Komatsu Hydraulic Excavator PC130-10M0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC130-10M0, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC130-10M0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN06852-05 - Hydraulic Excavator PC130-10M0 Shop Manual (SN 70413 and up).pdf
PRODUCT DETAILS:
Total Pages: 2,024 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
COVER...1
00 INDEX AND FOREWORD...1
INDEX...2
FOREWORD, SAFETY, BASIC INFORMATION...14
HOW TO READ THE SHOP MANUAL...14
SAFETY NOTICE FOR OPERATION...16
PRECAUTIONS TO PREVENT FIRE...24
ACTIONS IF FIRE OCCURS...25
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS...26
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...27
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS...30
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT...37
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...39
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...40
PRACTICAL USE OF KOMTRAX...41
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...42
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...42
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...43
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...46
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...50
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...51
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...53
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...54
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...56
HOW TO READ ELECTRICAL WIRE CODE...57
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...61
STANDARD TIGHTENING TORQUE TABLE...64
CONVERSION TABLE...71
ABBREVIATION LIST...76
01 SPECIFICATIONS...1
CONTENTS...2
SPECIFICATIONS...3
SPECIFICATION DRAWING...3
SPECIFICATION DRAWING: PC130-10M0...3
WORKING RANGE DRAWINGS...5
WORKING RANGE DRAWINGS: PC130-10M0...5
SPECIFICATIONS...6
SPECIFICATIONS: PC130-10M0...6
WEIGHT TABLE...10
WEIGHT TABLE: PC130-10M0...10
FUEL, COOLANT, LUBRICANT...12
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...12
10 STRUCTURE AND FUNCTION...1
CONTENTS...2
BOOT-UP SYSTEM...5
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL)...5
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...6
SYSTEM OPERATING LAMP SYSTEM...7
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL)...7
SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...7
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH KOMTRAX TERMINAL)...7
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...8
BATTERY DISCONNECT SWITCH...10
FUNCTION OF BATTERY DISCONNECT SWITCH...10
ENGINE SYSTEM...11
LAYOUT DRAWING OF ENGINE SYSTEM...11
ENGINE CONTROL SYSTEM...12
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL)...12
SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...12
OPERATION OF ENGINE CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL)...13
OPERATION OF ENGINE CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...14
AUTO-DECELERATION SYSTEM...16
SYSTEM DIAGRAM OF AUTO-DECELERATION SYSTEM...16
FUNCTION OF AUTO-DECELERATION SYSTEM...16
OPERATION OF AUTO-DECELERATION SYSTEM...17
ENGINE AUTOMATIC WARM-UP SYSTEM...18
SYSTEM DIAGRAM OF ENGINE AUTOMATIC WARM-UP SYSTEM...18
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM...18
OVERHEAT PREVENTION SYSTEM...20
FUNCTION OF OVERHEAT PREVENTION SYSTEM...20
TURBOCHARGER PROTECTION SYSTEM...22
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM...22
COMPONENT PARTS OF ENGINE SYSTEM...23
PTO...23
COOLING SYSTEM...24
LAYOUT DRAWING OF COOLING SYSTEM...24
SPECIFICATIONS OF COOLING SYSTEM...25
CONTROL SYSTEM...26
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL)...26
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...28
MACHINE MONITOR SYSTEM...30
SYSTEM DIAGRAM OF MACHINE MONITOR (MACHINE WITH KOMTRAX TERMINAL)...30
SYSTEM DIAGRAM OF MACHINE MONITOR (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...31
FUNCTION OF MACHINE MONITOR SYSTEM...31
KOMTRAX SYSTEM...33
KOMTRAX SYSTEM DIAGRAM (MACHINE WITH KOMTRAX TERMINAL)...33
SYSTEM DIAGRAM OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...33
FUNCTION OF KOMTRAX SYSTEM...34
COMPONENT PARTS OF CONTROL SYSTEM...35
MACHINE MONITOR...35
KOMTRAX TERMINAL...48
GATEWAY FUNCTION CONTROLLER...50
COMMUNICATION TERMINAL...53
PUMP CONTROLLER...55
RESISTOR FOR PC-EPC VALVE...60
CAN TERMINATING RESISTOR...61
ENGINE CONTROLLER...62
FUEL CONTROL DIAL...67
HYDRAULIC SYSTEM...69
LAYOUT DRAWING OF HYDRAULIC SYSTEM...69
CLSS...71
STRUCTURE OF CLSS...71
FUNCTION OF CLSS...72
ENGINE AND PUMP COMBINED CONTROL SYSTEM...74
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM...74
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM...75
COMPONENT PARTS OF HYDRAULIC SYSTEM...80
HYDRAULIC TANK...80
MAIN PUMP...82
CONTROL VALVE...107
WORK EQUIPMENT SYSTEM...167
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...167
STRUCTURE OF VALVE CONTROL...170
PPC LOCK SYSTEM...171
SYSTEM DIAGRAM OF PPC LOCK SYSTEM...171
FUNCTION OF PPC LOCK SYSTEM...171
ONE-TOUCH POWER MAXIMIZING SYSTEM...172
SYSTEM DIAGRAM OF ONE-TOUCH POWER MAXIMIZING SYSTEM...172
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM...172
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...173
