Komatsu HYDRAULIC EXCAVATOR PC138US-10 Shop Manual WENBM00011 PDF

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Komatsu HYDRAULIC EXCAVATOR PC138US-10 Shop Manual WENBM00011 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC138US-10 Shop Manual WENBM00011 – PDF DOWNLOAD

Language : English
Pages :1458
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC138US-10 Shop Manual WENBM00011 – PDF DOWNLOAD

SERIAL NUMBERS PC138US-10 F40003 and up

General precautions

Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.

• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual. • Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. •
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing. 1. Always wear the protective eyeglasses when hitting parts with a hammer. 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• • Only qualified workers must perform the work and operation which require license or qualification.
• Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, lift truck, service vehicle, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC138US-10 Shop Manual WENBM00011 – PDF DOWNLOAD

SERIAL NUMBERS PC138US-10 F40003 and up

Table of contents 4
Foreword, safety and general information 17
Important safety notice 17
Fire prevention 22
Dispose of waste materials 23
How to read the shop manual 24
Explanation of terms for maintenance standard 26
Handling equipment of fuel system devices 28
Handling of intake system parts 29
Handling of hydraulic equipment 30
Method of disconnecting and connecting of push-pull type coupler 32
Type 1 32
Type 2 33
Type 3 34
Handling of electrical equipment 35
How to read electric wire code 43
Precautions when performing operation 46
Practical use of KOMTRAX 51
Standard tightening torque table 52
List of abbreviation 58
Conversion table 63
Contents 70
Specifications 71
Specification drawing 71
PC138US-10 71
2-Piece boom 72
Working range drawings 73
PC138US-10 73
Specifications 74
PC138US-10 74
Weight table 78
Table of fuel, coolant, and lubricants 80
10 Structure and function 81
Contents 82
Engine and cooling system 84
Engine related parts 84
PTO 86
Specifications 86
VFT 87
Specifications 89
Operation 90
EGR system piping drawing 91
Function 91
EGR system circuit diagram 93
Operation 93
EGR valve 94
Structure 94
Operation 95
EGR cooler 96
Operation 97
KCCV layout drawing 98
Operation 99
KCCV ventilator 100
Function 100
Operation 100
CDR valve 101
KDOC muffler 102
Structure 102
Function 103
Cooling system 104
Specifications 105
Power train 106
Power train system 106
Swing circle 108
Specifications 108
Swing machinery 109
Specifications 110
Undercarriage and frame 111
Track frame 111
Specifications 111
Idler cushion 112
Specifications 112
Hydraulic system 113
Hydraulic component layout 113
Exterior 113
Upper structure 114
Valve control 115
Hydraulic tank 116
Specifications 116
Oil filler cap 117
CLSS 118
Structure of CLSS 118
Features 118
Configuration 118
Basic principle 119
Main pump 122
LS valve 130
PC valve 135
PC-EPC valve 144
Check valve 147
Shuttle valve 148
Control valve 149
Unload valve 169
Introduction of LS pressure 174
LS bypass plug 176
Pressure compensation valve 179
Boom regeneration circuit 183
Arm regeneration circuit 185
Merge-divider valve 187
LS separation valve 189
Self-pressure reducing valve 191
Travel junction valve 192
Boom hydraulic drift prevention valve 194
Back pressure check valve 197
Oil cooler bypass valve 198
Swing motor 199
Swing parking brake 202
Relief valve 204
Swing modulating relief valve function 206
Swing motor reverse prevention valve 208
Travel motor 211
Structure 214
Operation of travel motor 215
Brake valve 217
Relief valve 220
Work equipment and swing PPC valve 222
Operation 225
Travel PPC valve 229
Operation 231
Blade PPC valve 235
2-piece boom PPC valve 237
1st-line attachment PPC valve (with EPC valve) 239
EPC valve 241
Solenoid valve 246
Operation 250
Attachment circuit selector valve (for low pressure circuit) 252
Function 252
Operation 253
Quick coupler control valve 255
Center swivel joint 259
Blade specifications 259
PPC circuit accumulator 261
Specifications 261
Function 261
Attachment circuit accumulator (for low pressure circuit) 262
Specifications 262
Function 262
Work equipment 263
Work equipment 263
Work equipment shim 264
Structure 264
Function 264
Bucket play adjustment shim 265
Structure 265
Cab and its attachments 266
Cab mount and cab tipping stopper 266
Structure 266
ROPS cab 267
Function 267
Take wiring harness out of cab 268
Structure 268
Electrical system 269
Electrical control system 269
General system drawing 269
Engine control function 272
