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KOMATSU PC138USLC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:4001 & UP) – PDF DOWNLOAD
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- KOMATSU PC138USLC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- Serial Number:4001 & UP
- Publication Number:SEN06062-01
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Description
KOMATSU PC138USLC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:4001 & UP)
KOMATSU PC138USLC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:4001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC138USLC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:4001 & UP)
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
KOMATSU PC138USLC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:4001 & UP)
Cover............................................................................................................................. 1 00 Index and foreword ............................................................................................................ 3 Index ........................................................................................................................ 4 Foreword, safety and general information ..................................................................................... 15 Important safety notice .................................................................................................. 15 How to read the shop manual .............................................................................................. 22 Explanation of terms for maintenance standard ............................................................................ 24 Handling equipment of fuel system devices ................................................................................ 26 Handling of intake system parts .......................................................................................... 27 Handling of hydraulic equipment .......................................................................................... 28 Method of disconnecting and connecting of push-pull type coupler ......................................................... 30 Handling of electrical equipment ......................................................................................... 33 How to read electric wire code ........................................................................................... 41 Precautions when performing operation .................................................................................... 44 Practical use of KOMTRAX ................................................................................................. 49 Standard tightening torque table ......................................................................................... 50 List of abbreviation ..................................................................................................... 56 Conversion table ......................................................................................................... 61 01 Specification ................................................................................................................. 67 Table of contents ............................................................................................................ 68 Specifications ............................................................................................................... 69 Specification drawing .................................................................................................... 69 Working range drawings ................................................................................................... 70 Specifications ........................................................................................................... 71 Weight table ............................................................................................................. 75 Table of fuel, coolant, and lubricants ................................................................................... 77 10 Structure and function ........................................................................................................ 79 Table of contents ............................................................................................................ 80 Engine and cooling system .................................................................................................... 81 Engine related parts ..................................................................................................... 81 PTO ...................................................................................................................... 83 VFT ...................................................................................................................... 84 EGR system piping drawing ................................................................................................ 88 EGR system circuit diagram ............................................................................................... 90 EGR valve ................................................................................................................ 91 EGR cooler ............................................................................................................... 93 KCCV layout drawing ...................................................................................................... 95 KCCV ventilator .......................................................................................................... 97 KDOC muffler ............................................................................................................. 99 Cooling system ........................................................................................................... 101 Power train .................................................................................................................. 103 Power train system ....................................................................................................... 103 Swing circle ............................................................................................................. 105 Swing machinery .......................................................................................................... 106 Undercarriage and frame ...................................................................................................... 108 Track frame .............................................................................................................. 108 Idler cushion ............................................................................................................ 109 Hydraulic system ............................................................................................................. 110 Hydraulic component layout ............................................................................................... 110 Valve control ............................................................................................................ 112 Hydraulic tank ........................................................................................................... 113 CLSS ..................................................................................................................... 115 Main pump ................................................................................................................ 119 Control valve ............................................................................................................ 146 Swing motor .............................................................................................................. 191 Travel motor ............................................................................................................. 203 Work equipment and swing PPC valve ....................................................................................... 214 Travel PPC valve ......................................................................................................... 221 Blade PPC valve .......................................................................................................... 227 1st-line attachment PPC valve (with EPC valve) ........................................................................... 229 Solenoid valve ........................................................................................................... 237 Attachment circuit selector valve (for low pressure circuit) ............................................................. 243 Attachment circuit selector valve (for high pressure circuit) ............................................................ 246 Multi-control valve ...................................................................................................... 248 Center swivel joint ...................................................................................................... 249 PPC circuit accumulator .................................................................................................. 