Komatsu Hydraulic Excavator PC138USLC-10 Shop Manual SEN06062-04 PDF

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Komatsu Hydraulic Excavator PC138USLC-10 Shop Manual SEN06062-04 – PDF DOWNLOAD

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Komatsu Hydraulic Excavator PC138USLC-10 Shop Manual SEN06062-04 – PDF DOWNLOAD

Language : English
Pages :1420
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Hydraulic Excavator PC138USLC-10 Shop Manual SEN06062-04 – PDF DOWNLOAD

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 2 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 PC138USLC-10 Shop Manual SEN06062-04 – PDF DOWNLOAD

Cover 1
00 Index and foreword 3
Index 4
Foreword, safety and general information 15
Important safety notice 15
How to read the shop manual 22
Explanation of terms for maintenance standard 24
Handling equipment of fuel system devices 26
Handling of intake system parts 27
Handling of hydraulic equipment 28
Method of disconnecting and connecting of push-pull type coupler 30
Handling of electrical equipment 33
How to read electric wire code 41
Precautions when performing operation 44
Practical use of KOMTRAX 49
Standard tightening torque table 50
List of abbreviation 56
Conversion table 61
01 Specification 67
Table of contents 68
Specifications 69
Specification drawing 69
Working range drawings 70
Specifications 71
Weight table 75
Table of fuel, coolant, and lubricants 77
10 Structure and function 79
Table of contents 80
Engine and cooling system 81
Engine related parts 81
PTO 83
Variable flow turbocharger 84
EGR system piping drawing 88
EGR system circuit diagram 90
EGR valve 91
EGR cooler 93
KCCV layout drawing 95
KCCV ventilator 97
KDOC muffler 99
Cooling system 101
Power train 103
Power train system 103
Swing circle 105
Swing machinery 106
Undercarriage and frame 108
Track frame 108
Idler cushion 109
Hydraulic system 110
Hydraulic component layout 110
Valve control 112
Hydraulic tank 113
CLSS 115
Main pump 119
Control valve 146
Swing motor 191
Travel motor 203
Work equipment and swing PPC valve 214
Travel PPC valve 221
Blade PPC valve 227
1st-line attachment PPC valve (with EPC valve) 229
Solenoid valve 237
Attachment circuit selector valve (for low pressure circuit) 243
Attachment circuit selector valve (for high pressure circuit) 246
Multi-control valve 248
Anti-drop valve for boom 249
Anti-drop valve for arm 253
Center swivel joint 257
PPC circuit accumulator 259
Attachment circuit accumulator (for low pressure circuit) 260
Attachment circuit accumulator (for high pressure circuit) 261
Work equipment 262
Work equipment 262
Work equipment shim 263
Bucket play adjustment shim 264
Cab and its attachments 265
Cab mount and cab tipping stopper 265
ROPS cab 266
Electrical system 268
Electrical control system 268
Machine monitor system 300
KOMTRAX system 321
Sensor 338
20 Standard value tables 351
Table of contents 352
Standard service value table 353
Standard value table for engine 353
Standard value table for machine 354
Standard value table for electrical system 367
30 Testing and adjusting 373
Table of contents 374
Related information on testing and adjusting 375
Tools for testing and adjusting 375
Sketch of tools for testing and adjusting 378
Engine and cooling system 380
Testing engine speed 380
Testing exhaust gas color 381
Testing and adjusting valve clearance 382
Testing compression pressure 384
Testing blowby pressure 387
Testing engine oil pressure 388
Testing fuel pressure 389
Testing fuel return rate and leakage 390
Bleeding air from fuel system 393
Testing fuel circuit for leakage 395
Handling cylinder cutout mode operation 396
Handling no-injection cranking operation 397
Testing and adjusting air conditioner compressor belt tension 398
Check fan belt, replace 399
Check auto-tensioner, replace 401
Writing compensation values at replacement of injector and engine controller 404
Power train 408
Testing swing circle bearing clearance 408
Undercarriage and frame 409
