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UENBM00590

HYDRAULIC EXCAVATOR

PC360LC I-11E0 PC360NLCI-11E0 SERIAL NUMBERS

91258 and up K77001 and up

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00 INDEX AND FOREWORD

PC360LCI-11E0

00-1

INDEX

00 INDEX AND FOREWORD

INDEX 00 INDEX AND FOREWORD ........................................................................................................................ 00-1 ABBREVIATION LIST ........................................................................................................................... 00-24 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 PRECAUTIONS FOR DEF............................................................................................................. 00-42 STORE AdBlue/DEF ...................................................................................................................... 00-43 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-44 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-47 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-54 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-56 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-57 PRACTICAL USE OF KOMTRAX .................................................................................................. 00-58 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-59 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-63 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-67 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-68 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-70 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-71 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE . ................................................................................................................................................... 00-73 HOW TO READ ELECTRICAL WIRE CODE ................................................................................. 00-74 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-78 STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-81 CONVERSION TABLE ................................................................................................................... 00-88 01 SPECIFICATIONS .................................................................................................................................... 01-1 CONTENTS ............................................................................................................................................ 01-2 SPECIFICATIONS .................................................................................................................................. 01-3 SPECIFICATION DRAWING............................................................................................................ 01-3 WORKING RANGE DRAWINGS ..................................................................................................... 01-5 SPECIFICATIONS ........................................................................................................................... 01-6 WEIGHT TABLE .............................................................................................................................. 01-9 TABLE OF FUEL, COOLANT, AND LUBRICANTS .........................................................................01-11 10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1 CONTENTS ............................................................................................................................................ 10-2 UREA SCR SYSTEM.............................................................................................................................. 10-7 LAYOUT DRAWING OF UREA SCR SYSTEM ................................................................................ 10-7 UREA SCR SYSTEM DIAGRAM ....................................................................................................10-11 FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-12 COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-22 BOOT-UP SYSTEM .............................................................................................................................. 10-31 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-31 SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-33 BATTERY DISCONNECT SWITCH ............................................................................................... 10-35 ENGINE SYSTEM ................................................................................................................................ 10-36 LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-36 ENGINE CONTROL SYSTEM ....................................................................................................... 10-38 AUTO-DECELERATION SYSTEM ................................................................................................. 10-41 ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-43 OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-45 TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-47 AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-49 00-2

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-52 COOLING SYSTEM.............................................................................................................................. 10-69 LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-69 CONTROL SYSTEM............................................................................................................................. 10-71 LAYOUT DRAWING OF CONTROL SYSTEM ............................................................................... 10-71 MACHINE MONITOR SYSTEM ..................................................................................................... 10-74 KomVision SYSTEM ...................................................................................................................... 10-76 KOMTRAX SYSTEM...................................................................................................................... 10-80 PPC LEVERS ................................................................................................................................ 10-81 AUTOMATIC GREASE SYSTEM ................................................................................................... 10-83 COMPONENT PARTS OF CONTROL SYSTEM............................................................................ 10-95 SENSOR..............................................................................................................................................10-133 STRUCTURE OF AMBIENT PRESSURE SENSOR .....................................................................10-133 FUNCTION OF AMBIENT PRESSURE SENSOR ........................................................................10-134 STRUCTURE OF ENGINE OIL PRESSURE SWITCH .................................................................10-135 FUNCTION OF ENGINE OIL PRESSURE SWITCH .....................................................................10-136 STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR ..................10-137 FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR......................10-138 STRUCTURE OF COOLANT TEMPERATURE SENSOR.............................................................10-139 FUNCTION OF COOLANT TEMPERATURE SENSOR ................................................................10-140 STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR ............................................................10-141 FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR ...............................................................10-142 STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR .............................................................10-143 FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR.................................................................10-144 STRUCTURE OF COMMON RAIL PRESSURE SENSOR ...........................................................10-145 FUNCTION OF COMMON RAIL PRESSURE SENSOR ...............................................................10-146 STRUCTURE OF EGR VALVE LIFT SENSOR .............................................................................10-147 FUNCTION OF EGR VALVE LIFT SENSOR.................................................................................10-148 STRUCTURE OF VGT SPEED SENSOR.....................................................................................10-149 FUNCTION OF KVGT SPEED SENSOR ......................................................................................10-150 STRUCTURE OF KVGT POSITION SENSOR..............................................................................10-151 FUNCTION OF KVGT POSITION SENSOR .................................................................................10-152 STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR .........................................10-153 STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .....10-154 FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR .........10-155 STRUCTURE OF CRANKCASE PRESSURE SENSOR...............................................................10-156 FUNCTION OF CRANKCASE PRESSURE SENSOR ..................................................................10-157 STRUCTURE OF ENGINE OIL LEVEL SENSOR.........................................................................10-158 STRUCTURE OF AIR CLEANER CLOGGING SENSOR .............................................................10-159 FUNCTION OF AIR CLEANER CLOGGING SENSOR .................................................................10-160 STRUCTURE OF WATER-IN-FUEL SENSOR..............................................................................10-161 FUNCTION OF WATER-IN-FUEL SENSOR .................................................................................10-162 STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH .............................10-163 SPECIFICATIONS - QUICK COUPLER LOW PRESSURE WARNING SWITCH..........................10-164 FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH .................................10-165 STRUCTURE OF AUTO GREASE PRESSURE SWITCH ............................................................10-166 SPECIFICATIONS - AUTO GREASE PRESSURE SWITCH.........................................................10-167 FUNCTION OF AUTO GREASE PRESSURE SWITCH................................................................10-168 STRUCTURE OF OVERLOAD CAUTION SENSOR.....................................................................10-169 SPECIFICATIONS - OVERLOAD CAUTION SENSOR .................................................................10-170 FUNCTION OF OVERLOAD CAUTION SENSOR ........................................................................10-171 HYDRAULIC SYSTEM.........................................................................................................................10-172 LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-172 CLSS ............................................................................................................................................10-175 ENGINE AND PUMP COMBINED CONTROL SYSTEM...............................................................10-194 PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-200 COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-203 WORK EQUIPMENT SYSTEM ............................................................................................................10-286 PC360LCI-11E0

00-3

INDEX

00 INDEX AND FOREWORD

LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-286 STRUCTURE OF VALVE CONTROL............................................................................................10-291 BUCKET CONTROL SYSTEM .....................................................................................................10-293 ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-294 MACHINE PUSH-UP SYSTEM .....................................................................................................10-296 PPC LOCK SYSTEM ....................................................................................................................10-298 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-299 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-301 TOOL CONTROL SYSTEM ..........................................................................................................10-303 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-305 ICT SYSTEM .......................................................................................................................................10-328 LAYOUT DRAWING OF ICT SYSTEM..........................................................................................10-328 ICT CONTROL SYSTEM DIAGRAM.............................................................................................10-332 BUCKET EDGE POSITION DETECTION SYSTEM......................................................................10-333 THE INTELLIGENT MACHINE CONTROL SYSTEM....................................................................10-335 CUSHION SYSTEM FOR ARM IN END........................................................................................10-361 CUSHION SYSTEM FOR BOOM RAISE END..............................................................................10-363 BOOM SECONDARY DRIVE SWITCH.........................................................................................10-365 COMPONENT PARTS OF ICT SYSTEM ......................................................................................10-366 SWING SYSTEM .................................................................................................................................10-395 LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-395 SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-398 COMPONENT PARTS OF SWING SYSTEM................................................................................10-402 TRAVEL SYSTEM................................................................................................................................10-416 LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-416 TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-420 COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-422 UNDERCARRIAGE AND FRAME........................................................................................................10-442 LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-442 WORK EQUIPMENT............................................................................................................................10-444 STRUCTURE OF WORK EQUIPMENT ........................................................................................10-444 FUNCTION OF WORK EQUIPMENT ...........................................................................................10-445 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-446 BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-447 CAB AND ITS ATTACHMENTS ...........................................................................................................10-448 ROPS CAB ...................................................................................................................................10-448 CAB MOUNT ................................................................................................................................10-449 CAB TIPPING STOPPER .............................................................................................................10-450 20 STANDARD VALUE TABLE ...................................................................................................................... 20-1 CONTENTS ............................................................................................................................................ 20-2 STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-3 STANDARD VALUE TABLE FOR ENGINE: PC360LCI-11E0 ........................................................... 20-3 STANDARD VALUE TABLE FOR MACHINE........................................................................................... 20-8 STANDARD VALUE TABLE FOR MACHINE: PC360LCI-11E0 ........................................................ 20-8 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-31 30 TESTING AND ADJUSTING ..................................................................................................................... 30-1 CONTENTS ............................................................................................................................................ 30-2 RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................. 30-6 TOOLS FOR TESTING AND ADJUSTING....................................................................................... 30-6 SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-17 ENGINE AND COOLING SYSTEM....................................................................................................... 30-19 TEST ENGINE SPEED .................................................................................................................. 30-19 TEST BOOST PRESSURE............................................................................................................ 30-23 TEST EXHAUST GAS COLOR ...................................................................................................... 30-25 TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-27 TEST COMPRESSION PRESSURE.............................................................................................. 30-30 TEST BLOWBY PRESSURE ......................................................................................................... 30-33 TEST ENGINE OIL PRESSURE .................................................................................................... 30-35 00-4

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

TEST EGR VALVE AND VGT OIL PRESSURE ............................................................................. 30-37 TEST FUEL PRESSURE ............................................................................................................... 30-39 TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-46 BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-53 TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-54 HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-56 HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-57 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-58 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-59 TEST SCR RELATED FUNCTIONS............................................................................................... 30-60 CLEAN AdBlue/DEF TANK ............................................................................................................ 30-85 POWER TRAIN..................................................................................................................................... 30-89 TEST SWING CIRCLE BEARING CLEARANCE ........................................................................... 30-89 UNDERCARRIAGE AND FRAME......................................................................................................... 30-90 TEST AND ADJUST TRACK TENSION......................................................................................... 30-90 HYDRAULIC SYSTEM.......................................................................................................................... 30-92 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................. 30-92 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS ........ ................................................................................................................................................... 30-98 TEST OIL PRESSURE OF CONTROL CIRCUIT .......................................................................... 30-111 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ...................................30-113 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT....................................30-116 TEST OUTLET PRESSURE OF SOLENOID VALVE ....................................................................30-121 TEST PPC VALVE OUTPUT PRESSURE.....................................................................................30-124 TEST ATTACHMENT CIRCUIT OIL PRESSURE..........................................................................30-126 ADJUST WORK EQUIPMENT AND SWING PPC VALVES ..........................................................30-127 TEST PUMP SWASH PLATE SENSOR........................................................................................30-128 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-129 TEST OIL LEAKAGE ....................................................................................................................30-131 BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-134 CAB AND ITS ATTACHMENTS ...........................................................................................................30-139 TEST CAB TIPPING STOPPER ...................................................................................................30-139 METHOD FOR ADJUSTING MIRRORS .......................................................................................30-140 ELECTRICAL SYSTEM .......................................................................................................................30-146 SET AND OPERATE MACHINE MONITOR..................................................................................30-146 METHOD FOR STARTING UP KOMTRAX SYSTEM....................................................................30-253 ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-258 ADJUST KomVision CAMERA ANGLE .........................................................................................30-261 ADJUST KomVision RELATED ITEMS .........................................................................................30-266 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-285 HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-286 TEST DIODES ..............................................................................................................................30-287 ICT SYSTEM .......................................................................................................................................30-288 SET AND OPERATE CONTROL BOX ..........................................................................................30-288 CALIBRATE INTELLIGENT MACHINE CONTROL .......................................................................30-316 Pm CLINIC...........................................................................................................................................30-760 Pm CLINIC SERVICE ...................................................................................................................30-760 40 TROUBLESHOOTING .............................................................................................................................. 40-1 CONTENTS ............................................................................................................................................ 40-2 RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-16 GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-16 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-17 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-29 CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-31 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-33 TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-35 PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM..................................... 40-55 PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-66 PC360LCI-11E0

00-5

INDEX

00 INDEX AND FOREWORD

SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-69 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-74 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................................................................................................ 40-76 CONNECTOR LIST AND LAYOUT ................................................................................................ 40-79 CONNECTOR CONTACT IDENTIFICATION ................................................................................. 40-95 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-135 FUSE LOCATION TABLE .............................................................................................................40-141 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..........................40-144 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])..........................................................................................................................40-148 FAILURE CODES TABLE .............................................................................................................40-150 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-172 FAILURE CODE [879AKA]............................................................................................................40-172 FAILURE CODE [879AKB]............................................................................................................40-173 FAILURE CODE [879BKA]............................................................................................................40-174 FAILURE CODE [879BKB]............................................................................................................40-176 FAILURE CODE [879CKA]............................................................................................................40-178 FAILURE CODE [879CKB]............................................................................................................40-179 FAILURE CODE [879DKZ]............................................................................................................40-180 FAILURE CODE [879EMC] ...........................................................................................................40-182 FAILURE CODE [879FMC] ...........................................................................................................40-183 FAILURE CODE [879GKX] ...........................................................................................................40-184 FAILURE CODE [989L00] .............................................................................................................40-186 FAILURE CODE [989M00] ............................................................................................................40-187 FAILURE CODE [989N00] ............................................................................................................40-188 FAILURE CODE [A1U0N3] ...........................................................................................................40-189 FAILURE CODE [A1U0N4] ...........................................................................................................40-191 FAILURE CODE [A900FR]............................................................................................................40-193 FAILURE CODE [A900N6] ............................................................................................................40-194 FAILURE CODE [A900NY]............................................................................................................40-195 FAILURE CODE [AA10NX] ...........................................................................................................40-196 FAILURE CODE [AB00KE] ...........................................................................................................40-198 FAILURE CODE [AQ10N3] ...........................................................................................................40-201 FAILURE CODE [AS00N3]............................................................................................................40-203 FAILURE CODE [AS00R2]............................................................................................................40-205 FAILURE CODE [AS00R3]............................................................................................................40-206 FAILURE CODE [AS00R4]............................................................................................................40-207 FAILURE CODE [AS00R5]............................................................................................................40-208 FAILURE CODE [AS00R6]............................................................................................................40-209 FAILURE CODE [AS00ZK]............................................................................................................40-210 FAILURE CODE [AS10KM]...........................................................................................................40-211 FAILURE CODE [AS10NR] ...........................................................................................................40-212 FAILURE CODE [AS10NT] ...........................................................................................................40-213 FAILURE CODE [B@BAZG] .........................................................................................................40-214 FAILURE CODE [B@BAZK]..........................................................................................................40-215 FAILURE CODE [B@BCNS] .........................................................................................................40-217 FAILURE CODE [B@BCQA].........................................................................................................40-218 FAILURE CODE [B@BCZK] .........................................................................................................40-220 FAILURE CODE [B@HANS] .........................................................................................................40-222 FAILURE CODE [CA115] ..............................................................................................................40-223 FAILURE CODE [CA122] ..............................................................................................................40-224 FAILURE CODE [CA123] ..............................................................................................................40-226 FAILURE CODE [CA131] ..............................................................................................................40-228 FAILURE CODE [CA132] ..............................................................................................................40-230 FAILURE CODE [CA144] ..............................................................................................................40-232 FAILURE CODE [CA145] ..............................................................................................................40-234 FAILURE CODE [CA153] ..............................................................................................................40-236 00-6

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [CA154] ..............................................................................................................40-239 FAILURE CODE [CA187] ..............................................................................................................40-242 FAILURE CODE [CA221] ..............................................................................................................40-244 FAILURE CODE [CA222] ..............................................................................................................40-246 FAILURE CODE [CA227] ..............................................................................................................40-248 FAILURE CODE [CA234] ..............................................................................................................40-249 FAILURE CODE [CA238] ..............................................................................................................40-250 FAILURE CODE [CA239] ..............................................................................................................40-252 FAILURE CODE [CA249] ..............................................................................................................40-254 FAILURE CODE [CA256] ..............................................................................................................40-256 FAILURE CODE [CA271] ..............................................................................................................40-258 FAILURE CODE [CA272] ..............................................................................................................40-260 FAILURE CODE [CA281] ..............................................................................................................40-262 FAILURE CODE [CA322] ..............................................................................................................40-263 FAILURE CODE [CA323] ..............................................................................................................40-265 FAILURE CODE [CA324] ..............................................................................................................40-267 FAILURE CODE [CA325] ..............................................................................................................40-269 FAILURE CODE [CA331] ..............................................................................................................40-271 FAILURE CODE [CA332] ..............................................................................................................40-273 FAILURE CODE [CA343] ..............................................................................................................40-275 FAILURE CODE [CA351] ..............................................................................................................40-276 FAILURE CODE [CA352] ..............................................................................................................40-277 FAILURE CODE [CA356] ..............................................................................................................40-280 FAILURE CODE [CA357] ..............................................................................................................40-282 FAILURE CODE [CA386] ..............................................................................................................40-284 FAILURE CODE [CA428] ..............................................................................................................40-285 FAILURE CODE [CA429] ..............................................................................................................40-287 FAILURE CODE [CA435] ..............................................................................................................40-289 FAILURE CODE [CA441] ..............................................................................................................40-291 FAILURE CODE [CA442] ..............................................................................................................40-293 FAILURE CODE [CA449] ..............................................................................................................40-294 FAILURE CODE [CA451] ..............................................................................................................40-298 FAILURE CODE [CA452] ..............................................................................................................40-301 FAILURE CODE [CA488] ..............................................................................................................40-303 FAILURE CODE [CA515] ..............................................................................................................40-304 FAILURE CODE [CA516] ..............................................................................................................40-306 FAILURE CODE [CA553] ..............................................................................................................40-308 FAILURE CODE [CA555] ..............................................................................................................40-309 FAILURE CODE [CA556] ..............................................................................................................40-310 FAILURE CODE [CA559] ..............................................................................................................40-311 FAILURE CODE [CA595] ..............................................................................................................40-315 FAILURE CODE [CA687] ..............................................................................................................40-316 FAILURE CODE [CA689] ..............................................................................................................40-318 FAILURE CODE [CA691] ..............................................................................................................40-323 FAILURE CODE [CA692] ..............................................................................................................40-325 FAILURE CODE [CA697] ..............................................................................................................40-327 FAILURE CODE [CA698] ..............................................................................................................40-328 FAILURE CODE [CA731] ..............................................................................................................40-329 FAILURE CODE [CA778] ..............................................................................................................40-331 FAILURE CODE [CA1117] ............................................................................................................40-336 FAILURE CODE [CA1664] ............................................................................................................40-337 FAILURE CODE [CA1669] ............................................................................................................40-339 FAILURE CODE [CA1673] ............................................................................................................40-340 FAILURE CODE [CA1677] ............................................................................................................40-341 FAILURE CODE [CA1678] ............................................................................................................40-342 FAILURE CODE [CA1682] ............................................................................................................40-343 FAILURE CODE [CA1683] ............................................................................................................40-345 FAILURE CODE [CA1684] ............................................................................................................40-347 PC360LCI-11E0

00-7

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [CA1686] ............................................................................................................40-349 FAILURE CODE [CA1691] ............................................................................................................40-350 FAILURE CODE [CA1694] ............................................................................................................40-353 FAILURE CODE [CA1695] ............................................................................................................40-356 FAILURE CODE [CA1696] ............................................................................................................40-357 FAILURE CODE [CA1712] ............................................................................................................40-359 FAILURE CODE [CA1713] ............................................................................................................40-362 FAILURE CODE [CA1714] ............................................................................................................40-364 FAILURE CODE [CA1715] ............................................................................................................40-365 FAILURE CODE [CA1776] ............................................................................................................40-366 FAILURE CODE [CA1777] ............................................................................................................40-369 FAILURE CODE [CA1843] ............................................................................................................40-372 FAILURE CODE [CA1844] ............................................................................................................40-374 FAILURE CODE [CA1879] ............................................................................................................40-377 FAILURE CODE [CA1881] ............................................................................................................40-380 FAILURE CODE [CA1883] ............................................................................................................40-382 FAILURE CODE [CA1885] ............................................................................................................40-385 FAILURE CODE [CA1887] ............................................................................................................40-387 FAILURE CODE [CA1921] ............................................................................................................40-389 FAILURE CODE [CA1922] ............................................................................................................40-392 FAILURE CODE [CA1942] ............................................................................................................40-397 FAILURE CODE [CA1993] ............................................................................................................40-398 FAILURE CODE [CA2185] ............................................................................................................40-401 FAILURE CODE [CA2186] ............................................................................................................40-403 FAILURE CODE [CA2249] ............................................................................................................40-405 FAILURE CODE [CA2265] ............................................................................................................40-406 FAILURE CODE [CA2266] ............................................................................................................40-408 FAILURE CODE [CA2271] ............................................................................................................40-410 FAILURE CODE [CA2272] ............................................................................................................40-413 FAILURE CODE [CA2288] ............................................................................................................40-416 FAILURE CODE [CA2311] ............................................................................................................40-417 FAILURE CODE [CA2349] ............................................................................................................40-418 FAILURE CODE [CA2353] ............................................................................................................40-421 FAILURE CODE [CA2357] ............................................................................................................40-423 FAILURE CODE [CA2381] ............................................................................................................40-424 FAILURE CODE [CA2382] ............................................................................................................40-427 FAILURE CODE [CA2383] ............................................................................................................40-430 FAILURE CODE [CA2386] ............................................................................................................40-433 FAILURE CODE [CA2387] ............................................................................................................40-435 FAILURE CODE [CA2555] ............................................................................................................40-436 FAILURE CODE [CA2556] ............................................................................................................40-439 FAILURE CODE [CA2637] ............................................................................................................40-442 FAILURE CODE [CA2639] ............................................................................................................40-444 FAILURE CODE [CA2771] ............................................................................................................40-447 FAILURE CODE [CA2777] ............................................................................................................40-453 FAILURE CODE [CA2976] ............................................................................................................40-456 FAILURE CODE [CA3133] ............................................................................................................40-458 FAILURE CODE [CA3134] ............................................................................................................40-460 FAILURE CODE [CA3135] ............................................................................................................40-462 FAILURE CODE [CA3142] ............................................................................................................40-465 FAILURE CODE [CA3143] ............................................................................................................40-466 FAILURE CODE [CA3144] ............................................................................................................40-467 FAILURE CODE [CA3146] ............................................................................................................40-469 FAILURE CODE [CA3147] ............................................................................................................40-470 FAILURE CODE [CA3148] ............................................................................................................40-471 FAILURE CODE [CA3151] ............................................................................................................40-473 FAILURE CODE [CA3165] ............................................................................................................40-479 FAILURE CODE [CA3229] ............................................................................................................40-481 00-8

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [CA3231] ............................................................................................................40-483 FAILURE CODE [CA3232] ............................................................................................................40-485 FAILURE CODE [CA3235] ............................................................................................................40-489 FAILURE CODE [CA3239] ............................................................................................................40-491 FAILURE CODE [CA3241] ............................................................................................................40-494 FAILURE CODE [CA3242] ............................................................................................................40-497 FAILURE CODE [CA3251] ............................................................................................................40-500 FAILURE CODE [CA3253] ............................................................................................................40-502 FAILURE CODE [CA3254] ............................................................................................................40-505 FAILURE CODE [CA3255] ............................................................................................................40-508 FAILURE CODE [CA3256] ............................................................................................................40-512 FAILURE CODE [CA3311] ............................................................................................................40-514 FAILURE CODE [CA3312] ............................................................................................................40-516 FAILURE CODE [CA3313] ............................................................................................................40-519 FAILURE CODE [CA3314] ............................................................................................................40-520 FAILURE CODE [CA3315] ............................................................................................................40-521 FAILURE CODE [CA3316] ............................................................................................................40-523 FAILURE CODE [CA3317] ............................................................................................................40-524 FAILURE CODE [CA3318] ............................................................................................................40-525 FAILURE CODE [CA3319] ............................................................................................................40-527 FAILURE CODE [CA3321] ............................................................................................................40-528 FAILURE CODE [CA3322] ............................................................................................................40-530 FAILURE CODE [CA3419] ............................................................................................................40-532 FAILURE CODE [CA3421] ............................................................................................................40-534 FAILURE CODE [CA3497] ............................................................................................................40-536 FAILURE CODE [CA3498] ............................................................................................................40-537 FAILURE CODE [CA3543] ............................................................................................................40-538 FAILURE CODE [CA3545] ............................................................................................................40-545 FAILURE CODE [CA3547] ............................................................................................................40-547 FAILURE CODE [CA3558] ............................................................................................................40-548 FAILURE CODE [CA3559] ............................................................................................................40-550 FAILURE CODE [CA3562] ............................................................................................................40-552 FAILURE CODE [CA3563] ............................................................................................................40-554 FAILURE CODE [CA3567] ............................................................................................................40-557 FAILURE CODE [CA3568] ............................................................................................................40-560 FAILURE CODE [CA3571] ............................................................................................................40-564 FAILURE CODE [CA3572] ............................................................................................................40-566 FAILURE CODE [CA3574] ............................................................................................................40-568 FAILURE CODE [CA3575] ............................................................................................................40-570 FAILURE CODE [CA3577] ............................................................................................................40-572 FAILURE CODE [CA3578] ............................................................................................................40-574 FAILURE CODE [CA3582] ............................................................................................................40-576 FAILURE CODE [CA3583] ............................................................................................................40-582 FAILURE CODE [CA3596] ............................................................................................................40-584 FAILURE CODE [CA3649] ............................................................................................................40-586 FAILURE CODE [CA3681] ............................................................................................................40-588 FAILURE CODE [CA3682] ............................................................................................................40-593 FAILURE CODE [CA3713] ............................................................................................................40-599 FAILURE CODE [CA3717] ............................................................................................................40-602 FAILURE CODE [CA3718] ............................................................................................................40-603 FAILURE CODE [CA3725] ............................................................................................................40-604 FAILURE CODE [CA3741] ............................................................................................................40-607 FAILURE CODE [CA3748] ............................................................................................................40-608 FAILURE CODE [CA3751] ............................................................................................................40-610 FAILURE CODE [CA3755] ............................................................................................................40-612 FAILURE CODE [CA3866] ............................................................................................................40-614 FAILURE CODE [CA3867] ............................................................................................................40-618 FAILURE CODE [CA3868] ............................................................................................................40-621 PC360LCI-11E0

00-9

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [CA3899] ............................................................................................................40-625 FAILURE CODE [CA3911] ............................................................................................................40-627 FAILURE CODE [CA3912] ............................................................................................................40-631 FAILURE CODE [CA3932] ............................................................................................................40-633 FAILURE CODE [CA3933] ............................................................................................................40-635 FAILURE CODE [CA3934] ............................................................................................................40-637 FAILURE CODE [CA3935] ............................................................................................................40-640 FAILURE CODE [CA3936] ............................................................................................................40-642 FAILURE CODE [CA4151] ............................................................................................................40-644 FAILURE CODE [CA4152] ............................................................................................................40-648 FAILURE CODE [CA4155] ............................................................................................................40-652 FAILURE CODE [CA4156] ............................................................................................................40-654 FAILURE CODE [CA4157] ............................................................................................................40-657 FAILURE CODE [CA4158] ............................................................................................................40-659 FAILURE CODE [CA4159] ............................................................................................................40-660 FAILURE CODE [CA4161] ............................................................................................................40-661 FAILURE CODE [CA4162] ............................................................................................................40-664 FAILURE CODE [CA4163] ............................................................................................................40-667 FAILURE CODE [CA4164] ............................................................................................................40-669 FAILURE CODE [CA4165] ............................................................................................................40-671 FAILURE CODE [CA4166] ............................................................................................................40-673 FAILURE CODE [CA4168] ............................................................................................................40-675 FAILURE CODE [CA4169] ............................................................................................................40-678 FAILURE CODE [CA4171] ............................................................................................................40-680 FAILURE CODE [CA4249] ............................................................................................................40-683 FAILURE CODE [CA4251] ............................................................................................................40-685 FAILURE CODE [CA4259] ............................................................................................................40-687 FAILURE CODE [CA4261] ............................................................................................................40-690 FAILURE CODE [CA4277] ............................................................................................................40-693 FAILURE CODE [CA4281] ............................................................................................................40-697 FAILURE CODE [CA4459] ............................................................................................................40-700 FAILURE CODE [CA4461] ............................................................................................................40-703 FAILURE CODE [CA4658] ............................................................................................................40-706 FAILURE CODE [CA4731] ............................................................................................................40-710 FAILURE CODE [CA4732] ............................................................................................................40-711 FAILURE CODE [CA4739] ............................................................................................................40-712 FAILURE CODE [CA4768] ............................................................................................................40-713 FAILURE CODE [CA4769] ............................................................................................................40-715 FAILURE CODE [CA4842] ............................................................................................................40-718 FAILURE CODE [CA4952] ............................................................................................................40-722 FAILURE CODE [CA5115] ............................................................................................................40-724 FAILURE CODE [CA5179] ............................................................................................................40-727 FAILURE CODE [CA5181] ............................................................................................................40-729 FAILURE CODE [CA5383] ............................................................................................................40-731 FAILURE CODE [D110KB]............................................................................................................40-733 FAILURE CODE [D19JKZ] ............................................................................................................40-735 FAILURE CODE [D1M3KA]...........................................................................................................40-737 FAILURE CODE [D1M3KB]...........................................................................................................40-739 FAILURE CODE [D1M3KY]...........................................................................................................40-741 FAILURE CODE [D1M3MA] ..........................................................................................................40-743 FAILURE CODE [D1M4KA]...........................................................................................................40-744 FAILURE CODE [D1M4KB]...........................................................................................................40-746 FAILURE CODE [D1M4KY]...........................................................................................................40-748 FAILURE CODE [D1M5KA]...........................................................................................................40-749 FAILURE CODE [D1M5KB]...........................................................................................................40-751 FAILURE CODE [D1M5KY]...........................................................................................................40-753 FAILURE CODE [D1M5MA] ..........................................................................................................40-755 FAILURE CODE [D811MC] ...........................................................................................................40-756 00-10

