Komatsu PC135F-10M0 Hydraulic Excavator Shop Manual LEBMP13X02 PDF

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Komatsu PC135F-10M0 Hydraulic Excavator Shop Manual LEBMP13X02 – PDF DOWNLOAD

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Komatsu PC135F-10M0 Hydraulic Excavator Shop Manual LEBMP13X02 – PDF DOWNLOAD

Language : English
Pages : 2090
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC135F-10M0 Hydraulic Excavator Shop Manual LEBMP13X02 – PDF DOWNLOAD

• SERIAL NUMBERS J10001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
FOREWORD, SAFETY, BASIC INFORMATION . 17
HOW TO READ THE SHOP MANUAL . 17
SAFETY NOTICE FOR OPERATION . 19
PRECAUTIONS TO PREVENT FIRE . 27
ACTIONS IF FIRE OCCURS 28
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS . 29
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 30
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS . 33
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 40
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 42
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 43
PRACTICAL USE OF KOMTRAX 44
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 45
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 45
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 46
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 49
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 53
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 56
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 57
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 59
HOW TO READ ELECTRICAL WIRE CODE 60
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 64
STANDARD TIGHTENING TORQUE TABLE 67
CONVERSION TABLE 74
ABBREVIATION LIST . 79
01 SPECIFICATIONS . 83
CONTENTS 84
SPECIFICATIONS 85
SPECIFICATION DRAWING . 85
SPECIFICATION DRAWING: PC130-10M0 . 85
WORKING RANGE DRAWINGS 87
WORKING RANGE DRAWINGS: PC130-10M0 87
SPECIFICATIONS 88
SPECIFICATIONS: PC130-10M0 88
WEIGHT TABLE 92
WEIGHT TABLE: PC130-10M0 92
FUEL, COOLANT, LUBRICANT 94
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE . 94
10 STRUCTURE AND FUNCTION . 97
CONTENTS 98
BOOT-UP SYSTEM 101
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 101
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 102
SYSTEM OPERATING LAMP SYSTEM 103
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 103
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 103
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 103
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 104
BATTERY DISCONNECT SWITCH . 106
FUNCTION OF BATTERY DISCONNECT SWITCH . 106
ENGINE SYSTEM . 107
LAYOUT DRAWING OF ENGINE SYSTEM . 107
ENGINE CONTROL SYSTEM . 108
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) . 108
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 108
OPERATION OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 109
OPERATION OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 110
AUTO-DECELERATION SYSTEM 112
SYSTEM DIAGRAM OF AUTO-DECELERATION SYSTEM 112
FUNCTION OF AUTO-DECELERATION SYSTEM 112
OPERATION OF AUTO-DECELERATION SYSTEM . 113
ENGINE AUTOMATIC WARM-UP SYSTEM . 114
SYSTEM DIAGRAM OF ENGINE AUTOMATIC WARM-UP SYSTEM . 114
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 114
OVERHEAT PREVENTION SYSTEM 116
FUNCTION OF OVERHEAT PREVENTION SYSTEM 116
TURBOCHARGER PROTECTION SYSTEM 118
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 118
COMPONENT PARTS OF ENGINE SYSTEM 119
PTO . 119
COOLING SYSTEM 120
LAYOUT DRAWING OF COOLING SYSTEM 120
SPECIFICATIONS OF COOLING SYSTEM 121
CONTROL SYSTEM 122
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL) 122
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 124
MACHINE MONITOR SYSTEM 126
SYSTEM DIAGRAM OF MACHINE MONITOR (MACHINE WITH KOMTRAX TERMINAL) . 126
SYSTEM DIAGRAM OF MACHINE MONITOR (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 127
FUNCTION OF MACHINE MONITOR SYSTEM 127
KOMTRAX SYSTEM 129
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL) 129
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 129
FUNCTION OF KOMTRAX SYSTEM 130
COMPONENT PARTS OF CONTROL SYSTEM . 131
MACHINE MONITOR . 131
KOMTRAX TERMINAL 144
GATEWAY FUNCTION CONTROLLER . 146
COMMUNICATION TERMINAL 149
PUMP CONTROLLER . 151
RESISTOR FOR PC-EPC VALVE . 156
CAN TERMINATING RESISTOR 157
ENGINE CONTROLLER . 158
FUEL CONTROL DIAL . 163
HYDRAULIC SYSTEM 165
LAYOUT DRAWING OF HYDRAULIC SYSTEM 165
CLSS 167
STRUCTURE OF CLSS . 167
FUNCTION OF CLSS 168
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 170
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 170
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 171
COMPONENT PARTS OF HYDRAULIC SYSTEM . 176
HYDRAULIC TANK 176
MAIN PUMP . 178
CONTROL VALVE . 203
WORK EQUIPMENT SYSTEM . 263
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 263
STRUCTURE OF VALVE CONTROL 266
PPC LOCK SYSTEM . 267
SYSTEM DIAGRAM OF PPC LOCK SYSTEM . 267
FUNCTION OF PPC LOCK SYSTEM . 267
ONE-TOUCH POWER MAXIMIZING SYSTEM . 268
SYSTEM DIAGRAM OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 268
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 268
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 269
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 269
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 270
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 271
WORK EQUIPMENT AND SWING PPC VALVE 271
