Komatsu PC138US-11 Hydraulic Excavator Shop Manual WENBM00131 PDF

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Komatsu PC138US-11 Hydraulic Excavator Shop Manual WENBM00131 – PDF DOWNLOAD

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Komatsu PC138US-11 Hydraulic Excavator Shop Manual WENBM00131 – PDF DOWNLOAD

Language : English
Pages : 2604
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC138US-11 Hydraulic Excavator Shop Manual WENBM00131 – PDF DOWNLOAD

• SERIAL NUMBERS PC138US-11 F50001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 20
FOREWORD, SAFETY, BASIC INFORMATION . 26
HOW TO READ THE SHOP MANUAL . 26
SAFETY NOTICE FOR OPERATION . 28
PRECAUTIONS TO PREVENT FIRE . 36
ACTIONS IF FIRE OCCURS 38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 39
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 40
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 43
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 50
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 52
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 53
PRACTICAL USE OF KOMTRAX 54
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 55
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 57
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 59
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 63
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 64
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 66
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 69
HOW TO READ ELECTRICAL WIRE CODE 70
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 74
STANDARD TIGHTENING TORQUE TABLE 77
CONVERSION TABLE 84
01 SPECIFICATIONS . 89
CONTENTS 90
ABBREVIATION LIST . 91
SPECIFICATIONS 97
SPECIFICATION DRAWING . 97
SPECIFICATION DRAWING: PC138US-11 . 97
WORKING RANGE DRAWINGS 99
WORKING RANGE: PC138US-11 . 99
SPECIFICATIONS 102
SPECIFICATIONS: PC138US-11 102
WEIGHT TABLE 106
WEIGHT TABLE: PC138US-11 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
10 STRUCTURE AND FUNCTION . 109
CONTENTS 110
ABBREVIATION LIST . 113
UREA SCR SYSTEM . 119
LAYOUT DRAWING OF UREA SCR SYSTEM . 119
UREA SCR SYSTEM DIAGRAM . 121
FUNCTION OF UREA SCR SYSTEM . 122
FUNCTION OF AdBlue/DEF SYSTEM . 122
INDUCEMENT STRATEGY . 124
COMPONENT PARTS OF UREA SCR SYSTEM 138
AdBlue/DEF MIXING TUBE 138
SCR ASSEMBLY 138
AdBlue/DEF TANK . 141
AdBlue/DEF PUMP . 143
AdBlue/DEF INJECTOR . 144
AdBlue/DEF HOSE . 145
AdBlue/DEF TANK HEATING VALVE . 146
BOOT-UP SYSTEM 147
LAYOUT DRAWING OF BOOT-UP SYSTEM 147
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH . 149
FUNCTION OF BATTERY DISCONNECT SWITCH . 149
ENGINE SYSTEM . 150
LAYOUT DRAWING OF ENGINE SYSTEM . 150
ENGINE CONTROL SYSTEM . 152
ENGINE CONTROL SYSTEM DIAGRAM . 152
FUNCTION OF ENGINE CONTROL SYSTEM . 153
AUTO-DECELERATION SYSTEM 155
AUTO-DECELERATION SYSTEM DIAGRAM 155
FUNCTION OF AUTO-DECELERATION SYSTEM 155
OPERATION OF AUTO-DECELERATION SYSTEM . 156
ENGINE AUTOMATIC WARM-UP SYSTEM . 157
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 157
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 157
OVERHEAT PREVENTION SYSTEM 159
FUNCTION OF OVERHEAT PREVENTION SYSTEM 159
TURBOCHARGER PROTECTION SYSTEM 161
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 161
AUTOMATIC IDLE STOP SYSTEM 162
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 162
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 162
COMPONENT PARTS OF ENGINE SYSTEM 165
PTO . 165
VARIABLE FLOW TURBOCHARGER 165
EGR SYSTEM 169
EGR VALVE . 171
EGR COOLER 172
KCCV SYSTEM . 173
KCCV VENTILATOR . 176
EXHAUST THROTTLE VALVE 178
KDOC 179
COOLING SYSTEM 181
LAYOUT DRAWING OF COOLING SYSTEM 181
SPECIFICATIONS OF COOLING SYSTEM 182
CONTROL SYSTEM 183
LAYOUT DRAWING OF CONTROL SYSTEM 183
MACHINE MONITOR SYSTEM 185
MACHINE MONITOR SYSTEM DIAGRAM 185
FUNCTION OF MACHINE MONITOR SYSTEM 185
KomVision SYSTEM 187
LAYOUT DRAWING OF KomVision SYSTEM 187
KomVision SYSTEM DIAGRAM 188
FUNCTION OF KomVision SYSTEM 189
KOMTRAX SYSTEM 191
KOMTRAX SYSTEM DIAGRAM 191
FUNCTION OF KOMTRAX SYSTEM 191
COMPONENT PARTS OF CONTROL SYSTEM . 192
MACHINE MONITOR . 192
KomVision CONTROLLER 205
KomVision CAMERA 209
KOMTRAX TERMINAL 209
PUMP CONTROLLER . 211
RESISTOR FOR PC-EPC VALVE . 215
CAN TERMINATING RESISTOR 216
ENGINE CONTROLLER . 217
FUEL CONTROL DIAL . 223
HYDRAULIC SYSTEM 225
LAYOUT DRAWING OF HYDRAULIC SYSTEM 225
CLSS 227
STRUCTURE OF CLSS . 227
FUNCTION OF CLSS 228
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 230
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 230
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 231
COMPONENT PARTS OF HYDRAULIC SYSTEM . 235
HYDRAULIC TANK 235
MAIN PUMP . 237
CONTROL VALVE . 260
WORK EQUIPMENT SYSTEM . 317
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 317
STRUCTURE OF VALVE CONTROL 320
PPC LOCK SYSTEM . 321
PPC LOCK SYSTEM DIAGRAM . 321
FUNCTION OF PPC LOCK SYSTEM . 321
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 322
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 322
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 322
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 322
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 324
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 324
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 325
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 326
WORK EQUIPMENT AND SWING PPC VALVE 326
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 331
BLADE PPC VALVE . 337
SOLENOID VALVE 340
VARIABLE BACK PRESSURE SOLENOID VALVE . 345
346
PILOT CIRCUIT ACCUMULATOR . 348
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) . 349
SWING SYSTEM 350
LAYOUT DRAWING OF SWING SYSTEM 350
SWING CONTROL SYSTEM DIAGRAM 352
FUNCTION OF SWING CONTROL SYSTEM 352
COMPONENT PARTS OF SWING SYSTEM . 355
SWING MOTOR . 355
SWING MACHINERY . 364
SWING CIRCLE 365
TRAVEL SYSTEM . 367
LAYOUT DRAWING OF TRAVEL SYSTEM . 367
TRAVEL CONTROL SYSTEM DIAGRAM . 369
FUNCTION OF TRAVEL CONTROL SYSTEM . 369
COMPONENT PARTS OF TRAVEL SYSTEM 373
TRAVEL MOTOR 373
TRAVEL PPC VALVE 383
CENTER SWIVEL JOINT . 387
UNDERCARRIAGE AND FRAME . 389
LAYOUT DRAWING OF UNDERCARRIAGE . 389
SPECIFICATIONS OF UNDERCARRIAGE . 389
IDLER CUSHION . 390
STRUCTURE OF IDLER CUSHION 390
SPECIFICATIONS OF IDLER CUSHION . 390
WORK EQUIPMENT 391
STRUCTURE OF WORK EQUIPMENT . 391
FUNCTION OF WORK EQUIPMENT 392
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 393
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 393
BUCKET CLEARANCE ADJUSTMENT SHIM 394
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 394
CAB AND ITS ATTACHMENTS . 395
ROPS CAB 395
