Day: June 9, 2025

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC150, PC150LC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC150-3, PC150LC-3, PC150-5, PC150LC-5 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.

SEBM021K0304 – Hydraulic Excavator PC150-3, PC150LC-3 Shop Manual.pdf
SEBM021K0502 – Hydraulic Excavator PC150-5 Shop Manual.pdf
SEBMA021KD500 – Hydraulic Excavator PC150LC-5 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,575 pages
File Format: PDF
Language: English

SEBM021K0304 – Hydraulic Excavator PC150-3, PC150LC-3 Shop Manual…2
SEBM021K0502 – Hydraulic Excavator PC150-5 Shop Manual…561
COVER…561
CONTENTS…562
10 STRUCTURE AND FUNCTION…577
POWER TRAIN…578
FINAL DRIVE…579
SWING CIRCLE…580
SWING MACHINERY…581
TRACK FRAME…582
IDLER…583
IDLER CUSHION…583
CARRIER ROLLER…584
TRACK ROLLER…584
TRACK SHOE…585
HYDRAULIC PIPING…587
HYDRAULIC CIRCUIT DIAGRAM…588
HYDRAULIC TANK…589
OLSS (OPEN CENTER LOAD SENSING SYSTEM)…590
HYDRAULIC PUMP…592
L.H. 6-SPOOL CONTROL VALVE…611
R.H. 5-SPOOL CONTROL VALVE…614
SWING MOTOR…617
CENTER SWIVEL JOINT…620
TRAVEL MOTOR…621
VALVE CONTROL…628
PPC VALVE…629
ACCUMULATOR…633
SAFETY LOCK VALVE…633
SOLENOID VALVE…634
SHUTTLE VALVE…638
BOOM HOLDING VALVE…639
HYDRAULIC CYLINDER…642
ELECTRICAL WIRING DIAGRAM…644
ELECTRICAL CIRCUIT DIAGRAM…646
ENGINE CONTROL SYSTEM…648
PEMC SYSTEM…659
EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)…686
20 TESTING AND ADJUSTING…693
TABLE OF JUDGEMENT STANDARD VALUE…694
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…706
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…717
ADJUSTING VALVE CLEARANCE…718
MEASURING COMPRESSION PRESSURE…719
TESTING AND ADJUSTING FUEL INJECTION TIMING…720
ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER…721
ADJUSTING ENGINE SPEED SENSOR…722
ADJUSTING TRAVEL LIMIT SWITCH…722
INSPECTION OF SWING CIRCLE BEARING CLEARANCE…723
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…724
TESTING AND ADJUSTING CHARGING PUMP PRESSURE…726
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE…728
MEASURING STROKE OF SERVO PISTON…735
TESTING AND ADJUSTING TRAVEL DEVIATION…736
MEASURING OUTPUT PRESSURE OF PPC VALVE…738
ADJUSTING PPC VALVE…739
TESTING PPC SHUTTLE VALVE…740
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE…741
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…742
BLEEDING AIR…744
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…746
TROUBLESHOOTING…747
POINTS TO REMEMBER WHEN TROUBLESHOOTING…748
SEQUENCE OF EVENTS IN TROUBLESHOOTING…749
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…750
CHECKS BEFORE TROUBLESHOOTING…757
ELECTRICAL CIRCUIT DIAGRAM…758
POSITION OF CONNECTORS FOR TROUBLESHOOTING…761
CONNECTION TABLE FOR CONNECTOR…763
HANDLING CONNECTORS…771
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM…772
DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER…775
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE…779
METHOD OF USING JUDGEMENT TABLE…782
METHOD OF USING TROUBLESHOOTING CHARTS…784
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)…786
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS…787
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM…788
E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)…789
E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED…791
E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED…792
E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED…793
E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED…794
E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED…796
E-7 [ABNORMALITY IN NO.2 THROTTLE SIGNAL] IS DISPLAYED…797
E-8 ENGINE DOES NOT START…799
E-9 ENGINE ROTATION IS IRREGULAR…801
a) IDLING ROTATION IS IRREGULAR…801
b) THERE IS HUNTING…803
E-10 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW)…805
E-11 ENGINE DOES NOT STOP…807
E-12 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE…809
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)…810
CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS…811
C-1 [OFF] SELF-DIAGNOSTIC DISPLAY OF CONTROLLER DOES NOT LIGHT UP…812
C-2 [01] [SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED…813
C-3 [03] [SHORT CIRCUIT IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED…814
C-4 [04] [SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED…815
C-5 [05] [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED…816
C-6 [07] [SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED…817
C-7 [08] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (1) ] IS DISPLAYED…818
C-8 [09] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (2) ] IS DISPLAYED…819
C-9 [11] [DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED…820
C-10 [13] [DISCONNECTION IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED…821
C-11 [14] [DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED…822
C-12 [15] [DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED…823
C-13 [17] [DISCONNECTION IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED…824
C-14 [18] [DISCONNECTION IN TVC SOLENOID SYSTEM] IS DISPLAYED…825
C-15 [21] [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM] IS DISPLAYED…826
C-16 [22] [ABNORMALITY IN THROTTLE SIGNAL SYSTEM] IS DISPLAYED…827
C-17 [23] [ABNORMALITY IN PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED…828
C-18 [25] [ABNORMALITY IN PUMP PRESSURE SENSOR POWER SOURCE SYSTEM] IS DISPLAYED…830
C-19 [26] [ABNORMALITY DISCONNECTION IN WIRING IN ENGINE SPEED SENSOR SYSTEM] IS DISPLAYED…831
C-20 [28] [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT SYSTEM] IS DISPLAYED…832
C-21 [29] [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM] IS DISPLAYED…833
C-22 [88] [CONTROLLER ABNORMAL SYSTEM] IS DISPLAYED…834
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)…835
F-1 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P1] [WORK EQUIPMENT OIL PRESSURE SWITCH]…836
F-2 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P2] [SWING OIL PRESSURE SWITCH]…837
F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P6] [TRAVEL LIMIT SWITCH]…838
F-4 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [b5] [SWING LOCK SWITCH]…839
F-5 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Hi] OR [Lo] [TRAVEL SPEED SWITCH]…840
F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Ad] [AUTO-DECELERATION SWITCH]…841
F-7 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [88] [DECIMAL POINT OF ENGINE SPEED SENSOR]…842
F-8 PUMP CONTROLLER WORKING MODE DISPLAY DOES NOT SWITCH…843
F-9 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH…844
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…845
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW…846
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…848
H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW…850
H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER…852
H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH…852
H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)…853
H-7 AUTO-DECELERATION DOES NOT ACTUATED…853
H-8 BOOM, ARM SPEED IS EXTREMELY SLOW…854
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW…855
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER…857
H-11 EXCESSIVE HYDRAULIC DRIFT…857
H-12 EXCESSIVE TIME LAG…859
H-13 DOES NOT ENTER FINISHING OPERATION (F.O) MODE…859
H-14 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE…860
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE…860
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE…862
H-15 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS…863
H-16 EXCESSIVE DEVIATION WHEN STARTING…864
H-17 TRAVEL LACKS POWER (OR SPEED IS SLOW)…866
H-18 TRAVEL SPEED DOES NOT SWITCH…866
H-19 MACHINE DOES NOT MOVE (ONE SIDE ONLY)…867
H-20 TRAVEL LEVER IS HEAVY…867
H-21 DOES NOT SWING…868
H-22 SWING SPEED IS SLOW OR ACCELERATION IS POOR…870
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…871
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING…871
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…872
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…872
H-27 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW…872
TABLE OF FAILURE MODES AND CAUSES…873
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)…874
P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON…875
a) NO MONITOR PANEL LAMPS LIGHT UP…875
b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP…875
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT…876
P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS SPECIFIED)…877
a) COOLANT LEVEL FLASHES…877
b) ENGINE OIL LEVEL FLASHES…878
P-4 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY LIGHTS UP…879
P-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH…880
a) ALTERNATOR SYSTEM…880
b) ENGINE OIL PRESSURE SYSTEM…880
P-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH…881
P-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE)…882
a) ENGINE OIL PRESSURE FLASHES…882
b) COOLANT LEVEL FLASHES…882
c) COOLANT TEMPERATURE FLASHES…883
d) CHARGE FLASHES…883
e) FUEL LEVEL FLASHES…884
P-8…885
(a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND…885
(b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS…885
P-9 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…886
P-10 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE…887
P-11 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING OPERATION,ON LEVEL OF GAUGE IS DISPLAYED)…887
P-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…888
P-13 FUEL GAUGE GIVES NO DISPLAY…888
P-14…889
(a) LAMPS DO NOT LIGHT UP…889
(b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NO OPERATED…889
P-15 …891
(a) WIPERS DO NOT WORK…891
(b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED…891
P-16…893
(a) FAN DOES NOT WORK…893
(b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED…893
P-17 WORKING MODE DOES NOT SWITCH…895
P-18 POWER SET DOES NOT SWITCH…896
P-19 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION; AUTO-DECELERATION IS NOT CANCELED)…897
P-20 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO…898
P-21 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 30℃, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30℃…899
P-22 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP…900
P-23 FUEL LEVEL SENSOR SYSTEM DEFECTIVE…901
P-24 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE…902
P-25 ENGINE OIL LEVEL SENSOR SYSTEM DEFECTIVE…903
P-26 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE…904
30 DISASSEMBLY AND ASSEMBLY…905
METHOD OF USING MANUAL…907
PRECAUTIONS WHEN CARRYING OUT OPERATION…908
SPECIAL TOOL LIST…910
WEIGHT TABLE…913
TIGHTENING TORQUES AND STANDARD VALUES TABLE…914
LUBRICANT AND COOLANT TABLE…920
STARTING MOTOR…921
REMOVAL…921
INSTALLATION…921
ALTERNATOR…921
REMOVAL…921
INSTALLATION…921
ENGINE OIL COOLER…923
REMOVAL…923
INSTALLATION…923
FUEL INJECTION PUMP…923
REMOVAL…923
INSTALLATION…923
WATER PUMP…925
REMOVAL…925
INSTALLATION…925
NOZZLE HOLDER…925
REMOVAL…925
INSTALLATION…925
TURBOCHARGER…927
REMOVAL…927
INSTALLATION…927
THERMOSTAT…927
REMOVAL…927
INSTALLATION…927
ENGINE FRONT SEAL…929
REMOVAL…929
INSTALLATION…929
ENGINE REAR SEAL…929
REMOVAL…929
INSTALLATION…929
GOVERNOR MOTOR…931
REMOVAL…931
INSTALLATION…931
CYLINDER HEAD…933
REMOVAL…933
INSTALLATION…933
HYDRAULIC COOLER…935
REMOVAL…935
INSTALLATION…935
RADIATOR, HYDRAULIC COOLER…935
REMOVAL…935
INSTALLATION…935
ENGINE, HYDRAULIC PUMP…937
REMOVAL…937
INSTALLATION…937
PTO…939
REMOVAL…939
INSTALLATION…939
DISASSEMBLY…939
ASSEMBLY…939
CENTER SWIVEL JOINT…941
REMOVAL…941
INSTALLATION…941
DISASSEMBLY…941
ASSEMBLY…941
FINAL DRIVE…943
REMOVAL…943
INSTALLATION…943
DISASSEMBLY…945
ASSEMBLY…947
TRAVEL MOTOR (HMV110ADT)…953
DISASSEMBLY…953
ASSEMBLY…958
SPROCKET…968
REMOVAL…968
INSTALLATION…968
SWING MOTOR…970
REMOVAL…970
INSTALLATION…970
SWING MACHINERY…970
REMOVAL…970
INSTALLATION…970
SWING MOTOR (KMF90-2 (AB))…972
DISASSEMBLY…972
ASSEMBLY…975
SWING MACHINERY…980
DISASSEMBLY…980
ASSEMBLY…982
REVOLVING FRAME…986
REMOVAL…986
INSTALLATION…986
SWING CIRCLE…986
REMOVAL…986
INSTALLATION…986
IDLER, RECOIL SPRING…988
REMOVAL…988
INSTALLATION…988
RECOIL SPRING…990
DISASSEMBLY…990
ASSEMBLY…990
TRACK ROLLER…992
REMOVAL…992
INSTALLATION…992
CARRIER ROLLER…992
REMOVAL…992
INSTALLATION…992
TRACK SHOE…994
REMOVAL…994
INSTALLATION…994
CHARGING PUMP…994
REMOVAL…994
INSTALLATION…994
MAIN PUMP INPUT SHAFT…996
REMOVAL…996
INSTALLATION…996
HYDRAULIC PUMP…996
REMOVAL…996
INSTALLATION…996
DISASSEMBLY…998
ASSEMBLY…1003
CONTROL VALVE…1015
REMOVAL…1015
INSTALLATION…1015
DISASSEMBLY…1017
ASSEMBLY…1017
MAIN RELIEF VALVE…1019
REMOVAL…1019
INSTALLATION…1019
DISASSEMBLY…1019
ASSEMBLY…1019
TVC VALVE…1021
REMOVAL…1021
INSTALLATION…1021
CO,NC VALVE…1021
REMOVAL…1021
INSTALLATION…1021
SERVO VALVE…1021
REMOVAL…1021
INSTALLATION…1021
WORK EQUIPMENT PPC VALVE…1023
REMOVAL…1023
INSTALLATION…1023
DISASSEMBLY…1023
ASSEMBLY…1023
PPC SHUTTLE VALVE…1025
REMOVAL…1025
INSTALLATION…1025
BOOM HOLDING VALVE…1027
REMOVAL…1027
INSTALLATION…1027
DISASSEMBLY…1027
ASSEMBLY…1027
BOOM CYLINDER…1029
REMOVAL…1029
INSTALLATION…1029
ARM CYLINDER…1031
REMOVAL…1031
INSTALLATION…1031
BUCKET CYLINDER…1033
REMOVAL…1033
INSTALLATION…1033
HYDRAULIC CYLINDER…1035
DISASSEMBLY…1035
ASSEMBLY…1037
WORK EQUIPMENT…1039
REMOVAL…1039
INSTALLATION…1039
BUCKET…1041
REMOVAL…1041
INSTALLATION…1041
ARM…1041
REMOVAL…1041
INSTALLATION…1041
ARM, BUCKET…1043
REMOVAL…1043
INSTALLATION…1043
BOOM…1045
REMOVAL…1045
INSTALLATION…1045
OPERATOR'S CAB…1047
REMOVAL…1047
INSTALLATION…1047
COUNTERWEIGHT…1047
REMOVAL…1047
INSTALLATION…1047
ENGINE THROTTLE CONTROLLER…1049
REMOVAL…1049
INSTALLATION…1049
PUMP CONTROLLER…1049
REMOVAL…1049
INSTALLATION…1049
MONITOR PANEL…1051
REMOVAL…1051
INSTALLATION…1051
40 MAINTENANCE STANDARD…1053
FINAL DRIVE…1054
SWING CIRCLE…1056
SWING MACHINERY…1057
TRACK FRAME…1058
IDLER…1059
TRACK ROLLER…1061
CARRIER ROLLER…1062
TRACK SHOE…1063
HYDRAULIC PUMP…1065
CHARGING PUMP AND RELIEF VALVE…1066
L.H. 6-SPOOL CONTROL VALVE…1067
R.H. 5-SPOOL CONTROL VALVE…1070
SWING MOTOR…1073
CENTER SWIVEL JOINT…1074
TRAVEL MOTOR…1075
PPC VALVE…1076
BOOM HOLDING VALVE…1077
HYDRAULIC CYLINDER…1078
WORK EQUIPMENT…1079
SEBMA021KD500 – Hydraulic Excavator PC150LC-5 Shop Manual…1081

Komatsu Hydraulic Excavator PC150, PC150LC Repair Service Manuals

---

INSTANT DOWNLOAD

---

---

INSTANT DOWNLOAD

---

Complete service repair manual with Electrical Wiring Diagrams for Komatsu PC150-6K, PC150LC-6K Hydraulic Excavator, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu PC150-6K, PC150LC-6K Hydraulic Excavator 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.