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [D862KA]............................................................................................................40-757 FAILURE CODE [D8ALKA] ...........................................................................................................40-759 FAILURE CODE [D8ALKB] ...........................................................................................................40-762 FAILURE CODE [D8AQKR] ..........................................................................................................40-764 FAILURE CODE [D8G1KT] ...........................................................................................................40-772 FAILURE CODE [D8G6KT] ...........................................................................................................40-773 FAILURE CODE [DA20MC] ..........................................................................................................40-774 FAILURE CODE [DA22KK] ...........................................................................................................40-775 FAILURE CODE [DA25KP] ...........................................................................................................40-778 FAILURE CODE [DA29KQ]...........................................................................................................40-781 FAILURE CODE [DA2LKA] ...........................................................................................................40-783 FAILURE CODE [DA2LKB] ...........................................................................................................40-786 FAILURE CODE [DA2QKR] ..........................................................................................................40-788 FAILURE CODE [DA2RKR] ..........................................................................................................40-798 FAILURE CODE [DAF0KM] ..........................................................................................................40-807 FAILURE CODE [DAF0MB] ..........................................................................................................40-808 FAILURE CODE [DAF0MC] ..........................................................................................................40-809 FAILURE CODE [DAF8KB] ...........................................................................................................40-810 FAILURE CODE [DAF9KQ]...........................................................................................................40-812 FAILURE CODE [DAFGMC] .........................................................................................................40-813 FAILURE CODE [DAFLKA] ...........................................................................................................40-814 FAILURE CODE [DAFLKB] ...........................................................................................................40-817 FAILURE CODE [DAFQKR] ..........................................................................................................40-819 FAILURE CODE [DAZ9KQ]...........................................................................................................40-828 FAILURE CODE [DAZQKR] ..........................................................................................................40-829 FAILURE CODE [DB2QKR] ..........................................................................................................40-834 FAILURE CODE [DB2RKR] ..........................................................................................................40-843 FAILURE CODE [DB90MC] ..........................................................................................................40-851 FAILURE CODE [DB92KK] ...........................................................................................................40-852 FAILURE CODE [DB95KP] ...........................................................................................................40-854 FAILURE CODE [DB96KP] ...........................................................................................................40-858 FAILURE CODE [DB99KQ]...........................................................................................................40-862 FAILURE CODE [DB9LKA] ...........................................................................................................40-865 FAILURE CODE [DB9LKB] ...........................................................................................................40-867 FAILURE CODE [DB9QKR] ..........................................................................................................40-869 FAILURE CODE [DB9RKR] ..........................................................................................................40-875 FAILURE CODE [DBP0KM] ..........................................................................................................40-884 FAILURE CODE [DBP0KT] ...........................................................................................................40-885 FAILURE CODE [DBP5KB]...........................................................................................................40-886 FAILURE CODE [DBP5KY]...........................................................................................................40-889 FAILURE CODE [DBPQKR]..........................................................................................................40-892 FAILURE CODE [DBR0MC]..........................................................................................................40-901 FAILURE CODE [DBR2KK]...........................................................................................................40-902 FAILURE CODE [DBR5KP]...........................................................................................................40-905 FAILURE CODE [DBR6KP]...........................................................................................................40-907 FAILURE CODE [DBR9KQ] ..........................................................................................................40-909 FAILURE CODE [DBRLKA]...........................................................................................................40-912 FAILURE CODE [DBRLKB]...........................................................................................................40-914 FAILURE CODE [DBRQKR]..........................................................................................................40-916 FAILURE CODE [DBRRKR]..........................................................................................................40-922 FAILURE CODE [DBRSKB] ..........................................................................................................40-931 FAILURE CODE [DBRTKB] ..........................................................................................................40-933 FAILURE CODE [DBUSKR] ..........................................................................................................40-935 FAILURE CODE [DBUSKR] ..........................................................................................................40-939 FAILURE CODE [DD20MA] ..........................................................................................................40-943 FAILURE CODE [DDNRKA]..........................................................................................................40-946 FAILURE CODE [DDNRKY]..........................................................................................................40-948 FAILURE CODE [DDNS00]...........................................................................................................40-950 PC360LCI-11E0

00-11

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [DFB1KZ] ...........................................................................................................40-952 FAILURE CODE [DFB2KZ] ...........................................................................................................40-954 FAILURE CODE [DFB3L8]............................................................................................................40-956 FAILURE CODE [DFB4L8]............................................................................................................40-958 FAILURE CODE [DFB5KZ] ...........................................................................................................40-960 FAILURE CODE [DFB6KZ] ...........................................................................................................40-962 FAILURE CODE [DGH2KA] ..........................................................................................................40-964 FAILURE CODE [DGH2KB] ..........................................................................................................40-966 FAILURE CODE [DGH2KB] ..........................................................................................................40-968 FAILURE CODE [DHA4KA]...........................................................................................................40-970 FAILURE CODE [DHAAMA]..........................................................................................................40-972 FAILURE CODE [DHACMA] .........................................................................................................40-974 FAILURE CODE [DHPAMA]..........................................................................................................40-976 FAILURE CODE [DHPBMA]..........................................................................................................40-979 FAILURE CODE [DHS3MA] ..........................................................................................................40-982 FAILURE CODE [DHS4MA] ..........................................................................................................40-985 FAILURE CODE [DHS8MA] ..........................................................................................................40-988 FAILURE CODE [DHS9MA] ..........................................................................................................40-991 FAILURE CODE [DHSAMA]..........................................................................................................40-994 FAILURE CODE [DHSBMA]..........................................................................................................40-997 FAILURE CODE [DHSCMA] .......................................................................................................40-1000 FAILURE CODE [DHSDMA] .......................................................................................................40-1003 FAILURE CODE [DHSFMA]........................................................................................................40-1006 FAILURE CODE [DHSGMA] .......................................................................................................40-1009 FAILURE CODE [DHSHMA] .......................................................................................................40-1012 FAILURE CODE [DHSJMA] ........................................................................................................40-1015 FAILURE CODE [DHUXMA] .......................................................................................................40-1018 FAILURE CODE [DHUYMA] .......................................................................................................40-1020 FAILURE CODE [DHZAMA]........................................................................................................40-1022 FAILURE CODE [DHZCL8] .........................................................................................................40-1026 FAILURE CODE [DHZAMA]........................................................................................................40-1027 FAILURE CODE [DHZCL8] .........................................................................................................40-1031 FAILURE CODE [DK80KM].........................................................................................................40-1032 FAILURE CODE [DK80KR] .........................................................................................................40-1033 FAILURE CODE [DK80KT] .........................................................................................................40-1038 FAILURE CODE [DK8DKB].........................................................................................................40-1039 FAILURE CODE [DK8CKT].........................................................................................................40-1041 FAILURE CODE [DK8CKR] ........................................................................................................40-1042 FAILURE CODE [DKG1KM]........................................................................................................40-1046 FAILURE CODE [DKG1L8] .........................................................................................................40-1047 FAILURE CODE [DKR0MA] ........................................................................................................40-1048 FAILURE CODE [DKR1MA] ........................................................................................................40-1051 FAILURE CODE [DKT0KM] ........................................................................................................40-1054 FAILURE CODE [DKT0L8]..........................................................................................................40-1055 FAILURE CODE [DKT1KA] .........................................................................................................40-1056 FAILURE CODE [DKT1KB] .........................................................................................................40-1058 FAILURE CODE [DKT2KA] .........................................................................................................40-1060 FAILURE CODE [DKT2KB] .........................................................................................................40-1062 FAILURE CODE [DKT4KM] ........................................................................................................40-1064 FAILURE CODE [DKT4L8]..........................................................................................................40-1065 FAILURE CODE [DKT5KA] .........................................................................................................40-1066 FAILURE CODE [DKT5KB] .........................................................................................................40-1068 FAILURE CODE [DKT6KA] .........................................................................................................40-1070 FAILURE CODE [DKT6KB] .........................................................................................................40-1072 FAILURE CODE [DKT8KA] .........................................................................................................40-1074 FAILURE CODE [DKT8KB] .........................................................................................................40-1076 FAILURE CODE [DKT9KA] .........................................................................................................40-1078 FAILURE CODE [DKT9KB] .........................................................................................................40-1080 00-12

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [DKTAKA].........................................................................................................40-1082 FAILURE CODE [DKTAKB].........................................................................................................40-1084 FAILURE CODE [DKTAMB] ........................................................................................................40-1086 FAILURE CODE [DKTBKX].........................................................................................................40-1087 FAILURE CODE [DKTBMC]........................................................................................................40-1089 FAILURE CODE [DKTEMB] ........................................................................................................40-1090 FAILURE CODE [DKTFKX].........................................................................................................40-1092 FAILURE CODE [DKTFMC] ........................................................................................................40-1094 FAILURE CODE [DKTJMB].........................................................................................................40-1095 FAILURE CODE [DKTUL8] .........................................................................................................40-1097 FAILURE CODE [DKTVKA].........................................................................................................40-1098 FAILURE CODE [DKTVKB].........................................................................................................40-1100 FAILURE CODE [DKTWKA]........................................................................................................40-1101 FAILURE CODE [DKTWKB]........................................................................................................40-1103 FAILURE CODE [DKU1MA] ........................................................................................................40-1104 FAILURE CODE [DKU2MA] ........................................................................................................40-1105 FAILURE CODE [DKUGKA]........................................................................................................40-1106 FAILURE CODE [DKUGKB]........................................................................................................40-1108 FAILURE CODE [DKUGKY]........................................................................................................ 40-1110 FAILURE CODE [DKUHKA] ........................................................................................................ 40-1112 FAILURE CODE [DKUHKB] ........................................................................................................ 40-1114 FAILURE CODE [DKUHKY] ........................................................................................................ 40-1116 FAILURE CODE [DKULKA]......................................................................................................... 40-1118 FAILURE CODE [DKULKB].........................................................................................................40-1120 FAILURE CODE [DKULKY].........................................................................................................40-1122 FAILURE CODE [DKV0KA].........................................................................................................40-1124 FAILURE CODE [DKV0KY].........................................................................................................40-1127 FAILURE CODE [DKV1KA].........................................................................................................40-1129 FAILURE CODE [DKV1KY].........................................................................................................40-1131 FAILURE CODE [DKV2KA].........................................................................................................40-1133 FAILURE CODE [DKV2KY].........................................................................................................40-1135 FAILURE CODE [DKV3KA].........................................................................................................40-1137 FAILURE CODE [DKV3KY].........................................................................................................40-1139 FAILURE CODE [DKV4MA] ........................................................................................................40-1141 FAILURE CODE [DKV5MA] ........................................................................................................40-1144 FAILURE CODE [DKV6MA] ........................................................................................................40-1147 FAILURE CODE [DKV7MA] ........................................................................................................40-1150 FAILURE CODE [DKV8MA] ........................................................................................................40-1153 FAILURE CODE [DKV9MA] ........................................................................................................40-1156 FAILURE CODE [DKVAMA] ........................................................................................................40-1159 FAILURE CODE [DKVBKA] ........................................................................................................40-1162 FAILURE CODE [DKVBKB] ........................................................................................................40-1164 FAILURE CODE [DKVBKY] ........................................................................................................40-1166 FAILURE CODE [DKVCKA] ........................................................................................................40-1168 FAILURE CODE [DKVCKB] ........................................................................................................40-1170 FAILURE CODE [DKVCKY] ........................................................................................................40-1172 FAILURE CODE [DKVDKA] ........................................................................................................40-1174 FAILURE CODE [DKVDKB] ........................................................................................................40-1176 FAILURE CODE [DKVDKY] ........................................................................................................40-1178 FAILURE CODE [DKVDMA]........................................................................................................40-1180 FAILURE CODE [DKVLMA] ........................................................................................................40-1181 FAILURE CODE [DKVMMA] .......................................................................................................40-1184 FAILURE CODE [DKVNKX] ........................................................................................................40-1187 FAILURE CODE [DKVNL8] .........................................................................................................40-1188 FAILURE CODE [DKVKKX] ........................................................................................................40-1189 FAILURE CODE [DKVKL8] .........................................................................................................40-1190 FAILURE CODE [DKVPMA]........................................................................................................40-1191 FAILURE CODE [DKVQMA] .......................................................................................................40-1194 PC360LCI-11E0

00-13

INDEX

00 INDEX AND FOREWORD

FAILURE CODE [DR10KA] .........................................................................................................40-1197 FAILURE CODE [DR12KA] .........................................................................................................40-1200 FAILURE CODE [DR20KA] .........................................................................................................40-1202 FAILURE CODE [DR21KX] .........................................................................................................40-1204 FAILURE CODE [DR30KA] .........................................................................................................40-1206 FAILURE CODE [DR31KX] .........................................................................................................40-1208 FAILURE CODE [DR40KA] .........................................................................................................40-1210 FAILURE CODE [DUMBKA]........................................................................................................40-1212 FAILURE CODE [DUMBKB]........................................................................................................40-1215 FAILURE CODE [DV20KB] .........................................................................................................40-1217 FAILURE CODE [DW43KA] ........................................................................................................40-1219 FAILURE CODE [DW43KB] ........................................................................................................40-1221 FAILURE CODE [DW43KY] ........................................................................................................40-1223 FAILURE CODE [DW45KA] ........................................................................................................40-1225 FAILURE CODE [DW45KB] ........................................................................................................40-1228 FAILURE CODE [DW45KY] ........................................................................................................40-1231 FAILURE CODE [DW4CKY]........................................................................................................40-1233 FAILURE CODE [DW4FKA] ........................................................................................................40-1234 FAILURE CODE [DW4FKB] ........................................................................................................40-1237 FAILURE CODE [DW4FKY] ........................................................................................................40-1239 FAILURE CODE [DW4GKA] .......................................................................................................40-1241 FAILURE CODE [DW4GKB] .......................................................................................................40-1244 FAILURE CODE [DW4GKY] .......................................................................................................40-1246 FAILURE CODE [DW4SKA]........................................................................................................40-1248 FAILURE CODE [DW4SKB]........................................................................................................40-1250 FAILURE CODE [DW4SKY]........................................................................................................40-1252 FAILURE CODE [DW91KA] ........................................................................................................40-1254 FAILURE CODE [DW91KB] ........................................................................................................40-1256 FAILURE CODE [DW91KY] ........................................................................................................40-1258 FAILURE CODE [DWA2KA] ........................................................................................................40-1260 FAILURE CODE [DWA2KB] ........................................................................................................40-1262 FAILURE CODE [DWA2KY] ........................................................................................................40-1264 FAILURE CODE [DWK0KA]........................................................................................................40-1266 FAILURE CODE [DWK0KB]........................................................................................................40-1268 FAILURE CODE [DWK0KY]........................................................................................................40-1270 FAILURE CODE [DWK2KA]........................................................................................................40-1272 FAILURE CODE [DWK2KB]........................................................................................................40-1274 FAILURE CODE [DWK2KY]........................................................................................................40-1276 FAILURE CODE [DWK8KA]........................................................................................................40-1278 FAILURE CODE [DWK8KB]........................................................................................................40-1280 FAILURE CODE [DWK8KY]........................................................................................................40-1282 FAILURE CODE [DWPUKA] .......................................................................................................40-1284 FAILURE CODE [DWPUKB] .......................................................................................................40-1286 FAILURE CODE [DWPUKY] .......................................................................................................40-1288 FAILURE CODE [DXA8KA].........................................................................................................40-1290 FAILURE CODE [DXA8KB].........................................................................................................40-1293 FAILURE CODE [DXA9KA].........................................................................................................40-1295 FAILURE CODE [DXA9KB].........................................................................................................40-1298 FAILURE CODE [DXE0KA].........................................................................................................40-1300 FAILURE CODE [DXE0KB].........................................................................................................40-1302 FAILURE CODE [DXE4KA].........................................................................................................40-1304 FAILURE CODE [DXE4KB].........................................................................................................40-1306 FAILURE CODE [DXE4KY].........................................................................................................40-1308 FAILURE CODE [DXE5KA].........................................................................................................40-1309 FAILURE CODE [DXE5KB].........................................................................................................40-1311 FAILURE CODE [DXE6KA].........................................................................................................40-1313 FAILURE CODE [DXE6KB].........................................................................................................40-1315 FAILURE CODE [DXE7KA].........................................................................................................40-1317 00-14

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

FAILURE CODE [DXE7KB].........................................................................................................40-1319 FAILURE CODE [DXE7KY].........................................................................................................40-1321 FAILURE CODE [DXE8KA].........................................................................................................40-1323 FAILURE CODE [DXE8KB].........................................................................................................40-1325 FAILURE CODE [DXE8KY].........................................................................................................40-1327 FAILURE CODE [DXE9KA].........................................................................................................40-1329 FAILURE CODE [DXE9KB].........................................................................................................40-1331 FAILURE CODE [DXE9KY].........................................................................................................40-1333 FAILURE CODE [DXEAKA] ........................................................................................................40-1335 FAILURE CODE [DXEAKB] ........................................................................................................40-1337 FAILURE CODE [DXEAKY] ........................................................................................................40-1339 FAILURE CODE [DXEKKA] ........................................................................................................40-1341 FAILURE CODE [DXEKKB] ........................................................................................................40-1343 FAILURE CODE [DXEKKY] ........................................................................................................40-1345 FAILURE CODE [DXELKA].........................................................................................................40-1347 FAILURE CODE [DXELKB].........................................................................................................40-1349 FAILURE CODE [DXELKY].........................................................................................................40-1351 FAILURE CODE [DXRWKA] .......................................................................................................40-1353 FAILURE CODE [DXRWKB] .......................................................................................................40-1355 FAILURE CODE [DXRWKY] .......................................................................................................40-1357 FAILURE CODE [DXRXKA] ........................................................................................................40-1359 FAILURE CODE [DXRXKB] ........................................................................................................40-1361 FAILURE CODE [DXRXKY] ........................................................................................................40-1363 FAILURE CODE [DY20KA] .........................................................................................................40-1365 FAILURE CODE [DY20MA].........................................................................................................40-1368 FAILURE CODE [DY2CKB].........................................................................................................40-1370 FAILURE CODE [DY2DKB].........................................................................................................40-1373 FAILURE CODE [DY2EKB].........................................................................................................40-1375 FAILURE CODE [F313KA] ..........................................................................................................40-1377 FAILURE CODE [F313KB] ..........................................................................................................40-1379 FAILURE CODE [F318KB] ..........................................................................................................40-1382 FAILURE CODE [F318KY] ..........................................................................................................40-1385 FAILURE CODE [F7FQKR].........................................................................................................40-1387 FAILURE CODE [F7G0MC] ........................................................................................................40-1396 FAILURE CODE [H16SL8] ..........................................................................................................40-1397 FAILURE CODE [H17SL8] ..........................................................................................................40-1399 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .........................................................40-1401 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ..............................................40-1401 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK........................................................40-1407 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ..................................................40-1410 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP.....40-1412 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING................................................................................................................................40-1414 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW ...........................................................40-1417 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW .................................................40-1418 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .......................................................................................................................................40-1419 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .......................................................................................................................................40-1420 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING... ................................................................................................................................................40-1421 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............40-1422 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................40-1423 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ......40-1424 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......................................................................................................................................40-1425 PC360LCI-11E0

00-15

INDEX

00 INDEX AND FOREWORD

E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1426 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......................................................................................................................................40-1427 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .................40-1428 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...............................40-1430 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.........................................................................................................................40-1431 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE..............................................................................................................40-1432 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ...............................................................................................................................40-1433 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .............................................................................................................................40-1435 E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ......................40-1436 E-24 FUNCTION SWITCH DOES NOT OPERATE .....................................................................40-1437 E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)..................40-1438 E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF ....................................................................40-1439 E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ....................40-1440 E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED ....................................................................................................................40-1441 E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED ......................................................................................................................40-1442 E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .................................................................................................................................40-1443 E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE .................................................................................................................................40-1444 E-32 ALARM BUZZER CANNOT BE CANCELED ......................................................................40-1446 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION......... ................................................................................................................................................40-1447 E-34 SERVICE MODE CANNOT BE SELECTED .......................................................................40-1448 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ....40-1449 E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK........40-1451 E-37 BUCKET DOES NOT MOVE WITH AUTO TILT FUNCTION ..............................................40-1452 E-38 MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED ..................................................................................................................................40-1453 E-39 WHILE SWING PARKING BRAKE RELEASE SWITCH IS TURNED ON, SWING BRAKE IS NOT OPERATED.............................................................................................................................40-1456 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR SHOWS NOTHING .........................................................................................................40-1458 E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED..............................40-1461 E-42 TRAVEL ALARM DOES NOT OPERATE DURING TRAVEL ..............................................40-1462 E-43 TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS.........................................40-1464 E-44 HORN DOES NOT MAKE SOUND.....................................................................................40-1465 E-45 HORN DOES NOT STOP SOUNDING...............................................................................40-1469 E-46 WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED . ................................................................................................................................................40-1471 E-47 WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED ...........................40-1472 E-48 WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED ...........................................................................................................................................40-1474 E-49 "BOOM RAISE" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION ...........40-1475 E-50 "BOOM LOWER" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .........40-1476 E-51 "ARM OUT" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION..................40-1477 E-52 "ARM IN" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .....................40-1478 E-53 BUCKET DUMP IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...........40-1479 E-54 "BUCKET CURL" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .........40-1480 E-55 "SWING" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION......................40-1481 E-56 "TRAVEL" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION ....................40-1482 00-16

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

E-57 SERVICE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .....................40-1483 E-58 ATTACHMENT CIRCUIT CANNOT BE CHANGED ............................................................40-1485 E-59 KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY...............................................40-1486 E-60 MACHINE PUSH-UP FUNCTION IS NOT CANCELED......................................................40-1487 E-61 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................40-1489 E-62 CONTROL BOX SHOWS THE MESSAGE [GPS RECEIVER NOT CONNECTED!] AND [SLOPE SENSOR NOT CONNECTED!], AND THEN SHUTS DOWN. .................................................40-1490 E-1 CONTROL BOX DISPLAYS THE MESSAGE [GPS receiver not connected!] .......................40-1493 E-64 CONTROL BOX SHOWS THE MESSAGE [WAITING FOR RADIO LINK] .........................40-1496 E-65 CONTROL BOX SHOWS THE MESSAGE [TILT BUCKET SENSOR OFFLINE!]...............40-1497 E-66 CONTROL BOX SHOWS THE MESSAGE [WAITING FOR SATELLITES...]......................40-1498 E-67 CONTROL BOX SHOWS THE MESSAGE [KOMATSU CONTROLLER NOT CONNECTED]......... ................................................................................................................................................40-1499 E-68 CONTROL BOX SHOWS THE MESSAGE [SENSORS ARE INVALID]..............................40-1502 E-69 CONTROL BOX SHOWS THE MESSAGE [WAITING TO INITIALIZE....]...........................40-1505 E-70 CONTROL BOX SHOWS THE MESSAGE [WAITING TO INITIALIZE....]...........................40-1506 E-71 CONTROL BOX SHOWS THE MESSAGE [LOCALIZATION ERROR]...............................40-1507 E-72 CONTROL BOX SHOWS THE MESSAGE [LOW PRECISIONS...]. ...................................40-1508 E-73 CONTROL BOX SHOWS THE MESSAGE [OUT OF DESIGN AREA] ...............................40-1509 E-74 CONTROL BOX SHOWS THE MESSAGE [AVOIDANCE AREA BREACH!]. .....................40-1510 E-75 CONTROL BOX SHOWS THE MESSAGE [HIGH CPU LOAD - CHECK DATA] ................40-1511 E-76 CONTROL BOX CANNOT BE TURNED ON ......................................................................40-1512 E-77 CONTROL BOX DOES NOT SHOW INTELLIGENT MACHINE CONTROL SCREEN .......40-1513 E-78 CONTROL BOX DOES NOT SHOW HYDRAULIC EXCAVATOR IMAGE. .........................40-1514 E-79 CONTROL BOX DOES NOT SHOW DESIGN SURFACE ..................................................40-1515 E-80 CONTROL BOX TOUCH PANEL DOES NOT RESPOND..................................................40-1516 E-81 TOUCH PANEL COORDINATES OF CONTROL BOX DOES NOT MATCH.......................40-1517 E-82 WHEN YOU CHECK AND ADJUST BUCKET BLADE EDGE POSITION, VALUE IS DIFFERENT LARGELY ................................................................................................................................40-1518 E-83 "SEMI-AUTO MODE" IS NOT SHOWN WHEN AUTO/MANUAL SWITCH IS PUSHED. ....40-1520 E-84 "SEMI-AUTO MODE" IS SHOWN BUT AUTO GRADE ASSIST FUNCTION DOES NOT WORK. .. ................................................................................................................................................40-1521 E-85 "SEMI-AUTO MODE" IS SHOWN BUT THE AUTO STOP CONTROL DOES NOT WORK.40-1522 E-86 "SEMI-AUTO MODE" IS SHOWN BUT THE WORKING MODE ICON IS NOT SHOWN....40-1523 E-87 BUCKET ANGLE HOLD CONTROL DOES NOT OPERATE..............................................40-1524 E-88 BLADE EDGE POSITION ON DESIGN SURFACE IS NOT ACCURATE WHEN AUTO GRADE ASSIST FUNCTION IS ON......................................................................................................40-1525 E-89 BLADE EDGE STOP POSITION IS NOT ACCURATE FOR DESIGN SURFACE WHEN AUTO STOP CONTROL FUNCTION IS ON ......................................................................................40-1527 E-90 FACING ANGLE COMPASS DOES NOT BECOME PERPENDICULAR TO TARGET .......40-1529 E-91 NG OCCURS FREQUENTLY IN IMU CALIBRATION DIAGNOSIS ....................................40-1530 E-92 CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK. ............................40-1531 E-93 CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK .......................................40-1532 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1535 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1535 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS ..........................................40-1536 FAILURE MODE AND CAUSE TABLE........................................................................................40-1538 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK......................................40-1549 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER ..................40-1550 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR............................................40-1553 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ..................................40-1554 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ..................................................40-1555 H-6 SPEED OR POWER OF BOOM IS LOW .............................................................................40-1557 H-7 ARM SPEED OR POWER IS LOW ......................................................................................40-1563 H-8 BUCKET SPEED OR POWER IS LOW................................................................................40-1568 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .....................................40-1572 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE ........................................................................40-1573 H-11 HYDRAULIC DRIFT OF ARM IS LARGE ...........................................................................40-1575 PC360LCI-11E0