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM...173
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...174
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...175
WORK EQUIPMENT AND SWING PPC VALVE...175
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...180
SOLENOID VALVE...187
VARIABLE BACK PRESSURE SOLENOID VALVE...192
PILOT CIRCUIT ACCUMULATOR...193
ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT)...194
SWING SYSTEM...195
LAYOUT DRAWING OF SWING SYSTEM...195
SWING CONTROL SYSTEM DIAGRAM...197
FUNCTION OF SWING CONTROL SYSTEM...197
COMPONENT PARTS OF SWING SYSTEM...200
SWING MOTOR...200
SWING MACHINERY...208
SWING CIRCLE...210
TRAVEL SYSTEM...211
LAYOUT DRAWING OF TRAVEL SYSTEM...211
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM...213
FUNCTION OF TRAVEL CONTROL SYSTEM...213
COMPONENT PARTS OF TRAVEL SYSTEM...217
TRAVEL MOTOR...217
TRAVEL PPC VALVE...227
CENTER SWIVEL JOINT...231
UNDERCARRIAGE AND FRAME...234
LAYOUT DRAWING OF UNDERCARRIAGE...234
SPECIFICATIONS OF UNDERCARRIAGE...234
IDLER CUSHION...235
STRUCTURE OF IDLER CUSHION...235
SPECIFICATIONS OF IDLER CUSHION...235
WORK EQUIPMENT...236
STRUCTURE OF WORK EQUIPMENT...236
FUNCTION OF WORK EQUIPMENT...237
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...238
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...238
BUCKET CLEARANCE ADJUSTMENT SHIM...239
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM...239
CAB AND ITS ATTACHMENTS...240
ROPS CAB...240
STRUCTURE OF ROPS CAB (MACHINE WITH KOMTRAX TERMINAL)...240
STRUCTURE OF ROPS CAB (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...240
FUNCTION OF ROPS CAB...241
CAB MOUNT...242
STRUCTURE OF CAB MOUNT...242
FUNCTION OF CAB MOUNT...243
CAB TIPPING STOPPER...244
STRUCTURE OF CAB TIPPING STOPPER...244
FUNCTION OF CAB TIPPING STOPPER...244
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20 STANDARD VALUE TABLE...1
CONTENTS...2
STANDARD VALUE TABLE FOR ENGINE...3
STANDARD VALUE TABLE FOR ENGINE: PC130-10M0...3
STANDARD VALUE TABLE FOR MACHINE...6
STANDARD VALUE TABLE FOR MACHINE: PC130-10M0...6
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE...20
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30 TESTING AND ADJUSTING...1
CONTENTS...2
RELATED INFORMATION ON TESTING AND ADJUSTING...5
TOOLS FOR TESTING AND ADJUSTING...5
SKETCH OF TOOLS FOR TESTING AND ADJUSTING...9
ENGINE AND COOLING SYSTEM...11
TEST ENGINE SPEED...11
TEST ENGINE SPEED...11
TEST EXHAUST GAS COLOR...13
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...13
TEST EXHAUST GAS COLOR BY SMOKE METER...14
TEST AND ADJUST VALVE CLEARANCE...15
TEST VALVE CLEARANCE...15
ADJUST VALVE CLEARANCE...16
TEST COMPRESSION PRESSURE...18
TEST COMPRESSION PRESSURE...18
TEST BLOWBY PRESSURE...20
TEST BLOWBY PRESSURE ON MACHINE MONITOR...20
TEST ENGINE OIL PRESSURE...22
TEST ENGINE OIL PRESSURE...22
TEST FUEL PRESSURE...24
TEST FUEL PRESSURE...24
TEST FUEL RETURN RATE AND LEAKAGE...25
TEST FUEL RETURN RATE AND LEAKAGE...27
BLEED AIR FROM FUEL SYSTEM...30
BLEED AIR FROM FUEL SYSTEM...30
TEST FUEL CIRCUIT FOR LEAKAGE...32
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...32
HANDLE CYLINDER CUT-OUT MODE OPERATION...34
HANDLE NO-INJECTION CRANKING OPERATION...35
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...36
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT...36
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT...36
TEST AND ADJUST FAN BELT TENSION...38
METHOD FOR CHECKING FAN BELT TENSION...38
METHOD FOR ADJUSTING FAN BELT TENSION...38
POWER TRAIN...40
TEST SWING CIRCLE BEARING CLEARANCE...40
TEST SWING CIRCLE BEARING CLEARANCE...40
UNDERCARRIAGE AND FRAME...41
TEST AND ADJUST TRACK TENSION...41
METHOD FOR TESTING TRACK TENSION...41
METHOD FOR ADJUSTING TRACK TENSION...41
HYDRAULIC SYSTEM...43
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM...43
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK...43
RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT...43
RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT...43
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT...44
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS...45
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS...45
ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...52
TEST OIL PRESSURE OF CONTROL CIRCUIT...55
TEST OIL PRESSURE OF CONTROL CIRCUIT...55
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...57
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)...57
TEST PC-EPC VALVE OUTLET PRESSURE...58
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...59
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...60
TEST LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR...60
TEST LS DIFFERENTIAL PRESSURE BY TESTING TOOL...62
TEST LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)...63
METHOD FOR ADJUSTING LS VALVE...64
TEST OUTLET PRESSURE OF SOLENOID VALVE...66
TEST OUTLET PRESSURE IN SOLENOID VALVE...66
OPERATING CONDITION OF SOLENOID VALVE...67
TEST OUTLET PRESSURE IN VARIABLE BACK PRESSURE SOLENOID VALVE...69
OPERATING CONDITION OF VARIABLE BACK PRESSURE SOLENOID VALVE...70
TEST OUTLET PRESSURE IN PPC VALVE...71
TEST OUTLET PRESSURE IN PPC VALVE...71