CEBM001601 – Hydraulic Excavator PC150-6K, PC150LC-6K Shop Manual.pdf
UEBD000701 – Hydraulic Excavator PC150-6K, PC150LC-6K Shop Manual.pdf
EEAM008801 – Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual.pdf
UEAD000401 – Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual.pdf
UEAM000403 – Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual.pdf

Total Pages: 2,095 pages
File Format: PDF
Language: English

CEBM001601 – Hydraulic Excavator PC150-6K, PC150LC-6K Shop Manual…2
EEAM008801 – Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual…619
COVER PAGE…619
1. FOREWORD…620
2. SAFETY INFORMATION…621
3. INTRODUCTION…622
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…623
5. CONTENTS…625
SAFETY…629
6. GENERAL PRECAUTIONS…630
7. PRECAUTIONS DURING OPERATION…636
7.1 BEFORE STARTING ENGINE…636
7.2 OPERATING MACHINE…638
7.3 TRANSPORTATION…643
7.4 BATTERY…644
7.5 TOWING…645
7.6 BUCKET WITH HOOK…646
8. PRECAUTIONS FOR MAINTENANCE…649
8.1 BEFORE CARRYING OUT MAINTENANCE…649
8.2 DURING MAINTENANCE…652
9. POSITION FOR ATTACHING SAFETY LABELS…656
OPERATION…660
10. GENERAL VIEW…661
10.1 GENERAL VIEW OF MACHINE…661
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…662
11. EXPLANATION OF COMPONENTS…663
11.1 MACHINE MONITOR…663
11.2 SWITCHES…674
11.3 CONTROL LEVERS, PEDALS…678
11.4 ROOF HATCH…683
11.5 FRONT WINDOW…684
11.6 DOOR LOCK…686
11.7 CAP, COVER WITH LOCK…687
11.8 LUGGAGE TRAY…688
11.9 ASHTRAY…688
11.10 HEATER…688
11.11 AIR CONDITIONER…689
11.12 CAB RADIO…692
11.13 FUSE…693
11.14 FUSIBLE LINK…694
11.15 CONTROLLERS…694
11.16 TOOL BOX…694
11.17 REFUELLING PUMP…694
11.18 HANDLING THE ACCUMULATOR…695
12. OPERATION…697
12.1 CHECK BEFORE STARTING ENGINE…697
12.2 STARTING ENGINE…707
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…710
12.4 MOVING MACHINE OFF…716
12.5 STEERING MACHINE…719
12.6 STOPPING MACHINE…721
12.7 SWINGING…722
12.8 OPERATION OF WORK EQUIPMENT…723
12.9 WORKING MODE SELECTION…724
12.10 PROHIBITIONS FOR OPERATION…726
12.11 PRECAUTIONS FOR OPERATION…728
12.12 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS…729
12.13 HOW TO ESCAPE FROM MUD…731
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…732
12.15 REPLACEMENT AND INVERSION OF BUCKET…733
12.16 PARKING THE MACHINE…735
12.17 CHECK AFTER FINISHING WORK…736
12.18 STOPPING ENGINE…737
12.19 CHECK AFTER STOPPING ENGINE…738
12.20 LOCKING…738
12.21 OVERLOAD WARNING DEVICE…738
13. TRANSPORTATION…739
13.1 LOADING, UNLOADING WORK…739
13.2 PRECAUTIONS FOR LOADING…741
13.3 PRECAUTIONS FOR TRANSPORTATION…742
13.4 LIFTING THE MACHINE…742
14. COLD WEATHER OPERATION…744
14.1 PRECAUTIONS FOR LOW TEMPERATURE…744
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…745
14.3 AFTER COLD WEATHER…745
15. LONG-TERM STORAGE…746
15.1 BEFORE STORAGE…746
15.2 DURING STORAGE…747
15.3 AFTER STORAGE…747
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…747
16. TROUBLESHOOTING…748
16.1 PHENOMENA THAT ARE NOT FAILURES…748
16.2 METHOD OF TOWING MACHINE…748
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…748
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…749
16.5 IF BATTERY IS DISCHARGED…749
16.6 OTHER TROUBLE…753
MAINTENANCE…758
17. GUIDES TO MAINTENANCE…759
18. OUTLINES OF SERVICE…762
18.1 OUTLINE OF OIL, FUEL, COOLANT…762
18.2 OUTLINE OF ELECTRIC SYSTEM…766
18.3 OUTLINE OF HYDRAULIC SYSTEM…767
19. WEAR PARTS LIST…768
20. USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…769
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…773
21.1 INTRODUCTION OF NECESSARY TOOLS…773
21.2 TORQUE LIST…774
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…775
23. MAINTENANCE SCHEDULE CHART…777
23.1 MAINTENANCE SCHEDULE CHART…777
23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER…779
24. SERVICE PROCEDURE…780
24.1 WHEN REQUIRED…781
24.2 CHECK BEFORE STARTING…802
24.3 EVERY 100 HOURS SERVICE…808
24.4 EVERY 250 HOURS SERVICE…811
24.5 EVERY 500 HOURS SERVICE…818
24.6 EVERY 1000 HOURS SERVICE…824
24.7 EVERY 2000 HOURS SERVICE…829
24.8 EVERY 4000 HOURS SERVICE…836
SPECIFICATIONS…837
25.0 SPECIFICATIONS…838
25.1 MACHINE SPECIFICATIONS…838
25.2 EXPLANATION OF LIFTING CAPACITY CHART…841
OPTIONS, ATTACHMENTS…845
26. GENERAL PRECAUTIONS…846
26.1 PRECAUTIONS RELATED TO SAFETY…846
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…847
27. HANDLING BUCKET WITH HOOK…848
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…848
27.2 PROHIBITED OPERATIONS…848
27.3 PRECAUTIONS DURING OPERATIONS…848
28. USING SEAT BELT…849
28.1 SEAT BELT…849
29. MACHINES READY FOR ATTACHMENTS…851
29.1 EXPLANATION OF COMPONENTS…851
29.2 HYDRAULIC CIRCUIT…853
29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…855
29.4 OPERATION…857
29.5 LONG TERM STORAGE…858
29.6 SPECIFICATIONS…858
30. INTRODUCTION OF ATTACHMENTS…859
30.1 SPECIFICATION, USE…859
30.2 ATTACHMENT INSTALLATION COMBINATION TABLE…860
30.3 SELECTION OF TRACK SHOES…861
30.4 SELECTION OF BUCKET TEETH…862
30.5 HANDLING TRAPEZOIDAL BUCKET…863
30.6 HANDLING THE CLAMSHELL BUCKET…864
31. EXTENDING MACHINE SERVICE LIFE…865
31.1 HYDRAULIC BREAKER…865
31.2 POWER RIPPER…868
31.3 FORK GRAB…869
31.4 GRAPPLE BUCKET…870
31.5 SCRAP GRAPPLE…871
31.6 CRUSHER & SMASHER…872
31.7 HYDRAULIC PILE DRIVER…873
31.8 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE…874
UEAD000401 – Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual…876
COVER…876
1. FOREWORD…877
2. SAFETY INFORMATION…878
3. INTRODUCTION…882
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…883
5. CONTENTS…885
SAFETY…889
6. GENERAL PRECAUTIONS…890
7. PRECAUTIONS DURING OPERATION…896
7.1 BEFORE STARTING ENGINE…896
7.2 OPERATING MACHINE…898
7.3 TRANSPORTATION…903
7.4 BATTERY…904
7.5 TOWING…905
7.6 BUCKET WITH HOOK…906
8. PRECAUTIONS FOR MAINTENANCE…909
8.1 BEFORE CARRYING OUT MAINTENANCE…909
8.2 DURING MAINTENANCE…912
9. POSITION FOR ATTACHING SAFETY LABELS…916
OPERATION…921
10. GENERAL VIEW…922
10.1 GENERAL VIEW OF MACHINE…922
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…923
11. EXPLANATION OF COMPONENTS…924
11.1 MACHINE MONITOR…924
11.2 SWITCHES…935
11.3 CONTROL LEVERS, PEDALS…939
11.4 ROOF HATCH…944
11.5 FRONT WINDOW…945
11.6 DOOR LOCK…947
11.7 CAP, COVER WITH LOCK…948
11.8 LUGGAGE BOX…949
11.9 ASHTRAY…949
11.10 HEATER…949
11.11 AIR CONDITIONER…951
11.12 CAB RADIO…954
11.13 FUSE…955
11.14 FUSIBLE LINK…956
11.15 CONTROLLERS…956
11.16 TOOL BOX…956
11.17 REFUELLING PUMP…956
11.18 HANDLING THE ACCUMULATOR…957
12. OPERATION…959
12.1 CHECK BEFORE STARTING ENGINE…959
12.2 STARTING ENGINE…969
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…972
12.4 MOVING MACHING OFF…978
12.5 STEERING MACHINE…981
12.6 STOPPING MACHINE…983
12.7 SWINGING…984
12.8 OPERATION OF WORK EQUIPMENT…985
12.9 WORKING WITH MODE/ACTIVE MODE SELECTION…986
12.10 PROHIBITIONS FOR OPERATION…990
12.11 PRECAUTIONS FOR OPERATION…992
12.12 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS…993
12.13 HOW TO ESCAPE FROM MUD…995
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…996
12.15 REPLACEMENT AND INVERSION OF BUCKET…997
12.16 PARKING THE MACHINE…999
12.17 CHECK AFTER FINISHING WORK…1000
12.18 STOPPING ENGINE…1001
12.19 CHECK AFTER STOPPING ENGINE…1002
12.20 LOCKING…1002
12.21 OVERLOAD WARNING DEVICE…1002
13. TRANSPORATION…1003
13.1 LOADING, UNLOADING WORK…1003
13.2 PRECAUTIONS FOR LOADING…1005
13.3 PRECAUTIONS FOR TRANSPORATION…1006
13.4 LIFTING THE MACHINE…1006
14. COLD WEATHER OPERATION…1008
14.1 PRECAUTIONS FOR LOW TEMPERATURE…1008
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…1009
14.3 AFTER COLD WEATHER…1009
15. LONG-TERM STORAGE…1010
15.1 BEFORE STORAGE…1010
15.2 DURING STORAGE…1011
15.3 AFTER STORAGE…1011
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…1011
16. TROUBLESHOOTING…1012
16.1 PHENOMENA THAT ARE NOT FAILURES…1012
16.2 METHOD OF TOWING MACHINE…1012
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…1012
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…1013
16.5 IF BATTERY IS DISCHARGED…1013
16.6 OTHER TROUBLE…1016
MAINTENANCE…1021
17. GUIDES TO MAINTENANCE…1022
18. OUTLINES OF SERVICE…1025
18.1 OUTLINE OF OIL, FUEL, COOLANT…1025
18.2 OULINE OF ELECTRIC SYSTEM…1029
18.3 OUTLINE OF HYDRAULIC SYSTEM…1030
19. WEAR PARTS LIST…1031
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1032
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1036
21.1 INTRODUCTION OF NECESSARY TOOLS…1036
21.2 TORQUE LIST…1037
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1038
23. MAINTENANCE SCHEDULE CHART…1040
23.1 MAINTENANCE SCHEDULE CHART…1040
23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER…1042
24. SERVICE PROCEDURE…1043
24.0 INITIAL 250 HOURS SERVICE…1043
24.1 WHEN REQUIRED …1044
24.2 CHECK BEFORE STARTING…1065
24.3 EVERY 100 HOURS SERVICE…1071
24.4 EVERY 250 HOURS SERVICE…1074
24.5 EVERY 500 HOURS SERVICE…1079
24.6 EVERY 1000 HOURS SERVICE…1086
24.7 EVERY 2000 HOURS SERVICE…1089
24.8 EVERY 4000 HOURS SERVICE…1092
24.9 EVERY 5000 HOURS SERVICE…1093
SPECIFICATIONS…1099
25. SPECIFICATION…1100
25.1 MACHINE SPECIFICATIONS…1100
25.2 EXPLANATION OF LIFTING CAPACITY CHART…1105
OPTIONS, ATTACHEMENTS…1107
26. GENERAL PRECAUTIONS…1108
26.1 PRECAUTIONS RELATED TO SAFETY…1108
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…1109
27. HANDLING BUCKET WITH HOOK…1110
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…1110
27.2 PROHIBITED OPERATIONS…1110
27.3 PRECAUTIONS DURING OPERATIONS…1110
28. USING SEAT BELT…1111
28.1 SEAT BELT…1111
29. MACHINES READY FOR ATTACHMENTS…1112
29.1 EXPLANATION OF COMPONENTS…1112
29.2 HYDRAULIC CIRCUIT…1114
29.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…1116
29.4 OPERATION…1118
29.5 LONG TERM STORAGE…1119
29.6 SPECIFICATIONS…1119
30. INTRODUCTION OF ATTACHMENTS…1120
30.1 SPECIFICATION, USE…1120
30.2 ATTACHMENT INSTALLATION COMBINATION TABLE…1121
30.3 SELECTION OF TRACK SHOES…1122
30.4 SELECTION OF BUCKET TEETH…1123
30.5 HANDLING TRAPEZOIDAL BUCKET…1124
30.6 HANDLING EXTENSTION ARM…1125
31. EXTENDING MACHINE SERVICE LIFE…1126
31.1 HYDRAULIC BREAKER…1126
31.2 POWER RIPPER…1129
31.3 FORK GRAB…1130
31.4 GRAPPLE BUCKET …1131
31.5 SCRAP GRAPPLE…1132
31.6 CRUSHER & SMASHER…1133
31.7 HYDRAULIC PILE DRIVER…1134
31.8 HYDRAULIC EXCAVATOR WITH MULIT-PURPOSE CRANE…1135
UEAM000403 – Hydraulic Excavator PC150-6K, PC150LC-6K Operation & Maintenance Manual…1137
FOREWORD…1139
SAFETY INFORMATION…1141
SAFETY MESSAGES…1141
VIBRATION…1142
INTRODUCTION…1143
INTENDED USE…1143
FEATURES…1143
BREAKING IN YOUR NEW MACHINE…1143
LOCATION OF PLATES, TABLES TO ENTER SERIAL NO. AND DISTRIBUTOR…1145
MACHINE SERIAL NO. PLATE POSITION…1145
ENGINE SERIAL NO. PLATE POSITION…1145
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1145
MACHINE SERIAL PLATE…1146
SAFETY…1151
GENERAL PRECAUTIONS…1152
PRECAUTIONS DURING OPERATION…1160
BEFORE STARTING ENGINE…1160
OPERATING MACHINE…1163
TRANSPORTATION…1170
BATTERY…1171
TOWING…1172
BUCKET WITH HOOK…1173
GENERAL PRECAUTIONS…1173
PRECAUTIONS FOR LIFTING OPERATION…1174
PRECAUTIONS FOR MAINTENANCE…1176
BEFORE CARRYING OUT MAINTENANCE…1176
DURING MAINTENANCE…1179
POSITION FOR ATTACHING SAFETY LABELS…1184
POSITION FOR ATTACHING SAFETY LABELS…1184
Memo…1189
OPERATION…1191
GENERAL VIEW…1192
GENERAL VIEW OF MACHINE…1192
GENERAL VIEW OF CONTROLS AND GAUGES…1193
EXPLANATION OF COMPONENTS…1195
MACHINE MONITOR…1195
A: BASIC CHECK ITEMS…1197
B: CAUTION ITEMS…1198
C: EMERGENCY STOP ITEMS…1199
D: METER DISPLAY PORTION…1200
METERS…1201
E: SWITCHES…1203
SWITCHES…1206
CONTROL LEVERS, PEDALS…1212
CEILING WINDOW…1216
CLEAR RAIN VISOR…1216
PULL DOWN SUN VISOR…1216
CUP HOLDER…1217
FRONT WINDOW…1218
DOOR LOCK…1220
CAP, COVER WITH LOCK…1220
LUGGAGE TRAY…1221
ASHTRAY…1222
HEATER…1223
VIEW OF CONTROL PANEL…1223
AIR CONDITIONER (option)…1225
GENERAL LOCATIONS ON CONTROL PANEL…1225
AIR CONDITIONER SWITCH…1227
OFF SWITCH…1227
DEFROSTER SELECTOR LEVER…1227
PRECAUTIONS WHEN USING AIR CONDITIONER…1227
CHECK, MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…1228
CAB RADIO (option)…1228
FUSE…1229
Fuse capacity and name of circuit…1229
FUSIBLE LINK…1230
CONTROLLERS…1230
TOOL BOX…1230
REFUELLING PUMP…1231
HANDLING THE ACCUMULATOR…1232
METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR…1232
OPERATION…1233
CHECK BEFORE STARTING ENGINE…1233
WALK-AROUND CHECK…1233
CHECK BEFORE STARTING…1234
ADJUSTMENT BEFORE OPERATION OPERATOR’S SEAT…1239
USING THE SEAT BELT…1241
OPERATIONS AND CHECKS BEFORE STARTING ENGINE…1242
STARTING ENGINE…1244
NORMAL STARTING…1244
STARTING IN COLD WEATHER…1245
OPERATIONS AND CHECKS AFTER STARTING ENGINE…1246
WHEN NORMAL…1246
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)…1248
MOVING MACHINE OFF…1252
MOVING MACHINE FORWARD…1252
MOVING MACHINE BACKWARD…1253
STEERING MACHINE…1254
STEERING (changing direction)…1254
STOPPING MACHINE…1256
SWINGING…1257
OPERATION OF WORK EQUIPMENT…1258
HANDLING ACTIVE MODE…1259
WORKING MODE SELECTION…1260
PROHIBITIONS FOR OPERATION…1262
PRECAUTIONS FOR OPERATION…1264
PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS…1265
HOW TO ESCAPE FROM MUD…1266
WHEN ONE SIDE IS STUCK…1266
WHEN BOTH SIDES ARE STUCK…1266
WORK POSSIBLE USING HYDRAULIC EXCAVATOR…1267
BACKHOE WORK…1267
SHOVEL WORK…1267
DITCHING WORK…1267
LOADING WORK…1268
REPLACEMENT AND INVERSION OF BUCKET…1268
REPLACEMENT…1268
INVERSION…1269
PARKING THE MACHINE…1270
CHECK AFTER FINISHING WORK…1271
STOPPING ENGINE…1271
CHECK AFTER STOPPING ENGINE…1272
LOCKING…1273
OVERLOAD WARNING DEVICE…1273
TRANSPORTATION…1274
LOADING, UNLOADING WORK…1274
PRECAUTIONS FOR LOADING…1276
PRECAUTIONS FOR TRANSPORTATION…1276
METHOD OF LIFTING MACHINE…1277
COLD WEATHER OPERATION…1279
PRECAUTIONS FOR LOW TEMPERATURE…1279
FUEL AND LUBRICANTS…1279
COOLANT…1279
BATTERY…1280
PRECAUTIONS AFTER COMPLETION OF WORK…1280
AFTER COLD WEATHER…1281
LONG-TERM STORAGE…1282
BEFORE STORAGE…1282
DURING STORAGE…1282
AFTER STORAGE…1283
STARTING MACHINE AFTER LONG-TERM STORAGE…1283
TROUBLESHOOTING…1284
PHENOMENA THAT ARE NOT FAILURES…1284
METHOD OF TOWING MACHINE…1284
USING METHOD FOR LIGHT-WEIGHT TOWING HOLE…1285
PRECAUTIONS ON PARTICULAR JOBSITES…1285
IF BATTERY IS DISCHARGED…1286
STARTING ENGINE WITH BOOSTER CABLE…1287
OTHER TROUBLE…1289
ELECTRICAL SYSTEM…1289
CHASSIS…1290
ENGINE…1291
ENGINE (cont’d)…1292
ELECTRONIC CONTROL SYSTEM…1293
MAINTENANCE…1295
GUIDES TO MAINTENANCE…1296
OUTLINES OF SERVICE…1299
OUTLINE OF OIL, FUEL, COOLANT…1299
OIL…1299
FUEL…1300
COOLANT…1300
GREASE…1301
STORING OIL AND FUEL…1301
FILTERS…1301
EXPLANATION OF LUBRICATION CHART DECAL…1302
OUTLINE OF ELECTRICAL SYSTEM…1304
OUTLINE OF HYDRAULIC SYSTEM…1304
WEAR PARTS LIST…1306
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1307
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…1307
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1309
LIST OF NECESSARY TOOLS…1309
TORQUE LIST…1310
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1311
MAINTENANCE SCHEDULE CHART…1313
MAINTENANCE SCHEDULE CHART…1313
MAINTENANCE WHEN USING HYDRAULIC BREAKER…1316
SERVICE PROCEDURE…1317
INITIAL 250 HOURS SERVICE…1317
WHEN REQUIRED…1317
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…1317
CLEAN INSIDE OF COOLING SYSTEM…1319
CHECKING COOLANT LEVEL…1321
DRAINING THE SYSTEM…1321
CLEANING THE SYSTEM…1322
FILLING THE SYSTEM…1323
REFILLING AN OVERHEATED SYSTEM…1323
CLEANING THE RADIATOR…1323
CLEANING THE RADIATOR PRE SCREEN…1324
THERMOSTATS…1324
FAN…1324
CHECK AND TIGHTEN TRACK SHOE BOLTS…1325
CHECK and adjust TRACK TENSION…1325
CHECK ELECTRICAL INTAKE AIR HEATER…1328
CHECK ALTERNATOR…1328
CHECK START MOTOR…1328
REPLACE BUCKET SIDE CUTTERS…1329
REPLACE BUCKET TEETH…1329
ADJUST BUCKET CLEARANCE…1330
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…1331
CHECK, MAINTAIN AIR CONDITIONER…1332
CLEAN INLINE FILTER…1333
CHECK BEFORE STARTING…1333
CHECK COOLANT LEVEL, ADD COOLANT…1333
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…1334
CHECK FUEL LEVEL, ADD FUEL…1334
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…1335
CHECK AIR CLEANER FOR CLOGGING…1336
CHECK ELECTRIC WIRINGS…1336
CHECK FUNCTION OF HORN…1337
CHECK FOR WATER IN FUEL SEDIMENTOR…1337
CHECK FOR WATER IN PRIMARY FUEL FILTER, DRAIN WATER…1337
EVERY 100 HOURS SERVICE…1338
LUBRICATING…1338
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…1340
DRAIN WATER AND SEDIMENT FROM FUEL TANK…1340
CLEAN FRESH AIR INTAKE FILTER…1341
EVERY 250 HOURS SERVICE…1342
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…1342
CHECK LEVEL OF BATTERY ELECTROLYTE…1342
LUBRICATE SWING CIRCLE (2 POINTS)…1343
BELTS, GENERAL…1343
CHECK ALTERNATOR, FAN AND WATER PUMP BELT TENSION, ADJUST CHECKING TENSION…1344
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…1345
EVERY 500 HOURS SERVICE…1346
REPLACE FUEL FILTER CARTRIDGE…1346
CHECK SWING PINION GREASE LEVEL, ADD GREASE…1348
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…1349
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED W….1350
REPLACE HYDRAULIC FILTER ELEMENT…1351