Function 272
Starting the engine 272
Engine speed control 273
Engine stop 273
Stopping the engine with engine shutdown secondary switch 273
Engine and pump combined control function 274
Input/output signal 275
Function 275
Control method in each mode 276
B and L mode 277
Matching point 277
Control function when traveling 278
Control function when emergency pump drive switch is “ON“ 279
Auto-deceleration function 280
Function 281
Operation 281
Engine automatic warm-up function 282
Function 284
Overheat prevention function 285
Turbocharger protection function 287
Swing control function 288
Function 288
Travel control function 291
Function 292
PPC lock function 295
Function 295
System operating lamp function 296
Function 296
ON/OFF of system operating lamp 296
Battery disconnect switch function 297
Function 298
Precautions for using battery disconnect switch 298
Oil flow adjuster function for attachment 299
Function 300
Machine monitor system 301
Function 301
Machine monitor 302
Precautions on the machine monitor display 302
Input and output signals of machine monitor 303
Display 305
Gauges 307
Alarm monitor 309
Pilot monitor 312
Switches 314
Guidance icon and function switch 316
Operator mode functions 319
Service mode functions 321
KOMTRAX system 322
KOMTRAX terminal 323
System component parts 325
Pump controller 330
Fuel control dial 334
Resister for PC-EPC valve 335
CAN terminating resistor 336
Engine oil pressure switch 337
PPC oil pressure switch 338
Sensor 339
Ambient pressure sensor 339
Charge (boost) pressure and temperature sensor 340
Coolant temperature sensor 341
Ne (crankshaft) speed sensor 341
Bkup (camshaft) speed sensor 342
Common rail pressure sensor 342
VFT motor (with position sensor) 343
EGR valve (with position sensor) 344
Mass air flow and temperature sensor 345
Crankcase pressure sensor 345
Engine oil level sensor 346
Fuel level sensor 347
Hydraulic oil temperature sensor 348
Oil pressure sensor of pump 349
PPC oil pressure sensor 350
20 Standard value tables 351
Contents 352
Standard service value table 353
Standard value table for engine 353
Standard value table for machine 354
Engine speed 354
Travel of control lever 354
Control effort of control lever 355
Oil pressure 356
Swing 358
Traveling 359
Work equipment 360
Pump performance 364
Machine posture and procedure for measuring performance 365
Standard value table for electrical system 370
Controller 370
Engine control 371
Machine control 373
Machine monitor 375
30 Testing and adjusting 377
Contents 378
General information on testing and adjusting 379
Tools for testing and adjusting 379
Sketch of tools for testing and adjusting 382
M4: Sensor adapter 382
M4: Nipple 382
M5: Sensor adapter 383
-: Socket 383
Engine and cooling system 384
Testing engine speed 384
Testing 384
Testing exhaust gas color 385
Testing 385
Testing and adjusting valve clearance 386
Adjusting 387
Testing compression pressure 388
Testing blowby pressure 391
Testing engine oil pressure 392
Testing fuel pressure 393
Testing fuel return rate and leakage 394
Testing 395
Bleeding air from fuel system 397
Bleeding air 397
Testing fuel circuit for leakage 399
Testing 399
Handling cylinder cutout mode operation 400
Handling no-injection cranking operation 401
Checking and adjusting air conditioner compressor belt tension 402
Testing 402
Adjusting 402
Replacing fan belt 403
Replace 403
Writing compensation values at replacement of injector and engine controller 404
Connecting PC 404
Start INSITE 404
Power train 408
Testing swing circle bearing clearance 408
Testing 408
Undercarriage and frame 409
Testing and adjusting track shoe tension 409
Testing 409
Adjusting 409
Hydraulic system 410
Releasing remaining pressure from hydraulic circuit 410
Releasing remaining pressure 410
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 411
Testing 411
Adjusting 413
Testing oil pressure of control circuit 414
Testing 414
Testing and adjusting oil pressure in pump PC control circuit 415
Testing 415
Adjusting 417
Testing and adjusting oil pressure in pump LS control circuit 418
Testing 418
Testing oil pressure with sensor adapter (special tool) 421
Adjusting 421
Testing outlet pressure of solenoid valve 423
Testing 423
Testing PPC valve output pressure 424
Connecting points of PPC piping 424
Testing 424
Adjusting play of work equipment and swing PPC valves 426
Adjusting 426
Isolating the parts causing hydraulic drift in work equipment 427
Testing 427
Testing and adjusting travel deviation 428
Testing 428
Adjusting 429
Testing oil leakage 430
Testing 430
Bleeding air from hydraulic circuit 432
Bleeding air 433
Cab and its attachments 435