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 276
SOLENOID VALVE 283
VARIABLE BACK PRESSURE SOLENOID VALVE . 288
PILOT CIRCUIT ACCUMULATOR . 289
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) . 290
SWING SYSTEM 291
LAYOUT DRAWING OF SWING SYSTEM 291
SWING CONTROL SYSTEM DIAGRAM 293
FUNCTION OF SWING CONTROL SYSTEM 293
COMPONENT PARTS OF SWING SYSTEM . 296
SWING MOTOR . 296
SWING MACHINERY . 304
SWING CIRCLE 306
TRAVEL SYSTEM . 307
LAYOUT DRAWING OF TRAVEL SYSTEM . 307
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM . 309
FUNCTION OF TRAVEL CONTROL SYSTEM . 309
COMPONENT PARTS OF TRAVEL SYSTEM 313
TRAVEL MOTOR 313
TRAVEL PPC VALVE 323
CENTER SWIVEL JOINT . 327
UNDERCARRIAGE AND FRAME . 330
LAYOUT DRAWING OF UNDERCARRIAGE . 330
SPECIFICATIONS OF UNDERCARRIAGE . 330
IDLER CUSHION . 331
STRUCTURE OF IDLER CUSHION 331
SPECIFICATIONS OF IDLER CUSHION . 331
WORK EQUIPMENT 332
STRUCTURE OF WORK EQUIPMENT . 332
FUNCTION OF WORK EQUIPMENT 333
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 334
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 334
BUCKET CLEARANCE ADJUSTMENT SHIM 335
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 335
CAB AND ITS ATTACHMENTS . 336
ROPS CAB 336
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL) . 336
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 336
FUNCTION OF ROPS CAB 337
CAB MOUNT . 338
STRUCTURE OF CAB MOUNT 338
FUNCTION OF CAB MOUNT . 339
CAB TIPPING STOPPER . 340
STRUCTURE OF CAB TIPPING STOPPER 340
FUNCTION OF CAB TIPPING STOPPER . 340
20 STANDARD VALUE TABLE . 341
CONTENTS 342
STANDARD VALUE TABLE FOR ENGINE . 343
STANDARD VALUE TABLE FOR ENGINE: PC130-10M0 . 343
STANDARD VALUE TABLE FOR MACHINE 346
STANDARD VALUE TABLE FOR MACHINE: PC130-10M0 346
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE . 360
30 TESTING AND ADJUSTING 365
CONTENTS 366
RELATED INFORMATION ON TESTING AND ADJUSTING 369
TOOLS FOR TESTING AND ADJUSTING . 369
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 373
ENGINE AND COOLING SYSTEM . 375
TEST ENGINE SPEED . 375
TEST ENGINE SPEED . 375
TEST EXHAUST GAS COLOR 377
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 377
TEST EXHAUST GAS COLOR BY SMOKE METER . 378
TEST AND ADJUST VALVE CLEARANCE . 379
TEST VALVE CLEARANCE 379
ADJUST VALVE CLEARANCE 380
TEST COMPRESSION PRESSURE . 382
TEST COMPRESSION PRESSURE . 382
TEST BLOWBY PRESSURE 384
TEST BLOWBY PRESSURE ON MACHINE MONITOR . 384
TEST ENGINE OIL PRESSURE 386
TEST ENGINE OIL PRESSURE 386
TEST FUEL PRESSURE 388
TEST FUEL PRESSURE 388
TEST FUEL RETURN RATE AND LEAKAGE . 389
TEST FUEL RETURN RATE AND LEAKAGE . 391
BLEED AIR FROM FUEL SYSTEM 394
BLEED AIR FROM FUEL SYSTEM 394
TEST FUEL CIRCUIT FOR LEAKAGE . 396
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 396
HANDLE CYLINDER CUT-OUT MODE OPERATION 398
HANDLE NO-INJECTION CRANKING OPERATION 399
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 400
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 400
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 400
TEST AND ADJUST FAN BELT TENSION 402
METHOD FOR CHECKING FAN BELT TENSION 402
METHOD FOR ADJUSTING FAN BELT TENSION . 402
POWER TRAIN . 404
TEST SWING CIRCLE BEARING CLEARANCE . 404
TEST SWING CIRCLE BEARING CLEARANCE . 404
UNDERCARRIAGE AND FRAME . 405
TEST AND ADJUST TRACK TENSION . 405
METHOD FOR TESTING TRACK TENSION 405
METHOD FOR ADJUSTING TRACK TENSION 405
HYDRAULIC SYSTEM 407
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 407
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 407
RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 407
RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT . 407
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 408
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS . 409
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 409
ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 416
TEST OIL PRESSURE OF CONTROL CIRCUIT 419
TEST OIL PRESSURE OF CONTROL CIRCUIT 419
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 421
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 421
TEST PC-EPC VALVE OUTLET PRESSURE . 422
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 423
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 424
TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 424
TEST LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 426
TEST LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 427
METHOD FOR ADJUSTING LS VALVE . 428
TEST OUTLET PRESSURE OF SOLENOID VALVE 430
TEST OUTLET PRESSURE IN SOLENOID VALVE 430
OPERATING CONDITION OF SOLENOID VALVE . 431
TEST OUTLET PRESSURE IN VARIABLE BACK PRESSURE SOLENOID VALVE . 433
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE 434
TEST OUTLET PRESSURE IN PPC VALVE . 435
TEST OUTLET PRESSURE IN PPC VALVE . 435
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 437
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 437
TEST AND ADJUST TRAVEL DEVIATION 438
TEST TRAVEL DEVIATION . 438
METHOD FOR ADJUSTING TRAVEL DEVIATION . 438
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 441
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 441
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 441
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 442
TEST OIL LEAKAGE 443
TEST OIL LEAKAGE FROM BOOM CYLINDER . 443
TEST OIL LEAKAGE FROM ARM CYLINDER 443
TEST OIL LEAKAGE FROM BUCKET CYLINDER . 444