ADJUST WORK EQUIPMENT AND SWING PPC VALVES...73
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES...73
TEST AND ADJUST TRAVEL DEVIATION...74
TEST TRAVEL DEVIATION...74
METHOD FOR ADJUSTING TRAVEL DEVIATION...74
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT...77
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER...77
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER...77
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE...78
TEST OIL LEAKAGE...79
TEST OIL LEAKAGE FROM BOOM CYLINDER...79
TEST OIL LEAKAGE FROM ARM CYLINDER...79
TEST OIL LEAKAGE FROM BUCKET CYLINDER...80
METHOD FOR TESTING OIL LEAKAGE FROM BLADE CYLINDER...80
TEST OIL LEAKAGE FROM SWING MOTOR...81
TEST OIL LEAKAGE FROM TRAVEL MOTOR...82
BLEED AIR FROM HYDRAULIC CIRCUIT...83
BLEED AIR FROM HYDRAULIC CIRCUIT...84
CAB RELATED PARTS...87
TEST CAB TIPPING STOPPER...87
METHOD FOR TESTING CAB TIPPING STOPPER...87
ADJUST MIRRORS...88
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)...89
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)...90
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...92
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)...93
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)...94
PROCEDURE FOR ADJUSTING MACHINE REAR COUNTERWEIGHT MIRROR (D)...95
ELECTRICAL SYSTEM...96
SET AND OPERATE MACHINE MONITOR...96
OPERATOR MODE...100
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...100
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN...100
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)...101
CHECKING FUNCTION OF SERVICE METER...101
USAGE LIMITATION AND CHANGING MAINTENANCE PASSWORD...101
SERVICE MODE...104
OPERATE SERVICE MODE...104
CHECK PRE-DEFINED MONITORING INFORMATION...105
CHECK MONITORING INFORMATION...108
ABNORMALITY RECORD MENU...116
CHECK MAINTENANCE RECORD...120
MAINTENANCE MODE SETTING...121
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING...125
DEFAULT MENU...127
DIAGNOSTIC TESTS MENU...133
ADJUSTMENT MENU...135
KOMTRAX SETTINGS MENU...147
METHOD FOR DISPLAYING SERVICE MESSAGE...152
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL)...154
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL)...159
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...161
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...167
ADJUST REARVIEW CAMERA ANGLE...169
ADJUST REARVIEW CAMERA ANGLE...169
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...171
BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL)...172
BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...173
TEST DIODES...174
METHOD FOR TESTING DIODE USING DIGITAL TESTER...174
METHOD FOR TESTING DIODE USING ANALOG TESTER...174
Pm-CLINIC...175
Pm CLINIC SERVICE...175
Pm CLINIC CHECK SHEET: PC130-10M0...177
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40 TROUBLESHOOTING...1
CONTENTS...2
RELATED INFORMATION ON TROUBLESHOOTING...8
GENERAL TROUBLESHOOTING POINTS...8
SEQUENCE OF EVENTS IN TROUBLESHOOTING...9
CHECKS BEFORE TROUBLESHOOTING...11
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...13
WALK-AROUND CHECK...13
TESTING IN ACCORDANCE WITH TESTING PROCEDURE...15
CHECK FUEL LEVEL AND TYPE...15
DRAIN WATER AND SEDIMENT FROM FUEL TANK...15
CHECK FUEL PREFILTER...16
CHECK WATER SEPARATOR, DRAIN WATER AND SEDIMENT...16
REPLACE FUEL PREFILTER CARTRIDGE...17
CHECK FUEL MAIN FILTER...18
TEST ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)...20
CHECK OIL LEVEL IN PTO GEAR CASE...21
CHECK COOLANT LEVEL (RESERVOIR TANK)...22
CHECK CLOGGING OF AIR CLEANER...23
CLEAN OUTER ELEMENT...23
REPLACE ELEMENT...26
CHECK HYDRAULIC OIL LEVEL...27
CHECK HYDRAULIC OIL STRAINER...29
CHECK HYDRAULIC OIL FILTER...29
CHECK OIL LEVEL IN SWING MACHINERY CASE...31
CHECK OIL LEVEL IN FINAL DRIVE CASE...32
BLEED AIR FROM FUEL SYSTEM...32
BLEED AIR FROM HYDRAULIC SYSTEM...32
CHECK ELECTRIC EQUIPMENT...32
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM...37
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR...37
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER...37
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER...38
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER...38
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL...38
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK...38
PROCEDURE FOR TESTING AND TROUBLESHOOTING...43
SYMPTOM AND TROUBLESHOOTING NUMBERS...46
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...50
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM...52
CONNECTOR LIST AND LAYOUT (MACHINES WITHOUT FUEL REFILL PUMP)...55
CONNECTOR LIST AND LAYOUT (MACHINES WITHOUT FUEL REFILL PUMP)...66
CONNECTOR CONTACT IDENTIFICATION...78
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...120
FUSE LOCATION TABLE (MACHINES WITHOUT FUEL REFILL PUMP)...126
FUSE LOCATION TABLE (MACHINES WITH FUEL REFILL PUMP)...128
FAILURE CODE TABLE...130
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...137
FAILURE CODE [879AKA]...137
FAILURE CODE [879AKB]...138
FAILURE CODE [879BKA]...139
FAILURE CODE [879BKB]...141
FAILURE CODE [879CKA]...143
FAILURE CODE [879CKB]...144
FAILURE CODE [879DKZ]...145
FAILURE CODE [879EMC]...147
FAILURE CODE [879FMC]...148
FAILURE CODE [879GKX]...149
FAILURE CODE [989L00]...151