EVERY 1000 HOURS SERVICE…1352
CHANGE OIL IN SWING MACHINERY CASE…1352
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…1353
CHECK PLAY OF TURBOCHARGER ROTOR…1353
CHECK AND ADJUST VALVE CLEARANCE…1353
CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB…1353
CHECK FAN BELT TENSION…1354
EVERY 2000 HOURS SERVICE…1354
CHANGE OIL IN FINAL DRIVE CASE…1354
CLEAN HYDRAULIC TANK STRAINER…1355
CLEAN, CHECK TURBOCHARGER…1355
CHECK ALTERNATOR, STARTING MOTOR…1355
CHECK ENGINE VALVE CLEARANCE, ADJUST…1355
CHECK VIBRATION DAMPER…1355
CHANGE ANTI FREEZE…1356
EVERY 4000 HOURS SERVICE…1356
CHECK WATER PUMP…1356
EVERY 5000 HOURS SERVICE…1356
CHANGE OIL IN HYDRAULIC TANK…1356
Memo…1361
SPECIFICATIONS…1363
SPECIFICATIONS…1364
PC150-6K, PC150LC-6K…1364
LIFTING CAPACITY CHART…1369
OPTIONS, ATTACHMENTS…1371
PRECAUTIONS RELATED TO SAFETY…1372
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…1373
HANDLING BUCKET WITH HOOK…1374
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…1374
PROHIBITED OPERATIONS…1374
PRECAUTIONS DURING OPERATIONS…1374
MACHINES READY FOR ATTACHMENTS…1375
1. STOP VALVE…1375
3. CONTROL PEDAL FOR ATTACHMENT…1375
4. ACCUMULATOR…1376
5. HYDRAULIC CIRCUIT…1376
Change-over hydraulic circuit…1376
CONNECTING HYDRAULIC CIRCUIT…1377
ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE…1378
OPERATION…1379
LONG TERM STORAGE…1380
SPECIFICATIONS…1381
INTRODUCTION OF ATTACHMENTS…1382
SPECIFICATION, USE…1382
ATTACHMENT INSTALLATION COMBINATION TABLE…1383
SELECTION OF TRACK SHOES…1384
SELECTION OF BUCKET TEETH…1386
HANDLING TRAPEZOIDAL BUCKET…1386
HANDLING THE CLAMSHELL BUCKET…1388
EXTENDING MACHINE SERVICE LIFE…1389
HYDRAULIC BREAKER…1389
POWER RIPPER…1392
MAIN FIELDS OF APPLICATIONS…1392
FORK GRAB…1394
GRAPPLE BUCKET…1395
SCRAP GRAPPLE…1396
CRUSHER & SMASHER…1397
HYDRAULIC PILE DRIVER…1399
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE…1400
Memo…1402
UEBD000701 – Hydraulic Excavator PC150-6K, PC150LC-6K Shop Manual…1403
COVER…1403
CONTENTS…1404
SAFETY…1408
SAFETY NOTICE…1408
FOREWORD…1410
GENERAL…1410
HOW TO READ THE SHOP MANUAL…1411
HOISTING INSTRUCTIONS…1412
COATING MATERIALS…1413
STANDARD TIGHTENING TORQUE…1414
ELECTRIC WIRE CODE…1416
CONVERSION TABLE…1417
01 GENERAL…1424
SPECIFICATIONS…1425
SPECIFICATON DRAWINGS…1428
WEIGHT TABLE…1429
FUEL, COOLANT AND LUBRICANTS…1431
10 STRUCTURE AND FUNCTION…1434
ENGINE RELATED PARTS…1435
RADIATOR • OIL COOLER…1436
POWER TRAIN…1437
FINAL DRIVE…1438
SWING CIRCLE…1439
SWING MACHINERY…1440
TRACK FRAME, RECOIL SPRING…1442
TRACK SHOE…1443
HYDRAULIC CIRCUIT DIAGRAM…1446
HYDRAULIC TANK…1447
HYDRAULIC PUMP…1449
CONTROL VALVE…1456
CLSS…1462
SWING MOTOR…1499
CENTER SWIVEL JOINT…1501
TRAVEL MOTOR…1502
VALVE CONTROL…1510
WORK EQUIPMENT – SWING PPC VALVE…1511
TRAVEL PPC PEDAL…1515
TRAVEL PPC VALVE PEDAL…1519
SAFETY LOCK VALVE…1522
PPC ACCUMULATOR…1522
PPC SHUTTLE • TRAVEL JUNCTION VALVE…1523
EPC • SOLENOID VALVE…1530
HYDRAULIC CYLINDER…1535
ADDITIONAL FILTER FOR BREAKING…1537
BOOM HOLDING VALVE…1538
WORK EQUIPMENT…1545
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE…1546
ENGINE CONTROL SYSTEM…1547
ELECTRONIC CONTROL SYSTEM…1553
MACHINE MONITOR SYSTEM…1577
20 TESTING AND ADJUSTING…1589
TABLE OF JUDGEMENT STANDARD VALUE…1590
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…1600
CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSORR…1608
ADJUSTING ENGINE SPEED SENSOR…1609
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE…1610
TESTING CLEARANCE OF SWING CIRCLE BEARING…1612
TESTING AND ADJUSTING TRACK SHOE TENSION…1613
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…1614
TESTING AND ADJUSTING TVC VALVE OUTPUT (SERVO PISTON INPUT PRESSURE)…1622
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL…1624
TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE…1627
TESTING AND ADJUSTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE…1629
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE…1631
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…1633
TESTING TRAVEL DEVIATION…1634
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…1635
MEASURING OIL LEAKAGE…1637
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…1639
BLEEDING AIR…1640
TROUBLESHOOTING…1643
POINTS TO REMEMBER WHEN TROUBLESHOOTING…1644
SEQUENCE OF EVENTS IN TROUBLESHOOTING…1645
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…1646
CHECKS BEFORE TROUBLESHOOTING…1653
CONNECTOR TYPES AND MOUNTING LOCATIONS…1654
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…1659
EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM…1672
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL…1673
METHOD OF USING JUDGEMENT TABLE…1681
METHOD OF USING TROUBLESHOOTING CHARTS…1683
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…1685
SERVICE CODE TABLE…1690
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)…1691
N-1 [E218] COMMUNICATION ABNOMALITY…1692
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)…1694
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM…1695
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…1696
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS…1700
ELECTRICAL CIRCUIT DIAGRAM OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) …1702
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)…1704
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…1705
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED…1706
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED…1707
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…1708
E-6 [E315] ABNORMALITY (SHORT CIRCUIT IN BATTERY RELAY OUTPUT)…1709
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED…1710
E-8 ENGINE DOES NOT START…1712
E-9 ENGINE SPEED IS IRREGULAR…1714
A) IDLING SPEED IS IRREGULAR…1714
B) THERE IS HUNTING…1716
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)…1718
E-11 ENGINE DOES NOT STOP…1720
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)…1722
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…1725
METHOD OF USING TROUBLESHOOTING CHARTS…1726
S-1 STARTING PERFORMANE IS POOR (STARTING ALWAYS TAKES TIME)…1730
S-2 ENGINE DOES NOT START…1731
(1) ENGINE DOES NOT RUN…1731
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…1732
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…1733
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…1734
S-4 ENGINE STOP DURING OPERATIONS…1735
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…1736
S-6 ENGINE LACKS OUTPUT (NO POWER)…1737
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…1738
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…1739
S-9 OIL BECOMES CONTAMINATED QUICKLY…1740
S-10 FUEL CONSUMPTION IS EXCESSIVE…1741
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR LEVEL GOES DOWN…1742
S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)…1743
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…1744
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…1745
S-15 ABNORMAL NOISE IS MADE…1746
S-16 VIBRATION IS EXCESSIVE…1747
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)…1748
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…1749
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…1750
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS…1756
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE…1758
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)…1760
C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED…1761
C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED…1763
C-6 [E201] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED…1765
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…1767
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…1769
C-10 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…1771
C-11 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENIOD SYSTEM IS DISPLAYED…1772
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED…1773
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED…1774
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED…1775
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…1777
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS…1778
C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…1779
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED…1780
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…1781
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)…1783
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE…1785
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP…1787
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…1788
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP…1789
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP…1790
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP…1791
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP…1792
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP…1793
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP…1794
F-9 BIT PATTERN 21-(3) SWING LOCK DOES NOT LIGHT UP…1795
F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP…1796
F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP…1797
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…1798
TABLE OF FAILURE MODES AND CAUSES…1799
ALL WORK EQUIPMENT, TRAVEL, SWING…1803
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…1803
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…1805
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…1806
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…1806
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)…1807
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…1807
WORK EQUIPMENT…1809
H-7 BOOM IS SLOW OR LACKS POWER…1809
H-8 ARM IS SLOW OR LACKS POWER…1811
H-9 BUCKET IS SLOW OR LACKS POWER…1813
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE…1814
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…1814
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING…1815
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…1815
H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED…1816
H-15 LACK OF POWER WHEN PRESSURE RISES…1816
COMPOUND OPERATIONS…1816
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…1816
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…1817
TRAVEL SYSTEM…1818
H-20 TRAVEL DEVIATION…1818
H-21 TRAVEL SPEED IS SLOW…1819
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER…1821
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…1823
H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…1823
SWING SYSTEM…1824
H-25 DOES NOT SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY)…1824
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW…1825
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY)…1827
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…1828
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…1828
H-30 EXCESSIVE HYDARULIC DRIFT OF SWING…1829
H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED…1830
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…1832
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…1833
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE…1836
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED…1838
M-1 [E102] ERROR IN CLOCK DATA IS DISPLAYED…1838
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTRACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED…1839
M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED…1840
M-4 [E106] DROP IN ENGINE OIL PRESSURE HI DETECTED IS DISPLAYED…1840
M-5 [E108] ENGINE WATER TEPERATURE 105°C DETECTED IS DISPLAYED…1841
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR THREE SECONDS…1842
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT…1844
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)…1844
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES…1845
M-10 PREHEATING IS NOT BEING USED BY (PREHEATING MONITOR LIGHT UP)…1847
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH…1848
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)…1850
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEM, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)…1852
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND…1855
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS…1855
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…1856
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE…1857
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)…1857
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…1858
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…1858
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP…1859
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH…1859
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING…1860
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED…1860
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM…1861
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM…1862
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM…1863
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…1864
M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…1865
30 DISASSEMBLY AND ASSEMBLY…1871
METHOD OF USING MANUAL…1873
PRECAUTIONS WHEN CARRYING OUT OPERATION…1875
SPECIAL TOOL LIST…1877
GOVERNOR MOTOR ASSEMBLY…1880
REMOVAL AND INSTALLATION…1880
HYDRAULIC OIL COOLER ASSEMBLY…1881
REMOVAL AND INSTALLATION…1881
RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY…1882
REMOVAL…1882
INSTALLATION…1883
ENGINE, MAIN PUMP ASSEMBLY…1884
REMOVAL…1884
INSTALLATION…1887
DAMPER ASSEMBLY…1888
REMOVAL AND INSTALLATION…1888
FUEL TANK/HYDRAULIC OIL TANK ASSEMBLY…1889
REMOVAL AND INSTALLATION…1889
CENTER SWIVEL JOINT ASSEMBLY…1891
DISASSEMBLY AND ASSEMBLY…1891
TRAVEL MOTOR ASSEMBLY…1892
REMOVAL AND INSTALLATION…1892
FINAL DRIVE ASSEMBLY…1893
REMOVAL AND INSTALLATION…1893
SPROCKET…1895
REMOVAL AND INSTALLATION…1895
SWING MOTOR ASSEMBLY…1896
REMOVAL AND INSTALLATION…1896
SWING MACHINERY ASSEMBLY…1897
REMOVAL AND INSTALLATION…1897
SWING MOTOR…1899
DISASSEMBLY AND ASSEMBLY…1899
REVOLVING FRAME ASSEMBLY…1906
REMOVAL…1906
INSTALLATION…1907
SWING CIRCLE ASSEMBLY…1908
REMOVAL AND INSTALLATION…1908
IDLER, RECOIL SPRING ASSEMBLY…1910
REMOVAL AND INSTALLATION…1910
RECOIL SPRING ASSEMBLY…1911
DISASSEMBLY…1911
ASSEMBLY…1912
IDLER ASSEMBLY…1913
DISASSEMBLY…1913
ASSEMBLY…1914
TRACK ROLLER ASSEMBLY…1916
REMOVAL AND INSTALLATION…1916
DISASSEMBLY…1917
ASSEMBLY…1918
CARRIER ROLLER ASSEMBLY…1920
REMOVAL AND INSTALLATION…1920
DISASSEMBLY…1921
ASSEMBLY…1922
TRACK SHOE ASSEMBLY…1924
REMOVAL AND INSTALLATION…1924
MAIN PUMP ASSEMBLY…1927
REMOVAL…1927
INSTALLATION…1928
CONTROL VALVE ASSEMBLY…1929
REMOVAL…1929
INSTALLATION…1930
DISASSEMBLY AND ASSEMBLY…1931
LS SELECT VALVE ASSEMBLY…1935
DISASSEMBLY AND ASSEMBLY…1935
LS SHUTTLE VALVE…1936
DISASSEMBLY AND ASSEMBLY…1936
PRESSURE COMPENSATION VALVE ASSEMBLY…1937
DISASSEMBLY AND ASSEMBLY…1937
MAIN RELIEF VALVE ASSEMBLY…1939
DISASSEMBLY…1939
ASSEMBLY…1940
LS CONTROL EPC VALVE ASSEMBLY…1941
REMOVAL AND INSTALLATION…1941
SOLENOID VALVE ASSEMBLY…1942
REMOVAL AND INSTALLATION…1942
PPC SHUTTLE VALVE ASSEMBLY…1943
REMOVAL…1943
INSTALLATION…1944
DISASSEMBLY…1945
ASSEMBLY…1946
WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY…1947
REMOVAL AND INSTALLATION…1947
TRAVEL PPC VALVE ASSEMBLY…1948
REMOVAL AND INSTALLATION…1948
DISASSEMBLY …1949
ASSEMBLY…1949
BOOM CYLINDER ASSEMBLY…1951
REMOVAL…1951
INSTALLATION…1952
ARM CYLINDER ASSEMBLY…1953
REMOVAL…1953
INSTALLATION…1954
BUCKET CYLINDER ASSEMBLY…1955
REMOVAL…1955
INSTALLATION…1956
HYDRAULIC CYLINDER ASSEMBLY…1957
DISASSEMBLY…1957
ASSEMBLY…1959
WORK EQUIPMENT ASSEMBLY…1962
REMOVAL…1962
INSTALLATION…1963
BUCKET ASSEMBLY…1964
REMOVAL…1964
INSTALLATION…1964
ARM ASSEMBLY…1964
REMOVAL…1964
INSTALLATION…1964
BUCKET, ARM ASSEMBLY…1966
REMOVAL…1966
INSTALLATION…1966
BOOM ASSEMBLY…1968
REMOVAL…1968
INSTALLATION…1969
OPERATOR'S CAB ASSEMBLY…1970
REMOVAL…1970
INSTALLATION…1972
COUNTERWEIGHT…1973
REMOVAL AND INSTALLATION…1973
GOVERNOR, PUMP CONTROLLER ASSEMBLY…1974
REMOVAL AND INSTALLATION…1974
MONITOR PANEL ASSEMBLY…1975
REMOVAL AND INSTALLATION…1975
FINAL DRIVE ASSEMBLY…1981
DISASSEMBLY…1981
ASSEMBLY…1992
SPECIAL TOOLS…2004
SWING MACHINERY ASSEMBLY…2011
DISASSEMBLY…2011
ASSEMBLY…2027
SPECIAL TOOLS…2047
40 MAINTENANCE STANDARD…2051
ENGINE MOUNT…2052
SWING MACHINERY…2053
SWING CIRCLE…2055
FINAL DRIVE…2056
TRACK FRAME, RECOIL SPRING…2058
IDLER…2059
CARRIER ROLLER…2061
TRACK ROLLER…2062
TRACK SHOE…2063
CONTROL VALVE…2065
SUCTION-SAFETY VALVE…2073
SWING MOTOR…2074
WORK EQUIPMENT, SWING PPC VALVE…2075
TRAVEL PPC VALVE…2076
SERVICE PPC VALVE…2077
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE…2078
EPC SOLENOID VALVE…2079
CENTER SWIVEL JOINT…2080
HYDRAULIC CYLINDER…2082
WORK EQUIPMENT…2083
90 OTHERS…2091
ELECTRICAL CIRCUIT DIAGRAM – SHEET 1 OF 4…2092
ELECTRICAL CIRCUIT DIAGRAM – SHEET 2 OF 4…2093
ELECTRICAL CIRCUIT DIAGRAM – SHEET 3 OF 4…2094
ELECTRICAL CIRCUIT DIAGRAM – SHEET 4 OF 4…2095