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 444
TEST OIL LEAKAGE FROM SWING MOTOR . 445
TEST OIL LEAKAGE FROM TRAVEL MOTOR 446
BLEED AIR FROM HYDRAULIC CIRCUIT 447
BLEED AIR FROM HYDRAULIC CIRCUIT 448
CAB RELATED PARTS . 451
TEST CAB TIPPING STOPPER 451
METHOD FOR TESTING CAB TIPPING STOPPER 451
ADJUST MIRRORS 452
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 453
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 454
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 456
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 457
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 458
PROCEDURE FOR ADJUSTING MACHINE REAR COUNTERWEIGHT MIRROR (D) . 459
ELECTRICAL SYSTEM . 460
SET AND OPERATE MACHINE MONITOR . 460
OPERATOR MODE . 464
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 464
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 464
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 465
CHECKING FUNCTION OF SERVICE METER 465
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD 465
SERVICE MODE 468
OPERATE SERVICE MODE 468
CHECK PRE-DEFINED MONITORING INFORMATION 469
CHECK MONITORING INFORMATION 472
ABNORMALITY RECORD MENU . 480
CHECK MAINTENANCE RECORD 484
MAINTENANCE MODE SETTING 485
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 489
DEFAULT MENU 491
DIAGNOSTIC TESTS MENU . 497
ADJUSTMENT MENU . 499
KOMTRAX SETTINGS MENU . 511
METHOD FOR DISPLAYING SERVICE MESSAGE . 516
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) . 518
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL) 523
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 525
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) . 531
ADJUST REARVIEW CAMERA ANGLE 533
ADJUST REARVIEW CAMERA ANGLE 533
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 535
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 535
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 537
BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL) . 538
BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 539
TEST DIODES . 540
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 540
METHOD FOR TESTING DIODE USING ANALOG TESTER 540
Pm-CLINIC . 541
Pm CLINIC SERVICE . 541
Pm CLINIC CHECK SHEET: PC130-10M0 . 543
40 TROUBLESHOOTING 553
CONTENTS 554
RELATED INFORMATION ON TROUBLESHOOTING 561
GENERAL TROUBLESHOOTING POINTS 561
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 562
CHECKS BEFORE TROUBLESHOOTING . 564
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 566
WALK-AROUND CHECK . 566
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 568
CHECK FUEL LEVEL AND TYPE . 568
DRAIN WATER AND SEDIMENT FROM FUEL TANK . 568
CHECK FUEL PREFILTER 569
CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT . 569
REPLACE FUEL PREFILTER CARTRIDGE 570
CHECK FUEL MAIN FILTER 571
TEST ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) . 573
CHECK OIL LEVEL IN PTO GEAR CASE 574
CHECK COOLANT LEVEL (RESERVOIR TANK) 575
CHECK CLOGGING OF AIR CLEANER . 576
CLEAN OUTER ELEMENT . 576
REPLACE ELEMENT . 579
CHECK HYDRAULIC OIL LEVEL . 580
CHECK HYDRAULIC OIL STRAINER 582
CHECK HYDRAULIC OIL FILTER 582
CHECK OIL LEVEL IN SWING MACHINERY CASE . 584
CHECK OIL LEVEL IN FINAL DRIVE CASE . 585
BLEED AIR FROM FUEL SYSTEM 585
BLEED AIR FROM HYDRAULIC SYSTEM . 585
CHECK ELECTRIC EQUIPMENT 585
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 590
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 590
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 590
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 591
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 591
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 591
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 591
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 596
SYMPTOM AND TROUBLESHOOTING NUMBERS . 599
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 603
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 605
CONNECTOR LIST AND LAYOUT (MACHINES WITHOUT FUEL REFILL PUMP) . 608
CONNECTOR LIST AND LAYOUT (MACHINES WITHOUT FUEL REFILL PUMP) . 619
CONNECTOR CONTACT IDENTIFICATION 631
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 674
FUSE LOCATION TABLE (MACHINES WITHOUT FUEL REFILL PUMP) . 680
FUSE LOCATION TABLE (MACHINES WITH FUEL REFILL PUMP) 682
FAILURE CODES TABLE . 684
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 692
FAILURE CODE [879AKA] . 692
FAILURE CODE [879AKB] . 693
FAILURE CODE [879BKA] . 694
FAILURE CODE [879BKB] . 696
FAILURE CODE [879CKA] . 698
FAILURE CODE [879CKB] . 699
FAILURE CODE [879DKZ] . 700
FAILURE CODE [879EMC] . 702
FAILURE CODE [879FMC] . 703
FAILURE CODE [879GKX] . 704
FAILURE CODE [989L00] . 706
FAILURE CODE [989M00] . 707
FAILURE CODE [989N00] . 708
FAILURE CODE [AA10NX] . 709
FAILURE CODE [AB00KE] . 711
FAILURE CODE [B@BAZG] . 713
FAILURE CODE [B@BAZK] . 714
FAILURE CODE [B@BCNS] . 716
FAILURE CODE [B@BCQA] . 717
FAILURE CODE [B@BCZK] . 719
FAILURE CODE [B@HANS] . 721
FAILURE CODE [CA111] 723
FAILURE CODE [CA122] 729
FAILURE CODE [CA123] 731
FAILURE CODE [CA131] 732
FAILURE CODE [CA132] 734
FAILURE CODE [CA144] 735
FAILURE CODE [CA145] 737
FAILURE CODE [CA153] 738
FAILURE CODE [CA154] 740
FAILURE CODE [CA221] 741
FAILURE CODE [CA222] 743
FAILURE CODE [CA234] 744
FAILURE CODE [CA238] 745
FAILURE CODE [CA271] 747
FAILURE CODE [CA272] 748
FAILURE CODE [CA322] 749
FAILURE CODE [CA324] 751
FAILURE CODE [CA331] 753