Checking cab tipping stopper 435
Checking 435
Testing, cleaning and lubricating slide door rail and roller 436
Testing 436
Electrical system 439
Special functions of machine monitor 439
Ordinary functions and special functions of machine monitor 441
Adjusting rearview camera angle 491
Adjusting 491
Handling voltage circuit of engine controller 493
Handling battery disconnect switch 494
Testing diodes 495
Testing 495
Pm clinic 496
Pm Clinic service 496
Check sheet 500
40 Troubleshooting 503
Contents 504
General information on troubleshooting 510
Troubleshooting points 510
Sequence of events in troubleshooting 512
Checks before troubleshooting 514
Inspection procedure before troubleshooting 516
Walk-around check 516
Testing in accordance with testing procedure 517
Testing 522
Preparation for troubleshooting of electrical system 533
Preparation 533
Classification and procedure for troubleshooting 537
Classification of troubleshooting 537
Procedure for troubleshooting 537
Symptom and troubleshooting numbers 540
Information in troubleshooting table 543
Troubleshooting method for open circuit in wiring harness of pressure sensor system 545
Connector list and layout 547
Layout of connectors (1/6) 551
Layout of connectors (2/6) 552
Layout of connectors (3/6) 553
Layout of connectors (4/6) 554
Layout of connectors (5/6) 555
Layout of connectors (6/6) 556
Connector contact identification 557
T-branch box and T-branch adapter table 594
Fuse location table 599
Locations of fusible links 599
Locations of fuse boxes and fuse No 599
Connection table of fuse box 599
Failure codes table 602
Troubleshooting by failure code (Display of code) 608
Failure code [879AKA] A/C Inner Sensor Open Circuit 608
Failure code [879AKB] A/C Inner Sensor Short Circuit 609
Failure code [879BKA] A/C Outer Sensor Open Circuit 610
Failure code [879BKB] A/C Outer Sensor Short Circuit 611
Failure code [879CKA] Ventilating Sensor Open Circuit 612
Failure code [879CKB] Ventilating Sensor Short Circuit 613
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit 614
Failure code [879EMC] Ventilation Damper Abnormality 615
Failure code [879FMC] Air Mix Damper Abnormality 616
Failure code [879GKX] Refrigerant Abnormality 617
Failure code [989L00] Engine Controller Lock Caution 1 618
Failure code [989M00] Engine Controller Lock Caution 2 619
Failure code [989N00] Engine Controller Lock Caution 3 620
Failure code [AB00KE] Charge Voltage Low 621
Failure code [B@BAZG] Eng Oil Press Low 623
Failure code [B@BAZK] Eng Oil Level Low 624
Failure code [B@BCNS] Eng Water Overheat 625
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 626
Failure code [CA122] Chg Air Press Sensor High Error 627
Failure code [CA123] Chg Air Press Sensor Low Error 629
Failure code [CA131] Throttle Sensor High Error 631
Failure code [CA132] Throttle Sensor Low Error 633
Failure code [CA144] Coolant Temp Sens High Error 635
Failure code [CA145] Coolant Temp Sens Low Error 637
Failure code [CA153] Chg Air Temp Sensor High Error 639
Failure code [CA154] Chg Air Temp Sensor Low Error 641
Failure code [CA187] Sensor 2 Supply Volt Low Error 643
Failure code [CA221] Ambient Press Sensor High Error 645
Failure code [CA222] Ambient Press Sensor Low Error 647
Failure code [CA227] Sensor 2 Supply Volt High Error 649
Failure code [CA234] Eng Overspeed 650
Failure code [CA238] Engine Speed Sensor Supply Volt Error 651
Failure code [CA239] Engine Speed Sens Supply Volt High Error 652
Failure code [CA271] IMV/PCV1 Short Error 653
Failure code [CA272] IMV/PCV1 Open Error 654
Failure code [CA322] Inj #1(L#1) Open/Short Error 655
Failure code [CA324] Inj #3(L#3) Open/Short Error 657
Failure code [CA331] Inj #2(L#2) Open/Short Error 659
Failure code [CA332] Inj #4(L#4) Open/Short Error 661
Failure code [CA343] ECM Critical Internal Failure 663
Failure code [CA351] Injectors Drive Circuit Error 664
Failure code [CA352] Sensor 1 Supply Volt Low Error 665
Failure code [CA356] Mass Air Flow Sensor High Error 667
Failure code [CA357] Mass Air Flow Sensor Low Error 669
Failure code [CA386] Sensor 1 Supply Volt High Error 671
Failure code [CA435] Eng Oil Press Sw Error 672
Failure code [CA441] Battery Voltage Low Error 673
Failure code [CA442] Battery Voltage High Error 675
Failure code [CA449] Rail Press Very High Error 676
Failure code [CA451] Rail Press Sensor High Error 677
Failure code [CA452] Rail Press Sensor Low Error 679
Failure code [CA466] KVGT Motor Driver Position Error 681
Failure code [CA515] Rail Press Sens Sup Volt High Error 683
Failure code [CA516] Rail Press Sens Sup Volt Low Error 685
Failure code [CA553] Rail Press High Error 687