STRUCTURE OF ROPS CAB . 395
FUNCTION OF ROPS CAB 395
CAB MOUNT . 396
STRUCTURE OF CAB MOUNT 396
FUNCTION OF CAB MOUNT . 396
TAKE WIRING HARNESS OUT OF CAB 398
20 STANDARD VALUE TABLE . 399
CONTENTS 400
ABBREVIATION LIST . 401
STANDARD VALUE TABLE FOR ENGINE . 407
STANDARD VALUE TABLE FOR ENGINE:PC138US-11 407
STANDARD VALUE TABLE FOR MACHINE 411
STANDARD VALUE TABLE FOR MACHINE:PC138US-11 . 411
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 426
30 TESTING AND ADJUSTING 431
CONTENTS 432
ABBREVIATION LIST . 435
RELATED INFORMATION ON TESTING AND ADJUSTING 441
TOOLS FOR TESTING AND ADJUSTING . 441
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 448
ENGINE AND COOLING SYSTEM . 450
TEST ENGINE SPEED . 450
METHOD FOR TESTING ENGINE SPEED . 450
TEST EXHAUST GAS COLOR 453
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 453
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 454
TEST THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 455
METHOD FOR MEASURING THE CLEARANCE OF THE EXHAUST THROTTLE VALVE 455
TEST AND ADJUST VALVE CLEARANCE . 458
METHOD FOR TESTING VALVE CLEARANCE 458
METHOD FOR ADJUSTING VALVE CLEARANCE 459
TEST COMPRESSION PRESSURE . 460
METHOD FOR TESTING COMPRESSION PRESSURE . 460
TEST BLOWBY PRESSURE 463
METHOD FOR TESTING BLOWBY PRESSURE 463
TEST ENGINE OIL PRESSURE 465
METHOD FOR TESTING ENGINE OIL PRESSURE 465
TEST FUEL PRESSURE 467
METHOD FOR TESTING FUEL PRESSURE 467
TEST FUEL RETURN RATE AND LEAKAGE . 469
METHOD FOR TESTING FUEL RETURN RATE AND LEAKAGE . 470
BLEED AIR FROM FUEL SYSTEM 473
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 473
TEST FUEL CIRCUIT FOR LEAKAGE . 475
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 475
HANDLE CYLINDER CUT-OUT MODE OPERATION 477
HANDLE NO-INJECTION CRANKING OPERATION 478
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 479
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 479
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 479
TEST COOLING FAN SPEED 481
METHOD FOR TESTING COOLING FAN SPEED 481
WRITE INJECTOR COMPENSATION VALUE TO ENGINE CONTROLLER 482
METHOD FOR WRITING INJECTOR COMPENSATION VALUE 482
TEST SCR RELATED FUNCTIONS 488
TEST AdBlue/DEF PUMP RAISED PRESSURE 491
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 494
TEST AdBlue/DEF LINE HEATER RELAY 1 . 498
TEST AdBlue/DEF LINE HEATER RELAY 2 . 501
TEST AdBlue/DEF PUMP HEATER RELAY . 504
TEST AdBlue/DEF TANK HEATER VALVE . 507
TEST DENITRATION EFFICIENCY OF SCR 511
CLEAN AdBlue/DEF TANK . 514
METHOD FOR CLEANING AdBlue/DEF TANK . 514
POWER TRAIN . 519
TEST SWING CIRCLE BEARING CLEARANCE . 519
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 519
UNDERCARRIAGE AND FRAME . 520
TEST AND ADJUST TRACK TENSION . 520
METHOD FOR TESTING TRACK TENSION 520
METHOD FOR ADJUSTING TRACK TENSION 520
HYDRAULIC SYSTEM 522
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 522
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 522
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 522
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 524
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 524
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS . 525
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 525
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS 532
TEST OIL PRESSURE OF CONTROL CIRCUIT 534
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 534
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 536
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 536
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE . 537
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 538
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 540
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 540
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 542
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 543
METHOD FOR ADJUSTING LS VALVE . 545
TEST OUTLET PRESSURE OF SOLENOID VALVE 546
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 546
OPERATING CONDITION OF SOLENOID VALVE . 547
METHOD FOR TESTING OUTLET PRESSURE OF VARIABLE BACK PRESSURE SOLENOID VALVE . 548
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE 550
TEST PPC VALVE OUTLET PRESSURE 551
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 551
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 553
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 553
TEST AND ADJUST TRAVEL DEVIATION 554
METHOD FOR TESTING TRAVEL DEVIATION . 554
METHOD FOR ADJUSTING TRAVEL DEVIATION . 554
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 557
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 558
TEST OIL LEAKAGE 559
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 559
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 559
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 560
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER 561
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 561
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 562
BLEED AIR FROM HYDRAULIC CIRCUIT 563
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 564
CAB AND ITS ATTACHMENTS . 567
TEST CAB TIPPING STOPPER 567
METHOD FOR TESTING CAB TIPPING STOPPER 567
METHOD FOR ADJUSTING MIRRORS 568
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 568
PROCEDURE FOR ADJUSTING MACHINE REAR MIRROR (B) . 568
ELECTRICAL SYSTEM . 570
SET AND OPERATE MACHINE MONITOR . 570
OPERATOR MODE . 573
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 573
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 573
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 574
CHECKING FUNCTION OF SERVICE METER 575
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 575
SERVICE MODE 577
METHOD FOR OPERATING SERVICE MODE . 577
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 580
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 586
ABNORMALITY RECORD MENU . 597
METHOD FOR CONFIRMING MAINTENANCE RECORD 601
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 602
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 605
DEFAULT MENU 606
DIAGNOSTIC TESTS MENU . 614
ADJUSTMENT MENU . 623
METHOD FOR PERFORMING NO-INJECTION CRANKING . 636
KOMTRAX SETTINGS MENU . 637
METHOD FOR DISPLAYING SERVICE MESSAGE . 639
METHOD FOR STARTING UP KOMTRAX TERMINAL . 641
ADJUST REARVIEW CAMERA ANGLE 646
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 646
ADJUST KomVision CAMERA ANGLE . 649
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 649
ADJUST KomVision RELATED ITEMS 651
SETTING OF KomVision (MAIN SETTING) . 651
SETTING OF KomVision (CAMERA SETTING) . 654
SETTING OF KomVision (CAMERA CALIBRATION) . 656
