980 FAILURE CODE [DXE0KA]...........................................................................................................40-982 FAILURE CODE [DXE0KB]...........................................................................................................40-984 FAILURE CODE [DXE4KA]...........................................................................................................40-986 FAILURE CODE [DXE4KB]...........................................................................................................40-988 FAILURE CODE [DXE4KY]...........................................................................................................40-990 FAILURE CODE [DXE5KA]...........................................................................................................40-991 FAILURE CODE [DXE5KB]...........................................................................................................40-993 FAILURE CODE [DXE6KA]...........................................................................................................40-995 FAILURE CODE [DXE6KB]...........................................................................................................40-997 FAILURE CODE [DXE7KA]...........................................................................................................40-999 FAILURE CODE [DXE7KB].........................................................................................................40-1001 FAILURE CODE [DXE7KY].........................................................................................................40-1003 FAILURE CODE [DXE8KA].........................................................................................................40-1005 FAILURE CODE [DXE8KB].........................................................................................................40-1007 FAILURE CODE [DXE8KY].........................................................................................................40-1009 FAILURE CODE [DXE9KA].........................................................................................................40-1011 FAILURE CODE [DXE9KB].........................................................................................................40-1013 FAILURE CODE [DXE9KY].........................................................................................................40-1015 FAILURE CODE [DXEAKA] ........................................................................................................40-1017 FAILURE CODE [DXEAKB] ........................................................................................................40-1019 FAILURE CODE [DXEAKY] ........................................................................................................40-1021 FAILURE CODE [DXEKKA] ........................................................................................................40-1023 FAILURE CODE [DXEKKB] ........................................................................................................40-1025 FAILURE CODE [DXEKKY] ........................................................................................................40-1027 FAILURE CODE [DXELKA].........................................................................................................40-1029 FAILURE CODE [DXELKB].........................................................................................................40-1031 FAILURE CODE [DXELKY].........................................................................................................40-1033 FAILURE CODE [DY20KA] .........................................................................................................40-1035 FAILURE CODE [DY20MA].........................................................................................................40-1038 FAILURE CODE [DY2CKB].........................................................................................................40-1040 FAILURE CODE [DY2DKB].........................................................................................................40-1043 FAILURE CODE [DY2EKB].........................................................................................................40-1045 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .........................................................40-1047 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ..............................................40-1047 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK........................................................40-1053 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ..................................................40-1056 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.....40-1058 00-12

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING................................................................................................................................40-1060 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW ...........................................................40-1063 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW .................................................40-1064 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .......................................................................................................................................40-1065 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .......................................................................................................................................40-1066 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING... ................................................................................................................................................40-1067 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............40-1068 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................40-1069 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ......40-1070 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......................................................................................................................................40-1071 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1072 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......................................................................................................................................40-1073 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .................40-1074 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...............................40-1076 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.........................................................................................................................40-1077 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE..............................................................................................................40-1078 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ...............................................................................................................................40-1079 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .............................................................................................................................40-1081 E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ......................40-1082 E-24 FUNCTION SWITCH DOES NOT OPERATE .....................................................................40-1083 E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)..................40-1084 E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF ....................................................................40-1085 E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ....................40-1086 E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED ....................................................................................................................40-1087 E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED ......................................................................................................................40-1088 E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .................................................................................................................................40-1089 E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE .................................................................................................................................40-1090 E-32 ALARM BUZZER CANNOT BE CANCELED ......................................................................40-1092 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION......... ................................................................................................................................................40-1093 E-34 SERVICE MODE CANNOT BE SELECTED .......................................................................40-1094 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ....40-1095 E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK........40-1097 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING ....................................................................................................................................40-1098 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE ...............................................................................................40-1101 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR ...............................................................................40-1103 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED ...........................40-1105 E-41 ALARM DOES NOT SOUND DURING TRAVEL ................................................................40-1106 PC360LC-11E0, PC360NLC-11E0

00-13

INDEX

00 INDEX AND FOREWORD

E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..........................40-1108 E-43 HORN DOES NOT SOUND................................................................................................40-1109 E-44 HORN DOES NOT STOP SOUNDING............................................................................... 40-1113 E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF . ................................................................................................................................................ 40-1115 E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE... 40-1116 E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE ......................................................................................................................................... 40-1118 E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ... ................................................................................................................................................ 40-1119 E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION . ................................................................................................................................................40-1120 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......... ................................................................................................................................................40-1121 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1122 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ................................................................................................................................................40-1123 E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION . ................................................................................................................................................40-1124 E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.40-1125 E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION40-1126 E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .......... ................................................................................................................................................40-1127 E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.......................................40-1129 E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1130 E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED .............................................40-1131 E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................40-1133 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1134 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1134 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ..........................................40-1135 FAILURE MODE AND CAUSE TABLE........................................................................................40-1137 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK......................................40-1148 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER ..................40-1149 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR............................................40-1152 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ..................................40-1153 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ..................................................40-1154 H-6 SPEED OR POWER OF BOOM IS LOW .............................................................................40-1156 H-7 ARM SPEED OR POWER IS LOW ......................................................................................40-1162 H-8 BUCKET SPEED OR POWER IS LOW................................................................................40-1167 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .....................................40-1171 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE ........................................................................40-1172 H-11 HYDRAULIC DRIFT OF ARM IS LARGE ...........................................................................40-1174 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................40-1176 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES ........................................................................................................................40-1177 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE .................................................................40-1178 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .........................40-1179 H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................40-1180 H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................40-1181 H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .....................................40-1182 H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER ...................................................................................................................40-1183 H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY ...... ................................................................................................................................................40-1184 H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW .... ................................................................................................................................................40-1185 H-22 MACHINE DOES NOT TRAVEL STRAIGHT ......................................................................40-1186 H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.............................40-1188 00-14

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

H-24 TRAVEL SPEED IS LOW ...................................................................................................40-1191 H-25 ONE OF TRACKS DOES NOT RUN ..................................................................................40-1193 H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ..40-1195 H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .................40-1196 H-28 SWINGS ONLY IN ONE DIRECTION.................................................................................40-1197 H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) ......................................................................................................................................40-1198 H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION ....................................................................................................................40-1199 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..................................................................................................................40-1200 H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)..................................................................................40-1201 H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .............................40-1202 H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING40-1203 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)40-1204 H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) ........ ................................................................................................................................................40-1205 H-37 Quick coupler cylinder will not extend.................................................................................40-1206 H-38 Quick coupler cylinder will not retract (but buzzer doesnot sound) .....................................40-1208 H-39 Buzzer does not sound (but quick coupler cylinder doesretract) .........................................40-1210 H-40 Quick coupler cylinder extends and retracts slowly.............................................................40-1212 TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1213 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1213 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION....... ................................................................................................................................................40-1214 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1215 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) ........................................................................................................40-1216 S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1218 S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1220 S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1222 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1224 S-8 ENGINE LACKS POWER.....................................................................................................40-1225 S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1227 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1229 S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1230 S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1231 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ....... ................................................................................................................................................40-1232 S-14 OIL PRESSURE DROPS ...................................................................................................40-1233 S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1235 S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1236 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1237 S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1238 S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1239 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1240 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1241 S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1243 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1244 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1245 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1247 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1248 TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED) ...40-1249 20 SUPPLY VOLTAGE > 32VDC ................................................................................................40-1249 21 SUPPLY VOLTAGE < 12VDC ................................................................................................40-1250 25 FILE ERROR FACTORY SETTINGS .....................................................................................40-1251 26 FILE ERROR USER SETTINGS ............................................................................................40-1252 PC360LC-11E0, PC360NLC-11E0

00-15

INDEX

00 INDEX AND FOREWORD

27 FILE ERROR INPUT DATA ....................................................................................................40-1253 30 PROXIMITY SWITCHES DIFFERENCE ................................................................................40-1254 86 ANGLE SENSOR A2 TIMEOUT.............................................................................................40-1255 96 ANGLE SENSOR A3/A5 TIMEOUT .......................................................................................40-1256 106 ANGLE SENSOR A4/A6 TIMEOUT .....................................................................................40-1257 116 ANGLE SENSOR PITCH TIMEOUT.....................................................................................40-1258 126 ANGLE SENSOR ROLL TIMEOUT......................................................................................40-1259 50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1 CONTENTS ............................................................................................................................................ 50-2 ABBREVIATION LIST ............................................................................................................................. 50-7 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ........................................................ 50-13 HOW TO READ THIS MANUAL..................................................................................................... 50-13 COATING MATERIALS LIST.......................................................................................................... 50-15 SPECIAL TOOLS LIST .................................................................................................................. 50-20 SKETCHES OF SPECIAL TOOLS................................................................................................. 50-35 ENGINE AND COOLING SYSTEM....................................................................................................... 50-43 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-43 REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-56 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-75 REMOVE AND INSTALL EGR VALVE ASSEMBLY.......................................................................50-103 REMOVE AND INSTALL EGR COOLER ASSEMBLY...................................................................50-106 REMOVE AND INSTALL STARTER ASSEMBLY ..........................................................................50-110 REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-112 REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-118 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-122 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-127 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-130 REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-158 REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-166 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-175 REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-179 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-186 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-197 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-209 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-216 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER............................................50-217 REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-222 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-229 REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-238 REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-244 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET ......................................................50-258 REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-266 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-269 REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-277 REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-284 REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-289 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-304 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-308 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-311 POWER TRAIN....................................................................................................................................50-313 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-313 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-316 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................50-329 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-332 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-343 UNDERCARRIAGE AND FRAME........................................................................................................50-345 SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-345 REMOVE AND INSTALL SPROCKET ..........................................................................................50-350 00-16

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-352 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-354 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-359 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-362 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................50-366 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-370 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-375 HYDRAULIC SYSTEM.........................................................................................................................50-379 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-379 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-383 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-386 REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-394 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-400 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-414 REMOVE AND INSTALL ATT BYPASS SOLENOID .....................................................................50-421 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-426 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-429 REMOVE AND INSTALL QUICK COUPLER VALVE.....................................................................50-432 WORK EQUIPMENT............................................................................................................................50-434 REMOVE AND INSTALL BUCKET ASSEMBLY............................................................................50-434 REMOVE AND INSTALL ARM ASSEMBLY ..................................................................................50-436 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-439 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY........................50-445 CAB AND ITS ATTACHMENTS ...........................................................................................................50-455 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-455 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-470 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-482 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-491 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-506 REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-518 REMOVE AND INSTALL SEAT BELT ...........................................................................................50-523 REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-525 ELECTRICAL SYSTEM .......................................................................................................................50-539 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-539 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-545 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY ................................................50-552 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-554 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ..........................................................50-561 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-563 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-565 REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-567 REMOVE AND INSTALL REARVIEW CAMERA ...........................................................................50-570 REMOVE AND INSTALL KomVision CAMERA .............................................................................50-573 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-576 60 MAINTENANCE STANDARD.................................................................................................................... 60-1 CONTENTS ............................................................................................................................................ 60-2 ABBREVIATION LIST ............................................................................................................................. 60-3 ENGINE AND COOLING SYSTEM......................................................................................................... 60-9 MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-9 MAINTENANCE STANDARD OF COOLING SYSTEM ...................................................................60-11 POWER TRAIN..................................................................................................................................... 60-13 MAINTENANCE STANDARD OF SWING CIRCLE ........................................................................ 60-13 MAINTENANCE STANDARD OF SWING MACHINERY................................................................ 60-14 MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-16 MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-18 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING......... 60-19 UNDERCARRIAGE AND FRAME......................................................................................................... 60-21 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-21 PC360LC-11E0, PC360NLC-11E0

00-17

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

INDEX

00 INDEX AND FOREWORD

MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-23 MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-25 MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-27 MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-28 MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-31 HYDRAULIC SYSTEM.......................................................................................................................... 60-32 MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-32 MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-33 MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-35 MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-38 MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-41 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-51 MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-54 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-57 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE ..................................... 60-60 MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-62 MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE .............................. 60-63 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE ........................... 60-65 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-66 WORK EQUIPMENT............................................................................................................................. 60-67 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-67 MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-76 MAINTENANCE STANDARD OF ARM CYLINDER ....................................................................... 60-77 MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-78 WORK EQUIPMENT - PC390HRD-11E0 .............................................................................................. 60-79 WORK EQUIPMENT - HIGH REACH DEMOLITION ..................................................................... 60-79 WORK EQUIPMENT - DEMOLITION DIGGING ............................................................................ 60-84 80 APPENDIX................................................................................................................................................ 80-1 CONTENTS ............................................................................................................................................ 80-2 ABBREVIATION LIST ............................................................................................................................. 80-4 AIR CONDITIONER SYSTEM .............................................................................................................. 80-10 PRECAUTIONS FOR REFRIGERANT .......................................................................................... 80-10 AIR CONDITIONER COMPONENT ................................................................................................80-11 SPECIFICATIONS OF AIR CONDITIONER ................................................................................... 80-13 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................. 80-14 OUTLINE OF REFRIGERATION CYCLE ....................................................................................... 80-15 COMPONENT PARTS OF AIR CONDITIONER SYSTEM .................................................................... 80-17 AIR CONDITIONER UNIT.............................................................................................................. 80-17 COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-21 AIR CONDITIONER CONTROLLER .............................................................................................. 80-25 COMPRESSOR ............................................................................................................................. 80-26 CONDENSER ................................................................................................................................ 80-27 RECEIVER DRIER......................................................................................................................... 80-28 SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-29 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...... .......................................................................................................................................................... 80-31 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-33 AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-35 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-36 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .. .......................................................................................................................................................... 80-38 TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-42 METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-42 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................ 80-44 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR .......................................................................................................... 80-45 TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-46 METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-46 00-18

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

INDEX

TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-48 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-48 TEST SUNLIGHT SENSOR.................................................................................................................. 80-49 METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-49 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.................................................................. 80-50 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................ 80-50 TEST RELAYS...................................................................................................................................... 80-51 METHOD FOR TESTING RELAYS ................................................................................................ 80-51 AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-52 AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-53 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-56 FAILURE CODE [879AKA].................................................................................................................... 80-58 FAILURE CODE [879AKB].................................................................................................................... 80-59 FAILURE CODE [879BKA].................................................................................................................... 80-60 FAILURE CODE [879BKB].................................................................................................................... 80-62 FAILURE CODE [879CKA].................................................................................................................... 80-64 FAILURE CODE [879CKB].................................................................................................................... 80-65 FAILURE CODE [879DKZ].................................................................................................................... 80-66 FAILURE CODE [879EMC] ................................................................................................................... 80-68 FAILURE CODE [879FMC] ................................................................................................................... 80-69 FAILURE CODE [879GKX] ................................................................................................................... 80-70 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE). .......................................................................................................................................................... 80-72 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)... .......................................................................................................................................................... 80-74 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) ..................................................................................................................................... 80-77 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-79 TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-81 CONNECTION OF SERVICE TOOL ..................................................................................................... 80-84 METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-84 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...................................................................................................................................... 80-86 HANDLE COMPRESSOR OIL .............................................................................................................. 80-88 90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1 CONTENTS ............................................................................................................................................ 90-2 ABBREVIATION LIST ............................................................................................................................. 90-3 HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-9 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-9 HYDRAULIC CIRCUIT DIAGRAM (1/3) ......................................................................................... 90-13 HYDRAULIC CIRCUIT DIAGRAM (2/3) ......................................................................................... 90-15 HYDRAULIC CIRCUIT DIAGRAM (3/3) ......................................................................................... 90-17 HYDRAULIC CIRCUIT DIAGRAM (1/3) - PC390HRD-11E0 .......................................................... 90-19 HYDRAULIC CIRCUIT DIAGRAM (2/3) - PC390HRD-11E0 .......................................................... 90-21 HYDRAULIC CIRCUIT DIAGRAM (3/3) - PC390HRD-11E0 .......................................................... 90-23 ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-25 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-25 ELECTRICAL DIAGRAM (1/12) ..................................................................................................... 90-29 ELECTRICAL DIAGRAM (2/12) ..................................................................................................... 90-31 ELECTRICAL DIAGRAM (3/12) ..................................................................................................... 90-33 ELECTRICAL DIAGRAM (4/12) ..................................................................................................... 90-35 ELECTRICAL DIAGRAM (5/12) ..................................................................................................... 90-37 ELECTRICAL DIAGRAM (6/12) ..................................................................................................... 90-39 ELECTRICAL DIAGRAM (7/12) ..................................................................................................... 90-41 ELECTRICAL DIAGRAM (8/12) ..................................................................................................... 90-43 ELECTRICAL DIAGRAM (9/12) ..................................................................................................... 90-45 ELECTRICAL DIAGRAM (10/12) ................................................................................................... 90-47 ELECTRICAL DIAGRAM (11/12) ................................................................................................... 90-49 PC360LC-11E0, PC360NLC-11E0

00-19

INDEX

00 INDEX AND FOREWORD

ELECTRICAL DIAGRAM (12/12) ................................................................................................... 90-51 INDEX..................................................................................................................................................................1

00-20

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

ABBREVIATION LIST

ABBREVIATION LIST •

This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.