Failure code [CA555] Crankcase Press High Error 1 688
Failure code [CA556] Crankcase Press High Error 2 689
Failure code [CA559] Rail Press Low Error 690
Failure code [CA689] Engine Speed Sensor Error 693
Failure code [CA691] Intake Air Temp Sens High Error 695
Failure code [CA692] Intake Air Temp Sens Low Error 697
Failure code [CA697] ECM Internal Temp Sensor High Error 699
Failure code [CA698] ECM Int Temp Sensor Low Error 700
Failure code [CA731] Eng Bkup Speed Sens Phase Error 701
Failure code [CA778] Eng Bkup Speed Sensor Error 702
Failure code [CA1117] Persistent Data Lost Error 706
Failure code [CA1695] Sensor 5 Supply Volt High Error 707
Failure code [CA1696] Sensor 5 Supply Volt Low Error 708
Failure code [CA1843] Crankcase Press Sens High Error 709
Failure code [CA1844] Crankcase Press Sens Low Error 711
Failure code [CA1896] EGR Valve Stuck Error 713
Failure code [CA1942] Crankcase Press Sens In Range Error 714
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error 715
Failure code [CA2185] Throt Sensor Sup Volt High Error 716
Failure code [CA2186] Throt Sensor Sup Volt Low Error 718
Failure code [CA2249] Rail Press Very Low Error 720
Failure code [CA2272] EGR Valve Pos Sens Low Error 721
Failure code [CA2311] IMV Solenoid Error 723
Failure code [CA2349] EGR Valve Solenoid Open Error 724
Failure code [CA2353] EGR Valve Solenoid Short Error 726
Failure code [CA2357] EGR Valve Servo Error 728
Failure code [CA2765] Inj Trim Data Error 729
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 730
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 732
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 734
Failure code [CA3918] KVGT Stuck Error 736
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error 737
Failure code [CA3921] KVGT Servo Error 2 738
Failure code [CA3922] KVGT Motor Driver Open Error 739
Failure code [CA3923] KVGT Motor Driver Short Error 741
Failure code [D110KB] Battery Relay Drive Short Circuit 743
Failure code [D19JKZ] Personal Code Relay Abnormality 745
Failure code [D811MC] KOMTRAX Error 748
Failure code [D862KA] GPS Antenna Open Circuit 749
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 750
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 752
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 753
Failure code [DA20MC] Pump Controller Malfunction 755
Failure code [DA22KK] Pump Solenoid Power Low Error 756
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 758
Failure code [DA29KQ] Model Selection Abnormality 760
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 762
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) 764
Failure code [DA2QKR] CAN2 Discon (Pump Con) 765
Failure code [DA2RKR] CAN1 Discon (Pump Con) 767
Failure code [DAF0MB] Monitor ROM Abnormality 768
Failure code [DAF0MC] Monitor Error 769
Failure code [DAF8KB] Camera Power Supply Short Circuit 770
Failure code [DAF9KQ] Model Selection Abnormality 772
Failure code [DAFGMC] GPS Module Error 773
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 774
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 776
Failure code [DAFQKR] CAN2 Discon (Monitor) 777
Failure code [DAZ9KQ] A/C Model Selection Abnormality 778
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 779
Failure code [DB2QKR] CAN2 Discon (Engine Con) 783
Failure code [DB2RKR] CAN1 Discon (Engine Con) 787
Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality 791
Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality 793
Failure code [DFB5KZ] Service Lever Sub Potentio 1 Abnormality 795
Failure code [DFB6KZ] Service Lever Sub Potentio 2 Abnormality 797
Failure code [DFB3L8] Service Lever 1 Potentio Error 799
Failure code [DFB4L8] Service Lever 2 Potentio Error 800
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 801
Failure code [DHPAMA] Pump Press Sensor Abnormality 803
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 805
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 807
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 809
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 811
Failure code [DHSKMA] Blade Raise PPC Press Sensor Abnormality 813
Failure code [DHSLMA] Blade Lower PPC Press Sensor Abnormality 815
Failure code [DHX1MA] Overload Sensor Abnormality 817
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 818
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 820
Failure code [DV20KB] Travel Alarm Short Circuit 821
Failure code [DW43KA] Travel Speed Sol Open Circuit 823
Failure code [DW43KB] Travel Speed Sol Short Circuit 825
Failure code [DW45KA] Swing Brake Sol Open Circuit 827