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 669
HANDLE BATTERY DISCONNECT SWITCH 670
TEST DIODES . 671
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 671
METHOD FOR TESTING DIODE USING ANALOG TESTER 671
Pm CLINIC . 672
Pm CLINIC SERVICE . 672
Pm CLINIC CHECK SHEET:PC138US-11 673
40 TROUBLESHOOTING 683
CONTENTS 684
ABBREVIATION LIST . 694
RELATED INFORMATION ON TROUBLESHOOTING 700
GENERAL TROUBLESHOOTING POINTS 700
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 701
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 713
CHECKS BEFORE TROUBLESHOOTING . 715
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 717
WALK-AROUND CHECK . 717
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 719
CHECK FUEL LEVEL AND TYPE . 719
CHECK FUEL PREFILTER 720
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 720
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 720
CHECK MAIN FILTER . 722
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 723
CHECK OIL LEVEL IN PTO GEAR CASE 724
CHECK COOLANT LEVEL (RESERVOIR TANK) 725
CHECK CLOGGING OF AIR CLEANER . 725
OUTER ELEMENT – CLEAN . 726
ELEMENTS – REPLACE 728
CHECK HYDRAULIC OIL LEVEL . 729
CHECK HYDRAULIC OIL STRAINER 731
CHECK HYDRAULIC FILTER 731
CHECK OIL LEVEL IN SWING MACHINERY CASE . 732
CHECK OIL LEVEL IN FINAL DRIVE CASE . 733
BLEED AIR FROM FUEL SYSTEM 734
BLEED AIR FROM HYDRAULIC SYSTEM . 734
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 734
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 739
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 739
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 739
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 740
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL . 740
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK . 741
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 746
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 749
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 754
CONNECTOR LIST AND LAYOUT . 757
CONNECTOR CONTACT IDENTIFICATION 770
FUSE LOCATION TABLE . 810
PRECAUTIONS FOR REPLACING KDOC 812
FAILURE CODES TABLE . 813
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 829
FAILURE CODE [6AZ0ZG] . 829
FAILURE CODE [879AKA] . 831
FAILURE CODE [879AKB] . 832
FAILURE CODE [879BKA] . 833
FAILURE CODE [879BKB] . 835
FAILURE CODE [879CKA] . 837
FAILURE CODE [879CKB] . 838
FAILURE CODE [879DKZ] . 839
FAILURE CODE [879EMC] . 841
FAILURE CODE [879FMC] . 842
FAILURE CODE [879GKX] . 843
FAILURE CODE [989L00] . 845
FAILURE CODE [989M00] . 846
FAILURE CODE [989N00] . 847
FAILURE CODE [A1U0N3] . 848
FAILURE CODE [A1U0N4] . 850
FAILURE CODE [A900FR] . 852
FAILURE CODE [A900N6] . 853
FAILURE CODE [A900NY] . 854
FAILURE CODE [AA10NX] . 855
FAILURE CODE [AB00KE] . 857
FAILURE CODE [AQ10MB] . 859
FAILURE CODE [AQ10N3] . 861
FAILURE CODE [AS00R2] . 862
FAILURE CODE [AS00R3] . 863
FAILURE CODE [AS00R4] . 864
FAILURE CODE [AS00R5] . 865
FAILURE CODE [AS00R6] . 866
FAILURE CODE [AS00ZK] . 867
FAILURE CODE [AS10KM] . 868
FAILURE CODE [AS10NR] . 869
FAILURE CODE [AS10NT] . 870
FAILURE CODE [AU10QA] . 871
FAILURE CODE [B@BAZG] . 872
FAILURE CODE [B@BAZK] . 873
FAILURE CODE [B@BCNS] . 875
FAILURE CODE [CA115] 876
FAILURE CODE [CA122] 877
FAILURE CODE [CA123] 879
FAILURE CODE [CA131] 881
FAILURE CODE [CA132] 883
FAILURE CODE [CA144] 885
FAILURE CODE [CA145] 887
FAILURE CODE [CA153] 889
FAILURE CODE [CA154] 892
FAILURE CODE [CA187] 895
FAILURE CODE [CA221] 897
FAILURE CODE [CA222] 899
FAILURE CODE [CA227] 901
FAILURE CODE [CA234] 902
FAILURE CODE [CA238] 903
FAILURE CODE [CA239] 905
FAILURE CODE [CA249] 907
FAILURE CODE [CA256] 909
FAILURE CODE [CA271] 911
FAILURE CODE [CA272] 913
FAILURE CODE [CA322] 915
FAILURE CODE [CA324] 917
FAILURE CODE [CA331] 919
FAILURE CODE [CA332] 921
FAILURE CODE [CA343] 923
FAILURE CODE [CA351] 924
FAILURE CODE [CA352] 925
FAILURE CODE [CA356] 928
FAILURE CODE [CA357] 930
FAILURE CODE [CA386] 932
FAILURE CODE [CA435] 933
FAILURE CODE [CA441] 935
FAILURE CODE [CA442] 937
FAILURE CODE [CA449] 938
FAILURE CODE [CA451] 939
FAILURE CODE [CA452] 941
FAILURE CODE [CA515] 943
FAILURE CODE [CA516] 945
FAILURE CODE [CA553] 947
FAILURE CODE [CA555] 948
FAILURE CODE [CA556] 949
FAILURE CODE [CA559] 950
FAILURE CODE [CA689] 954
FAILURE CODE [CA691] 956
FAILURE CODE [CA692] 958
FAILURE CODE [CA697] 960
FAILURE CODE [CA698] 961
FAILURE CODE [CA731] 962
FAILURE CODE [CA778] 964
FAILURE CODE [CA1117] . 969
FAILURE CODE [CA1664] . 970
FAILURE CODE [CA1669] . 972
FAILURE CODE [CA1673] . 973
FAILURE CODE [CA1677] . 974
FAILURE CODE [CA1678] . 975
FAILURE CODE [CA1682] . 976
FAILURE CODE [CA1683] . 978
FAILURE CODE [CA1684] . 980
FAILURE CODE [CA1686] . 982
FAILURE CODE [CA1691] . 983
FAILURE CODE [CA1694] . 985
FAILURE CODE [CA1695] . 987
FAILURE CODE [CA1696] . 988
FAILURE CODE [CA1712] . 990
FAILURE CODE [CA1713] . 993
FAILURE CODE [CA1714] . 995
FAILURE CODE [CA1715] . 996
FAILURE CODE [CA1776] . 997
FAILURE CODE [CA1777] .1000
FAILURE CODE [CA1843] .1003
FAILURE CODE [CA1844] .1005
FAILURE CODE [CA1885] .1008
FAILURE CODE [CA1887] .1010
FAILURE CODE [CA1896] .1012
FAILURE CODE [CA1938] .1013
FAILURE CODE [CA1942] .1015
FAILURE CODE [CA1961] .1016
FAILURE CODE [CA2185] .1017
FAILURE CODE [CA2186] .1019
FAILURE CODE [CA2249] .1021
FAILURE CODE [CA2272] .1022
FAILURE CODE [CA2311] .1025
FAILURE CODE [CA2349] .1026
FAILURE CODE [CA2353] .1028
FAILURE CODE [CA2357] .1030
FAILURE CODE [CA2636] .1031
FAILURE CODE [CA2637] .1034
FAILURE CODE [CA2765] .1036
FAILURE CODE [CA2771] .1037
FAILURE CODE [CA2976] .1043
FAILURE CODE [CA3142] .1045
FAILURE CODE [CA3143] .1046
FAILURE CODE [CA3144] .1047
FAILURE CODE [CA3146] .1049
FAILURE CODE [CA3147] .1050
FAILURE CODE [CA3148] .1051
FAILURE CODE [CA3151] .1053
FAILURE CODE [CA3165] .1059
FAILURE CODE [CA3229] .1061
FAILURE CODE [CA3231] .1063
FAILURE CODE [CA3232] .1065
FAILURE CODE [CA3235] .1069
FAILURE CODE [CA3239] .1071
FAILURE CODE [CA3241] .1074
FAILURE CODE [CA3242] .1077
FAILURE CODE [CA3251] .1080
FAILURE CODE [CA3313] .1082
FAILURE CODE [CA3314] .1083
FAILURE CODE [CA3315] .1084
FAILURE CODE [CA3419] .1086
FAILURE CODE [CA3421] .1088
FAILURE CODE [CA3497] .1090
FAILURE CODE [CA3498] .1091
FAILURE CODE [CA3543] .1092
FAILURE CODE [CA3545] .1098
FAILURE CODE [CA3547] .1100
FAILURE CODE [CA3558] .1101
FAILURE CODE [CA3559] .1103
FAILURE CODE [CA3562] .1105
FAILURE CODE [CA3563] .1107
FAILURE CODE [CA3567] .1110
FAILURE CODE [CA3568] .1113
FAILURE CODE [CA3571] .1116
FAILURE CODE [CA3572] .1118
FAILURE CODE [CA3574] .1120
FAILURE CODE [CA3575] .1122
FAILURE CODE [CA3577] .1124