•

Abbreviations that are used in general society may not be included.

•

Special abbreviations which appear infrequently are noted in the text.

•

This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)

Abbreviation

Actual word spelled out

ABS

Antilock Brake System

AISS

Automatic Idling Setting Engine System

This is a function that automatically sets the idle speed.

Steering AJSS

Advanced Joystick Steering System

This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.

ARAC

Automatic Retarder Accelerator Control

Travel and brake (HD, HM)

(WA) Travel and brake (HD, HM) Travel and brake

Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.

This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill.

This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.

ARSC

Automatic Retarder Speed Control

ASR

Travel and brake Automatic Spin Regulator (HD, HM)

This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.

ATT

Attachment

A function or component that can be added to the standard specification.

BCV

BRAKE Brake cooling oil control valve (HD)

CAN

Controller Area Network

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

CDR

Crankcase Depression Regulator

Engine

This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.

CLSS

Closed-center Load Sensing System

Hydraulic system

This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).

PC360LC-11E0, PC360NLC-11E0

(HD, HM)

Work equipment

This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.

00-21

ABBREVIATION LIST

Abbreviation

Actual word spelled out

00 INDEX AND FOREWORD

Purpose of use (major applicable machine (*1), or component/system)

Explanation

Engine

This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.

Electronic control system

This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)

CRI

Common Rail Injection

ECM

Electronic Control Module

ECMV

Electronic Control Modulation Valve

ECSS

Travel Electronically Controlled Suspension System (WA)

This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.

ECU

Electronic Control Unit

This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)

EGR

Exhaust Gas RecirculaEngine tion

This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.

EMMS

Equipment ManageMachine monitor ment Monitoring System

This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).

EPC

Electromagnetic ProporHydraulic system tional Control

Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.

FOPS

Falling Object Protective Cab and canopy Structure

Transmission (D, HD, WA, etc)

Electronic control system

This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.

This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.

F-N-R

Forward-Neutral-Reverse

GPS

Global Positioning System

GNSS

Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)

HSS

Hydrostatic Steering System

HST

Hydro Static Transmission

Operation Communication (KOMTRAX, KOMTRAX Plus)

Steering

00-22

(D Series) Transmission (D, WA)

Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.

This is a general term for system uses satellites such as GPS, GALILEO, etc.

This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft.

Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

ABBREVIATION LIST

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*1), or component/system)

Explanation

ICT

Information and Communication Technology

Communication and electronic control

A general term for the engineering and its socially applied technology of information processing and communication.

IMA

Inlet Metering Actuator

Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)

IMU

Inertial Measurement Unit

Engine

This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.

IMV

Inlet Metering Valve

Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)

KCCV

Komatsu Closed CrankEngine case Ventilation

This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.

KCSF

Komatsu Catalyzed Soot Filter

KDOC

Komatsu Diesel Oxidation Catalyst

KDPF

Engine

Engine

Komatsu Diesel ParticuEngine late Filter

This is a filter that captures soot in exhaust gas.

It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas.

It is built in to KDPF or assembled with the muffler.

This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it.

It is installed instead of the conventional muffler.

Travel and brake

This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.

KTCS

Komatsu Traction Control System

(HM)

LCD

Liquid Crystal Display

Machine monitor

This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.

LED

Light Emitting Diode

Electronic parts

This is a semiconductor element that emits light when the voltage is applied in forward direction.

LIN

Local Interconnect Network

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

LS

Load Sensing

Hydraulic system

This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.

LVDS

Low Voltage Differential Signaling

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

Engine

This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.

MAF

Mass Air Flow

PC360LC-11E0, PC360NLC-11E0

00-23

ABBREVIATION LIST

00 INDEX AND FOREWORD

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*1), or component/system)

MMS

Multimedia Messaging Service

Communication

NC

Normally Closed

This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.

NO

Normally Open

This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.

OLSS

Open-center Load Sensing System

Hydraulic system

PC

Pressure Compensation Hydraulic system

PCCS

Palm command control system

PCV

Pre-stroke Control Valve Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.

PPC

Proportional Pressure Control

This is a system that operates actuators in proportion to the oil pressure.

PPM

Piston Pump and Motor

PTO

Power Take Off

PTP

Power Tilt and power Pitch dozer

Steering

ROPS

Roll-Over Protective Structure

(D Series)

Hydraulic system Hydraulic system (D, PC, etc)

Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.

This is a hydraulic system that can operate multiple actuators at the same time regardless of the load.

This is a function that corrects the oil pressure.

This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.

Piston type hydraulic pump and motor.

Power train system

Power take-off mechanism

Work equipment

This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.

(D Series)

Cab and canopy

ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2.

This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.

SCR

Selective Catalytic Reduction

SI

Le Systeme International d' Unites (Internation- Unit al unit system)

Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.

SOL

Solenoid

This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.

00-24

Urea SCR system

Electrical system

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

Abbreviation

TOPS

ABBREVIATION LIST

Purpose of use (major applicable machine (*1), or component/system)

Actual word spelled out

Tip-Over Protective Structure

Cab and canopy

Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.

TWV

2-Way Valve

Hydraulic system

This is a solenoid valve that switches over direction of flow.

VGT

Variable Geometry Turbocharger

Engine

This is a turbocharger on which the cross-section area of the exhaust passage is variable.

VHPC

Variable Horse Power Control

Engine control

This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.

*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader

List of abbreviations used in the circuit diagrams Actual word spelled out

Abbreviation A/C

Air Conditioner

A/D

Analogue-to-Digital

A/M

Air Mix Damper

ACC

Accessory

ADD

Additional

AUX

Auxiliary

BR

Battery Relay

CW

Clockwise

CCW

Counter Clockwise

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actuator

NC

No Connection

PC360LC-11E0, PC360NLC-11E0

00-25

ABBREVIATION LIST

Abbreviation S/T STRG

Actual word spelled out Steering

SIG

Signal

SOL

Solenoid

STD

Standard

OPT OP

Option

PRESS

Pressure

SPEC

Specification

SW

Switch

TEMP

Temperature

T/C

Torque Converter

T/M

Transmission

00-26

00 INDEX AND FOREWORD

PC360LC-11E0, PC360NLC-11E0

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

00 INDEX AND FOREWORD

HOW TO READ THE SHOP MANUAL

FOREWORD, SAFETY, BASIC INFORMATION HOW TO READ THE SHOP MANUAL •

Some of the attachments and options described in this shop manual may not be available in some areas. If they are required, consult your Komatsu distributor.

•

The materials and specifications are subject to change without notice.

•

Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual for the machine which has the same engine model.

•

Actual machine may differ from the images which are contained in this manual. A typical model is shown in the illustrations of this shop manual.

Composition of the shop manual This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.

00 INDEX AND FOREWORD This section describes the index, foreword, safety, and basic information.

01 SPECIFICATIONS This section describes the specifications of the machine.

10 STRUCTURE AND FUNCTION This section describes the structure and operation of each component with respect to each system. “STRUCTURE AND FUNCTION” is helpful in not only understanding the structure of each component but performing troubleshooting.

20 STANDARD VALUE TABLE This section describes the standard values for new machine and failure criteria for testing and adjusting, and troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge troubles in troubleshooting.

30 TESTING AND ADJUSTING This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described in “STANDARD VALUE TABLE”.

40 TROUBLESHOOTING This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.

Descriptions of troubleshooting are sorted by failure mode.

50 DISASSEMBLY AND ASSEMBLY This section describes the special tools, work procedures, and safety precautions necessary for removal, installation, disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and weight of the coating materials, lubricants, and coolant necessary to these works are shown.

60 MAINTENANCE STANDARD This section describes the maintenance standard value of each component. The maintenance standard shows the criteria and remedies for disassembly and assembly.

80 THE OTHER INFORMATION This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which cannot be separately classified in the appendix.

90 Circuit diagrams This section describes hydraulic circuit diagrams and electrical circuit diagrams.

PC360LC-11E0, PC360NLC-11E0

00-27

HOW TO READ THE SHOP MANUAL

00 INDEX AND FOREWORD

Symbols Important safety and quality portions are marked with the following symbols so that shop manual is used effectively.

Symbol

Item

Remark

Danger

This signal indicates an extremely hazardous situation which will result in death or serious injury if it is not avoided.

Warning

This signal indicates a potentially hazardous situation which will result in death or serious injury if it is not avoided.

Caution

This signal indicates a potentially hazardous situation which will result in injury or property damage around the machine if it is not avoided.

Weight

This signal indicates the weight of parts and components, and items which requires great attention to a selection of wires and working posture for slinging work.

Tightening torque

This signal indicates the tightening torque for portions which requires special care in assembling work.

Coat

This signal indicates a place to be coated with adhesive, grease, etc. in assembling work.

Oil and coolant

This signal indicates a place to supply oil, coolant, etc. and the quantity.

Draining

This signal indicates a place to drain oil, coolant, etc. and the quantity.

Signal word Signal word for notice and remark describes the following.

Symbol

Item

Remark

NOTICE

Notice

If the precaution of this signal word is not observed, the machine damage or shortening of service life may occur.

REMARK

Remark

This signal word contains useful information to know.

Unit International System of Units (SI) is used in this manual. For reference, units that have been used in the past are given in { }.

00-28

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

SAFETY NOTICE FOR OPERATION •

Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require the use of special tools designed by Komatsu for special purposes.

•

The symbol mark

is indicated for such matters that require special precautions. The work indicated with

should be performed according to the instructions with special attention. Should a this warning mark hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every necessary measures.

Safety matters •

Well organized work place

•

Correct work clothes

•

Observance of work standard

•

Enforcement of hand signals

•

Prohibition against unlicensed persons operating and handling the machine

•

Safety check before starting work

•

Wear suitable eye, face and body protection (for cleaning or grinding work)

•

Wear suitable eye, face and body protection with correct protective shading (for welding work)

•

Being in good physical condition, and good preparation

•

Always be alert and careful.

General precautions k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the

operation and maintenance manual before operation. Read and understand what is described in this manual before operation.

•

Read and understand the meaning of all the safety labels stuck to the machine before performing any greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Operation and Maintenance Manual.

•

Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on the floor. Smoke only in the designated areas. Never smoke while working.

•

Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the tools, machine, forklift truck, service car, etc. thoroughly before starting the work.

•

Always wear safety shoes and helmet when performing any operation. Do not wear loose clothes, or clothes with buttons missing.

PC360LC-11E0, PC360NLC-11E0

00-29

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

•

Always wear suitable eye, face and body protection when hitting parts with a hammer.

•

Always wear suitable eye, face and body protection when grinding parts with a grinder, etc.

•

When performing any operation with multiple workers, always agree on the operating procedure before starting. Be clear in verbal communication, and observe hand signals.

Hang “UNDER REPAIR” warning tag in the operator's compartment Before starting work.

•

Work and operation which require license or qualification should be performed by qualified workers.

•

Welding repairs should be performed by trained and experienced welders. When performing welding work, always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.

•

Warm up before starting the work with exercise which increases alertness and the range of motion in order to prevent injury.

•

Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe area.

,&

Precautions for preparatory work •

Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving before adding oil or making any repairs.

•

Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang “UNDER REPAIR” warning tag on them.

•

When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.

•

Remove all mud and oil from the steps or other places for going up and down on the machine. Always use the handrails, ladders or steps when for going up and down on the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing. Do not use handrails, ladders, or steps if they are damaged or deformed, repair or replace immediately.

,&

Precautions during work •

For the machine with the battery disconnect switch, check before starting the work that the system operating lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.

REMARK Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.

For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) terminal first.

•

For the machine with the quick release battery terminal (-), check before starting the work that the system operating lamp is not lit. Then, disconnect the quick release battery terminal (-).

REMARK For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two minutes or more before starting the work. Disconnect the quick release battery terminal (-).

00-30

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

•

Release the remaining pressure from the circuit before starting the work of disconnecting and removing of oil, fuel, water, or air from the circuit. When removing the oil filler cap, drain plug, or hydraulic pressure measuring plug, it should be done slowly to prevent oil from spurting out.

•

When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.

•

The coolant and oil in the circuits are hot when the engine is shut down. Be careful not to get scalded. Wait for the oil and coolant to cool before performing any work on the oil or coolant circuits.

•

Before starting work, shut down the engine. When working on or around a rotating part, in particular, shut down the engine. When checking the machine without shutting down the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts.

•

When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, webbing slings, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.

•

When removing a part which is under internal pressure or under reaction force of a spring, always leave 2 bolts in diagonal positions. Loosen those 2 bolts gradually and alternately to release the pressure, and then remove the part.

•

When removing components, do not break or damage the electrical wiring. Damaged wiring may cause a fire.

•

When removing piping, do not spill the fuel or oil. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.

•

Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in particular.

PC360LC-11E0, PC360NLC-11E0

,&

00-31

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

•

Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not be damaged by contact with other parts when the machine is operated.

•

When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that high pressure hoses and tubes are correctly installed.

•

When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are installed correctly.

•

Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.

•

Check that the measuring tools are correctly assembled and installed when measuring hydraulic pressure.

•

Take care when removing or installing the tracks of track-type machines. Since the track shoe may separate suddenly when you remove it, never let anyone stand at either end of the track shoe.

•

If the engine is operated for a long time in a closed place with poor ventilation, it may cause gas poisoning. Open the windows and doors to ventilate the place well.

,&

Precautions for slinging work and making signals •

Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. k Never stand under the load.

k Do not move a load over a person. k Never step on the load.

k Do not prevent the load from swinging or falling down by holding it simply with the hands.

k The sling workers and assistant workers other than the guide must move to a place where they

are not caught between the load and materials or equipment on the ground or hit by the load even if the crane starts abruptly.

•

Check the slings before starting sling work.

•

Wear suitable gloves during sling work. (Use leather gloves if available.)

•

Measure the weight of the load visually and check its center of gravity.

•

Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall.

•

Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically.

k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or

slipping of the rope from its original slinging position on the load, which can result in a dangerous accident.

•

Hanging angle must be 60 ° or smaller as a rule.

•

When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of the hook.