251 Attachment circuit accumulator (for low pressure circuit) ................................................................ 252 Attachment circuit accumulator (for high pressure circuit) ............................................................... 253 Work equipment ............................................................................................................... 254 Work equipment ........................................................................................................... 254 Work equipment shim ...................................................................................................... 255 Bucket play adjustment shim .............................................................................................. 256 Cab and its attachments ...................................................................................................... 257 Cab mount and cab tipping stopper ........................................................................................ 257 ROPS cab ................................................................................................................. 258 Electrical system ............................................................................................................ 260 Electrical control system ................................................................................................ 260 Machine monitor system ................................................................................................... 292 KOMTRAX system ........................................................................................................... 313 Sensor ................................................................................................................... 330 20 Standard value tables ......................................................................................................... 343 Table of contents ............................................................................................................ 344 Standard service value table ................................................................................................. 345 Standard value table for engine .......................................................................................... 345 Standard value table for machine ......................................................................................... 346 Standard value table for electrical system ............................................................................... 359 30 Testing and adjusting ......................................................................................................... 365 Table of contents ............................................................................................................ 366 General information on testing and adjusting ................................................................................. 367 Tools for testing and adjusting .......................................................................................... 367 Sketch of tools for testing and adjusting ................................................................................ 370 Engine and cooling system .................................................................................................... 372 Testing engine speed ..................................................................................................... 372 Testing exhaust gas color ................................................................................................ 373 Testing and adjusting valve clearance .................................................................................... 374 Testing compression pressure ............................................................................................. 376 Testing blowby pressure .................................................................................................. 379 Testing engine oil pressure .............................................................................................. 380 Testing fuel pressure .................................................................................................... 381 Testing fuel return rate and leakage ..................................................................................... 382 Bleeding air from fuel system ............................................................................................ 385 Testing fuel circuit for leakage ......................................................................................... 387 Handling cylinder cutout mode operation .................................................................................. 388 Handling no-injection cranking operation ................................................................................. 389 Checking and adjusting air conditioner compressor belt tension ........................................................... 390 Replacing fan belt ....................................................................................................... 391 Writing compensation values at replacement of injector and engine controller ............................................. 392 Power train .................................................................................................................. 396 Testing swing circle bearing clearance ................................................................................... 396 Undercarriage and frame ...................................................................................................... 397 Testing and adjusting track shoe tension ................................................................................. 397 Hydraulic system ............................................................................................................. 398 Releasing remaining pressure from hydraulic circuit ...................................................................... 398 Testing and adjusting oil pressure in work equipment, swing, and travel circuits ......................................... 399 Testing oil pressure of control circuit .................................................................................. 402 Testing and adjusting oil pressure in pump PC control circuit ............................................................ 403 Testing and adjusting oil pressure in pump LS control circuit ............................................................ 406 Testing outlet pressure of solenoid valve ................................................................................ 411 Testing PPC valve output pressure ........................................................................................ 412 Adjusting play of work equipment and swing PPC valves .................................................................... 414 Isolating the parts causing hydraulic drift in work equipment ............................................................ 415 Testing and adjusting travel deviation ................................................................................... 416 Testing oil leakage ...................................................................................................... 418 Bleeding air from hydraulic circuit ...................................................................................... 420 Cab and its attachments ...................................................................................................... 423 Checking cab tipping stopper ............................................................................................. 423 Testing, cleaning and lubricating slide door rail and roller ............................................................. 424 Adjusting mirrors ........................................................................................................ 425 Electrical system ............................................................................................................ 427 Special functions of machine monitor ..................................................................................... 427 Adjusting rearview camera angle .......................................................................................... 479 Handling voltage circuit of engine controller ............................................................................ 481 Handling battery disconnect switch ....................................................................................... 482 Testing diodes ........................................................................................................... 483 Pm clinic .................................................................................................................... 484 Pm Clinic service ........................................................................................................ 484 40 Troubleshooting ............................................................................................................... 491 Table of contents ............................................................................................................ 