Komatsu PC150-6K, PC150LC-6K Hydraulic Excavators Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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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: 2,012 pages
File Format: PDF
Language: English

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

!!! new_index = 81
!!! num_start = 1
!!! num_style = Arabic

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

!!! new_index = 95
!!! num_start = 1
!!! num_style = Arabic

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

!!! new_index = 339
!!! num_start = 1
!!! num_style = Arabic

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

!!! new_index = 363
!!! num_start = 1
!!! num_style = Arabic

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

!!! new_index = 549
!!! num_start = 1
!!! num_style = Arabic

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

!!! new_index = 1187
!!! num_start = 1
!!! num_style = Arabic

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

!!! new_index = 1815
!!! num_start = 1
!!! num_style = Arabic

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

!!! new_index = 1889
!!! num_start = 1
!!! num_style = Arabic

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

!!! new_index = 1967
!!! num_start = 1
!!! num_style = Arabic

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

Komatsu Hydraulic Excavator PC130-10M0 Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC130-6K, PC150LGP-6K, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC130-6K, PC150LGP-6K 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.

EEBM001501 – Hydraulic Excavator PC130-6K, PC150LGP-6K Shop Manual.pdf
SEAM021K0303 – Hydraulic Excavator PC150-3, PC150LC-3, PC150HD-3, PC150NHD-3 Operation & Maintenance Manual.pdf
UEAM000602 – Hydraulic Excavator PC130-6K, PC150LGP-6K Operation & Maintenance Manual.pdf
UEAM003601 – Hydraulic Excavator PC130-7K Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 1,329 pages
File Format: PDF
Language: English

EEBM001501 – Hydraulic Excavator PC130-6K, PC150LGP-6K Shop Manual….2
01 General….26
10 Structure and function ….43
20 Testing and adjusting….238
30 Dissasembly and Assembly….531
40 Maintenance Standard….682
90 Others….726
SEAM021K0303 – Hydraulic Excavator PC150-3, PC150LC-3, PC150HD-3, PC150NHD-3 Operation & Maintenance Manual….732
COVER….732
FOREWORD….733
BREAKING IN YOUR NEW MACHINE….734
CONTENTS….735
GENERAL LOCATIONS AND SPECIFICATIONS….736
INSTRUMENTS AND CONTROLS….738
CHECK BEFORE STARTING….770
OPERATING YOUR MACHINE….775
INVERSION AND REPLACEMENT OF BUCKET….788
COLD WEATHER OPERATION….789
PERIODIC MAINTENANCE….794
MAINTENANCE TABLE….795
OIL FILLER AND LEVEL GAUGE POSITIONS….798
CHECK BEFORE STARTING….799
EVERY 50 HOURS SERVICE….799
EVERY 100 HOURS SERVICE….800
INITIAL 250 HOURS SERVICE….803
EVERY 250 HOURS SERVICE….803
EVERY 500 HOURS SERVICE….808
EVERY 1000 HOURS SERVICE….812
EVERY 2000 HOURS SERVICE….815
EVERY 4000 HOURS SERVICE….821
WHEN REQUIRED….822
ADJUSTMENT….834
TROUBLE SHOOTING GUIDE….835
SERVICE METER….838
MACHINE AND ENGINE SERIAL NUMBERS….839
FUEL,COOLANT AND LUBRICANTS….840
SAFETY AND OPERATION….842
CONTENTS….843
SAFETY HINTS….844
RADIO….857
LOCKING CAP….859
OPERATING THE CAR COOLER….860
OPERATING THE AIR CONDITIONER….862
EXCAVATOR'S WORK….868
HANDLING OF BATTERY….869
TRANSPORTATION….872
PRECAUTIONS FOR MAINTENANCE….874
STORAGE….880
COOLANT AND LUBRICANTS….882
UEAM000602 – Hydraulic Excavator PC130-6K, PC150LGP-6K Operation & Maintenance Manual….884
UEAM000602KAFT.pdf….0
Operation & Maintenance Manual….884
PC200EN-6K….884
PC200EL-6K….884
serial number….884
PC200EN-6K – k34049 and up….884
pc200EL-6K – k34049 and up….884
hydraulic excavator….884
UEAM000203….884
UEAM003601 – Hydraulic Excavator PC130-7K Operation & Maintenance Manual….1144
FOREWORD….1146
FOREWORD….1147
SAFETY INFORMATION….1148
NOISE….1150
VIBRATION….1150
INTRODUCTION….1151
DIRECTIONS OF MACHINE….1151
BREAKING-IN THE NEW MACHINE….1151
PRODUCT INFORMATION….1152
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….1152
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….1152
SERVICE METER LOCATION….1153
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….1153
MACHINE SERIAL NUMBER PLATE….1154
FOREWORD….1155
SAFETY….1155
OPERATION….1155
MAINTENANCE….1158
SPECIFICATIONS….1160
ATTACHMENTS AND OPTIONS….1160
INDEX….1161
COLOPHON….1161
SAFETY….1162
SAFETY INFORMATION….1163
SAFETY LABELS….1165
LOCATION OF SAFETY LABELS….1165
SAFETY LABELS….1166
SAFETY INFORMATION….1173
SAFETY MACHINE OPERATION….1182
STARTING ENGINE….1182
OPERATION….1184
TRANSPORTATION….1191
BATTERY….1192
TOWING….1194
LIFTING OBJECTS WITH BUCKET….1195
SAFETY MAINTENANCE INFORMATION….1197
OPERATION….1204
MACHINE VIEW ILLUSTRATIONS….1205
OVERALL MACHINE VIEW….1205
CONTROLS AND GAUGES….1206
DETAILED CONTROLS AND GAUGES….1207
MONITORING SYSTEM….1207
Basic Check Monitors….1208
Caution Monitors….1210
Emergency Monitors….1212
Meter Display Portion….1214
Monitor Switches Portion….1217
SWITCHES….1220
CONTROL LEVERS AND PEDALS….1226
SUN ROOF….1229
WINDSHIELD….1229
EMERGENCY EXIT FROM OPERATOR'S CAB….1234
DOOR LOCK….1234
CAP WITH LOCK….1235
HOT AND COOL BOX….1237
MAGAZINE BOX….1237
ASHTRAY….1237
AIR CONDITIONER CONTROLS….1238
Air Conditioner Control Panel….1238
Method of Operation….1243
Use Air Conditioner with Care….1249
Inspection and maintenance of Air Conditioner Equipped Machine….1249
Other Functions….1250
CAB RADIO CASSETTE….1251
Controls of Radio cassette….1251
Precautions when Using….1251
AUXILIARY ELECTRIC POWER….1252
24V power source….1252
12V power source….1252
FUSE….1252
FUSIBLE LINK….1253
CONTROLLERS….1254
TOOL BOX….1254
GREASE GUN HOLDER….1254
HANDLING GREASE GUN….1255
REFUELLING PUMP….1256
ACCUMULATOR….1258
Releasing Hydraulic Pressure with Accumulator….1258
MACHINE OPERATIONS AND CONTROLS….1259
BEFORE STARTING ENGINE….1259
Walk-around Checks….1259
Checks Before Starting….1261
Adjustment….1267
Seat Belt….1270
Operations Before Starting Engine….1271
STARTING ENGINE….1273
Normal Starting….1273
Starting Engine in Cold Weather….1275
AFTER STARTING ENGINE….1277
Warming-up Operation….1277
In Cold Weather Areas….1280
STOPPING THE ENGINE….1284
MACHINE OPERATION….1285
Preparations for Moving the Machine Off….1285
Moving Machine Forward….1286
Moving Machine Backward….1287
Stopping Machine….1288
STEERING THE MACHINE….1289
Steering….1289
SWINGING….1291
WORK EQUIPMENT CONTROLS AND OPERATIONS….1292
WORKING MODE….1294
PROHIBITED OPERATIONS….1295
GENERAL OPERATION INFORMATION….1297
TRAVELING ON SLOPES….1298
ESCAPE FROM MUD….1300
Stuck One Side of Track….1300
Stuck Both Sides of Tracks….1300
RECOMMENDED APPLICATIONS….1301
Backhoe Work….1301
Shovel Work….1301
Ditching Work….1301
Loading Work….1302
BUCKET REPLACEMENT AND INVERSION….1303
Replacement….1303
Inversion….1304
PARKING MACHINE….1305
CHECK AFTER SHUT OFF ENGINE….1306
MACHINE INSPECTION AFTER DAILY WORK….1307
LOCKING….1307
OVERLOAD WARNING DEVICE….1307
TRANSPORTATION….1308
TRANSPORTATION PROCEDURE….1308
LOADING AND UNLOADING WITH TRAILER….1309
Loading….1310
Securing Machine….1312
Unloading….1314
LIFTING MACHINE….1316
COLD WEATHER OPERATION….1317
COLD WEATHER OPERATION INFORMATION….1317
Fuel and Lubricants….1317
Cooling System Coolant….1317
Battery….1318
AFTER DAILY WORK COMPLETION….1319
AFTER COLD WEATHER SEASON….1319
LONG TERM STORAGE….1320
BEFORE STORAGE….1320
DURING STORAGE….1320
AFTER STORAGE….1321
STARTING MACHINE AFTER LONG-TERM STORAGE….1321
TROUBLES AND ACTIONS….1322
RUNNING OUT OF FUEL….1322
PHENOMENA THAT ARE NOT FAILURES….1322
TOWING THE MACHINE….1323
LIGHTWEIGHT TOWING HOLE….1323
SEVERE JOB CONDITION….1324
DISCHARGED BATTERY….1325
Battery Removal and Installation….1325
Battery Charges….1326
Starting Engine with Booster Cables….1327
OTHER TROUBLE….1329
Electrical System….1329
Chassis….1330
Engine….1331
Electronic Control System….1333
MAINTENANCE….1334
MAINTENANCE INFORMATION….1335
LUBRICANTS, COOLANT AND FILTERS….1338
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….1338
Oil….1338
Fuel….1338
Cooling System Coolant….1339
Grease….1339
Carrying Out KOWA (Komatsu Oil Wear Analysis)….1340
Oil and Fuel Storage….1341
Filters….1341
ELECTRIC SYSTEM MAINTENANCE….1341
WEAR PARTS….1342
WEAR PARTS LIST….1342
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….1343
PROPER SELECTION….1343
TIGHTENING TORQUE SPECIFICATIONS….1347
TIGHTENING TORQUE LIST….1347
SAFETY CRITICAL PARTS….1348
SAFETY CRITICAL PARTS LIST….1348
MAINTENANCE SCHEDULE….1349
MAINTENANCE SCHEDULE CHART….1349
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….1351
MAINTENANCE PROCEDURE….1352
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….1352
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)….1352
WHEN REQUIRED….1353
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….1353
CLEAN INSIDE OF COOLING SYSTEM….1358
CHECK AND TIGHTEN TRACK SHOE BOLTS….1361
CHECK AND ADJUST TRACK TENSION….1362
CHECK ELECTRICAL INTAKE AIR HEATER….1364
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….1365
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….1368
ADJUST BUCKET CLEARANCE….1369
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….1370
CHECK AND ADJUST AIR CONDITIONER….1371
WASH WASHABLE FLOOR….1372
BLEEDING AIR FROM HYDRAULIC SYSTEM….1376
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT….1379
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit)….1379
CHECK BEFORE STARTING….1380
EVERY 100 HOURS MAINTENANCE….1381
LUBRICATING….1381
CHECK SWING MACHINERY CASE OIL, ADD OIL….1383
EVERY 250 HOURS MAINTENANCE….1384
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….1384
CHECK LEVEL OF BATTERY ELECTROLYTE….1385
EVERY 500 HOURS MAINTENANCE….1388
REPLACE FUEL FILTER CARTRIDGE….1388
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….1389
CHECK SWING PINION GREASE LEVEL, ADD GREASE….1390
LUBRICATE SWING CIRCLE….1390
Radiator Core and Fins – Check/Clean….1391
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….1392
REPLACE HYDRAULIC OIL FILTER ELEMENT….1394
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….1395
CHECK AND ADJUST COOLING FAN BELT TENSION….1396
CHECK, ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION….1397
EVERY 1000 HOURS MAINTENANCE….1398
CHANGE OIL IN SWING MACHINERY CASE….1398
CHANGE OIL IN FINAL DRIVE CASE….1399
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER….1399
CHECK PLAY TURBOCHARGER ROTOR….1399
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)….1399
EVERY 2000 HOURS MAINTENANCE….1400
CHECK PTO GEAR CASE, ADD OIL….1400
CLEAN HYDRAULIC TANK STRAINER….1401
CLEAN, CHECK TURBOCHARGER….1401
CHECK ALTERNATOR, STARTING MOTOR….1401
CHECK ENGINE VALVE CLEARANCE, ADJUST….1401
EVERY 4000 HOURS MAINTENENCE….1402
CHECK WATER PUMP….1402
EVERY 5000 HOURS MAINTENANCE….1403
CHANGE OIL IN HYDRAULIC TANK….1403
SPECIFICATIONS….1404
SPECIFICATIONS….1405
EXPLANATION OF LIFTING CAPACITY CHART (PC130-7K 1- PC BOOM)….1407
EXPLANATION OF LIFTING CAPACITY CHART (PC130-7K 2-PC BOOM)….1408
ATTACHMENTS AND OPTIONS….1412
GENERAL PRECAUTIONS FOR SAFETY….1413
PRECAUTIONS WHEN SELECTING….1413
READ THE INSTRUCTION MANUAL THOROUGHLY….1413
PRECAUTIONS WHEN REMOVING OR INSTALLING….1413
PRECAUTIONS WHEN USING….1414
BUCKET WITH HOOK….1415
HOOK CONDITION….1415
PROHIBITED OPERATIONS….1415
MACHINE READY FOR ATTACHMENT….1416
LOCATIONS….1416
HYDRAULIC CIRCUIT….1419
Hydraulic Circuit Connection….1419
ATTACHMENT REMOVAL AND INSTALLATION….1420
Attachment Removal….1420
Attachment Installation….1420
ATTACHMENT OPERATIONS….1422
When Using Breaker….1422
When Using General Attachment Such as Crusher….1423
ACCUMULATOR….1424
Hydraulic System – Pressure Release….1424
LONG TERM STORAGE….1425
SPECIFICATIONS….1425
ATTACHMENT GUIDE….1426
OTHER ATTACHMENTS….1426
ATTACHMENT COMBINATIONS….1427
TRACK SHOES SELECTION….1428
BUCKET TEETH SELECTION….1429
Teeth Selection….1429
Selection Guide for Horizontal or Vertical Pin Type Tooth….1429
HANDLING OF RUBBER PAD SHOE AND ROAD LINER….1430
Working Environment….1430
Working Conditions….1430
Storage, Protection….1431
Extent of Damage to Rubber….1431
Check Road Liner….1431
Replace Road Liner….1431
RECOMMENDED ATTACHMENT OPERATIONS….1432
HYDRAULIC BREAKER….1432
2-PC BOOM….1437
FEATURES OF 2-PIECE BOOM & ARM….1437
OPERATION….1438
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE….1439
TESTING AND ADJUSTING….1440
PERODIC MAINTENANCE….1440
TRANSPORTATION….1441
INDEX….1444
COLOPHON….1448

Komatsu Hydraulic Excavator PC130-6K, PC150LGP-6K Repair Service Manuals

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INSTANT DOWNLOAD

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INSTANT DOWNLOAD

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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC130, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC130-7, PC130-8 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.