FAILURE CODE [CA332] 755
FAILURE CODE [CA351] 757
FAILURE CODE [CA352] 761
FAILURE CODE [CA386] 762
FAILURE CODE [CA435] 764
FAILURE CODE [CA441] 765
FAILURE CODE [CA442] 766
FAILURE CODE [CA449] 767
FAILURE CODE [CA451] 768
FAILURE CODE [CA452] 770
FAILURE CODE [CA553] 771
FAILURE CODE [CA559] 772
FAILURE CODE [CA689] 776
FAILURE CODE [CA731] 778
FAILURE CODE [CA757] 779
FAILURE CODE [CA778] 785
FAILURE CODE [CA2185] . 787
FAILURE CODE [CA2186] . 789
FAILURE CODE [CA2249] . 790
FAILURE CODE [CA2311] . 791
FAILURE CODE [D110KB] . 792
FAILURE CODE [D19JKZ] . 794
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL) . 796
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 797
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL) . 798
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 799
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL) . 800
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 802
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL) . 805
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 807
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL) . 809
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 812
FAILURE CODE [D8G1KT] . 818
FAILURE CODE [D8G6KT] . 819
FAILURE CODE [DA20MC] . 820
FAILURE CODE [DA22KK] . 821
FAILURE CODE [DA25KP] . 823
FAILURE CODE [DA26KP] . 825
FAILURE CODE [DA29KQ] . 828
FAILURE CODE [DA2LKA] (MACHINE WITH KOMTRAX TERMINAL) . 830
FAILURE CODE [DA2LKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 832
FAILURE CODE [DA2LKB] (MACHINE WITH KOMTRAX TERMINAL) . 835
FAILURE CODE [DA2LKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 837
FAILURE CODE [DA2QKR] (MACHINE WITH KOMTRAX TERMINAL) . 839
FAILURE CODE [DA2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 844
FAILURE CODE [DA2RKR] (MACHINE WITH KOMTRAX TERMINAL) . 850
FAILURE CODE [DA2RKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 855
FAILURE CODE [DAF0MB] . 861
FAILURE CODE [DAF0MC] . 862
FAILURE CODE [DAF8KB] . 863
FAILURE CODE [DAF9KQ] . 865
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL) . 866
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 867
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL) . 868
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 870
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL) . 873
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 875
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL) . 877
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 881
FAILURE CODE [DAZ9KQ] . 886
FAILURE CODE [DAZQKR] (MACHINE WITH KOMTRAX TERMINAL) . 887
FAILURE CODE [DAZQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 890
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL) . 896
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 901
FAILURE CODE [DGH2KA] . 907
FAILURE CODE [DGH2KB] . 909
FAILURE CODE [DHA4KA] . 911
FAILURE CODE [DHE5MA] . 913
FAILURE CODE [DHPAMA] . 917
FAILURE CODE [DHS3MA] . 919
FAILURE CODE [DHS4MA] . 921
FAILURE CODE [DHS8MA] . 923
FAILURE CODE [DHS9MA] . 925
FAILURE CODE [DHSAMA] . 927
FAILURE CODE [DHSBMA] . 929
FAILURE CODE [DHSCMA] . 931
FAILURE CODE [DHSDMA] . 933
FAILURE CODE [DHSFMA] . 935
FAILURE CODE [DHSGMA] . 937
FAILURE CODE [DHSHMA] . 939
FAILURE CODE [DHSJMA] . 941
FAILURE CODE [DHSKMA] . 943
FAILURE CODE [DHSLMA] . 945
FAILURE CODE [DJG1KX] . 947
FAILURE CODE [DKR2MA] . 951
FAILURE CODE [DKR2NX] . 955
FAILURE CODE [DV20KB] . 958
FAILURE CODE [DW43KA] . 960
FAILURE CODE [DW43KB] . 962
FAILURE CODE [DW43KY] . 964
FAILURE CODE [DW45KA] . 965
FAILURE CODE [DW45KB] . 968
FAILURE CODE [DW45KY] . 971
FAILURE CODE [DW91KA] . 973
FAILURE CODE [DW91KB] . 975
FAILURE CODE [DW91KY] . 977
FAILURE CODE [DWA2KA] . 979
FAILURE CODE [DWA2KB] . 981
FAILURE CODE [DWA2KY] . 983
FAILURE CODE [DWJ0KA] . 985
FAILURE CODE [DWJ0KB] . 987
FAILURE CODE [DWJ0KY] . 989
FAILURE CODE [DWK0KA] . 991
FAILURE CODE [DWK0KB] . 993
FAILURE CODE [DWK0KY] . 995
FAILURE CODE [DWK2KA] . 997
FAILURE CODE [DWK2KB] . 999
FAILURE CODE [DWK2KY] .1001
FAILURE CODE [DWNSKA] .1003
FAILURE CODE [DWNSKB] .1005
FAILURE CODE [DWNSKY] .1007
FAILURE CODE [DXA8KA] .1008
FAILURE CODE [DXA8KB] .1010
FAILURE CODE [DXE4KA] .1012
FAILURE CODE [DXE4KB] .1014
FAILURE CODE [DXE4KY] .1016
FAILURE CODE [DY20KA] .1018
FAILURE CODE [DY20MA] .1020
FAILURE CODE [DY2CKB] .1022
FAILURE CODE [DY2DKB] .1024
FAILURE CODE [DY2EKB] .1026
FAILURE CODE [F@BBZL] .1028
FAILURE CODE [F311KA] .1031
FAILURE CODE [F311KB] .1033
FAILURE CODE [F312KA] .1035
FAILURE CODE [F312KB] .1037
FAILURE CODE [F313KA] .1039
FAILURE CODE [F313KB] .1041
FAILURE CODE [F314KA] .1042
FAILURE CODE [F314KB] .1044
FAILURE CODE [F316KB] .1046
FAILURE CODE [F316KY] .1048
FAILURE CODE [F318KB] .1050
FAILURE CODE [F318KY] .1052
FAILURE CODE [F31AKB] .1053
FAILURE CODE [F31AKY] .1055
FAILURE CODE [F31BKB] .1057
FAILURE CODE [F31BKY] .1059
FAILURE CODE [F31CKB] .1061
FAILURE CODE [F31CKY] .1063
FAILURE CODE [F31DKB] .1065
FAILURE CODE [F31DKY] .1067
FAILURE CODE [F31EKB] .1069
FAILURE CODE [F31EKY] .1071
FAILURE CODE [FS10ZE] .1073
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1074
ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1074
MANUAL PREHEATING SYSTEM DOES NOT WORK 1085
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP 1089
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR SHOWS NOTHING 1092
WHILE ENGINE IS IN OPERATION, ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE .1097