Testing and adjusting track tension 409
Hydraulic system 410
Releasing remaining pressure from hydraulic circuit 410
Testing and adjusting oil pressure in work equipment, swing, and travel circuits 415
Testing oil pressure of control circuit 418
Testing and adjusting oil pressure in pump PC control circuit 419
Testing and adjusting oil pressure in pump LS control circuit 422
Testing outlet pressure of solenoid valve 427
Testing PPC valve output pressure 428
Adjusting play of work equipment and swing PPC valves 430
Isolating the parts causing hydraulic drift in work equipment 431
Testing and adjusting travel deviation 433
Testing oil leakage 435
Bleeding air from hydraulic circuit 437
Cab and its attachments 440
Testing cab tipping stopper 440
Testing, cleaning and lubricating slide door rail and roller 441
Adjusting mirrors 442
Electrical system 444
Special functions of machine monitor 444
Adjusting rearview camera angle 495
Handling voltage circuit of engine controller 497
Handling battery disconnect switch 498
Testing diodes 499
Pm clinic 500
Pm Clinic service 500
40 Troubleshooting 507
Table of contents 508
Related information on troubleshooting 514
Troubleshooting points 514
Sequence of events in troubleshooting 516
Checks before troubleshooting 518
Inspection procedure before troubleshooting 520
Preparation for troubleshooting of electrical system 537
Classification and procedure for troubleshooting 541
Symptom and troubleshooting numbers 544
Information in troubleshooting table 547
Troubleshooting method for open circuit in wiring harness of pressure sensor system 549
Connector list and layout 551
Connector contact identification 561
T-branch box and T-branch adapter table 600
Fuse location table 605
Failure codes table 607
Troubleshooting by failure code (Display of code) 613
Failure code [879AKA] A/C Inner Sensor Open Circuit 613
Failure code [879AKB] A/C Inner Sensor Short Circuit 614
Failure code [879BKA] A/C Outer Sensor Open Circuit 615
Failure code [879BKB] A/C Outer Sensor Short Circuit 616
Failure code [879CKA] Ventilating Sensor Open Circuit 617
Failure code [879CKB] Ventilating Sensor Short Circuit 618
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit 619
Failure code [879EMC] Ventilation Damper Abnormality 620
Failure code [879FMC] Air Mix Damper Abnormality 621
Failure code [879GKX] Refrigerant Abnormality 622
Failure code [989L00] Engine Controller Lock Caution 1 623
Failure code [989M00] Engine Controller Lock Caution 2 624
Failure code [989N00] Engine Controller Lock Caution 3 625
Failure code [AB00KE] Charge Voltage Low 626
Failure code [B@BAZG] Eng Oil Press Low 628
Failure code [B@BAZK] Eng Oil Level Low 629
Failure code [B@BCNS] Eng Water Overheat 630
Failure code [B@HANS] Hyd Oil Overheat 631
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 633
Failure code [CA122] Chg Air Press Sensor High Error 634
Failure code [CA123] Chg Air Press Sensor Low Error 636
Failure code [CA131] Throttle Sensor High Error 638
Failure code [CA132] Throttle Sensor Low Error 640
Failure code [CA144] Coolant Temp Sens High Error 642
Failure code [CA145] Coolant Temp Sens Low Error 644
Failure code [CA153] Chg Air Temp Sensor High Error 646
Failure code [CA154] Chg Air Temp Sensor Low Error 648
Failure code [CA187] Sensor 2 Supply Volt Low Error 650
Failure code [CA221] Ambient Press Sensor High Error 652
Failure code [CA222] Ambient Press Sensor Low Error 654
Failure code [CA227] Sensor 2 Supply Volt High Error 656
Failure code [CA234] Eng Overspeed 657
Failure code [CA238] Ne Speed Sensor Supply Volt Error 658
Failure code [CA239] Ne Speed Sens Supply Volt High Error 659
Failure code [CA271] IMV/PCV1 Short Error 660
Failure code [CA272] IMV/PCV1 Open Error 661
Failure code [CA322] Inj #1(L#1) Open/Short Error 662
Failure code [CA324] Inj #3(L#3) Open/Short Error 664
Failure code [CA331] Inj #2(L#2) Open/Short Error 666
Failure code [CA332] Inj #4(L#4) Open/Short Error 668
Failure code [CA343] ECM Critical Internal Failure 670