Failure code [DW45KB] Swing Brake Sol Short Circuit 830
Failure code [DW91KA] Travel Junction Sol Open Circuit 832
Failure code [DW91KB] Travel Junction Sol Short Circuit 834
Failure code [DWA2KA] Attachment Sol Open Circuit 836
Failure code [DWA2KB] Attachment Sol Short Circuit 838
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 840
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 842
Failure code [DXA8KA] PC-EPC Sol Open Circuit 844
Failure code [DXA8KB] PC-EPC Sol Short Circuit 846
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 848
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 850
Failure code [DXEAKA] Service Current EPC1 Discon 852
Failure code [DXEAKB] Service Current EPC1 Short 854
Failure code [DXE7KA] Service Current EPC2 Discon 856
Failure code [DXE7KB] Service Current EPC2 Short 858
Failure code [DXE8KA] Service Current EPC3 Discon 860
Failure code [DXE8KB] Service Current EPC3 Short 862
Failure code [DXE9KA] Service Current EPC4 Discon 864
Failure code [DXE9KB] Service Current EPC4 Short 866
Failure code [DY20KA] Wiper Working Abnormality 868
Failure code [DY20MA] Wiper Parking Abnormality 870
Failure code [DY2CKB] Washer Drive Short Circuit 872
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 874
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 876
Troubleshooting of electrical system (E-mode) 878
E-1 Engine does not start (Engine does not crank) 878
E-2 Manual preheating system does not work 884
E-3 While preheating is working, preheating monitor does not light up 887
E-4 When starting switch is turned to ON position, machine monitor displays nothing 889
E-5 When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow 892
E-6 Engine coolant temperature monitor lights up in white while engine is running 893
E-7 Hydraulic oil temperature monitor lights up in white while engine is running 894
E-8 Charge level monitor lights up while engine is running 895
E-9 Fuel level monitor lights up in red while engine is running 896
E-10 Engine coolant temperature monitor lights up in red while engine is running 897
E-11 Hydraulic oil temperature monitor lights up in red while engine is running 898
E-12 Engine oil pressure monitor lights up in red while engine is running 899
E-13 Fuel gauge display does not move from minimum or maximum 900
E-14 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 901
E-15 Engine coolant temperature gauge display does not move from minimum or maximum 902
E-16 Engine coolant temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) 903
E-17 Hydraulic oil temperature gauge does not move from minimum or maximum 904
E-18 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) 906
E-19 Some areas of machine monitor screen are not displayed 907
E-20 Function switch does not work 908
E-21 Automatic warm-up system does not operate (in cold season) 909
E-22 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated 910
E-23 Auto-deceleration function does not operate or is not canceled while lever is operated 911
E-24 Working mode selection screen is not displayed while working mode selector switch is operated 912
E-25 Setting of engine and hydraulic pump is not changed while working mode is changed 913
E-26 Travel speed monitor does not change while travel speed switch is operated 914
E-27 Travel speed does not change while travel speed selection is changed 915
E-28 Alarm buzzer does not stop sounding 916
E-29 Service meter is not displayed, while starting switch is in OFF position 917
E-30 Service mode cannot be selected 918
E-31 Any of work equipment, swing and travel does not work 919
E-32 Any of work equipment, swing and travel cannot be locked 921
E-33 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position 923
E-34 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position 925
E-35 Alarm does not sound during travel 927
E-36 Alarm does not stop sounding while machine is stopped 928
E-37 – Horn does not sound 929
E-38 Horn does not stop sounding 931
E-39 – Wiper monitor does not light up, or does not go out, while wiper switch is operated 932
E-40 Wiper does not operate while wiper switch is operated 933
E-41 Window washer does not operate while window washer switch is operated 935
E-42 Boom Lower is not displayed correctly with monitoring function 936
E-43 Arm OUT is not displayed correctly with monitoring function 938
E-44 Arm IN is not displayed correctly with monitoring function 940
E-45 Boom Raise is not displayed correctly with monitoring function 942
E-46 Bucket Curl is not displayed correctly with monitoring function 944
E-47 Bucket Dump is not displayed correctly with monitoring function 946