492 General information on troubleshooting ....................................................................................... 497 Troubleshooting points ................................................................................................... 497 Sequence of events in troubleshooting .................................................................................... 499 Checks before troubleshooting ............................................................................................ 501 Inspection procedure before troubleshooting .............................................................................. 503 Preparation for troubleshooting of electrical system ..................................................................... 520 Classification and procedure for troubleshooting ......................................................................... 524 Symptom and troubleshooting numbers ...................................................................................... 527 Information in troubleshooting table ..................................................................................... 530 Troubleshooting method for open circuit in wiring harness of pressure sensor system ...................................... 532 Connector list and layout ................................................................................................ 534 Connector contact identification ......................................................................................... 544 T-branch box and T-branch adapter table .................................................................................. 582 Fuse location table ...................................................................................................... 587 Failure codes table ...................................................................................................... 589 Troubleshooting by failure code (Display of code) ............................................................................ 595 Failure code [879AKA] A/C Inner Sensor Open Circuit ...................................................................... 595 Failure code [879AKB] A/C Inner Sensor Short Circuit ..................................................................... 596 Failure code [879BKA] A/C Outer Sensor Open Circuit ...................................................................... 597 Failure code [879BKB] A/C Outer Sensor Short Circuit ..................................................................... 598 Failure code [879CKA] Ventilating Sensor Open Circuit .................................................................... 599 Failure code [879CKB] Ventilating Sensor Short Circuit ................................................................... 600 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit .............................................................. 601 Failure code [879EMC] Ventilation Damper Abnormality ..................................................................... 602 Failure code [879FMC] Air Mix Damper Abnormality ......................................................................... 603 Failure code [879GKX] Refrigerant Abnormality ............................................................................ 604 Failure code [989L00] Engine Controller Lock Caution 1 ................................................................... 605 Failure code [989M00] Engine Controller Lock Caution 2 ................................................................... 606 Failure code [989N00] Engine Controller Lock Caution 3 ................................................................... 607 Failure code [AB00KE] Charge Voltage Low ................................................................................. 608 Failure code [B@BAZG] Eng Oil Press Low .................................................................................. 610 Failure code [B@BAZK] Eng Oil Level Low .................................................................................. 611 Failure code [B@BCNS] Eng Water Overheat ................................................................................. 612 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................................... 613 Failure code [CA122] Chg Air Press Sensor High Error ..................................................................... 614 Failure code [CA123] Chg Air Press Sensor Low Error ...................................................................... 616 Failure code [CA131] Throttle Sensor High Error .......................................................................... 618 Failure code [CA132] Throttle Sensor Low Error ........................................................................... 620 Failure code [CA144] Coolant Temp Sens High Error ........................................................................ 622 Failure code [CA145] Coolant Temp Sens Low Error ......................................................................... 624 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................................... 626 Failure code [CA154] Chg Air Temp Sensor Low Error ....................................................................... 628 Failure code [CA187] Sensor 2 Supply Volt Low Error ...................................................................... 630 Failure code [CA221] Ambient Press Sensor High Error ..................................................................... 632 Failure code [CA222] Ambient Press Sensor Low Error ...................................................................... 634 Failure code [CA227] Sensor 2 Supply Volt High Error ..................................................................... 636 Failure code [CA234] Eng Overspeed ....................................................................................... 637 Failure code [CA238] Ne Speed Sensor Supply Volt Error ................................................................... 638 Failure code [CA239] Ne Speed Sens Supply Volt High Error ................................................................ 639 Failure code [CA271] IMV/PCV1 Short Error ................................................................................ 640 Failure code [CA272] IMV/PCV1 Open Error ................................................................................. 641 Failure code [CA322] Inj #1(L#1) Open/Short Error ........................................................................ 642 Failure code [CA324] Inj #3(L#3) Open/Short Error ........................................................................ 644 Failure code [CA331] Inj #2(L#2) Open/Short Error ........................................................................ 646 Failure code [CA332] Inj #4(L#4) Open/Short Error ........................................................................ 648 Failure code [CA343] ECM Critical Internal Failure ....................................................................... 650 Failure code [CA351] Injectors Drive Circuit Error ....................................................................... 651 Failure code [CA352] Sensor 1 Supply Volt Low Error ...................................................................... 652 Failure code [CA356] Mass Air Flow Sensor High Error ..................................................................... 654 Failure code [CA357] Mass Air Flow Sensor Low Error ...................................................................... 656 Failure code [CA386] Sensor 1 Supply Volt High Error ..................................................................... 658 Failure code [CA435] Eng Oil Press Sw Error .............................................................................. 659 Failure code [CA441] Battery Voltage Low Error ........................................................................... 660 Failure code [CA442] Battery Voltage High Error .......................................................................... 662 Failure code [CA449] Rail Press Very High Error .......................................................................... 663 Failure code [CA451] Rail Press Sensor High Error ........................................................................ 664 Failure code [CA452] Rail Press Sensor Low Error ......................................................................... 666 Failure code [CA466] KVGT Motor Driver Position Error .................................................................... 668 Failure code [CA515] Rail Press Sens Sup Volt High Error ................................................................. 670 Failure code [CA516] Rail Press Sens Sup Volt Low Error .................................................................. 672 Failure code [CA553] Rail Press High Error ............................................................................... 674 Failure code [CA555] Crankcase Press High Error 1 ........................................................................ 675 Failure code [CA556] Crankcase Press High Error 2 ........................................................................ 676 Failure code [CA559] Rail Press Low Error ................................................................................ 