Komatsu A35001 Shop Manual Download Page 1 | Manualshive

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Komatsu A35001 Shop Manual Download Page 1

CEBM029105

Shop

Manual

PC360LC

-11

PC390LC

-11

HYDRAULIC EXCAVATOR

SERIAL NUMBERS

PC360LC-11 A35001

and up

PC390LC-11 A30401

and up

ENGINE

6D114E-5

This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2017 Komatsu
Printed in U.S.A.
Komatsu America Corp.

February 2017

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Summary of Contents for A35001

Page 1: ...orp It is our policy to improve our products whenever it is possible and practical to do so We reserve the right to make changes or improvements at any time without incurring any obligation to install...

Page 2: ...Find manuals at https best manuals com...

Page 3: ...00 INDEX AND FOREWORD PC360LC 11 PC390LC 11 00 1 Find manuals at https best manuals com...

Page 4: ...H LOCK TO PULL 00 67 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 68 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 00 70 HOW TO READ ELECTRICAL WIR...

Page 5: ...ACHINE 20 14 STANDARD VALUE TABLE FOR MACHINE PC360LC 11 PC390LC 11 20 14 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 20 29 STANDARD VALUE TABLE FOR ELECTRICAL 20 33 STANDARD VALUE TABLE F...

Page 6: ...TROLLER 30 226 HANDLE BATTERY DISCONNECT SWITCH 30 227 TEST DIODES 30 228 Pm CLINIC 30 229 Pm CLINIC SERVICE 30 229 40 TROUBLESHOOTING 40 1 CONTENTS 40 2 ABBREVIATION LIST 40 13 RELATED INFORMATION ON...

Page 7: ...0ZK 40 202 FAILURE CODE AS10KM 40 203 FAILURE CODE AS10NR 40 204 FAILURE CODE AS10NT 40 205 FAILURE CODE B BAZG 40 206 FAILURE CODE B BAZK 40 207 FAILURE CODE B BCNS 40 209 FAILURE CODE B BCZK 40 210...

Page 8: ...E CA689 40 308 FAILURE CODE CA691 40 313 FAILURE CODE CA692 40 315 FAILURE CODE CA697 40 317 FAILURE CODE CA698 40 318 FAILURE CODE CA731 40 319 FAILURE CODE CA778 40 321 FAILURE CODE CA1117 40 326 FA...

Page 9: ...AILURE CODE CA2639 40 434 FAILURE CODE CA2771 40 437 FAILURE CODE CA2777 40 443 FAILURE CODE CA2976 40 446 FAILURE CODE CA3133 40 448 FAILURE CODE CA3134 40 450 FAILURE CODE CA3135 40 452 FAILURE CODE...

Page 10: ...AILURE CODE CA3583 40 574 FAILURE CODE CA3596 40 576 FAILURE CODE CA3649 40 578 FAILURE CODE CA3681 40 580 FAILURE CODE CA3682 40 585 FAILURE CODE CA3713 40 591 FAILURE CODE CA3717 40 594 FAILURE CODE...

Page 11: ...CODE CA5179 40 718 FAILURE CODE CA5181 40 720 FAILURE CODE CA5383 40 722 FAILURE CODE D110KB 40 724 FAILURE CODE D19JKZ 40 726 FAILURE CODE D811MC 40 729 FAILURE CODE D862KA 40 730 FAILURE CODE D8ALKA...

Page 12: ...ODE DV20KB 40 852 FAILURE CODE DW43KA 40 854 FAILURE CODE DW43KB 40 856 FAILURE CODE DW43KY 40 858 FAILURE CODE DW45KA 40 860 FAILURE CODE DW45KB 40 863 FAILURE CODE DW45KY 40 866 FAILURE CODE DW4CKY...

Page 13: ...WITCH IS TURNED TO ON POSITION MACHINE MONITOR DISPLAYS NOTHING 40 986 E 6 WHILE STARTING SWITCH IS TURNED TO ON POSITION WITH ENGINE STOPPED EN GINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 40 989 E 7 W...

Page 14: ...DOES NOT OPERATE 40 1027 E 39 ONE TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY OR INDI CATOR NOT DISPLAYED ON MONITOR 40 1029 E 40 ONE TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 40...

Page 15: ...SPEED DROPS LARGELY 40 1107 H 21 IN COMBINED OPERATION OF SWING AND BOOM RAISE BOOM RISING SPEED IS LOW 40 1108 H 22 MACHINE DOES NOT TRAVEL STRAIGHT 40 1109 H 23 MACHINE IS NOT STEERED WELL OR STEER...

Page 16: ...3 COATING MATERIALS LIST 50 15 SPECIAL TOOLS LIST 50 20 SKETCHES OF SPECIAL TOOLS 50 35 ENGINE AND COOLING SYSTEM 50 43 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 50 43 REMOVE AND INSTALL INJECTOR ASSEMB...

Page 17: ...VALVE ASSEMBLY 50 385 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 50 399 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 50 406 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 50 40...

Page 18: ...53 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 60 55 MAINTENANCE STANDARD OF TRAVEL PPC VALVE 60 58 MAINTENANCE STANDARD OF 1ST LINE ATTACHMENT PPC VALVE WITH EPC VALVE 60 61 MAINTENANC...