00-32

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

REMARK When slinging a load with 2 or more ropes, the force subjected to each rope increases with the hanging angle. The figure below shows the variation of allowable load in kN {kg} when slinging is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, they can sling up to 2000 kg of total weight. This weight is reduced to 1000 kg when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 2000 kg load at a hanging angle of 150 °, each rope is subjected to a force as large as 39.2 kN {4000 kg} .

•

When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping.

•

Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.

•

Apply wire ropes to the middle part of the hook.

k Do not use hooks if it does not have a latch sys-

tem.

k Slinging

near the tip of the hook may cause the rope to slip off the hook during hoisting.

REMARK The strength of the hook is maximum at its central part.

•

Never use a wire rope which has breaks in strands (A), reduced diameter (B), or kinks (C). There is a danger that the rope may break during the towing operation.

Precautions for slinging up •

Wind in the crane slowly until wire ropes are stretched.

When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught.

•

After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.

•

If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.

•

Do not lift up the load at an angle.

Precautions for slinging down •

When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.

•

Check that the load is stable, and then remove the sling.

•

Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.

Precautions for using mobile crane REMARK Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.

Precautions for using overhead travelling crane k When raising a heavy component (heavier than 25 kg), use a hoist or crane.

PC360LC-11E0, PC360NLC-11E0

00-33

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

REMARK Weight of component whose weight is heavier than 25 kg is shown with symbol ASSEMBLY”.

•

in “DISASSEMBLY AND

Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device, ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energizing caution lamp, and check the following safety items.

•

Observe the signals for sling work.

•

Operate the hoist at a safe place.

•

Be sure to check the directions of the direction indication plate (north, south, east and west) and the operating button.

•

Do not sling a load at an angle. Do not move the crane while the slung load is swinging.

•

Do not raise or lower a load while the crane is moving longitudinally or laterally.

•

Do not drag a sling.

•

When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.

•

Consider the travel route in advance and lift up a load to a safe height.

•

Place the control switch in a position where it is not an obstacle to work and passage.

•

After operating the hoist, do not swing the control switch.

•

Remember the position of the main switch so that you can turn off the power immediately in an emergency.

•

If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not in operating condition.

•

If you find an obstacle around the hoist, stop the operation.

•

After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.

Selecting wire ropes Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.

REMARK The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.

Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)

00-34

Nominal diameter of rope (mm)

Allowable load (kN {t} )

10

8.8 {0.9}

12

12.7 {1.3}

14

17.3 {1.7}

16

22.6 {2.3}

18

28.6 {2.9}

20

35.3 {3.6}

25

55.3 {5.6}

30

79.6 {8.1}

40

141.6 {14.4}

50

221.6 {22.6}

60

318.3 {32.4}

PC360LC-11E0, PC360NLC-11E0

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

00 INDEX AND FOREWORD

SAFETY NOTICE FOR OPERATION

Precautions for disconnecting air conditioner piping NOTICE When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc., collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting the air conditioner hoses.

REMARK • Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas: R134a).

• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.

k Wear suitable eye and face protection, gloves and suitable working clothes with long sleeves while

you are collecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may lose your sight, and when it touches your skin, you may suffer from frostbite.

•

When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one wrench to fix and use the other one to loosen the nut.

Precautions for air conditioner piping •

When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.

•

Check that the O-rings are fitted to the joints when connecting the air conditioner piping.

•

Do not reuse an O-ring because it is deformed and deteriorated if it is used once.

•

When removing the O-rings, use a soft tool so that the piping is not damaged.

•

Check that the O-ring is not damaged or deteriorated.

•

Apply compressor oil for refrigerant (R134a) to O-ring.

REMARK Do not apply oil to the threaded portion of a bolt, nut or union.

Part name

Manufacturer DENSO

ND-OIL8

VALEO THERMAL SYSTEMS

ZXL100PG (PAG46 or equivalent)

SANDEN

SP-10

When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).

PC360LC-11E0, PC360NLC-11E0

00-35

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

REMARK • The figure shows an example of fitting of O-ring.

• An O-ring is fitted to every joint of the air conditioner piping.

For tightening torques, see THE OTHER INFORMATION, “Precautions for disconnection and connection of air conditioner piping”.

00-36

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

PRECAUTIONS TO PREVENT FIRE

PRECAUTIONS TO PREVENT FIRE Fire caused by fuel, oil, coolant or window washer fluid Do not bring any open flame close to fuel, oil, coolant or window washer fluid. Always observe the following.

•

Do not smoke or use any open flame near fuel or other flammable substances.

•

Shut down the engine before adding fuel.

•

Do not leave the machine when adding fuel or oil.

•

Tighten all the fuel and oil caps securely.

•

Be careful not to spill fuel on overheated surfaces or on parts of the electrical system.

•

After adding fuel or oil, wipe up any spilled fuel or oil.

•

Put greasy rags and other flammable materials into a safe container to maintain safety at the workplace.

•

When washing parts with oil, use a non-flammable oil. Do not use diesel oil or gasoline.There is danger that they may catch fire.

•

Do not weld or use a cutting torch to cut any pipes or tubes that contain flammable liquids.

•

Determine well-ventilated areas for storing oil and fuel.

Keep the oil and fuel in the specified place and do not allow unauthorized persons to enter.

•

When performing grinding or welding work on the machine, move any flammable materials to a safe place before starting.

,&

,&

Fire caused by accumulation or attachment of flammable material •

Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.

•

To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil cooler) or on the undercover.

Fire coming from electric wiring Short circuits in the electrical system can cause fire. Always observe the following.

•

Keep all the electric wiring connections clean and securely tightened.

•

Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring clamps. Repair or replace any damaged wiring.

Fire caused by piping Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.

If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury or death.

Fire around the machine due to highly heated exhaust gas Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).

KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (regeneration), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not bring any flammable materials close to exhaust pipe outlet.

PC360LC-11E0, PC360NLC-11E0

00-37

PRECAUTIONS TO PREVENT FIRE

•

00 INDEX AND FOREWORD

When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disable the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused

by KDPF regeneration.

See the Operation and Maintenance Manual for the setting procedure.

Explosion caused by lighting equipment •

When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion specifications.

•

When taking the electrical power for the lighting equipment from the machine, follow the instructions in the Operation and Maintenance Manual.

00-38

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

ACTIONS IF FIRE OCCURS

ACTIONS IF FIRE OCCURS •

Turn the starting switch to OFF position to stop the engine.

•

Use the handrails and steps to get off the machine.

•

Do not jump off the machine. You may fall and suffer serious injury.

•

The fumes generated by a fire contain harmful materials which have a bad influence on your body when they are inhaled.

Do not breathe the fumes.

•

After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on your body.

Be sure to wear rubber gloves when handling the materials left after the fire.

The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in the lower temperature environment).

When wearing cotton work gloves, wear rubber gloves under them.

PC360LC-11E0, PC360NLC-11E0

00-39

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS To prevent pollution, pay full attention to the way to dispose of waste materials.

•

Always drain the oil from your machine in containers. Never drain the oil and coolant directly onto the ground or dump into the sewage system, rivers, seas, or lakes.

•

Obey appropriate laws and regulations when disposing of harmful objects such as oil, fuel, coolant, solvent, filters, batteries, and DEF.

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.

•

When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the local regulations for disposing industrial waste products.

00-40

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS This machine complies with either: [1] EU Stage V emission regulation in the European Union only or [2] EPA Tier4 Final emission regulation in North America and EU Stage V emission regulation in the European Union.

To confirm which engine emission regulation the engine conforms to refer to the "METHOD FOR CHECKING ENGINE TYPE" section of this manual.

This machine is equipped with the following two exhaust gas treatment systems: •

Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to purify exhaust gas. This process performs the combustion of soot referred to as “regeneration”.

•

Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen oxides into nitrogen and water.

Urea SCR system is not installed to some machine models or specifications.

Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.

AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of Germany).

DEF is the abbreviation for Diesel Exhaust Fluid.

Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.

This solution will be represented as DEF throughout this manual.

About DEF DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc.

If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.

•

In Europe, use AdBlue®.

•

In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).

The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification Mark when purchasing DEF. API Diesel Exhaust Fluid Certification Mark is the trade mark of API (American Petroleum Institute).

PC360LC-11E0, PC360NLC-11E0

00-41

METHOD FOR CHECKING ENGINE TYPE

00 INDEX AND FOREWORD

METHOD FOR CHECKING ENGINE TYPE NOTICE Different engine types have different Inducement strategies. Inducement is required by the authorities on engine systems that use Urea SCR systems. Inducement is intended for the operator to take prompt actions to maintain and correct inappropriate behaviours of Urea SCR systems by utilizing visible and audible alerts, and engine power derate in addition. Alerts in Inducement of the Komatsu Urea SCR system progresses step by step starting from visual indications on the machine monitor and audible sounds to engine power derate to avoid getting into unsafe conditions. The warning steps for Inducement are different for EU Stage V emission regulation and EPA Tier4 Final emission regulation. To confirm the Inducement strategy which will apply to the machine the engine type must be confirmed.

Machine can be supplied with two different engines which conform to either: [1] EU Stage V emission regulation in the European Union only, or [2] Both EPA Tier4 Final emission regulation in North America and EU Stage V emission regulation in the European Union.

Engine type can be confirmed by checking the engine number plate.

Location of Engine Number Plate It is located on top of the engine cylinder head cover.

Engine Number Plate The regulation the engine conforms to can be checked with the Engine Number Plate.

Engine type [1] EU Stage V which comply to EU Stage V emission regulation have the engine number plate shown below.

[1] EU Stage V

g0134055 Emission information states "THIS ENGINE CONFORMS TO REGULATION (EU) 2016/1628. THIS ENGINE IS CERTIFIED TO OPERATE ON ULTRA LOW SULPHUR DIESEL FUEL."

00-42

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

METHOD FOR CHECKING ENGINE TYPE

Engine type [2] EPA + Stage V which comply to EPA Tier4 Final emission regulation and EU Stage V emission regulation have the engine number plate shown below.

[2] EPA + EU Stage V

g0134056 Emission information states "THIS ENGINE COMPLIES WITH U.S. EPA REGULATIONS FOR [MODEL YEAR] NONROAD DIESEL ENGINES AND CALIFORNIA REGULATIONS FOR [MODEL YEAR] OFF-ROAD DIESEL ENGINE. ULTRA LOW SULPHUR FUEL ONLY."

PC360LC-11E0, PC360NLC-11E0

00-43

PRECAUTIONS FOR DEF

00 INDEX AND FOREWORD

PRECAUTIONS FOR DEF GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING DEF is a colourless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require immediate action: •

If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or begins to hurt, immediately consult a doctor for treatment.

•

Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor for treatment.

•

Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doctor for treatment.

•

Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear rubber gloves when you perform work handling DEF to avoid skin contact.

PRECAUTIONS FOR ADDING Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a fire. Some fluids or agents added can create and emit a toxic gas.

When opening the cap of DEF tank of the machine, the ammonia vapour may escape. Keep your face away from the filler port during opening or refilling.

PRECAUTIONS FOR STORING If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage. When opening the container, perform it where there is good ventilation. For storage, see “STORE AdBlue/DEF”.

Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum container, toxic gas may develop and a chemical reaction may corrode the container.

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE AdBlue/DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base of “Actions if fire occurs”.

If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left unattended and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical reactions.

THE OTHER PRECAUTIONS When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precautions for disposing of waste materials”. It should be treated in the same way.

Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when handling the fluid waste of AdBlue/DEF. Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.

Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can cause serious damage to the environment as well as violation of laws.

00-44

PC360LC-11E0, PC360NLC-11E0

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

00 INDEX AND FOREWORD

STORE AdBlue/DEF

STORE AdBlue/DEF •

If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up its container for storage. Only open containers in a well-ventilated area.

•

Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum container, toxic gas may develop and a chemical reaction may corrode the container.

•

AdBlue/DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above.

The relation between the upper limit of storage temperature and the storage period of AdBlue/DEF is shown in the table.

Temperature of storage area

Storage period

Max.10 °C

Up to 36 months

Max.25 °C

Up to 18 months

Max.30 °C

Up to 12 months

Max.35 °C

Up to 6 months

*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

Handling AdBlue/DEF in cold weather •

AdBlue/DEF freezes at –11 °C. AdBlue/DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank may be affected. Add AdBlue/DEF to the specified amount for cold weather (below the level of when AdBlue/DEF may freeze).

•

In cold weather, keep AdBlue/DEF or the machine installed with AdBlue/DEF in the indoors where the temperature is at –11 °C or higher to prevent AdBlue/DEF in the tank from freezing.

If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temperature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze.

Drain AdBlue/DEF to prevent it from freezing.

PC360LC-11E0, PC360NLC-11E0

00-45

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or when disassembling, or assembling the hydraulic components.

Select an appropriate workplace •

In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the machine.

Disassembly and maintenance work in the field k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit

and it may result in serious personal injury or death when removing and disassembling of the hydraulic equipment is performed. k Release the remaining pressure from the hydraulic circuit always before performing the work.

•

In the field, there is a risk of dust entering the component during disassembling or maintenance work, and performance check is hardly performed. Replacement of the assembly is recommended.

•

Perform disassembling and maintenance work in the dust proof area.

Sealing of openings (prevention of flowing out of oil) Plug the openings of the piping and the parts which have been removed to prevent foreign material from entering and oil from flowing out.

NOTICE Do not expose the openings or block with rag, otherwise foreign material may enter or leaked oil may pollute the environment.

Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.

REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs.

00-46

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Preventing intrusion of foreign materials during refilling •

During refilling with hydraulic oil, do not let water enter the electrical components.

•

Clean the oil filler port and surrounding area, refilling pump, oil jug, etc.

•

Refilling by using an oil cleaning device is better method as it can filtrate the contaminants accumulated in the oil during storage.

Replacing hydraulic oil while its temperature is high •

The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are easily discharged from the circuit. Perform the replacement while oil temperature is high.

•

Old hydraulic oil needs to be drained as much as possible when replacing.

NOTICE Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludges, and the service life of the hydraulic oil is shortened.

REMARK Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the circuit.

Avoid reusing the hydraulic oil and lubricating oil Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.

If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.

Flushing operation •

Flushing is required to completely dislodge the contaminants and sludges, and existing oil containing those inside the hydraulic circuit after disassembling and assembling, and when replacing the oil with the new one.

•

Normally, flushing is performed twice. Primary flushing is performed by using the flushing oil (1) and the secondary flushing is performed by using the specified hydraulic oil.

Cleaning operation Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic device (pump, or control valve) or during operation of the machine.

PC360LC-11E0, PC360NLC-11E0

00-47

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

00 INDEX AND FOREWORD

REMARK The oil cleaning equipment can remove the ultra fine (approximately 3 μm) particles that the filter built in the hydraulic equipment cannot remove. So, it is very effective device.

00-48

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS When performing “testing and adjusting” of the machine, “removal and installation” and “disassembly and assembly” of the components, observe the following precautions.

Precautions for removal and disassembling work •

If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage rashly.

•

After disconnecting the hoses or tubes, plug them to prevent dust from entering.

•

When draining oil, prepare a container with sufficient capacity.

•

Check the matchmarks which indicate the installing position, and put matchmarks on the places where they seem necessary before removal of the components to prevent any mistake when assembling.

•

To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.

•

Attach the tags to wires and hoses so that installation is done to the correct installing positions.

•

Check the thickness and number of shims when storing shims.

•

When hoisting the components, prepare the slings with sufficient strength.

•

When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.

•

Before removing any component, clean the surrounding area and cover the component to prevent any foreign material from entering after removal.

•

To disconnect the face seal type hose from the cylinder tube, loosen the joint by gripping the two wrenches together, one is the wrench (1) on the hose side, and another is the wrench (2) on the cylinder tube reaction force point as shown in the following figure. Use the grip strength only.Check after disconnecting the hose that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient.