E-48 Swing is not displayed correctly with monitoring function 948
E-49 Travel is not displayed correctly with monitoring function 950
E-50 Service is not displayed correctly with monitoring function 951
E-51 Attachment hydraulic circuit cannot be changed 954
E-52 KOMTRAX system does not operate normally 955
Troubleshooting of hydraulic and mechanical system (H-mode) 957
Information described in troubleshooting table (H-mode) 957
System chart of hydraulic and mechanical systems 958
Failure mode and cause table 960
H-1 All of work equipment, swing and travel operation lacks speed or power 968
H-2 Engine speed drops significantly or engine stalls 970
H-3 Any of work equipment, swing and travel does not work 971
H-4 Unusual sound is heard from around hydraulic pump 972
H-5 Fine control performance or response is poor 973
H-6 Boom speed or power is low 974
H-7 Arm speed or power is low 977
H-8 Bucket speed or power is low 979
H-9 Work equipment does not move in single operation 981
H-10 Hydraulic drift of boom is large 982
H-11 Hydraulic drift of arm is large 983
H-12 Hydraulic drift of bucket is large 984
H-13 Time lag of work equipment is large 985
H-14 In combined operation of work equipment , equipment having heavier load moves slower 987
H-15 In combined operation of swing and boom RAISE, boom rising speed is low 988
H-16 In combined operation of swing and travel, travel speed drops largely 989
H-17 Machine does not travel straight 990
H-18 Travel speed is slow 992
H-19 Machine is hard to steer or travel power is low 994
H-20 Travel speed does not change, or travel speed is too slow or fast 997
H-21 One of tracks does not run 998
H-22 Upper structure does not swing to the right or left1000
H-23 Upper structure swing only to the right or left1001
H-24 Swing acceleration or swing speed is low in both directions (right and left)1002
H-25 Swing acceleration performance is poor or swing speed is slow in only one direction1003
H-26 Upper structure overruns excessively when it stops swinging (both right and left)1004
H-27 Upper structure overruns excessively when it stops swinging (either right or left)1005
H-28 Shock is large when upper structure stops swinging1006
H-29 Large unusual noise is heard when upper structure stops swinging1007
H-30 Swing drift on a slope is large while swing parking brake is applied1008
H-31 Swing drift on a slope is large while swing parking brake is released1009
H-32 Attachment hydraulic circuit cannot be changed while attachment is installed1010
H-33 Oil flow in attachment circuit cannot be controlled1011
Troubleshooting of engine (S-mode)1012
Information mentioned in troubleshooting table (S mode)1012
S-1 Engine does not crank when starting switch is turned to START position1013
S-2 Engine cranks but no exhaust smoke comes out1014
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)1015
S-4 Engine startability is poor1016
S-5 Engine does not pick up smoothly1018
S-6 Engine stops during operation1020
S-7 Engine runs rough or is unstable1022
S-8 Engine lacks power1023
S-9 Exhaust smoke is black1025
S-10 Engine oil consumption is excessive1027
S-11 Oil becomes contaminated quickly1028
S-12 Fuel consumption is excessive1029
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)1030
S-14 Oil pressure drops1031
S-15 Fuel mixes into engine oil1033
S-16 Water mixes into engine oil (milky)1034
S-17 Coolant temperature rises too high (overheating)1035
S-18 Unusual noise is heard1036
S-19 Vibration is excessive1037
S-20 Air cannot be bled from fuel circuit1038
50 Disassembly and assembly1039
Contents1040
General information on disassembly and assembly1042
How to read this manual1042
Coating materials list1044
Adhesive1044
Liquid gasket1045
Molybdenum disulfide lubricant1045
Seizure prevention compound1046
Grease1046
Primer1047
Adhesive1047
Caulking material1047
Special tools list1048
Sketches of special tools1052
Engine and cooling system1054
Removal and installation of supply pump assembly1054
Installation1056
Removal and installation of injector assembly1058
Installation1060
Removal and installation of cylinder head assembly1064
Removal1064
Installation1069
Removal and installation of radiator assembly1075
Removal1075
Installation1076
Removal and installation of hydraulic oil cooler assembly1077
Removal1077
Installation1078
Removal and installation of aftercooler assembly1080
Removal1080
Installation1080
Removal and installation of engine and main pump assembly1082
Removal1082
Installation1085
Removal and installation of engine front oil seal1087
Removal1087
Installation1087
Removal and installation of engine rear oil seal1088
Removal1088