677 Failure code [CA689] Eng Ne Speed Sensor Error ........................................................................... 680 Failure code [CA691] Intake Air Temp Sens High Error ..................................................................... 682 Failure code [CA692] Intake Air Temp Sens Low Error ...................................................................... 684 Failure code [CA697] ECM Internal Temp Sensor High Error ................................................................. 686 Failure code [CA698] ECM Int Temp Sensor Low Error ....................................................................... 687 Failure code [CA731] Eng Bkup Speed Sens Phase Error ..................................................................... 688 Failure code [CA778] Eng Bkup Speed Sensor Error ......................................................................... 691 Failure code [CA1117] Persistent Data Lost Error ......................................................................... 695 Failure code [CA1695] Sensor 5 Supply Volt High Error .................................................................... 696 Failure code [CA1696] Sensor 5 Supply Volt Low Error ..................................................................... 697 Failure code [CA1843] Crankcase Press Sens High Error .................................................................... 698 Failure code [CA1844] Crankcase Press Sens Low Error ..................................................................... 700 Failure code [CA1896] EGR Valve Stuck Error .............................................................................. 702 Failure code [CA1942] Crankcase Press Sens In Range Error ................................................................ 703 Failure code [CA1961] EGR_Motor Driver IC Over Temp Error ................................................................ 704 Failure code [CA2185] Throt Sensor Sup Volt High Error ................................................................... 705 Failure code [CA2186] Throt Sensor Sup Volt Low Error .................................................................... 707 Failure code [CA2249] Rail Press Very Low Error .......................................................................... 709 Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................................... 710 Failure code [CA2311] IMV Solenoid Error ................................................................................. 712 Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................................... 713 Failure code [CA2353] EGR Valve Solenoid Short Error ..................................................................... 715 Failure code [CA2357] EGR Valve Servo Error .............................................................................. 717 Failure code [CA2765] Inj Trim Data Error ................................................................................ 718 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................................... 719 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ............................................................ 721 Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error .............................................................. 723 Failure code [CA3918] KVGT Stuck Error ................................................................................... 725 Failure code [CA3919] KVGT Motor Driver IC Over Temp Error ............................................................... 726 Failure code [CA3921] KVGT Servo Error 2 ................................................................................. 727 Failure code [CA3922] KVGT Motor Driver Open Error ....................................................................... 728 Failure code [CA3923] KVGT Motor Driver Short Error ...................................................................... 730 Failure code [D110KB] Battery Relay Drive Short Circuit .................................................................. 732 Failure code [D19JKZ] Personal Code Relay Abnormality .................................................................... 734 Failure code [D811MC] KOMTRAX Error ...................................................................................... 737 Failure code [D862KA] GPS Antenna Open Circuit ........................................................................... 738 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) .............................................................. 739 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ............................................................. 741 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) .............................................................................. 742 Failure code [DA20MC] Pump Controller Malfunction ........................................................................ 744 Failure code [DA22KK] Pump Solenoid Power Low Error ...................................................................... 745 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ...................................................................... 747 Failure code [DA29KQ] Model Selection Abnormality ........................................................................ 749 Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) ............................................................. 751 Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ............................................................ 753 Failure code [DA2QKR] CAN2 Discon (Pump Con) ............................................................................. 754 Failure code [DA2RKR] CAN1 Discon (Pump Con) ............................................................................. 756 Failure code [DAF0MB] Monitor ROM Abnormality ............................................................................ 757 Failure code [DAF0MC] Monitor Error ...................................................................................... 758 Failure code [DAF8KB] Camera Power Supply Short Circuit .................................................................. 759 Failure code [DAF9KQ] Model Selection Abnormality ........................................................................ 761 Failure code [DAFGMC] GPS Module Error ................................................................................... 762 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) .............................................................. 763 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) ............................................................. 765 Failure code [DAFQKR] CAN2 Discon (Monitor) .............................................................................. 766 Failure code [DAZ9KQ] A/C Model Selection Abnormality .................................................................... 767 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................................... 768 Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................................... 772 Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................................... 776 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ....................................................................... 780 Failure code [DHPAMA] Pump Press Sensor Abnormality ...................................................................... 782 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ......................................................... 784 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality ......................................................... 786 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ......................................................... 788 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ......................................................... 790 Failure code [DHSKMA] Blade Raise PPC Press Sensor Abnormality ........................................................... 792 Failure code [DHSLMA] Blade Lower PPC Press Sensor Abnormality ........................................................... 794 Failure code [DHX1MA] Overload Sensor Abnormality ........................................................................ 796 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ............................................................ 797 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ............................................................ 799 Failure code [DV20KB] Travel Alarm Short Circuit ......................................................................... 800 Failure code [DW43KA] Travel Speed Sol Open Circuit ...................................................................... 802 Failure code [DW43KB] Travel Speed Sol Short Circuit ..................................................................... 804 Failure code [DW45KA] Swing Brake Sol Open Circuit ....................................................................... 806 Failure code [DW45KB] Swing Brake Sol Short Circuit ...................................................................... 