Failure code [CA351] Injectors Drive Circuit Error 671
Failure code [CA352] Sensor 1 Supply Volt Low Error 672
Failure code [CA356] Mass Air Flow Sensor High Error 674
Failure code [CA357] Mass Air Flow Sensor Low Error 676
Failure code [CA386] Sensor 1 Supply Volt High Error 678
Failure code [CA435] Eng Oil Press Sw Error 679
Failure code [CA441] Battery Voltage Low Error 680
Failure code [CA442] Battery Voltage High Error 682
Failure code [CA449] Rail Press Very High Error 683
Failure code [CA451] Rail Press Sensor High Error 684
Failure code [CA452] Rail Press Sensor Low Error 686
Failure code [CA466] KVGT Motor Driver Position Error 688
Failure code [CA515] Rail Press Sens Sup Volt High Error 690
Failure code [CA516] Rail Press Sens Sup Volt Low Error 692
Failure code [CA553] Rail Press High Error 694
Failure code [CA555] Crankcase Press High Error 1 695
Failure code [CA556] Crankcase Press High Error 2 696
Failure code [CA559] Rail Press Low Error 697
Failure code [CA689] Eng Ne Speed Sensor Error 700
Failure code [CA691] Intake Air Temp Sens High Error 702
Failure code [CA692] Intake Air Temp Sens Low Error 704
Failure code [CA697] ECM Internal Temp Sensor High Error 706
Failure code [CA698] ECM Int Temp Sensor Low Error 707
Failure code [CA731] Eng Bkup Speed Sens Phase Error 708
Failure code [CA778] Eng Bkup Speed Sensor Error 710
Failure code [CA1117] Persistent Data Lost Error 714
Failure code [CA1695] Sensor 5 Supply Volt High Error 715
Failure code [CA1696] Sensor 5 Supply Volt Low Error 716
Failure code [CA1843] Crankcase Press Sens High Error 717
Failure code [CA1844] Crankcase Press Sens Low Error 719
Failure code [CA1896] EGR Valve Stuck Error 721
Failure code [CA1942] Crankcase Press Sens In Range Error 722
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error 723
Failure code [CA2185] Throt Sensor Sup Volt High Error 724
Failure code [CA2186] Throt Sensor Sup Volt Low Error 726
Failure code [CA2249] Rail Press Very Low Error 728
Failure code [CA2272] EGR Valve Pos Sens Low Error 729
Failure code [CA2311] IMV Solenoid Error 731
Failure code [CA2349] EGR Valve Solenoid Open Error 732
Failure code [CA2353] EGR Valve Solenoid Short Error 734
Failure code [CA2357] EGR Valve Servo Error 736
Failure code [CA2765] Inj Trim Data Error 737
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 738
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 740
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 742
Failure code [CA3918] KVGT Stuck Error 744
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error 745
Failure code [CA3921] KVGT Servo Error 2 746
Failure code [CA3922] KVGT Motor Driver Open Error 747
Failure code [CA3923] KVGT Motor Driver Short Error 749
Failure code [D110KB] Battery Relay Drive Short Circuit 751
Failure code [D19JKZ] Personal Code Relay Abnormality 753
Failure code [D811MC] KOMTRAX Error 756
Failure code [D862KA] GPS Antenna Open Circuit 757
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 758
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 760
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 761
Failure code [DA20MC] Pump Controller Malfunction 763
Failure code [DA22KK] Pump Solenoid Power Low Error 764
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 766
Failure code [DA29KQ] Model Selection Abnormality 768
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 770
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) 772
Failure code [DA2QKR] CAN2 Discon (Pump Con) 773
Failure code [DA2RKR] CAN1 Discon (Pump Con) 775
Failure code [DAF0MB] Monitor ROM Abnormality 776
Failure code [DAF0MC] Monitor Error 777
Failure code [DAF8KB] Camera Power Supply Short Circuit 778
Failure code [DAF9KQ] Model Selection Abnormality 780
Failure code [DAFGMC] GPS Module Error 781
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 782
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 784
Failure code [DAFQKR] CAN2 Discon (Monitor) 785
Failure code [DAZ9KQ] A/C Model Selection Abnormality 786