NOTICE Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.

•

After disconnecting the piping or removing a pipe joint, install the following plugs.

NOTICE When disassembling the machine, check the part number by referring to the Parts Book and use the appropriate parts according to the usage conditions.

REMARK The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and transporting the machine.

PC360LC-11E0, PC360NLC-11E0

00-49

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

Introduction of parts for the disassembly of the face seal type hoses and tubes

Hose side

Pipe joint side

Plug (1)

Nut (2)

02

07376-70210

02789-00210

02896-11008

03

07376-70315

02789-00315

02896-11009

04

07376-70422

02789-00422

02896-11012

05

07376-70522

02789-00522

02896-11015

06

07376-70628

02789-00628

02896-11018

Nominal No.

O-ring (3)

Introduction of parts for the disconnection of the taper seal type hoses and tubes

Hose side

Pipe joint side

Plug (1)

Nut (2)

02

07376-50210

07222-00210

03

07376-50315

07222-00312

04

07376-50422

07222-00414

05

07376-50522

07222-00515

06

07376-50628

07222-00616

10

07376-51034

07222-01018

12

07376-51234

07222-01219

14

07376-51443

07222-01422

Nominal No.

00-50

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

Introduction of parts for the disconnection of the split flange type hoses and tubes

Nomi nal No.

Bolt pitch (mm) a

b

Flange (1)

04

38.1

17.5

07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823

05

42.9

19.8

07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823

06

47.6

22.2

07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032

10

52.4

26.2

07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032

58.7

30.2

07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032

66.7

31.8

07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232

69.9

35.8

07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232

79.4

36.5

07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445

77.8

42.8

07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232

96.8

44.5

07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845

24

88.9

50.8

07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232

30

106.4

62

07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645

34

120.6

69.8

07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645

40

130.2

77.8

07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645

50

152.4

92

07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645

12

14

20

Hose side

Tube side Split flange (2)

Sleeve head (3)

O-ring (4)

Bolt (5)

Washer (6)

Introduction of parts for the removal of O-ring boss type joint

PC360LC-11E0, PC360NLC-11E0

00-51

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

Nominal No.

Plug (1)

O-ring (2)

08

07040-10807

07002-10823

10

07040-11007

07002-11023

12

07040-11209

07002-11223

14

07040-11409

07002-11423

16

07040-11612

07002-11623

18

07040-11812

07002-11823

20

07040-12012

07002-12034

24

07040-12412

07002-12434

30

07041-13012

07002-13034

33

07040-13316

07002-13334

36

07041-13612

07002-13634

42

07040-14220

07002-14234

52

07040-15223

07002-15234

Introduction of parts for the removal of taper pipe thread type joint

Plug (1)

Nominal No.

Nominal thread size

Square head type (A)

Hexagonal socket head (B)

01

R1/8

07042-00108

07043-00108

02

R1/4

07042-00211

07043-00211

03

R3/8

07042-00312

07043-00312

04

R1/2

07042-00415

07043-00415

06

R3/4

07042-00617

07043-00617

10

R1

07042-01019

07043-01019

12

R11/4

07042-01222

07043-01222

14

R11/2

07042-01422

07043-01422

20

R2

07042-02026

07043-02026

Precautions for installation and assembling work •

Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.

•

Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.

00-52

PC360LC-11E0, PC360NLC-11E0

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

•

Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.

•

Bend the cotter pins and lock plates securely.

•

When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to the threaded portion.

•

When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that the surface is free from dust or damage.

•

Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.

•

Apply engine oil to the rotating parts and sliding surface.

•

Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.

•

After installing the snap ring, check that the snap ring is settled in the ring groove completely.

•

When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then connect them securely.

•

Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the eyes and the hook.

•

When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.

•

As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male screws which receive pressure.

REMARK If the threaded portion is difficult to degrease, you may use a seal tape.

When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the third thread in the advancing direction of the threads seeing from the screw end.

NOTICE If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come off. If the sealed tip is pushed outside, it may cause oil leakage.

•

To connect the face seal type hose to the cylinder tube, tighten the joint by gripping the two wrenches together, one is the wrench (1) on the hose side, and another is the wrench (2) on the cylinder tube reaction force point at the same time as shown in the following figure. Use the grip strength only.Check after connecting the hose that the joint portion of the cylinder and the cylinder tube is tightened to the specified torque. Re-tighten it if the tightening torque is insufficient.

NOTICE Cylinder tube is rotated due to the load applied to the reaction force point of the cylinder tube, and it is a cause of weakening of the tightening torque. It may lead to oil leakage.

NOTICE When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed, be sure to bleed air from the hydraulic circuit before operating it for the first time according to the following procedure.

1.

Start the engine, and run it at low idle.

2.

Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximately 100 mm before the stroke end for 4 or 5 times.

3.

Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke end for 3 or 4times.

PC360LC-11E0, PC360NLC-11E0

00-53

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

NOTICE After repair is finished, when operating the machine which has been stored for a long period, bleed air from the hydraulic circuit according to the same procedure.

Precautions at the time of completion of work Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF •

For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.

•

Supply the specified amount of grease to the work equipment parts.

•

When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reservoir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in the piping, and add the coolant to the specified level again.

•

When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level again.

•

If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system. See “TESTING AND ADJUSTING”.

Testing installed condition of cylinder heads and manifolds •

Check the cylinder head and intake and exhaust manifold mountings for looseness.

•

If there is any looseness, retighten the part.

REMARK For the tightening torques, see “DISASSEMBLY AND ASSEMBLY”.

Test engine piping for damage and looseness Intake and exhaust system Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak of air or exhaust gas from connecting portion.

If there is any looseness, damage, or gas leak, retighten or repair the part.

Cooling system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water leak from connecting portion.

If there is any looseness, damage, or water leak, retighten or repair the part.

Fuel system Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel leak from connecting portion.

If there is any looseness, damage, or fuel leak, retighten or repair the part.

Check the exhaust equipment and its installation portion for looseness and damage.

REMARK When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.)

• KDPF • AdBlue/DEF mixing tube • SCR assembly • KDOC muffler • Muffler • Exhaust pipe • Parts which connects the above, or etc.

Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there is any damage, replace the part.

00-54

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the installation portion.

If there is any looseness, retighten the part.

Check of function of muffler in exhaust system REMARK When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications or components of equipment are different depending on its models or specifications.)

• KDPF • AdBlue/DEF mixing tube • SCR assembly • KDOC muffler • Muffler • Exhaust pipe • Parts which connects the above, or etc.

Check that there is no unusual noise by comparing to it of the time when the machine was new.

If there is any unusual noise, repair KDPF or muffler, referring to “TROUBLESHOOTING” and “DISASSEMBLY AND ASSEMBLY”.

PC360LC-11E0, PC360NLC-11E0

00-55

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT To maintain the performance of the machine over a long period, and to prevent failures or troubles before they occur, correct “operation”, “maintenance and inspection” “troubleshooting”, and “repairs” must be performed.

This section deals particularly with correct repair procedures for mechatronics components and is aimed at improving the quality of repairs. For this purpose, it describes the working procedures in “Handling of electrical equipment”.

Handling wiring harnesses and connectors •

Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires.

•

Compared with other electrical components fitted in boxes or cases, wiring harnesses are likely to be directly affected by rain water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling and maintenance of the wiring harnesses.

•

If AdBlue/DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact.

Be careful not to spill it over electrical equipment, wiring harness and connectors since AdBlue/DEF is strongly corrosive to metal.

Main causes of failure in wiring harness Defective contact of connectors (defective contact between male and female connectors) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector,or because one or both of connectors are deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connectors approximately 10 times.

Defective crimping or soldering of connectors The pins of the male and female connectors are attached to wires by crimping or soldering. If excessive force is applied to the wire, the jointed portion (1) may become loose, and it may result in a defective connection or breakage.

00-56

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

Disconnection in wiring If the wiring harness is pulled to disconnect the connector, or the components are lifted with a crane while the wiring harness is still connected, or a heavy object hits the wiring harness, it may separate the crimping of the connector, or damage the soldering, or break the wiring harness.

Water entering the connector by high-pressure jetting The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet.

Do not spray water directly on the connector.

If the connector is waterproof, intruded water is hardly drained.

Once water enters into the connector, water goes through pins to cause short-circuit. Dry the water in the connector or take other appropriate actions before passing electricity through it.

Entry of water, dirt, or dust when disconnecting a connector If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a dry cloth or blow it with compressed air.

Oil, mud, or dust stuck to connector If any oil or grease is stuck to the connector and an oil film is formed on the mating surface of the male and female pins, the oil prevents electricity from passing through resulting in defective contact. If any oil, grease, dirt or dust is stuck to the connector, wipe it off with a dry cloth or blow it with compressed air, and wash it with electrical contact restorer.

NOTICE • When wiping the jointed portion of the connector, do not apply excessive force or deform the pins.

• If there is oil or water in the compressed air, it causes the contacts to become dirtier. Use clean air which any oil and water has been removed from.

PC360LC-11E0, PC360NLC-11E0

00-57

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.

Select an appropriate workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.

Sealing the opening Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.

NOTICE Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute the environment.

Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it appropriately.

How to clean parts when dirt is stuck If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.

Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge.

NOTICE The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material from entering this system, the filter employs a specially high performance of filter element. If a filter other than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the shop manual.

00-58

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT The machines equipped with Komatsu Variable Geometry Turbocharger (KVGT) consists of more precise parts (variable system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause a failure. Use special care to prevent entry of the foreign material when servicing the intake system.

Select an appropriate workplace Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in dusty environment.

Sealing the opening Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to prevent foreign material from entering.

NOTICE Do not expose the openings or plug with rags, as foreign material may enter.

PC360LC-11E0, PC360NLC-11E0

00-59

PRACTICAL USE OF KOMTRAX

00 INDEX AND FOREWORD

PRACTICAL USE OF KOMTRAX Various information which KOMTRAX system transmits by using the radio communication is useful for KOMTRAX operator to provide various services for the customers.

When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.

Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.

REMARK (KOMTRAX may not be installed to the machine in some countries or areas.)

Merit of using KOMTRAX •

The location where the machine is working at can be checked on the map in a personal computer.

•

Operation information such as service meter, operating hours, fuel consumption, and occurred caution as well as failure code can be checked.

•

The operator can check the hours used and replacement interval of consumable parts of the machine such as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.

•

Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be checked, and it is used to presume the machine operating condition.

•

Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is utilized as an advice tool for the user and operator.

•

KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the soundness of machine, in addition to KOMTRAX function described above. These data can be used on personal computer screens.

How to make a full use of KOMTRAX Making use of KOMTRAX enables the following activities.

•

•

•

Quick response to a request for immediate repair 1.

To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair request from a user.

2.

To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.

3.

To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.

Proactive maintenance 1.

To check the service summary screen of KOMTRAX, to find the machine which has high priority failure code indicated by a red or yellow flag.

2.

To check the condition of the machine with the customer and to make a plan to visit.

3.

To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the displayed failure code.

Practice of periodic maintenance and periodic inspection service 1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits for the consumable parts indicated by red flags are over.

2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replacement work to the customer.

3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.

How to operate KOMTRAX For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.

00-60

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER REMARK • Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.

• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even after the remaining pressure is released from the hydraulic tank.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER Disconnection 1.

Hold adapter (1), and push hose joint (2) into mating adapter (3).

REMARK • Push it in approximately 3.5 mm.

• Do not hold rubber cap portion (4).

2.

While having adapter (3) inserted into hose side joint (2), insert rubber cap (4) to adapter (3) side until it clicks.

3.

Hold hose adapter (1) or hose (5), and pull it out.

REMARK Provide an oil container to receive a quantity of hydraulic oil which may flow out.

Connection 1.

Hold hose adapter (1) or hose (5), and insert it in mating adapter (3), aligning the axis.

REMARK Do not hold rubber cap portion (4).

PC360LC-11E0, PC360NLC-11E0

00-61

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

2.

00 INDEX AND FOREWORD

After inserting the hose in the mating adapter perfectly, pull it back to check the connecting condition.

REMARK When the hose fitting is pulled back, the rubber cap moves approximately 3.5 mm toward the hose, but it is not a problem.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER Disconnection 1.

Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.

2.

While keeping the condition of step 1, turn lever (3) to the right (clockwise).

3.

While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.

REMARK Provide an container to receive a quantity of hydraulic oil which may flow out.

00-62

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

Connection Hold the tightening adapter part, and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER Disconnection 1.

Hold the tightening adapter part and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.

2.

While keeping the condition of step 1, push cover (3) straight until it contacts contact surface (a) of the hexagonal portion on the male side.

3.

While keeping the conditions of steps 1 and 2, pull out whole body (2) to disconnect it.

REMARK Provide an container to receive a quantity of hydraulic oil which may flow out.

PC360LC-11E0, PC360NLC-11E0

00-63

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

00 INDEX AND FOREWORD

Connection Hold the tightening adapter part, and push body (2) straight until sliding prevention ring (1) contacts contact surface (a) of the hexagonal part at the male end.

00-64

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS Disconnecting connectors 1.

Hold the connectors when disconnecting.

When disconnecting the connectors, always hold the connecting portion. If the connector is fixed with screw, loosen the screw of the connector completely, hold the both of male and female connectors, and pull them out in parallel.

NOTICE Do not pull the connectors with one hand.

REMARK If it is a lock stopper type connector, pull it out as pushing the stopper (1) with your thumb.

2.

When removing a connector from a clip •

Both of the connector and clip have stoppers (2), which are engaged with each other when the connector is connected.

•

When removing a connector from a clip, pull the connector in parallel with the clip as removing stoppers.

NOTICE If the connector is pried up and down or to the right or left, it may break the housing.

3.

Action to be taken after removing connectors After removing the connector, cover it with plastic bags to prevent entry of dust, dirt, oil, or water in the contact portion.

NOTICE Be sure to cover the connector with plastic bags when leaving the machine disassembled for a long time, otherwise defective contact may occur.

Connecting connectors 1.

Check the connector visually.

PC360LC-11E0, PC360NLC-11E0

00-65

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS

00 INDEX AND FOREWORD

•

Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).

•

Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.

•

Check that there is no damage or crack on the external surfaces of the connectors.

NOTICE • If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is any water intrusion into the connector, warm the inside of the connector and harness with a dryer. Do not overheat the connector, otherwise short circuit may occur.

• If there is any damage or breakage, replace the connector.

2.

Connecting the connector securely Position connector (1) correctly, and fit it in securely.

REMARK If the connector is lock stopper type, insert it until it clicks.

3.

Correct the protrusion of the boot and misalignment of the wiring harness.

•

If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is misaligned or the clamp is out of position, adjust it to its correct position.

REMARK If the protrusion of the boot and misalignment of the wiring harness cannot be fixed, remove the clamp to adjust them.

•

If the connector clamp is removed, be sure to return it to its original position. Check that there is no looseness.

Drying wiring harness REMARK If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.

If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows.

00-66

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

1.

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS

Disconnect the connector and wipe off the water with a dry cloth.

NOTICE If the connector is to be blown with dry compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow.

2.

Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry the connector.

NOTICE Hot air from a dryer can be used, but limit the time of using a dryer to prevent the connector or related parts from becoming too hot, as this will cause deformation or damage to the connector.

3.

Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected, connect T-adapter(1), and perform a continuity test to check for any short circuits between pins caused by water or etc.

REMARK After the connector is completely dried, blow the contact restorer, and reassemble them.

Handling controller

k When performing arc welding on the machine body, disconnect all of the wiring harness connectors

connected to the controller. Fit an arc welding ground close to the welding point.