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION .1098
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS IN OPERATION .1099
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1100
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1101
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION 1102
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .1103
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION .1104
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1105
FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL .1107
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1108
COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE .1109
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1110
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE .1112
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT SHOWN 1113
FUNCTION SWITCH DOES NOT OPERATE 1114
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER) .1115
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED 1116
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION 1117
WORK MODE SELECTOR SCREEN IS NOT SHOWN WHILE WORK MODE SWITCH IS OPERATED .1118
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED .1119
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED 1120
TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU OPERATE THE OPERATION TO CHANGE TRAVEL SPEED .1121
ALARM BUZZER CANNOT BE STOPPED 1122
SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION .1123
MACHINE DOES NOT CHANGE TO SERVICE MODE .1124
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE 1125
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK .1129
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED .1131
WHILE SWING PARKING BRAKE RELEASE SWITCH IS TURNED ON, SWING BRAKE IS NOT OPERATED 1133
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY .1135
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED .1139
TRAVEL ALARM DOES NOT OPERATE DURING TRAVEL .1141
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS .1143
HORN DOES NOT MAKE SOUND 1144
HORN DOES NOT STOP 1146
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED 1147
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED 1148
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED 1150
“BOOM RAISE” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1151
“BOOM LOWER” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1152
“ARM DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1153
“ARM IN” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1154
“BUCKET DUMP” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1155
“BUCKET CURL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1156
“SWING” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1157
“TRAVEL” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION 1158
SERVICE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1159
BLADE RAISE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1162
BLADE LOWER IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION .1163
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY .1164
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1165
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1165
FAILURE MODE AND CAUSE TABLE 1166
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1176
All WORK EQUIPMENT, SWING, AND TRAVEL SPEED IS LOW OR POWER IS LOW 1177
FINE CONTROL PERFORMANCE OR RESPONSE IS UNSATISFACTORY 1179
THERE IS UNUSUAL NOISE FROM AROUND HYDRAULIC PUMP .1180
ENGINE SPEED FALLS LARGELY OR ENGINE STOPS 1181
BOOM SPEED OR POWER IS LOW 1183
ARM SPEED IS LOW OR POWER IS LOW 1186
BUCKET SPEED OR POWER IS LOW 1189
BLADE SPEED OR POWER IS LOW .1192
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1194
HYDRAULIC DRIFT OF BOOM IS LARGE 1195
HYDRAULIC DRIFT OF ARM IS LARGE .1196
HYDRAULIC DRIFT OF BUCKET IS LARGE 1197
HYDRAULIC DRIFT OF BLADE IS LARGE .1198
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1200
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1201
TIME LAG OF WORK EQUIPMENT IS LARGE .1203
ATTACHMENT CIRCUIT CANNOT BE CHANGED 1204
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1205
IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER 1206
IN COMBINATION OPERATION OF SWING AND TRAVEL, TRAVEL SPEED FALLS LARGELY 1207
IN COMBINATION OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW .1208
MACHINE DOES NOT TRAVEL STRAIGHT 1209
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1212
TRAVEL SPEED IS SLOW 1215
ONE OF TRACKS DOES NOT RUN 1217
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST .1219
MACHINE DOES NOT SWING TO RIGHT OR LEFT .1220
SWINGS ONLY IN ONE DIRECTION 1221
SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT 1222
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 1223
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT) .1224
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION) .1225
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION .1226
THERE IS A LARGE UNUSUAL NOISE WHEN UPPER STRUCTURE STOPS SWING OPERATION .1227
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1228
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) .1229
50 DISASSEMBLY AND ASSEMBLY .1231
CONTENTS 1232
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1236
HOW TO READ THIS MANUAL .1236
COATING MATERIALS LIST 1237
SPECIAL TOOLS LIST 1242
SKETCHES OF SPECIAL TOOLS .1256
PREPARATION .1258
DRAIN AND ADD COOLANT .1258