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 787
Failure code [DB2QKR] CAN2 Discon (Engine Con) 791
Failure code [DB2RKR] CAN1 Discon (Engine Con) 795
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 799
Failure code [DHPAMA] Pump Press Sensor Abnormality 801
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 803
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 805
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 807
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 809
Failure code [DHSKMA] Blade Raise PPC Press Sensor Abnormality 811
Failure code [DHSLMA] Blade Lower PPC Press Sensor Abnormality 813
Failure code [DHX1MA] Overload Sensor Abnormality 815
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 816
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 818
Failure code [DV20KB] Travel Alarm Short Circuit 819
Failure code [DW43KA] Travel Speed Sol Open Circuit 821
Failure code [DW43KB] Travel Speed Sol Short Circuit 823
Failure code [DW45KA] Swing Brake Sol Open Circuit 825
Failure code [DW45KB] Swing Brake Sol Short Circuit 828
Failure code [DW91KA] Travel Junction Sol Open Circuit 830
Failure code [DW91KB] Travel Junction Sol Short Circuit 832
Failure code [DWA2KA] Attachment Sol Open Circuit 834
Failure code [DWA2KB] Attachment Sol Short Circuit 836
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 838
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 840
Failure code [DXA8KA] PC-EPC Sol Open Circuit 842
Failure code [DXA8KB] PC-EPC Sol Short Circuit 844
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 846
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 848
Failure code [DY20KA] Wiper Working Abnormality 850
Failure code [DY20MA] Wiper Parking Abnormality 852
Failure code [DY2CKB] Washer Drive Short Circuit 854
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 856
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 858
Troubleshooting of electrical system (E-mode) 860
E-1 Engine does not start (Engine does not crank) 860
E-2 Manual preheating system does not work 866
E-3 While preheating is working, preheating monitor does not light up 869
E-4 When starting switch is turned to ON position, machine monitor displays nothing 871
E-5 When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow 874
E-6 Engine coolant temperature monitor lights up in white while engine is running 875
E-7 Hydraulic oil temperature monitor lights up in white while engine is running 876
E-8 Charge level monitor lights up while engine is running 877
E-9 Fuel level monitor lights up in red while engine is running 878
E-10 Engine coolant temperature monitor lights up in red while engine is running 879
E-11 Hydraulic oil temperature monitor lights up in red while engine is running 880
E-12 Engine oil pressure monitor lights up in red while engine is running 881
E-13 Fuel gauge display does not move from minimum or maximum 882
E-14 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 883
E-15 Engine coolant temperature gauge display does not move from minimum or maximum 884
E-16 Engine coolant temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) 885
E-17 Hydraulic oil temperature gauge does not move from minimum or maximum 886
E-18 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) 888
E-19 Some areas of machine monitor screen are not displayed 889
E-20 Function switch does not work 890
E-21 Automatic warm-up system does not operate (in cold season) 891
E-22 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated 892
E-23 Auto-deceleration function does not operate or is not canceled while lever is operated 893
E-24 Working mode selection screen is not displayed while working mode selector switch is operated 894
E-25 Setting of engine and hydraulic pump is not changed while working mode is changed 895
E-26 Travel speed monitor does not change while travel speed switch is operated 896
E-27 Travel speed does not change while travel speed selection is changed 897
E-28 Alarm buzzer does not stop sounding 898