FAILURE CODE [989M00]...152
FAILURE CODE [989N00]...153
FAILURE CODE [AA10NX]...154
FAILURE CODE [AB00KE]...156
FAILURE CODE [B@BAZG]...158
FAILURE CODE [B@BAZK]...159
FAILURE CODE [B@BCNS]...161
FAILURE CODE [B@BCQA]...162
FAILURE CODE [B@BCZK]...164
FAILURE CODE [B@HANS]...166
FAILURE CODE [CA111]...168
FAILURE CODE [CA122]...174
FAILURE CODE [CA123]...176
FAILURE CODE [CA131]...177
FAILURE CODE [CA132]...179
FAILURE CODE [CA144]...180
FAILURE CODE [CA145]...182
FAILURE CODE [CA153]...183
FAILURE CODE [CA154]...185
FAILURE CODE [CA221]...186
FAILURE CODE [CA222]...188
FAILURE CODE [CA234]...189
FAILURE CODE [CA238]...190
FAILURE CODE [CA271]...192
FAILURE CODE [CA272]...193
FAILURE CODE [CA322]...194
FAILURE CODE [CA324]...196
FAILURE CODE [CA331]...198
FAILURE CODE [CA332]...200
FAILURE CODE [CA351]...202
FAILURE CODE [CA352]...206
FAILURE CODE [CA386]...207
FAILURE CODE [CA435]...209
FAILURE CODE [CA441]...210
FAILURE CODE [CA442]...211
FAILURE CODE [CA449]...212
FAILURE CODE [CA451]...213
FAILURE CODE [CA452]...215
FAILURE CODE [CA553]...216
FAILURE CODE [CA559]...217
FAILURE CODE [CA689]...221
FAILURE CODE [CA731]...223
FAILURE CODE [CA757]...224
FAILURE CODE [CA778]...230
FAILURE CODE [CA2185]...232
FAILURE CODE [CA2186]...234
FAILURE CODE [CA2249]...235
FAILURE CODE [CA2311]...236
FAILURE CODE [D110KB]...237
FAILURE CODE [D19JKZ]...239
FAILURE CODE [D811MC] (MACHINE WITH KOMTRAX TERMINAL)...241
FAILURE CODE [D811MC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...242
FAILURE CODE [D862KA] (MACHINE WITH KOMTRAX TERMINAL)...243
FAILURE CODE [D862KA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...244
FAILURE CODE [D8ALKA] (MACHINE WITH KOMTRAX TERMINAL)...245
FAILURE CODE [D8ALKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...247
FAILURE CODE [D8ALKB] (MACHINE WITH KOMTRAX TERMINAL)...250
FAILURE CODE [D8ALKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...252
FAILURE CODE [D8AQKR] (MACHINE WITH KOMTRAX TERMINAL)...254
FAILURE CODE [D8AQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...257
FAILURE CODE [D8G1KT]...263
FAILURE CODE [D8G6KT]...264
FAILURE CODE [DA20MC]...265
FAILURE CODE [DA22KK]...266
FAILURE CODE [DA25KP]...268
FAILURE CODE [DA26KP]...270
FAILURE CODE [DA29KQ]...273
FAILURE CODE [DA2LKA] (MACHINE WITH KOMTRAX TERMINAL)...275
FAILURE CODE [DA2LKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...277
FAILURE CODE [DA2LKB] (MACHINE WITH KOMTRAX TERMINAL)...280
FAILURE CODE [DA2LKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...282
FAILURE CODE [DA2QKR] (MACHINE WITH KOMTRAX TERMINAL)...284
FAILURE CODE [DA2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...289
FAILURE CODE [DA2RKR] (MACHINE WITH KOMTRAX TERMINAL)...295
FAILURE CODE [DA2RKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...300
FAILURE CODE [DAF0MB]...306
FAILURE CODE [DAF0MC]...307
FAILURE CODE [DAF8KB]...308
FAILURE CODE [DAF9KQ]...310
FAILURE CODE [DAFGMC] (MACHINE WITH KOMTRAX TERMINAL)...311
FAILURE CODE [DAFGMC] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...312
FAILURE CODE [DAFLKA] (MACHINE WITH KOMTRAX TERMINAL)...313
FAILURE CODE [DAFLKA] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...315
FAILURE CODE [DAFLKB] (MACHINE WITH KOMTRAX TERMINAL)...318
FAILURE CODE [DAFLKB] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...320
FAILURE CODE [DAFQKR] (MACHINE WITH KOMTRAX TERMINAL)...322
FAILURE CODE [DAFQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...326
FAILURE CODE [DAZ9KQ]...331
FAILURE CODE [DAZQKR] (MACHINE WITH KOMTRAX TERMINAL)...332
FAILURE CODE [DAZQKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...335
FAILURE CODE [DB2QKR] (MACHINE WITH KOMTRAX TERMINAL)...341
FAILURE CODE [DB2QKR] (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...346
FAILURE CODE [DGH2KA]...352
FAILURE CODE [DGH2KB]...354
FAILURE CODE [DHA4KA]...356
FAILURE CODE [DHE5MA]...358
FAILURE CODE [DHPAMA]...362
FAILURE CODE [DHS3MA]...364
FAILURE CODE [DHS4MA]...366
FAILURE CODE [DHS8MA]...368
FAILURE CODE [DHS9MA]...370
FAILURE CODE [DHSAMA]...372
FAILURE CODE [DHSBMA]...374
FAILURE CODE [DHSCMA]...376
FAILURE CODE [DHSDMA]...378
FAILURE CODE [DHSFMA]...380
FAILURE CODE [DHSGMA]...382
FAILURE CODE [DHSHMA]...384
FAILURE CODE [DHSJMA]...386
FAILURE CODE [DHSKMA]...388
FAILURE CODE [DHSLMA]...390
FAILURE CODE [DJG1KX]...392
FAILURE CODE [DKR2MA]...396
FAILURE CODE [DKR2NX]...400
FAILURE CODE [DV20KB]...403
FAILURE CODE [DW43KA]...405
FAILURE CODE [DW43KB]...407
FAILURE CODE [DW43KY]...409
FAILURE CODE [DW45KA]...410
FAILURE CODE [DW45KB]...413
FAILURE CODE [DW45KY]...416
FAILURE CODE [DW91KA]...418
FAILURE CODE [DW91KB]...420
FAILURE CODE [DW91KY]...422
FAILURE CODE [DWA2KA]...424
FAILURE CODE [DWA2KB]...426
FAILURE CODE [DWA2KY]...428
FAILURE CODE [DWJ0KA]...430
FAILURE CODE [DWJ0KB]...432
FAILURE CODE [DWJ0KY]...434
FAILURE CODE [DWK0KA]...436
FAILURE CODE [DWK0KB]...438
FAILURE CODE [DWK0KY]...440
FAILURE CODE [DWK2KA]...442
FAILURE CODE [DWK2KB]...444
FAILURE CODE [DWK2KY]...446
FAILURE CODE [DWNSKA]...448
FAILURE CODE [DWNSKB]...450
FAILURE CODE [DWNSKY]...452
FAILURE CODE [DXA8KA]...453
FAILURE CODE [DXA8KB]...455
FAILURE CODE [DXE4KA]...457
FAILURE CODE [DXE4KB]...459