FAILURE CODE [CA3578] .1126
FAILURE CODE [CA3582] .1128
FAILURE CODE [CA3583] .1134
FAILURE CODE [CA3596] .1136
FAILURE CODE [CA3649] .1139
FAILURE CODE [CA3681] .1141
FAILURE CODE [CA3682] .1146
FAILURE CODE [CA3713] .1151
FAILURE CODE [CA3717] .1154
FAILURE CODE [CA3718] .1155
FAILURE CODE [CA3724] .1156
FAILURE CODE [CA3725] .1157
FAILURE CODE [CA3748] .1160
FAILURE CODE [CA3755] .1163
FAILURE CODE [CA3866] .1165
FAILURE CODE [CA3867] .1168
FAILURE CODE [CA3868] .1171
FAILURE CODE [CA3899] .1175
FAILURE CODE [CA3911] .1177
FAILURE CODE [CA3912] .1181
FAILURE CODE [CA3918] .1183
FAILURE CODE [CA3921] .1185
FAILURE CODE [CA3928] .1186
FAILURE CODE [CA3932] .1187
FAILURE CODE [CA3933] .1189
FAILURE CODE [CA3934] .1191
FAILURE CODE [CA3935] .1194
FAILURE CODE [CA3936] .1196
FAILURE CODE [CA4152] .1198
FAILURE CODE [CA4155] .1202
FAILURE CODE [CA4156] .1204
FAILURE CODE [CA4157] .1207
FAILURE CODE [CA4159] .1209
FAILURE CODE [CA4164] .1210
FAILURE CODE [CA4165] .1212
FAILURE CODE [CA4166] .1214
FAILURE CODE [CA4168] .1215
FAILURE CODE [CA4169] .1218
FAILURE CODE [CA4171] .1220
FAILURE CODE [CA4249] .1223
FAILURE CODE [CA4251] .1225
FAILURE CODE [CA4261] .1227
FAILURE CODE [CA4277] .1230
FAILURE CODE [CA4281] .1233
FAILURE CODE [CA4459] .1237
FAILURE CODE [CA4461] .1240
FAILURE CODE [CA4533] .1243
FAILURE CODE [CA4534] .1244
FAILURE CODE [CA4731] .1245
FAILURE CODE [CA4732] .1246
FAILURE CODE [CA4739] .1247
FAILURE CODE [CA4768] .1248
FAILURE CODE [CA4769] .1250
FAILURE CODE [CA4842] .1253
FAILURE CODE [CA4952] .1256
FAILURE CODE [CA5115] .1258
FAILURE CODE [CA5179] .1261
FAILURE CODE [CA5181] .1263
FAILURE CODE [CA5271] .1265
FAILURE CODE [CA5272] .1267
FAILURE CODE [CA5273] .1269
FAILURE CODE [CA5274] .1271
FAILURE CODE [CA5275] .1272
FAILURE CODE [CA5276] .1274
FAILURE CODE [CA5277] .1276
FAILURE CODE [CA5387] .1277
FAILURE CODE [CA5388] .1279
FAILURE CODE [CA5389] .1281
FAILURE CODE [CA5391] .1283
FAILURE CODE [CA5392] .1287
FAILURE CODE [CA5393] .1288
FAILURE CODE [CA5394] .1291
FAILURE CODE [CA5395] .1294
FAILURE CODE [CA5396] .1297
FAILURE CODE [CA5631] .1298
FAILURE CODE [CA5938] .1300
FAILURE CODE [D110KB] .1302
FAILURE CODE [D19JKZ] .1304
FAILURE CODE [D811MC] .1306
FAILURE CODE [D862KA] .1307
FAILURE CODE [D8ALKA] .1308
FAILURE CODE [D8ALKB] .1310
FAILURE CODE [D8AQKR] .1312
FAILURE CODE [DA20MC] .1316
FAILURE CODE [DA22KK] .1317
FAILURE CODE [DA25KP] .1320
FAILURE CODE [DA26KP] .1324
FAILURE CODE [DA29KQ] .1326
FAILURE CODE [DA2LKA] .1328
FAILURE CODE [DA2LKB] .1330
FAILURE CODE [DA2QKR] .1332
FAILURE CODE [DA2RKR] .1337
FAILURE CODE [DAF0MB] .1342
FAILURE CODE [DAF0MC] .1343
FAILURE CODE [DAF8KB] .1344
FAILURE CODE [DAF9KQ] .1346
FAILURE CODE [DAFGMC] .1347
FAILURE CODE [DAFLKA] .1348
FAILURE CODE [DAFLKB] .1350
FAILURE CODE [DAFQKR] .1352
FAILURE CODE [DAZ9KQ] .1356
FAILURE CODE [DAZQKR] .1357
FAILURE CODE [DB2QKR] .1361
FAILURE CODE [DB2RKR] .1366
FAILURE CODE [DBP0KM] .1371
FAILURE CODE [DBP0KT] .1372
FAILURE CODE [DBPQKR] .1373
FAILURE CODE [DDNRKA] .1378
FAILURE CODE [DDNRKY] .1381
FAILURE CODE [DDNS00] .1383
FAILURE CODE [DGH2KA] .1385
FAILURE CODE [DGH2KB] .1387
FAILURE CODE [DHA4KA] .1388
FAILURE CODE [DHPAMA] .1390
FAILURE CODE [DHS3MA] .1392
FAILURE CODE [DHS4MA] .1394
FAILURE CODE [DHS8MA] .1396
FAILURE CODE [DHS9MA] .1398
FAILURE CODE [DHSAMA] .1400
FAILURE CODE [DHSBMA] .1402
FAILURE CODE [DHSCMA] .1404
FAILURE CODE [DHSDMA] .1406
FAILURE CODE [DHSFMA] .1408
FAILURE CODE [DHSGMA] .1410
FAILURE CODE [DHSHMA] .1412
FAILURE CODE [DHSJMA] .1414
FAILURE CODE [DHSKMA] .1416
FAILURE CODE [DHSLMA] .1418
FAILURE CODE [DKULKA] .1420
FAILURE CODE [DKULKB] .1422
FAILURE CODE [DKULKY] .1424
FAILURE CODE [DLM5KA] .1426
FAILURE CODE [DLM5MB] .1428
FAILURE CODE [DR10KA] .1430
FAILURE CODE [DR21KX] .1433
FAILURE CODE [DUMBKA] .1435
FAILURE CODE [DUMBKB] .1437
FAILURE CODE [DV20KB] .1439
FAILURE CODE [DW43KA] .1441
FAILURE CODE [DW43KB] .1443
FAILURE CODE [DW43KY] .1445
FAILURE CODE [DW45KA] .1446
FAILURE CODE [DW45KB] .1449
FAILURE CODE [DW45KY] .1452
FAILURE CODE [DW4CKY] .1454
FAILURE CODE [DW91KA] .1456
FAILURE CODE [DW91KB] .1458
FAILURE CODE [DW91KY] .1460
FAILURE CODE [DWA2KA] .1462
FAILURE CODE [DWA2KB] .1464
FAILURE CODE [DWA2KY] .1466
FAILURE CODE [DWJ0KA] .1468
FAILURE CODE [DWJ0KB] .1470
FAILURE CODE [DWJ0KY] .1472
FAILURE CODE [DWK2KA] .1474
FAILURE CODE [DWK2KB] .1476
FAILURE CODE [DWK2KY] .1478
FAILURE CODE [DWN5KA] .1480
FAILURE CODE [DWN5KB] .1482
FAILURE CODE [DWN5KY] .1484
FAILURE CODE [DWNSKA] .1486
FAILURE CODE [DWNSKB] .1488
FAILURE CODE [DWNSKY] .1490
FAILURE CODE [DXA8KA] .1491
FAILURE CODE [DXA8KB] .1493
FAILURE CODE [DY20KA] .1495
FAILURE CODE [DY20MA] .1497
FAILURE CODE [DY2CKB] .1499
FAILURE CODE [DY2DKB] .1501
FAILURE CODE [DY2EKB] .1503
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1505
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1505
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1511
E-3 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1514
E-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1516
E-5 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1519
E-6 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1520
E-7 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1521
E-8 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1522
E-9 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1523
E-10 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1524
E-11 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1525
E-12 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1526
E-13 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1527
E-14 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1529
E-15 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1530
E-16 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1531
E-17 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1532
E-18 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1534
E-19 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1535
E-20 FUNCTION SWITCH DOES NOT OPERATE .1536
E-21 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1537
E-22 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1538
E-23 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1539
E-24 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1541
E-25 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1542
E-26 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1543
E-27 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1544
E-28 ALARM BUZZER CANNOT BE CANCELED 1545
E-29 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1546
E-30 SERVICE MODE CANNOT BE SELECTED 1547