E-29 Service meter is not displayed, while starting switch is in OFF position 899
E-30 Service mode cannot be selected 900
E-31 Any of work equipment, swing and travel does not work 901
E-32 Any of work equipment, swing and travel cannot be locked 903
E-33 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position 905
E-34 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position 907
E-35 Alarm does not sound during travel 909
E-36 Alarm does not stop sounding while machine is stopped 910
E-37 Horn does not sound 911
E-38 Horn does not stop sounding 912
E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated 913
E-40 Wiper does not operate while wiper switch is operated 914
E-41 Window washer does not operate while window washer switch is operated 916
E-42 Boom Lower is not displayed correctly with monitoring function 917
E-43 Arm OUT is not displayed correctly with monitoring function 919
E-44 Arm IN is not displayed correctly with monitoring function 921
E-45 Boom Raise is not displayed correctly with monitoring function 923
E-46 Bucket Curl is not displayed correctly with monitoring function 925
E-47 Bucket Dump is not displayed correctly with monitoring function 927
E-48 Swing is not displayed correctly with monitoring function 929
E-49 Travel is not displayed correctly with monitoring function 931
E-50 Service is not displayed correctly with monitoring function 932
E-51 Attachment hydraulic circuit cannot be changed 934
E-52 KOMTRAX system does not operate normally 935
Troubleshooting of hydraulic and mechanical system (H-mode) 937
Information described in troubleshooting table (H-mode) 937
System chart of hydraulic and mechanical systems 938
Failure mode and cause table 940
H-1 All of work equipment, swing and travel operation lacks speed or power 948
H-2 Engine speed drops significantly or engine stalls 950
H-3 Any of work equipment, swing and travel does not work 951
H-4 Unusual sound is heard from around hydraulic pump 952
H-5 Fine control performance or response is poor 953
H-6 Boom speed or power is low 954
H-7 Arm speed or power is low 957
H-8 Bucket speed or power is low 959
H-9 Work equipment does not move in single operation 961
H-10 Hydraulic drift of boom is large 962
H-11 Hydraulic drift of arm is large 963
H-12 Hydraulic drift of bucket is large 964
H-13 Time lag of work equipment is large 965
H-14 In combined operation of work equipment , equipment having heavier load moves slower 967
H-15 In combined operation of swing and boom RAISE, boom rising speed is low 968
H-16 In combined operation of swing and travel, travel speed drops largely 969
H-17 Machine does not travel straight 970
H-18 Travel speed is slow 972
H-19 Machine is hard to steer or travel power is low 974
H-20 Travel speed does not change, or travel speed is too slow or fast 977
H-21 One of tracks does not run 978
H-22 Upper structure does not swing to the right or left 980
H-23 Upper structure swing only to the right or left 981
H-24 Swing acceleration or swing speed is low in both directions (right and left) 982
H-25 Swing acceleration performance is poor or swing speed is slow in only one direction 983
H-26 Upper structure overruns excessively when it stops swinging (both right and left) 984
H-27 Upper structure overruns excessively when it stops swinging (either right or left) 985
H-28 Shock is large when upper structure stops swinging 986
H-29 Large unusual noise is heard when upper structure stops swinging 987
H-30 Swing drift on a slope is large while swing parking brake is applied 988
H-31 Swing drift on a slope is large while swing parking brake is released 989
H-32 Attachment hydraulic circuit cannot be changed while attachment is installed 990
H-33 Oil flow in attachment circuit cannot be controlled 991
Troubleshooting of engine (S-mode) 992
Information mentioned in troubleshooting table (S mode) 992
S-1 Engine does not crank when starting switch is turned to START position 993
S-2 Engine cranks but no exhaust smoke comes out 994