809 Failure code [DW91KA] Travel Junction Sol Open Circuit ................................................................... 811 Failure code [DW91KB] Travel Junction Sol Short Circuit .................................................................. 813 Failure code [DWA2KA] Attachment Sol Open Circuit ........................................................................ 815 Failure code [DWA2KB] Attachment Sol Short Circuit ....................................................................... 817 Failure code [DWJ0KA] Merge-divider Sol Open Circuit ..................................................................... 819 Failure code [DWJ0KB] Merge-divider Sol Short Circuit .................................................................... 821 Failure code [DXA8KA] PC-EPC Sol Open Circuit ............................................................................ 823 Failure code [DXA8KB] PC-EPC Sol Short Circuit ........................................................................... 825 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ................................................................... 827 Failure code [DXE4KB] Attachment Flow EPC Short Circuit .................................................................. 829 Failure code [DY20KA] Wiper Working Abnormality .......................................................................... 831 Failure code [DY20MA] Wiper Parking Abnormality .......................................................................... 833 Failure code [DY2CKB] Washer Drive Short Circuit ......................................................................... 835 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .................................................................... 837 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .................................................................... 839 Troubleshooting of electrical system (E-mode) ................................................................................ 841 E-1 Engine does not start (Engine does not crank) ........................................................................ 841 E-2 Manual preheating system does not work ............................................................................... 847 E-3 While preheating is working, preheating monitor does not light up .................................................... 850 E-4 When starting switch is turned to ON position, machine monitor displays nothing ...................................... 852 E-5 When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow .... 855 E-6 Engine coolant temperature monitor lights up in white while engine is running ........................................ 856 E-7 Hydraulic oil temperature monitor lights up in white while engine is running ......................................... 857 E-8 Charge level monitor lights up while engine is running ............................................................... 858 E-9 Fuel level monitor lights up in red while engine is running .......................................................... 859 E-10 Engine coolant temperature monitor lights up in red while engine is running ......................................... 860 E-11 Hydraulic oil temperature monitor lights up in red while engine is running .......................................... 861 E-12 Engine oil pressure monitor lights up in red while engine is running ................................................ 862 E-13 Fuel gauge display does not move from minimum or maximum ............................................................ 863 E-14 Fuel gauge indicates incorrect amount (indicates neither full nor empty) ............................................ 864 E-15 Engine coolant temperature gauge display does not move from minimum or maximum ...................................... 865 E-16 Engine coolant temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) ............ 866 E-17 Hydraulic oil temperature gauge does not move from minimum or maximum ............................................... 867 E-18 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither minimum nor maximum) ............. 869 E-19 Some areas of machine monitor screen are not displayed .............................................................. 870 E-20 Function switch does not work ....................................................................................... 871 E-21 Automatic warm-up system does not operate (in cold season) .......................................................... 872 E-22 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated ......... 873 E-23 Auto-deceleration function does not operate or is not canceled while lever is operated .............................. 874 E-24 Working mode selection screen is not displayed while working mode selector switch is operated ....................... 875 E-25 Setting of engine and hydraulic pump is not changed while working mode is changed ................................... 876 E-26 Travel speed monitor does not change while travel speed switch is operated .......................................... 877 E-27 Travel speed does not change while travel speed selection is changed ................................................ 878 E-28 Alarm buzzer does not stop sounding ................................................................................. 879 E-29 Service meter is not displayed, while starting switch is in OFF position ............................................ 880 E-30 Service mode cannot be selected ..................................................................................... 881 E-31 Any of work equipment, swing and travel does not work ............................................................... 882 E-32 Any of work equipment, swing and travel cannot be locked ............................................................ 884 E-33 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position .................... 886 E-34 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position ...................... 888 E-35 Alarm does not sound during travel .................................................................................. 890 E-36 Alarm does not stop sounding while machine is stopped ............................................................... 891 E-37 Horn does not sound ................................................................................................. 892 E-38 Horn does not stop sounding ......................................................................................... 893 E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated ................................. 894 E-40 Wiper does not operate while wiper switch is operated ............................................................... 895 E-41 Window washer does not operate while window washer switch is operated ............................................... 897 E-42 Boom Lower is not displayed correctly with monitoring function ...................................................... 898 E-43 Arm OUT is not displayed correctly with monitoring function ......................................................... 900 E-44 Arm IN is not displayed correctly with monitoring function .......................................................... 902 E-45 Boom Raise is not displayed correctly with monitoring function ...................................................... 904 E-46 Bucket Curl is not displayed correctly with monitoring function ..................................................... 906 E-47 Bucket Dump is not displayed correctly with monitoring function ..................................................... 908 E-48 Swing is not displayed correctly with monitoring function ........................................................... 910 E-49 Travel is not displayed correctly with monitoring function .......................................................... 912 E-50 Service is not displayed correctly with monitoring function ......................................................... 913 E-51 Attachment hydraulic circuit cannot be changed ...................................................................... 915 E-52 KOMTRAX system does not operate normally ............................................................................ 916 Troubleshooting of hydraulic and mechanical system (H-mode) .................................................................. 918 Information described in troubleshooting table (H-mode) .................................................................. 918 System chart of hydraulic and mechanical systems ......................................................................... 919 Failure mode and cause table ............................................................................................. 921 H-1 All of work equipment, swing and travel operation lacks speed or power ............................................... 929 H-2 Engine speed drops significantly or engine stalls .................................................................... 931 H-3 Any of work equipment, swing and travel does not work ................................................................ 