E-31 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1548
E-32 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1551
E-33 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1553
E-34 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1555
E-35 WORK EQUIPMENT DOES NOT OPERATE WHILE LOCK LEVER AUTOMATIC RELEASE SWITCH IS IN RELEASE POSITION .1557
E-36 ALARM DOES NOT SOUND DURING TRAVEL .1559
E-37 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1561
E-38 HORN DOES NOT SOUND 1562
E-39 HORN DOES NOT STOP SOUNDING 1564
E-40 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1565
E-41 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1566
E-42 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1568
E-43 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1569
E-44 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1570
E-45 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1571
E-46 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1572
E-47 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1573
E-48 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1574
E-49 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1575
E-50 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1576
E-51 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1577
E-52 BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 1580
E-53 BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 1581
E-54 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1582
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1583
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1583
FAILURE MODE AND CAUSE TABLE 1584
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1592
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1593
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1595
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1596
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1597
H-6 SPEED OR POWER OF BOOM IS LOW .1599
H-7 ARM SPEED OR POWER IS LOW .1602
H-8 BUCKET SPEED OR POWER IS LOW 1605
H-9 BLADE SPEED OR POWER IS LOW .1608
H-10 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .1610
H-11 HYDRAULIC DRIFT OF BOOM IS LARGE .1611
H-12 HYDRAULIC DRIFT OF ARM IS LARGE 1612
H-13 HYDRAULIC DRIFT OF BUCKET IS LARGE .1613
H-14 HYDRAULIC DRIFT OF BLADE IS LARGE 1614
H-15 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1616
H-16 TIME LAG OF WORK EQUIPMENT IS LARGE 1617
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1618
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1619
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1620
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1621
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1622
H-22 MACHINE DOES NOT TRAVEL STRAIGHT .1623
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1626
H-24 TRAVEL SPEED IS LOW 1628
H-25 ONE OF TRACKS DOES NOT RUN .1630
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1632
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1633
H-28 SWINGS ONLY IN ONE DIRECTION .1634
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1635
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1636
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1637
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1638
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1639
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1640
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1641
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1642
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .1643
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN .1644
TROUBLESHOOTING OF ENGINE (S-MODE) 1645
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1645
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1646
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1647
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1648
S-4 ENGINE STARTABILITY IS POOR .1649
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1651
S-6 ENGINE STOPS DURING OPERATION .1653
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1655
S-8 ENGINE LACKS POWER 1656
S-9 EXHAUST SMOKE IS BLACK 1658
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1660
S-11 OIL BECOMES CONTAMINATED QUICKLY .1661
S-12 FUEL CONSUMPTION IS EXCESSIVE 1662
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1663
S-14 OIL PRESSURE DROPS .1664
S-15 FUEL MIXES INTO ENGINE OIL .1665
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1666
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1667
S-18 UNUSUAL NOISE IS HEARD .1668
S-19 VIBRATION IS EXCESSIVE .1670
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1671
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1672
S-22 ACTIVE REGENERATION TAKES TIME .1673
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1674
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1675
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1677
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1678
50 DISASSEMBLY AND ASSEMBLY .1679
CONTENTS 1680
ABBREVIATION LIST .1685
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1691
HOW TO READ THIS MANUAL .1691
COATING MATERIALS LIST 1693
SPECIAL TOOLS LIST 1697
SKETCHES OF SPECIAL TOOLS .1713
ENGINE AND COOLING SYSTEM .1716
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1716
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1716
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1721
REMOVE AND INSTALL INJECTOR ASSEMBLY 1726
METHOD FOR REMOVING INJECTOR ASSEMBLY .1726
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1732
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1742
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1742
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1756
REMOVE AND INSTALL EGR VALVE ASSEMBLY .1775
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1775
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1776
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1779
METHOD FOR REMOVING EGR COOLER ASSEMBLY .1779
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .1781
REMOVE AND INSTALL STARTER ASSEMBLY .1784
METHOD FOR REMOVING STARTER ASSEMBLY 1784
METHOD FOR INSTALLING STARTER ASSEMBLY 1787
REMOVE AND INSTALL ALTERNATOR BELT 1792
METHOD FOR REMOVING ALTERNATOR BELT .1792
METHOD FOR INSTALLING ALTERNATOR BELT .1794
REMOVE AND INSTALL RADIATOR ASSEMBLY 1795
METHOD FOR REMOVING RADIATOR ASSEMBLY .1795
METHOD FOR INSTALLING RADIATOR ASSEMBLY .1797
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 1800
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .1800
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .1803