DRAIN COOLANT .1258
ADD COOLANT .1259
DRAIN AND ADD HYDRAULIC OIL .1261
DRAIN HYDRAULIC OIL .1261
ADD HYDRAULIC OIL .1263
DRAIN AND ADD FUEL 1264
DRAIN FUEL 1264
ADD FUEL 1265
COLLECT AND REFILL REFRIGERANT 1266
COLLECT REFRIGERANT .1266
REFILL REFRIGERANT 1267
ENGINE AND COOLING SYSTEM .1268
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1268
REMOVE SUPPLY PUMP ASSEMBLY .1269
INSTALL SUPPLY PUMP ASSEMBLY 1272
REMOVE AND INSTALL INJECTOR ASSEMBLY 1278
REMOVE INJECTOR ASSEMBLY 1279
INSTALL INJECTOR ASSEMBLY .1282
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1286
REMOVE CYLINDER HEAD ASSEMBLY .1287
INSTALL CYLINDER HEAD ASSEMBLY 1297
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY 1310
REMOVE STARTING MOTOR ASSEMBLY 1310
INSTALL STARTING MOTOR ASSEMBLY .1312
REMOVE AND INSTALL FAN BELT .1313
REMOVE FAN BELT .1314
INSTALL FAN BELT 1315
REMOVE AND INSTALL RADIATOR ASSEMBLY 1317
REMOVE RADIATOR ASSEMBLY 1318
INSTALL RADIATOR ASSEMBLY .1321
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1325
REMOVE HYDRAULIC OIL COOLER ASSEMBLY 1326
INSTALL HYDRAULIC OIL COOLER ASSEMBLY .1330
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .1335
REMOVE AFTERCOOLER ASSEMBLY .1336
INSTALL AFTERCOOLER ASSEMBLY 1339
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1343
REMOVE ENGINE AND MAIN PUMP ASSEMBLY 1345
INSTALL ENGINE AND MAIN PUMP ASSEMBLY .1363
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1384
REMOVE ENGINE FRONT OIL SEAL 1385
INSTALL ENGINE FRONT OIL SEAL .1386
REMOVE AND INSTALL ENGINE REAR OIL SEAL .1388
REMOVE ENGINE REAR OIL SEAL .1389
INSTALL ENGINE REAR OIL SEAL 1390
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .1393
REMOVE FUEL COOLER ASSEMBLY .1394
INSTALL FUEL COOLER ASSEMBLY 1395
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .1396
REMOVE ENGINE HOOD ASSEMBLY .1396
INSTALL ENGINE HOOD ASSEMBLY 1397
REMOVE AND INSTALL FUEL TANK ASSEMBLY .1399
REMOVE FUEL TANK ASSEMBLY .1400
INSTALL FUEL TANK ASSEMBLY 1403
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .1407
REMOVE AIR CLEANER ASSEMBLY .1408
INSTALL AIR CLEANER ASSEMBLY 1410
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 1413
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY 1414
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .1415
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .1418
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY .1418
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 1420
POWER TRAIN .1422
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1422
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1423
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .1425
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1427
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .1439
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 1457
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .1478
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY .1479
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 1482
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .1484
DISASSEMBLE SWING MACHINERY ASSEMBLY 1485
ASSEMBLE SWING MACHINERY ASSEMBLY .1488
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 1494
REMOVE SWING CIRCLE ASSEMBLY 1494
INSTALL SWING CIRCLE ASSEMBLY .1495
UNDERCARRIAGE AND FRAME .1496
SEPARATE AND INSTALL TRACK ASSEMBLY .1496
SEPARATE TRACK ASSEMBLY .1497
INSTALL TRACK ASSEMBLY 1499
REMOVE AND INSTALL SPROCKET .1502
REMOVE SPROCKET .1502
INSTALL SPROCKET 1503
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .1504
REMOVE IDLER AND IDLER CUSHION ASSEMBLY .1504
INSTALL IDLER AND IDLER CUSHION ASSEMBLY 1505
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .1506
DISASSEMBLE IDLER CUSHION ASSEMBLY 1506
ASSEMBLE IDLER ASSEMBLY .1507
DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY .1510
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .1510
ASSEMBLE IDLER CUSHION ASSEMBLY .1512
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 1514
DISASSEMBLE TRACK ROLLER ASSEMBLY .1514
ASSEMBLE TRACK ROLLER ASSEMBLY 1515
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .1517
REMOVE REVOLVING FRAME ASSEMBLY .1518
INSTALL REVOLVING FRAME ASSEMBLY 1523
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .1528
REMOVE COUNTERWEIGHT ASSEMBLY .1529
INSTALL COUNTERWEIGHT ASSEMBLY 1530
HYDRAULIC SYSTEM 1533
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .1533
REMOVE CENTER SWIVEL JOINT ASSEMBLY .1534
INSTALL CENTER SWIVEL JOINT ASSEMBLY 1538
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .1543
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .1544
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 1545
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 1546
REMOVE HYDRAULIC TANK ASSEMBLY 1547
INSTALL HYDRAULIC TANK ASSEMBLY .1556
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .1566
REMOVE MAIN PUMP ASSEMBLY .1567
INSTALL MAIN PUMP ASSEMBLY 1573
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .1580
REMOVE CONTROL VALVE ASSEMBLY .1582
INSTALL CONTROL VALVE ASSEMBLY 1596
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .1610
ASSEMBLE CONTROL VALVE ASSEMBLY .1610
REPLACE PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY 1612
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1615
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 1615
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 1615