00-17

INDEX

00 INDEX AND FOREWORD

H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................40-1577 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES ........................................................................................................................40-1578 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE .................................................................40-1579 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .........................40-1580 H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................40-1581 H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................40-1582 H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .....................................40-1583 H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER ...................................................................................................................40-1584 H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY ...... ................................................................................................................................................40-1585 H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW .... ................................................................................................................................................40-1586 H-22 MACHINE DOES NOT TRAVEL STRAIGHT ......................................................................40-1587 H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.............................40-1589 H-24 TRAVEL SPEED IS LOW ...................................................................................................40-1592 H-25 ONE OF TRACKS DOES NOT RUN ..................................................................................40-1594 H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ..40-1596 H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .................40-1597 H-28 SWINGS ONLY IN ONE DIRECTION.................................................................................40-1598 H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) ......................................................................................................................................40-1599 H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION ....................................................................................................................40-1600 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..................................................................................................................40-1601 H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)..................................................................................40-1602 H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .............................40-1603 H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING40-1604 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)40-1605 H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) ........ ................................................................................................................................................40-1606 TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1607 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1607 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION....... ................................................................................................................................................40-1608 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1609 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) ........................................................................................................40-1610 S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1612 S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1614 S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1616 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1618 S-8 ENGINE LACKS POWER.....................................................................................................40-1619 S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1621 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1623 S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1624 S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1625 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) ....... ................................................................................................................................................40-1626 S-14 OIL PRESSURE DROPS ...................................................................................................40-1627 S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1629 S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1630 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1631 S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1632 S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1633 00-18

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1634 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1635 S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1637 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1638 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1639 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1641 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1642 50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1 CONTENTS ............................................................................................................................................ 50-2 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .......................................................... 50-8 HOW TO READ THIS MANUAL....................................................................................................... 50-8 COATING MATERIALS LIST.......................................................................................................... 50-10 SPECIAL TOOLS LIST .................................................................................................................. 50-14 SKETCHES OF SPECIAL TOOLS................................................................................................. 50-29 ENGINE AND COOLING SYSTEM....................................................................................................... 50-38 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-38 REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-51 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-70 REMOVE AND INSTALL EGR VALVE ASSEMBLY........................................................................ 50-98 REMOVE AND INSTALL EGR COOLER ASSEMBLY...................................................................50-101 REMOVE AND INSTALL STARTER ASSEMBLY ..........................................................................50-105 REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-107 REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-113 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-117 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-122 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY ...............................................50-125 REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-153 REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-161 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-170 REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-175 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-184 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-195 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-208 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-210 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER............................................50-211 REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-216 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-223 REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-232 REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-238 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET ......................................................50-252 REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-260 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-263 REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-271 REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-278 REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-284 REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-299 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-303 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-306 POWER TRAIN....................................................................................................................................50-308 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-308 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-311 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................50-324 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-327 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-338 UNDERCARRIAGE AND FRAME........................................................................................................50-340 SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-340 REMOVE AND INSTALL SPROCKET ..........................................................................................50-345 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-347 PC360LCI-11E0

00-19

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INDEX

00 INDEX AND FOREWORD

DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-349 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-354 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-357 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................50-361 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-365 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-372 HYDRAULIC SYSTEM.........................................................................................................................50-376 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-376 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-380 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-383 REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-393 REMOVE AND INSTALL JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL... ..................................................................................................................................................50-399 REMOVE AND INSTALL PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL .......50-404 REMOVE AND INSTALL BOOM SPOOL STROKE SENSOR ......................................................50-410 REMOVE AND INSTALL ARM SPOOL STROKE SENSOR .........................................................50-412 REMOVE AND INSTALL JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL.................................................................................................................................50-416 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-420 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-432 REMOVE AND INSTALL ATT BYPASS SOLENOID .....................................................................50-439 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-444 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-447 WORK EQUIPMENT............................................................................................................................50-450 REMOVE AND INSTALL BUCKET ASSEMBLY............................................................................50-450 REMOVE AND INSTALL ARM ASSEMBLY ..................................................................................50-452 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-458 DISASSEMBLE AND ASSEMBLE STROKE SENSING BOOM CYLINDER ASSEMBLY..............50-467 DISASSEMBLE AND ASSEMBLE STROKE SENSING ARM CYLINDER ASSEMBLY ................50-480 DISASSEMBLE AND ASSEMBLE STROKE SENSING BUCKET CYLINDER ASSEMBLY ..........50-495 CAB AND ITS ATTACHMENTS ...........................................................................................................50-512 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-512 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-535 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-547 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-556 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-570 REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-585 REMOVE AND INSTALL SEAT BELT ...........................................................................................50-591 REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-593 ELECTRICAL SYSTEM .......................................................................................................................50-608 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-608 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-614 REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY ................................50-626 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY ................................................50-631 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-634 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ..........................................................50-641 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-643 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-645 REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-647 REMOVE AND INSTALL REARVIEW CAMERA ...........................................................................50-650 REMOVE AND INSTALL KomVision CAMERA .............................................................................50-653 REMOVE AND INSTALL GATEWAY CONTROLLER ASSEMBLY ................................................50-656 REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS ............................50-671 REMOVE AND INSTALL COMMUNICATION TERMINAL.............................................................50-694 REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY ...........................................50-698 REMOVE AND INSTALL JUNCTION HARNESS OF CONTROL BOX .........................................50-704 REMOVE AND INSTALL CONTROL BOX HARNESS ..................................................................50-709 REMOVE AND INSTALL GNSS RECEIVER.................................................................................50-710 00-20

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

REMOVE AND INSTALL NETWORK MODEM .............................................................................50-711 REMOVE AND INSTALL NETWORK RADIO................................................................................50-712 REMOVE AND INSTALL GNSS RECEIVER ANTENNA ...............................................................50-717 REMOVE AND INSTALL NETWORK MODEM ANTENNA ...........................................................50-720 REMOVE AND INSTALL GNSS ANTENNA ..................................................................................50-722 REMOVE AND INSTALL IMU SENSOR .......................................................................................50-725 60 MAINTENANCE STANDARD.................................................................................................................... 60-1 CONTENTS ............................................................................................................................................ 60-2 ENGINE AND COOLING SYSTEM......................................................................................................... 60-3 MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-3 MAINTENANCE STANDARD OF COOLING SYSTEM .................................................................... 60-5 POWER TRAIN....................................................................................................................................... 60-7 MAINTENANCE STANDARD OF SWING CIRCLE .......................................................................... 60-7 MAINTENANCE STANDARD OF SWING MACHINERY.................................................................. 60-8 MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-10 MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-12 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING......... 60-13 UNDERCARRIAGE AND FRAME......................................................................................................... 60-15 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-15 MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-17 MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-19 MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-21 MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-22 MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-25 HYDRAULIC SYSTEM.......................................................................................................................... 60-26 MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-26 MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-27 MAINTENANCE STANDARD OF SWING MOTOR........................................................................ 60-29 MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-32 MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-35 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-47 MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-50 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-53 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE ..................................... 60-56 MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-58 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE ........................... 60-59 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-60 WORK EQUIPMENT............................................................................................................................. 60-61 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-61 MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-70 MAINTENANCE STANDARD OF STROKE SENSING BOOM CYLINDER .................................... 60-71 MAINTENANCE STANDARD OF STROKE SENSING ARM CYLINDER....................................... 60-73 MAINTENANCE STANDARD OF STROKE SENSING BUCKET CYLINDER ................................ 60-75 MAINTENANCE STANDARD OF STROKE SENSOR FOR BOOM CYLINDER ............................ 60-77 MAINTENANCE STANDARD OF STROKE SENSOR FOR ARM CYLINDER ............................... 60-78 MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BUCKET CYLINDER.... 60-79 80 APPENDIX................................................................................................................................................ 80-1 CONTENTS ............................................................................................................................................ 80-2 AIR CONDITIONER SYSTEM ................................................................................................................ 80-4 PRECAUTIONS FOR REFRIGERANT ............................................................................................ 80-4 AIR CONDITIONER COMPONENT ................................................................................................. 80-5 SPECIFICATIONS OF AIR CONDITIONER ..................................................................................... 80-7 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................... 80-8 OUTLINE OF REFRIGERATION CYCLE ......................................................................................... 80-9 COMPONENT PARTS OF AIR CONDITIONER SYSTEM .....................................................................80-11 AIR CONDITIONER UNIT...............................................................................................................80-11 COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-15 AIR CONDITIONER CONTROLLER .............................................................................................. 80-19 PC360LCI-11E0

00-21

INDEX

00 INDEX AND FOREWORD

COMPRESSOR ............................................................................................................................. 80-20 CONDENSER ................................................................................................................................ 80-21 RECEIVER DRIER......................................................................................................................... 80-22 SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-23 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...... .......................................................................................................................................................... 80-25 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-27 AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-29 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-30 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .. .......................................................................................................................................................... 80-32 TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-36 METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-36 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................ 80-37 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR .......................................................................................................... 80-38 TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-39 METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-39 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-40 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-40 TEST SUNLIGHT SENSOR.................................................................................................................. 80-41 METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-41 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.................................................................. 80-42 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................ 80-42 TEST RELAYS...................................................................................................................................... 80-43 METHOD FOR TESTING RELAYS ................................................................................................ 80-43 AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-44 AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-45 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-48 FAILURE CODE [879AKA].................................................................................................................... 80-50 FAILURE CODE [879AKB].................................................................................................................... 80-51 FAILURE CODE [879BKA].................................................................................................................... 80-52 FAILURE CODE [879BKB].................................................................................................................... 80-54 FAILURE CODE [879CKA].................................................................................................................... 80-56 FAILURE CODE [879CKB].................................................................................................................... 80-57 FAILURE CODE [879DKZ].................................................................................................................... 80-58 FAILURE CODE [879EMC] ................................................................................................................... 80-60 FAILURE CODE [879FMC] ................................................................................................................... 80-61 FAILURE CODE [879GKX] ................................................................................................................... 80-62 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE). .......................................................................................................................................................... 80-64 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)... .......................................................................................................................................................... 80-66 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) ..................................................................................................................................... 80-69 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-71 TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-73 CONNECTION OF SERVICE TOOL ..................................................................................................... 80-76 METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-76 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...................................................................................................................................... 80-78 HANDLE COMPRESSOR OIL .............................................................................................................. 80-80 90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1 CONTENTS ............................................................................................................................................ 90-2 HOW TO READ THE CODES FOR ELECTRIC CABLE ......................................................................... 90-3 HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-7 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-7 HYDRAULIC CIRCUIT DIAGRAM (1/4) ..........................................................................................90-11 00-22

PC360LCI-11E0

00 INDEX AND FOREWORD

INDEX

HYDRAULIC CIRCUIT DIAGRAM (2/4) ......................................................................................... 90-13 HYDRAULIC CIRCUIT DIAGRAM (3/4) ......................................................................................... 90-15 HYDRAULIC CIRCUIT DIAGRAM (4/4) ........................................................................................ 90-17 ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-19 SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM ................................................................... 90-19 ELECTRICAL CIRCUIT DIAGRAM (1/15)...................................................................................... 90-23 ELECTRICAL CIRCUIT DIAGRAM (2/15)...................................................................................... 90-25 ELECTRICAL CIRCUIT DIAGRAM (3/15)...................................................................................... 90-27 ELECTRICAL CIRCUIT DIAGRAM (4/15)...................................................................................... 90-29 ELECTRICAL CIRCUIT DIAGRAM (5/15)...................................................................................... 90-31 ELECTRICAL CIRCUIT DIAGRAM (6/15)...................................................................................... 90-33 ELECTRICAL CIRCUIT DIAGRAM (7/15)...................................................................................... 90-35 ELECTRICAL CIRCUIT DIAGRAM (8/15)...................................................................................... 90-37 ELECTRICAL CIRCUIT DIAGRAM (9/15)...................................................................................... 90-39 ELECTRICAL CIRCUIT DIAGRAM (10/15).................................................................................... 90-41 ELECTRICAL CIRCUIT DIAGRAM (11/15) .................................................................................... 90-43 ELECTRICAL CIRCUIT DIAGRAM (12/15).................................................................................... 90-45 ELECTRICAL CIRCUIT DIAGRAM (13/15).................................................................................... 90-47 ELECTRICAL CIRCUIT DIAGRAM (14/15).................................................................................... 90-49 ELECTRICAL CIRCUIT DIAGRAM (15/15) .................................................................................... 90-51 INDEX..................................................................................................................................................................1

PC360LCI-11E0

00-23

ABBREVIATION LIST

00 INDEX AND FOREWORD

ABBREVIATION LIST •

This list of abbreviations includes the abbreviations for functions, devices, and parts which are used in the shop manual.

•

Commonly used abbreviations are not included.

•

Special abbreviations which are not shown frequently are included in the text as additional information.

List of abbreviations used in the text Abbreviation

Actual word spelled out

Explanation

API

American Petroleum Institute

API is the abbreviation for American Petroleum Institute.

BOC

Bolt-On Cutting edge

BOC is a cutting edge that is attached with bolts to the bucket.

CAN

Controller Area Network

CAN is one of networks that communicate between the machine monitor and controllers.

CDR valve

Crankcase Depression Regulator valve

CDR valve is a valve that is attached to the KCCV ventilator.

CLSS

Closed-center Load Sensing System

CLSS is a hydraulic system that provides total control over the pumps, valves, and actuators. When actuators are in neutral, pump circuits are closed.

CRI

Common Rail Injection

CRI is a function that is composed of the supply pump, common rail, and injector, and that controls the fuel injection rate and injection timing.

DEF

Diesel Exhaust Fluid

DEF is a urea solution that is used for the SCR system.

ECM

Electronic Control Module

ECM is an electronic device that controls actuators adequately with signals from sensors.

ECU

Electronic Control Unit

ECU is an electronic device that controls actuators adequately with signals from sensors.

EGR

Exhaust Gas Recirculation

EGR is a function that recirculates part of exhaust gas to the intake side to control NOx emissions.

EPC

Electromagnetic Proportional Control

EPC is a function that controls the pressure of the hydraulic circuit in proportion to the electric current.

EPC

Electrical Pressure Control

EPC is a function that controls the pressure of the hydraulic circuit in proportion to the electric current.

FOPS

Falling Object Protective Structure

FOPS is a structure that protects operators from falling objects.

GNSS

Global Navigation Satellite System

GNSS is a general term for satellite positioning systems.

GPS

Global Positioning System

GPS is one of satellite positioning systems.

IMA

Inlet Metering Actuator

IMA is a device that controls fuel intake volume at the inlet of the supply pump.

IMU

Inertial Measurement Unit

IMU is a device that senses the angles (or angular velocity) and acceleration of the three axes.

IMV

Inlet Metering Valve

IMV is a device that controls fuel intake volume at the inlet of the supply pump.

KCCV

KOMATSU Closed Crankcase Ventilation

KCCV is a function that isolates oil from blowby gas in the engine and returns the blowby gas to the intake side.

KCSF

KOMATSU Catalyzed Soot Filter KCSF is a filter that catches soot in exhaust gas.

KDOC

KOMATSU Diesel Oxidation CatKDOC is a device that purifies exhaust gas. alyst

00-24

PC360LCI-11E0

00 INDEX AND FOREWORD

Abbreviation

ABBREVIATION LIST

Actual word spelled out

Explanation

KDPF

KOMATSU Diesel Particulate Fil- KDPF is a device that is composed of the KCSF and KDOC, and ter catches soot (Particulate Matter, PM) in exhaust gas.

KOWA

Komatsu Oil and Wear Analysis

KOWA is a preventive maintenance service that collects and analyzes oil in the machine at the specified interval so that wear of the machine and other problems can be found at short time.

LIN

Local Interconnect Network

LIN is one of networks that communicate between controllers and sensors or actuators.

Load Sensing

LS is a function that senses the load pressure of actuators and controls hydraulic pumps.

Mass Air Flow sensor

MAF sensor is a device that measures the engine intake air flow.

Normally Closed

NC is an electrical circuit where contact pair is closed while the device is not in operation.

Normally Open

NO is an electrical circuit where contact pair is open while the device is not in operation.

OLSS

Open-center Load Sensing System

OLSS is a hydraulic system that provides total control over the pumps, valves, and actuators. When actuators are in neutral, pump circuits are open.

OPG

Operator Protective Guards

OPG is a structure that protects operators from falling objects.

Pressure Compensation

PC is a function that controls discharged volume of the hydraulic pump by use of the discharged pressure.

PCV

Pressure Control Valve

PCV is a device that controls fuel discharged volume at the outlet of the supply pump.

PPC

Proportional Pressure Control

PPC is a function that controls the pressure of the hydraulic circuit in proportion to the degree of the lever operation.

PTO

Power Take Off

PTO is a mechanism that takes out the engine power.

ROPS

Roll-Over Protective Structure

ROPS is a structure that protects operators from falling objects or in the event of a machine roll-over.

SCR

Selective Catalytic Reduction

SCR is a device that purifies nitrogen oxides (NOx) in exhaust gas from the engine.

TOPS

Tip-Over Protectuive Structure

TOPS is a protection structure that protects operators in the event of a machine tip-over.

VGT

Variable Geometry Turbocharger VGT is a variable type turbocharger.

MAF sensor

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

Battery Relay

Clockwise

CCW

Counter Clockwise

PC360LCI-11E0

00-25

ABBREVIATION LIST

Abbreviation

Actual word spelled out

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actuator

No Connection

S/T STRG

Steering

SIG

Signal

SOL

Solenoid

STD

Standard

OPT OP

Option

PRESS

Pressure

SPEC

Specification

Switch

TEMP

Temperature

T/C

Torque Converter

T/M

Transmission

00-26

00 INDEX AND FOREWORD

PC360LCI-11E0

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.

PC360LCI-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

PC360LCI-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 of dust glasses (for cleaning or grinding work)

•

Wear of welding goggles and protectors (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.

PC360LCI-11E0

00-29

SAFETY NOTICE FOR OPERATION

00 INDEX AND FOREWORD

•

Always wear the protective eyeglasses when hitting parts with a hammer.

•

Always wear the protective eyeglasses 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 it or replace it 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

PC360LCI-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 cap of oil filter, drain plug, or oil pressure plug, it should be done slowly otherwise the oil spills.

•

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.

PC360LCI-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 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.

•

Keep putting on gloves during sling work. (Put on leather gloves, if available.)

•

Measure the weight of the load by the eye 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

PC360LCI-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 kgf} 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 {4000kgf} . •

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 traveling crane k When raising a heavy component (heavier than 25 kg), use a hoist or crane.

PC360LCI-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} )

8.8 {0.9}

12.7 {1.3}

17.3 {1.7}

22.6 {2.3}

28.6 {2.9}

35.3 {3.6}

55.3 {5.6}

79.6 {8.1}

141.6 {14.4}

221.6 {22.6}

318.3 {32.4}

PC360LCI-11E0

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 Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-

lecting 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).

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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

PC360LCI-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.

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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

PC360LCI-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.

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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

PC360LCI-11E0

00 INDEX AND FOREWORD

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS This machine complies with either regulation Tier4 Final (North America) or Stage IV (EU) (until 2018), Stage V (EU) (after 2019). 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).

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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.

00-42

PC360LCI-11E0

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.

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00-43

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 device which have been removed to prevent foreign material from entering and oil from flowing out. 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. REMARK Cover the places tightly with caps, tapes, or plastic bags if it is hard to provide the plugs.

00-44

PC360LCI-11E0

00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

Preventing intrusion of foreign materials during refilling •

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

•

Clean the oil filler port and its around, refilling pump, oil jug, or etc.

•

Refilling by using an oil cleaning device is better method since 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.

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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.

00-46

PC360LCI-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.

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00-47

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)

07376-70210

02789-00210

02896-11008

07376-70315

02789-00315

02896-11009

07376-70422

02789-00422

02896-11012

07376-70522

02789-00522

02896-11015

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)

07376-50210

07222-00210

07376-50315

07222-00312

07376-50422

07222-00414

07376-50522

07222-00515

07376-50628

07222-00616

07376-51034

07222-01018

07376-51234

07222-01219

07376-51443

07222-01422

Nominal No.

00-48

PC360LCI-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

Flange (1)

38.1

17.5

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

42.9

19.8

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

47.6

22.2

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

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

88.9

50.8

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

106.4

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

120.6

69.8

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

130.2

77.8

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

152.4

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

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

PC360LCI-11E0

00-49

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PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

00 INDEX AND FOREWORD

Nominal No.

Plug (1)

O-ring (2)

07040-10807

07002-10823

07040-11007

07002-11023

07040-11209

07002-11223

07040-11409

07002-11423

07040-11612

07002-11623

07040-11812

07002-11823

07040-12012

07002-12034

07040-12412

07002-12434

07041-13012

07002-13034

07040-13316

07002-13334

07041-13612

07002-13634

07040-14220

07002-14234

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)

R1/8

07042-00108

07043-00108

R1/4

07042-00211

07043-00211

R3/8

07042-00312

07043-00312

R1/2

07042-00415

07043-00415

R3/4

07042-00617

07043-00617

07042-01019

07043-01019

R11/4

07042-01222

07043-01222

R11/2

07042-01422

07043-01422

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.

00-50

PC360LCI-11E0

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.

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.

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

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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. 00-52

PC360LCI-11E0

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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”.

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00-53

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 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 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.

00-54

PC360LCI-11E0

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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. Drying the drenched connector or take appropriate actions before providing electricity.

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.

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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.

00-56

PC360LCI-11E0

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PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT The machines equipped with Variable Geometry Turbocharger (VGT) 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.

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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.

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

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.

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

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.

00-58

PC360LCI-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).

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

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).

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DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

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.

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

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.

00-60

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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.

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.

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.

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00-61

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.

00-62

PC360LCI-11E0

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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.

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.

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.

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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.

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.

00-64

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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.

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.

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.

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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.

00-66

PC360LCI-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)

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.

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00-67

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.

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).

00-68

PC360LCI-11E0

00 INDEX AND FOREWORD

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.

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00-69

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”.

00-70

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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.

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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.

00-72

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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.

Turn housing (H1) clockwise until it clicks.

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00-73

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

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

00-74

AEX

Heat-resistant crosslinked polyethylene

-50 to +110

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

PC360LCI-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)

Number of strands

Diameter of strand

0.18

0.32

0.18

0.32

0.18

0.32

0.26

0.32

0.26

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

2.3

2.4

3.0

AVS

Standard

2.0

2.2

2.5

2.9

3.5

3.6

Standard

4.6

AEX

Standard

2.0

2.2

2.7

3.0

3.1

3.8

4.6

Nominal No.

100

Number of strands

108

127

169

217

Diameter of strand

0.45

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

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

Diameter of strand

round compression

Cross-sectional area (mm2)

0.56

0.88

1.29

d (approx.)

0.9

1.1

1.4

PC360LCI-11E0

round compression

00-75

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

Black

LgW

Light green and White

Brown

LgY

Light green and Yellow

BrB

Brown and Black

Blue and Red

BrR

Brown and Red

Blue and White

BrW

Brown and White

Blue and Yellow

BrY

Brown and Yellow

Orange

Charcoal

Pink

Dark green

Red

Green

Red and Black

Green and Black

Red and Green

Green and Blue

Red and Blue

Gray

Red and White

Green and Red

Red and Yellow

Green and White

Sky Blue

Green and Yellow

Yellow

Blue

Yellow and Black

Blue and Black

Yellow and Green

Light green

Yellow and Blue

LgB

Light green and Black

Yellow and Red

LgR

Light green and Red

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”.

00-76

PC360LCI-11E0

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HOW TO READ ELECTRICAL WIRE CODE

Types of circuits and color codes Type of wire

AVS, AV, CAVS

AEX

Charge

Ground

Start

Light

Instrument

Signal

BrW

BrR

BrY

BrB

LgR

LgY

LgB

LgW

Type of circuit

Others

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00-77

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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

00-78

Tolerance Shaft

Hole

-0.030

+0.046

-0.076

PC360LCI-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.

PC360LCI-11E0

00-79

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.

00-80

PC360LCI-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

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}

320 to 400 {33 to 41}

455 to 565 {46.5 to 58}

610 to 765 {62.5 to 78}

785 to 980 {80 to 100}

1150 to 1440 {118 to 147}

1520 to 1910 {155 to 195}

1960 to 2450 {200 to 250}

2450 to 3040 {250 to 310}

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.

PC360LCI-11E0

00-81

STANDARD TIGHTENING TORQUE TABLE

Thread diameter (mm)

Width across flats (mm)

00 INDEX AND FOREWORD

Tightening torque (Nm {kgfm} )

5.9 to 9.8 {0.6 to 1.0}

13.7 to 23.5 {1.4 to 2.4}

34.3 to 46.1 {3.5 to 4.7}

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.

Type of bolt Nominal size threads per inch

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}

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

00-82

PC360LCI-11E0

00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

Type of bolt Nominal size threads per inch

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

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}

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}

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}

PC360LCI-11E0

00-83

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)

03, 04

05, 06

10, 12

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.

00-84

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

Tightening torque (Nm {kgfm} ) Range

Target

5.88 to 8.82 {0.6 to 0.9}

7.35 {0.75}

9.8 to 12.74 {1.0 to 1.3}

11.27 {1.15}

14.7 to 19.6 {1.5 to 2.0}

17.64 {1.8}

19.6 to 24.5 {2.0 to 2.5}

22.54 {2.3}

24.5 to 34.3 {2.5 to 3.5}

29.4 {3.0}

PC360LCI-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

34.3 to 44.1 {3.5 to 4.5}

39.2 {4.0}

44.1 to 53.9 {4.5 to 5.5}

49.0 {5.0}

58.8 to 78.4 {6.0 to 8.0}

68.6 {7.0}

93.1 to 122.5 {9.5 to 12.5}

107.8 {11.0}

107.8 to 147.0 {11.0 to 15.0}

127.4 {13.0}

127.4 to 176.4 {13.0 to 18.0}

151.9 {15.5}

181.3 to 240.1 {18.5 to 24.5}

210.7 {21.5}

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)

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}

54 to 93 {5.5 to 9.5}

74 {7.5}

59 to 98 {6.0 to 10.0}

78 {8.0}

84 to 132 {8.5 to 13.5}

16-18UN

14.3

16-16UN

17.5

103 {10.5}

13/ -16UN 16

20.6

128 to 186 {13.0 to 19.0}

157 {16.0}

1 -14UNS

25.4

177 to 245 {18.0 to 25.0}

216 {22.0}

13/16-12UN

30.2

(10)

177 to 245 {18.0 to 25.0}

216 {22.0}

(12)

197 to 294 {20.0 to 30.0}

245 {25.0}

(14)

246 to 343 {25.0 to 35.0}

294 {30.0}

PC360LCI-11E0

11/

00-85

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)

Tightening torque (Nm {kgfm} )

Face seal Nominal size threads per inch

Thread root diameter(mm) (reference)

Range

Target

14 to 16 {1.4 to 1.6}

15 {1.5}

16-18UN

14.3

24 to 27 {2.4 to 2.7}

25.5 {2.6}

11/ -16UN 16

17.5

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)

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} )

10±2 {1.02±0.20}

24±4 {2.45±0.41}

43±6 {4.38±0.61}

77±12 {7.85±1.22}

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.

00-86

PC360LCI-11E0

00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE

Thread diameter (mm)

Tightening torque (Nm {kgfm} )

8±2 {0.81±0.20}

10±2 {1.02±0.20}

12±2 {1.22±0.20}

24±4 {2.45±0.41}

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} )

15±2 {1.53±0.20}

5±1 {0.51±0.10}

20±2 {2.04±0.20}

15±2 {1.53±0.20}

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}

55±6 {5.61±0.61}

35±4 {3.57±0.41}

75±8 {7.65±0.82}

45±5 {4.59±0.51}

PC360LCI-11E0

00-87

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).