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .1807
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 1807
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 1808
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 1810
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .1810
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .1815
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 1823
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .1824
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .1833
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 1845
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .1845
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .1846
REMOVE AND INSTALL ENGINE REAR OIL SEAL .1848
METHOD FOR REMOVING ENGINE REAR OIL SEAL 1848
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 1849
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .1853
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 1853
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 1854
REMOVE AND INSTALL KDOC ASSEMBLY 1855
METHOD FOR REMOVING KDOC ASSEMBLY .1855
METHOD FOR INSTALLING KDOC ASSEMBLY .1859
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 1863
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY .1864
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY .1870
REMOVE AND INSTALL FUEL TANK ASSEMBLY .1878
METHOD FOR REMOVING FUEL TANK ASSEMBLY 1878
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 1884
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .1891
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 1891
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 1896
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .1901
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 1901
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 1905
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .1910
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 1910
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 1910
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .1912
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 1912
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 1912
REMOVE AND INSTALL SCR ASSEMBLY .1913
METHOD FOR REMOVING SCR ASSEMBLY 1913
METHOD FOR INSTALLING SCR ASSEMBLY 1917
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY BRACKET 1922
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY BRACKET .1922
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY BRACKET .1925
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 1930
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY .1930
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY .1933
REMOVE AND INSTALL KCCV ASSEMBLY 1937
METHOD FOR REMOVING KCCV ASSEMBLY .1937
METHOD FOR INSTALLING KCCV ASSEMBLY .1938
REMOVE AND INSTALL EXHAUST THROTTLE VALVE .1940
METHOD FOR REMOVING EXHAUST THROTTLE VALVE 1940
METHOD FOR INSTALLING EXHAUST THROTTLE VALVE 1945
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .1952
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 1952
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 1957
REMOVE AND INSTALL AdBlue/DEF INJECTOR 1962
METHOD FOR REMOVING AdBlue/DEF INJECTOR .1962
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .1965
REMOVE AND INSTALL AdBlue/DEF PUMP 1970
METHOD FOR REMOVING AdBlue/DEF PUMP .1970
METHOD FOR INSTALLING AdBlue/DEF PUMP .1974
REMOVE AND INSTALL AdBlue/DEF HOSE 1979
METHOD FOR REMOVING AdBlue/DEF HOSE .1979
METHOD FOR INSTALLING AdBlue/DEF HOSE .1988
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .1996
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 1996
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 1998
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2002
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2002
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2004
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2006
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2006
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2007
POWER TRAIN .2009
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2009
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2010
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2010
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2012
METHOD FOR DISASSEMBLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2023
METHOD FOR ASSEMBLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2041
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2058
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2059
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2061
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2063
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2064
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2067
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2073
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2073
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2074
UNDERCARRIAGE AND FRAME .2075
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2075
METHOD FOR SEPARATING TRACK ASSEMBLY 2076
METHOD FOR INSTALLING TRACK ASSEMBLY 2077
REMOVE AND INSTALL SPROCKET .2081
METHOD FOR REMOVING SPROCKET 2081
METHOD FOR INSTALLING SPROCKET 2082
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2083
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2083
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2084
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2085
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2085
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2086
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2090
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2090
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2091
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2093
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2093
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2094
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2097
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2097
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2100
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2103
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2104
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2108
HYDRAULIC SYSTEM 2114
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2114
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2114
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2117
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2119
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2120