PC360LC-11E0, PC360NLC-11E0

00-67

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS

00 INDEX AND FOREWORD

NOTICE • Controller has been assembled with electronic circuits for control including microcomputers. These electronic circuits inside of the controller must be handled with care since they control the machine.

• Do not leave things on the controller.

• Cover the connector portion of the controller with a tape and a plastic bag. Do not touch the connecting portion of connector.

• Do not leave the controller in a place where it is exposed to rain.

• Do not place the controller on oil, water, soil or any places where the temperature is likely to be high even for a short period of time (Place it on a suitable dry stand).

Precautions for troubleshooting electrical circuits •

Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.

•

Before performing troubleshooting, check all the related connectors for loose connection.

REMARK Check the related connectors for their performance by disconnecting and connecting them several times.

•

Be sure to connect all the disconnected connectors before proceeding to the next step.

NOTICE If the starting switch is turned to ON position while the connectors are disconnected, an unrelated failure beside the actual failed part may be displayed.

•

When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current, etc.), shake the related wiring harnesses and connectors several times and check that the multimeter reading does not change.

NOTICE If the value changes on the multimeter, there may be a defective contact in the circuit.

00-68

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR Method for disconnecting Deutsch connector While pressing locks (a) and (b) from each side respectively, pull out female connector (2).

Method for connecting Deutsch connector 1.

Push in female connector (2) horizontally, and insert it straight until it clicks. (Arrow: x)

2.

In order to check whether locks (a) and (b) are completely inserted, insert female connector (2) by rocking it vertically (in the arrow z direction). (Arrow: x, y, z) REMARK Lock (a) in the figure is pulled down (not set completely), and lock (b) is set completely.

PC360LC-11E0, PC360NLC-11E0

00-69

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) 1.

Slide lock (L1) to the right.

2.

While pressing lock (L2), pull out connector (1) toward you.

REMARK If portion A does not float when lock (L2) is pressed, and if connector (1) does not come out when it is pulled toward you, push up portion A with a small flat-head screwdriver while pressing lock (L2), and then pull out connector (1) toward you.

Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) Insert it straight until it clicks.

Method for disconnecting slide lock type connector (FRAMATOME-24) 1.

Slide down lock (red) (L1).

00-70

PC360LC-11E0, PC360NLC-11E0

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

00 INDEX AND FOREWORD

2.

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR

While pressing lock (L2), pull out connector (1).

REMARK Lock (L2) is located behind connector (1) in the figure.

Method for connecting slide lock type connector (FRAMATOME-24) Insert it straight until it clicks.

PC360LC-11E0, PC360NLC-11E0

00-71

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL Method for disconnecting connector with lock to pull Disconnect the connector (2) by pulling lock (B) (on the wiring harness side) of connector (2) outward.

Method for connecting connector with lock to pull Insert the connector securely until it “clicks”.

00-72

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH Method for disconnecting connector with lock to push (BOSCH-3) While pressing lock (C), pull out connector (3) in the direction of the arrow.

• 114 series

•

107 series

REMARK If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.

While pushing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.

Method for connecting connector with lock to push (BOSCH-3) Insert it straight until it clicks.

PC360LC-11E0, PC360NLC-11E0

00-73

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH

00 INDEX AND FOREWORD

Method for disconnecting connector with lock to push (AMP-3) While pressing lock (E), pull out connector (5) in the direction of the arrow.

Method for connecting connector with lock to push (AMP-3) Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-3) While pressing lock (E), pull out connector (5) in the direction of the arrow.

REMARK Pull up the connector straight.

Method for connecting connector with lock to push (SUMITOMO-3) Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-4) While pressing lock (D), pull out connector (4) in the direction of the arrow.

Method for connecting connector with lock to push (SUMITOMO-4) Insert it straight until it clicks.

00-74

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE Method for disconnecting connector with housing to rotate Turn housing (H1) to the left, and pull it out.

REMARK Housing (H1) is left on the wiring harness side.

Method for connecting connector with housing to rotate 1.

Insert the connector to the end while aligning its groove to the other.

2.

Turn housing (H1) clockwise until it clicks.

PC360LC-11E0, PC360NLC-11E0

00-75

HOW TO READ ELECTRICAL WIRE CODE

00 INDEX AND FOREWORD

HOW TO READ ELECTRICAL WIRE CODE In the electrical circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.

The electrical wire code is helpful in understanding the electrical circuit diagram.

Example) AEX 0.85 L: Indicates heat-resistant, low-voltage blue wire for automobile, having nominal No. of 0.85 Indicates type of wire by symbol.

AEX

0.85 L

Type, symbol, and material of wire are shown in (Table 1).

(Since the use of AV and AVS wires depends on size (nominal No.), the symbols are not indicated on the diagram.)

Indicates size of wire by nominal No. Sizes (Nominal Nos.) are shown in (Table 2).

Indicates color of wire by color code.

Color codes are shown in (Table 3).

Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the coating. CAVS has a circular compressed conductor. It differs from AV and AVS in the outside diameter of conductor and thickness of the coating.

AEX is similar to AV in thickness and outside diameter of the coating but different from AV and AVS in material of the coating.

(Table 1) Type

Symbol

Low-voltage wire for automobile

AV

Thin-cover low-voltage wire for automobile

Insulator material

Temperature range (°C) in use

Example of use For large current wiring (nominal No. 5 and above)

General wiring

AVS Soft polyvinyl chloride

(Type 1) Thin-cover low-voltage wire for automobile

Conductor material

-30 to +60

Annealed copper for electric appliance

(nominal No. 3 and lower)

For mid- to small-size excavators

CAVS

(nominal No. 1.25 and lower)

(Type 2) Heat-resistant low-voltage wire for automobile

00-76

AEX

Heat-resistant crosslinked polyethylene

-50 to +110

General wiring for extremely cold weather specification Wiring at high-temperature place

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

HOW TO READ ELECTRICAL WIRE CODE

Dimensions

(Table 2) Nominal No.

Coating D

Conductor

0.5f

(0.5)

0.75f

(0.85)

1.25f

(1.25)

2f

2

3f

3

5

Number of strands

20

7

30

11

50

16

37

26

58

41

65

Diameter of strand

0.18

0.32

0.18

0.32

0.18

0.32

0.26

0.32

0.26

0.32

0.32

Cross-sectional area (mm2)

0.51

0.56

0.76

0.88

1.27

1.29

1.96

2.09

3.08

3.30

5.23

d (approx.)

1.0

1.2

1.5

1.9

1.9

2.3

2.4

3.0

AVS

Standard

2.0

2.2

2.5

2.9

2.9

3.5

3.6

-

AV

Standard

-

-

-

-

-

-

-

4.6

AEX

Standard

2.0

2.2

2.7

3.0

3.1

-

3.8

4.6

Nominal No.

8

15

20

30

40

50

60

85

100

Number of strands

50

84

41

70

85

108

127

169

217

Diameter of strand

0.45

0.45

0.80

0.80

0.80

0.80

0.80

0.80

0.80

Cross-sectional area (mm2)

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

d (approx.)

3.7

4.8

6.0

8.0

8.6

9.8

10.4

12.0

13.6

AVS

Standard

-

-

-

-

-

-

-

-

-

AV

Standard

5.5

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

AEX

Standard

5.3

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

Coating D

Conductor

Nominal No.

Conductor

0.5f

0.5

0.75f

0.85

1.25f

1.25

Number of strands

-

7

-

11

-

16

Diameter of strand

-

round compression

-

round compression

Cross-sectional area (mm2)

-

0.56

-

0.88

-

1.29

d (approx.)

-

0.9

-

1.1

-

1.4

PC360LC-11E0, PC360NLC-11E0

round compression

00-77

Coating D

HOW TO READ ELECTRICAL WIRE CODE

00 INDEX AND FOREWORD

Nominal No.

0.5f

0.5

0.75f

0.85

1.25f

1.25

CAVS Standard

-

1.6

-

1.8

-

2.1

REMARK “f” of nominal No. denotes “flexible”.

Color codes table (Table 3) Color Code

Color of wire

Color Code

Color of wire

B

Black

LgW

Light green and White

Br

Brown

LgY

Light green and Yellow

BrB

Brown and Black

LR

Blue and Red

BrR

Brown and Red

LW

Blue and White

BrW

Brown and White

LY

Blue and Yellow

BrY

Brown and Yellow

O

Orange

Ch

Charcoal

P

Pink

Dg

Dark green

R

Red

G

Green

RB

Red and Black

GB

Green and Black

RG

Red and Green

GL

Green and Blue

RL

Red and Blue

Gr

Gray

RW

Red and White

GR

Green and Red

RY

Red and Yellow

GW

Green and White

Sb

Sky Blue

GY

Green and Yellow

Y

Yellow

L

Blue

YB

Yellow and Black

LB

Blue and Black

YG

Yellow and Green

Lg

Light green

YL

Yellow and Blue

LgB

Light green and Black

YR

Yellow and Red

LgR

Light green and Red

YW

Yellow and White

REMARK In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking.

Example) GW indicates that the background is “Green” and marking is “White”.

00-78

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

HOW TO READ ELECTRICAL WIRE CODE

Types of circuits and color codes Type of wire

AVS, AV, CAVS

AEX

Charge

R

WG

-

-

-

-

R

-

Ground

B

-

-

-

-

-

B

-

Start

R

-

-

-

-

-

R

-

Light

RW

RB

RY

RG

RL

-

O

-

Instrument

Y

YR

YB

YG

YL

YW

Y

Gr

Signal

G

GW

GR

GY

GB

GL

G

Br

L

LW

LR

LY

LB

-

L

-

Br

BrW

BrR

BrY

BrB

-

-

-

Lg

LgR

LgY

LgB

LgW

-

-

-

O

-

-

-

-

-

-

-

Gr

-

-

-

-

-

-

-

P

-

-

-

-

-

-

-

Sb

-

-

-

-

-

-

-

Dg

-

-

-

-

-

-

-

Ch

-

-

-

-

-

-

-

Type of circuit

Others

PC360LC-11E0, PC360NLC-11E0

00-79

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

00 INDEX AND FOREWORD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD The maintenance standard section shows the judgment criteria whether the equipment or parts should be replaced or can be reused when the machine is disassembled for the maintenance. The following terms are the descriptions of the judgment criteria.

Standard dimension and tolerance •

The finished dimension of a part is slightly different from one to another actually.

•

A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the part.

•

The dimension set as the standard is called the standard dimension and the allowable range of difference from this standard dimension is called “tolerance”.

•

An indication example of a standard dimension and tolerance is shown in the following table.

(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative symbol on the right side)

Example: Standard dimension

Tolerance -0.022

120

-0.126

•

The tolerance may be indicated in the text and a table as “standard dimension (upper limit of tolerance/ lower limit of tolerance).”

Example) 120 (-0.022/ -0.126)

•

Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is determined by the tolerance.

•

A dimension indication example of a shaft and hole is shown in the following table.

(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive or negative symbol at the center and that of the hole on the right side) Standard dimension

60

00-80

Tolerance Shaft

Hole

-0.030

+0.046

-0.076

0

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

Standard clearance and standard value •

The clearance made when new parts are assembled is called the standard clearance, which is indicated by the range from the minimum clearance to the maximum clearance.

•

When some parts are repaired, the clearance is generally adjusted to the standard clearance.

•

The values indicating performance and function of new products or equivalent are called “standard value”, which is indicated by a range or a target value.

•

When some parts are repaired, the value of performance/ function is set to the standard value.

Standard interference •

When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller than that of the shaft to be inserted, the difference between those diameters is called “interference”.

•

Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Subtract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range between (A) and (B) is “standard interference”.

•

After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the interference is in the standard range.

Repair limit and allowable value or allowable dimension •

The dimension of parts changes due to the wear or deformation while they are used. When the dimension changes exceeding certain value, parts cannot be used any longer. This value is called “repair limit”.

•

If a part is worn to the repair limit, it must be replaced or repaired.

•

The performance and function of products lower while they are used. A value with which the product can be used without causing a problem is called “allowable value” or “allowable dimension”.

•

A product whose dimension is out of the allowable value, must be repaired. However, since the allowable values are generally estimated through various tests or experiences in most cases, the judgment must be made in consideration of the operating condition and customer's requirement.

Allowable clearance •

Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called “allowable clearance”.

•

If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.

Allowable interference •

The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called “allowable interference”.

•

The allowable interference shows the repair limit of the part of smaller tolerance.

PC360LC-11E0, PC360NLC-11E0

00-81

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

•

00 INDEX AND FOREWORD

The parts whose interferences are out of the allowable interference must be replaced or repaired.

00-82

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

STANDARD TIGHTENING TORQUE TABLE Table of tightening torque for bolts and nuts REMARK Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.

Thread diameter (mm) 6

8

10

12 14 16

Width across flats (mm) 10 (*2) 10 13 (*2) 12 17 (*1, *2) 14 19 (*1, *2) 17 22 24 (*1) 22

Tightening torque (Nm {kgfm} ) 11.8 to 14.7 {1.2 to 1.5}

27 to 34 {2.8 to 3.5}

59 to 74 {6 to 7.5}

98 to 123 {10 to 12.5} 153 to 190 {15.5 to 19.5} 235 to 285 {23.5 to 29.5}

18

27

320 to 400 {33 to 41}

20

30

455 to 565 {46.5 to 58}

22

32

610 to 765 {62.5 to 78}

24

36

785 to 980 {80 to 100}

27

41

1150 to 1440 {118 to 147}

30

46

1520 to 1910 {155 to 195}

33

50

1960 to 2450 {200 to 250}

36

55

2450 to 3040 {250 to 310}

39

60

2890 to 3630 {295 to 370}

*1: Split flange bolt *2: Flanged bolt REMARK Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in the table below.

PC360LC-11E0, PC360NLC-11E0

00-83

STANDARD TIGHTENING TORQUE TABLE

Thread diameter (mm)

Width across flats (mm)

00 INDEX AND FOREWORD

Tightening torque (Nm {kgfm} )

6

10

5.9 to 9.8 {0.6 to 1.0}

8

12

13.7 to 23.5 {1.4 to 2.4}

10

14

34.3 to 46.1 {3.5 to 4.7}

12

17

74.5 to 90.2 {7.6 to 9.2}

REMARK Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise specified.

A

Type of bolt Nominal size threads per inch

B

Tightening torque (Nm {kgfm} )

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

9.8 to 14.7 {1 to 1.5}

12.7 {1.3}

2.9 to 3.9 {0.3 to 0.4}

3.43 {0.35}

5/

16-18UNC

24.5 to 34.3 {2.5 to 3.5}

29.4 {3}

6.9 to 8.8 {0.7 to 0.9}

7.8 {0.8}

3/ -16UNC 8

44.1 to 58.8 {4.5 to 6}

52.0 {5.3}

9.8 to 14.7 {1 to 1.5}

11.8 {1.2}

7/ -14UNC 16

73.5 to 98.1 {7.5 to 10}

86.3 {8.8}

19.6 to 24.5 {2 to 2.5}

21.6 {2.2}

1/ -13UNC 2

108 to 147 {11 to 15}

127 {13}

29.4 to 39.2 {3 to 4}

34.3 {3.5}

9/ -12UNC 16

157 to 216 {16 to 22}

186 {19}

44.1 to 58.8 {4.5 to 6}

51.0 {5.2}

5/ -11UNC 8

226 to 294 {23 to 30}

265 {27}

63.7 to 83.4 {6.5 to 8.5}

68.6 {7}

3/ -10UNC 4

392 to 530 {40 to 54}

461 {47}

108 to 147 {11 to 15}

127 {13}

7/ -9UNC 8

637 to 853 {65 to 87}

745 {76}

177 to 235 {18 to 24}

206 {21}

1/ -20UNC 4

00-84

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

Type of bolt Nominal size threads per inch

A

B

Tightening torque (Nm {kgfm} )

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

1-8UNC

883 to 1196 {90 to 122}

1040 {106}

245 to 333 {25 to 34}

284 {29}

11/8-7UNC

1187 to 1608 {121 to 164}

1393 {142}

333 to 451 {34 to 46}

392 {40}

11/4-7UNC

1598 to 2157 {163 to 220}

1873 {191}

451 to 608 {46 to 62}

530 {54}

11/2-6UNC

2354 to 3177 {240 to 324}

2765 {282}

657 to 892 {67 to 91}

775 {79}

REMARK Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise specified.