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 1617
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 1617
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .1618
WORK EQUIPMENT 1620
REMOVE AND INSTALL BLADE ASSEMBLY .1620
REMOVE BLADE ASSEMBLY .1621
INSTALL BLADE ASSEMBLY 1622
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 1624
REMOVE WORK EQUIPMENT ASSEMBLY 1626
INSTALL WORK EQUIPMENT ASSEMBLY .1629
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY .1633
DISASSEMBLE BUCKET CYLINDER ASSEMBLY 1634
ASSEMBLE BUCKET CYLINDER ASSEMBLY .1636
DISASSEMBLE AND ASSEMBLE BOOM CYLINDER ASSEMBLY .1640
DISASSEMBLE BOOM CYLINDER ASSEMBLY 1641
ASSEMBLE BOOM CYLINDER ASSEMBLY .1643
DISASSEMBLE AND ASSEMBLE ARM CYLINDER ASSEMBLY 1647
DISASSEMBLE ARM CYLINDER ASSEMBLY .1648
ASSEMBLE ARM CYLINDER ASSEMBLY 1650
DISASSEMBLE AND ASSEMBLE BLADE CYLINDER ASSEMBLY 1655
DISASSEMBLE BLADE CYLINDER ASSEMBLY .1656
ASSEMBLE BLADE CYLINDER ASSEMBLY 1658
DISASSEMBLE AND ASSEMBLE OIL PASSAGE INTEGRATED CYLINDER ASSEMBLY .1663
DISASSEMBLE OIL PASSAGE INTEGRATED CYLINDER ASSEMBLY 1664
ASSEMBLE OIL PASSAGE INTEGRATED CYLINDER ASSEMBLY .1665
CAB RELATED PARTS .1671
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL) 1671
REMOVE OPERATOR CAB ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL) 1672
INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL) .1681
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1692
REMOVE OPERATOR CAB ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1692
INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1703
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .1714
REMOVE OPERATOR CAB GLASS (ADHERED GLASS) .1716
INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 1716
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 1727
REMOVE FRONT WINDOW ASSEMBLY 1727
INSTALL FRONT WINDOW ASSEMBLY .1730
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .1736
REMOVE FLOOR FRAME ASSEMBLY .1737
INSTALL FLOOR FRAME ASSEMBLY 1743
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL) 1750
REMOVE AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL) 1751
INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL) .1759
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1767
REMOVE AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER) .1768
INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 1776
REMOVE AND INSTALL OPERATOR SEAT 1784
REMOVE OPERATOR’S SEAT 1784
INSTALL OPERATOR’S SEAT .1785
REMOVE AND INSTALL SEATBELT .1786
REMOVE SEATBELT .1786
INSTALL SEATBELT 1787
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY 1788
REMOVE WORK EQUIPMENT CONTROL LEVER ASSEMBLY 1788
INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY .1794
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .1801
REMOVE FRONT WIPER ASSEMBLY .1801
INSTALL FRONT WIPER ASSEMBLY 1806
ELECTRICAL SYSTEM .1814
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .1814
REMOVE ENGINE CONTROLLER ASSEMBLY .1815
INSTALL ENGINE CONTROLLER ASSEMBLY 1818
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .1823
REMOVE PUMP CONTROLLER ASSEMBLY .1823
INSTALL PUMP CONTROLLER ASSEMBLY 1825
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .1829
REMOVE MACHINE MONITOR ASSEMBLY .1829
INSTALL MACHINE MONITOR ASSEMBLY 1832
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 1836
REMOVE KOMTRAX TERMINAL ASSEMBLY 1836
INSTALL KOMTRAX TERMINAL ASSEMBLY .1839
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .1842
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY .1842
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 1846
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 1850
REMOVE COMMUNICATION TERMINAL WIRING HARNESS 1850
INSTALL COMMUNICATION TERMINAL WIRING HARNESS .1857
REMOVE AND INSTALL COMMUNICATION TERMINAL .1866
REMOVE COMMUNICATION TERMINAL .1866
INSTALL COMMUNICATION TERMINAL 1868
60 MAINTENANCE STANDARD .1871
CONTENTS 1872
ENGINE AND COOLING SYSTEM .1873
MAINTENANCE STANDARD OF ENGINE MOUNT 1873
MAINTENANCE STANDARD OF PTO .1874
MAINTENANCE STANDARD OF COOLING SYSTEM 1875
POWER TRAIN .1876
MAINTENANCE STANDARD OF SWING CIRCLE 1876
MAINTENANCE STANDARD OF SWING MACHINERY .1877
MAINTENANCE STANDARD OF SPROCKET 1879
UNDERCARRIAGE AND FRAME .1880
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .1880
MAINTENANCE STANDARD OF IDLER .1882
MAINTENANCE STANDARD OF TRACK ROLLER 1883
MAINTENANCE STANDARD OF CARRIER ROLLER 1884
MAINTENANCE STANDARD OF TRACK SHOE 1885
MAINTENANCE STANDARD OF TRIPLE SHOE .1888
HYDRAULIC SYSTEM 1889
MAINTENANCE STANDARD OF HYDRAULIC TANK 1889
MAINTENANCE STANDARD OF MAIN PUMP .1890
MAINTENANCE STANDARD OF PC-EPC VALVE 1894
MAINTENANCE STANDARD OF SWING MOTOR .1895
MAINTENANCE STANDARD OF TRAVEL MOTOR 1898
MAINTENANCE STANDARD OF CONTROL VALVE .1899
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 1910
MAINTENANCE STANDARD OF BLADE PPC VALVE .1913
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 1915
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 1918
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 1920
MAINTENANCE STANDARD OF SOLENOID VALVE 1921
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE .1925
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 1926
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 1927
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .1928
WORK EQUIPMENT 1930
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 1930