932 H-4 Unusual sound is heard from around hydraulic pump .................................................................... 933 H-5 Fine control performance or response is poor ......................................................................... 934 H-6 Boom speed or power is low ........................................................................................... 935 H-7 Arm speed or power is low ............................................................................................ 938 H-8 Bucket speed or power is low ......................................................................................... 940 H-9 Work equipment does not move in single operation ..................................................................... 942 H-10 Hydraulic drift of boom is large .................................................................................... 943 H-11 Hydraulic drift of arm is large ..................................................................................... 944 H-12 Hydraulic drift of bucket is large .................................................................................. 945 H-13 Time lag of work equipment is large ................................................................................. 946 H-14 In combined operation of work equipment , equipment having heavier load moves slower ................................ 948 H-15 In combined operation of swing and boom RAISE, boom rising speed is low ............................................. 949 H-16 In combined operation of swing and travel, travel speed drops largely ............................................... 950 H-17 Machine does not travel straight .................................................................................... 951 H-18 Travel speed is slow ................................................................................................ 953 H-19 Machine is hard to steer or travel power is low ..................................................................... 955 H-20 Travel speed does not change, or travel speed is too slow or fast ................................................... 958 H-21 One of tracks does not run .......................................................................................... 959 H-22 Upper structure does not swing to the right or left ................................................................. 961 H-23 Upper structure swing only to the right or left ..................................................................... 962 H-24 Swing acceleration or swing speed is low in both directions (right and left) ........................................ 963 H-25 Swing acceleration performance is poor or swing speed is slow in only one direction ................................. 964 H-26 Upper structure overruns excessively when it stops swinging (both right and left) ................................... 965 H-27 Upper structure overruns excessively when it stops swinging (either right or left) .................................. 966 H-28 Shock is large when upper structure stops swinging .................................................................. 967 H-29 Large unusual noise is heard when upper structure stops swinging .................................................... 968 H-30 Swing drift on a slope is large while swing parking brake is applied ................................................ 969 H-31 Swing drift on a slope is large while swing parking brake is released ............................................... 970 H-32 Attachment hydraulic circuit cannot be changed while attachment is installed ........................................ 971 H-33 Oil flow in attachment circuit cannot be controlled ................................................................. 972 Troubleshooting of engine (S-mode) ........................................................................................... 973 Information mentioned in troubleshooting table (S mode) .................................................................. 973 S-1 Engine does not crank when starting switch is turned to START position ............................................... 974 S-2 Engine cranks but no exhaust smoke comes out ......................................................................... 975 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ....................... 976 S-4 Engine startability is poor .......................................................................................... 977 S-5 Engine does not pick up smoothly ..................................................................................... 979 S-6 Engine stops during operation ........................................................................................ 981 S-7 Engine runs rough or is unstable ..................................................................................... 983 S-8 Engine lacks power ................................................................................................... 984 S-9 Exhaust smoke is black ............................................................................................... 986 S-10 Engine oil consumption is excessive ................................................................................. 988 S-11 Oil becomes contaminated quickly .................................................................................... 989 S-12 Fuel consumption is excessive ....................................................................................... 990 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .................................................... 991 S-14 Oil pressure drops .................................................................................................. 992 S-15 Fuel mixes into engine oil .......................................................................................... 993 S-16 Water mixes into engine oil (milky) ................................................................................. 994 S-17 Coolant temperature rises too high (overheating) .................................................................... 995 S-18 Unusual noise is heard .............................................................................................. 996 S-19 Vibration is excessive .............................................................................................. 997 S-20 Air cannot be bled from fuel circuit ................................................................................ 998 50 Disassembly and assembly ...................................................................................................... 999 Table of contents ............................................................................................................1000 General information on disassembly and assembly ..............................................................................1002 How to read this manual ..................................................................................................1002 Coating materials list ...................................................................................................1004 Special tools list .......................................................................................................1008 Sketches of special tools ................................................................................................1012 Engine and cooling system ....................................................................................................1014 Removal and installation of supply pump assembly .........................................................................1014 Removal and installation of injector assembly ............................................................................1018 Removal and installation of cylinder head assembly .......................................................................1024 Removal and installation of radiator assembly ............................................................................1035 Removal and installation of hydraulic oil cooler assembly ................................................................1037 Removal and installation of aftercooler assembly .........................................................................1040 Removal and installation of engine and main pump assembly ................................................................1042 Removal and installation of engine front oil seal ........................................................................1048 Removal and installation of engine rear oil seal .........................................................................1049 Removal and installation of fuel cooler assembly .........................................................................1051 Removal and installation of fuel tank assembly ...........................................................................1052 Removal and installation of KDOC assembly ................................................................................1055 Removal and installation of KCCV assembly ................................................................................1056 