FAILURE CODE [DXE4KY]...461
FAILURE CODE [DY20KA]...463
FAILURE CODE [DY20MA]...465
FAILURE CODE [DY2CKB]...467
FAILURE CODE [DY2DKB]...469
FAILURE CODE [DY2EKB]...471
FAILURE CODE [F@BBZL]...473
FAILURE CODE [F313KA]...476
FAILURE CODE [F313KB]...478
FAILURE CODE [F318KB]...479
FAILURE CODE [F318KY]...481
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...482
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...482
MANUAL PREHEATING SYSTEM DOES NOT WORK...493
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP...497
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR SHOWS NOTHING...500
WHILE ENGINE IS IN OPERATION, ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE...505
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS IN OPERATION...506
AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS IN OPERATION...507
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...508
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...509
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...510
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...511
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION...512
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM...513
FUEL GAUGE DOES NOT SHOW CORRECT FUEL LEVEL...515
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM...516
COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE...517
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM...518
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE...520
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT SHOWN...521
FUNCTION SWITCH DOES NOT OPERATE...522
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER)...523
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED...524
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION...525
WORK MODE SELECTOR SCREEN IS NOT SHOWN WHILE WORK MODE SWITCH IS OPERATED...526
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED...527
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED...528
TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU OPERATE THE OPERATION TO CHANGE TRAVEL SPEED...529
ALARM BUZZER CANNOT BE STOPPED...530
SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION...531
MACHINE DOES NOT CHANGE TO SERVICE MODE...532
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE...533
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK...537
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED...539
WHILE SWING PARKING BRAKE RELEASE SWITCH IS TURNED ON, SWING BRAKE IS NOT OPERATED...541
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY...543
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED...547
TRAVEL ALARM DOES NOT OPERATE DURING TRAVEL...549
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS...551
HORN DOES NOT MAKE SOUND...552
HORN DOES NOT STOP...554
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED...555
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED...556
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED...558
“BOOM RAISE” IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...559
"BOOM LOWER" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...560
"ARM DUMP" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...561
"ARM IN" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...562
"BUCKET DUMP" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...563
"BUCKET CURL" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...564
"SWING" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...565
"TRAVEL" IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...566
SERVICE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...567
BLADE RAISE IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...570
BLADE LOWER IS NOT SHOWN CORRECTLY WITH MONITORING FUNCTION...571
KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY...572
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...573
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...573
FAILURE MODE AND CAUSE TABLE...574
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK...584
All WORK EQUIPMENT, SWING, AND TRAVEL SPEED IS LOW OR POWER IS LOW...585
FINE CONTROL PERFORMANCE OR RESPONSE IS UNSATISFACTORY...587
THERE IS UNUSUAL NOISE FROM AROUND HYDRAULIC PUMP...588
ENGINE SPEED FALLS LARGELY OR ENGINE STOPS...589
BOOM SPEED OR POWER IS LOW...591
ARM SPEED IS LOW OR POWER IS LOW...594
BUCKET SPEED OR POWER IS LOW...597
BLADE SPEED OR POWER IS LOW...600
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION...602
HYDRAULIC DRIFT OF BOOM IS LARGE...603
HYDRAULIC DRIFT OF ARM IS LARGE...604
HYDRAULIC DRIFT OF BUCKET IS LARGE...605
HYDRAULIC DRIFT OF BLADE IS LARGE...606
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...608
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE...609
TIME LAG OF WORK EQUIPMENT IS LARGE...611
ATTACHMENT CIRCUIT CANNOT BE CHANGED...612
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...613
IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER...614
IN COMBINATION OPERATION OF SWING AND TRAVEL, TRAVEL SPEED FALLS LARGELY...615
IN COMBINATION OPERATION OF SWING AND BOOM RAISE, BOOM RAISE SPEED IS LOW...616
MACHINE DOES NOT TRAVEL STRAIGHT...617
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW...620