Type of bolt Nominal size threads per inch

A

B

Tightening torque (Nm {kgfm} )

Tightening torque (Nm {kgfm} )

Range

Target

Range

Target

1/ -28UNF 4

14.7 to 19.6 {1.5 to 2}

17.7 {1.8}

3.9 to 4.9 {0.4 to 0.5}

4.41 {0.45}

5/

16-24UNF

34.3 to 39.2 {3.5 to 4}

34.3 {3.5}

7.8 to 9.8 {0.8 to 1}

8.8 {0.9}

3/ -24UNF 8

53.9 to 68.6 {5.5 to 7}

61.8 {6.3}

14.7 to 19.6 {1.5 to 2}

16.7 {1.7}

7/ -20UNF 16

83.4 to 108 {8.5 to 11}

96.1 {9.8}

24.5 to 29.4 {2.5 to 3}

26.5 {2.7}

1/ -20UNF 2

127 to 167 {13 to 17}

147 {15}

34.3 to 49.0 {3.5 to 5}

41.2 {4.2}

9/

16-18UNF

186 to 245 {19 to 25}

216 {22}

49.0 to 68.6 {5 to 7}

58.8 {6}

5/ -18UNF 8

255 to 343 {26 to 35}

294 {30}

73.5 to 98.1 {7.5 to 10}

83.4 {8.5}

3/ -16UNF 4

441 to 598 {45 to 61}

520 {53}

127 to 167 {13 to 17}

147 {15}

7/ -14UNF 8

716 to 961 {73 to 98}

843 {86}

196 to 265 {20 to 27}

226 {23}

1-14UNF

1020 to 1373 {104 to 140}

1196 {122}

284 to 382 {29 to 39}

333 {34}

11/8-12UNF

1353 to 1844 {138 to 188}

1598 {163}

382 to 520 {39 to 53}

451 {46}

11/4-12UNF

1804 to 2432 {184 to 248}

2118 {216}

510 to 686 {52 to 70}

598 {61}

11/2-12UNF

2707 to 3658 {276 to 373}

3177 {324}

765 to 1030 {78 to 105}

892 {91}

PC360LC-11E0, PC360NLC-11E0

00-85

STANDARD TIGHTENING TORQUE TABLE

00 INDEX AND FOREWORD

Table of tightening torque for O-ring boss piping joints REMARK Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.

Nominal No.

Thread di- Width across ameter (mm) flats (mm)

02

14

-

18

03, 04

20

05, 06

24

10, 12

33

14

42

Varies depending on type of connector.

Tightening torque (Nm {kgfm} ) Range

Target

35 to 63 {3.5 to 6.5}

44 {4.5}

59 to 98 {6.0 to 10.0}

78 {8.0}

84 to 132 {8.5 to 13.5}

103 {10.5}

128 to 186 {13.0 to 19.0}

157 {16.0}

363 to 480 {37.0 to 49.0}

422 {43.0}

746 to 1010 {76.0 to 103}

883 {90.0}

Table of tightening torque for O-ring boss plugs REMARK Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.

Nominal No.

00-86

Thread diam- Width across eter (mm) flats (mm)

Tightening torque (Nm {kgfm} ) Range

Target

08

8

14

5.88 to 8.82 {0.6 to 0.9}

7.35 {0.75}

10

10

17

9.8 to 12.74 {1.0 to 1.3}

11.27 {1.15}

12

12

19

14.7 to 19.6 {1.5 to 2.0}

17.64 {1.8}

14

14

22

19.6 to 24.5 {2.0 to 2.5}

22.54 {2.3}

16

16

24

24.5 to 34.3 {2.5 to 3.5}

29.4 {3.0}

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

Nominal No.

STANDARD TIGHTENING TORQUE TABLE

Tightening torque (Nm {kgfm} )

Thread diam- Width across eter (mm) flats (mm)

Range

Target

18

18

27

34.3 to 44.1 {3.5 to 4.5}

39.2 {4.0}

20

20

30

44.1 to 53.9 {4.5 to 5.5}

49.0 {5.0}

24

24

32

58.8 to 78.4 {6.0 to 8.0}

68.6 {7.0}

30

30

32

93.1 to 122.5 {9.5 to 12.5}

107.8 {11.0}

33

33

-

107.8 to 147.0 {11.0 to 15.0}

127.4 {13.0}

36

36

36

127.4 to 176.4 {13.0 to 18.0}

151.9 {15.5}

42

42

-

181.3 to 240.1 {18.5 to 24.5}

210.7 {21.5}

52

52

-

274.4 to 367.5 {28.0 to 37.5}

323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type) REMARK • Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table unless otherwise specified.

• The table is applied to the threaded portion coated with engine oil (wet threaded portion).

Nominal No. of hose

Width across flats (mm)

02

19

Tightening torque (Nm {kgfm} )

Taper seal

Face seal Nominal size - Thread root threads per diameter(mm) inch (reference)

Range

Target

Thread size (mm)

34 to 54 {3.5 to 5.5}

44 {4.5}

-

34 to 63 {3.5 to 6.5}

44 {4.5}

14

22

54 to 93 {5.5 to 9.5}

74 {7.5}

-

24

59 to 98 {6.0 to 10.0}

78 {8.0}

04

27

84 to 132 {8.5 to 13.5}

05

32

06

9/

16-18UN

14.3

-

-

16-16UN

17.5

18

-

-

103 {10.5}

22

13/ -16UN 16

20.6

128 to 186 {13.0 to 19.0}

157 {16.0}

24

1 -14UNS

25.4

36

177 to 245 {18.0 to 25.0}

216 {22.0}

30

13/16-12UN

30.2

(10)

41

177 to 245 {18.0 to 25.0}

216 {22.0}

33

-

-

(12)

46

197 to 294 {20.0 to 30.0}

245 {25.0}

36

-

-

(14)

55

246 to 343 {25.0 to 35.0}

294 {30.0}

42

-

-

03

PC360LC-11E0, PC360NLC-11E0

11/

00-87

STANDARD TIGHTENING TORQUE TABLE

00 INDEX AND FOREWORD

Table of tightening torque for face seal joints REMARK • The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated low pressure piping which is used for engine.

• The table is applied to the threaded portion coated with engine oil (wet threaded portion).

• Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.

Outside diameter of adequate pipe (mm)

Width across flats (mm)

8

Tightening torque (Nm {kgfm} )

Face seal Nominal size threads per inch

Thread root diameter(mm) (reference)

Range

Target

19

14 to 16 {1.4 to 1.6}

15 {1.5}

9/

16-18UN

14.3

10

22

24 to 27 {2.4 to 2.7}

25.5 {2.6}

11/ -16UN 16

17.5

12

24 (27)

43 to 47 {4.4 to 4.8}

45 {4.6}

13/

16-16UN

20.6

15 (16)

30 (32)

60 to 68 {6.1 to 6.8}

64 {6.5}

1 -14UNS

25.4

22 (20)

36

90 to 95 {9.2 to 9.7}

92.5 {9.4}

13/16-12UN

30.2

Tightening torque table for bolts and nuts on 102, 107 and 114 series engines REMARK Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in the following table unless otherwise specified.

Thread diameter (mm)

Tightening torque (Nm {kgfm} )

6

10±2 {1.02±0.20}

8

24±4 {2.45±0.41}

10

43±6 {4.38±0.61}

12

77±12 {7.85±1.22}

14

-

Tightening torque table for 102, 107, and 114 series engines (joint bolts) REMARK Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following table unless otherwise specified.

00-88

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

Thread diameter (mm)

Tightening torque (Nm {kgfm} )

6

8±2 {0.81±0.20}

8

10±2 {1.02±0.20}

10

12±2 {1.22±0.20}

12

24±4 {2.45±0.41}

14

36±5 {3.67±0.51}

Tightening torque table for tapered screws on 102, 107, and 114 series engines (National taper pipe thread (NPT)) REMARK Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the torques shown in the following table unless otherwise specified.

Material of female screw

In cast iron or steel

In aluminum

Nominal thread size

Tightening torque (Nm {kgfm} )

Tightening torque (Nm {kgfm} )

1/

16

15±2 {1.53±0.20}

5±1 {0.51±0.10}

1/

8

20±2 {2.04±0.20}

15±2 {1.53±0.20}

1/

4

25±3 {2.55±0.31}

20±2 {2.04±0.20}

3/ 8

35±4 {3.57±0.41}

25±3 {2.55±0.31}

1/

2

55±6 {5.61±0.61}

35±4 {3.57±0.41}

4

75±8 {7.65±0.82}

45±5 {4.59±0.51}

3/

PC360LC-11E0, PC360NLC-11E0

00-89

CONVERSION TABLE

00 INDEX AND FOREWORD

CONVERSION TABLE Method of using the conversion table The conversion table is provided to enable simple conversion of the numerical numbers between the different units. For further details of the method of using the conversion table, see the examples given below.

Examples of using the conversion table to convert a unit from mm to in.

When converting 55 mm to in 1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).

2.

Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).

3.

Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit from mm to in. Accordingly, 55 mm = 2.165 in.

When converting 550 mm to in 1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left) to get 55 mm.

2. Convert 55 mm to 2.165 in according to the preceding procedure.

3.

The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point one place to the right) to restore the target value. This gives 550 mm = 21.65 in

mm to in (B) 1 mm = 0.03937 in 0

1

2

3

4

5

6

7

8

9

0

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

(C) (A)

50

1.969

2.008

2.017

2.087

2.126

2.165

2.205

2.244

2.283

2.323

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.847

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.780

3.819

3.858

3.898

mm to in 1 mm = 0.03937 in 0

1

2

3

4

5

6

7

8

9

0

0

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

10

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

20

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

30

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

40

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

50

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

00-90

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

CONVERSION TABLE

1 mm = 0.03937 in 0

1

2

3

4

5

6

7

8

9

60

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

70

2.756

2.795

2.835

2.847

2.913

2.953

2.992

3.032

3.071

3.110

80

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

90

3.543

3.583

3.622

3.661

3.701

3.740

3.780

3.819

3.858

3.898

kg to lb 1 kg = 2.2046 lb 0

1

2

3

4

5

6

7

8

9

0

0

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

10

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

20

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

30

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

40

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

50

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

60

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

70

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

80

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

90

198.42

200.62

202.83

205.03

207.24

209.44

211.64

213.85

216.05

218.26

ℓ to U.S.Gal 1 ℓ = 0.2642 U.S.Gal 0

1

2

3

4

5

6

7

8

9

0

0

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

10

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

20

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

30

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

40

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

50

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

60

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

70

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

80

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

90

23.775

24.040

24.304

24.568

24.832

25.096

25.361

25.625

25.889

26.153

ℓ to U.K.Gal 1 ℓ = 0.21997 U.K.Gal 0

1

2

3

4

5

6

7

8

9

0

0

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

10

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

20

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

PC360LC-11E0, PC360NLC-11E0

00-91

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

CONVERSION TABLE

00 INDEX AND FOREWORD

1 ℓ = 0.21997 U.K.Gal 0

1

2

3

4

5

6

7

8

9

30

6.599

6.819

7.039

7.259

7.479

7.699

7.919

8.139

8.359

8.579

40

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

50

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

60

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

70

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

80

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

90

19.797

20.017

20.237

20.457

20.677

20.897

21.117

21.337

21.557

21.777

kgfm to lbft 1 kgfm = 7.233 lbft 0

1

2

3

4

5

6

7

8

9

0

0

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

10

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

20

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

30

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

40

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

50

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

60

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

70

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

80

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

90

651.0

658.2

665.4

672.7

679.9

687.1

694.4

701.6

708.8

716.1

100

723.3

730.5

737.8

745.0

752.2

759.5

766.7

773.9

781.2

788.4

110

795.6

802.9

810.1

817.3

824.6

831.8

839.0

846.3

853.5

860.7

120

868.0

875.2

882.4

889.7

896.9

904.1

911.4

918.6

925.8

933.1

130

940.3

947.5

954.8

962.0

969.2

976.5

983.7

990.9

998.2

1005.4

140

1012.6

1019.9

1027.1

1034.3

1041.5

1048.8

1056.0

1063.2

1070.5

1077.7

150

1084.9

1092.2

1099.4

1106.6

1113.9

1121.1

1128.3

1135.6

1142.8

1150.0

160

1157.3

1164.5

1171.7

1179.0

1186.2

1193.4

1200.7

1207.9

1215.1

1222.4

170

1129.6

1236.8

1244.1

1251.3

1258.5

1265.8

1273.0

1280.1

1287.5

1294.7

180

1301.9

1309.2

1316.4

1323.6

1330.9

1338.1

1345.3

1352.6

1359.8

1367.0

190

1374.3

1381.5

1388.7

1396.0

1403.2

1410.4

1417.7

1424.9

1432.1

1439.4

kgf/cm2 to lb/in2 1 kgf/cm2 = 14.2233 lb/in2 0

1

2

3

4

5

6

7

8

9

0

0

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

10

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

20

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

00-92

PC360LC-11E0, PC360NLC-11E0

00 INDEX AND FOREWORD

CONVERSION TABLE

1 kgf/cm2 = 14.2233 lb/in2 0

1

2

3

4

5

6

7

8

9

30

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

40

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

50

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

60

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

70

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

80

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

90

1280

1294

1309

1323

1337

1351

1365

1380

1394

1408

100

1422

1437

1451

1465

1479

1493

1508

1522

1536

1550

110

1565

1579

1593

1607

1621

1636

1650

1664

1678

1693

120

1707

1721

1735

1749

1764

1778

1792

1806

1821

1835

130

1849

1863

1877

1892

1906

1920

1934

1949

1963

1977

140

1991

2005

2020

2034

2048

2062

2077

2091

2105

2119

150

2134

2148

2162

2176

2190

2205

2219

2233

2247

2262

160

2276

2290

2304

2318

2333

2347

2361

2375

2389

2404

170

2418

2432

2446

2460

2475

2489

2503

2518

2532

2546

180

2560

2574

2589

2603

2617

2631

2646

2660

2674

2688

190

2702

2717

2731

2745

2759

2773

2788

2802

2816

2830

200

2845

2859

2873

2887

2901

2916

2930

2944

2958

2973

210

2987

3001

3015

3030

3044

3058

3072

3086

3101

3115

220

3129

3143

3158

3172

3186

3200

3214

3229

3243

3257

230

3271

3286

3300

3314

3328

3343

3357

3371

3385

3399

240

3414

3428

3442

3456

3470

3485

3499

3513

3527

3542

Temperature Conversion of Fahrenheit to Celsius •

A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa is to see the number in the center column of the following table. The figures in the center of the following table show the temperatures in both Fahrenheit and Celsius.

•

When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Celsius temperature in the column at the left.

•

When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius values, and read the corresponding Fahrenheit temperature on the right.