Removal and installation of air cleaner assembly .........................................................................1057 Removal and installation of fan belt .....................................................................................1059 Power train system ...........................................................................................................1061 Removal and installation of travel motor and final drive assembly ........................................................1061 Disassembly and assembly of travel motor and final drive assembly ........................................................1062 Removal and installation of swing motor and swing machinery assembly .....................................................1097 Disassembly and assembly of swing machinery assembly .....................................................................1099 Removal and installation of swing circle assembly ........................................................................1105 Undercarriage and frame ......................................................................................................1106 Separation and connection of track .......................................................................................1106 Removal and installation of sprocket .....................................................................................1109 Removal and installation of idler and idler cushion assembly .............................................................1110 Disassembly and assembly of idler assembly ...............................................................................1111 Disassembly and assembly of idler cushion assembly .......................................................................1114 Disassembly and assembly of track roller assembly ........................................................................1117 Removal and installation of revolving frame assembly .....................................................................1120 Removal and installation of counterweight assembly [For machines with additional counterweight] ..........................1122 Hydraulic system .............................................................................................................1125 Removal and installation of center swivel joint assembly .................................................................1125 Disassembly and assembly of center swivel joint assembly .................................................................1127 Removal and installation of hydraulic tank assembly ......................................................................1128 Removal and installation of main pump assembly ...........................................................................1131 Removal and installation of control valve assembly .......................................................................1135 Disassembly and assembly of control valve assembly .......................................................................1141 Disassembly and assembly of work equipment PPC valve assembly ............................................................1143 Disassembly and assembly of travel PPC valve assembly ....................................................................1145 Work equipment ...............................................................................................................1147 Removal and installation of work equipment assembly ......................................................................1147 Disassembly and assembly of work equipment cylinder assembly .............................................................1151 Cab and its attachments ......................................................................................................1156 Removal and installation of operator's cab assembly ......................................................................1156 Removal and installation of operator's cab door ..........................................................................1159 Removal and installation of operator's cab glass (adhered glass) .........................................................1162 Removal and installation of front window assembly ........................................................................1173 Removal and installation of floor frame assembly .........................................................................1174 Removal and installation of air conditioner unit assembly ................................................................1181 Removal and installation of air conditioner compressor assembly ..........................................................1185 Removal and installation of air conditioner condenser assembly ...........................................................1187 Removal and installation of operator's seat ..............................................................................1189 Removal and installation of seat belt ....................................................................................1190 Removal and installation of front wiper assembly .........................................................................1191 Electrical system ............................................................................................................1197 Removal and installation of engine controller assembly ...................................................................1197 Removal and installation of pump controller assembly .....................................................................1198 Removal and installation of machine monitor assembly .....................................................................1200 Removal and installation of mass air flow and temperature sensor .........................................................1202 Removal and installation of KOMTRAX terminal assembly ....................................................................1203 60 Maintenance standard ..........................................................................................................1205 Table of contents ............................................................................................................1206 Engine and cooling system ....................................................................................................1207 Engine mount .............................................................................................................1207 PTO ......................................................................................................................1208 Cooling system ...........................................................................................................1209 Power train ..................................................................................................................1210 Swing circle .............................................................................................................1210 Swing machinery ..........................................................................................................1211 Sprocket .................................................................................................................1212 Undercarriage and frame ......................................................................................................1213 Track frame ..............................................................................................................1213 Idler cushion ............................................................................................................1214 Idler ....................................................................................................................1215 Track roller .............................................................................................................1216 Carrier roller ...........................................................................................................1217 Track shoe ...............................................................................................................1218 Hydraulic system .............................................................................................................1223 Hydraulic tank ...........................................................................................................1223 Main pump ................................................................................................................1224 Control valve ............................................................................................................1227 Swing motor ..............................................................................................................1238 Travel motor .............................................................................................................1241 Work equipment and swing PPC valve .......................................................................................1242 Travel PPC valve .........................................................................................................1245 Blade PPC valve ..........................................................................................................1248 1st-line attachment PPC valve (with EPC valve) ...........................................................................1250 Solenoid valve ...........................................................................................................1253 Attachment circuit selector valve (for low pressure circuit) .............................................................1255 Attachment circuit selector valve (for high pressure circuit) ............................................................1256 Center swivel joint ......................................................................................................1257 Cab and its attachments ......................................................................................................1258 Cab mount and cab tipping stopper ........................................................................................1258 Work equipment ...............................................................................................................1259 Work equipment ...........................................................................................................1259 Boom cylinder ............................................................................................................1268 Arm cylinder .............................................................................................................1269 Bucket cylinder ..........................................................................................................1270 Blade cylinder ...........................................................................................................1271 80 Appendix ......................................................................................................................1273 Table of contents ............................................................................................................1274 Air conditioner components ...................................................................................................1275 Precautions for refrigerant ..............................................................................................1275 Air conditioner component ................................................................................................1276 Configuration and function of refrigeration cycle ........................................................................1279 Outline of refrigeration cycle ...........................................................................................1280 Air conditioner unit .....................................................................................................1282 Dual pressure switch .....................................................................................................1287 Air conditioner controller ...............................................................................................1288 Compressor ...............................................................................................................1289 Air conditioner condenser ................................................................................................1290 Sunlight sensor ..........................................................................................................1292 Outer temperature sensor (outside air temperature sensor) ................................................................1293 Procedure for testing and troubleshooting ................................................................................1294 Circuit diagram and arrangement of connector pins ........................................................................1296 System diagram ...........................................................................................................1298 Input and output signals of the air conditioner controller ...............................................................1299 Air conditioner unit .....................................................................................................1301 Parts and connectors layout ..............................................................................................1303 Testing air leakage (duct) ...............................................................................................1309 Testing with self-diagnosis function .....................................................................................1312 Testing vent (mode) changeover ...........................................................................................1315 Testing FRESH/RECIRC air changeover ......................................................................................1316 Testing sunlight sensor ..................................................................................................1317 Testing (dual) pressure switch for refrigerant ...........................................................................1318 Testing relays ...........................................................................................................1320 Troubleshooting chart 1 ..................................................................................................1321 Troubleshooting chart 2 ..................................................................................................1322 Information in troubleshooting table .....................................................................................1325 Failure code list related to air conditioner .............................................................................1326 Failure code [879AKA] A/C Inner Sensor Open Circuit ......................................................................1327 Failure code [879AKB] A/C Inner Sensor Short Circuit .....................................................................1328 Failure code [879BKA] A/C Outer Sensor Open Circuit ......................................................................1329 Failure code [879BKB] A/C Outer Sensor Short Circuit .....................................................................1331 Failure code [879CKA] Ventilating Sensor Open Circuit ....................................................................1333 Failure code [879CKB] Ventilating Sensor Short Circuit ...................................................................1334 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ..............................................................1335 Failure code [879EMC] Ventilation Damper Abnormality .....................................................................1337 Failure code [879FMC] Air Mix Damper Abnormality .........................................................................1338 Failure code [879GKX] Refrigerant Abnormality ............................................................................1339 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ...........................................1340 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ............................................1342 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ...................................1345 A-4 Troubleshooting for FRESH/RECIRC air changeover ......................................................................1347 Troubleshooting with gauge pressure ......................................................................................1349 Connection of service tool ...............................................................................................1352 Precautions for disconnecting and connecting refrigerant piping ..........................................................1354 Handling of compressor oil ...............................................................................................1356 Desiccant replacement ....................................................................................................1358 90 Diagrams and drawings .........................................................................................................1361 Table of contents ............................................................................................................1362 Hydraulic circuit diagram ....................................................................................................1363 Symbols in hydraulic circuit diagram .....................................................................................1363 Hydraulic circuit diagram.................................................................................................1367 Electric circuit diagram .....................................................................................................1368 Symbols in electric circuit diagram ......................................................................................1368 Electrical circuit diagram................................................................................................1372 Electrical circuit diagram for air conditioner unit.......................................................................1378
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