TRAVEL SPEED IS SLOW...623
ONE OF TRACKS DOES NOT RUN...625
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST...627
MACHINE DOES NOT SWING TO RIGHT OR LEFT...628
SWINGS ONLY IN ONE DIRECTION...629
SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT...630
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION...631
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT)...632
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION)...633
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION...634
THERE IS A LARGE UNUSUAL NOISE WHEN UPPER STRUCTURE STOPS SWING OPERATION...635
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)...636
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)...637
50 DISASSEMBLY AND ASSEMBLY...1
CONTENTS...2
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...6
HOW TO READ THIS MANUAL...6
COATING MATERIALS LIST...8
SPECIAL TOOLS LIST...12
SKETCHES OF SPECIAL TOOLS...26
PREPARATION...28
DRAIN AND ADD COOLANT...28
DRAIN COOLANT...28
ADD COOLANT...29
DRAIN AND ADD HYDRAULIC OIL...31
DRAIN HYDRAULIC OIL...31
ADD HYDRAULIC OIL...33
DRAIN AND ADD FUEL...34
DRAIN FUEL...34
ADD FUEL...35
COLLECT AND REFILL REFRIGERANT...36
COLLECT REFRIGERANT...36
REFILL REFRIGERANT...37
ENGINE AND COOLING SYSTEM...38
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...38
REMOVE SUPPLY PUMP ASSEMBLY...39
INSTALL SUPPLY PUMP ASSEMBLY...42
REMOVE AND INSTALL INJECTOR ASSEMBLY...48
REMOVE INJECTOR ASSEMBLY...49
INSTALL INJECTOR ASSEMBLY...52
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...56
REMOVE CYLINDER HEAD ASSEMBLY...57
INSTALL CYLINDER HEAD ASSEMBLY...67
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY...80
REMOVE STARTING MOTOR ASSEMBLY...80
INSTALL STARTING MOTOR ASSEMBLY...82
REMOVE AND INSTALL FAN BELT...83
REMOVE FAN BELT...84
INSTALL FAN BELT...85
REMOVE AND INSTALL RADIATOR ASSEMBLY...87
REMOVE RADIATOR ASSEMBLY...88
INSTALL RADIATOR ASSEMBLY...91
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...95
REMOVE HYDRAULIC OIL COOLER ASSEMBLY...96
INSTALL HYDRAULIC OIL COOLER ASSEMBLY...100
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...105
REMOVE AFTERCOOLER ASSEMBLY...106
INSTALL AFTERCOOLER ASSEMBLY...109
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY...113
REMOVE ENGINE AND MAIN PUMP ASSEMBLY...115
INSTALL ENGINE AND MAIN PUMP ASSEMBLY...133
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...154
REMOVE ENGINE FRONT OIL SEAL...155
INSTALL ENGINE FRONT OIL SEAL...156
REMOVE AND INSTALL ENGINE REAR OIL SEAL...158
REMOVE ENGINE REAR OIL SEAL...159
INSTALL ENGINE REAR OIL SEAL...160
REMOVE AND INSTALL FUEL COOLER ASSEMBLY...163
REMOVE FUEL COOLER ASSEMBLY...164
INSTALL FUEL COOLER ASSEMBLY...165
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...166
REMOVE ENGINE HOOD ASSEMBLY...166
INSTALL ENGINE HOOD ASSEMBLY...167
REMOVE AND INSTALL FUEL TANK ASSEMBLY...169
REMOVE FUEL TANK ASSEMBLY...170
INSTALL FUEL TANK ASSEMBLY...173
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...177
REMOVE AIR CLEANER ASSEMBLY...178
INSTALL AIR CLEANER ASSEMBLY...180
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...183
REMOVE AIR CONDITIONER COMPRESSOR ASSEMBLY...184
INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...185
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...188
REMOVE AIR CONDITIONER CONDENSER ASSEMBLY...188
INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...190
POWER TRAIN...192
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...192
REMOVE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...193
INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...195
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...197
DISASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...209
ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...227
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY...248
REMOVE SWING MOTOR AND SWING MACHINERY ASSEMBLY...249
INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY...252
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...254
DISASSEMBLE SWING MACHINERY ASSEMBLY...255
ASSEMBLE SWING MACHINERY ASSEMBLY...258
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY...264
REMOVE SWING CIRCLE ASSEMBLY...264
INSTALL SWING CIRCLE ASSEMBLY...265
UNDERCARRIAGE AND FRAME...266
SEPARATE AND INSTALL TRACK ASSEMBLY...266
SEPARATE TRACK ASSEMBLY...267
INSTALL TRACK ASSEMBLY...269
REMOVE AND INSTALL SPROCKET...272
REMOVE SPROCKET...272
INSTALL SPROCKET...273
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...274
REMOVE IDLER AND IDLER CUSHION ASSEMBLY...274
INSTALL IDLER AND IDLER CUSHION ASSEMBLY...275
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY...276
DISASSEMBLE IDLER CUSHION ASSEMBLY...276
ASSEMBLE IDLER ASSEMBLY...277
DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY...280
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY...280
ASSEMBLE IDLER CUSHION ASSEMBLY...282
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY...284
DISASSEMBLE TRACK ROLLER ASSEMBLY...284
ASSEMBLE TRACK ROLLER ASSEMBLY...285
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY...287
REMOVE REVOLVING FRAME ASSEMBLY...288
INSTALL REVOLVING FRAME ASSEMBLY...293
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...298