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

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.017

2.087

2.126

2.165

2.205

2.244

2.283

2.323

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.847

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

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

0.039

0.079

0.118

0.157

0.197

0.236

0.276

0.315

0.354

0.394

0.433

0.472

0.512

0.551

0.591

0.630

0.669

0.709

0.748

0.787

0.827

0.866

0.906

0.945

0.984

1.024

1.063

1.102

1.142

1.181

1.220

1.260

1.299

1.339

1.378

1.417

1.457

1.496

1.536

1.575

1.614

1.654

1.693

1.732

1.772

1.811

1.850

1.890

1.929

1.969

2.008

2.047

2.087

2.126

2.165

2.205

2.244

2.283

2.323

00-88

PC360LCI-11E0

00 INDEX AND FOREWORD

CONVERSION TABLE

1 mm = 0.03937 in 0

2.362

2.402

2.441

2.480

2.520

2.559

2.598

2.638

2.677

2.717

2.756

2.795

2.835

2.847

2.913

2.953

2.992

3.032

3.071

3.110

3.150

3.189

3.228

3.268

3.307

3.346

3.386

3.425

3.465

3.504

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

2.20

4.41

6.61

8.82

11.02

13.23

15.43

17.64

19.84

22.05

24.25

26.46

28.66

30.86

33.07

35.27

37.48

39.68

41.89

44.09

46.30

48.50

50.71

51.91

55.12

57.32

59.53

61.73

63.93

66.14

68.34

70.55

72.75

74.96

77.16

79.37

81.57

83.78

85.98

88.18

90.39

92.59

94.80

97.00

99.21

101.41

103.62

105.82

108.03

110.23

112.44

114.64

116.85

119.05

121.25

123.46

125.66

127.87

130.07

132.28

134.48

136.69

138.89

141.10

143.30

145.51

147.71

149.91

152.12

154.32

156.53

158.73

160.94

163.14

165.35

167.55

169.76

171.96

174.17

176.37

178.57

180.78

182.98

185.19

187.39

189.60

191.80

194.01

196.21

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

0.264

0.528

0.793

1.057

1.321

1.585

1.849

2.113

2.378

2.642

2.906

3.170

3.434

3.698

3.963

4.227

4.491

4.755

5.019

5.283

5.548

5.812

6.076

6.340

6.604

6.869

7.133

7.397

7.661

7.925

8.189

8.454

8.718

8.982

9.246

9.510

9.774

10.039

10.303

10.567

10.831

11.095

11.359

11.624

11.888

12.152

12.416

12.680

12.944

13.209

13.473

13.737

14.001

14.265

14.529

14.795

15.058

15.322

15.586

15.850

16.115

16.379

16.643

16.907

17.171

17.435

17.700

17.964

18.228

18.492

18.756

19.020

19.285

19.549

19.813

20.077

20.341

20.605

20.870

21.134

21.398

21.662

21.926

22.190

22.455

22.719

22.983

23.247

23.511

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

0.220

0.440

0.660

0.880

1.100

1.320

1.540

1.760

1.980

2.200

2.420

2.640

2.860

3.080

3.300

3.520

3.740

3.950

4.179

4.399

4.619

4.839

5.059

5.279

5.499

5.719

5.939

6.159

6.379

PC360LCI-11E0

00-89

CONVERSION TABLE

00 INDEX AND FOREWORD

1 ℓ = 0.21997 U.K.Gal 0

6.599

6.819

7.039

7.259

7.479

7.699

7.919

8.139

8.359

8.579

8.799

9.019

9.239

9.459

9.679

9.899

10.119

10.339

10.559

10.778

10.998

11.281

11.438

11.658

11.878

12.098

12.318

12.528

12.758

12.978

13.198

13.418

13.638

13.858

14.078

14.298

14.518

14.738

14.958

15.178

15.398

15.618

15.838

16.058

16.278

16.498

16.718

16.938

17.158

17.378

17.598

17.818

18.037

18.257

18.477

18.697

18.917

19.137

19.357

19.577

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

7.2

14.5

21.7

28.9

36.2

43.4

50.6

57.9

65.1

72.3

79.6

86.8

94.0

101.3

108.5

115.7

123.0

130.2

137.4

144.7

151.9

159.1

166.4

173.6

180.8

188.1

195.3

202.5

209.8

217.0

224.2

231.5

238.7

245.9

253.2

260.4

267.6

274.9

282.1

289.3

296.6

303.8

311.0

318.3

325.5

332.7

340.0

347.2

354.4

361.7

368.9

376.1

383.4

390.6

397.8

405.1

412.3

419.5

426.8

434.0

441.2

448.5

455.7

462.9

470.2

477.4

484.6

491.8

499.1

506.3

513.5

520.8

528.0

535.2

542.5

549.7

556.9

564.2

571.4

578.6

585.9

593.1

600.3

607.6

614.8

622.0

629.3

636.5

643.7

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

14.2

28.4

42.7

56.9

71.1

85.3

99.6

113.8

128.0

142.2

156.5

170.7

184.9

199.1

213.4

227.6

241.8

256.0

270.2

284.5

298.7

312.9

327.1

341.4

355.6

369.8

384.0

398.3

412.5

00-90

PC360LCI-11E0

00 INDEX AND FOREWORD

CONVERSION TABLE

1 kgf/cm2 = 14.2233 lb/in2 0

426.7

440.9

455.1

469.4

483.6

497.8

512.0

526.3

540.5

554.7

568.9

583.2

597.4

611.6

625.8

640.1

654.3

668.5

682.7

696.9

711.2

725.4

739.6

753.8

768.1

782.3

796.5

810.7

825.0

839.2

853.4

867.6

881.8

896.1

910.3

924.5

938.7

953.0

967.2

981.4

995.6

1010

1024

1038

1053

1067

1081

1095

1109

1124

1138

1152

1166

1181

1195

1209

1223

1237

1252

1266

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

51.8

7.8

114.8

27.2

177.8

-37.2

-35

-31.0

-11.1

53.6

8.3

116.6

27.8

179.6

-34.4

-30

-22.0

-10.6

55.4

8.9

118.4

28.3

181.4

-31.7

-25

-13.0

-10.0

57.2

9.4

120.2

28.9

183.2

-28.9

-20

-4.0

-9.4

59.0

10.0

122.0

29.4

185.0

-28.3

-19

-2.2

-8.9

60.8

10.6

123.8

30.0

186.8

PC360LCI-11E0

00-91

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

62.6

11.1

125.6

30.6

188.6

-27.2

-17

1.4

-7.8

64.4

11.7

127.4

31.1

190.4

-26.7

-16

3.2

-7.2

66.2

12.2

129.2

31.7

192.2

-26.1

-15

5.0

-6.7

68.0

12.8

131.0

32.2

194.0

-25.6

-14

6.8

-6.1

69.8

13.3

132.8

32.8

195.8

-25.0

-13

8.6

-5.6

71.6

13.9

134.6

33.3

197.6

-24.4

-12

10.4

-5.0

73.4

14.4

136.4

33.9

199.4

-23.9

-11

12.2

-4.4

75.2

15.0

138.2

34.4

201.2

-23.3

-10

14.0

-3.9

77.0

15.6

140.0

35.0

203.0

-22.8

-9

15.8

-3.3

78.8

16.1

141.8

35.6

204.8

-22.2

-8

17.6

-2.8

80.6

16.7

143.6

36.1

206.6

-21.7

-7

19.4

-2.2

82.4

17.2

145.4

36.7

208.4

-21.1

-6

21.2

-1.7

84.2

17.8

147.2

37.2

210.2

-20.6

-5

23.0

-1.1

86.0

18.3

149.0

37.8

100

212.0

-20.0

-4

24.8

-0.6

87.8

18.9

150.8

40.6

105

221.0

-19.4

-3

26.6

89.6

19.4

152.6

43.3

110

230.0

-18.9

-2

28.4

0.6

91.4

20.0

154.4

46.1

115

239.0

-18.3

-1

30.2

1.1

93.2

20.6

156.2

48.9

120

248.0

-17.8

32.0

1.7

95.0

21.1

158.0

51.7

125

257.0

-17.2

33.8

2.2

96.8

21.7

159.8

54.4

130

266.0

-16.7

35.6

2.8

98.6

22.2

161.6

57.2

135

275.0

-16.1

37.4

3.3

100.4

22.8

163.4

60.0

140

284.0

-15.6

39.2

3.9

102.2

23.3

165.2

62.7

145

293.0

-15.0

41.0

4.4

104.0

23.9

167.0

65.6

150

302.0

-14.4

42.8

5.0

105.8

24.4

168.8

68.3

155

311.0

-13.9

44.6

5.6

107.6

25.0

170.6

71.1

160

320.0

-13.3

46.4

6.1

109.4

25.6

172.4

73.9

165

329.0

-12.8

48.2

6.7

111.2

26.1

174.2

76.7

170

338.0

-12.2

50.0

7.2

113.0

26.7

176.0

79.4

175

347.0

00-92

PC360LCI-11E0

01 SPECIFICATIONS

PC360LCI-11E0

01-1

CONTENTS

01 SPECIFICATIONS

CONTENTS SPECIFICATIONS ......................................................................................................................................... 01-3 SPECIFICATION DRAWING................................................................................................................... 01-3 SPECIFICATION DRAWING: PC360LCI-11E0, PC360NLCI-11E0 .................................................. 01-3 WORKING RANGE DRAWINGS ............................................................................................................ 01-5 WORKING RANGE: PC360LCI-11E0, PC360NLCI-11E0 ................................................................ 01-5 SPECIFICATIONS .................................................................................................................................. 01-6 SPECIFICATIONS: PC360LCI-11E0, PC360NLCI-11E0 .................................................................. 01-6 WEIGHT TABLE ..................................................................................................................................... 01-9 WEIGHT TABLE: PC360LCI-11E0, PC360NLCI-11E0 ..................................................................... 01-9 TABLE OF FUEL, COOLANT, AND LUBRICANTS ................................................................................01-11

01-2

PC360LCI-11E0

01 SPECIFICATIONS

SPECIFICATION DRAWING

SPECIFICATIONS SPECIFICATION DRAWING SPECIFICATION DRAWING: PC360LCI-11E0, PC360NLCI-11E0

Item

Unit

PC360LCI-11E0

PC360NLCI-11E0

Machine weight

36560

36080

Bucket capacity

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)

11145

3367

C Overall width

3290

2990

D Shoe width

700

600

E Cab height

3160

F Tail swing radius

3445

G Overall length of the track

4955

Distance between tumbler centers

4030

Height of handrail (including GNSS antenna mounted portion)

3255

J Height of engine cover

3630

K Height of GNSS antenna

3320

Min.ground clearance

498

Travel speed (Lo/Mi/Hi)

km/h

3.2/4.5/5.5

Continuous swing speed

rpm

9.5

PC360LCI-11E0

01-3

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.

01-4

PC360LCI-11E0

01 SPECIFICATIONS

WORKING RANGE DRAWINGS

WORKING RANGE DRAWINGS WORKING RANGE: PC360LCI-11E0, PC360NLCI-11E0

Item

Unit

PC360LCI-11E0,PC360NLCI-11E0

Max. digging reach

11100

Max. digging depth

7280

Max. digging height

10210

Max. vertical wall digging depth

6480

Max. dumping height

7110

Min. dumping height

2640

10920

G Max. digging reach at ground level

PC360LCI-11E0

01-5

SPECIFICATIONS

01 SPECIFICATIONS

SPECIFICATIONS SPECIFICATIONS: PC360LCI-11E0, PC360NLCI-11E0 Item

Unit

Bucket capacity

Machine weight

PC360LCI-11E0

PC360NLCI-11E0 1.4

36560

36080

Performance Working ranges Max. digging depth

7445

Max. vertical wall digging depth

6480

Max. digging reach

11127

Max. digging reach at ground level

11100

Max. digging height

10600

Max. dumping height

7110

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

211.8 {21600} kN {kg}

226.5 {23100}

min-1 {rpm}

9.5 {9.5}

Swing operation max. slope angle

deg.

Travel speed (Lo/Mi/Hi)

km/h

3.2/4.5/5.5

Gradeability

deg.

Continuous swing speed

Ground pressure (standard shoe)

kPa {kgf/cm2}

58.2 {0.60}

65.2 {0.68}

Dimensions Overall length

11145

Overall width

Overall height (for transport) (*1)

3367

Ground clearance of upper structure bottom (*2)

1185

Min. ground clearance

498

Tail swing radius

3445

Min. swing radius of work equipment

4310

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

8520

Overall width of track

Overall length of the track

Track gauge

Distance between tumbler centers

4030

Machine cab height

3160

Width of standard shoe

3290

2990

3290

2990 4955

2590

700

2390

600

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

01-6

PC360LCI-11E0

01 SPECIFICATIONS

Item

SPECIFICATIONS

Unit

PC360LCI-11E0

PC360NLCI-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

6 - 114 x 144.5

Total piston displacement

ℓ {cc}

8.85 {8850}

Performance Rated power •

ISO 14396

•

ISO 9249

Max. torque

202 {271} /1950{1950}

rpm Nm {kgfm} /min-1rpm

192{271} /1950 {1950} 1171 {119.4} /1450 {1450}

Max. speed with no load • •

When mounted on machine (*3)

2050 {2050}

rpm

At basic engine

2050 {2050}

Min. speed with no load

rpm

1000 {1000}

Min. fuel consumption ratio

g/kWh

212 {156}

Starting motor

24 V, 11 kW

Alternator

24V, 11kW {24V, 90A }

Battery (*4)

12 V, 140 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.

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

PC360LCI-11E0

01-7

SPECIFICATIONS

Item Travel motor

01 SPECIFICATIONS

Unit -

PC360LCI-11E0

PC360NLCI-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

140

Piston rod diameter

100

Stroke

1469

Max. distance between pins

3525

Min. distance between pins

2056

Arm cylinder (*6) Type

Double-acting piston type

Cylinder bore

160

Piston rod diameter

110

Stroke

1822

Max. distance between pins

4255

Min. distance between pins

2433

Bucket cylinder Type

Double-acting piston type

Cylinder bore

140

Piston rod diameter

100

Stroke

1285

Max. distance between pins

3224.5

Min. distance between pins

1939.5

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.

01-8

PC360LCI-11E0

01 SPECIFICATIONS

WEIGHT TABLE

WEIGHT TABLE WEIGHT TABLE: PC360LCI-11E0, PC360NLCI-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

PC360LCI-11E0

PC360NLCI-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

Counterweight

6920

Swing machinery

348

Control valve

224

Swing motor

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)

6920 (600mm)

Boom assembly

2428

Arm assembly

1094

Bucket assembly

1508

Stroke sensing boom cylinder assembly

263

Stroke sensing arm cylinder assembly

399

Stroke and reset sensing bucket cylinder assembly

261

PC360LCI-11E0

01-9

WEIGHT TABLE

01 SPECIFICATIONS

Unit:: kg Item

PC360LCI-11E0

PC360NLCI-11E0

Bucket link (large) assembly

316

Bucket link (small) assembly

Boom foot pin

Boom cylinder bottom pin

Stroke sensing boom cylinder bottom pin

Stroke sensing boom cylinder head pin

Stroke sensing arm cylinder bottom pin

Stroke sensing arm cylinder head pin

Boom and arm connecting pin

Bucket cylinder bottom pin

Stroke and reset sensing bucket cylinder bottom pin

Bucket pin

30 x 2

Bucket link pin

27 x 2

01-10

PC360LCI-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

Swing machinery case

Final drive case (each on right and left sides)

Damper case

1.3

Hydraulic oil system

365

188

Cooling system

Fuel tank

605

AdBlue/DEF tank

PC360LCI-11E0

01-11

10 STRUCTURE AND FUNCTION

PC360LCI-11E0

10-1

CONTENTS

10 STRUCTURE AND FUNCTION

CONTENTS UREA SCR SYSTEM..................................................................................................................................... 10-7 LAYOUT DRAWING OF UREA SCR SYSTEM ....................................................................................... 10-7 UREA SCR SYSTEM DIAGRAM ...........................................................................................................10-11 FUNCTION OF UREA SCR SYSTEM................................................................................................... 10-12 FUNCTION OF AdBlue/DEF SYSTEM........................................................................................... 10-12 INDUCEMENT STRATEGY ........................................................................................................... 10-14 COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-22 AdBlue/DEF MIXING TUBE ........................................................................................................... 10-22 SCR ASSEMBLY ........................................................................................................................... 10-22 AdBlue/DEF TANK ......................................................................................................................... 10-25 AdBlue/DEF PUMP ........................................................................................................................ 10-27 AdBlue/DEF INJECTOR................................................................................................................. 10-28 AdBlue/DEF HOSE ........................................................................................................................ 10-29 AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-30 BOOT-UP SYSTEM ..................................................................................................................................... 10-31 LAYOUT DRAWING OF BOOT-UP SYSTEM........................................................................................ 10-31 SYSTEM OPERATING LAMP SYSTEM ............................................................................................... 10-33 SYSTEM OPERATING LAMP SYSTEM DIAGRAM ....................................................................... 10-33 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM ............................................................... 10-33 BATTERY DISCONNECT SWITCH ...................................................................................................... 10-35 FUNCTION OF BATTERY DISCONNECT SWITCH ...................................................................... 10-35 ENGINE SYSTEM ....................................................................................................................................... 10-36 LAYOUT DRAWING OF ENGINE SYSTEM .......................................................................................... 10-36 SPECIFICATIONS OF ENGINE SYSTEM ..................................................................................... 10-37 FUNCTION OF ENGINE SYSTEM ................................................................................................ 10-37 ENGINE CONTROL SYSTEM .............................................................................................................. 10-38 ENGINE CONTROL SYSTEM DIAGRAM...................................................................................... 10-38 FUNCTION OF ENGINE CONTROL SYSTEM .............................................................................. 10-39 AUTO-DECELERATION SYSTEM ........................................................................................................ 10-41 AUTO-DECELERATION SYSTEM DIAGRAM ............................................................................... 10-41 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................ 10-41 OPERATION OF AUTO-DECELERATION SYSTEM...................................................................... 10-42 ENGINE AUTOMATIC WARM-UP SYSTEM ......................................................................................... 10-43 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM................................................................. 10-43 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM ......................................................... 10-44 OVERHEAT PREVENTION SYSTEM ................................................................................................... 10-45 OVERHEAT PREVENTION SYSTEM DIAGRAM........................................................................... 10-45 FUNCTION OF OVERHEAT PREVENTION SYSTEM ................................................................... 10-46 TURBOCHARGER PROTECTION SYSTEM ........................................................................................ 10-47 TURBOCHARGER PROTECTION SYSTEM DIAGRAM ............................................................... 10-47 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM........................................................ 10-48 AUTOMATIC IDLE STOP SYSTEM ...................................................................................................... 10-49 AUTOMATIC IDLE STOP SYSTEM DIAGRAM.............................................................................. 10-49 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM ...................................................................... 10-49 COMPONENT PARTS OF ENGINE SYSTEM ...................................................................................... 10-52 VGT ............................................................................................................................................... 10-52 EGR SYSTEM ............................................................................................................................... 10-55 EGR VALVE ................................................................................................................................... 10-57 EGR COOLER ............................................................................................................................... 10-59 KCCV SYSTEM ............................................................................................................................. 10-60 KCCV VENTILATOR ...................................................................................................................... 10-62 KDPF ............................................................................................................................................. 10-64 COOLING SYSTEM..................................................................................................................................... 10-69 LAYOUT DRAWING OF COOLING SYSTEM ....................................................................................... 10-69 SPECIFICATIONS OF COOLING SYSTEM................................................................................... 10-70 CONTROL SYSTEM.................................................................................................................................... 10-71 10-2

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

CONTENTS

LAYOUT DRAWING OF CONTROL SYSTEM ...................................................................................... 10-71 MACHINE MONITOR SYSTEM ............................................................................................................ 10-74 MACHINE MONITOR SYSTEM DIAGRAM.................................................................................... 10-74 FUNCTION OF MACHINE MONITOR SYSTEM ............................................................................ 10-74 KomVision SYSTEM ............................................................................................................................. 10-76 LAYOUT DRAWING OF KOMVISION SYSTEM ............................................................................ 10-76 KomVision SYSTEM DIAGRAM..................................................................................................... 10-78 FUNCTION OF KomVision SYSTEM ............................................................................................. 10-78 KOMTRAX SYSTEM............................................................................................................................. 10-80 KOMTRAX SYSTEM DIAGRAM .................................................................................................... 10-80 FUNCTION OF KOMTRAX SYSTEM ............................................................................................ 10-80 PPC LEVERS ....................................................................................................................................... 10-81 LH PPC LEVER ............................................................................................................................. 10-81 RH PPC LEVER............................................................................................................................. 10-82 AUTOMATIC GREASE SYSTEM .......................................................................................................... 10-83 OUTLINE OF AUTO GREASE SYSTEM ....................................................................................... 10-83 COMPONENT PARTS OF CONTROL SYSTEM................................................................................... 10-95 MACHINE MONITOR..................................................................................................................... 10-95 KomVision CONTROLLER............................................................................................................10-109 KomVision CAMERA.....................................................................................................................10-113 GATEWAY FUNCTION CONTROLLER ........................................................................................10-114 COMMUNICATION TERMINAL ....................................................................................................10-117 PUMP CONTROLLER ..................................................................................................................10-119 RESISTOR FOR PC-EPC VALVE .................................................................................................10-123 CAN TERMINATING RESISTOR ..................................................................................................10-123 PPC OIL PRESSURE SWITCH ....................................................................................................10-124 ENGINE CONTROLLER ...............................................................................................................10-125 FUEL CONTROL DIAL .................................................................................................................10-131 SENSOR.....................................................................................................................................................10-133 STRUCTURE OF AMBIENT PRESSURE SENSOR ............................................................................10-133 FUNCTION OF AMBIENT PRESSURE SENSOR ...............................................................................10-134 STRUCTURE OF ENGINE OIL PRESSURE SWITCH ........................................................................10-135 FUNCTION OF ENGINE OIL PRESSURE SWITCH ............................................................................10-136 STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR .........................10-137 FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR.............................10-138 STRUCTURE OF COOLANT TEMPERATURE SENSOR....................................................................10-139 FUNCTION OF COOLANT TEMPERATURE SENSOR .......................................................................10-140 STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR ...................................................................10-141 FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR ......................................................................10-142 STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR ....................................................................10-143 FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR........................................................................10-144 STRUCTURE OF COMMON RAIL PRESSURE SENSOR ..................................................................10-145 FUNCTION OF COMMON RAIL PRESSURE SENSOR ......................................................................10-146 STRUCTURE OF EGR VALVE LIFT SENSOR ....................................................................................10-147 FUNCTION OF EGR VALVE LIFT SENSOR........................................................................................10-148 STRUCTURE OF VGT SPEED SENSOR............................................................................................10-149 FUNCTION OF KVGT SPEED SENSOR .............................................................................................10-150 STRUCTURE OF KVGT POSITION SENSOR.....................................................................................10-151 FUNCTION OF KVGT POSITION SENSOR ........................................................................................10-152 STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR ................................................10-153 STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR ............10-154 FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR ................10-155 STRUCTURE OF CRANKCASE PRESSURE SENSOR......................................................................10-156 FUNCTION OF CRANKCASE PRESSURE SENSOR .........................................................................10-157 STRUCTURE OF ENGINE OIL LEVEL SENSOR................................................................................10-158 STRUCTURE OF AIR CLEANER CLOGGING SENSOR ....................................................................10-159 FUNCTION OF AIR CLEANER CLOGGING SENSOR ........................................................................10-160 STRUCTURE OF WATER-IN-FUEL SENSOR.....................................................................................10-161 PC360LCI-11E0

10-3

CONTENTS

10 STRUCTURE AND FUNCTION

FUNCTION OF WATER-IN-FUEL SENSOR ........................................................................................10-162 STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH ....................................10-163 SPECIFICATIONS - QUICK COUPLER LOW PRESSURE WARNING SWITCH.................................10-164 FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH ........................................10-165 STRUCTURE OF AUTO GREASE PRESSURE SWITCH ...................................................................10-166 SPECIFICATIONS - AUTO GREASE PRESSURE SWITCH................................................................10-167 FUNCTION OF AUTO GREASE PRESSURE SWITCH.......................................................................10-168 STRUCTURE OF OVERLOAD CAUTION SENSOR............................................................................10-169 SPECIFICATIONS - OVERLOAD CAUTION SENSOR ........................................................................10-170 FUNCTION OF OVERLOAD CAUTION SENSOR ...............................................................................10-171 HYDRAULIC SYSTEM................................................................................................................................10-172 LAYOUT DRAWING OF HYDRAULIC SYSTEM ..................................................................................10-172 CLSS ...................................................................................................................................................10-175 STRUCTURE OF CLSS................................................................................................................10-175 OPERATION OF UNLOAD VALVE AND LS PRESSURE .............................................................10-177 PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL ..............................................................10-178 PRESSURE COMPENSATION CONTROL...................................................................................10-191 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................10-194 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM .............................................10-194 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................10-195 PUMP AND VALVE CONTROL SYSTEM ............................................................................................10-200 PUMP AND VALVE CONTROL SYSTEM DIAGRAM ....................................................................10-200 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM ............................................................10-201 COMPONENT PARTS OF HYDRAULIC SYSTEM ..............................................................................10-203 HYDRAULIC TANK .......................................................................................................................10-203 MAIN PUMP..................................................................................................................................10-206 CONTROL VALVE ........................................................................................................................10-229 WORK EQUIPMENT SYSTEM ...................................................................................................................10-286 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM .....................................................................10-286 STRUCTURE OF VALVE CONTROL...................................................................................................10-291 BUCKET CONTROL SYSTEM ............................................................................................................10-293 OPERATION OF BUCKET CONTROL SYSTEM ..........................................................................10-293 ONE-TOUCH POWER MAXIMIZING SYSTEM ...................................................................................10-294 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM ...........................................................10-294 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM ..................................................10-295 MACHINE PUSH-UP SYSTEM ............................................................................................................10-296 MACHINE PUSH-UP SYSTEM DIAGRAM ...................................................................................10-296 FUNCTION OF MACHINE PUSH-UP SYSTEM............................................................................10-297 PPC LOCK SYSTEM ...........................................................................................................................10-298 PPC LOCK SYSTEM DIAGRAM...................................................................................................10-298 FUNCTION OF PPC LOCK SYSTEM ...........................................................................................10-298 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM .....................................................10-299 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM.............................10-299 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM .....................10-299 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...................10-300 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT........................................................................10-301 OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT ...............................................10-301 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT .......................................10-302 TOOL CONTROL SYSTEM .................................................................................................................10-303 TOOL CONTROL SYSTEM DIAGRAM.........................................................................................10-303 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ..................................................................10-305 WORK EQUIPMENT AND SWING PPC VALVE ...........................................................................10-305 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) .........................................................10-310 2ND-LINE ATTACHMENT PPC VALVE.........................................................................................10-315 SOLENOID VALVE .......................................................................................................................10-317 2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE..................................................................10-320 ATTACHMENT CIRCUIT SELECTOR VALVE ...............................................................................10-322 PILOT CIRCUIT ACCUMULATOR ................................................................................................10-326 10-4

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

CONTENTS

ATTACHMENT CIRCUIT ACCUMULATOR...................................................................................10-327 ICT SYSTEM ..............................................................................................................................................10-328 LAYOUT DRAWING OF ICT SYSTEM.................................................................................................10-328 ICT CONTROL SYSTEM DIAGRAM....................................................................................................10-332 BUCKET EDGE POSITION DETECTION SYSTEM.............................................................................10-333 BUCKET EDGE POSITION DETECTION SYSTEM DIAGRAM ....................................................10-333 FUNCTION OF BUCKET EDGE POSITION DETECTION SYSTEM ............................................10-333 OPERATION OF BUCKET EDGE POSITION DETECTION SYSTEM ..........................................10-333 THE INTELLIGENT MACHINE CONTROL SYSTEM...........................................................................10-335 FUNCTION OF INTELLIGENT MACHINE CONTROL SYSTEM...................................................10-335 AUTO GRADE ASSIST CONTROL ..............................................................................................10-336 BUCKET ANGLE HOLD CONTROL .............................................................................................10-342 AUTO STOP CONTROL ...............................................................................................................10-344 TILT AUTOMATIC CONTROL (MACHINES WITH AUTO TILT BUCKET) .....................................10-358 CUSHION SYSTEM FOR ARM IN END...............................................................................................10-361 CUSHION SYSTEM FOR ARM IN END DIAGRAM ......................................................................10-361 FUNCTION OF CUSHION SYSTEM FOR ARM IN END ..............................................................10-361 OPERATION OF CUSHION SYSTEM FOR ARM IN END ............................................................10-361 CUSHION SYSTEM FOR BOOM RAISE END.....................................................................................10-363 CUSHION SYSTEM FOR BOOM RAISE END DIAGRAM ............................................................10-363 FUNCTION OF CUSHION SYSTEM FOR BOOM RAISE END ....................................................10-363 OPERATION OF CUSHION SYSTEM FOR BOOM RAISE END ..................................................10-363 BOOM SECONDARY DRIVE SWITCH................................................................................................10-365 CONTROL FUNCTION WHEN BOOM SECONDARY DRIVE SWITCH IS TURNED TO ON POSITION. ..................................................................................................................................................10-365 COMPONENT PARTS OF ICT SYSTEM .............................................................................................10-366 ICT SENSOR CONTROLLER.......................................................................................................10-366 WORK EQUIPMENT CONTROLLER ...........................................................................................10-370 CONTROL BOX............................................................................................................................10-374 GNSS RECEIVER ........................................................................................................................10-377 GNSS ANTENNA..........................................................................................................................10-379 IMU SENSOR ...............................................................................................................................10-380 INTELLIGENT MACHINE CONTROL EPC VALVE .......................................................................10-382 STROKE SENSOR FOR BOOM CYLINDER ................................................................................10-385 STROKE SENSOR FOR ARM CYLINDER ...................................................................................10-386 STROKE AND RESET SENSOR FOR BUCKET CYLINDER .......................................................10-388 RESET SENSOR FOR BOOM CYLINDER...................................................................................10-390 RESET SENSOR FOR ARM CYLINDER......................................................................................10-391 BOOM SPOOL STROKE SENSOR ..............................................................................................10-392 ARM SPOOL STROKE SENSOR .................................................................................................10-393 SWING SYSTEM ........................................................................................................................................10-395 LAYOUT DRAWING OF SWING SYSTEM ..........................................................................................10-395 SWING CONTROL SYSTEM DIAGRAM .............................................................................................10-398 FUNCTION OF SWING CONTROL SYSTEM...............................................................................10-398 COMPONENT PARTS OF SWING SYSTEM.......................................................................................10-402 SWING MOTOR ...........................................................................................................................10-402 SWING MACHINERY ...................................................................................................................10-413 SWING CIRCLE............................................................................................................................10-415 TRAVEL SYSTEM.......................................................................................................................................10-416 LAYOUT DRAWING OF TRAVEL SYSTEM .........................................................................................10-416 TRAVEL CONTROL SYSTEM DIAGRAM ............................................................................................10-420 FUNCTION OF TRAVEL CONTROL SYSTEM .............................................................................10-420 COMPONENT PARTS OF TRAVEL SYSTEM .....................................................................................10-422 TRAVEL MOTOR ..........................................................................................................................10-422 FINAL DRIVE................................................................................................................................10-434 TRAVEL PPC VALVE ....................................................................................................................10-435 CENTER SWIVEL JOINT..............................................................................................................10-440 UNDERCARRIAGE AND FRAME...............................................................................................................10-442 PC360LCI-11E0