SEBM036300 – Hydraulic Excavator PC130-7 Shop Manual.pdf
SEBM036301 – Hydraulic Excavator PC130-7 Shop Manual.pdf
SEBM036303 – Hydraulic Excavator PC130-7 Shop Manual.pdf
SEN03763-03 – Hydraulic Excavator PC130-8 Shop Manual.pdf
SEN03763-10 – Hydraulic Excavator PC130-8 Shop Manual.pdf
TEN00166-01 – Hydraulic Excavator GALEO PC130-7 Shop Manual.pdf
TEN00266-00TH – Hydraulic Excavator PC130-8 Operation & Maintenance Manual.pdf
TEN00266-06 – Hydraulic Excavator PC130-8 Operation & Maintenance Manual.pdf
TEN00485-00 – Hydraulic Excavator PC130-8 Operation & Maintenance Manual.pdf
TEN00510-00 – Hydraulic Excavator PC130-8 Operation & Maintenance Manual.pdf
TEN00526-00 – Hydraulic Excavator PC130-8 Operation & Maintenance Manual.pdf
UEAM003604 – Hydraulic Excavator PC130-7 Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 5,718 pages
File Format: PDF
Language: English

SEBM036300 – Hydraulic Excavator PC130-7 Shop Manual….2
01(01-10).pdf….0
01 GENERAL….4
general assembly Drawing….5
Specifications….7
Weight table….10
List of lubricants and water….12
10(001-100).pdf….0
10 STRUCTURE AND FUNCTION….4
PTO….15
cooling system….16
Power Train….18
Swing circle….19
SWING MACHINERY….20
Track frame….21
Idler Cushion….22
Hydraulic component Layout….23
valve Control….25
Hydraulic tank and filter….27
Hydraulic Pump (Piston Pump)….28
Control Valve….49
Suction Safety Valve….59
CLSS….60
Self Pressure Reducing Valve….92
Center Swivel Joint….99
Travel Motor (Final Drive)….100
Swing Motor….109
10(101-154).pdf….0
Solenoid Valve….115
PPC Accumulator….117
PPC Valve….118
WORK EQUIPMENT….129
Air Conditioner Piping….130
ENGINE CONTROL….131
Electric Control System….135
Monitor System….163
40(01-48).pdf….0
40 MAINTENANCE STANDARD….4
SWING MACHINERY….170
SWING CIRCLE….172
Track Frame, Idler Cushion….173
carrier roller….175
track roller….176
sprocket….177
Track shoe….178
hydraulic pump….182
CONTROL VALVE….183
Suction Safety Valve….192
Self Pressure Reduction Valve….193
Travel Motor….194
swing motor….195
Solenoid Valve….196
center swivel joint….197
ppc valve….198
hydraulic cylinder….202
WORK equipment….204
dimension of work equipment….206
90(1-).pdf….0
90 OTHERS….210
90(03-)_A2.pdf….0
Hydraulic circuit diagram….212
Electrical circuit diagram (1/4)….214
Electrical circuit diagram (2/4)….216
Electrical circuit diagram (3/4)….218
Electrical circuit diagram (4/4)….220
SEBM036301 – Hydraulic Excavator PC130-7 Shop Manual….222
20-201–.pdf….0
POINTS TO REMEMBER WHEN TROUBLESHOOTING….313
1. When carrying out troubleshooting, do not hurry to disassemble the components….313
2. Points to ask user or operator….313
1) Have any other problems occurred apart from the problem that has been reported?….313
2) Was there anything strange about the machine before the failure occurred?….313
3) Did the failure occur suddenly, or were there problems with the machine condition before this?….313
4) Under what conditions did the failure occur?….313
5) Had any repairs been carried out before the failure?….313
6) Has the same kind of failure occurred before?….313
3. Check before troubleshooting….313
1) Check the oil level….313
2) Check for any external leakage of oil from the piping or hydraulic equipment….313
3) Check the travel of the control levers….313
4) Check the stroke of the control valve spool….313
5) Other maintenance items can be checked externally, so check any item that is considered to be …..313
4. Confirming failure….313
5. Troubleshooting….313
1) Start from the simple points….313
2) Start from the most likely points….313
3) Investigate other related parts or information….313
6. Measures to remove root cause of failure….313
SEQUENCE OF EVENTS IN TROUBLESHOOTING….314
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….315
To maintain the performance of the machine over a long period, and to prevent failures or other t…..315
1. Points to remember when handling electric equipment….315
1) Handling wiring harnesses and connectors….315
1) Defective contact of connectors (defective contact between male and female)….315
2) Defective crimping or soldering of connectors….315
3) Disconnections in wiring….316
4) High-pressure water entering connector….316
5) Oil or dirt stuck to connector….316
2) Removing, installing, and drying connectors and wiring harnesses….317
1) Hold the connectors when disconnecting….317
2) When removing from clips….317
3) Action to take after removing connectors….317
1) Check the connector visually….318
1) Check that there is no oil, dirt, or water stuck to the connector pins (mating portion)….318
2) Check that there is no deformation, defective contact, corrosion, or damage to the connector p…..318
3) Check that there is no damage or breakage to the outside of the connector….318
2) Fix the connector securely….318
3) Correct any protrusion of the boot and any misalignment of the wiring harness….318
4) If the connector clamp has been removed, be sure to return it to its original position. Check …..318
1) Disconnect the connector and wipe off the water with a dry cloth….319
2) Dry the inside of the connector with a dryer….319
3) Carry out a continuity test on the connector….319
3) Handling control box….320
1) The control box contains a microcomputer and electronic control circuits. These control all of…..320
2) Do not open the cover of the control box unless necessary….320
3) Do not place objects on top of the control box….320
4) Cover the control connectors with tape or a vinyl bag….320
5) During rainy weather, do not leave the control box in a place where it is exposed to rain….320
6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time….320
7) Precautions when carrying out arc welding….320
2. Points to remember when troubleshooting electric circuits….320
1) Always turn the power OFF before disconnecting or connect connectors….320
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted….320
3) Always connect any disconnected connectors before going on to the next step….320
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, …..320
3. Points to remember when handling hydraulic equipment….321
With the increase in pressure and precision of hydraulic equipment, the most common cause of fail…..321
1) Be careful of the operating environment….321
2) Disassembly and maintenance work in the field….321
3) Sealing openings….321
4) Do not let any dirt or dust get in during refilling operations….321
5) Change hydraulic oil when the temperature is high….322
6) Flushing operations….322
7) Cleaning operations….322
Inspection before troubleshooting….323
Classification of and procedures for troubleshooting….324
If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No…..324
1. Procedure for troubleshooting to be taken when user code is displayed on monitor panel:….324
2. Procedure for troubleshooting when electrical system error code or mechanical system error cod…..324
3. Procedure for troubleshooting to be taken when user code is not displayed and error history is…..324
Connector arrangement drawing and electric circuit diagram of each system….328
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….345
[The pin No. is also marked on the connector (electric wire insertion end)]….359
[The pin No. is also marked on the connector (electric wire insertion end)]….360
[The pin No. is also marked on the connector (electric wire insertion end)]….361
[The pin No. is also marked on the connector (electric wire insertion end)]….362
[The pin No. is also marked on the connector (electric wire insertion end)]….363
[The pin No. is also marked on the connector (electric wire insertion end)]….364
[The pin No. is also marked on the connector (electric wire insertion end)]….365
8GR: 799-601-9060….365
8B: 799-601-9070….365
8G: 799-601-9080….365
8BR: 799-601-9090….365
12GR: 799-601-9110….365
12B: 799-601-9120….365
12G: 799-601-9130….365
12BR: 799-601-9140….365
[The pin No. is also marked on the connector (electric wire insertion end)]….366
[The pin No. is also marked on the connector (electric wire insertion end)]….366
[The pin No. is also marked on the connector (electric wire insertion end)]….367
T-BRANCH BOX AND T-BRANCH TABLE….368
TROUBLESHOOTING….312
SEBM036303 – Hydraulic Excavator PC130-7 Shop Manual….564
COVER….564
CONTENTS….565
01 GENERAL….589
GENERAL ASSEMBLY DRAWING….590
SPECIFICATIONS….592
WEIGHT TABLE….595
LIST OF LUBRICANTS AND WATER….597
10 STRUCTURE AND FUNCTION ….598
PTO….599
COOLING SYSTEM….600
POWER TRAIN ….602
SWING CIRCLE….603
SWING MACHINERY….604
TRACK FRAME….605
IDLER CUSHION….606
HYDRAULIC COMPONENT LAYOUT….607
VALVE CONTROL….609
HYDRAULIC TANK AND FILTER….611
HYDRAULIC PUMP (PISTON PUMP)….612
CONTROL VALVE….633
SUCTION SAFETY VALVE….643
CLASS….644
SELF PRESSURE REDUCING VALVE….680
CENTER SWIVEL JOINT….687
TRAVEL MOTOR (FINAL DRIVE)….688
SWING MOTOR….697
SOLENOID VALVE….703
PPC ACCUMULATOR….705
PPC VALVE….706
WORK EQUIPMENT….717
AIR CONDITIONER PIPING….718
ENGINE CONTROL ….719
ELECTRIC CONTROL SYSTEM….723
MONITOR SYSTEM….750
20 TESTING AND ADJUSTING….756
STANDARD VALUE TABLE FOR ENGINE….757
STANDARD VALUE TABLE FOR CHASSIS….758
TESTING AND ADJUSTING….767
TOOLS FOR TESTING,ADJUSTING, AND TROUBLESHOOTING….768
TESTING AND ADJUSTING ENGINE SPEED….770
MEASURING EXHAUST GAS COLOR….771
ADJUSTING VALVE CLEARANCE….773
MEASURING COMPRESSION PRESSURE….775
MEASURING BLOW-BY PRESSURE….776
MEASURING ENGINE OIL PRESSURE….777
TESTING AND ADJUSTING FOR FUEL INJECTION TIMING….778
ADJUSTING ENGINE SPEED SENSOR….782
TESTING AND ADJUSTING FAN BELT TENSION….783
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION….784
MEASURING CLEARANCE OF SWING CIRCLE BEARING….785
TESTING AND ADJUSTING TRACK SHOE TENSION….786
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,SWING,AND TRAVEL CIRCUITS….788
MEASURING CONTROL CIRCUIT BASIC PRESSURE….791
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT….792
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT….795
MEASURING SOLENOID VALVE OUTPUT PRESSURE….799
MEASURING PPC VALVE OUTPUT PRESSURE….801
ADJUSTMENT PLAY OF WORK EQUIPMENT AND SWING PPC VALVES….802
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT….803
MEASURING OIL LEAKAGE….805
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT….808
BLEEDING AIR FROM EACH PART….809
TESTING PROCEDURES FOR DIODE….812
SPECIAL FUNCTIONS OF MONITOR PANEL ….813
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM….831
PM-CLINIC SERVICE….832
TROUBLESHOOTING….837
POINTS TO REMEMBER WHEN TROUBLESHOOTING….838
SEQUENCE OF EVENTS IN TROUBLESHOOTING….839
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE….840
INSPECTION BEFORE TROUBLESHOOTING….848
CLASSIFICATION OF AND PROCEDURES FOR TROUBLESHOOTING ….849
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF EACH SYSTEM….853
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS….868
T-BRANCH BOX AND T-BRANCH TABLE….891
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (DISPLAY OF ERROR CODE)….893
BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED….894
INFORMATION IN TROUBLESHOOTING TABLE….899
ERROR CODE [104] (CLOGGING OF AIR CLEANER)….901
ERROR CODE [108] (OVERHEATING OF ENGINE COOLANT)….902
ERROR CODE [112] (SHORT CIRCUIT IN WIPER MOTOR DRIVE FORWARD SYSTEM)….903
ERROR CODE [113] (SHORT CIRCUIT IN WIPER MOTOR DRIVE REVERSE SYSTEM)….905
ERROR CODE [114] (SHORT CIRCUIT IN WIND SHIELD WASHER DRIVE SYSTEM)….907
ERROR CODE [115] (TROUBLE IN OPERATION OF WINDSHIELD WIPER)….909
ERROR CODE [116] (TROUBLE IN STORAGE OF WINDSHIELD WIPER)….911
ERROR CODE [203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID)….913
ERROR CODE [205] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID)….915
ERROR CODE [206] (SHORT CIRCUIT IN TRAVEL SPEED SHIFTING SOLENOID)….917
ERROR CODE [213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)….919
ERROR CODE [215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID)….921
ERROR CODE [216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)….923
ERROR CODE [217] (ABNORMALITY IN INPUT MODEL CODE)….925
ERROR CODE [218] (DISCONNECTION IN S-NET SIGNAL LINE)….927
ERROR CODE [222] (SHORT CIRCUIT IN LS-EPC SOLENOID)….929
ERROR CODE [223] (DISCONNECTION IN LS-EPC SOLENOID)….930
ERROR CODE [224] (ABNORMALITY IN PUMP PRESSURE SENSOR)….931
ERROR CODE [226] (ABNORMALITY IN PRESSURE SENSOR POWER SUPPLY)….933
ERROR CODE [227] (ABNORMALITY IN ENGINE SPEED SENSOR)….935
ERROR CODE [232] (SHORT CIRCUIT IN PC-EPC SOLENOID)….937
ERROR CODE [233] (DISCONNECTION IN PC-EPC SOLENOID)….939
ERROR CODE [251] (ABNORMALITY IN OVERLOAD PRESSURE SENSOR)….941
ERROR CODE [301] (ENGINE LOW IDLING SPEED OUT OF STANDARD RANGE)….943
ERROR CODE [302] (ENGINE HIGH IDLING SPEED OUT OF STANDARD RANGE)….943
ERROR CODE [306] (ABNORMALITY IN GOVERNOR POTENTIOMETER)….944
ERROR CODE [308] (ABNORMALITY IN FUEL CONTROL DIAL)….946
ERROR CODE [315] (SHORT CIRCUIT IN BATTERY RELAY OUTPUT LINE)….948
ERROR CODE [316] (STEP-OUT OF GOVERNOR MOTOR)….950
ERROR CODE [317] (DISCONNECTION IN PHASES A AND B OF GOVERNOR MOTOR)….951
ERROR CODE [318] (SHORT CIRCUIT IN PHASES A AND B OF GOVERNOR MOTOR)….953
TROUBLESHOOTING FOR ELECTRICAL SYSTEM (E-MODE)….955
BEFORE CARRYING OUT TROUBLESHOOTING WHEN CODE IS DISPLAYED….956
INFORMATION IN TROUBLESHOOTING TABLE….957
E-1 ENGINE DOES NOT START ….958
E-2 ENGINE STOPS DURING OPERATION….961
E-3 ENGINE SPEED IS UNSTABLE OR ENGINE HUNTS….963
E-4 ENGINE DOES NOT STOP….965
E-5 AUTO-DECELERATOR DOES NOT OPERATE….967
E-6 AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE….968
E-7 PREHEATER DOES NOT OPERATE….969
E-8 WORK EQUIPMENT, SWING AND TRAVEL SYSTEM DO NOT OPERATE….971
E-9 ONE-TOUCH POWER MAXIMIZING SYSTEM DOES NOT OPERATE….973
E-10 NO ITEMS OF MONITOR PANEL LIGHT UP….974
E-11 7-SEGMENT LED'S OF MONITOR PANEL DOES NOT LIGHT UP PARTIALLY….975
E-12 MONITOR LAMP OF MONITOR PANEL IS DIFFERENT FROM MOUNTED MODEL….975
E-13 WHEN STARTING SWITH IS TURNED ON,BASIC CHECK ITEMS LIGHT UP OR FLASH….976
E-14 WHILE ENGINE IS RUNNING,CAUTION ITEMS FLASH….977
E-15 WHILE ENGINE IS RUNNING,EMERGENCY STOP ITEMS FLASH….981
E-16 ENGINE COOLANT THERMOMETER IS ABNORMAL….983
E-17 FUEL LEVEL GAUGE IS ABNORMAL….984
E-18 SWING LOCK MONITOR IS ABNORMAL….985
E-19 WHEN MONITOR SWITCH IS OPERATED,DISPLAY BY LAMP DOES NOT CHANGE ….987
E-20 WINDSHIELD WIPER AND WINDSHIELD WASHER DO NOT OPERATE….988
E-21 LOWER WINDSHIELD WIPER DOES NOT OPERATE….992
E-22 CAUTION BUZZER DOES NOT STOP….994
E-23 MONITORING FUNCTION DOES NOT DISPLAY "BOOM RAISE" NORMALLY….996
E-24 MONITORING FUNCTION DOES NOT DISPLAY "BOOM LOWER" NORMALLY….998
E-25 MONITORING FUNCTION DOES NOT DISPLAY "ARM IN" NORMALLY….1000
E-26 MONITORING FUNCTION DOES NOT DISPLAY "ARM OUT" NORMALLY….1002
E-27 MONITORING FUNCTION DOES NOT DISPLAY "BUCKET CURL" NORMALLY….1004
E-28 MONITORING FUNCTION DOES NOT DISPLAY "BUCKET DUMP" NORMALLY….1006
E-29 MONITORING FUNCTION DOES NOT DISPLAY "SWING" NORMALLY….1008
E-30 MONITORING FUNCTION DOES NOT DISPLAY "TRAVEL" NORMALLY….1010
E-31 MONITORING FUNCTION DOES NOT DISPLAY "SERVICE" NORMALLY….1012
E-32 TROUBLESHOOTING OF AIR CONDITIONER ….1016
E-33 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING….1027
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)….1029
INFORMATION IN TROUBLESHOOTING TABLE….1030
HYDRAULIC AND MECHANICAL SYSTEM DIAGRAM….1031
H-1 SPEED OR POWER OF WHOLE WORK EQUIPMENT,SWING,AND TRAVEL IS LOW….1033
H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS….1034
H-3 WORK EQUIPMENT,SWING,AND TRAVEL SYSTEMS DO NOT WORK….1035
H-4 ABNORMAL SOUND COMES OUT FROM AROUND HYDRAULIC PUMP….1035
H-5 AUTO-DECELERATOR DOES NOT OPERATE….1036
H-6 FINE CONTROL PERFORMANCE OR RESPONSE IS LOW….1036
H-7 SPEED OR POWER OF BOOM IS LOW….1037
H-8 SPEED OR POWER OF ARM IS LOW….1038
H-9 SPEED OR POWER OF BUCKET IS LOW….1039
H-10 WORK EQUIPMENT DOES NOT MOVE SINGLY….1040
H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE….1041
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE….1042
H-13 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK….1042
H-14 IN COMPOUND OPERATION OF WORK EQUIPMENT,SPEED OF PART LOADED MORE IS LOW….1043
H-15 WHEN MACHINE SWINGS AND RAISES BOOM SIMULTANEOUSLY,BOOM RISING SPEED IS LOW….1043
H-16 WHEN MACHINE OPERATES WORK EQUIPMENT OR SWINGS AND TRAVELS SIMULTANEOUSLY,TRAVEL SPEED LOWERS LARGELY….1043
H-17 MACHINES DEVIATES DURING TRAVEL….1044
H-18 TRAVEL SPEED IS LOW….1045
H-19 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW….1046
H-20 TRAVEL SPEED DOES NOT CHANGE….1046
H-21 TRAVEL MOTOR DOES NOT WORK (ONLY ONE SIDE)….1047