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 995
S-4 Engine startability is poor 996
S-5 Engine does not pick up smoothly 998
S-6 Engine stops during operation 1000
S-7 Engine runs rough or is unstable 1002
S-8 Engine lacks power 1003
S-9 Exhaust smoke is black 1005
S-10 Engine oil consumption is excessive 1007
S-11 Oil becomes contaminated quickly 1008
S-12 Fuel consumption is excessive 1009
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1010
S-14 Oil pressure drops 1011
S-15 Fuel mixes into engine oil 1012
S-16 Water mixes into engine oil (milky) 1013
S-17 Coolant temperature rises too high (overheating) 1014
S-18 Unusual noise is heard 1015
S-19 Vibration is excessive 1016
S-20 Air cannot be bled from fuel circuit 1017
50 Disassembly and assembly 1019
Table of contents 1020
Related information on disassembly and assembly 1022
How to read this manual 1022
Coating materials list 1024
Special tools list 1028
Sketches of special tools 1033
Engine and cooling system 1036
Removal and installation of supply pump assembly 1036
Removal and installation of injector assembly 1040
Removal and installation of cylinder head assembly 1046
Removal and installation of radiator assembly 1057
Removal and installation of hydraulic oil cooler assembly 1059
Removal and installation of aftercooler assembly 1062
Removal and installation of engine and main pump assembly 1064
Removal and installation of engine front oil seal 1070
Removal and installation of engine rear oil seal 1071
Removal and installation of fuel cooler assembly 1073
Removal and installation of fuel tank assembly 1074
Removal and installation of KDOC assembly 1077
Removal and installation of KCCV assembly 1078
Removal and installation of air cleaner assembly 1079
Removal and installation of fan belt 1081
Power train system 1083
Removal and installation of travel motor and final drive assembly 1083
Disassembly and assembly of travel motor and final drive assembly 1084
Removal and installation of swing motor and swing machinery assembly 1119
Disassembly and assembly of swing machinery assembly 1121
Removal and installation of swing circle assembly 1127
Undercarriage and frame 1128
Separation and connection of track 1128
Removal and installation of sprocket 1131
Removal and installation of idler and idler cushion assembly 1132
Disassembly and assembly of idler assembly 1133
Disassembly and assembly of idler cushion assembly 1136
Disassembly and assembly of track roller assembly 1139
Removal and installation of revolving frame assembly 1142
Removal and installation of counterweight assembly [For machines with additional counterweight] 1144
Hydraulic system 1147
Removal and installation of center swivel joint assembly 1147
Disassembly and assembly of center swivel joint assembly 1149
Removal and installation of hydraulic tank assembly 1150
Removal and installation of main pump assembly 1153
Removal and installation of main pump input shaft oil seal 1157
Removal and installation of control valve assembly 1158
Disassembly and assembly of control valve assembly 1164
Disassembly and assembly of work equipment PPC valve assembly 1166
Disassembly and assembly of travel PPC valve assembly 1168
Work equipment 1170
Removal and installation of work equipment assembly 1170
Removal and installation of anti-drop valve for boom assembly 1174
Removal and installation of anti-drop valve for arm assembly 1177
Disassembly and assembly of anti-drop valve assembly 1180
Disassembly and assembly of work equipment cylinder assembly 1181
Cab and its attachments 1186
Removal and installation of operator’s cab assembly 1186
Removal and installation of operator’s cab door 1189
Removal and installation of operator’s cab glass (adhered glass) 1192
Removal and installation of front window assembly 1203
Removal and installation of floor frame assembly 1204
Removal and installation of air conditioner unit assembly 1211
Removal and installation of air conditioner compressor assembly 1215