10-5

CONTENTS

10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF UNDERCARRIAGE .......................................................................................10-442 SPECIFICATIONS OF UNDERCARRIAGE...................................................................................10-442 WORK EQUIPMENT...................................................................................................................................10-444 STRUCTURE OF WORK EQUIPMENT ...............................................................................................10-444 FUNCTION OF WORK EQUIPMENT ..................................................................................................10-445 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...................................................................10-446 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM ..................................10-446 BUCKET CLEARANCE ADJUSTMENT SHIM .....................................................................................10-447 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM .....................................................10-447 CAB AND ITS ATTACHMENTS ..................................................................................................................10-448 ROPS CAB ..........................................................................................................................................10-448 STRUCTURE OF ROPS CAB.......................................................................................................10-448 FUNCTION OF ROPS CAB ..........................................................................................................10-448 CAB MOUNT .......................................................................................................................................10-449 STRUCTURE OF CAB MOUNT....................................................................................................10-449 FUNCTION OF CAB MOUNT .......................................................................................................10-449 CAB TIPPING STOPPER ....................................................................................................................10-450 STRUCTURE OF CAB TIPPING STOPPER.................................................................................10-450 FUNCTION OF CAB TIPPING STOPPER ....................................................................................10-450

10-6

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF UREA SCR SYSTEM

UREA SCR SYSTEM SCR Abbreviation for Selective Catalytic Reduction

LAYOUT DRAWING OF UREA SCR SYSTEM SCR: Abbreviation for Selective Catalytic Reduction

PC360LCI-11E0

10-7

LAYOUT DRAWING OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

1: AdBlue/DEF tank

8: AdBlue/DEF mixing tube

2: AdBlue/DEF filler port

9: KDPF

3: AdBlue/DEF pump

10: AdBlue/DEF tank coolant outlet hose

4: AdBlue/DEF suction hose

11: AdBlue/DEF tank coolant inlet hose

5: AdBlue/DEF return hose

12: AdBlue/DEF tank heating valve

6: AdBlue/DEF pressure hose (low temperature side)

13: AdBlue/DEF injector

7: AdBlue/DEF pressure hose (high-temperature side)

14: SCR assembly

16: AdBlue/DEF tank sensor

15: AdBlue/DEF injector coolant hose

10-8

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF UREA SCR SYSTEM

Detailed drawing of SCR assembly

1: Turbocharger outlet NOx sensor

4: SCR outlet temperature sensor

2: Ammonia sensor

5: SCR outlet NOx sensor

3: SCR temperature sensor

Detailed drawing of temperature sensor

PC360LCI-11E0

10-9

LAYOUT DRAWING OF UREA SCR SYSTEM

1: Engine room temperature sensor

10-10

10 STRUCTURE AND FUNCTION

2: Ambient temperature sensor

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

UREA SCR SYSTEM DIAGRAM

A: Coolant inlet

B: Coolant outlet

1: Mass air flow and temperature sensor

21: Ammonia sensor controller

2: Engine

22: SCR temperature sensor

3: Engine controller

23: SCR outlet temperature sensor

4: KDPF assembly

24: SCR temperature sensor controller

5: KDOC unit

25: SCR outlet NOx sensor

6: KCSF unit

26: SCR outlet NOx sensor controller

7: KDPF differential pressure sensor

27: Smart sensor

8: KDPF outlet pressure sensor

28: Ambient temperature sensor

9: Turbocharger outlet NOx sensor

29: Engine room temperature sensor

10: Turbocharger outlet NOx sensor controller

30: AdBlue/DEF system

11: KDOC inlet temperature sensor

31: AdBlue/DEF tank heating valve

12: KDOC outlet temperature sensor

32: AdBlue/DEF tank

13: KDPF outlet temperature sensor

33: AdBlue/DEF tank sensor

14: KDPF temperature sensor controller

34: AdBlue/DEF suction line

15: AdBlue/DEF mixing tube

35: AdBlue/DEF return line

16: AdBlue/DEF injector

36: AdBlue/DEF pressure line

17: SCR assembly

37: AdBlue/DEF pump

18: Upstream SCR catalyst

38: AdBlue/DEF line heater relay

19: Downstream SCR catalyst and ammonia oxidation catalyst (integrated type)

39: Machine monitor

20: Ammonia sensor

PC360LCI-11E0

10-11

FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

1: Engine

5: AdBlue/DEF injector

2: Engine controller

6: KDPF

3: AdBlue/DEF pump

7: SCR catalyst

4: AdBlue/DEF tank

8: Ammonia oxidation catalyst

•

Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless nitrogen and water.

•

By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.

FUNCTION OF AdBlue/DEF SYSTEM 1: AdBlue/DEF tank

2: AdBlue/DEF suction hose

3: AdBlue/DEF Pump

3A: Selector valve 3B: Pump 3C: AdBlue/DEF filter 3D: Pressure sensor

4: AdBlue/DEF return hose 5: AdBlue/DEF pressure hose 6: AdBlue/DEF injector •

AdBlue/DEF system consists of AdBlue/DEF tank (1), AdBlue/DEF hoses (2), (4), (5), AdBlue/DEF pump (3), and AdBlue/DEF injector (6). It injects AdBlue/DEF into mixing tube.

•

This system automatically starts operation after starting the engine.

•

This system has a heating function to thaw AdBlue/DEF and to prevent AdBlue/DEF from freezing since AdBlue/DEF freezes at -11 °C.

10-12

1 3A

3D P

3C 3B

A4P15761

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

AdBlue/DEF injection function •

AdBlue/DEF injection function is a function that injects AdBlue/DEF which is pressurized with AdBlue/DEF pump into mixing tube.

•

Engine controller controls the injection volume by using AdBlue/DEF injector.

•

Engine controller determines the injection volume by the information from the turbocharger outlet NOx sensor, SCR temperature sensor, and the intake gas flow sensor while correcting it by ammonia sensor and SCR outlet NOx sensor.

•

AdBlue/DEF injection is controlled according to the system temperature as well since the urea SCR system does not operate efficiently at low temperature. The temperature sensor is used for this monitoring.

•

The engine controller commands to stop injection, and injector does not inject when a failure code is displayed due to an abnormality which is detected by any sensor which determines the injection volume.

•

The urea in AdBlue/DEF are deposited in the mixing tube, and it may stick to block the passage if an abnormality occurs.

AdBlue/DEF purge function •

This is a function that purges remaining AdBlue/DEF in AdBlue/DEF system automatically after engine is stopped.

•

It purges AdBlue/DEF from inside of injector or pump in order to prevent blocking or sticking by deposited urea in AdBlue/DEF, or defective operation of equipment by frozen AdBlue/DEF in cold weather. For this reason, the system operates for few minutes even after engine is stopped, but this is not an abnormality.

5 6 4

NOTICE Do not turn off the battery disconnect switch while purging AdBlue/DEF.

1 3A

3D P

3C 3B

A4P15762

AdBlue/DEF function of thawing and preventing from freezing •

Thawing control system has the thawing mode and freeze prevention mode.

•

Thawing mode is the function to thaw the frozen AdBlue/DEF.

•

After starting engine, if the engine controller judges that AdBlue/DEF must be thawed, this function automatically heats the system.

•

At this time, pressure control of AdBlue/DEF pump and injection of AdBlue/DEF are not performed until the thawing is completed.

Freeze prevention mode is the function to keep AdBlue/DEF warm to prevent it from freezing. •

This function automatically heats the system to prevent it from freezing while operating the machine, if engine controller judges that AdBlue/DEF could be frozen.

•

This function stops the pressure control of AdBlue/DEF pump and injection of AdBlue/DEF if it judges that AdBlue/DEF is frozen while operating the machine.

Thawing and freeze prevention are controlled by sensor, and the control sensors vary by devices which AdBlue/DEF system consists of. The following table shows the relationship between the object devices of thawing control, heating system, and control sensors for each mode.

PC360LCI-11E0

10-13

FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

Object devices of thawing control, heating system, and control sensors for each mode Heating system

Thawing mode

Heater around hose

Ambient temperature sensor

AdBlue/DEF pressure hose (hightemperature side)

Heater around hose

Engine room temperature Engine room temperature sensor sensor

AdBlue/DEF pump

Heater which is built in the pump

AdBlue/DEF pump temperature sensor

AdBlue/DEF tank

Circulation of coolant

AdBlue/DEF tank temper- AdBlue/DEF tank temperature sensor ature sensor

AdBlue/DEF suction hose and return hoses AdBlue/DEF pressure hose (lowtemperature side)

Freeze prevention mode Ambient temperature sensor

Ambient temperature sensor

INDUCEMENT STRATEGY •

The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions control system.

•

Inducement strategy is a control action to ensure prompt correction of various failures in the engine emissions control system. It requires actions to limit engine performance and defines required indication such as warning lamps and messages, as well as alarms while the control actions are imposed. The warning steps of Inducement are different between for North America and for European Union.

•

The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information” screen of the machine monitor.

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BECOMES LOW (FOR EUROPEAN UNION) •

When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine monitor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including engine power deration is activated.

•

The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Inducement, and Severe Inducement.

•

Up to the start of Severe Inducement the start of each warning step is triggered by the amount of AdBlue/DEF in the AdBlue/DEF tank.

•

The Inducement strategy status can be checked on “SCR Information” screen of the user menu.

•

The table shows warning indications and engine power derations by each Inducement strategy status.

Status

AdBlue/DEF level (*1) (AdBlue/DEF level gauge) 10%

Warning

(The bottom two gradations light on) 5%

Continuous Warning (Warning 2)

10-14

(Within the gradation of the second from the bottom )

Machine monitor AdBlue/DEF Message of level caution SCR Informa- lamp tion (Action level)

Tone of audible alert

Red 1: DEF low level warning appears.

2: Without treatment, engine power will be derated.

Activated failure code (*2)

Engine deration (*3)

CA3497 No sound

Red Triplet (*4)

(AdBlue/DEF No deration level low error 1)

CA3498

(AdBlue/DEF No deration Short intermitlevel low error tently (*5) 2)

PC360LCI-11E0

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10 STRUCTURE AND FUNCTION

Status

AdBlue/DEF level (*1) (AdBlue/DEF level gauge)

FUNCTION OF UREA SCR SYSTEM

Machine monitor AdBlue/DEF Message of level caution SCR Informa- lamp tion (Action level)

Tone of audible alert

Activated failure code (*2)

Engine deration (*3)

Red

Low-Level Inducement (Inducement 1)

2.5% 3: Engine (The gradation of the end power is unof the bottom der deration. lights on)

Red

CA1673 Long intermit- (AdBlue/DEF Torque: over tently level low error 25% 3)

Red

Severe Inducement (Inducement 2)

0% (All gradations lights off)

4: Engine power is under heavy deration.

CA1673 CA3547 Red

Continuously

Torque: 50%

(AdBlue/DEF and level low error RPM: 40% 4)

*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”. *2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM”. *3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed. *4: Construction equipment with crawler *5: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE AdBlue/DEF QUALITY OR IN THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION) •

AdBlue/DEF system caution lamp lights up on machine monitor, and an action level is displayed when an abnormality occurs in quality in AdBlue/DEF or in urea SCR system. In addition to the caution by the AdBlue/DEF system caution lamp, alarm sounds as time passes after the abnormality occurred. Then, inducement strategy starts so that the engine output is lowered.

•

The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Information” screen of the machine monitor.

•

The table shows warning indications and engine power derations by each Inducement strategy status.

PC360LCI-11E0

10-15

FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

Machine monitor

Status

Elapsed time (*1)

AdBlue/DE F system Message of caution Failure code Tone of auSCR Infor- lamp for abnormalidible alert mation ty (*2),(*3) (Action level)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Yellow

Warning

5 hours

1: Please inspect and maintain SCR system.

Yellow

No sound

CA3571 CB3571

No indication

No deration

Yellow

Continuous Warning 10 hours (Warning 2)

2: Without treatment, engine power will be derated.

Yellow

Triplet (*6)

AS00R2

Short inter- CA3571 mittently CB3571 (*7)

(Warning 2 No deration (SCR Device Abnormality))

Red

Low-Level Inducement (Inducement 1)

20 hours

3: Engine power is under deration.

AS00R3 Red

Long intermittently

CA3571 CB3571

(Inducement 1 (SCR Device Abnormality))

Torque: over 25%

AS00R4

Torque: 50%

Red

Severe Inducement (Inducement 2)

4: Engine power is Until repairunder ing heavy deration.

Red

Continuously

CA3571 CB3571

(Inducement 2 (SCR Device Abnormality))

and RPM: 40%

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM”. *3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines. *4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. *5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed. *6: Construction equipment with crawler *7: Construction equipment with wheel

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYSTEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION) •

The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. It has 4 levels totally which is the same as that, but it has different display on the machine monitor, and engine power deration (torque lowering ratio is 25% or more) and alarm starts from “Warning”.

•

The table shows warning indications and engine power derations by each Inducement strategy status. Machine monitor Status

Elapsed time (*1)

Caution Message of lamp Failure code Tone of auSCR Inforfor abnormali(Action lev- dible alert mation ty (*2),(*3) el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Warning

5 hours

1: Please inspect and maintain SCR system.

Red

Long intermittently

CA4151 CB4151

No indication

Torque: over 25%

Red

Continuous Warning 10 hours (Warning 2)

2: Without treatment, engine power will be derated.

Yellow

Triplet (*6)

AS00R2

Short inter- CA4151 mittently CB4151 (*7)

Torque: over (Warning 2 (SCR Device 25% Abnormality))

Red

PC360LCI-11E0

10-17

FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

Machine monitor Status

Elapsed time (*1)

Caution Message of lamp Failure code Tone of auSCR Inforfor abnormali(Action lev- dible alert mation ty (*2),(*3) el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Low-Level Inducement (Inducement 1)

20 hours

3: Engine power is under deration.

Red

AS00R3 Long intermittently

CA4151 CB4151

(Inducement 1 (SCR Device Abnormality))

Torque: over 25%

AS00R4

Torque: 50%

Red

Severe Inducement (Inducement 2)

4: Engine power is Until repairunder ing heavy deration.

Red Continuously

CA4151 CB4151

(Inducement 2 (SCR Device Abnormality))

and RPM: 40%

Red

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warning”stage. Final Inducement is not cleared till abnormality is repaired. *2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. The failure code shown here is an example of failure code which is displayed on the machine monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM”. *3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devices branching off to 2 lines. *4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in the service mode. *5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from the rated speed. *6: Construction equipment with crawler *7: Construction equipment with wheel

10-18

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYSTEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION) •

The Inducement strategy is different if Inducement is triggered by abnormalities in EGR. It has 4 levels totally which is the same as that, but it has different display on the machine monitor, and engine power deration (torque lowering ratio is 25% or more) and alarm starts from “Warning”.

•

The table shows warning indications and engine power derations by each Inducement strategy status. Machine monitor Status

Elapsed time (*1)

Caution Message of lamp Failure code Tone of auSCR Inforfor abnormali(Action lev- dible alert mation ty (*2),(*3) el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Warning

5 hours

1: Please inspect and maintain SCR system.

Red

Long intermittently

CA2271 CB2271

No indication

Torque: over 25%

Red

Continuous Warning 10 hours (Warning 2)

2: Without treatment, engine power will be derated.

Yellow

Triplet (*6)

AS00R2

Short inter- CA2271 mittently CB2271 (*7)

Torque: over (Warning 2 (SCR Device 25% Abnormality))

Red

Low-Level Inducement (Inducement 1)

20 hours

3: Engine power is under deration.

Red

AS00R3 Long intermittently

CA2271 CB2271

(Inducement 1 (SCR Device Abnormality))

Torque: over 25%

Red

PC360LCI-11E0

10-19

FUNCTION OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

Machine monitor Status

Elapsed time (*1)

Caution Message of lamp Failure code Tone of auSCR Inforfor abnormali(Action lev- dible alert mation ty (*2),(*3) el)

Failure code Engine defor Induceration (*5) ment strategy status (*4)

Red

Severe Inducement

(Inducement 2)

4: Engine power is Until repairunder ing heavy deration.

Red

AS00R4 Continuously

CA2271 CB2271

(Inducement 2 (SCR Device Abnormality))

Torque: 50% and RPM: 40%

Red

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EUROPEAN UNION) •

Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or troubleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these difficulties the operator can restore engine power for a short time to the deration of “Low-Level Inducement” through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine power.

•

“Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 operations are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another restoration capability.

•

To activate Temporary Restoration, follow the procedures described below.

10-20

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

FUNCTION OF UREA SCR SYSTEM

REMARK For the operating procedure on this function, refer to “TEMPORARY RESTORATION FROM INDUCEMENT” on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40 HOURS (FOR EUROPEAN UNION) •

The Urea SCR system continuously monitors its operation conditions and stores information on inappropriate operations including malfunctions.

•

The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnormality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.

•

If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were corrected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities is the same as the previous ones or not, it is judged as a recurrence.

•

If a recurrence occurs, the Inducement strategy will be activated.

•

Inducement in the recurrence resumes counting time at the time when the previous abnormalities were corrected if the previous Inducement is in “Warning”, “Continuous Warning” or “Low-Level Inducement”. The alerts resume the previous Inducement.

•

If the time the previous abnormalities were corrected is in “Severe Inducement”, Inducement in the recurrence starts from “Low-Level Inducement” but the remaining time to “Severe Inducement” is 1 hour or 2 hours depending on abnormalities. If the 1 hour or 2 hours are used up without correcting the new abnormalities, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.

PC360LCI-11E0

10-21

COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM SCR Abbreviation for Selective Catalytic Reduction

AdBlue/DEF MIXING TUBE STRUCTURE OF AdBlue/DEF MIXING TUBE REMARK The shape is subject to machine models.

A: Exhaust gas inlet (from KDPF)

B: Exhaust gas outlet (to SCR)

1: Clamp

4: AdBlue/DEF mixing tube (connector)

2: AdBlue/DEF injector

5: AdBlue/DEF mixing tube (tube)

3: Gasket for AdBlue/DEF injector

FUNCTION OF AdBlue/DEF MIXING TUBE It mixes AdBlue/DEF injected from AdBlue/DEF injector with exhaust gas, and decomposes it to ammonia which is needed to purge NOx from SCR assembly.

SCR ASSEMBLY SCR Abbreviation for Selective Catalytic Reduction

STRUCTURE OF SCR ASSEMBLY REMARK The shape is subject to machine models. 10-22

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM

A: From AdBlue/DEF mixing tube

B: To exhaust pipe

1: SCR body

3: SCR outlet NOx sensor

2: SCR temperature sensor

4: SCR outlet temperature sensor

PC360LCI-11E0

10-23

COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

5: Temperature sensor controller

12: Catalyzer hold mat

6: Ammonia sensor

13: Water dam

7: Hanger plate 8: water baffle

14: Downstream SCR catalyst and ammonia oxidation catalyst (integrated type)

9: Water drain port

15: Upstream SCR catalyst

10: Sensor table

16: Rectifier tube

11: Sensor table band •

SCR assembly consists of rectifier tube (16) equalizing the distribution of flow speed by leading exhaust gas, upstream SCR catalyst (15), downstream SCR catalyst, ammonia oxidation catalyst (14), and water dam which prevents rain water from entering into downstream SCR catalyst and ammonia oxidation catalyst (14) while exhausting gas.

•

Ammonia oxidation catalyst (a part of 14) oxidizes ammonia to water and nitrogen with ammonia oxidation catalyst (a part of 14) to prevent ammonia which is supplied to SCR assembly from being released out because SCR catalyst (a part of 14, 15)cannot completely consume it.

•

Each 1 piece of SCR temperature sensor (2), SCR outlet temperature sensor (4), ammonia sensor (6), and SCR outlet NOx sensor (3) are installed. These sensors are usable for various troubleshooting, such as they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly functions or not.

•

Rectifying tube (16) equalizes the distribution of exhaust gas flow speed.

•

SCR catalyst (15, a part of 14) uses the ceramic honeycomb.

•

The catalyzer holding mat (12) is made of a specific fiber and protects the ceramic catalyst against vibrations by the engine and the machine body. It also protects the outer periphery of SCR assembly against a heat transfer of the ceramics during operation.

•

Water dam (13) is located at the upstream side of the outlet and prevents rainwater from entering into downstream SCR catalyst unit and ammonia oxidation catalyst (14).

•

Water baffle (8) is located at the downstream side of the outlet and prevents rainwater at outlet from splashing over the detection part of NOx sensor.

10-24

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF TANK STRUCTURE OF AdBlue/DEF TANK

A: Coolant inlet

D: From AdBlue/DEF pump

B: Coolant outlet

E: To breather

C: To AdBlue/DEF pump 1: Sensor flange assembly

5: AdBlue/DEF tank sensor

2: Cap

6: AdBlue/DEF tank filter

3: Sight gauge

7: Drain plug

4: AdBlue/DEF tank PC360LCI-11E0

10-25

COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

AdBlue/DEF TANK SENSOR STRUCTURE OF AdBlue/DEF TANK SENSOR REMARK The shape is subject to machine models.

1: Connector

3: Temperature sensing part

2: Concentration Sensing part

4: Level sensing part

FUNCTION OF AdBlue/DEF TANK SENSOR •

This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and AdBlue/DEF temperature through CAN communication.

•

AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.

•

When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.

10-26

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF PUMP STRUCTURE OF AdBlue/DEF PUMP A: Suction from AdBlue/DEF tank B: Return to AdBlue/DEF tank C: Pressurized sending to AdBlue/DEF injector 1: AdBlue/DEF pump 2: AdBlue/DEF inlet connector 3: AdBlue/DEF return connector 4: AdBlue/DEF outlet connector 5: Electric connector 6: AdBlue/DEF filter cap 7: AdBlue/DEF filter (built-in)

•

The followings are built-in: The filter to collect the dust in AdBlue/DEF, the valve to switch the flow direction when purging, and the heater to thaw AdBlue/DEF when it is frozen.

•

It sucks AdBlue/DEF from AdBlue/DEF tank, pressurizes it to 900 kPa {9.18 kgf/cm2} , and sends it to AdBlue/DEF injector.

•

To prevent wrong connection of connectors, the return connectors are white and can be distinguished from others. The sizes of inlet connector and outlet connector are different and they cannot be connected each other.

A4P15769

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10-27

COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

AdBlue/DEF INJECTOR STRUCTURE OF AdBlue/DEF INJECTOR A: Pressurized sending from AdBlue/DEF pump B: Coolant inlet C: Coolant outlet 1: AdBlue/DEF injector 2: AdBlue/DEF inlet connector 3: Coolant inlet connector 4: Coolant outlet connector 5: Electric connector

FUNCTION OF AdBlue/DEF INJECTOR •

It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.

•

The injection amount is controlled by the valve opening or closing time while the pressure is constant.

•

It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.

OPERATION OF AdBlue/DEF INJECTOR Principle of injection of the injector is described. Following figure shows the state of injection. 1. Engine controller sends the electrical signal to control AdBlue/DEF injector. 2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves from injection port (1) to make opening state. Pressurized AdBlue/DEF by AdBlue/DEF pump is injected. 3. When the electrical signal is not sent, seal ball (2) closes injection port (1) with spring force (3), so AdBlue/DEF is not injected.

10-28

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF HOSE STRUCTURE OF AdBlue/DEF HOSE

1: Connector

5: Insulation tape

2: Housing

6: Heating wire

3: Coupling

7: Nylon tube

4: Corrugated tube •

It is used as AdBlue/DEF piping between AdBlue/DEF tank and AdBlue/DEF pump or between AdBlue/DEF pump and AdBlue/DEF injector.

•

The shape of the engaging portion between AdBlue/DEF tank and AdBlue/DEF pump or AdBlue/DEF injector pin is based on 3/8 inches or 5/16 inches of SAE J2044. It can be disconnected or connected with one touch.

•

There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.

•

There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one according to the model and the part to use.

FUNCTION OF AdBlue/DEF HOSE •

In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube while machine is stopped.

•

It also keeps temperature to prevent AdBlue/DEF from freezing again while machine is operated.

PC360LCI-11E0

10-29

COMPONENT PARTS OF UREA SCR SYSTEM

10 STRUCTURE AND FUNCTION

AdBlue/DEF TANK HEATING VALVE STRUCTURE OF AdBlue/DEF TANK HEATING VALVE

A: Engine coolant inlet

B: Engine coolant outlet

1: Solenoid

5: Plunger

2: Solenoid core

6: Diaphragm

3: Solenoid coil

7: Valve

4: Spring

FUNCTION OF AdBlue/DEF TANK HEATING VALVE •

AdBlue/DEF tank heating valve thaws AdBlue/DEF tank, and opening/closing of the valve (7) is done by solenoid (1).

•

The opening position of valve is fixed and the control is only for opening/closing. When the solenoid (1) is de-energized, the valve is closed.

•

Diaphragm (6) prevents entering of engine coolant into solenoid (1).

OPERATION OF AdBlue/DEF TANK HEATING VALVE 1.

When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (7) which is directly connected to plunger (5).

When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down by spring (4) and valve (7) is closed.

10-30

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF BOOT-UP SYSTEM

BOOT-UP SYSTEM LAYOUT DRAWING OF BOOT-UP SYSTEM

1: Battery

4: Fuse box

2: Pump controller

5: KOMTRAX terminal

3: Engine controller

6: Machine monitor

PC360LCI-11E0

10-31

LAYOUT DRAWING OF BOOT-UP SYSTEM

7: Battery disconnect switch

10 STRUCTURE AND FUNCTION

9: Fusible link

8: System operating lamp

10-32

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

SYSTEM OPERATING LAMP SYSTEM

SYSTEM OPERATING LAMP SYSTEM SYSTEM OPERATING LAMP SYSTEM DIAGRAM

1: Battery disconnect switch

7: Engine controller

2: Battery

8: Pump controller

3: Fusible link

9: KOMTRAX terminal

4: Fuse box

10: ICT sensor controller

5: System operating lamp

11: Work equipment controller

6: Machine monitor

12: KomVision controller (*1)

*1: Machine with KomVision.

FUNCTION OF SYSTEM OPERATING LAMP SYSTEM The operation state of each controller is checked by ON/OFF of the system operating lamp. This lamp is lit while any controller is in operation. Accordingly, the operator must not shut off the battery power circuit while this lamp is lit.

k Before shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and

check that the system operating lamp goes out, then turn the battery disconnect switch to “OFF” position.

k If the battery disconnect switch is turned to “OFF” position (battery power supply circuit is OFF)

while the system operating lamp is lit, data loss error of controller may occur. Never operate the battery disconnect switch while the system operating lamp is lit. REMARK • The system operating lamp goes out in max. 6 minutes after the starting switch is turned to “OFF” position. • The system operating lamp may sometimes light up while the starting switch is in “OFF” position, because KOMTRAX terminal may maintain its communication under this condition.

ON and OFF of system operating lamp •

Voltage of 24 V is constantly applied to one side of system operating lamp (LED (Light Emitting Diode)).