H-22 UPPER STRUCTURE DOES NOT SWING….1048
H-23 SWING ACCELERATION OR SWING SPEED IS LOW….1049
H-24 UPPER STRUCTURE OVERTURNS REMARKABLY WHEN IT STOPS SWINGING….1050
H-25 LARGE SHOCK IS MADE WHEN UPPER STRUCTURE STOPS SWINGING….1051
H-26 LARGE SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGING….1051
H-27 HYDRAULIC DRIFT OF SWING IS LARGE….1052
TROUBLESHOOTING OF ENGINE (S-MODE)….1053
METHOD OF USING TROUBLESHOOTING CHARTS….1054
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)….1058
S-2 ENGINE DOES NOT START….1060
(1) ENGINE DOES NOT TURN….1060
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)….1061
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS NOT BEING INJECTED)….1062
S-3 ENGINE DOES NOT PICK-UP SMOOTHLY (FOLLOW-UP IS POOR)….1063
S-4 ENGINE STOPS DURING OPERATIONS….1064
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)….1065
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)….1066
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)….1067
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)….1068
S-9 OIL BECOMES CONTAMINATED QUICKLY….1069
S-10 FUEL CONSUMPTION IS EXCESSIVE….1070
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN….1071
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)….1072
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)….1073
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)….1074
S-15 ABNORMAL NOISE IS MADE….1075
S-16 VIBRATION IS EXCESSIVE….1076
30 DISASSEMBLY AND ASSEMBLY….1077
HOW TO READ THIS MANUAL….1078
PRECAUTIONS WHEN PERFORMING OPERATION….1080
SPECIAL TOOL LIST….1082
SKETCH OF SPECIAL TOOL ….1085
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY….1086
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY….1089
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY….1094
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY….1095
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY….1097
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY….1099
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY….1104
REMOVAL AND INSTALLATION OF SPROCKET….1106
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY….1107
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY….1108
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING….1111
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY….1115
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY….1116
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY….1117
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY….1118
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT….1124
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY….1126
REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY….1127
REMOVAL AND INSTALLATION OF REVOLVING FRAME….1130
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY….1132
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY….1133
REMOVAL AND INSTALLATION OF CONTROL VALUE ASSEMBLY….1136
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY….1139
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY….1141
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP INPUT SHAFT OIL SEAL….1144
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY….1145
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY….1151
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY….1152
REMOVAL AND INSTALLATION OF OPERATOR'S CAB….1155
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)….1159
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY….1170
REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY….1177
REMOVAL AND INSTALLATION OF CONTROLLER ASSEMBLY….1178
40 MAINTENANCE STANDARD….1179
SWING MACHINERY….1180
SWING CIRCLE ….1182
TRACK FRAME,IDLER CUSHION….1183
IDLER….1184
CARRIER ROLLER….1185
TRACK ROLLER….1186
SPROCKET….1187
TRACK SHOE….1188
HYDRAULIC PUMP….1192
CONTROL VALVE….1193
SUCTION SAFETY VALVE….1202
SELF PRESSURE REDUCTION VALVE….1203
TRAVEL MOTOR….1204
SWING MOTOR….1205
SOLENOID VALVE….1206
CENTER SWIVEL JOINT….1207
PPC VALVE….1208
HYDRAULIC CYLINDER….1211
WORK EQUIPMENT….1213
DIMENSION OF WORK EQUIPMENT….1215
90 OTHERS….1219
HYDRAULIC CIRCUIT DIAGRAM ….1220
ELECTRICAL CIRCUIT DIAGRAM (1/4)….1221
ELECTRICAL CIRCUIT DIAGRAM (2/4)….1222
ELECTRICAL CIRCUIT DIAGRAM (3/4)….1223
ELECTRICAL CIRCUIT DIAGRAM (4/4)….1224
SEN03763-03 – Hydraulic Excavator PC130-8 Shop Manual….1225
COVER….1225
00 Index and foreword….0
Index….1226
Composition of shop manual….1227
Table of contents….1229
Foreword and general information….1238
Safety notice….1239
How to read the shop manual….1244
Explanation of terms for maintenance standard….1246
Handling of electric equipment and hydraulic component….1248
Handling of connectors newly used for engines….1257
How to read electric wire code….1260
Precautions when carrying out operation….1263
Method of disassembling and connecting push-pull type coupler….1266
Standard tightening torque table….1269
Conversion table….1273
01 Specification….0
Specification and technical data….1280
Specification dimension drawings….1281
Working range diagram….1282
Specifications….1283
List of weights….1287
List of lubricant and coolant to be filled….1289
10 Structure, function and maintenance standard….0
Engine and cooling system….1292
Engine mount….1293
PTO….1294
Cooling system….1295
Power train….1298
Power train….1299
Swing circle….1300
Swing machinery….1301
Undercarriage and frame….1304
Track frame….1305
Idler cushion….1306
Idler….1307
Track roller….1308
Carrier roller….1309
Sprocket….1310
Track shoe….1311
Hydraulic system, Part 1….1316
Hydraulic equipment layout drawing….1317
Valve control….1319
Hydraulic tank and filter….1321
Hydraulic pump….1323
Hydraulic system, Part 2….1352
Control valve….1353
CLSS….1363
Functions and operation by valve….1367
Hydraulic system, Part 3….1398
PPC valve….1399
Swing motor….1414
Travel motor….1422
Center swivel joint….1431
Solenoid valve….1433
Accumulator….1437
Holding valve….1439
Hydraulic cylinder….1445
Work equipment….1448
Work equipment….1449
Dimensions of components….1451
Cab and its attachments….1456
Air conditioner….1457
Electrical system….1460
Electronic control system….1461
Machine monitor system….1492
KOMTRAX system….1506
Sensor….1508
20 Standard value table….0
Standard service value table….1516
Standard value table for engine related parts….1517
Standard value table for chassis related parts….1518
30 Testing and adjusting….0
Testing and adjusting, Part 1….1528
Tools for testing, adjusting, and troubleshooting….1530
Testing engine speed….1534
Testing exhaust temperature….1535
Checking exhaust gas color….1536
Adjusting valve clearance….1537
Testing compression pressure….1539
Testing blow-by pressure….1541
Testing engine oil pressure….1542
Handling fuel system parts….1543
Releasing residual pressure from fuel system….1543
Testing fuel pressure….1544
Testing fuel return rate and fuel leakage….1545
Bleeding air from fuel circuit….1547
Checking fuel circuit for leakage….1549
Testing and adjusting alternator belt tension….1550
Checking and adjusting air conditioner compressor belt tension….1551
Testing swing circle bearing clearance….1552
Checking and adjusting track shoe tension….1553
Testing and adjusting oil pressure in work equipment, swing, and travel circuits….1555
Testing control circuit basic pressure….1558
Testing and adjusting oil pressure in pump PC control circuit….1559
Testing and adjusting oil pressure in pump LS control circuit….1562
Testing solenoid valve output pressure….1565
Testing PPC valve output pressure….1569
Adjusting play of work equipment and swing PPC valves….1570
Checking parts which cause hydraulic drift of work equipment….1571
Testing and adjusting travel deviation….1573
Releasing residual pressure from hydraulic circuit….1575
Testing oil leakage….1576
Bleeding air from each part….1579
Checking cab tipping stopper….1581
Installation and adjustment of mirrors and camera….1582
Inspection of air conditioner Recirc/Fresh air filter….1586
Testing and adjusting, Part 2….1588
Special functions of machine monitor….1589
Testing and adjusting, Part 3….1640
Handling voltage circuit of engine controller….1641
Preparation work for troubleshooting of electrical system….1642
Procedure for testing diodes….1647
Pm Clinic service….1648
40 Troubleshooting….0
Failure code table and fuse locations….1654
Failure code table….1655
Fuse locations….1659
General information on troubleshooting….1662
Points to remember when troubleshooting….1663
Sequence of events in troubleshooting….1664
Checks before troubleshooting….1665
Classification and procedures for troubleshooting….1666
Information in troubleshooting table….1667
Phenomena looking like troubles and troubleshooting Nos….1669
Connection table for connector pin numbers….1672
T- branch box and T- branch adapter table….1708
Troubleshooting by failure code, Part 1….1712
Failure code [989L00] Engine controller lock caution 1….1714
Failure code [989M00] Engine controller lock caution 2….1714
Failure code [989N00] Engine controller lock caution 3….1715
Failure code [AA10NX] Air cleaner clogging….1716
Failure code [AB00KE] Charge voltage low….1717
Failure code [B@BAZG] Eng oil press. low….1719
Failure code [B@BAZK] Eng oil level low….1720
Failure code [B@BCNS] Eng coolant overheat….1721
Failure code [B@BCZK] Eng water level low….1723
Failure code [B@HANS] Hydr oil overheat….1725
Failure code [CA111] ECM critical internal failure….1727
Failure code [CA115] Eng Ne and Bkup speed sensor error….1730
Failure code [CA122] Charge air press sensor high error….1731
Failure code [CA123] Charge air press sensor low error….1733
Failure code [CA131] Throttle sensor high error….1735
Failure code [CA132] Throttle sensor low error….1737
Failure code [CA144] Coolant temp. sensor high error….1739
Failure code [CA145] Coolant temp. sensor low error….1741
Failure code [CA153] Charge air temp. sensor high error….1743
Failure code [CA154] Charge air temp. sensor low error….1745
Failure code [CA155] Chg air temp high speed derate….1745
Failure code [CA187] Sensor sup. 2 volt. low error….1746
Failure code [CA221] Ambient air press. sensor high error….1747
Failure code [CA222] Ambient air press. sensor low error….1749
Failure code [CA227] Sensor sup. 2 volt. high error….1750
Failure code [CA234] Eng. overspeed….1751
Failure code [CA238] Ne speed sensor sup. volt. error….1753
Failure code [CA271] IMV/PCV1 short error….1755
Failure code [CA272] IMV/PCV1 open error….1756
Failure code [CA322] Injector #1 (L #1) system open/short error….1757
Failure code [CA324] Injector #3 (L #3) system open/short error….1759
Failure code [CA331] Injector #2 (L #2) system open/short error….1761
Failure code [CA332] Injector #4 (L #4) system open/short error….1763
Troubleshooting by failure code, Part 2….1766
Failure code [CA342] Calibration code incompatibility….1768
Failure code [CA351] Inj. drive circuit error….1769
Failure code [CA352] Sensor sup. 1 volt. low error….1772
Failure code [CA386] Sensor sup. 1 volt. high error….1773
Failure code [CA435] Abnormality in engine oil pressure switch….1775
Failure code [CA441] Battery voltage low error….1776
Failure code [CA442] Battery voltage high error….1777
Failure code [CA449] Rail press. very high error….1778
Failure code [CA451] Rail press. sensor high error….1779
Failure code [CA452] Rail press. sensor low error….1781
Failure code [CA488] Chg air temp high torque derate….1782
Failure code [CA553] Rail press. high error….1783
Failure code [CA559] Rail press. low error….1784
Failure code [CA689] Eng. Ne speed sensor error….1787
Failure code [CA731] Eng. Bkup speed sensor phase error….1789
Failure code [CA757] All persistent data lost error….1790
Failure code [CA778] Eng. Bkup speed sensor error….1791
Failure code [CA1633] KOMNET datalink timeout error….1793
Failure code [CA2185] Throttle sens. sup. volt. high error….1795
Failure code [CA2186] Throttle sens. sup. volt. low error….1797
Failure code [CA2249] Rail press. very low error….1797
Failure code [CA2311] Abnormality in IMV solenoid….1798
Failure code [D110KB] Battery relay drive short….1799
Failure code [D19JKZ] Personal code relay abnormality….1801
Failure code [D862KA] GPS antenna discon….1803
Failure code [DA22KK] Pump solenoid power low error….1805
Failure code [DA25KP] 5V sensor 1 power abnormality….1807
Failure code [DA26KP] 5V sensor 2 power abnormality….1810
Failure code [DA29KQ] Model selection abnormality….1811
Troubleshooting by failure code, Part 3….1814
Failure code [DA2RMC] CAN discon (Pump controller detected)….1817
Failure code [DAF8KB] Short circuit in camera power supply….1819
Failure code [DAFGMC] GPS module error….1821
Failure code [DAFRMC] CAN discon (Monitor detected)….1823
Failure code [DGH2KB] Hydr oil sensor short….1825
Failure code [DHPAMA] Pump press sensor abnormality….1827
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality….1829
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality….1831
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality….1833
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality….1835
Failure code [DHX1MA] Overload sensor abnormality (Analog)….1837
Failure code [DV20KB] Travel alarm short circuit….1838
Failure code [DW43KA] Travel speed sol discon….1839
Failure code [DW43KB] Travel speed sol short….1840
Failure code [DW45KA] Swing brake sol discon….1841
Failure code [DW45KB] Swing brake sol short….1843
Failure code [DW91KA] Travel junction sol discon….1845
Failure code [DW91KB] Travel junction sol short….1847
Failure code [DWJ0KA] Merge-divider sol discon….1849
Failure code [DWJ0KB] Merge-divider sol short….1851
Failure code [DWK0KA] 2-stage relief sol discon….1853
Failure code [DWK0KB] 2-stage relief sol short….1855
Troubleshooting by failure code, Part 4….1858
Failure code [DXA8KA] PC-EPC sol discon….1859
Failure code [DXA8KB] PC-EPC sol short….1861
Failure code [DXE4KA] Service current EPC discon….1863
Failure code [DXE4KB] Service current EPC short….1865
Failure code [DY20KA] Wiper working abnormality….1867
Failure code [DY20MA] Wiper parking abnormality….1869
Failure code [DY2CKA] Washer drive discon….1871
Failure code [DY2CKB] Washer drive short….1873
Failure code [DY2DKB] Wiper drive (for) short….1875
Failure code [DY2EKB] Wiper drive (rev) short….1877
Troubleshooting of electrical system (E-mode)….1880
Before carrying out troubleshooting of electrical system….1882
Information in troubleshooting table….1884
E-1 When starting switch turned ON, machine monitor displays nothing….1885
E-2 When starting switch turned ON (before starting engine), basic check item lights up….1887
E-3 Engine does not start (Engine does not turn)….1890
E-4 Preheater does not operate….1893
E-5 Automatic warm-up system does not operate (in cold season)….1895
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked….1897
E-7 Precaution lights up while engine is running….1899
E-8 Emergency stop item lights up while engine is running….1904
E-9 Engine coolant temperature gauge does not indicate normally….1905
E-10 Hydraulic oil temperature gauge does not indicate normally….1906
E-11 Fuel level gauge does not indicate normally….1908
E-12 Contents of display by machine monitor are different from applicable machine….1910
E-13 Machine monitor does not display some items….1910
E-14 Function switch does not work….1910
E-15 Auto-decelerator does not operate normally….1911
E-16 Working mode does not change….1912
E-17 Travel speed does not change….1913
E-18 Alarm buzzer cannot be stopped….1914
E-19 Windshield wiper and window washer do not operate….1915
E-20 Power maximizing function does not operate normally….1919
E-21 Swing holding brake does not operate normally….1921
E-22 Travel alarm does not sound or does not stop sounding….1923
E-23 Air conditioner does not operate normally (including air conditioner abnormality record)….1924
E-24 While starting switch is in OFF position, service meter is not displayed….1936
E-25 Machine monitor cannot be set in service mode….1936
E-26 Monitoring function does not display lever control signal normally….1937
E-27 KOMTRAX system does not operate normally….1953
Troubleshooting of hydraulic and mechanical system (H-mode)….1956
Information contained in troubleshooting table….1958
System chart for hydraulic and mechanical systems….1959
H-1 Speed or power of all work equipment, swing, and travel are low….1961
H-2 Engine speed sharply drops or engine stalls….1962
H-3 No work equipment, travel and swing move….1963
H-4 Abnormal noise is heard from around hydraulic pump….1963