Removal and installation of air conditioner condenser assembly 1217
Removal and installation of operator’s seat 1219
Removal and installation of seat belt 1220
Removal and installation of front wiper assembly 1221
Electrical system 1228
Removal and installation of engine controller assembly 1228
Removal and installation of pump controller assembly 1229
Removal and installation of machine monitor assembly 1231
Removal and installation of mass air flow and temperature sensor 1233
Removal and installation of KOMTRAX terminal assembly 1234
60 Maintenance standard 1235
Table of contents 1236
Engine and cooling system 1237
Engine mount 1237
PTO 1238
Cooling system 1239
Power train 1240
Swing circle 1240
Swing machinery 1241
Sprocket 1242
Undercarriage and frame 1243
Track frame 1243
Idler cushion 1244
Idler 1245
Track roller 1246
Carrier roller 1247
Track shoe 1248
Hydraulic system 1253
Hydraulic tank 1253
Main pump 1254
Control valve 1257
Swing motor 1268
Travel motor 1271
Anti-drop valve for boom 1272
Anti-drop valve for arm 1274
Work equipment and swing PPC valve 1276
Travel PPC valve 1279
Blade PPC valve 1281
1st-line attachment PPC valve (with EPC valve) 1283
Solenoid valve 1286
Attachment circuit selector valve (for low pressure circuit) 1288
Attachment circuit selector valve (for high pressure circuit) 1289
Center swivel joint 1290
Cab and its attachments 1291
Cab mount and cab tipping stopper 1291
Work equipment 1292
Work equipment 1292
Boom cylinder 1301
Arm cylinder 1302
Bucket cylinder 1303
Blade cylinder 1304
80 Appendix 1305
Table of contents 1306
Air conditioner components 1307
Precautions for refrigerant 1307
Air conditioner component 1308
Configuration and function of refrigeration cycle 1311
Outline of refrigeration cycle 1312
Air conditioner unit 1314
Dual pressure switch 1319
Air conditioner controller 1320
Compressor 1321
Air conditioner condenser 1322
Sunlight sensor 1324
Outer temperature sensor (outside air temperature sensor) 1325
Procedure for testing and troubleshooting 1326
Circuit diagram and arrangement of connector pins 1328
System diagram 1330
Input and output signals of the air conditioner controller 1331
Air conditioner unit 1333
Parts and connectors layout 1335
Testing air leakage (duct) 1341
Testing with self-diagnosis function 1344
Testing vent (mode) changeover 1347
Testing FRESH/RECIRC air changeover 1348
Testing sunlight sensor 1349
Testing (dual) pressure switch for refrigerant 1350
Testing relays 1352
Troubleshooting chart 1 1353
Troubleshooting chart 2 1354
Information in troubleshooting table 1357
Failure code list related to air conditioner 1358
Failure code [879AKA] A/C Inner Sensor Open Circuit 1359
Failure code [879AKB] A/C Inner Sensor Short Circuit 1360
Failure code [879BKA] A/C Outer Sensor Open Circuit 1361
Failure code [879BKB] A/C Outer Sensor Short Circuit 1363
Failure code [879CKA] Ventilating Sensor Open Circuit 1365
Failure code [879CKB] Ventilating Sensor Short Circuit 1366
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 1367
Failure code [879EMC] Ventilation Damper Abnormality 1369
Failure code [879FMC] Air Mix Damper Abnormality 1370
Failure code [879GKX] Refrigerant Abnormality 1371
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1372
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1374
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1377
A-4 Troubleshooting for FRESH/RECIRC air changeover 1379
Troubleshooting with gauge pressure 1381
Connection of service tool 1384
Precautions for disconnecting and connecting refrigerant piping 1386
Handling of compressor oil 1388
Desiccant replacement 1390
90 Diagrams and drawings 1393
Table of contents 1394
Hydraulic circuit diagram 1395
Symbols in hydraulic circuit diagram 1395
Hydraulic circuit diagram 1399
Electric circuit diagram 1400
Symbols in electric circuit diagram 1400
Electrical circuit diagram 1404
Electrical circuit diagram of air conditioner unit 1409
INDEX1411

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24