1 °C = 33.8 °F °C

°F

°C

°F

°C

°F

°C

°F

-40.4

-40

-40.0

-11.7

11

51.8

7.8

46

114.8

27.2

81

177.8

-37.2

-35

-31.0

-11.1

12

53.6

8.3

47

116.6

27.8

82

179.6

-34.4

-30

-22.0

-10.6

13

55.4

8.9

48

118.4

28.3

83

181.4

-31.7

-25

-13.0

-10.0

14

57.2

9.4

49

120.2

28.9

84

183.2

-28.9

-20

-4.0

-9.4

15

59.0

10.0

50

122.0

29.4

85

185.0

-28.3

-19

-2.2

-8.9

16

60.8

10.6

51

123.8

30.0

86

186.8

PC360LC-11E0, PC360NLC-11E0

00-93

CONVERSION TABLE

00 INDEX AND FOREWORD

1 °C = 33.8 °F °C

°F

°C

°F

°C

°F

°C

°F

-27.8

-18

-0.4

-8.3

17

62.6

11.1

52

125.6

30.6

87

188.6

-27.2

-17

1.4

-7.8

18

64.4

11.7

53

127.4

31.1

88

190.4

-26.7

-16

3.2

-7.2

19

66.2

12.2

54

129.2

31.7

89

192.2

-26.1

-15

5.0

-6.7

20

68.0

12.8

55

131.0

32.2

90

194.0

-25.6

-14

6.8

-6.1

21

69.8

13.3

56

132.8

32.8

91

195.8

-25.0

-13

8.6

-5.6

22

71.6

13.9

57

134.6

33.3

92

197.6

-24.4

-12

10.4

-5.0

23

73.4

14.4

58

136.4

33.9

93

199.4

-23.9

-11

12.2

-4.4

24

75.2

15.0

59

138.2

34.4

94

201.2

-23.3

-10

14.0

-3.9

25

77.0

15.6

60

140.0

35.0

95

203.0

-22.8

-9

15.8

-3.3

26

78.8

16.1

61

141.8

35.6

96

204.8

-22.2

-8

17.6

-2.8

27

80.6

16.7

62

143.6

36.1

97

206.6

-21.7

-7

19.4

-2.2

28

82.4

17.2

63

145.4

36.7

98

208.4

-21.1

-6

21.2

-1.7

29

84.2

17.8

64

147.2

37.2

99

210.2

-20.6

-5

23.0

-1.1

30

86.0

18.3

65

149.0

37.8

100

212.0

-20.0

-4

24.8

-0.6

31

87.8

18.9

66

150.8

40.6

105

221.0

-19.4

-3

26.6

0

32

89.6

19.4

67

152.6

43.3

110

230.0

-18.9

-2

28.4

0.6

33

91.4

20.0

68

154.4

46.1

115

239.0

-18.3

-1

30.2

1.1

34

93.2

20.6

69

156.2

48.9

120

248.0

-17.8

0

32.0

1.7

35

95.0

21.1

70

158.0

51.7

125

257.0

-17.2

1

33.8

2.2

36

96.8

21.7

71

159.8

54.4

130

266.0

-16.7

2

35.6

2.8

37

98.6

22.2

72

161.6

57.2

135

275.0

-16.1

3

37.4

3.3

38

100.4

22.8

73

163.4

60.0

140

284.0

-15.6

4

39.2

3.9

39

102.2

23.3

74

165.2

62.7

145

293.0

-15.0

5

41.0

4.4

40

104.0

23.9

75

167.0

65.6

150

302.0

-14.4

6

42.8

5.0

41

105.8

24.4

76

168.8

68.3

155

311.0

-13.9

7

44.6

5.6

42

107.6

25.0

77

170.6

71.1

160

320.0

-13.3

8

46.4

6.1

43

109.4

25.6

78

172.4

73.9

165

329.0

-12.8

9

48.2

6.7

44

111.2

26.1

79

174.2

76.7

170

338.0

-12.2

10

50.0

7.2

45

113.0

26.7

80

176.0

79.4

175

347.0

00-94

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

PC360LC-11E0, PC360NLC-11E0

01-1

CONTENTS

01 SPECIFICATIONS

CONTENTS ABBREVIATION LIST .................................................................................................................................... 01-3 SPECIFICATIONS ......................................................................................................................................... 01-9 SPECIFICATION DRAWING................................................................................................................... 01-9 SPECIFICATION DRAWING: PC360LC-11E0, PC360NLC-11E0 .................................................... 01-9 WORKING RANGE DRAWINGS ...........................................................................................................01-11 WORKING RANGE: PC360LC-11E0, PC360NLC-11E0 .................................................................01-11 SPECIFICATIONS ................................................................................................................................ 01-12 SPECIFICATIONS: PC360LC-11E0, PC360NLC-11E0 .................................................................. 01-12 WEIGHT TABLE ................................................................................................................................... 01-15 WEIGHT TABLE: PC360LC-11E0, PC360NLC-11E0 ..................................................................... 01-15 TABLE OF FUEL, COOLANT, AND LUBRICANTS ............................................................................... 01-17 SPECIFICATIONS - PC390HRD-11E0......................................................................................................... 01-18 SPECIFICATION DRAWING................................................................................................................. 01-18 SPECIFICATION DRAWING: PC390HRD-11E0 ............................................................................ 01-18 SPECIFICATIONS ................................................................................................................................ 01-21 SPECIFICATIONS: PC390HRD-11E0............................................................................................ 01-21 WEIGHT TABLE ................................................................................................................................... 01-23 WEIGHT TABLE: PC390HRD-11E0 ............................................................................................... 01-23

01-2

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

ABBREVIATION LIST

ABBREVIATION LIST •

This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, components, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of the meaning.

•

Abbreviations that are used in general society may not be included.

•

Special abbreviations which appear infrequently are noted in the text.

•

This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of the manual, and the second part is a list of the abbreviations used in the circuit diagrams.

List of abbreviations used in the text Purpose of use (major applicable machine (*1), or component/system)

Abbreviation

Actual word spelled out

ABS

Antilock Brake System

AISS

Automatic Idling Setting Engine System

This is a function that automatically sets the idle speed.

Steering AJSS

Advanced Joystick Steering System

This is a function that performs the steering operations with a lever instead of using a steering wheel. This function performs gear shifting and changing forward and reverse direction.

ARAC

Automatic Retarder Accelerator Control

Travel and brake (HD, HM)

(WA) Travel and brake (HD, HM) Travel and brake

Explanation This is a function that releases the brake when the tires skid (tires are not rotated). This function applies the brake again when the tires rotate.

This is a function that automatically operates the retarder with a constant braking force when letting go of the accelerator pedal on the downhill.

This is a function that automatically operates the retarder to ensure that the machine speed does not accelerate above the speed set by the operator when letting go of the accelerator pedal on the downhill.

ARSC

Automatic Retarder Speed Control

ASR

Travel and brake Automatic Spin Regulator (HD, HM)

This is a function that drives both wheels automatically using the optimum braking force when the tire on one side spins on the soft ground surfaces.

ATT

Attachment

A function or component that can be added to the standard specification.

BCV

BRAKE Brake cooling oil control valve (HD)

CAN

Controller Area Network

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

CDR

Crankcase Depression Regulator

Engine

This is a regulator valve that is installed to KCCV ventilator. It is written as CDR valve and is not used independently.

CLSS

Closed-center Load Sensing System

Hydraulic system

This is a system that can actuate multiple actuators simultaneously regardless of the load (provides better combined operation than OLSS).

PC360LC-11E0, PC360NLC-11E0

(HD, HM)

Work equipment

This is a valve that bypasses a part of the brake cooling oil to reduce the load applied to the hydraulic pump when the retarder is not being used.

01-3

ABBREVIATION LIST

Abbreviation

Actual word spelled out

01 SPECIFICATIONS

Purpose of use (major applicable machine (*1), or component/system)

Explanation

Engine

This is a function that maintains optimum fuel injection amount and fuel injection timing. This is performed the engine controller which electronically controls supply pump, common rail, and injector.

Electronic control system

This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECU)

CRI

Common Rail Injection

ECM

Electronic Control Module

ECMV

Electronic Control Modulation Valve

ECSS

Travel Electronically Controlled Suspension System (WA)

This is a device that ensures smooth high-speed travel by absorbing vibration of machine during travel with hydraulic spring effect of accumulator.

ECU

Electronic Control Unit

This is an electronic control device that send the command to actuators using the signals from the sensors on the machine so that the optimum actuation is performed. (Same as ECM)

EGR

Exhaust Gas RecirculaEngine tion

This is a function that recirculates a part of exhaust gas to combustion chamber, so that it reduces combustion temperature, and reduces emission of NOx.

EMMS

Equipment ManageMachine monitor ment Monitoring System

This is a function with which operator can check information from each sensor on the machine (filter, oil replacement interval, malfunctions on machine, failure code, and failure history).

EPC

Electromagnetic ProporHydraulic system tional Control

Electromagnetic proportional control This is a mechanism with which actuators operate in proportion to the current.

FOPS

Falling Object Protective Cab and canopy Structure

Transmission (D, HD, WA, etc)

Electronic control system

This is a proportional electromagnetic valve that decreases the transmission shock by gradually increasing oil pressure for engaging clutch.

This structure protects the operator's head from falling objects. (Falling object protective structure) This performance is standardized as ISO 3449.

F-N-R

Forward-Neutral-Reverse

GPS

Global Positioning System

GNSS

Communication Global Navigation Satel(KOMTRAX, KOMTRAX lite System Plus)

HSS

Hydrostatic Steering System

HST

Hydro Static Transmission

Operation Communication (KOMTRAX, KOMTRAX Plus)

Steering

01-4

(D Series) Transmission (D, WA)

Forward - Neutral - Reverse This system uses satellites to determine the current location on the earth.

This is a general term for system uses satellites such as GPS, GALILEO, etc.

This is a function that enables the machine to turn without steering clutch by controlling a difference in travel speed of right and left tracks with a combination of hydraulic motor and bevel shaft.

Hydraulic transmission system that uses a combination of hydraulic pump and hydraulic motor without using gears for stepless gear shifting.

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

ABBREVIATION LIST

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*1), or component/system)

Explanation

ICT

Information and Communication Technology

Communication and electronic control

A general term for the engineering and its socially applied technology of information processing and communication.

IMA

Inlet Metering Actuator

Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump fuel discharged volume. (Same as IMV)

IMU

Inertial Measurement Unit

Engine

This is a device to detect the angle (or angular velocity) and acceleration of the 3 axes that control motions.

IMV

Inlet Metering Valve

Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control the supply pump combustion discharged volume. (Same as IMA)

KCCV

Komatsu Closed CrankEngine case Ventilation

This is a mechanism that burns the blowby gas again by separating oil from blowby gas and returning it to the intake side. It primarily consists of filters.

KCSF

Komatsu Catalyzed Soot Filter

KDOC

Komatsu Diesel Oxidation Catalyst

KDPF

Engine

Engine

Komatsu Diesel ParticuEngine late Filter

This is a filter that captures soot in exhaust gas.

It is built in to KDPF. This is a catalyst that is used for purifying exhaust gas.

It is built in to KDPF or assembled with the muffler.

This is a component that is used to purify the exhaust gas. KDOC (catalyst) and KCSF (filter to capture soot) are built-in it.

It is installed instead of the conventional muffler.

Travel and brake

This is a function that performs braking with the optimum force and recovers the driving force of the wheels by actuating the inter-axle differential lock when the wheels runs idle while the machine travels on the soft ground.

KTCS

Komatsu Traction Control System

(HM)

LCD

Liquid Crystal Display

Machine monitor

This is an image display equipment such as a monitor in which the liquid crystal elements are assembled.

LED

Light Emitting Diode

Electronic parts

This is a semiconductor element that emits light when the voltage is applied in forward direction.

LIN

Local Interconnect Network

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

LS

Load Sensing

Hydraulic system

This is a function that detects differential pressure of pump, and controls discharged volume corresponding to load.

LVDS

Low Voltage Differential Signaling

Communication and electronic control

This is one of communication standards that are used in the network on the machine.

Engine

This indicates engine intake air flow. This is not used independently but is used as combined with sensor. Mass air flow sensor can be called as MAF sensor.

MAF

Mass Air Flow

PC360LC-11E0, PC360NLC-11E0

01-5

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

ABBREVIATION LIST

01 SPECIFICATIONS

Abbreviation

Actual word spelled out

Purpose of use (major applicable machine (*1), or component/system)

MMS

Multimedia Messaging Service

Communication

NC

Normally Closed

This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally closed if it is not actusystem ated, and it opens when it is actuated.

NO

Normally Open

This is a characteristic of electrical or hydraulic Electrical system, hydraulic circuits. Circuit is normally open if it is not actusystem ated, and it closes when it is actuated.

OLSS

Open-center Load Sensing System

Hydraulic system

PC

Pressure Compensation Hydraulic system

PCCS

Palm command control system

PCV

Pre-stroke Control Valve Engine

This is a valve that adjusts the fuel intake amount at the pump inlet in order to control fuel discharged volume of supply pump.

PPC

Proportional Pressure Control

This is a system that operates actuators in proportion to the oil pressure.

PPM

Piston Pump and Motor

PTO

Power Take Off

PTP

Power Tilt and power Pitch dozer

Steering

ROPS

Roll-Over Protective Structure

(D Series)

Hydraulic system Hydraulic system (D, PC, etc)

Explanation This is a service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.

This is a hydraulic system that can operate multiple actuators at the same time regardless of the load.

This is a function that corrects the oil pressure.

This is a function that electrically controls the engine and transmission in an optimal way with the controller instantly analyzing data from levers, pedals, and dials.

Piston type hydraulic pump and motor.

Power train system

Power take-off mechanism

Work equipment

This is a function that performs hydraulic control of the tilt and pitch of the dozer blade of the bulldozer.

(D Series)

Cab and canopy

ROPS is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine rolls over. (Roll-over protective structure) This performance is standardized as ISO 3471 or ISO 12117-2.

This is an exhaust gas purifier using urea water that converts nitrogen oxides (NOx) into harmless nitrogen and water by oxidation-reduction reaction. It may also be mentioned as exhaust gas purification catalyst or part of the name of related devices.

SCR

Selective Catalytic Reduction

SI

Le Systeme International d' Unites (Internation- Unit al unit system)

Abbreviation for “International System of Units” It is the universal unit system and “a single unit for a single quantity” is the basic principle applied.

SOL

Solenoid

This is an actuator that consists of a solenoid and an iron core that is operated by the magnetic force when the solenoid is energized.

01-6

Urea SCR system

Electrical system

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

Abbreviation

TOPS

ABBREVIATION LIST

Purpose of use (major applicable machine (*1), or component/system)

Actual word spelled out

Tip-Over Protective Structure

Cab and canopy

Explanation This is a protective structure that intended to protect the operator wearing seat belt from suffering injury which may be caused if the cab is crushed when the machine tips over. (Roll-over protective structure of hydraulic excavator) This performance is standardized as ISO 12117.

TWV

2-Way Valve

Hydraulic system

This is a solenoid valve that switches over direction of flow.

VGT

Variable Geometry Turbocharger

Engine

This is a turbocharger on which the cross-section area of the exhaust passage is variable.

VHPC

Variable Horse Power Control

Engine control

This is a function that finely controls the maximum output of the machine so that high work efficiency and low fuel consumption rate are both achieved.