Installation1088
Removal and installation of fuel cooler assembly1090
Removal1090
Installation1090
Removal and installation of fuel tank assembly1091
Removal1091
Installation1093
Removal and installation of KDOC assembly1094
Removal1094
Installation1094
Removal and installation of KCCV assembly1095
Removal1095
Installation1095
Removal and installation of air cleaner assembly1096
Removal1096
Installation1096
Removal and installation of fan belt1098
Removal1098
Installation1099
Power train system1100
Removal and installation of travel motor and final drive assembly1100
Removal1100
Installation1100
Disassembly and assembly of travel motor and final drive assembly1101
Disassembly1109
Assembly1122
Assembly procedures1122
Removal and installation of swing motor and swing machinery assembly1135
Removal1135
Installation1135
Disassembly and assembly of swing machinery assembly1137
Disassembly1137
Assembly1139
Removal and installation of swing circle assembly1143
Removal1143
Installation1143
Undercarriage and frame1144
Separation and connection of track1144
Separation1144
Installation1145
Removal and installation of sprocket1147
Removal1147
Installation1147
Removal and installation of idler and idler cushion assembly1148
Removal1148
Installation1148
Disassembly and assembly of idler assembly1149
Disassembly1149
Assembly1149
Disassembly and assembly of idler cushion assembly1152
Disassembly1153
Assembly1154
Disassembly and assembly of track roller assembly1155
Disassembly1155
Assembly1155
Removal and installation of revolving frame assembly1158
Removal1158
Installation1159
Removal and installation of counterweight assembly [For machines with additional counterweight]1160
Removal1160
Installation1161
Hydraulic system1163
Removal and installation of center swivel joint assembly1163
Removal1163
Installation1164
Disassembly and assembly of center swivel joint assembly1165
Disassembly1165
Assembly1165
Removal and installation of hydraulic tank assembly1166
Removal1166
Installation1168
Removal and installation of main pump assembly1169
Removal1169
Installation1172
Removal and installation of control valve assembly1173
Removal1173
Installation1177
Disassembly and assembly of control valve assembly1179
Assembly of control valve assembly1180
Disassembly and assembly of work equipment PPC valve assembly1181
Disassembly1181
Assembly1182
Disassembly and assembly of travel PPC valve assembly1183
Disassembly1183
Assembly1183
Work equipment1185
Removal and installation of work equipment assembly (with standard boom)1185
Removal1185
Installation1188
Removal and installation of work equipment assembly (with 2-piece boom)1189
Removal1189
Installation1191
Removal and installation of 1st boom assembly1192
Removal1192
Installation1193
Removal and installation of 2nd boom1194
Removal1194
Installation1196
Removal and installation of arm1197
Removal1197
Installation1198
Removal and installation of boom cylinders (with 2 piece boom)1199
Removal1199
Installation1200
Removal and installation of 2-piece boom cylinder1201
Removal1201
Installation1202
Disassembly and assembly of work equipment cylinder assembly1203
Disassembly1203
Assembly1205
Cab and its attachments1208
Removal and installation of operator’s cab assembly1208
Removal1208
Installation1209
Removal and installation of operator’s cab door1211
Installation1211
Removal and installation of operator’s cab glass (adhered glass)1213
Removal1215
Installation1216
Removal and installation of front window assembly1223
Removal1223
Installation1223
Removal and installation of floor frame assembly1224
Removal1224
Installation1229
Removal and installation of air conditioner unit assembly1231
Removal1231
Installation1234
Removal and installation of air conditioner compressor assembly1235
Removal1235
Installation1235
Removal and installation of air conditioner condenser assembly1237
Removal1237
Installation1238
Removal and installation of operator’s seat1239
Removal1239
Installation1239
Removal and installation of seat belt1240
Removal1240
Installation1240
Removal and installation of front wiper assembly1241
Removal1241
Installation1243
Electrical system1247
Removal and installation of engine controller assembly1247
Removal1247
Installation1247
Removal and installation of pump controller assembly1248
Removal1248
Installation1249
Removal and installation of machine monitor assembly1250
Removal1250
Installation1251
Removal and installation of mass air flow and temperature sensor1252
Removal1252
Installation1252
Removal and installation of KOMTRAX terminal assembly1253
Removal1253
Installation1253
60 Maintenance standard1255
Contents1256