•

When any controller is in operation, the controller side outputs Low (0 V), and a current flows through the diode and the system operating lamp lights up.

•

When all controllers are stopped, the controller side outputs High (24 V), and no current flows through the diode and the system operating lamp goes off.

•

KOMTRAX terminal performs communication periodically even if the starting switch is kept in “OFF” position, thus it starts and stops repeatedly.

•

The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the communication state and machine stop time. So the lamp can be lit as long as approximately 1 hour.

•

The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the minute leakage of current and not an abnormal phenomenon.

PC360LCI-11E0

10-33

SYSTEM OPERATING LAMP SYSTEM

10 STRUCTURE AND FUNCTION

REMARK • When you want to cut off the battery circuit for maintenance but the system operating lamp is kept lit, turn the starting switch to “ON” position once, and then turn it to “OFF” position, and the lamp goes out in max. 6 minutes. After the system operating lamp goes out, turn the battery disconnect switch immediately to “OFF” position. • After the engine is stopped, AdBlue/DEF in AdBlue/DEF injector or AdBlue/DEF pump is automatically sucked into AdBlue/DEF tank to prevent malfunction caused by freezing of AdBlue/DEF or deposition of urea. Accordingly, the system operating lamp keeps lit for a while after the starting switch is turned to “OFF” position, and this is normal.

10-34

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

BATTERY DISCONNECT SWITCH

BATTERY DISCONNECT SWITCH FUNCTION OF BATTERY DISCONNECT SWITCH (O): OFF position (I): ON position •

•

Usually, battery disconnect switch (1) is used instead of disconnecting the cable from the negative terminal of the battery in the following cases. •

When storing the machine for a long period (1 month or longer)

•

When servicing or repairing the electrical system

•

When performing electric welding

•

When handling the battery

•

When replacing the fuse, etc.

When battery disconnect switch (1) is turned to OFF position (the contact is opened), all the continuous power supplies for the components, including the starting switch B terminal and controllers, are all cut out, and the condition is the same as the condition when the battery is not connected. Accordingly, all of the electrical system of the machine does not operate.

NOTICE • Do not turn battery disconnect switch (1) to OFF position while the system operating lamp is lit. If battery disconnect switch (1) is turned to OFF position while the system operating lamp is lit, the data in the controller may be lost and the controller may be damaged seriously. • Do not turn battery disconnect switch (1) to OFF position while the engine is running or immediately after the engine is stopped. If battery disconnect switch (1) is turned to OFF position while the alternator is generating power, the generated current has nowhere to go, leading to overvoltage in the electrical system of the machine, which may cause serious damage to the electrical system, including the electric devices and controllers. REMARK • The system operating lamp lights up while the controller is in operation or AdBlue/DEF pump is in operation. It lights up when KOMTRAX is performing communication, even if the starting switch is set to OFF position. • If battery disconnect switch (1) has been at OFF position for a long period, the machine monitor and the clock of the radio may be initialized. In this case, re-setting is required.

PC360LCI-11E0

10-35

LAYOUT DRAWING OF ENGINE SYSTEM

10 STRUCTURE AND FUNCTION

ENGINE SYSTEM LAYOUT DRAWING OF ENGINE SYSTEM

1: EGR cooler

4: KCCV ventilator

2: VGT

5: Air Cleaner

3: SCR assembly

6: Vibration damper

10-36

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF ENGINE SYSTEM

7: Auto-tensioner

12: Damper

8: Alternator

13: Rear engine mount

9: Starting motor

14: Front engine mount

10: KDPF

15: Engine controller

11: Engine oil filter

SPECIFICATIONS OF ENGINE SYSTEM Type of damper: Wet type Oil for damper: TO30 Quantity of damper oil: 1.3 ℓ

FUNCTION OF ENGINE SYSTEM

•

VGT (1) is a turbocharger which can change the cross-sectional area of the exhaust passage.

•

EGR cooler (2) cools the exhaust gas with the coolant.

•

KDPF (3) has KDOC (catalyst) and KCSF (soot collecting filter) and purifies the exhaust gas.

•

KCCV ventilator (4) separates oil and returns it to the intake side to burn the blowby gas again. It mainly consists of filters.

PC360LCI-11E0

10-37

ENGINE CONTROL SYSTEM

10 STRUCTURE AND FUNCTION

ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM DIAGRAM 9 6 16

12 BR

ACC

HEAT

OFF

ON STRAT

5 7

13 19 8

18 20 G0000219

1: Battery disconnect switch

11: Starting motor cut-off relay (for PPC lock)

2: Battery

12: Starting motor cut-off relay (for personal code)

3: Battery relay

13: Fuel control dial

4: Fusible link

14:Safety relay

5: Fuse box

15: Starting motor

6: Starting switch

16: Fuel supply pump

7: Engine shutdown secondary switch

17: Various sensors

8: Engine controller

18: Machine monitor

9: Lock lever

19: Gateway function Controller

10: PPC lock switch

20: Pump controller

10-38

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

ENGINE CONTROL SYSTEM

FUNCTION OF ENGINE CONTROL SYSTEM Mechanism and function of engine starting system

•

When starting switch (6) is turned to ON position, engine controller (8) sends a command current to fuel supply pump (16). Accordingly, a fail-safe mechanism is provided, that is, the engine stops when the electrical system has trouble.

•

When starting switch (6) is turned to START position while lock lever (9) is in LOCK position, the starting current is supplied to starting motor (15) and the engine starts. If lock lever (9) is in FREE position, starting motor cut-off relay (11) operates to cut off the starting current to starting motor (15) and the engine does not start, that is, a neutral safety mechanism.

•

Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the signal to machine monitor (18). Machine monitor (18) operates starting motor cut-off relay (12) to cut off the starting current to starting motor (15), thus the engine does not start.

Mechanism and function of engine speed control system

PC360LCI-11E0

10-39

ENGINE CONTROL SYSTEM

10 STRUCTURE AND FUNCTION

Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8) selects the lower throttle signal and sends the command current to fuel supply pump (16). Fuel supply pump (16) adjust the fuel injection rate to control the engine speed.

Mechanism and function of engine stopping system

When starting switch (6) is turned to OFF position, the current from terminal ACC of starting switch (6) to engine controller (8) is cut off, and the command current to fuel supply pump (16) is also cut off. Fuel supply pump (16) stops supplying fuel, the engine speed decreases, and the engine stops.

Mechanism and function of engine stopping system with engine shutdown secondary switch

When engine shutdown secondary switch (7) is set to the engine stop position, the current from terminal ACC of starting switch (6) to engine controller (8) is cut off forcibly. The condition becomes the same as when starting switch (6) is turned to OFF position, and the engine stops.

10-40

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

AUTO-DECELERATION SYSTEM

AUTO-DECELERATION SYSTEM AUTO-DECELERATION SYSTEM DIAGRAM

a: CAN signal

d: 1st throttle signal

b: Oil pressure sensor signal

e: Fuel supply pump control signal

c: Oil pressure switch signal

f: Various sensor signals

1: Pump controller

8: Oil pressure sensor

2: Engine controller

9: Main pump

3: Machine monitor

10: Control valve

4: Fuel control dial

10a: Self-pressure reducing valve

5: Fuel supply pump

10b: Merge-divider valve

6: Various sensors

10c: Travel junction valve

7: Oil pressure switch

11: PPC lock solenoid valve

FUNCTION OF AUTO-DECELERATION SYSTEM •

When all the control levers are set to NEUTRAL positions while waiting for a dump truck or next work, the engine speed decreases to the control speed automatically to improve the fuel economy and reduce the noise.

•

If any control lever is operated, the engine speed returns immediately to the speed set with the fuel control dial.

PC360LCI-11E0

10-41

AUTO-DECELERATION SYSTEM

10 STRUCTURE AND FUNCTION

OPERATION OF AUTO-DECELERATION SYSTEM A: All work equipment control levers in NEUTRAL B: Work equipment control lever operated C: Fuel control dial set speed D: Engine control speed (approximately 1000 rpm) E: 4 sec F: Max. 2 sec. G: Max. 1 sec.

When control lever is at NEUTRAL While the engine is running at approximately 1000 rpm or higher speed, when all the control levers are kept in neutral for 4 seconds or more, engine speed is decreased to approximately 1000 rpm and kept to the engine control speed (approximately 1000 rpm) until any control lever is operated.

When control lever is operated While the engine speed is kept at the engine control speed (approximately 1000 rpm), when any control lever is operated, the engine speed increases immediately to the fuel control dial set speed.

10-42

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

ENGINE AUTOMATIC WARM-UP SYSTEM

ENGINE AUTOMATIC WARM-UP SYSTEM ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM

a: Front pump PC-EPC valve drive signal

e: Hydraulic oil temperature signal

b: Rear pump PC-EPC valve drive signal

f: 1st throttle signal

c: Solenoid valve GND

g: Fuel supply pump control signal

d: CAN signal

h: Various sensor signals

1: Battery disconnect switch

16: Front pump

2: Battery

16a: Servo

3: Battery relay

16b: LS valve

4: Fusible link

16c: PC valve

5: Fuse box

17: Rear pump

6: Resistor for PC-EPC valve

17a: Servo

7: Pump controller

17b: LS valve

8: Engine controller

17c: PC valve

9: Machine monitor

18: Control valve

10: Air conditioner unit

18a: Self-pressure reducing valve

11: Pump drive secondary switch

18b: Merge-divider valve

12: Fuel control dial

18c: Travel junction valve

13: Fuel supply pump

19: Front pump PC-EPC valve

14: Various sensors

20: Rear pump PC-EPC valve

15: Hydraulic oil temperature sensor

PC360LCI-11E0

10-43

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ENGINE AUTOMATIC WARM-UP SYSTEM

10 STRUCTURE AND FUNCTION

FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM •

This system increases the engine speed to warm up the engine when the coolant temperature is low after the engine is started.

•

The engine automatic warm-up function has 2 types; “Heater warm-up” and “Normal warm-up”, either can be used according to the purpose. The purpose of the heater warm-up is to increase the coolant temperature to improve the heat efficiency. The purpose of the normal warm-up is to heat the engine to prevent damage on the engine caused by low temperature. Operating conditions 1

Machine specification: Air conditioner specification Air conditioner: Blower “ON” Coolant temperature: Below 50 °C Ambient temperature: Below 5 °C Manual stationary regeneration: OFF Soot accumulation: Max. 4 g/ℓ ↓

↓

When any of operating conditions 1 is not satisfied

When all of operating conditions 1 are satisfied

Heater warm-up disabled (normal warm-up)

Heater warm-up enabled

Operating conditions 2 ↓

(Operates when all of the following conditions are satisfied) Coolant temperature: Below 30 °C

↓

Engine speed: Max. 1250 rpm ↓

↓

Operation

Engine speed1250 rpm

Engine speedMin. 1300 rpm ↓

↓

Condition to cancel

(Canceled when any of the following conditions is satisfied)

Automat- Coolant temperature: Min. 30 °C ic Warm-up operation time: Min. 10 minutes

Coolant temperature: Min. 55 °C

Manual

Fuel control dial: Held at 70 % or more of High idle (MAX) for 3 seconds and longer.

Ambient temperature: Min. 10 °C

↓

↓ Cancellation

Engine speed: Any

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

OVERHEAT PREVENTION SYSTEM

OVERHEAT PREVENTION SYSTEM OVERHEAT PREVENTION SYSTEM DIAGRAM

a: Front pump PC-EPC valve drive signal

e: Hydraulic oil temperature signal

b: Rear pump PC-EPC valve drive signal

f: 1st throttle signal

c: Solenoid valve GND

g: Fuel supply pump control signal

d: CAN signal

h: Various sensor signals

1: Battery disconnect switch

16: Front pump

2: Battery

16a: Servo

3: Battery relay

16b: LS valve

4: Fusible link

16c. PC valve

5: Fuse box

17: Rear pump

6: Resistor for PC-EPC valve

17a: Servo

7: Pump controller

17b: LS valve

8: Engine controller

17c: PC valve

9: Machine monitor

18: Control valve

10: Air conditioner unit

18a: Self-pressure reducing valve

11. Pump secondary drive switch

18b: Merge-divider valve

12: Fuel control dial

18c: Travel junction valve

13: Fuel supply pump

19: Front pump PC-EPC valve

14: Various sensors

20: Rear pump PC-EPC valve

15: Hydraulic oil temperature sensor

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OVERHEAT PREVENTION SYSTEM

10 STRUCTURE AND FUNCTION

FUNCTION OF OVERHEAT PREVENTION SYSTEM This system prevents overheating by reducing the pump load and by lowering the engine speed to protect engine and hydraulic components when coolant temperature or hydraulic temperature becomes too high. Operating condition Working mode: Travel (Hi speed)

Operation and remedy

→

Engine speed: Kept as it is

Condition to cancel Hydraulic oil temperature: Below 93 °C →

Pump discharged volume: Throttled

Hydraulic oil temperature: Min. 95 °C

Operating condition

Operation and remedy

Coolant temperature: Below 100 °C →

Engine speed: Kept as it is

→

Pump discharged volume: Throttled

Hydraulic oil temperature: Below 100 °C •

Hydraulic oil temperature: Min. 100 °C Operating condition

Operation and remedy

When above condition is satisfied, it is restored to the state before operation (automatic restoration). Condition to cancel

Coolant temperature: Below102 °C

Working mode: P, E, B, ATT/P, or ATT/E mode Coolant temperature: Min. 102 °C

When above condition is satisfied, it is restored to the state before operation (automatic restoration). Condition to cancel

Working mode: P, ATT/P mode Coolant temperature: Min. 100 °C

•

→

Engine speed: Kept as it is

→

Pump discharged volume: Throttled

Hydraulic oil temperature: Below 102 °C •

Hydraulic oil temperature: Min. 102 °C Operation and remedy

Operating condition

When above condition is satisfied, it is restored to the state before operation (automatic restoration). Condition to cancel

Coolant temperature: Below 105 °C Working mode: All modes Coolant temperature: Min. 105 °C or Hydraulic oil temperature: Min. 105 °C

10-46

→

Engine speed: Low idle Alarm monitor: Lights up Alarm buzzer: Sounds

Hydraulic oil temperature: Below 105 °C →

Fuel control dial: Return to Low idle (MIN) position. •

When above condition is satisfied, it is restored to the state before operation (manual restoration).

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

TURBOCHARGER PROTECTION SYSTEM

TURBOCHARGER PROTECTION SYSTEM TURBOCHARGER PROTECTION SYSTEM DIAGRAM

a: Front pump PC-EPC valve drive signal

e: Hydraulic oil temperature signal

b: Rear pump PC-EPC valve drive signal

f: 1st throttle signal

c: Solenoid valve GND

g: Fuel supply pump control signal

d: CAN signal

h: Various sensor signals

1: Battery disconnect switch

16: Front pump

2: Battery

16a: Servo

3: Battery relay

16b: LS valve

4: Fusible link

16c: PC valve

5: Fuse box

17: Rear pump

6: Resistor for PC-EPC valve

17a: Servo

7: Pump controller

17b: LS valve

8: Engine controller

17c: PC valve

9: Machine monitor

18: Control valve

10: Air conditioner unit

18a: Self-pressure reducing valve

11: Pump drive secondary switch

18b: Merge-divider valve

12: Fuel control dial

18c: Travel junction valve

13: Fuel supply pump

19: Front pump PC-EPC valve

14: Various sensors

20: Rear pump PC-EPC valve

15: Hydraulic oil temperature sensor

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10-47

TURBOCHARGER PROTECTION SYSTEM

10 STRUCTURE AND FUNCTION

FUNCTION OF TURBOCHARGER PROTECTION SYSTEM This function limits the engine speed to prevent seizure of the turbocharger when the engine speed is increased suddenly just after the engine is started. Operating condition Engine oil pressure: Below 50 kPa {0.51 kgf/cm2}

Operation →

Turbocharger protection (See figure below)

A: Starting of engine B: Turbocharger protection time (approximately 0 to 20 seconds) C: Modulation time (approximately 1 second) D: 500 rpm E: Approximately 1000 rpm F: 2050 rpm (when working mode is P mode) Fuel control dial: High idle (MAX) position with travel lever operated When swing lock is ON

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

AUTOMATIC IDLE STOP SYSTEM

AUTOMATIC IDLE STOP SYSTEM AUTOMATIC IDLE STOP SYSTEM DIAGRAM 8 14

11 d 12 a

a 6

c 10

C ACC

HEAT

d 15

OFF ON

START

3 b 2

G0000285

a: CAN signal

c: Lock lever signal

b: BR signal

d: Signals from sensors

1: Battery disconnect switch

9: PPC lock switch

2: Battery

10: Pump controller

3: Battery relay

11: Machine monitor

4: Fusible link

12: Engine controller

5: Fuse box

13: Gateway function Controller

6: Starting switch

14: Engine

7: Relay

15: Hydraulic oil temperature sensor

8: Lock lever

16: Coolant temperature sensor

FUNCTION OF AUTOMATIC IDLE STOP SYSTEM •

When the auto idle stop function is enabled and the conditions for operation are satisfied, the engine is stopped after the set time.

•

Engine stops by auto idle stop function when engine controller judges the applicable condition and stops the engine.

•

When the engine is stopped by the auto idle stop function while it is running at high speed, a message to turn ON the auto-deceleration function is displayed on the machine monitor, and the auto-deceleration function is set to ON.

•

The operating time of the auto idle stop function can be set by user menu or service menu on the machine monitor.

Operating condition of automatic idle stop system The auto idle stop function starts when all of the following conditions are satisfied at the same time. •

Engine is running.

•

Lock lever is in LOCK position.

•

Working mode is “P”, “E”, “ATT/P”, “ATT/E”, or “B”. (Disabled when working mode is “L” or “Arm crane”).

•

Engine automatic warm-up function of “Normal warm-up” mode is not being operated.

•

Engine coolant is not overheating (below 102 °C).

•

Hydraulic oil is not overheating (below 102 °C)

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AUTOMATIC IDLE STOP SYSTEM

10 STRUCTURE AND FUNCTION

•

Auto idle stop time on machine monitor has not been reset.

•

Machine monitor is not set in service mode. (*1)

•

None of following failure codes is occurring.

*1: See “Setting time”. Corresponding failure codes are as follows. Failure code

Failure (displayed on screen)

B@BCNS

Eng Water Overheat

B@HANS

Hydraulic Oil Overheat

CA144

Coolant Temperature Sensor High Error

CA145

Coolant Temperature Sensor Low Error

D8AQKR

CAN 2 Defective Communication (KOMTRAX)

DA2RKR

Controller Area Network 1 Defective Communication (Pump Controller)

DA2QKR

Controller Area Network 2 Defective Communication (Pump Controller)

DAFQKR

CAN 2 Defective Communication (Monitor)

DB2RKR

CAN 1 Defective Communication (Engine Controller)

DB2QKR

CAN 2 Defective Communication (Engine Controller)

DGH2KA

Hydraulic Oil Temperature Sensor Open Circuit

DGH2KB

Hydraulic Oil Temperature Sensor Ground Fault

Setting time The set time for the auto idle stop function is set in the following menus. For setting of each menu, see “Testing and adjusting”. Fixing auto idle stop time (service menu) Setting

Contents of setting

Variable

In auto idle stop time setting menu, operator can select OFF or minimum set time in auto idle stop setting to maximum time of 60 minutes. (Default)

OFF

The auto idle stop function does not operate, and the auto idle stop time setting menu is not displayed.

Fix to X min.

In auto idle stop time setting menu, operator can select set time in auto idle stop setting to X minutes (set time at left). (Cannot select OFF)

Fixing auto idle stop time (user menu) Contents of setting

Setting OFF

Auto idle stop function does not operate. (Default)

Y min.

Stop the engine at Y minutes (set time at left) after setting the lock lever to LOCK position.

NOTICE When “Fix X min.” is selected in the Auto idle stop time fixing menu, the screen changes to the operator screen automatically and the auto idle stop function operates 60 minutes after the lock lever is set to LOCK position, even if the Service menu is being used. Before performing work with the Service menu, check the set value of the auto idle stop function.

Sensing abrupt engine stop •

When the engine is stopped by the auto idle stop function, if the auto-deceleration function is OFF and the fuel control dial is at a position above MIN., abrupt engine stop is sensed and the failure code is sent.

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

AUTOMATIC IDLE STOP SYSTEM

•

The failure code is recorded in the mechanical system abnormality record.

•

If abrupt engine stop is sensed, the auto-deceleration function is turned ON automatically.

•

The failure code displayed at abrupt engine stop varies with the number of occurrence, and the message displayed on the machine monitor varies according to the failure code. Action level

Failure code

Failure (displayed on screen)

L00

A900N6

Abrupt Engine Stop by Auto Idle Stop 1

L01

A900NY

Abrupt Engine Stop by Auto Idle Stop 2

L03

A900FR

Abrupt Engine Stop by Auto Idle Stop 3

•

When failure code “A900FR” of action level “L03” is sent, the turbocharger assembly must be replaced since the durability of the engine may decrease.

•

After replacing the turbocharger assembly, reset the number of occurrence by using “Reset number of abrupt stops by auto idle stop” in “Inspection” on the service menu.

REMARK If the number of occurrence is not reset by using “Reset number of abrupt stops by auto idle stop”, failure code “A900FR” is sent again next time and after. Accordingly, be sure to reset after replacing the turbocharger assembly.

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10-51

COMPONENT PARTS OF ENGINE SYSTEM

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM VGT VGT Abbreviation for Variable Geometry Turbocharger

STRUCTURE OF VGT REMARK The shape is subject to machine models.

General view, sectional view

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM

A: Intake air inlet

C: Exhaust inlet

B: Intake air outlet

D: Exhaust outlet

1: Blower housing

7: Nozzle ring

2: VGT speed sensor

8: Push rod

3: Hydraulic actuator

9: Shaft

4: Turbine housing

10: Blower impeller

5: Plate

11: Turbine impeller

6: Vane

12: Piston

FUNCTION OF VGT

C: Blower impeller

T: Turbine impeller

1: Air cleaner

5: SCR assembly(*1)

2: VGT

6: EGR cooler

3: KDPF

7: EGR valve

4: AdBlue/DEF mixing tube(*1) *1: This may not be installed on some machine models and specifications. •

The exhaust gas regulations are applied to the exhaust gas from the engine running at low speed, as well as at high speed. To meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount of fresh suction air)

•

To attain high EGR ratio, turbine inlet pressure (P3) must be set higher than boost pressure (P2) (P3 > P2). For this reason, the variable turbocharger (VGT) is employed, in which the exhaust gas pressure acting on turbine impeller (T) is adjustable. Also, since the boost pressure increases more quickly, generation of particulate caused by lack of oxygen during low-speed operation (rotation) is reduced.

•

The shaft joined to turbine impeller (T) drives blower impeller (C) and sends much air to the cylinder for combustion. If VGT (2) sends more air, the fuel injection rate can be increased, thus the engine output is increased. In addition, the air cooled by aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel injection rate can be increased and the engine output is increased.

NOTICE Adequate amount of clean high quality oil is required to maintain VGT performance. Be sure to use Komatsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when replacing oil or oil filter. REMARK It sounds like air is leaking from VGT or a boost pipe, but it is not abnormal.

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COMPONENT PARTS OF ENGINE SYSTEM

10 STRUCTURE AND FUNCTION

OPERATION OF VGT

The exhaust gas enters (C) of turbine housing (4) and flows out through portion (P) and (D). Portion (P) is surrounded by plate (5) fixed to turbine housing, nozzle ring (7), and vanes (6). The area of its passage is changed by sliding push rod (8) to the right or left.

Hydraulic actuator (3) moves piston (12) in the actuator up and down with the hydraulic pressure controlled by EPC valve installed to the front cover, and slides push rod (8) to the right and left.

The exhaust gas flowing through vanes (6) rotates blower impeller (10) through shaft (9) joined to turbine impeller (11). As the result, the blower impeller works as a compressor, and the intake air entering through (A) is compressed and discharge through (B).

When the exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed is in low range), push rod (8) slides to the right and narrows portion (P).

The exhaust gas acting on turbine impeller (11) increases, the turbocharger speed increases, and more air (oxygen) is taken in. VGT speed sensor (2) detects the rotation of the turbocharger.

When nozzle ring is “closed” 1.

During low speed operation (rotation), exhaust gas inlet passage (P) is narrow (L1). (It is not fully closed, however.)

If the turbine inlet pressure increases while the nozzle ring is closed, the turbine inflow speed increases, and accordingly the turbocharger speed increases.

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM

When nozzle ring is “open” 1.

During high speed operation (rotation), exhaust gas inlet passage (P) is wide (L2).

As the engine speed increases and the turbine inlet pressure (exhaust gas pressure) increases exhaust gas inlet passage (P) is widened (L2) so that the exhaust gas acts on turbine impeller (11) efficiently.

REMARK • Nozzle ring (7), vanes (6), and push rod (8) are all-in-one unit, and it slides only and does not rotate. • Hydraulic actuator (3) is equipped with VGT position sensor. VGT position sensor is calibrated together with the variable mechanism of VGT and the result is written in the memory in VGT position sensor. Accordingly, if any of hydraulic actuator (3), VGT position sensor, and VGT unit fails, whole VGT must be replaced.

Operation of hydraulic actuator 1.

Hydraulic actuator (1) is controlled by EPC valve (2) installed to the front cover and driven hydraulically.

The hydraulic pressure supplied by engine boost oil pump (3) is used for this purpose.

The position of hydraulic actuator (1) is fed back to engine controller by the signals from VGT position sensor (4).

EGR SYSTEM EGR Abbreviation for Exhaust Gas Recirculation

LAYOUT DRAWING OF EGR SYSTEM REMARK The shape is subject to machine models.

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COMPONENT PARTS OF ENGINE SYSTEM

10 STRUCTURE AND FUNCTION

1: VGT

4: Intake connector

2: EGR valve

5: Exhaust manifold

3: Intake pipe

6: EGR cooler

FUNCTION OF EGR SYSTEM •

EGR valve (hydraulically driven type) (2) controls the gas flowing from the exhaust section to the intake section. Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake side.

•

EGR cooler (6) cools down the exhaust gas. Engine coolant is used for cooling.

•

It controls EGR circuit on the basis of the information from the sensors installed to various parts so that clean exhaust gas is always discharged to obtain EGR ratio corresponding to the operating condition. (EGR ratio means the ratio of EGR gas contained in the intake gas.)

•

It monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure from occurring.

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM

CIRCUIT DIAGRAM OF EGR SYSTEM

C: Blower impeller

T: Turbine impeller

1: Air Cleaner

9: EGR valve lift sensor

2: KDPF, AdBlue/DEF mixing tube, SCR assembly

10: EPC valve (for VGT)

3: Ambient pressure sensor

11: Exhaust manifold

4: Aftercooler

12: Engine boost oil pump

5: EGR cooler

13: Intake manifold

6: EGR valve

14: Charge (boost) pressure and temperature sensor

7: Hydraulic actuator (power piston)

15: Engine controller

8: EPC valve (for EGR valve)

16: Mass air flow and temperature sensor

OPERATION OF EGR SYSTEM 1.

The engine controller outputs signals in order to open EGR valve (6) most properly in accordance with the engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.

When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (11) into EGR cooler (5) through the EGR piping.

The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in the intake connector, and then flows in intake manifold (13).

EGR VALVE EGR Abbreviation for Exhaust Gas Recirculation

STRUCTURE OF EGR VALVE REMARK The shape is subject to machine models. PC360LCI-11E0

10-57

COMPONENT PARTS OF ENGINE SYSTEM

10 STRUCTURE AND FUNCTION

Sectional view

A: EGR gas inlet (from EGR cooler)

D: Servo drive oil outlet

B: EGR gas outlet (to intake manifold)

E: VGT control hydraulic outlet

C: Servo drive oil inlet

F: VGT drive pressure outlet

1: Valve

5: Spring

2: Spring

6: EGR valve lift sensor

3: Power piston

7: EPC valve (for EGR)

4: Spool

8: EPC valve (for VGT)

Structure •

EGR valve consists of the EGR gas flow control mechanism and EPC valve.

•

There are 2 EPC valves, one for the EGR valve and the other for VGT.

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM

OPERATION OF EGR VALVE 1.

The oil from the engine boost oil pump flows in port (C) of EGR valve. The control pressure from EPC valve solenoid enters port (E).

Spool (4) is moved to the right by the reaction force of spring (5), and valve (1) is closed by the reaction for spring (2). Accordingly, the exhaust gas from EGR cooler does not flow to the intake side.