H-5 Fine control mode does not function….1964
H-6 Speed or power of boom is low….1965
H-7 Speed or power of arm is low….1966
H-8 Speed or power of bucket is low….1967
H-9 Work equipment does not move in its single operation….1968
H-10 Hydraulic drift of work equipment is large….1969
H-11 Time lag of work equipment is large….1970
H-12 Power maximizing function does not operate normally….1970
H-13 Work equipment loaded more is slower during compound operation….1971
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE….1971
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel….1972
H-16 Machine deviates during travel….1973
H-17 Travel speed is low….1974
H-18 Machine cannot be steered easily or steering power is low….1975
H-19 Travel speed does not change or it is kept low or high….1976
H-20 Track does not move (Only either side)….1976
H-21 Machine does not swing….1977
H-22 Swing acceleration or swing speed is low….1978
H-23 Excessive overrun when stopping swing….1979
H-24 When upper structure stops swinging, it makes large shock….1980
H-25 When upper structure stops swinging, it makes large sound….1980
H-26 Hydraulic drift of swing is large….1981
H-27 Flow rate in attachment circuit cannot be adjusted….1982
Troubleshooting of engine (S-mode)….1984
Method of using troubleshooting chart….1987
S-1 Starting performance is poor….1991
S-2 Engine does not start….1992
S-3 Engine does not pick up smoothly….1995
S-4 Engine stops during operations….1996
S-5 Engine does not rotate smoothly….1997
S-6 Engine lacks output (or lacks power)….1998
S-7 Exhaust smoke is black (incomplete combustion)….1999
S-8 Oil consumption is excessive (or exhaust smoke is blue)….2000
S-9 Oil becomes contaminated quickly….2001
S-10 Fuel consumption is excessive….2002
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)….2003
S-12 Oil pressure drops….2004
S-13 Oil level rises (Entry of coolant or fuel)….2005
S-14 Coolant temperature becomes too high (overheating)….2006
S-15 Abnormal noise is made….2007
S-16 Vibration is excessive….2008
50 Disassembly and assembly….0
General information on disassembly and assembly….2010
How to read this manual….2011
Coating materials list….2013
Special tool list….2016
Sketch of special tool….2020
Engine and cooling system….2026
Removal and installation of fuel supply pump assembly….2027
Removal and installation of fuel injector assembly….2030
Removal and installation of front oil seal….2033
Removal and installation of rear oil seal….2035
Removal and installation of cylinder head assembly….2038
Removal and installation of radiator assembly….2048
Removal and installation of aftercooler assembly….2050
Removal and installation of work equipment oil cooler assembly….2052
Removal and installation of engine and work equipment pump assembly….2054
Removal and installation of fuel tank assembly….2062
Power train….2066
Removal and installation of travel motor and final drive assembly….2067
Removal and installation of swing motor and swing machinery assembly….2069
Disassembly and assembly of swing machinery assembly….2071
Removal and installation of swing circle assembly….2077
Undercarriage and frame….2080
Disassembly and assembly of track roller….2081
Disassembly and assembly of idler assembly….2084
Disassembly and assembly of recoil spring….2087
Spreading and installation of track shoe assembly….2090
Removal and installation of sprocket….2092
Removal and installation of revolving frame assembly….2093
Removal and installation of counterweight assembly….2095
Hydraulic system….2098
Removal and installation of center swivel joint assembly….2099
Disassembly and assembly of center swivel joint assembly….2101
Removal and installation of hydraulic tank assembly….2102
Removal and installation of work equipment pump assembly….2105
Removal and installation of control valve assembly….2109
Disassembly and assembly of control valve assembly….2113
Disassembly and assembly of work equipment PPC valve assembly….2125
Disassembly and assembly of travel PPC valve assembly….2127
Disassembly and assembly of hydraulic cylinder assembly….2130
Work equipment….2138
Removal and installation of work equipment assembly….2139
Cab and its attachments….2144
Removal and installation of operator's cab assembly….2145
Removal and installation of operator cab glass (stuck glass)….2148
Removal and installation of front window assembly….2158
Removal and installation of floor frame assembly….2165
Electrical system….2170
Removal and installation of air compressor assembly….2171
Removal and installation of air conditioner condenser….2172
Removal and installation of air compressor unit assembly….2173
Removal and installation of KOMTRAX communication modem assembly….2176
Removal and installation of monitor assembly….2177
Removal and installation of pump controller assembly….2179
Removal and installation of engine controller assembly….2181
90 Diagrams and drawings….0
Hydraulic diagrams and drawings….2184
Hydraulic circuit diagram (1/2)….2186
Hydraulic circuit diagram (2/2)….2187
Electrical diagrams and drawings….2190
Electrical circuit diagram (1/5)….2192
Electrical circuit diagram (2/5)….2193
Electrical circuit diagram (3/5)….2194
Electrical circuit diagram (4/5)….2195
Electrical circuit diagram (5/5)….2196
Connectors table and arrangement drawing….2197
SEN03763-10 – Hydraulic Excavator PC130-8 Shop Manual….2200
Cover….2200
00 Index and foreword….0
Index….2202
Composition of shop m….2203
Table of cont….2205
Foreword and general information….2215
Safety notice….2216
How to read the shop manual….2221
Explanation of terms for maintenance standard….2223
Handling of electric equipment and hydraulic component….2225
Handling of connectors newly used for engines….2234
How to read electric wire code….2237
Precautions when carrying out operation….2240
Method of disassembling and connecting push-pull type coupler….2243
Standard tightening torque table….2246
Conversion table….2250
01 Specification….0
Specification and technical data….2257
Specification dimension drawings….2258
Working range diagram….2259
Specifications….2260
List of weights….2264
List of lubricant and coolant to be filled….2266
10 Structure, function and maintenance standard….0
Engine and cooling system….2269
Engine mount….2270
PTO….2271
Cooling system….2272
Power train….2275
Power train….2276
Swing circle….2277
Swing machinery….2278
Undercarriage and frame….2281
Track frame….2282
Idler cushion….2283
Idler….2284
Track roller….2285
Carrier roller….2286
Sprocket….2287
Track shoe….2288
Hydraulic system, Part 1….2293
Hydraulic equipment layout drawing….2294
Valve control….2296
Hydraulic tank and filter….2298
Hydraulic pump….2300
Hydraulic system, Part 2….2329
Control valve….2330
CLSS….2340
Functions and operation by valve….2344
Hydraulic system, Part 3….2375
PPC valve….2376
Swing motor….2391
Travel motor….2399
Center swivel joint….2408
Solenoid valve….2410
Accumulator….2414
Holding valve….2416
Hydraulic cylinder….2422
Work equipment….2425
Work equipment….2426
Dimensions of components….2428
Cab and its attachments….2433
Air conditioner….2434
Electrical system….2438
Electronic control system….2439
Machine monitor sy….2471
KOMTRAX system….2485
Sensor….2487
20 Standard value table….0
Standard service value table….2437
Standard value table for engine related parts….2496
Standard value table for chassis related parts….2497
30 Testing and adjusting….0
Testing and adjusting, Part 1….2507
Tools for testing, adjusting, and troubleshooting….2509
Sketches of special tools….2514
Testing engine speed….2515
Testing exhaust temperature….2516
Checking exhaust gas color….2517
Adjusting valve clearance….2518
Testing compression pressure….2520
Testing blow-by pressure….2522
Testing engine oil pressure….2523
Reduced cylinder mode operation….2524
No-injection cranking….2524
Handling fuel system parts….2525
Releasing residual pressure from fuel system….2525
Testing fuel pressure….2526
Testing fuel return rate and fuel leakage….2527
Bleeding air from fuel circuit….2529
Checking fuel circuit for leakage….2530
Testing and adjusting alternator belt tension….2531
Checking and adjusting air conditioner compressor belt tension….2532
Testing swing circle bearing clearance….2533
Checking and adjusting track shoe tension….2534
Testing and adjusting oil pressure in work equipment, swing, and travel circuits….2536
Testing control circuit basic pressure….2539
Testing and adjusting oil pressure in pump PC control circuit….2540
Testing and adjusting oil pressure in pump LS control circuit….2543
Testing solenoid valve output pressure….2546
Testing PPC valve output pressure….2550
Adjusting play of work equipment and swing PPC valves….2551
Checking parts which cause hydraulic drift of work equipment….2552
Testing and adjusting travel deviation….2554
Releasing residual pressure from hydraulic circuit….2556
Testing oil leakage….2557
Bleeding air from each part….2560
Checking cab tipping stopper….2562
Installation and adjustment of mirrors and camera….2563
Inspection of air conditioner Recirc/Fresh air filter….2572
Testing and adjusting, Part 2….2575
Special functions of machine monitor….2576
Testing and adjusting, Part 3….2627
Handling voltage circuit of engine controller….2628
Preparation work for troubleshooting of electrical system….2629
Procedure for testing diodes….2634
Pm Clinic service….2635
40 Troubleshooting….0
Failure code table and fuse locations….2641
Failure code table….2642
Fuse locations….2646
General information on troubleshooting….2649
Points to remember when troubleshooting….2650
Sequence of events in troubleshooting….2651
Checks before troubleshooting….2652
Classification and procedures for troubleshooting….2653
Information in troubleshooting table….2654
Phenomena looking like troubles and troubleshooting Nos….2656
Connection table for connector pin numbers….2659
T- branch box and T- branch adapter table….2695
Troubleshooting by failure code, Part 1….2699
Failure code [989L00] Engine controller lock caution 1….2701
Failure code [989M00] Engine controller lock caution 2….2701
Failure code [989N00] Engine controller lock caution 3….2702
Failure code [AA10NX] Air cleaner clogging….2703
Failure code [AB00KE] Charge voltage low….2704
Failure code [B@BAZG] Eng oil press. low….2706
Failure code [B@BAZK] Eng oil level low….2707
Failure code [B@BCNS] Eng coolant overheat….2708
Failure code [B@BCZK] Eng water level low….2710
Failure code [B@HANS] Hydr oil overheat….2712
Failure code [CA111] ECM critical internal failure….2714
Failure code [CA115] Eng Ne and Bkup speed sensor error….2717
Failure code [CA122] Charge air press sensor high error….2718
Failure code [CA123] Charge air press sensor low error….2720
Failure code [CA131] Throttle sensor high error….2722
Failure code [CA132] Throttle sensor low error….2724
Failure code [CA144] Coolant temp. sensor high error….2726
Failure code [CA145] Coolant temp. sensor low error….2728
Failure code [CA153] Charge air temp. sensor high error….2730
Failure code [CA154] Charge air temp. sensor low error….2732
Failure code [CA155] Chg air temp high speed derate….2732
Failure code [CA187] Sensor sup. 2 volt. low error….2733
Failure code [CA221] Ambient air press. sensor high error….2734
Failure code [CA222] Ambient air press. sensor low error….2736
Failure code [CA227] Sensor sup. 2 volt. high error….2737
Failure code [CA234] Eng. overspeed….2738
Failure code [CA238] Ne speed sensor sup. volt. error….2740
Failure code [CA271] IMV/PCV1 short error….2742
Failure code [CA272] IMV/PCV1 open error….2743
Failure code [CA322] Injector #1 (L #1) system open/short error….2744
Failure code [CA324] Injector #3 (L #3) system open/short error….2746
Failure code [CA331] Injector #2 (L #2) system open/short error….2748
Failure code [CA332] Injector #4 (L #4) system open/short error….2750
Troubleshooting by failure code, Part 2….2753
Failure code [CA342] Calibration code incompatibility….2755
Failure code [CA351] Inj. drive circuit error….2756
Failure code [CA352] Sensor sup. 1 volt. low error….2759
Failure code [CA386] Sensor sup. 1 volt. high error….2760
Failure code [CA435] Abnormality in engine oil pressure switch….2762
Failure code [CA441] Battery voltage low error….2763
Failure code [CA442] Battery voltage high error….2764
Failure code [CA449] Rail press. very high error….2765
Failure code [CA451] Rail press. sensor high error….2766
Failure code [CA452] Rail press. sensor low error….2768
Failure code [CA488] Chg air temp high torque derate….2769
Failure code [CA553] Rail press. high error….2770
Failure code [CA559] Rail press. low error….2771
Failure code [CA689] Eng. Ne speed sensor error….2774
Failure code [CA731] Eng. Bkup speed sensor phase error….2776
Failure code [CA757] All persistent data lost error….2777
Failure code [CA778] Eng. Bkup speed sensor error….2778
Failure code [CA1633] KOMNET datalink timeout error….2780
Failure code [CA2185] Throttle sens. sup. volt. high error….2782
Failure code [CA2186] Throttle sens. sup. volt. low error….2784
Failure code [CA2249] Rail press. very low error….2784
Failure code [CA2311] Abnormality in IMV solenoid….2785
Failure code [D110KB] Battery relay drive short….2786
Failure code [D19JKZ] Personal code relay abnormality….2788
Failure code [D862KA] GPS antenna discon….2790
Failure code [DA22KK] Pump solenoid power low error….2792
Failure code [DA25KP] 5V sensor 1 power abnormality….2794
Failure code [DA26KP] 5V sensor 2 power abnormality….2797
Failure code [DA29KQ] Model selection abnormality….2798
Troubleshooting by failure code, Part 3….2801
Failure code [DA2RMC] CAN discon (Pump controller detected)….2804
Failure code [DAF8KB] Short circuit in camera power supply….2806
Failure code [DAFGMC] GPS module error….2808
Failure code [DAFRMC] CAN discon (Monitor detected)….2810
Failure code [DGH2KB] Hydr oil sensor short….2812
Failure code [DHPAMA] Pump press sensor abnormality….2814
Failure code [DHSFMA] Travel left forward PPC press sensor abnormality….2816
Failure code [DHSGMA] Travel right forward PPC press sensor abnormality….2818
Failure code [DHSHMA] Travel left reverse PPC press sensor abnormality….2820
Failure code [DHSJMA] Travel right reverse PPC press sensor abnormality….2822
Failure code [DHX1MA] Overload sensor abnormality (Analog)….2824
Failure code [DV20KB] Travel alarm short circuit….2825
Failure code [DW43KA] Travel speed sol discon….2826
Failure code [DW43KB] Travel speed sol short….2827
Failure code [DW45KA] Swing brake sol discon….2828
Failure code [DW45KB] Swing brake sol short….2830
Failure code [DW91KA] Travel junction sol discon….2832
Failure code [DW91KB] Travel junction sol short….2834
Failure code [DWJ0KA] Merge-divider sol discon….2836
Failure code [DWJ0KB] Merge-divider sol short….2838
Failure code [DWK0KA] 2-stage relief sol discon….2840
Failure code [DWK0KB] 2-stage relief sol short….2842
Troubleshooting by failure code, Part 4….2845
Failure code [DXA8KA] PC-EPC sol discon….2846
Failure code [DXA8KB] PC-EPC sol short….2848
Failure code [DXE4KA] Service current EPC discon….2850
Failure code [DXE4KB] Service current EPC short….2852
Failure code [DY20KA] Wiper working abnormality….2854
Failure code [DY20MA] Wiper parking abnormality….2856
Failure code [DY2CKA] Washer drive discon….2858
Failure code [DY2CKB] Washer drive short….2860
Failure code [DY2DKB] Wiper drive (for) short….2862
Failure code [DY2EKB] Wiper drive (rev) short….2864
Troubleshooting of electrical system (E-mode)….2867
Before carrying out troubleshooting of electrical system….2869
Information in troubleshooting table….2871
E-1 When starting switch turned ON, machine monitor displays nothing….2872
E-2 When starting switch turned ON (before starting engine), basic check item lights up….2874
E-3 Engine does not start (Engine does not turn)….2877
E-4 Preheater does not operate….2880
E-5 Automatic warm-up system does not operate (in cold season)….2882
E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked….2884
E-7 Precaution lights up while engine is running….2886
E-8 Emergency stop item lights up while engine is running….2891
E-9 Engine coolant temperature gauge does not indicate normally….2892
E-10 Hydraulic oil temperature gauge does not indicate normally….2893
E-11 Fuel level gauge does not indicate normally….2895
E-12 Contents of display by machine monitor are different from applicable machine….2897
E-13 Machine monitor does not display some items….2897
E-14 Function switch does not work….2897