Page 19: ...9AKA 80 58 FAILURE CODE 879AKB 80 59 FAILURE CODE 879BKA 80 60 FAILURE CODE 879BKB 80 62 FAILURE CODE 879CKA 80 64 FAILURE CODE 879CKB 80 65 FAILURE CODE 879DKZ 80 66 FAILURE CODE 879EMC 80 68 FAILURE...

Page 20: ...ICAL CIRCUIT DIAGRAM 5 8 90 27 ELECTRICAL CIRCUIT DIAGRAM 6 8 90 29 ELECTRICAL CIRCUIT DIAGRAM 7 8 90 31 ELECTRICAL CIRCUIT DIAGRAM 8 8 90 33 INDEX 1 INDEX 00 INDEX AND FOREWORD 00 18 PC360LC 11 PC390...

Page 21: ...o matically applies the retarder with a constant braking force HD HM ARSC Automatic Retarder Speed Control Travel and brake When the accelerator pedal is released while the machine is traveling downhi...

Page 22: ...ic system This mechanism allows actuators to be operated in proportion to the current supplied FOPS Falling Object Protective Structure Cab and canopy This structure protects the operator s head from...

Page 23: ...he same time activates the in ter axle differential lock when the wheels idle while the machine travels on the soft ground road HM LCD Liquid Crystal Display Machine monitor Image display equipment su...

Page 24: ...pment This function performs hydraulic control of the tilt and pitch of the bulldozer blade D ROPS Roll Over Protective Structure Cab and canopy Sturcture protects the operator who wear the seatbelt s...

Page 25: ...ons used in the circuit diagrams Abbreviation Actual word spelled out A C Air Conditioner A D Analogue to Digital A M Air Mix Damper ACC Accessory ADD Additional AUX Auxiliary BR Battery Relay CW Cloc...

Page 26: ...Abbreviation Actual word spelled out T C Torque Converter T M Transmission ABBREVIATION LIST 00 INDEX AND FOREWORD 00 24 PC360LC 11 PC390LC 11...

Page 27: ...sting 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...

Page 28: ...sture for slinging work Tightening torque This signal indicates the tightening torque for portions which requires spe cial care in assembling work Coat This signal indicates a place to be coated with...

Page 29: ...d 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...

Page 30: ...s 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 oi...

Page 31: ...in ro tating 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 fre...

Page 32: ...s must communicate with each other fre quently 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 con...

Page 33: ...maximum at its central part Never use a wire rope which has breaks in strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Precautions for sli...

Page 34: ...k 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 emer gency If the hoist stops beca...

Page 35: ...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 n...

Page 36: ...ring is fitted to every joint of the air conditioner piping For tightening torques see THE OTHER INFORMATION Pre cautions for disconnection and connection of air conditioner piping SAFETY NOTICE FOR...

Page 37: ...ched 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 d...

Page 38: ...e 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 explos...

Page 39: ...ey 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...

Page 40: ...kes 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 toxi...

Page 41: ...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 t...

Page 42: ...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 D...

Page 43: ...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 f...

Page 44: ...aining 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 perform ance check...

Page 45: ...ain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir cuit Avoid reusing the hydraulic oil and lubricating oil Avoid reusing the hydraulic oil a...

Page 46: ...emove the ultra fine approxi mately 3 m particles that the filter built in the hydraulic equip ment cannot remove So it is very effective device PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX A...

Page 47: ...s 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...

Page 48: ...he split flange type hoses and tubes Nomi nal No Bolt pitch mm Hose side Tube side O ring 4 Bolt 5 Washer 6 a b Flange 1 Split flange 2 Sleeve head 3 04 38 1 17 5 07379 00400 07371 30400 07378 10400 0...

Page 49: ...1232 30 106 4 62 07379 03010 07371 13010 07378 13000 07000 12085 07372 51650 01643 51645 34 120 6 69 8 07379 03411 07371 13411 07378 13400 07000 12100 07372 51650 01643 51645 40 130 2 77 8 07379 04012...

Page 50: ...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 part...

Page 51: ...fied 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 reser voir with the coolant Komatsu recommends...

Page 52: ...tallation portion If there is any damage replace the part Check that there is no looseness on the exhaust equipment and mounting bolts nuts and clamps on the instal lation portion If there is any loos...

Page 53: ...ary to be extremely careful when handling and maintenance of the wiring harnesses If AdBlue DEF is spilled over wiring harness and connectors it may cause corrosion and defective contact Be careful no...

Page 54: ...Entry of water dirt or dust when disconnecting a con nector 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...

Page 55: ...ute the environ ment 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...

Page 56: ...vicing the intake system Select an appropriate workplace Avoid the work of adding hydraulic oil replacing filters or repairing the machine in rainy or windy weather or in dusty environment Sealing the...

Page 57: ...s of machine in addition to KOMTRAX function described above These data can be used on per sonal computer screens How to make a full use of KOMTRAX Making use of KOMTRAX enables the following activiti...

Page 58: ...tion 1 Hold adapter 1 and push hose joint 2 into mating adapter 3 REMARK Push it in approximately 3 5 mm Do not hold rubber cap portion 4 2 While having adapter 3 inserted into hose side joint 2 inser...

Page 59: ...nection 1 Hold the tightening adapter part and push body 2 straight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition of st...

Page 60: ...t until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition of step 1 push cover 3 straight until it contacts contact surface a of...

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