To open valve (1), the control pressure from EPC valve enters port (E) first. The position of spool (4) is determined by the balance of the control pressure and spring (5).

Since the notch of power piston (3) opens, the oil from the engine boost oil pump flows through port (C) and pushes power piston (3) to the left.

The oil from the engine boost oil pump acts on power piston (3) and generates force (Fp).

When force (Fp) increases more than reaction force (Fs) of spring (2), EGR valve (1) opens and the exhaust gas flows to the intake side.

Reaction force (Fs) of spring (2) and force (Fp) of power piston are balanced since the engine controller controls the control pressure with EPC valve solenoid.

Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which is in contact with power piston (3).

EGR valve lift sensor senses the displacement of spool (4).

EGR COOLER EGR Abbreviation for Exhaust Gas Recirculation

STRUCTURE OF EGR COOLER REMARK The shape is subject to machine models.

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COMPONENT PARTS OF ENGINE SYSTEM

10 STRUCTURE AND FUNCTION

General view and sectional view

A: EGR gas inlet

D: EGR gas outlet (to EGR valve)

B: Air vent

E: Coolant inlet

C: Coolant outlet 1: Flat tube

Detailed drawing of flat tube 1: Flat tube 2: Inner fin

OPERATION OF EGR COOLER •

EGR gas enters through (A) and flows through flat tubes (1) (11 pieces).

•

Coolant enters through (E), flows outside of flat tubes (1) in the case, and goes out through (C).

•

Flat tube (1) has inner fins (2), thus EGR gas is cooled efficiently and discharged through EGR gas outlet (D).

KCCV SYSTEM KCCV Abbreviation for KOMATSU Closed Crankcase Ventilation

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM

LAYOUT DRAWING OF KCCV SYSTEM REMARK The shape is subject to machine models.

A: Blowby gas

C: Removed engine oil (to engine oil pan)

B: Blowby gas from which engine oil is removed (to VGT) 1: KCCV ventilator

3: VGT

2: CDR valve

4: Check valve

FUNCTION OF KCCV SYSTEM •

In the past, blowby gas (A) was allowed to be released into the atmosphere in the past, but now it is restricted by emission regulations.

•

Blowby gas (A) contains ingredients of the engine oil. A filter is installed to KCCV ventilator (1) to remove the engine oil to prevent the following possible problems if it is recirculated to VGT (3) as it is. •

Deterioration of turbocharger and aftercooler performance caused by sticking engine oil

•

Abnormal combustion in engine

•

Malfunction of each sensor caused by sticking engine oil

PC360LCI-11E0

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COMPONENT PARTS OF ENGINE SYSTEM

10 STRUCTURE AND FUNCTION

OPERATION OF KCCV SYSTEM Drawing on the left shows the conventional flow of blowby gas. Drawing on the right shows the flow of blowby gas which is sucked in KCCV ventilator and recirculated.

A: Blowby gas

C: Engine oil

B: Clean gas 1: Air cleaner

5: Breather

2: Turbocharger

6: KCCV ventilator

3: Aftercooler

7: Engine oil pan

4: Cylinder block (crankcase) 8: VGT 1. This system removes engine oil (C) from blowby gas (A) in cylinder block (4) by using the filter in KCCV ventilator (6), and recirculate clean gas (B) to the air intake side of VGT (8). 2. Separated engine oil (C) is drained to engine oil pan (7) through the check valve.

KCCV VENTILATOR KCCV Abbreviation for KOMATSU Closed Crankcase Ventilation

STRUCTURE OF KCCV VENTILATOR REMARK The shape is subject to machine models.

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM

General view and sectional view

A: Blowby gas inlet (from engine breather)

C: Oil drain port (to engine oil pan)

B: Blowby gas outlet (to VGT intake side) 1: Case

4: Relief valve

2: CDR valve

5: Impactor

3: Crankcase pressure sensor

6: Filter

Structure •

Filter (6) is classified by the working direction for filter replacement into the top load type (removed upward) and bottom load type (removed downward).

•

The top load type (removed upward) and bottom load type (removed downward) are different from each other in the position of the crankcase pressure sensor. In the top load type (removed upward), the crankcase pressure sensor is installed to the bottom of KCCV ventilator. In the bottom load type (removed downward), the crankcase pressure sensor is installed to the top of KCCV ventilator.

FUNCTION OF KCCV VENTILATOR •

If the blowby gas is returned to the intake side of VGT and crankcase pressure becomes negative, the dust may be sucked in through crank seal. The pressure inside the crankcase is controlled by CDR valve (2) to prevent this to occur.

•

Crankcase pressure may increase and oil leakage may occur if filter (6) of KCCV ventilator is clogged. Thus, crankcase pressure sensor detects the clogging of filter (6).

•

Relief valve (4) is inside case (1), and it operates to bypass the blowby gas and protect both KCCV ventilator and the engine when filter (6) is blocked.

PC360LCI-11E0

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COMPONENT PARTS OF ENGINE SYSTEM

10 STRUCTURE AND FUNCTION

OPERATION OF KCCV VENTILATOR 1.

When the blowby gas enters blowby gas inlet (A) and passes through the hole of impactor (5) in filter (6), large particles in the oil mist are separated.

Small particles in the oil mist are separated by filter (6).

The separated oil oozes out from the bottom of the filter (6), and flows to oil drain port (C), and then flows to the engine oil pan.

The crankcase pressure sensor senses the crankcase pressure (blowby gas pressure). If the engine controller judges through detected value of crankcase pressure sensor that the filter is clogged, it displays failure code CA555, and if the pressure increases further, it displays failure code CA556.

Relief valve (4) is installed in case (1) and operates when filter (6) is blocked.

When the crankcase pressure becomes negative, CDR valve (2) operates for it not to become excessively negative.

CDR VALVE CDR Abbreviation for Crankcase Depression Regulator

OPERATION OF CDR VALVE 1.

Spring (2) normally pushes up diaphragm (1), and the blowby gas flows from crankcase side (A) into turbocharger side (air intake side) (B).

As the intake air at turbochaeger side (air intake side) (B) increases, pressure on crankcase side (P1) decreases.

The reaction force of spring (2) is overwhelmed by ambient pressure (P2). Diaphragm (1) shuts the passage and temporarily blocks the flow.

When the blowby gas accumulates in the crankcase, pressure (P1) on the crankcase side increases, and it pushes up diaphragm (1) again and blowby gas starts to flow.

KDPF KDPF Abbreviation for KOMATSU Diesel Particulate Filter

STRUCTURE OF KDPF REMARK The shape is subject to machine models.

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PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF ENGINE SYSTEM

General view

A: From VGT

B: To AdBlue/DEF mixing connector

1: Inlet unit

8: KDPF outlet temperature sensor

2: Hanger bracket

9: Centralized connector box

3: Sensor bracket

10: KDOC outlet temperature sensor

4: Sensor bracket band

11: KDOC inlet temperature sensor

5: Outlet unit

12: KDPF differential pressure sensor port

6: KCSF unit

13: KDPF differential pressure sensor

7: KDOC unit

14: KDPF differential pressure sensor port

Structure •

KDPF consists of inlet unit (1) to introduce the exhaust gas, KDOC unit (7) to store the oxidation catalyst, KCSF unit (6) to store the soot collecting filter equipped with catalyst, and outlet unit (5) to discharge the exhaust gas.

•

KDOC unit (7) consists of ceramic honeycomb equipped with the oxidation catalyst.

•

The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics under the vibration condition of the engine and machine body. This mat also thermally insulates the periphery of KDPF from the ceramics which becomes high temperature during operation.

•

KCSF unit (6) consists of ceramic honeycomb equipped with the oxidation catalyst, similarly to KDOC unit (7). The inside of KCSF unit (6) consists of many cells partitioned by ceramic walls. The cells blocked on the inlet side and those blocked on the outlet side are arranged alternately.

•

KDPF is equipped with KDPF temperature sensor (assembly of KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF outlet temperature sensor) and the differential pressure sensor (assembly of KDPF differential pressure sensor and KDPF outlet pressure sensor).

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Combination of temperatures detected by these 3 temperature sensors is used to monitor that KCSF unit (6) and KDOC unit (7) are functioning normally, and to troubleshoot various components. The differential pressure sensor monitors accumulation of soot in KCSF unit (6) by sensing the pressure difference between both sides of KCSF unit (6), and uses the obtained data for troubleshooting of various components, similarly to the temperature sensor.

FUNCTION OF KDPF A: Flow of exhaust gas 1: KDOC (oxidation catalyst) 2: KCSF 3: Seal (ceramic made) 4: Cell 5: Ceramics honeycomb •

KDPF purifies the exhaust gas by catching large amount of chainlike soot or PM (Particulate Matter such as soot) which is contained in the engine exhaust gas.

•

KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen monoxide) contained in the exhaust gas into NO 2 (nitrogen dioxide), and regenerates (*1) KCSF.

•

KCSF (2) captures soot.

•

Accumulated soot in KCSF (2) in operation range where the temperature of exhaust gas is relatively high state is naturally oxidized and burnt away by the effect of KDOC (oxidation catalyst) (1). (This is called “passive regeneration”) REMARK “Passive regeneration” cannot be performed if the light load operation and low temperature state of the exhaust gas continue. Accumulated soot is gradually increased.

•

Engine controller always monitors 2 soot accumulation values and compares them. One is presumed soot accumulation based on the engine operating conditions, and the other is the calculated soot accumulation based on the signal from the differential pressure sensor which is attached to KCSF (2).

•

If the amount of accumulated soot and the temperature of engine exhaust gas exceed the specified level, engine controller performs “automatic regeneration” to burn (oxydize) the soot. While performing automatic regeneration, the engine controller calculates the exhaust gas temperature at KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust gas. (This is called “exhaust gas temperature raise control”) The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the injector, and exhaust gas volume is controlled by VGT. The engine controller enhances the oxidation power in KDOC (1) by raising the temperature of engine exhaust gas automatically, and improves combustion efficiency of soot captured in KCSF (2). REMARK When regeneration function on the machine monitor is disabled, or outside air temperature is extremely low, or continuous light load operation is carried out, relatively low exhaust temperature continues. In such case, “automatic regeneration” is not performed and the amount of soot accumulation is increased.

•

If “automatic regeneration” is not performed due to the excess amount of accumulated soot in KCSF (2), perform “manual stationary regeneration” to burn (oxydize) the soot and reduce the amount of soot inside KCSF (2).

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COMPONENT PARTS OF ENGINE SYSTEM

REMARK Excessive amount of the soot interferes the flow of exhaust gas to worsen fuel consumption and engine combustion state. It may lead to other failures. If the amount of soot increases further, “manual stationary regeneration” cannot be performed safely. This will result in a KDPF failure and replacement is unavoidable. Make sure to follow the procedures in the Operation and Maintenance Manual when performing “manual stationary regeneration”. *1: Soot purification (oxidation) treatment

TYPES OF REGENERATION FUNCTIONS Regeneration means to purify (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF or maintain the urea SCR system normal.

Passive regeneration When the exhaust temperature of the engine is relatively high, the oxidation power of soot in the exhaust gas components is increased by the catalysis of KDOC to oxidize (burn) the soot accumulated in KCSF naturally.

Active regeneration (engine exhaust temperature rise control + fuel dosing) •

Automatic regeneration •

When soot is accumulated more than a certain level or the urea SCR system makes a request to maintain itself normal, the engine enters the exhaust temperature rise control mode (*1) and performs fuel dosing (*2) and starts regeneration automatically. The automatic regeneration is also performed by the direction from the engine controller at a set time after the previous regeneration, regardless of soot accumulation in KCSF. *1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or VGT. *2: Fuel injection performed to accelerate regeneration by increasing the exhaust temperature.

•

Manual stationary regeneration •

When the exhaust temperature does not reach a certain level, depending on the operating condition of the machine, or when the operator disables regeneration, the automatic regeneration is not performed and accumulated soot in KCSF increases. Also, when the automatic regeneration is performed upon receiving a request from the urea SCR system, the exhaust temperature may not reach a certain level, depending on the operating condition of the machine. In these cases, a request for the manual stationary regeneration request is displayed on the machine monitor, and the operator must perform regeneration by the operation on the machine monitor screen. In addition, when the engine controller is replaced or ash in KCSF is washed, a serviceman performs regeneration by the operation on the machine monitor screen (“active regeneration for service”).

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NOTICE • For the procedure to start and stop the regeneration of KDPF, see the Operation and Maintenance Manual for each machine. • Always use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a failure in KDPF. • Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the specified one is used, it can clog KDPF quickly, and that can increase fuel consumption and cause a failure in KDPF. • Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally and may have trouble. • Do not give strong impacts to KDPF by standing on it, dropping it, or hitting it, etc. KDPF has ceramic parts in it, and they may be broken by a strong impact. • During the “automatic regeneration” and the “manual stationary regeneration”, especially at low temperature, white smoke may be discharged through the exhaust pipe outlet for a short time. This phenomenon is not abnormal. Be sure to perform regeneration in a well-ventilated area, since carbon monoxide may be generated. • During the “automatic regeneration” and the “manual stationary regeneration”, the temperature of the exhaust gas discharged from the exhaust pipe may increase above 650 °C. To prevent a fire, check that there is no combustible around the exhaust pipe. Also, check that there is no person in the blow-out direction of the exhaust gas and confirm the safety around the machine. REMARK • If the mixing ratio of the bio-fuel in the diesel fuel is high, the regeneration of KDPF may become more frequent. • Even when soot is not accumulated much, the engine controller may start “automatic regeneration”. This is automatic regeneration to maintain the function of KDPF or urea SCR system normal, and is not an abnormal operation. Automatic regeneration to maintain the function of urea SCR system normal or manual stationary regeneration takes approximately 1 hour. • During the “automatic regeneration” and the “manual stationary regeneration”, VGT operates automatically and the engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and accordingly the exhaust sound changes. These phenomena are not abnormal. • During the “automatic regeneration” and the “manual stationary regeneration”, the exhaust pipe may smell different from usual. This is not abnormal phenomenon. • KDPF has “KDPF dry operation” function to prevent excessive accumulation of unburnt fuel in KDPF when operation is continued at relatively low temperature for long hours.This is a function that the engine controller increases the engine exhaust temperature automatically and performs dry operation of KCSF when the set condition is satisfied. When the automatic dry operation is insufficient for the treatment, manual stationary regeneration may be required. • The standard temperature of KDPF is shown below. KDOC In (KDOC inlet temperature sensor) While regeneration is not performed (idling state) While regeneration is performed (thermal mode)

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KDOC Out (KDOC outlet temperature sensor)

KDPF Out (KDPF outlet temperature sensor)

100 to 250 °C 100 to 250 °C

400 to 550 °C

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LAYOUT DRAWING OF COOLING SYSTEM

COOLING SYSTEM LAYOUT DRAWING OF COOLING SYSTEM

1: Reservoir tank

4: Shroud

2: Aftercooler

5: Oil cooler

3: Fan guard

6: Radiator cap

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LAYOUT DRAWING OF COOLING SYSTEM

7: Radiator

10 STRUCTURE AND FUNCTION

9: Radiator outlet hose

8: Radiator inlet hose

SPECIFICATIONS OF COOLING SYSTEM Radiator Core type: CF90-4 Fin pitch: 3.5/2 mm Total heat dissipation area: 76.39 m2 Cracking pressure of pressure valve: 0.05 MPa {0.5 kgf/cm2} Cracking pressure of vacuum valve: -0.005 MPa {-0.05 kgf/cm2}

Oil cooler Core type: 62 thickness Fin pitch: 3.5/2 mm Total heat dissipation area: 32.13 m2

Aftercooler Core type: Aluminum wave Fin pitch: 4.0/2 mm Total heat dissipation area: 17.55 m2

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LAYOUT DRAWING OF CONTROL SYSTEM

CONTROL SYSTEM LAYOUT DRAWING OF CONTROL SYSTEM Chassis part

1: Camera

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LAYOUT DRAWING OF CONTROL SYSTEM

2: CAN terminating resistor

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3: Engine controller

PC360LCI-11E0

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10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF CONTROL SYSTEM

Around cab and floor

1: Machine monitor

7: Resistor for PC-EPC valve

2: Control box

8: Gateway Function Controller

3: Communication terminal

9: Work equipment controller

4: GNSS antenna

10: ICT sensor controller

5: GNSS receiver

11: KomVision controller

6: Pump controller

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MACHINE MONITOR SYSTEM MACHINE MONITOR SYSTEM DIAGRAM

a: Power supply

d: Drive signal

b: CAN signal

e: Camera signal

c: Sensor signal and switch signal

f: Image signal

1: Machine monitor

8: Wiper motor and window washer motor

2: Battery

9: Rearview camera (*1)

3: Pump controller

10: KomVision controller (*2)

4: Engine controller

11: KomVision camera (*2)

5: Air conditioner controller

12: Work equipment controller

6: KOMTRAX terminal

13: ICT sensor controller

7: Sensors and switches *1: Machine without KomVision. *2: Machine with KomVision.

FUNCTION OF MACHINE MONITOR SYSTEM •

The monitor system keeps the operator informed of all the machine conditions, by monitoring them by using the sensors and switches installed in various parts of the machine and processing them instantly to display on the machine monitor.

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MACHINE MONITOR SYSTEM

The information displayed on the machine monitor falls into the following types:

•

Alarm when the machine has trouble

•

Machine state display (coolant temperature, power train oil temperature, hydraulic oil temperature, fuel level, etc.)

•

Display of camera image (machine with camera)

The switches on the machine monitor also have the functions to control the machine.

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KomVision SYSTEM LAYOUT DRAWING OF KOMVISION SYSTEM Chassis part

1: R.H. front camera

3: Rear camera

2: R.H. camera

4: L.H. camera

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KomVision SYSTEM

Around cab and floor

1: Machine monitor

PC360LCI-11E0

2: KomVision controller

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KomVision SYSTEM

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KomVision SYSTEM DIAGRAM

1: Machine monitor

4: Rear camera

2: KomVision controller

5: R.H. camera

3: L.H. camera

6: R.H. front camera (*1)

*1: When four cameras are installed

FUNCTION OF KomVision SYSTEM •

KomVision system is the system that captures the vision around the machine by cameras attached to the various positions of the machine, and reflects the vision on the machine monitor.

•

The machine monitor shows the bird's eye view and the camera view.

•

The bird's eye view displayed on the machine monitor is an image which is electrically composed with images captured by cameras attached to the machine.

•

The camera image displayed on the machine monitor is an image which is captured by camera installed to the machine. The images to be displayed can be selected freely.

k The image displayed on the machine monitor does not reflect all around the machine. Perform the

visual check always when operating the machine.

k Do not rely only on the image displayed on the machine monitor for the safety.

k The cameras do not capture the objects which are located higher than the cameras. Be careful about

the objects which are located higher than the cameras such as a work equipment of the large machine, a branch of the tree, etc.

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KomVision SYSTEM

REMARK • The upper part of the monitor screen does not always mean the front of the machine when the machine is with swing function. • The upper part of the monitor screen recognizes the work equipment side of the upper structure as the front side, and the longitudinal and lateral directions are determined with that. The direction of the undercarriage is not recognized. • For the function and the method of operation of KomVision system, see “Operation and Maintenance Manual”. • Resetting of the items will be required when the blade is replaced or the track length is changed by referring to TESTING AND ADJUSTING, “SETTING OF KomVision (MAIN SETTING)”.

The area KomVision cameras can capture The area KomVision cameras can capture for the bird's eye view varies as shown below, it depends on how many cameras are installed to the machine.

When three cameras are installed 1: L.H. camera 2: Rear camera 3: R.H. camera

When four cameras are installed 1: L.H. camera 2: Rear camera 3: R.H. camera 4: R.H. front camera

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KOMTRAX SYSTEM KOMTRAX SYSTEM DIAGRAM

1: Gateway Function Controller 2: Communication terminal 3: GNSS antenna 4: Communication antenna (Iridium communication version)

FUNCTION OF KOMTRAX SYSTEM The KOMTRAX system is a system that does a check of various types of information on the machine remotely. The Gateway Function Controller collects the information to transmit it to the data server via wireless communication. •

Position information

•

Working information

•

Alarm and failure information

•

Fuel consumption information

•

Maintenance information

•

Machine working condition information

Above information is the examples. KOMTRAX administrators can use this information to supply different services to customers. The radio station for KOMTRAX needs to be established separately to start the KOMTRAX services.

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PPC LEVERS

PPC LEVERS LH PPC LEVER

Lever

Gaiter

Harness

Connector

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PPC LEVERS

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RH PPC LEVER

Lever

Gaiter

Harness

Connector

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AUTOMATIC GREASE SYSTEM

AUTOMATIC GREASE SYSTEM OUTLINE OF AUTO GREASE SYSTEM 3

11 8 12

9 14

Distribution Block 16

Distribution Block

1 2

Distribution Block

In-Cab Display Pressure switch

Assembly Greasing system generally consists of the following components (see figure 1): 1. Electrically-driven plunger-pump with grease reservoir 2.

Control unit (integrated in the pump housing)

Distribution blocks

Metering units

Secondary grease lines

Grease pressure switch

Primary grease line A

Primary grease line B

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5 4

3 8

Figure 1 Overview of the automatic greasing system

Components (a) The Grease Pump The relief valve A relief valve is mounted in the grease line between the plunger-pump and the diverter-valves. When the grease pressure exceeds25 MPa during the pumping phase, the relief valve will redirect the grease to the reservoir. The maximum grease procedure will be exceeded when: • A malfunction of the grease pressure switch, which is mounted in the system occurs. •

A malfunction in the cable of the grease pressure switch occurs.

The grease pressure switch is intended to end the pumping phase, as soon as the minimum required grease pressure is reached.

The minimum-level switch A level switch maintains the grease level in the reservoir. When the grease reaches the minimum level, the level switch will notify the control unit. At the beginning of every following grease cycle a signal lamp in the cabin will flash as a warning that the reservoir has to be refilled.

The test push-button The grease system can be tested by starting one or more test cycles by means of the test push-button on the pump unit. This button also can be used to reset the control unit.

(b) Distribution Blocks and Metering Units Various types of metering units with the greasing system are available, each with a different grease output. Each greasing point can receive the correct dose of grease cycle by a careful choice of the type of metering unit. The metering units are mounted on a brass distribution block per group (see figure 2). These primary grease lines are connected. The blocks are deliverable with 2, 3, 4, 5, 6, 7, 8, 9, 12, 14, 18, 20, 21 or 22 ports (exits). Greasing points are connected to these ports through metering units and secondary grease lines. Unused ports are sealed with a blind plug. The metering units and distribution blocks are made of brass. The various metering units are distinguished from each other using numbers (see figure 2).

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Figure 2 Distribution block with metering units

The table below is an overview of the metering unit numbers and their grease capacity. Position

Metering Unit

Grease Capacity

0.400

0.150

0.100

0.150

0.050

0.400

0.050

0.400

0.200

1.000

0.100

1.000

2.000

0.200

2.000

(c) Grease Pressure Switch The grease pressure switch notifies the control unit that sufficient pressure has been built during the greasing cycle (in the pumping phase). If the required pressure is not reached in the maximum adjusted pumping time, an alarm follows.

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(d) The Display The display continuously indicates the adjusted operating mode with green lamps. A yellow lamp lights when the minimum grease level is reached and a red lamp lights when a malfunction occurs. The display is also equipped with a push-button with which another operating mode can be chosen at any moment.

The greasing cycle Every greasing cycle consists of four phases. The greasing cycles are carried out alternately by the grease lines A and B (see figure 3). The 5/2 valve, which is integrated in the pump housing, determines which primary grease line is connected to the pump and which is connected to the grease reservoir. The total greasing cycle has a predetermined time; however, the length of the four phases depend on the circumstances. The different greasing cycles and phases are discussed below.

Figure 3 Overview of the various phases of the greasing cycles

Greasing Cycle A The pumping phase The greasing cycle begins with a pumping phase. In this phase the grease is pumped from the reservoir, through primary grease line A, to the distribution blocks. The pumping phase ends when the pressure at the pressure switch reaches a predetermined level. The time needed to reach that predetermined pressure depends on various factors as temperature, grease consistency (thickness) and the dimensions of the greasing system. The duration of the pumping phase is therefore not directly adjustable. During the pumping phase, the metering units press a certain amount of grease (the dosage) through the secondary grease lines to the greasing points.

The re-grease phase The re-grease phase follows the pumping phase; a period in which the pressure in the primary grease lines is maintained at a certain pressure. During the re-grease phase, the metering units can deliver the grease dosage, which (for various reasons) was not delivered during the pumping phase. The duration of the regrease phase depends on the duration of the pumping phase. This dependency is expressed in the parameter bmf, bleeding multiplication factor. • Example: When the bmf is 1, the re-grease phase is 1/10th of the length of the pumping phase. When the bmf is 10, the re-grease is 10/10th of the length of the pumping phase.

The pressure decrease phase The pressure decrease phase follows the re-grease phase. In this phase, the pressure in the primary grease line is decreased through the 5/2 valve. To accomplish this, the control unit energises the 5/2 valve, so the grease pressure in primary grease line A is decreased and the grease flows back to the reservoir. The duration of the pressure decrease phase is equal to that of the re-grease phase and therefore proportional to the duration of the pumping phase. When the greasing system needs more time to build up the required grease pressure (because of low temperature or grease with a high viscosity), the system will also need more time to decrease that same pressure.

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The pause phase The pause phase is the period between the pressure decrease phase and the beginning of the next pumping phase. The length of the pause phase is equal to the predetermined cycle-time minus the length of the other phases. When the cycle-time is adjusted too short to carry out a complete greasing cycle, the program will ignore the cycle-time. The pumping, re-grease and pressure decrease phase will be carried out completely. However the pause phase will be omitted, because the predetermined cycle-time is exceeded. The greasing system begins directly with the first phase of the next greasing cycle.

Greasing cycle B Greasing cycle B begins when the control unit restarts the pump. During pumping phase B and re-grease phase B, the control unit still has the 5/2 valve energised, causing the pump to be connected to primary grease line B. Primary grease line A is shut off from the pump during these phases and connected to the reservoir. During the phase B pressure decrease, the control unit de-energises the 5/2 valve, so the grease pressure in the grease line decreases and the grease flows back to the reservoir.

Introduction In this chapter the principles of the operation of the various parts of the automatic greasing system are discussed. The pump unit, metering units, grease pressure valve, control unit, signal lamp and display are discussed.

(a) Pump unit The pump unit consists of various parts. These parts are shown in figure 4.

16 4

19 14

13 12

7 8

9 Figure 4 Pump unit assembly

1. Grease follower piston

11. Electro-motor

2. Grease reservoir

12. Test push-button

3. Stirring gear

13. Filler coupling with grease filter

4. Cam

14. Relief valve

5. Cylinders and plungers (3 x)

15. Follower piston guide

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6. 5/2 Magnetic valve

16. Electric connector

7. Primary grease line 'A' coupling

17. Minimum level switch

8. Primary grease line 'B' coupling

18. Bleeding and grease overflow channel

9. Mechanical transmission

19. Bleeding and grease overflow channel at right side of pump connected to the grease overflow channel in follower piston guide (Nos. 15 and 18)

10. Control Unit

The heart of the pump is an electrical-driven plunger-pump. This pump consists of three radially-placed fixed cylinders and plungers (5, see figure 4). The electro-motor drives the axle through the mechanical drive. A cam (4) is fixed on the axle that moves the three plungers to and fro, so the grease is pumped to the distribution blocks through the primary grease line. In addition to the cam, the axle drives the stirring gear (3) located at the bottom of the reservoir and pushes the grease downwards. A compression channel is located between the pump and the grease channels to the primary grease lines. A relief valve (14) and a 5/2 valve (6) are located in the compression channel. The relief valve is a protection that leads the grease back to the reservoir when the grease pressure exceeds 25 MPa. The 5/2 valve determines the primary grease line (A or B) through which greasing takes place. It has an important task in fulfilling the four phases of the greasing cycle.

The grease reservoir and the grease follower piston The reservoir (2, see figure 4) is made of a transparent, impact-proof plastic that resists the affect of variable temperatures and other environmental influences. The volume of the reservoir depends on the height of the reservoir. The maximum grease level is indicated on the reservoir. A warning signal in the cabin indicates when the minimum level has been reached. A grease follower piston (1) is located in the reservoir, above the grease. This piston follows the level of the grease. When the grease level falls, the piston also falls under the influence of a draw spring. The grease follower piston locks out air and condensation, so preventing: • Oxidation of the grease •

Mingling of the grease with the water of condensation

•

Saponifying of the grease

The grease level in the reservoir can always be determined at a glance, because the grease follower piston scrapes the walls of the reservoir. Also the grease follower piston prevents funnel-forming in the grease, so the grease supply can and will be used in its entirety.