REMOVE COUNTERWEIGHT ASSEMBLY...299
INSTALL COUNTERWEIGHT ASSEMBLY...300
HYDRAULIC SYSTEM...303
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY...303
REMOVE CENTER SWIVEL JOINT ASSEMBLY...304
INSTALL CENTER SWIVEL JOINT ASSEMBLY...308
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...313
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...314
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...315
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...316
REMOVE HYDRAULIC TANK ASSEMBLY...317
INSTALL HYDRAULIC TANK ASSEMBLY...326
REMOVE AND INSTALL MAIN PUMP ASSEMBLY...336
REMOVE MAIN PUMP ASSEMBLY...337
INSTALL MAIN PUMP ASSEMBLY...343
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...350
REMOVE CONTROL VALVE ASSEMBLY...352
INSTALL CONTROL VALVE ASSEMBLY...366
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY...380
ASSEMBLE CONTROL VALVE ASSEMBLY...380
REPLACE PRESSURE REDUCING VALVE CARTRIDGE ASSEMBLY...382
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...385
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY...385
ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...385
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY...387
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY...387
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY...388
WORK EQUIPMENT...390
REMOVE AND INSTALL BLADE ASSEMBLY...390
REMOVE BLADE ASSEMBLY...391
INSTALL BLADE ASSEMBLY...392
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...394
REMOVE WORK EQUIPMENT ASSEMBLY...396
INSTALL WORK EQUIPMENT ASSEMBLY...399
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY...403
DISASSEMBLE BUCKET CYLINDER ASSEMBLY...404
ASSEMBLE BUCKET CYLINDER ASSEMBLY...406
DISASSEMBLE AND ASSEMBLE BOOM CYLINDER ASSEMBLY...410
DISASSEMBLE BOOM CYLINDER ASSEMBLY...411
ASSEMBLE BOOM CYLINDER ASSEMBLY...413
DISASSEMBLE AND ASSEMBLE ARM CYLINDER ASSEMBLY...417
DISASSEMBLE ARM CYLINDER ASSEMBLY...418
ASSEMBLE ARM CYLINDER ASSEMBLY...420
DISASSEMBLE AND ASSEMBLE BLADE CYLINDER ASSEMBLY...425
DISASSEMBLE BLADE CYLINDER ASSEMBLY...426
ASSEMBLE BLADE CYLINDER ASSEMBLY...428
DISASSEMBLE AND ASSEMBLE OIL PASSAGE INTEGRATED CYLINDER ASSEMBLY...433
DISASSEMBLE OIL PASSAGE INTEGRATED CYLINDER ASSEMBLY...434
ASSEMBLE OIL PASSAGE INTEGRATED CYLINDER ASSEMBLY...435
CAB RELATED PARTS...441
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL)...441
REMOVE OPERATOR CAB ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL)...442
INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL)...451
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...462
REMOVE OPERATOR CAB ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...462
INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...473
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...484
REMOVE OPERATOR CAB GLASS (ADHERED GLASS)...486
INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...486
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY...497
REMOVE FRONT WINDOW ASSEMBLY...497
INSTALL FRONT WINDOW ASSEMBLY...500
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY...506
REMOVE FLOOR FRAME ASSEMBLY...507
INSTALL FLOOR FRAME ASSEMBLY...513
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL)...520
REMOVE AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL)...521
INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL)...529
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...537
REMOVE AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...538
INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER)...546
REMOVE AND INSTALL OPERATOR SEAT...554
REMOVE OPERATOR'S SEAT...554
INSTALL OPERATOR'S SEAT...555
REMOVE AND INSTALL SEATBELT...556
REMOVE SEATBELT...556
INSTALL SEATBELT...557
REMOVE AND INSTALL FRONT WIPER ASSEMBLY...558
REMOVE FRONT WIPER ASSEMBLY...558
INSTALL FRONT WIPER ASSEMBLY...564
ELECTRICAL SYSTEM...572
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...572
REMOVE ENGINE CONTROLLER ASSEMBLY...573
INSTALL ENGINE CONTROLLER ASSEMBLY...576
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY...581
REMOVE PUMP CONTROLLER ASSEMBLY...581
INSTALL PUMP CONTROLLER ASSEMBLY...583
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...587
REMOVE MACHINE MONITOR ASSEMBLY...587
INSTALL MACHINE MONITOR ASSEMBLY...590
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...594
REMOVE KOMTRAX TERMINAL ASSEMBLY...594
INSTALL KOMTRAX TERMINAL ASSEMBLY...597
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY...600
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY...600
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY...604
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS...608
REMOVE COMMUNICATION TERMINAL WIRING HARNESS...608
INSTALL COMMUNICATION TERMINAL WIRING HARNESS...615
REMOVE AND INSTALL COMMUNICATION TERMINAL...624
REMOVE COMMUNICATION TERMINAL...624
INSTALL COMMUNICATION TERMINAL...626
60 MAINTENANCE STANDARD...1
CONTENTS...2
ENGINE AND COOLING SYSTEM...3
MAINTENANCE STANDARD OF ENGINE MOUNT...3
MAINTENANCE STANDARD OF PTO...4
MAINTENANCE STANDARD OF COOLING SYSTEM...5
POWER TRAIN...6
MAINTENANCE STANDARD OF SWING CIRCLE...6
MAINTENANCE STANDARD OF SWING MACHINERY...7
MAINTENANCE STANDARD OF SPROCKET...9