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2121
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2122
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2122
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2125
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2129
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2130
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2134
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2138
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2139
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2146
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2152
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2152
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2155
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2155
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2156
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2158
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2158
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2158
WORK EQUIPMENT 2160
REMOVE AND INSTALL BLADE ASSEMBLY .2160
METHOD FOR REMOVING BLADE ASSEMBLY 2160
METHOD FOR INSTALLING BLADE ASSEMBLY 2161
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2164
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2165
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2170
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY (with 2-piece boom) .2174
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY (with 2-piece boom) .2177
METHOD FOR REMOVING 1ST BOOM ASSEMBLY (with 2-piece boom) .2178
METHOD FOR INSTALLING 1ST BOOM ASSEMBLY (with 2-piece boom) .2181
METHOD FOR REMOVING 2ND BOOM ASSEMBLY (with 2-piece boom) .2182
METHOD FOR INSTALLING 2ND BOOM ASSEMBLY (with 2-piece boom) .2185
METHOD FOR REMOVING ARM .2186
METHOD FOR INSTALLING ARM .2188
METHOD FOR REMOVING BOOM CYLINDERS (with 2-piece boom) 2189
METHOD FOR INSTALLING BOOM CYLINDERS (with 2-piece boom) 2191
METHOD FOR REMOVING 2-PIECE BOOM CYLINDER .2191
METHOD FOR INSTALLING 2-PIECE BOOM CYLINDER .2192
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2194
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2195
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2197
CAB AND ITS ATTACHMENTS .2204
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2204
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2204
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2208
REMOVE AND INSTALL OPERATOR’S CAB DOOR 2213
METHOD FOR INSTALLING OPERATOR’S CAB DOOR .2213
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2217
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2218
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2219
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2230
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2231
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2232
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2233
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2233
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2241
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2249
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2249
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2254
REMOVE AND INSTALL OPERATOR’S SEAT 2259
METHOD FOR REMOVING OPERATOR’S SEAT .2259
METHOD FOR INSTALLING OPERATOR’S SEAT .2259
REMOVE AND INSTALL SEAT BELT 2261
METHOD FOR REMOVING SEAT BELT .2261
METHOD FOR INSTALLING SEAT BELT .2262
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2263
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2263
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2268
ELECTRICAL SYSTEM .2277
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2277
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2277
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2279
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2280
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2280
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2282
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2285
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2285
METHOD FOR INSTALLING KomVision CONTROLLER 2286
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2288
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2288
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2291
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2294
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2294
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2296
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2297
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2297
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2299
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2302
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2302
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2303
REMOVE AND INSTALL REARVIEW CAMERA 2304
METHOD FOR REMOVING REARVIEW CAMERA .2304
METHOD FOR INSTALLING REARVIEW CAMERA .2305
REMOVE AND INSTALL KomVision CAMERA .2307
METHOD FOR REMOVING KomVision CAMERA 2307
METHOD FOR INSTALLING KomVision CAMERA 2309
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2312
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2312
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2314
60 MAINTENANCE STANDARD .2317
CONTENTS 2318
ABBREVIATION LIST .2319
ENGINE AND COOLING SYSTEM .2325
MAINTENANCE STANDARD OF ENGINE MOUNT 2325
MAINTENANCE STANDARD FOR PTO 2326
MAINTENANCE STANDARD OF COOLING SYSTEM 2327
POWER TRAIN .2328
MAINTENANCE STANDARD OF SWING CIRCLE 2328
MAINTENANCE STANDARD OF SWING MACHINERY .2329
MAINTENANCE STANDARD OF SPROCKET 2331
UNDERCARRIAGE AND FRAME .2332
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2332
MAINTENANCE STANDARD OF IDLER .2334
MAINTENANCE STANDARD OF TRACK ROLLER 2335
MAINTENANCE STANDARD OF CARRIER ROLLER 2336
MAINTENANCE STANDARD OF TRACK SHOE 2337
MAINTENANCE STANDARD OF TRIPLE SHOE .2340
MAINTENANCE STANDARD OF ROAD LINER 2341
HYDRAULIC SYSTEM 2342
MAINTENANCE STANDARD OF HYDRAULIC TANK 2342
MAINTENANCE STANDARD OF MAIN PUMP .2343
MAINTENANCE STANDARD OF PC-EPC VALVE 2347
MAINTENANCE STANDARD OF SWING MOTOR .2348
MAINTENANCE STANDARD OF TRAVEL MOTOR 2351
MAINTENANCE STANDARD OF CONTROL VALVE .2352
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2363
MAINTENANCE STANDARD OF BLADE PPC VALVE .2366
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2368
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2371
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2372
MAINTENANCE STANDARD OF 2-PIECE BOOM PPC VALVE 2374
MAINTENANCE STANDARD OF SOLENOID VALVE 2376