The 5/2 Magnetic Valve

Figure 4.1 5/2 Magnetic Valve

A: Primary grease line A (port A) B: Primary grease line B (port B) P: From pump RA: Return line A to grease reservoir RB: Return line B to grease reservoir When the 5/2 magnetic valve is at stationary (not energised by the control unit, see figure 4.1), greasing will take place through the primary grease line A and the pressure in primary grease line B will decrease and the grease will lead back to the reservoir through return line RB.

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When the 5/2 magnetic valve is energised by the control unit, the grease supply channel P will be connected to primary grease line B and primary grease line A will be connected to return line RA in the pump. Greasing takes place through primary grease line B, the pressure grease line A will decrease and the grease will be lead back to the reservoir through return line RA . For an extensive description of the greasing cycle and the influence of the position of the 5/2 magnetic valve on the greasing cycle , see paragraph ''The Greasing Cycle''.

(b) Metering units Do not open the metering units. Prevent intrusion of dirt and thus a possible cause of malfunction. Two grease chambers are located in a metering unit (one for each primary grease line, A and B). These chambers are filled with an exact amount of grease. When the actual greasing takes place through one of both chambers, the grease is pressed from the chambers to the relevant greasing point. The principle of operation of the metering unit is explained in the four phases below.

Phase 1 In this phase, the metering unit has not yet filled with grease (see figure 4.2)

Figure 4.2 Principle of operation of the metering unit - first phase

While in operation (system completely filled with grease) phases 3 and 4 will take place alternately.

Phase 2 Grease is pumped into the metering unit (pumping phase A) through primary channel A (see figure 4.3). Because of the grease pressure, plunger (3) is pushed to the right, passed channel (1). The grease fills chamber (2) through channel (1) and presses plunger (4) to the right. 1

Figure 4.3 Principle of operation of the metering unit - second phase

After a while the pressure drops in primary channel A (during the pressure decrease phase of the greasing cycle). This has no influence on the metering unit.

Phase 3 Grease is pumped into channel (6) of the metering unit (pump phase B) through primary channel B (see figure 4.4). Because of the grease pressure, plunger (3) is pushed back leftwards, passed channel (8). The grease fills chamber (7) and pushes plunger (4) back to the left. The complete grease volume of chamber (2), to the left of plunger (4), is pressed through channel (1), plunger (3) and channel (9) and the secondary grease line (5) to the greasing point. Sphere (10) in the non-return valve is pushed back to clear the path to the secondary grease line.

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1 2

7 4

5 10

Figure 4.4 Principle of operation of the metering unit - third phase

After a while, the pressure drops in primary channel B (during the pressure decrease phase of the greasing cycle). This has no influence on the metering unit.

Phase 4 In this phase the same happens as in phase 2. However chamber (7) (see figure 4.4) is now filled with grease. Plunger (4) is pushed to the right (see figure 4.5) while chamber (2) is filled. The complete grease volume of chamber (7) is pressed through channel (8), plunger (3) and channel (9) and the secondary grease line (5) to the greasing point. Sphere (10) in the non-return valve is pushed back to clear the path to the secondary grease line. 2 3

8 4

10 9

Figure 4.5 Principle of operation of the metering unit - fourth phase

Phase 1 During this phase both channels A and B are not under pressure (see figure 4.6). There is also no pressure in chamber (1). Spring (10) pushes switch plunger (2) to the left. The electrical contact (3 and 4) is open.

* Figure 4.6 Principle of operation of grease pressure switch - rst phase

Phase 2 (pumping phase A) During pumping phase A grease is pressed into channel A (see figure 4.7). While the grease pressure is built up, piston (6) is pushed to the right. Chamber (1) is connected to channel A (through the channels 7, 8 and 9). As soon as the pressure in chamber (1) is more than the pressure force of the spring (10), plunger (2) goes to the right. The electrical contact (3 and 4) is closed by the contact plate (5). During the pressure decrease phase, as soon as the grease pressure in channel A is lower than the pressure force of the spring, the connection of contacts is broken.

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* Figure 4.7 Principle of operation of grease pressure switch - second phase

Phase 3 (pumping phase B) During pumping phase B grease is pressed into channel B (see figure 4.8). While the grease pressure is built up, chamber (11) fills with grease (through channel 12). The grease pressure pushes piston (6) to the left. Because of that the channel (8) is opened, causing the grease to flow to chamber (1) through channel (7) and channel (9). As soon as the pressure in chamber (1) is greater than the pressure force of the spring (10), the plunger (2) goes to the right. The electrical contact (3 and 4) is closed by the contact plate (5). As soon as the grease pressure, during the pressure decrease phase, in channel B is lower than the pressure force of the spring, spring (10) pushes plunger (2) back to the left and the connection of the contacts is broken.

* Figure 4.8 Principle of operation of grease pressure switch - third phase

(d) Control unit Introduction The greasing system is controlled by an electronic control unit. The sensors that check specific parts or the complete greasing system for malfunctions are connected to the control unit. The control unit controls the greasing system by: • The parameters that are saved in the control unit. To recall or change the system parameters requires a laptop and software: •

The signals that the control unit receives from the various sensors and controls applied in the greasing system: e.g., grease pressure switch, grease level switch, test push-button, push-button with signal lamp in the cabin.

The control unit records an automatic log, in which the relevant events are stored. All data in the control unit will always be retained, even when the power is shut off or when the system is turned off. To view the log requires a laptop and software. In this paragraph the following system parameters are discussed: • The length of the greasing cycles; •

Maximum length of the pumping phase;

•

Length of the re-grease phase and the pressure phase;

•

Reaction of the system to grease pressure malfunctions;

•

Repeating frequency of the flashing code;

•

The log.

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10 STRUCTURE AND FUNCTION

The length of the greasing cycles The meaning of the various phases of the greasing cycle is described in paragraph 3. (further see figure 4.9)

Figure 4.9 Overview of the various phases of the greasing cycle

The duration of a greasing cycle (adjustment range: 0 ... 1440 minutes) is defined as the period that expires between two successive pumping phases: beginning from the start of one pumping phase and ending at the start of the next pumping phase. A greasing cycle is divided into a pumping phase, a re-grease phase, a pressure decrease phase and a pause phase. The greasing cycles are alternately taken care of by primary grease lines A and B.

Maximum length of the pumping phase Normally, the pumping phase will end when the grease pressure switch notifies the control unit that the required pressure in the greasing system has been reached. Prevent the pump from pumping indefinitely when the notification does not occur. A maximum pumping time is therefore stored in the control unit (adjustment range: 1 ... 60 minutes). At a normal (average) pumping phase, shorter than 5 minutes, the maximum pumping phase is adjusted as follows: multiply the normal pumping time by 2. When the normal pumping phase is longer than 5 minutes, the maximum pumping time is adjusted to: normal duration +5 minutes.

Length of the re-grease and pressure decrease phases The duration of the re-grease phase is equal to the length of the pressure decrease phase. The pressure decrease phase is proportional to the length of the pumping phase. In the control unit a multiplication factor is stored. The duration of the pressure decrease phase is calculated by the control unit by multiplying the duration of the pumping phase with that factor. (adjustment range: 1 ... 100 - which corresponds to multiplication factors 0, 1 ... 10). The standard adjustable value is 1 (multiplication factor 0, 1), when the duration of the re-grease phase and the pressure decrease phase is one tenth of the duration of the pumping phase. When circumstances require and extended pressure decrease phase, a higher factor is adjusted.

Reaction of the system to grease pressure malfunctions. When the required grease pressure during several pumping phases is not reached, it indicates e.g., a leak in a primary line. To prevent the contents of the reservoir being pumped into the environment, the greasing system should be shut down. Greasing is stopped, until the cause of the malfunction is repaired and the control unit is reset with the test push-button. Normally the pump is shut off by the control unit when in 10 successive greasing cycles the required grease pressure has not been reached during the pumping phase. Meaning: the control unit shuts off the pump when the grease pressure has not been reached 10 successive times while greasing alternately through lines A and B, thus 5 times A and 5 times B but the control unit also shuts off the pump when the grease pressure is not

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AUTOMATIC GREASE SYSTEM

reached 10 times successively when greasing through line B, however through line A the pressure is still reached and also the other way around. With parameter 'noa' (number of attempts), a different value for the maximum number of attempts can be adjusted. The adjustment depends on the malfunction sensitivity of the connected greasing points. The adjustment range is 1 to 25 greasing cycles.

Display A display is also deliverable instead of the operating mode push-button with integrated signal lamp. On this display green lamps continuously indicate the adjusted operating mode. In addition, this display is equipped with a yellow warning lamp (minimum grease level reached), a red lamp (system malfunction) and a pushbutton to adjust the desired operating mode.

In the following table an overview is given of the normal signal Meaning

Indication The red lamp (6) flashes as soon as the ignition has been switched on.

1. The pump is not powered. Check fuses and connections to earth. Immediate action required.

No lamp is lighting up when the starting switch is in the ON position.

1. The system is not powered. Check fuses and connections to earth. Immediate action required.

Yellow lamp (5) flashing

Minimum level in the reservoir has been reached.

2. The connection between the in-cab display and pump is defective, replace if necessary.

2. The display or wiring of the in-cab display is defective. Check in-cab display and wiring and replace if necessary. Reset by refilling the reservoir.

Red lamp (6) flashing

System out of order. Immediate action required! Possible causes: • Insufficient grease pressure during 10 consecutive cycles (or 10 consecutive times in

the same main line). Check for cause and reset by depressing the test button at the pump for at least 1 second while the ignition is switched on.

• Green lamp (4) flashing

Reservoir empty; reset by refilling reservoir and after that depressing the test button for at least 1 second while the ignition is switched on.

Low duty

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Green lamp (4) flashing

10 STRUCTURE AND FUNCTION

Normal duty

Green lamp (4) flashing

Heavy duty

A green lamp is flashing during one complete cycle (2.0 sec on/2.0 sec off)

Single test run being executed (see tests).

A green lamp is Continuous test run being executed (see tests). flashing continuously (0.2 sec on/0.2 sec off)

REMARK 1. The display communicates with the control unit every 20 secs. A started test cycle can only be shown on the display after 20 secs. 2. The display is equipped with a light-sensitive cell. Therefore the light intensity of the lamps is automatically dimmed when the surroundings become darker.

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COMPONENT PARTS OF CONTROL SYSTEM

COMPONENT PARTS OF CONTROL SYSTEM MACHINE MONITOR FUNCTION OF MACHINE MONITOR

•

The machine monitor has the monitor display function, mode selection function, and switch function of the electrical components, etc. It also has the built-in warning buzzer.

•

CPU (Central Processing Unit) is mounted inside, and it processes, displays, and outputs information.

•

The monitor system monitors the machine state by obtaining the information with the sensors and switches installed in various parts of the machine, processes the information instantly to display on the machine monitor, and informs the operator of the machine condition. The information displayed on the machine monitor falls into the following types.

•

Alarm when the machine has trouble

•

Machine state display (engine coolant temperature, hydraulic oil temperature, fuel level, etc.)

•

Display of camera image

The switches on the machine monitor have functions to control the machine.

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REMARK • The machine monitor consists of the display and switch section. The display is LCD (Liquid Crystal Display), and the switch section consists of flat sheet switches. • If there is abnormality in the machine monitor, controller, or wiring between the machine monitor and controller, the machine monitor does not display normally. • The battery voltage may drop sharply when the engine is started depending on the ambient temperature and battery condition. In this case, the display may disappear for a while, but it is not an abnormal phenomenon. • If environmental temperature of the machine monitor is high, brightness may be automatically reduced to protect the liquid crystal. • Intensity or color of the objects may change because of the automatic adjustment function of the camera. • See “Operation and Maintenance Manual” for the following items. •

Display (screen display)

•

Switches

•

Guidance icons and function switches

INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR 070-18P “CM01” Pin No.

Signal name

Input/output signal

Continuous power supply (24 V)

Input

Continuous power supply (24 V)

Input

GND (continuous power supply)

External starting signal

Input

Starting motor cut-off relay (for personal code)

Output

(*1)

System operating lamp

Lamp switch

Input

Starting switch (ACC)

Input

Starting switch (C)

Input

Preheating

Input

Engine shutdown secondary switch

Input

(*1)

Fuel level sensor

Input

Charge level (alternator terminal R)

Input

(*1)

Input/Output

*1: Never connect these pins. Malfunctions or failures may occur.

070-12P “CM02” Signal name

Pin No.

10-96

Input/output signal

Seat belt alarm switch

Input

Engine oil level sensor

Input

Radiator coolant level sensor

Input

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10 STRUCTURE AND FUNCTION

Pin No.

COMPONENT PARTS OF CONTROL SYSTEM

Signal name

Input/output signal

Air cleaner clogging sensor

Input

Swing lock switch

Input

(*1)

CAN (C) terminating resistor terminal

CAN (C)_H

Input/Output

CAN (C)_L

Input/Output

CAN (R) terminating resistor terminal

CAN (R)_H

Input/Output

CAN (R)_L

Input/Output

*1: Never connect these pins. Malfunctions or failures may occur.

070-20P “CM03” Pin No.

Signal name

Input/output signal

(*1)

*1: Never connect these pins. Malfunctions or failures may occur.

070-8P “CM04” Signal name

Pin No.

Input/output signal

Power supply for camera (8 V)

Output

Camera NTSC signal 1

Input

Camera NTSC signal 2

Input

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COMPONENT PARTS OF CONTROL SYSTEM

Pin No.

10 STRUCTURE AND FUNCTION

Signal name

Input/output signal

Camera NTSC signal 3

Input

GND (power supply for camera)

Camera 2 normal image/mirror image selection

Output

Camera 3 normal image/mirror image selection

Output

GND (shield)

TYPES OF GAUGES AND METERS DISPLAYED ON MACHINE MONITOR *1: The gauge pointer disappears if the gauge signal is not available due to an open circuit in the CAN communication line. *2: Display can be switched by selecting another item in ECO Guidance → Configurations on user menu. Gauge

Item displayed

Description Range

Engine coolant temperature gauge (*1)

105 °C

Red

102 °C

Red

100 °C

Blue

85 °C

Blue

60 °C

Blue

30 °C

White

10-98

Temperature

Monitor background

105 °C

Red

102 °C

Red

100 °C

Blue

85 °C

Blue

40 °C

Blue

20 °C

White

Range

Fuel gauge (*1)

Monitor background

Range

Hydraulic oil temperature gauge (*1)

Temperature

Remarks

Quantity

Monitor background

462 ℓ

Blue

347 ℓ

Blue

278 ℓ

Blue

139 ℓ

Blue

100 ℓ

Blue

56 ℓ

Red

•

Indicates corresponding temperature range.

•

Alarm buzzer sounds at 105 °C or higher.

•

If monitor background color is white, warm up the engine.

•

Indicates corresponding temperature range.

•

Alarm buzzer sounds at 105 °C or higher.

•

If monitor background color is white, warm up the hydraulic components.

Indicates corresponding remaining quantity.

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10 STRUCTURE AND FUNCTION

Gauge

COMPONENT PARTS OF CONTROL SYSTEM

Item displayed

Description Segment Green

1 to 8

Orange

9, 10

ECO gauge (*2)

Range

AdBlue/DEF level gauge

Service meter

Load level Indicates instantaneous fuel consumption (average of fuel consumption by 3 Light to seconds) in 10 steps. medium (Displays when ECO Guidance → Configurations → ECO Gauge on user menu is set to ON.) Heavy Gauge range

Quantity

100 %

Green

75 %

Green

50 %

Green

25 %

Green

10 %

Green

2.5 %

Red

Indicates corresponding remaining quantity.

Indicates accumulated engine operating hours (alternator is generating).

00000.0 h to 99999.9 h

• Clock

Fuel consumption gauge (*2)

Remarks

(Press F4 switch to change to clock display.) Displays the time.

12-hour system display (AM/PM)

•

24-hour system display

•

1 Day

•

Split time

•

None

(Press F4 switch to change to service meter display.) Displays average fuel consumption. (Display can be switched by selecting another item in ECO Guidance → Configurations → Average Fuel Consumption Display on user menu.)

TYPES OF CAUTION LAMPS DISPLAYED ON MACHINE MONITOR Range and method for display Symbol

Item to be displayed

Coolant temperature (*1)

PC360LCI-11E0

Range

Caution lamp display (background color)

Remarks

Action level display

102 °C or higher

Lit (red)

L02

30 °C or higher, and lower than 102 °C

Lit (blue)

Below 30 °C

Lit (white)

•

Monitor background color changes depending on the temperature detected.

•

Alarm buzzer sounds when the temperature exceeds 105 °C.

•

If monitor background color is white, warm up the engine.

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10 STRUCTURE AND FUNCTION

Range and method for display Symbol

Item to be displayed

Hydraulic oil temperature (*1)

Fuel level (*1)

Range

(background color)

•

Monitor background color changes depending on the temperature detected.

•

Alarm buzzer sounds when the temperature exceeds 105 °C.

•

If monitor background color is white, warm up the hydraulic components.

Lit (red)

Background color of monitor changes according to fuel level.

Lit (blue)

Lit (red)

L02

20 °C or higher, and lower than 102 °C

Lit (blue)

Below 20 °C

Lit (white)

Below 56 ℓ 56 ℓ or higher

(Below specified level) (Below specified level) Normal

Lit (red)

Lit (yellow)

L01 (*3)

Not lit

Engine oil pressure (*1)

Engine oil level (*1)

Air cleaner is clogged (*1)

10-100

When it is abnormal (Below specified pressure) When it is abnormal (below specified level)

Lit (red)

Lit (yellow)

L03

Lit (yellow)

Caution lamp background color changes depending on the hours detected.

•

When the background color of caution lamp is red, the warning buzzer sounds.

Caution lamp lights up and alarm buzzer sounds when an abnormality is detected while engine is running. Caution lamp lights up and alarm buzzer sounds when an abnormality is detected while engine is running.

L01 (*3)

Caution lamp lights up if an abnormality is detected when engine stops.

L01 (*3)

Caution lamp lights up if an abnormality is detected while engine is running.

When it is abnormal (Above the specified pressure)

• L02

When charging is faulty

Battery charge (charge voltage (*1) < battery voltage)

Remarks

Action level display

102 °C or higher

For an entire hour Radiator coolant level (*1)

Caution lamp display

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF CONTROL SYSTEM

Range and method for display Symbol

Item to be displayed

Range

When maintenance due time is over Maintenance due time warnWhen mainteing nance notice time is over (*2)

State of system

State of engine system

Lit (red)

L04, L03

When action level L01 is detected

Lit (yellow)

L01 (*3)

When action level L04 or L03 is detected

Lit (red)

L04, L03

When action level L01 is detected

Lit (yellow)

L01 (*3)

When action level L04 or L03 is detected

Lit (red)

L04, L03

Lit (yellow)

L01 (*3)

Lit (red)

L04, L03

Lit (yellow)

L01 (*3)

When action level L04 or L03 is detected

Lit (red)

L03

When action level L01 is detected

Lit (yellow)

L01 (*3)

When engine overruns

Lit (red)

•

The display changes depending on how long it has passed since the maintenance due time was over.

•

After starting switch is turned to ON position, caution lamp lights up if condition for lighting it up is satisfied, and then goes out in 30 seconds.

•

Caution lamp lights up when an abnormality is detected in machine system.

•

When the background color of caution lamp is red, the warning buzzer sounds.

•

Caution lamp lights up when an abnormality in engine system is detected.

•

When the background color of caution lamp is red, the warning buzzer sounds.

•

Caution lamp lights up when an abnormality is detected in hydraulic system.

•

When the background color of caution lamp is red, the warning buzzer sounds.

•

Caution lamp lights up when an abnormality in KDPF system is detected.

•

When the background color of caution lamp is red, the warning buzzer sounds.

•

Caution lamp lights up when soot is accumulated inside the KDPF or cleaning function is abnormally degraded.

•

When the background color of caution lamp is red, the warning buzzer sounds.

When action level L04 or L03 is detected

el L01 is detected

PC360LCI-11E0

Lit (red)

When action level L04 or L03 is State of KDPF detected system When action lev-

Engine overrun

(background color)

Remarks

Action level display

Lit (yellow)

State of hydraulic system When action level L01 is detected

Accumulation of soot in KDPF

Caution lamp display

L02

Caution lamp lights up and warning buzzer sounds when engine overrun is detected.

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COMPONENT PARTS OF CONTROL SYSTEM

10 STRUCTURE AND FUNCTION

Range and method for display Symbol

Item to be displayed

State of air conditioner

AdBlue/DEF level

State of AdBlue/DEF system

Range

Caution lamp display (background color)

When air conditioner is abnormal

Lit (yellow)

L01 (*3)

0.09 % or low

Lit (red)

L04

2.5 % or low

Lit (red)

L03

10 % or low

Lit (red)

Exceeds 10 %

Lit (blue)

When action level L04 or L03 is detected

Lit (red)

L04, L03

When action level L01 is detected

Lit (yellow)

L01 (*3)

Engine stops High temperawhile the tem- ture is detected perature of in AdBlue/DEF AdBlue/DEF system 150 system is high. times or more

Lit (yellow)

L01 (*3)

Lit (red)

L03

Lit (yellow)

L01 (*3)

When action level L04 is detected

Lit (red)

L04

When action level L03 is detected

Lit (red)

L03

When action level L02 is detected

Lit (red)

L02

When action level L01 is detected

Lit (yellow)

L01 (*3)

Engine abruptly stops 2000 times or more

Remarks

Action level display

Caution lamp lights up when an abnormality is detected in air conditioner system. •

The background color of caution lamp changes corresponding to the fuel level.

•

Alarm buzzer sounds at 2.5 % or lower.

•

Caution lamp lights up when an abnormality is detected in AdBlue/DEF system.

•

Alarm buzzer sounds when the monitor background is red.

When the engine is stopped with high temperature of AdBlue/DEF being detected more than 150 times, the caution lamp lights up.

Engine abrupt- Engine abruptly ly stops by AIS stops 1000 times or more, and less than 2000 times

Action level

Camera system (*4)

10-102

When action level L01 is detected

Lit (yellow)

L01

•

Caution lamp lights up when abnormality is detected in the machine.

•

When the background color of caution lamp is red, the warning buzzer sounds.

Caution lamp lights up when an abnormality caused by open circuit of cables, looseness of connectors, or abnormality of camera signals caused by disconnection is detected.

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF CONTROL SYSTEM

Range and method for display Symbol

Item to be displayed

Camera system (*4)

ICT component abnormality

ICT System Abnormality

Range

PC360LCI-11E0

(background color)

Lit (yellow)

L01

Range

Monitor display (background color)

Action level monitor

When action level L04 is detected

Lit (red)

L04

When action level L03 is detected

Lit (red)

L03

When action level L02 is detected

Lit (red)

L02

When action level L01 is detected

Lit (yellow)

L01

Range

Monitor display (background color)

Action level monitor

When action level L04 is detected

Lit (red)

L04

When action level L03 is detected

Lit (red)

L03

When action level L02 is detected

Lit (red)

L02

When action level L01 is detected

Lit (yellow)

L01

When action level L00b is detected

Lit (yellow)

Remarks

Action level display

When action level L01 is detected

ICT calibration When action levhas not been el L01 is detecperformed yet. ted IMU initial process abnormality

Caution lamp display

L01

Caution lamp lights up when an abnormality is detected in KomVision system. •

Monitor lights up when abnormality is detected in ICT component.

•

Alarm buzzer sounds when the background color is red.

•

Monitor lights up when abnormality is detected in ICT system.

•

Alarm buzzer sounds when the background color is red.

•

Monitor lights up when calibration is detected as not having been performed yet.

Monitor lights up when internal sensor output error is detected in IMU.

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COMPONENT PARTS OF CONTROL SYSTEM

10 STRUCTURE AND FUNCTION

Range and method for display Symbol

Item to be displayed

State of cylinder function

Range

Caution lamp display (background color)

Cylinder has not been reset.

Lit (yellow)

Remarks

Action level display

Lit when none of the cylinder reset for arm, boom, or bucket has been performed after turning the starting switch to ON position.

*1: These are included in the Check before starting items. these symbols are lit for 2 seconds after the starting switch is turned to ON position, and returns to the standard state if no failure is found. *2: Maintenance notice time can be changed on Maintenance Mode Display Setting of service mode. *3: These items are lit for 2 seconds, and then go out. *4: For machine with KomVision.

TYPES OF PILOT LAMPS DISPLAYED ON MACHINE MONITOR Symbol

Item displayed

Description •

Operates automatically Indicates the operation status of preheater. at low temperature. (Lights up for approx.30 sec. at maximum.)

•

Goes off after engine is started.

Automatic preheating

Preheating

Manual preheating

One-touch power max. switch One-touch power maximizing

10-104

Remarks

Elapsed time after turning starting switch to HEAT (preheat)

Monitor display

0 to 30 seconds

Lights up

30 to 40 seconds

Flashes

40 seconds or longer

Goes off

Monitor display

Indicates operation status of one-touch power maximizing function.

Lights up ON

(Goes off approx. 8.5 seconds after, if held down)

OFF

Goes off

PC360LCI-11E0

10 STRUCTURE AND FUNCTION

Symbol

COMPONENT PARTS OF CONTROL SYSTEM

Item displayed

Description Swing parking brake cancel switch

Monitor display

OFF

Goes off

OFF

Lights up

OFF

Flashes

Swing lock switch Swing lock

Remarks

INT: Intermittent operation Wiper

ON: Continuous operation

Displays operation state of swing lock.

Displays the operation state of front window wiper.

Goes off: Stopped

Air conditioner

Seat belt

Engine stopped

Aftertreatment devices regeneration

Aftertreatment devices regeneration disable

Lights up: ON Goes off: OFF

Lights up: Not fastened

Lights up: When engine is stopped

Indicates the operation status of engine.

Goes off: While engine is running Lights up: Aftertreatment devices regeneration in progress

Indicates regeneration state of aftertreatment devices.

Lights off: Aftertreatment devices regeneration completed

Lights up: Aftertreatment devices regeneration disabled Lights off: When aftertreatment devices regeneration disable is canceled

Lights up: There is unread message.

(Unread)

Goes off: No message.

Message

Lights up: There is already-read message (No return mesbut return message for it is not sent yet. sage, alreadyGoes off: No message. read message)

PC360LCI-11E0

Indicates whether seat belt is fastened.

Goes off: Fastened

Message

Auto-deceleration

Indicates the operation status of air conditioner and blower.

Lights up: ON

•

Indicates regeneration state of aftertreatment devices.

•

When manual stationary regeneration is necessary, KDPF soot accumulation caution lamp lights up.

Displays the state of message.

Displays operation state of autodeceleration function.

Goes off: OFF

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COMPONENT PARTS OF CONTROL SYSTEM

Symbol

Item displayed

10 STRUCTURE AND FUNCTION

Description P: Heavy-duty operation

Remarks Indicates the set working mode.

E: Low-fuel consumption operation L: Fine control operation Working mode

B: Breaker operation ATT/P: 2-way attachment operation ATT/E: 2-way attachment operation with low fuel consumption Lo: Low-speed travel

Travel speed

Mi: Middle-speed travel

Displays the set mode of travel speed.

Hi: High-speed travel

ECO guidance

•

Idle stop guidance

•

Deterrence guidance of hydraulic relief

•

Economy Mode (recommended) guidance

•

Reduce travel speed recommendation guidance

•

Low fuel level guidance

Indicates the guidance to support operation of the machine.

OPERATOR MODE FUNCTION OF MACHINE MONITOR The information items in this mode are displayed ordinarily. The operator can display and set them by operating the switches. Display and setting of some items need special operations of the switches. Items available in the operator mode are as follows: *1: The operator mode items are classified as follows. A: Display from the time when the starting switch is turned to “ON” position to the time when display changes to the standard screen, and display after starting switch is turned to “OFF” position B: Display when the machine monitor switch is operated C: Display when condition is satisfied D: Display that requires special operations of switches *2: Display sequence from the time when the starting switch is turned to ON position to the time when the standard screen appears varies depending on the settings and conditions of the machine as follows: V: When engine start lock is enabled W: When engine start lock is disabled X: When working mode at start is set to “Breaker mode (B)” Y: When any abnormality is detected by the check before starting Z: When any item is detected as the maintenance due time is over REMARK • For how to operate the operator mode functions, see the Operation and Maintenance Manual. • For the operating method of the engine start lock function, see “Password setting and canceling manual”.

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