*1: Code for applicable machine model D: Bulldozer HD: Dump truck HM: Articulate dump truck PC: Hydraulic excavator WA: Wheel loader

List of abbreviations used in the circuit diagrams Actual word spelled out

Abbreviation A/C

Air Conditioner

A/D

Analogue-to-Digital

A/M

Air Mix Damper

ACC

Accessory

ADD

Additional

AUX

Auxiliary

BR

Battery Relay

CW

Clockwise

CCW

Counter Clockwise

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actuator

NC

No Connection

PC360LC-11E0, PC360NLC-11E0

01-7

ABBREVIATION LIST

Abbreviation S/T STRG

Steering Signal

SOL

Solenoid

STD

Standard

OP

01-8

Actual word spelled out

SIG

OPT

01 SPECIFICATIONS

Option

PRESS

Pressure

SPEC

Specification

SW

Switch

TEMP

Temperature

T/C

Torque Converter

T/M

Transmission

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

SPECIFICATION DRAWING

SPECIFICATIONS SPECIFICATION DRAWING SPECIFICATION DRAWING: PC360LC-11E0, PC360NLC-11E0

Item

Unit

PC360LC-11E0

PC360NLC-11E0

Machine weight

kg

36280

35800

Bucket capacity

m3

1.4

Engine model

-

Komatsu SAA6D114E-6 diesel engine

Engine power

kW/rpm

A Overall length B

Overall height (including head guard)

202 / 1950 (ISO 14396) 192 / 1950 (ISO 9249)

mm

11145

mm

3320

C Overall width

mm

3290

2990

D Shoe width

mm

700

600

E Cab height

mm

3160

F Tail swing radius

mm

3445

G Overall length of the track

mm

4955

H

Distance between tumbler centers

mm

4030

I

Height of handrail

mm

3255

J Min. ground clearance

mm

498

Travel speed (Lo/Mi/Hi)

km/h

3.2/4.5/5.5

Continuous swing speed

rpm

9.5

PC360LC-11E0, PC360NLC-11E0

01-9

SPECIFICATION DRAWING

01 SPECIFICATIONS

REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine.

01-10

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

WORKING RANGE DRAWINGS

WORKING RANGE DRAWINGS WORKING RANGE: PC360LC-11E0, PC360NLC-11E0

Item

Unit

PC360LC-11E0, PC360NLC-11E0

A

Max. digging reach

mm

11100

B

Max. digging depth

mm

7380

C

Max. digging height

mm

10210

D

Max. vertical wall digging depth

mm

6480

E

Max. dumping height

mm

7110

F

Min. dumping height

mm

2640

mm

10920

G Max. digging reach at ground level

PC360LC-11E0, PC360NLC-11E0

01-11

SPECIFICATIONS

01 SPECIFICATIONS

SPECIFICATIONS SPECIFICATIONS: PC360LC-11E0, PC360NLC-11E0 Item

Unit

Bucket capacity

m3

Machine weight

kg

PC360LC-11E0

PC360NLC-11E0 1.4

36280

35800

Performance Working ranges Max. digging depth

mm

7380

Max. vertical wall digging depth

mm

6480

Max. digging reach

mm

11100

Max. digging reach at ground level

mm

10920

Max. digging height

mm

10210

Max. dumping height

mm

7110

Max. digging force (When one-touch power maximizing function operates)

211.8 {21600} kN {kg}

227.5 {23200}

min-1 {rpm}

9.5

Swing operation max. slope angle

deg.

21

Travel speed (Lo/Mi/Hi)

km/h

3.2/4.5/5.5

Gradeability

deg.

35

Continuous swing speed

Ground pressure (standard shoe)

kPa {kgf/cm2}

57.8 {0.59}

65.7 {0.67}

Dimensions Overall length

mm

11145

Overall width

mm

Overall height (for transport) (*1)

mm

3320

Ground clearance of upper structure bottom (*2)

mm

1185

Min. ground clearance

mm

498

Tail swing radius

mm

3445

Min. swing radius of work equipment

mm

4310

Max. height of work equipment in min. swing radius posture

mm

8520

Overall width of track

mm

Overall length of the track

mm

Track gauge

mm

Distance between tumbler centers

mm

4030

Machine cab height

mm

3160

Width of standard shoe

mm

3290

2990

3290

2990 4955

2590

700

2390

600

*1: Including grouser height (36 mm) *2: Excluding grouser height (36 mm) Engine

01-12

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

Item

SPECIFICATIONS

Unit

PC360LC-11E0

PC360NLC-11E0

Model

-

SAA6D114E-6

Type

-

4-cycle, water-cooled, in-line, vertical, direct injection, with variable geometry turbocharger and aircooled aftercooler

No. of cylinders - bore x stroke

mm

6 - 114 x 144.5

Total piston displacement

ℓ {cc}

8.85 {8850}

Performance Rated power •

ISO 14396

•

ISO 9249

Max. torque

202 /1950

rpm Nm {kgfm} /min-1 {rpm}

192 /1950 1171 {119.4} /1450 {1450}

Max. speed with no load • •

When mounted on machine (*3)

2050

rpm

At basic engine

2050

Min. speed with no load

rpm

1000

Min. fuel consumption ratio

g/kWh

212

Starting motor

-

24 V, 11 kW

Alternator

-

24 V, 90 A

Battery (*4)

-

12 V, 180 Ah x 2 pcs.

Radiator type

-

CF90-4

*3: When swing lock is ON *4: The battery capacity (Ah) is indicated in the 5-hour rate.

REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine.

Undercarriage Carrier roller

-

2 (each side)

Track roller

-

8 (each side)

Track shoe

-

Assembly type triple grouser shoe, 48 pieces on each side

-

Variable displacement piston type (HPV140 + 140) x 2 pcs.

ℓ/min

267.5 x 2

MPa {kgf/cm2}

37.3 {380}

Hydraulic system Hydraulic pump Type x quantity Discharged volume Set pressure Control valve Type x quantity

-

6-spool + 1-spool type x 1 pc.

Operating method

-

Hydraulic type

PC360LC-11E0, PC360NLC-11E0

01-13

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

SPECIFICATIONS

Item Travel motor

01 SPECIFICATIONS

Unit -

PC360LC-11E0

PC360NLC-11E0

Variable displacement piston type (HMV180ADT-2) x 2 pcs. (with brake valve and shaft brake)

Swing motor

-

Fixed displacement piston type (KMF160ABE-5) x 1 piece (with safety valve, shaft brake, and reverse prevention valve)

Boom cylinder (*5) Type

-

Double-acting piston type

Cylinder bore

mm

140

Piston rod diameter

mm

100

Stroke

mm

1480

Max. distance between pins

mm

3525

Min. distance between pins

mm

2045

Arm cylinder (*6) Type

-

Double-acting piston type

Cylinder bore

mm

160

Piston rod diameter

mm

110

Stroke

mm

1825

Max. distance between pins

mm

4255

Min. distance between pins

mm

2430

Bucket cylinder Type

-

Double-acting piston type

Cylinder bore

mm

140

Piston rod diameter

mm

100

Stroke

mm

1285

Max. distance between pins

mm

3155

Min. distance between pins

mm

1870

Hydraulic tank

-

Box-shaped sealed type

Hydraulic oil filter

-

Tank return side

Hydraulic oil cooler

-

Air-cooled type (CF40-1)

*5: With cushion on head side. *6: With cushions on head side and bottom side.

01-14

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

WEIGHT TABLE

WEIGHT TABLE WEIGHT TABLE: PC360LC-11E0, PC360NLC-11E0

k This weight table is provided for your reference when handling or transporting the components. k This weight table shows the dry weight.

Unit:: kg Item

PC360LC-11E0

PC360NLC-11E0

Engine assembly

1136

•

Engine

911

•

Damper

14.3

•

Main pump

211

Cooling assembly (excluding hydraulic oil and coolant)

248

Hydraulic tank and filter assembly

190

Fuel tank assembly

236

Revolving frame

3014

Operator cab (including head guard and front half guard)

520

Operator's seat

35

Counterweight

6920

Swing machinery

348

Control valve

224

Swing motor

91

Travel motor

171 x 2

Center swivel joint

30.2

Track frame assembly (excluding track shoes)

8179

8054

4314

4197

•

Track frame

•

Swing circle

•

Idler

164 x 2

•

Idler cushion

276 x 2

•

Carrier roller

27.5 x 4

•

Track roller (single flange)

51.4 x 16

•

Final drive (including travel motor and sprocket)

611 x 2

491

Track shoe assembly Wide triple shoe

4300 (700mm)

3290 (600mm)

Boom assembly

2428

Arm assembly

1094

Bucket assembly

1508

Boom cylinder assembly

261 x 2

Arm cylinder assembly

390

Bucket cylinder assembly

235

PC360LC-11E0, PC360NLC-11E0

01-15

WEIGHT TABLE

01 SPECIFICATIONS

Unit:: kg Item

PC360LC-11E0

PC360NLC-11E0

Bucket link (large) assembly

316

Bucket link (small) assembly

-

Boom foot pin

76

Boom cylinder bottom pin

15 x 2

Boom cylinder head pin

57

Arm cylinder bottom pin

21

Arm cylinder head pin

17

Boom and arm connecting pin

42

Bucket cylinder bottom pin

13

Bucket pin

30 x 2

Bucket link pin

27 x 2

01-16

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

TABLE OF FUEL, COOLANT, AND LUBRICANTS

TABLE OF FUEL, COOLANT, AND LUBRICANTS For details of notes (Note 1, Note 2...) in the table, see the Operation and Maintenance Manual.

Unit: ℓ Location

Specified capacity

Refill capacity

Engine oil system

39.5

38.5

Swing machinery case

16

14

Final drive case (each on right and left sides)

9

9

Damper case

1.3

1.3

Hydraulic oil system

365

188

Cooling system

41

37

Fuel tank

605

-

AdBlue/DEF tank

60

-

PC360LC-11E0, PC360NLC-11E0

01-17

SPECIFICATION DRAWING

01 SPECIFICATIONS

SPECIFICATIONS - PC390HRD-11E0 SPECIFICATION DRAWING SPECIFICATION DRAWING: PC390HRD-11E0 Extended High Reach Demolition (ExHRD)

High Reach Demolition

Medium Reach Demolition Work Equipment (Straight)

Medium Reach Demolition Work Equipment (Cranked)

01-18

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

SPECIFICATION DRAWING

Demolition Digging Work Equipment (Straight)

Demolition Digging Work Equipment (Cranked)

MRD

MRD

Dig Boom Dig Boom

Unit

Ex HRD

HRD

Machine weight (700mm shoe)

kg

55300

52450

52700

52700

44560

44560

Tool capacity

kg

2500

3350

4000

4000

-

-

Bucket capacity

m3

-

-

-

-

1.4

1.4

Engine model

-

Komatsu SAA6D114E-6 diesel engine

Engine power

kW /rpm

202 / 1950 (ISO 14396)

Item

(Straight) (Cranked) (Straight) (Cranked)

192 / 1950 (ISO 9249)

A

Overall length

mm

19530

16530

15705

14860

12680

11930

B

Height (top of boom)

mm

3280

3190

2985

3770

3090

3310

C

Overall width (600mm shoe)

mm

D

Shoe width Shoe width

2890~3390 600

mm

700

E

Height of cab including OPG)

mm

3495

F

Tail swing radius

mm

3800

G

Overall crawler length

mm

5385

H

Distance between tumbler centres

mm

4350

J

Min. ground clearance

mm

683

Travel speed (Lo/Mi/Hi)

km/h

2.8/3.7/4.5

Continuous swing speed

rpm

PC360LC-11E0, PC360NLC-11E0

3.3

9.5

01-19

SPECIFICATION DRAWING

01 SPECIFICATIONS

REMARK The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly the same as that when it is installed on a machine.

01-20

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

SPECIFICATIONS

SPECIFICATIONS SPECIFICATIONS: PC390HRD-11E0 Hydraulic System Item

Unit

PC390HRD-11E0

-

Variable displacement piston type (HPV140 + 140) x 2 pcs.

ℓ/min

267.5 x 2

MPa {kgf/cm2}

37.3 {380}

Type x quantity

-

10 spool type: 1

Operating method

-

Hydraulic type

Hydraulic system Hydraulic pump Type x quantity Discharged volume Set pressure Control valve

Variable displacement piston type Travel motor

-

(HMV180ADT-2) x 2 pcs. (with brake valve and shaft brake) Fixed displacement piston type

Swing motor

-

(KMF160ABE-5) x 1 piece (with safety valve, shaft brake, and reverse prevention valve)

Hydraulic cylinder Boom (*1) Type

-

Double-acting piston type

Cylinder bore

mm

170

Piston rod diameter

mm

110

Stroke

mm

1460

Max. distance between pins

mm

3531

Min. distance between pins

mm

1460

Type

-

Double-acting piston type

Cylinder bore

mm

160

Piston rod diameter

mm

110

Stroke

mm

1745

Max. distance between pins

mm

4175

Min. distance between pins

mm

2430

Type

-

Double-acting piston type

Cylinder bore

mm

140

Piston rod diameter

mm

100

Stroke

mm

1020

Max. distance between pins

mm

2770

HRD Link, HRD Arm (*1), (*2)

HRD Bucket

PC360LC-11E0, PC360NLC-11E0

01-21

SPECIFICATIONS

01 SPECIFICATIONS

Item

Unit

PC390HRD-11E0

Min. distance between pins

mm

1750

Type

-

Double-acting piston type

Cylinder bore

mm

160

Piston rod diameter

mm

110

Stroke

mm

1825

Max. distance between pins

mm

4255

Min. distance between pins

mm

2430

Type

-

Double-acting piston type

Cylinder bore

mm

140

Piston rod diameter

mm

110

Stroke

mm

1285

Max. distance between pins

mm

3155

Min. distance between pins

mm

1870

Hydraulic tank

-

Box-shaped sealed type

Hydraulic oil filter

-

Tank return side

Hydraulic oil cooler

-

Air-cooled type (CF40-1)

Demolition Dig Boom Arm

Demolition Digging Bucket

*1: With cushion on head side. *2: With cushion on bottom side.

01-22

PC360LC-11E0, PC360NLC-11E0

01 SPECIFICATIONS

WEIGHT TABLE

WEIGHT TABLE WEIGHT TABLE: PC390HRD-11E0 HRD Unique Components

k This weight table is provided for your reference when handling or transporting the components. k This weight table shows the dry weight.

Unit:: kg Item

PC390HRD-11E0

Revolving frame

3505

Tilting frame

375

Tilt frame cylinders

33 x 2

Counterweight

6920

Additional counterweight

6150

Control valve

335

HRD Work Equipment First Boom assembly

2365

Second Boom assembly

3140

Link assembly

995

Arm assembly

1545

Boom cylinder assembly

405 x 2

Link cylinder assembly

420

Arm cylinder assembly

420

Bucket cylinder assembly

350

Bucket link assembly

165

First Boom pin Second Boom pin

76 + 13 x 2 + 57 + 18 50 + 21 + 42

Link pin

19 x 2

Arm pin

31 + 19 + 12

Bucket pin

20 x 2

Bucket link pin

17 x 2

Extension Boom Extension Boom assembly

2085

Extension Boom pin

50 + 18

Demolition Digging Work Equipment Digging Boom assembly

2490

Arm assembly

1340

Arm cylinder assembly

420

Bucket cylinder assembly

370

Bucket link assembly

215

PC360LC-11E0, PC360NLC-11E0

01-23

WEIGHT TABLE

01 SPECIFICATIONS

Unit:: kg Item

PC390HRD-11E0

Boom pin

50 + 21 + 42

Arm pin

17 + 13

Bucket pin

29 x 2

Bucket link pin

26 x 2

01-24

PC360LC-11E0, PC360NLC-11E0

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL

• Thank you very much for reading the preview of the manual.

• You can download the complete manual from: www.heydownloads.com by clicking the link below

• Please note: If there is no response to CLICKING the link, please download this PDF first and then click on it.

CLICK HERE TO

DOWNLOAD THE COMPLETE MANUAL