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE .2379
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2380
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2381
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT) 2382
MAINTENANCE STANDARD OF ARM DUMP QUICK RETURN VALVE .2383
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2384
WORK EQUIPMENT 2385
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2385
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE (2-piece boom specification) .2390
DIMENSION OF ARM 2395
DIMENSIONS OF BUCKET 2397
MAINTENANCE STANDARD OF BOOM CYLINDER .2399
MAINTENANCE STANDARD OF BOOM CYLINDER (2-piece boom specification) 2400
MAINTENANCE STANDARD OF ARM CYLINDER 2401
MAINTENANCE STANDARD OF ARM CYLINDER (2-piece boom specification) .2402
MAINTENANCE STANDARD OF BUCKET CYLINDER .2403
MAINTENANCE STANDARD OF BLADE CYLINDER 2404
MAINTENANCE STANDARD OF 2-PIECE BOOM CYLINDER .2405
CAB AND ITS ATTACHMENTS .2406
MAINTENANCE STANDARD OF CAB MOUNT .2406
80 APPENDIX .2407
CONTENTS 2408
ABBREVIATION LIST .2410
AIR CONDITIONER SYSTEM 2416
PRECAUTIONS FOR REFRIGERANT .2416
AIR CONDITIONER COMPONENT .2417
SPECIFICATIONS OF AIR CONDITIONER .2419
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2420
OUTLINE OF REFRIGERATION CYCLE 2421
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2423
AIR CONDITIONER UNIT 2423
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2423
FUNCTION OF AIR CONDITIONER UNIT 2425
COMPONENT PARTS OF AIR CONDITIONER UNIT .2426
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2426
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2426
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2426
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2427
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2428
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2428
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2428
FUNCTION OF DUAL PRESSURE SWITCH 2429
AIR CONDITIONER CONTROLLER 2430
STRUCTURE OF AIR CONDITIONER CONTROLLER .2430
COMPRESSOR 2431
STRUCTURE OF COMPRESSOR .2431
SPECIFICATIONS OF COMPRESSOR 2431
FUNCTION OF COMPRESSOR 2431
CONDENSER .2432
STRUCTURE OF CONDENSER 2432
SPECIFICATIONS OF CONDENSER .2432
FUNCTION OF CONDENSER .2432
SENSORS FOR AIR CONDITIONER SYSTEM 2434
STRUCTURE OF SUNLIGHT SENSOR 2434
FUNCTION OF SUNLIGHT SENSOR .2434
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2434
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2434
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2436
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2438
AIR CONDITIONER SYSTEM DIAGRAM 2440
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2441
FUNCTION OF AIR CONDITIONER CONTROLLER 2442
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2443
TESTING AIR LEAKAGE (DUCT) 2452
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2452
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2454
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2455
TEST VENT (MODE) CHANGEOVER .2456
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2456
TESTING FRESH/RECIRC AIR CHANGEOVER .2457
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2457
TEST SUNLIGHT SENSOR 2458
METHOD FOR TESTING SUNLIGHT SENSOR 2458
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2459
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2459
TEST RELAYS .2461
METHOD FOR TESTING RELAYS .2461
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2462
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2463
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2466
FAILURE CODE [879AKA] .2468
FAILURE CODE [879AKB] .2469
FAILURE CODE [879BKA] .2470
FAILURE CODE [879BKB] .2472
FAILURE CODE [879CKA] .2474
FAILURE CODE [879CKB] .2475
FAILURE CODE [879DKZ] .2476
FAILURE CODE [879EMC] .2478
FAILURE CODE [879FMC] .2479
FAILURE CODE [879GKX] .2480
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2482
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2484
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2487
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2489
TROUBLESHOOTING USING GAUGE PRESSURE 2491
CONNECTION OF SERVICE TOOL 2493
METHOD FOR CONNECTING SERVICE TOOL 2493
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2495
HANDLE COMPRESSOR OIL .2497
METHOD FOR REPLACING DESICCANT 2499
SUPER LONG FRONT KIT 2501
Contents 2501
Components of the SLF kit .2501
Installation procedure 2502
Preparation .2502
Procedure sequence for installation .2502
Removal of original working equipment .2503
Removal of cover on the machine .2504
Removal of the original work equipment assembly .2505
Removal of the boom cylinder assemblies .2506
Installation of SLF boom 2508
Preparation of the two SLF boom cylinder kits .2508
Installation of the SLF boom cylinder kit .2511
Installation of the SLF boom kit 2513
Installation of the SLF arm kit .2515
Installation of speed limiter and safety valve on the bucket element of the control valve .2518
Testing the machine .2520
Finishing the work 2521
90 CIRCUIT DIAGRAMS .2523
CONTENTS 2524
ABBREVIATION LIST .2525
HYDRAULIC CIRCUIT DIAGRAM .2531
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2531
HYDRAULIC CIRCUIT DIAGRAM (1/3) .2535
HYDRAULIC CIRCUIT DIAGRAM (2/3) .2537
HYDRAULIC CIRCUIT DIAGRAM (3/3) .2539
ELECTRICAL CIRCUIT DIAGRAM 2541
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2541
ELECTRICAL CIRCUIT DIAGRAM (1/10) .2545
ELECTRICAL CIRCUIT DIAGRAM (2/10) .2547
ELECTRICAL CIRCUIT DIAGRAM (3/10) .2549
ELECTRICAL CIRCUIT DIAGRAM (4/10) .2551
ELECTRICAL CIRCUIT DIAGRAM (5/10) .2553
ELECTRICAL CIRCUIT DIAGRAM (6/10) .2555
ELECTRICAL CIRCUIT DIAGRAM (7/10) .2557
ELECTRICAL CIRCUIT DIAGRAM (8/10) .2559
ELECTRICAL CIRCUIT DIAGRAM (9/10) .2561
ELECTRICAL CIRCUIT DIAGRAM (10/10) 2563
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (1/10) 2565
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (2/10) 2567
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (3/10) 2569
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (4/10) 2571
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (5/10) 2573
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (6/10) 2575
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (7/10) 2577
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (8/10) 2579
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (9/10) 2581
ELECTRICAL CIRCUIT DIAGRAM (2-PIECE BOOM SPECIFICATION) (10/10) .2583
INDEX .2585

DESCRIPTION:

Komatsu PC138US-11 Hydraulic Excavator Shop Manual WENBM00131 – PDF DOWNLOAD

• SERIAL NUMBERS PC138US-11 F50001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 31/12/24