UNDERCARRIAGE AND FRAME...10
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...10
MAINTENANCE STANDARD OF IDLER...12
MAINTENANCE STANDARD OF TRACK ROLLER...13
MAINTENANCE STANDARD OF CARRIER ROLLER...14
MAINTENANCE STANDARD OF TRACK SHOE...15
MAINTENANCE STANDARD OF TRIPLE SHOE...18
HYDRAULIC SYSTEM...19
MAINTENANCE STANDARD OF HYDRAULIC TANK...19
MAINTENANCE STANDARD OF MAIN PUMP...20
MAINTENANCE STANDARD OF PC-EPC VALVE...24
MAINTENANCE STANDARD OF SWING MOTOR...25
MAINTENANCE STANDARD OF TRAVEL MOTOR...28
MAINTENANCE STANDARD OF CONTROL VALVE...29
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE...40
MAINTENANCE STANDARD OF BLADE PPC VALVE...43
MAINTENANCE STANDARD OF TRAVEL PPC VALVE...45
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...48
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE...50
MAINTENANCE STANDARD OF SOLENOID VALVE...51
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE...55
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)...56
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT)...57
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT...58
WORK EQUIPMENT...60
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...60
DIMENSIONS OF ARM...66
DIMENSIONS OF BUCKET...68
MAINTENANCE STANDARD OF BOOM CYLINDER...70
MAINTENANCE STANDARD OF ARM CYLINDER...71
MAINTENANCE STANDARD OF BUCKET CYLINDER...72
MAINTENANCE STANDARD OF BLADE CYLINDER...73
CAB AND ITS ATTACHMENTS...74
MAINTENANCE STANDARD OF CAB MOUNT...74
80 OTHERS...1
CONTENTS...2
AIR CONDITIONER SYSTEM...4
PRECAUTIONS FOR REFRIGERANT...4
AIR CONDITIONER...5
SPECIFICATIONS OF AIR CONDITIONER...7
CONFIGURATION OF REFRIGERATION CYCLE...8
FUNCTION OF REFRIGERATION CYCLE...9
SYSTEM DIAGRAM OF AIR CONDITIONER...10
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...11
AIR CONDITIONER UNIT...11
STRUCTURE OF AIR CONDITIONER UNIT...12
FUNCTION OF AIR CONDITIONER UNIT...13
COMPONENT PARTS OF AIR CONDITIONER UNIT...14
AIR CONDITIONER CONTROLLER...18
STRUCTURE OF AIR CONDITIONER CONTROLLER...18
FUNCTION OF AIR CONDITIONER CONTROLLER...18
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...18
COMPRESSOR...20
STRUCTURE OF COMPRESSOR...20
SPECIFICATIONS OF COMPRESSOR...20
FUNCTION OF COMPRESSOR...20
OPERATION OF COMPRESSOR...20
CONDENSER...21
STRUCTURE OF CONDENSER...21
SPECIFICATIONS OF CONDENSOR...21
FUNCTION OF COMPRESSOR...21
AIR CONDITIONER RELATED SENSORS...23
STRUCTURE OF SUNLIGHT SENSOR...23
FUNCTION OF SUNLIGHT SENSOR...23
STRUCTURE OF OUTSIDE TEMPERATURE SENSOR...23
FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR...23
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER...24
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...26
TEST AIR LEAKAGE (DUCT CONNECTION)...30
TEST AIR LEAKAGE (DUCT CONNECTION)...30
TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION...33
TEST VENT (MODE) CHANGEOVER...34
TEST VENT (MODE) CHANGEOVER...34
TEST FRESH/RECIRC AIR CHANGEOVER...36
TEST FRESH/RECIRC AIR CHANGEOVER...36
TEST SUNLIGHT SENSOR...37
TEST SUNLIGHT SENSOR...37
TEST DUAL PRESSURE SWITCH...38
TEST DUAL PRESSURE SWITCH...38
TEST RELAY...39
TEST RELAY...39
SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS...41
PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER...42
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...43
FAILURE CODE [879AKA]...46
FAILURE CODE [879AKB]...47
FAILURE CODE [879BKA]...48
FAILURE CODE [879BKB]...50
FAILURE CODE [879CKA]...52
FAILURE CODE [879CKB]...53
FAILURE CODE [879DKZ]...54
FAILURE CODE [879EMC]...56
FAILURE CODE [879FMC]...57
FAILURE CODE [879GKX]...58
TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...60
TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...63
TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...66
TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...68
CONNECT SERVICE TOOL...71
CONNECT SERVICE TOOL...72
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING...73
HANDLE COMPRESSOR OIL...75
REPLACE DESICCANT...77
90 CIRCUIT DIAGRAMS...1
CONTENTS...2
HOW TO READ THE CODES FOR ELECTRIC CABLE...3
HYDRAULIC CIRCUIT DIAGRAM...7
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...7
HYDRAULIC CIRCUIT DIAGRAM (1/3)...11
HYDRAULIC CIRCUIT DIAGRAM (2/3)...13
HYDRAULIC CIRCUIT DIAGRAM (3/3)...15
ELECTRICAL CIRCUIT DIAGRAM...17
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...17
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (1/6)...21
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (2/6)...23
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (3/6)...25
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (4/6)...27
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (5/6)...29
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITHOUT FUEL REFILL PUMP) (6/6)...31
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (1/6)...33
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (2/6)...35
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (3/6)...37
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (4/6)...39
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (5/6)...41
ELECTRICAL CIRCUIT DIAGRAM (MACHINES WITH FUEL REFILL PUMP) (6/6)...43
INDEX...1
Komatsu Hydraulic Excavator PC130-10M0 Repair Service Manual