Engine and cooling system1257
Engine mount1257
PTO1258
Cooling system1259
Power train1260
Swing circle1260
Swing machinery1261
Sprocket1262
Undercarriage and frame1263
Track frame1263
Idler cushion1264
Idler1265
Track roller1266
Carrier roller1267
Track shoe1268
Triple grouser shoe1271
Road liner1272
Hydraulic system1273
Hydraulic tank1273
Main pump1274
PC-EPC valve1276
Control valve1277
Swing motor1288
Travel motor1291
Work equipment and swing PPC valve1292
Travel PPC valve1295
Blade PPC valve1298
2-piece boom PPC valve1300
1st-line attachment PPC valve (with EPC valve)1302
EPC valve1304
Solenoid valve1305
Attachment circuit selector valve (for low pressure circuit)1306
Center swivel joint1307
Blade specifications1307
Cab and its attachments1308
Cab mount and cab tipping stopper1308
Work equipment1309
Work equipment (standard boom specification)1309
Work equipment (2-piece boom specification)1314
Dimensions of arm1319
Dimensions of bucket1321
Boom cylinder (for standard boom)1323
Arm cylinder (for standard boom)1324
Bucket cylinder1325
Blade cylinder1326
Boom cylinder (for 2-piece boom)1327
Arm cylinder (for 2-piece boom)1328
2-piece boom cylinder1329
80 Appendix1331
Contents1332
Air conditioner components1333
Precautions for refrigerant1333
Air conditioner component1334
Specifications1336
Configuration and function of refrigeration cycle1337
Outline of refrigeration cycle1338
Air conditioner unit1340
Function1341
Functions of major components1342
Dual pressure switch1345
Function1345
Air conditioner controller1346
Compressor1347
Specification1347
Function1347
Air conditioner condenser1348
Specification1348
Function1348
Sunlight sensor1350
Function1350
Output characteristics1350
Outer temperature sensor (outside air temperature sensor)1351
Function1351
Procedure for testing and troubleshooting1352
Circuit diagram and arrangement of connector pins1354
System diagram1356
Input and output signals of the air conditioner controller1357
Function1357
Air conditioner unit1359
Parts and connectors layout1361
Details1361
Testing air leakage (duct)1367
Testing1367
Testing with self-diagnosis function1370
Testing outline1370
How to open the electrical system abnormality record screen in service mode of the machine monitor1370
Testing vent (mode) changeover1373
Testing1373
Testing FRESH/RECIRC air changeover1374
Testing1374
Testing sunlight sensor1375
Testing1375
Testing (dual) pressure switch for refrigerant1376
Testing1376
Testing relays1378
Testing1378
Troubleshooting chart 11379
Troubleshooting chart 21380
Information in troubleshooting table1383
Information in troubleshooting table1383
Failure code list related to air conditioner1384
Failure code [879AKA] A/C Inner Sensor Open Circuit1385
Failure code [879AKB] A/C Inner Sensor Short Circuit1386
Failure code [879BKA] A/C Outer Sensor Open Circuit1387
Failure code [879BKB] A/C Outer Sensor Short Circuit1389
Failure code [879CKA] Ventilating Sensor Open Circuit1391
Failure code [879CKB] Ventilating Sensor Short Circuit1392
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit1393
Failure code [879EMC] Ventilation Damper Abnormality1395
Failure code [879FMC] Air Mix Damper Abnormality1396
Failure code [879GKX] Refrigerant Abnormality1397
A-1 Troubleshooting for power supply system (Air conditioner does not operate)1398
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)1400
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)1403
A-4 Troubleshooting for FRESH/RECIRC air changeover1405
Troubleshooting with gauge pressure1407
Connection of service tool1410
Precautions for disconnecting and connecting refrigerant piping1412
Handling of compressor oil1414
Desiccant replacement1416
90 Diagrams and drawings1419
Contents1420
Hydraulic circuit diagram1421
Symbols in hydraulic circuit diagram1421
Hydraulic circuit diagram (1/2)1425
Hydraulic circuit diagram (2/2)1427
Electric circuit diagram1429
Symbols in electric circuit diagram1429
Electrical circuit diagram – Standard boom (1/6)1433
Electrical circuit diagram – Standard boom (2/6)1435
Electrical circuit diagram – Standard boom (3/6)1437
Electrical circuit diagram – Standard boom (4/6)1439
Electrical circuit diagram – Standard boom (5/6)1441
Electrical circuit diagram – Standard boom (6/6)1443
Electrical circuit diagram – 2-piece boom (1/6)1445
Electrical circuit diagram – 2-piece boom (2/6)1447
Electrical circuit diagram – 2-piece boom (3/6)1449
Electrical circuit diagram – 2-piece boom (4/6)1451
Electrical circuit diagram – 2-piece boom (5/6)1453
Electrical circuit diagram – 2-piece boom (6/6)1455
Electrical circuit diagram for air conditioner unit1457

S.M 31/12/24