DIMENSIONS OF ARM .1936
DIMENSIONS OF BUCKET 1938
MAINTENANCE STANDARD OF BOOM CYLINDER .1940
MAINTENANCE STANDARD OF ARM CYLINDER 1941
MAINTENANCE STANDARD OF BUCKET CYLINDER .1942
MAINTENANCE STANDARD OF BLADE CYLINDER 1943
CAB AND ITS ATTACHMENTS .1944
MAINTENANCE STANDARD OF CAB MOUNT .1944
80 OTHERS .1945
CONTENTS 1946
AIR CONDITIONER SYSTEM 1948
PRECAUTIONS FOR REFRIGERANT .1948
AIR CONDITIONER .1949
SPECIFICATIONS OF AIR CONDITIONER .1951
CONFIGURATION OF REFRIGERATION CYCLE 1952
FUNCTION OF REFRIGERATION CYCLE .1953
SYSTEM DIAGRAM OF AIR CONDITIONER .1954
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .1955
AIR CONDITIONER UNIT 1955
STRUCTURE OF AIR CONDITIONER UNIT .1956
FUNCTION OF AIR CONDITIONER UNIT 1957
COMPONENT PARTS OF AIR CONDITIONER UNIT .1958
AIR CONDITIONER CONTROLLER 1962
STRUCTURE OF AIR CONDITIONER CONTROLLER .1962
FUNCTION OF AIR CONDITIONER CONTROLLER 1962
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 1962
COMPRESSOR 1964
STRUCTURE OF COMPRESSOR .1964
SPECIFICATIONS OF COMPRESSOR 1964
FUNCTION OF COMPRESSOR 1964
OPERATION OF COMPRESSOR .1964
CONDENSER .1965
STRUCTURE OF CONDENSER 1965
SPECIFICATIONS OF CONDENSOR .1965
FUNCTION OF COMPRESSOR 1965
AIR CONDITIONER RELATED SENSORS .1967
STRUCTURE OF SUNLIGHT SENSOR 1967
FUNCTION OF SUNLIGHT SENSOR .1967
STRUCTURE OF OUTSIDE TEMPERATURE SENSOR .1967
FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR 1967
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER 1968
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .1970
TEST AIR LEAKAGE (DUCT CONNECTION) 1974
TEST AIR LEAKAGE (DUCT CONNECTION) 1974
TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION .1977
TEST VENT (MODE) CHANGEOVER .1978
TEST VENT (MODE) CHANGEOVER .1978
TEST FRESH/RECIRC AIR CHANGEOVER 1980
TEST FRESH/RECIRC AIR CHANGEOVER 1980
TEST SUNLIGHT SENSOR 1981
TEST SUNLIGHT SENSOR 1981
TEST DUAL PRESSURE SWITCH .1982
TEST DUAL PRESSURE SWITCH .1982
TEST RELAY 1983
TEST RELAY 1983
SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS 1985
PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER .1986
INFORMATION DESCRIBED IN TROUBLESHOOTING 1987
FAILURE CODE [879AKA] .1990
FAILURE CODE [879AKB] .1991
FAILURE CODE [879BKA] .1992
FAILURE CODE [879BKB] .1994
FAILURE CODE [879CKA] .1996
FAILURE CODE [879CKB] .1997
FAILURE CODE [879DKZ] .1998
FAILURE CODE [879EMC] .2000
FAILURE CODE [879FMC] .2001
FAILURE CODE [879GKX] .2002
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2004
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2007
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2011
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2013
CONNECT SERVICE TOOL 2016
CONNECT SERVICE TOOL 2017
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING 2018
HANDLE COMPRESSOR OIL .2020
REPLACE DESICCANT .2022
90 CIRCUIT DIAGRAMS .2025
CONTENTS 2026
HOW TO READ THE CODES FOR ELECTRIC CABLE 2028
HYDRAULIC CIRCUIT DIAGRAM .2032
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2032
HYDRAULIC CIRCUIT DIAGRAM (1/5) .2037
HYDRAULIC CIRCUIT DIAGRAM (2/5) .2039
HYDRAULIC CIRCUIT DIAGRAM (3/5) .2041
HYDRAULIC CIRCUIT DIAGRAM (4/5) .2043
HYDRAULIC CIRCUIT DIAGRAM (5/5) .2045
ELECTRICAL CIRCUIT DIAGRAM 2047
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2047
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (1/6) 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (2/6) 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (3/6) 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (4/6) 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (5/6) 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (6/6) 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (1/6) 2051
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (2/6) 2053
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (3/6) 2055
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (4/6) 2057
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (5/6) 2059
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (6/6) 2061
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (1/6) . 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (2/6) . 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (3/6) . 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (4/6) . 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (5/6) . 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70413 to 70446) (6/6) . 0
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (1/6) .2063
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (2/6) .2065
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (3/6) .2067
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (4/6) .2069
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (5/6) .2071
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (APPLICABLE MACHINE:70447 and up) (6/6) .2073
INDEX 2075

DESCRIPTION:

Komatsu PC135F-10M0 Hydraulic Excavator Shop Manual LEBMP13X02 – PDF DOWNLOAD

• SERIAL NUMBERS J10001 and up

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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see STRUCTURE AND OPERATION,
“CAUTION LAMPS SHOWN ON MACHINE MONITOR” and “PILOT LAMPS SHOWN ON MACHINE
MONITOR”.
• For details of the switches of the machine monitor, see TESTING AND ADJUSTING, “SET AND OPERATE
MACHINE MONITOR”.
• For details of the switches, see the “Operation and Maintenance 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.

G.B 30/12/24