E-15 Auto-decelerator does not operate normally….2898
E-16 Working mode does not change….2899
E-17 Travel speed does not change….2900
E-18 Alarm buzzer cannot be stopped….2901
E-19 Windshield wiper and window washer do not operate….2902
E-20 Power maximizing function does not operate normally….2906
E-21 Swing holding brake does not operate normally….2908
E-22 Travel alarm does not sound or does not stop sounding….2910
E-23 Air conditioner does not operate normally (including air conditioner abnormality record)….2911
E-24 While starting switch is in OFF position, service meter is not displayed….2923
E-25 Machine monitor cannot be set in service mode….2923
E-26 Monitoring function does not display lever control signal normally….2924
E-27 KOMTRAX system does not operate normally….2940
Troubleshooting of hydraulic and mechanical system (H-mode)….2943
Information contained in troubleshooting table….2945
System chart for hydraulic and mechanical systems….2946
H-1 Speed or power of all work equipment, swing, and travel are low….2948
H-2 Engine speed sharply drops or engine stalls….2949
H-3 No work equipment, travel and swing move….2950
H-4 Abnormal noise is heard from around hydraulic pump….2950
H-5 Fine control mode does not function….2951
H-6 Speed or power of boom is low….2952
H-7 Speed or power of arm is low….2953
H-8 Speed or power of bucket is low….2954
H-9 Work equipment does not move in its single operation….2955
H-10 Hydraulic drift of work equipment is large….2956
H-11 Time lag of work equipment is large….2957
H-12 Power maximizing function does not operate normally….2957
H-13 Work equipment loaded more is slower during compound operation….2958
H-14 Boom RAISE speed is low in compound operation of swing + boom RAISE….2958
H-15 Travel speed lowers largely during compound operation of work equipment/swing + travel….2959
H-16 Machine deviates during travel….2960
H-17 Travel speed is low….2961
H-18 Machine cannot be steered easily or steering power is low….2962
H-19 Travel speed does not change or it is kept low or high….2963
H-20 Track does not move (Only either side)….2963
H-21 Machine does not swing….2964
H-22 Swing acceleration or swing speed is low….2965
H-23 Excessive overrun when stopping swing….2966
H-24 When upper structure stops swinging, it makes large shock….2967
H-25 When upper structure stops swinging, it makes large sound….2967
H-26 Hydraulic drift of swing is large….2968
H-27 Flow rate in attachment circuit cannot be adjusted….2969
Troubleshooting of engine (S-mode)….2971
Method of using troubleshooting chart….2974
S-1 Starting performance is poor….2978
S-2 Engine does not start….2979
S-3 Engine does not pick up smoothly….2982
S-4 Engine stops during operations….2983
S-5 Engine does not rotate smoothly….2984
S-6 Engine lacks output (or lacks power)….2985
S-7 Exhaust smoke is black (incomplete combustion)….2986
S-8 Oil consumption is excessive (or exhaust smoke is blue)….2987
S-9 Oil becomes contaminated quickly….2988
S-10 Fuel consumption is excessive….2989
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)….2990
S-12 Oil pressure drops….2991
S-13 Oil level rises (Entry of coolant or fuel)….2992
S-14 Coolant temperature becomes too high (overheating)….2993
S-15 Abnormal noise is made….2994
S-16 Vibration is excessive….2995
50 Disassembly and assembly….0
General information on disassembly and assembly….2997
How to read this manual….2998
Coating materials list….3000
Special tool list….3003
Sketch of special tool….3007
Engine and cooling system….3013
Removal and installation of fuel supply pump assembly….3014
Removal and installation of fuel injector assembly….3017
Removal and installation of front oil seal….3020
Removal and installation of rear oil seal….3022
Removal and installation of cylinder head assembly….3025
Removal and installation of radiator assembly….3035
Removal and installation of aftercooler assembly….3037
Removal and installation of work equipment oil cooler assembly….3039
Removal and installation of engine and work equipment pump assembly….3041
Removal and installation of fuel tank assembly….3049
Power train….3053
Removal and installation of travel motor and final drive assembly….3054
Disassembly and assembly of travel motor and final drive assembly….3056
Removal and installation of swing motor and swing machinery assembly….3093
Disassembly and assembly of swing machinery assembly….3095
Removal and installation of swing circle assembly….3101
Undercarriage and frame….3103
Disassembly and assembly of track roller….3104
Disassembly and assembly of idler assembly….3107
Disassembly and assembly of recoil spring….3110
Spreading and installation of track shoe assembly….3113
Removal and installation of sprocket….3115
Removal and installation of revolving frame assembly….3116
Removal and installation of counterweight assembly….3118
Hydraulic system….3121
Removal and installation of center swivel joint assembly….3122
Disassembly and assembly of center swivel joint assembly….3124
Removal and installation of hydraulic tank assembly….3125
Removal and installation of work equipment pump assembly….3128
Removal and installation of control valve assembly….3132
Disassembly and assembly of control valve assembly….3136
Disassembly and assembly of work equipment PPC valve assembly….3148
Disassembly and assembly of travel PPC valve assembly….3150
Disassembly and assembly of hydraulic cylinder assembly….3153
Work equipment….3161
Removal and installation of work equipment assembly….3162
Cab and its attachments….3167
Removal and installation of operator's cab assembly….3168
Removal and installation of operator cab glass (stuck glass)….3171
Removal and installation of front window assembly….3181
Removal and installation of floor frame assembly….3188
Electrical system….3193
Removal and installation of air compressor assembly….3194
Removal and installation of air conditioner condenser….3195
Removal and installation of air compressor unit assembly….3196
Removal and installation of KOMTRAX communication modem assembly….3199
Removal and installation of monitor assembly….3200
Removal and installation of pump controller assembly….3202
Removal and installation of engine controller assembly….3204
90 Diagrams and drawings….0
Hydraulic diagrams and drawings….3207
Hydraulic circuit diagram (1/2)….3209
Hydraulic circuit diagram (2/2)….3210
Electrical diagrams and drawings….3213
Electrical circuit diagram (1/5)….3215
Electrical circuit diagram (2/5)….3216
Electrical circuit diagram (3/5)….3217
Electrical circuit diagram (4/5)….3218
Electrical circuit diagram (5/5)….3219
Connectors table and arrangement drawing….3220
TEN00166-01 – Hydraulic Excavator GALEO PC130-7 Shop Manual….3223
COVER….3223
FOREWORD….3224
FOREWORD….3225
SAFETY INFORMATION….3228
INTRODUCTION….3230
DIRECTIONS OF MACHINE….3230
BREAKING-IN THE NEW MACHINE….3230
PRODUCT INFORMATION….3231
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….3231
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….3231
SERVICE METER LOCATION….3232
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….3232
CONTENTS….3233
SAFETY….3236
SAFETY….3237
SAFETY LABELS….3239
LOCATION OF SAFETY LABELS….3239
SAFETY LABELS….3240
GENERAL PRECAUTIONS….3246
SAFETY RULES….3246
IF PROBLEMS ARE FOUND….3246
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS….3246
FIRE EXTINGUISHER AND FIRST AID KIT….3246
SAFETY EQUIPMENT….3246
KEEP MACHINE CLEAN….3247
KEEP OPERATOR'S COMPARTMENT CLEAN….3247
LEAVING OPERATOR'S SEAT WITH LOCK….3247
HANDRAILS AND STEPS….3248
MOUNTING AND DISMOUNTING….3248
NO PERSONS ON ATTACHMENTS….3248
BURN PREVENTION….3249
FIRE PREVENTION AND EXPLOSION PREVENTION….3250
ACTION IF FIRE OCCURS….3251
WINDSHIELD WASHER FLUID….3251
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION….3251
ATTACHMENT INSTALLATION….3251
ATTACHMENT COMBINATIONS….3251
CAB WINDOW GLASSES….3251
UNAUTHORIZED MODIFICATIONS….3252
SAFETY AT JOBSITE….3252
WORKING ON LOOSE GROUND….3252
DISTANCE TO HIGH VOLTAGE CABLES….3253
ENSURE GOOD VISIBILITY….3253
VENTILATION FOR ENCLOSED AREA….3254
SIGNALMAN'S SIGNAL AND SIGNS….3254
EMERGENCY EXIT FROM OPERATOR'S CAB….3254
ASBESTOS DUST HAZARD PREVENTION….3254
SAFETY MACHINE OPERATION….3255
STARTING ENGINE….3255
CHECKS BEFORE STARTING ENGINE….3255
SAFETY RULES FOR STARTING ENGINE….3255
STARTING ENGINE IN COLD WEATHER….3256
OPERATION….3257
CHECKS BEFORE OPERATION….3257
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS….3257
SAFETY RULES FOR TRAVELING….3258
TRAVELING ON SLOPES….3259
OPERATIONS ON SLOPES….3260
PROHIBITED OPERATIONS….3260
OPERATIONS ON SNOW….3261
PARKING MACHINE….3262
TRANSPORTATION….3263
LOADING AND UNLOADING….3263
SHIPPING THE MACHINE….3263
BATTERY….3264
BATTERY HAZARD PREVENTION….3264
STARTING ENGINE WITH BOOSTER CABLES….3265
TOWING….3266
SAFETY RULES FOR TOWING….3266
LIFTING OBJECTS WITH BUCKET….3267
LIFTING WORK USING BUCKET WITH HOOK….3267
SAFETY RULES FOR LIFTING OBJECTS….3267
SAFETY MAINTENANCE INFORMATION….3269
WARNING TAG….3269
KEEP WORK PLACE CLEAN AND TIDY….3269
APPOINT LEADER WHEN WORKING WITH OTHERS….3269
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE….3270
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING….3271
PROPER TOOLS….3271
ACCUMULATOR….3271
PERSONNEL….3272
ATTACHMENTS….3272
WORK UNDER THE MACHINE….3272
NOISE….3272
WHEN USING HAMMER….3272
WELDING WORKS….3273
REMOVING BATTERY TERMINALS….3273
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION….3273
DO NOT DISASSEMBLE RECOIL SPRINGS….3273
SAFETY RULES FOR HIGH-PRESSURE OIL….3274
SAFETY HANDLING HIGH-PRESSURE HOSES….3274
WASTE MATERIALS….3274
AIR CONDITIONER MAINTENANCE….3274
COMPRESSED AIR….3275
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS….3275
OPERATION….3276
MACHINE VIEW ILLUSTRATIONS….3277
OVERALL MACHINE VIEW….3277
CONTROLS AND GAUGES….3278
DETAILED CONTROLS AND GAUGES….3279
MONITORING SYSTEM….3279
SWITCHES….3292
CONTROL LEVERS AND PEDALS….3296
SUN ROOF….3299
WINDSHIELD….3299
EMERGENCY EXIT FROM OPERATOR'S CAB….3304
DOOR LOCK….3304
CAP WITH LOCK….3305
HOT AND COOL BOX….3306
MAGAZINE BOX….3306
ASHTRAY….3306
AIR CONDITIONER CONTROLS….3307
RADIO….3321
AUXILIARY ELECTRIC POWER….3326
FUSE….3327
FUSIBLE LINK….3328
CONTROLLER….3328
TOOL BOX….3328
GREASE GUN HOLDER….3328
HANDLING GREASE GUN….3329
ACCUMULATOR….3330
MACHINE OPERATIONS AND CONTROLS….3331
BEFORE STARTING ENGINE….3331
STARTING ENGINE….3347
AFTER STARTING ENGINE….3351
STOPPING THE ENGINE….3358
MACHINE OPERATION….3359
STEERING THE MACHINE….3363
SWINGING….3365
WORK EQUIPMENT CONTROLS AND OPERATIONS….3366
WORKING MODE….3368
PROHIBITED OPERATIONS….3369
GENERAL OPERATION INFORMATION….3371
TRAVELING ON SLOPES….3372
ESCAPE FROM MUD….3374
RECOMMENDED APPLICATIONS….3375
BUCKET REPLACEMENT AND INVERSION….3377
PARKING MACHINE….3379
CHECK AFTER SHUT OFF ENGINE….3380
MACHINE INSPECTION AFTER DAILY WORK….3381
LOCKING….3381
TRANSPORTATION….3382
TRANSPORTATION PROCEDURE….3382
LOADING AND UNLOADING WITH TRAILER….3382
LIFTING MACHINE….3391
COLD WEATHER OPERATION….3392
COLD WEATHER OPERATION INFORMATION….3392
AFTER DAILY WORK COMPLETION….3394
AFTER COLD WEATHER SEASON….3394
LONG TERM STORAGE….3395
BEFORE STORAGE….3395
DURING STORAGE….3395
AFTER STORAGE….3395
STARTING MACHINE AFTER LONG-TERM STORAGE….3396
TROUBLES AND ACTIONS….3397
RUNNING OUT OF FUEL….3397
PHENOMENA THAT ARE NOT FAILURES….3397
TOWING THE MACHINE….3398
LIGHTWEIGHT TOWING HOLE….3398
SEVERE JOB CONDITION….3398
DISCHARGED BATTERY….3399
OTHER TROUBLE….3403
MAINTENANCE….3408
MAINTENANCE INFORMATION….3409
OUTLINE OF SERVICE….3411
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….3411
ELECTRIC SYSTEM MAINTENANCE….3414
WEAR PARTS….3415
WEAR PARTS LIST….3415
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….3416
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….3418
TIGHTENING TORQUE SPECIFICATIONS….3419
TIGHTENING TORQUE LIST….3419
SAFETY CRITICAL PARTS….3420
SAFETY CRITICAL PARTS LIST….3420
MAINTENANCE SCHEDULE….3421
MAINTENANCE SCHEDULE CHART….3421
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….3423
MAINTENANCE PROCEDURE….3424
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….3424
WHEN REQUIRED….3425
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….3425
CLEAN INSIDE OF COOLING SYSTEM….3428
CHECK AND TIGHTEN TRACK SHOE BOLTS….3431
CHECK AND ADJUST TRACK TENSION….3432
CHECK ELECTRICAL INTAKE AIR HEATER….3434
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….3435
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….3438
ADJUST BUCKET CLEARANCE….3439
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….3440
CHECK AND MAINTENANCE AIR CONDITIONER….3441
WASH WASHABLE FLOOR….3442
BLEEDING AIR FROM HYDRAULIC SYSTEM….3445
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT….3447
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (CONTROL CIRCUIT)….3448
CHECK BEFORE STARTING….3449
EVERY 100 HOURS MAINTENANCE….3450
LUBRICATING….3450
CHECK SWING MACHINERY CASE OIL, ADD OIL….3452
EVERY 250 HOURS MAINTENANCE….3453
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….3453
CHECK LEVEL OF BATTERY ELECTROLYTE….3454
EVERY 500 HOURS MAINTENANCE….3457
REPLACE FUEL FILTER CARTRIDGE….3457
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….3458
CHECK SWING PINION GREASE LEVEL, ADD GREASE….3458
LUBRICATE SWING CIRCLE….3459
RADIATOR CORE AND FINS – CHECK/CLEAN….3459
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….3460
REPLACE HYDRAULIC OIL FILTER ELEMENT….3461
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….3462
CHECK AND ADJUST COOLING FAN BELT TENSION….3463
CHECK, ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION….3464
EVERY 1000 HOURS MAINTENANCE….3465
CHANGE OIL IN SWING MACHINERY CASE….3465
CHANGE OIL IN FINAL DRIVE CASE….3466
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER….3466
CHECK PLAY TURBOCHARGER ROTOR….3466
REPLACE CORROSION RESISTOR CARTRIDGE….3467
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)….3467
EVERY 2000 HOURS MAINTENANCE….3468
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL….3468
CLEAN HYDRAULIC TANK STRAINER….3469
CLEAN, CHECK TURBOCHARGER….3469
CHECK ALTERNATOR, STARTING MOTOR….3469
CHECK ENGINE VALVE CLEARANCE, ADJUST….3469
EVERY 4000 HOURS MAINTENANCE….3470
CHECK WATER PUMP….3470
EVERY 5000 HOURS MAINTENANCE….3471
CHANGE OIL IN HYDRAULIC TANK….3471
SPECIFICATIONS….3472
SPECIFICATIONS….3473
ATTACHMENTS, OPTIONS….3476
GENERAL PRECAUTIONS FOR SAFETY….3477
PRECAUTIONS WHEN SELECTING….3477
READ THE INSTRUCTION MANUAL THOROUGHLY….3477
PRECAUTIONS WHEN REMOVING OR INSTALLING….3477
PRECAUTIONS WHEN USING….3477
BUCKET WITH HOOK….3478
HOOK CONDITION….3478
PROHIBITED OPERATIONS….3478
MACHINE READY FOR ATTACHMENT….3479
LOCATIONS….3479
HYDRAULIC CIRCUIT….3483
ATTACHMENT REMOVAL AND INSTALLATION….3486
ATTACHMENT OPERATIONS….3488
ACCUMULATOR….3490
LONG TERM STORAGE….3491
SPECIFICATIONS….3491
ATTACHMENT GUIDE….3492
OTHER ATTACHMENTS….3492
ATTACHMENT COMBINATIONS….3493
TRACK SHOES SELECTION….3494
BUCKET TEETH SELECTION….3495
HANDLING OF RUBBER PAD SHOE AND ROAD LINER….3496
RECOMMENDED ATTACHMENT OPERATIONS….3498
HYDRAULIC BREAKER….3498
INDEX….3504
TEN00266-00TH – Hydraulic Excavator PC130-8 Operation & Maintenance Manual….3508
TEN00266-06 – Hydraulic Excavator PC130-8 Operation & Maintenance Manual….3889
COVER….3889
FOREWORD….3890
BEFORE READING THIS MANUAL….3891
SAFETY INFORMATION….3892
INTRODUCTION….3893
USE OF MACHINE….3893
DIRECTIONS OF MACHINE….3893
VISIBILITY FROM OPERATOR'S SEAT….3893
PRODUCT INFORMATION….3894
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….3894
EPA REGULATIONS, ENGINE NUMBER PLATE….3894
SERVICE METER LOCATION….3895
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….3895
CONTENTS….3896
SAFETY….3900
SAFETY….3901
SAFETY LABELS….3904
LOCATION OF SAFETY LABELS….3905
SAFETY LABELS….3906
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….3912
PRECAUTIONS BEFORE STARTING OPERATION….3912
PREPARATIONS FOR SAFE OPERATION….3912
FIRE PREVENTION….3914
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….3915
DO NOT GET CAUGHT IN WORK EQUIPMENT….3917
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….3917
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….3918
UNAUTHORIZED MODIFICATION….3918
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….3918
PRECAUTIONS RELATED TO CAB GLASS….3918
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….3919
PRECAUTIONS FOR OPERATION….3920
PRECAUTIONS FOR JOBSITE….3920
STARTING ENGINE….3922
OPERATION….3924
TRANSPORTATION….3932
TOWING….3933
LIFTING OBJECTS WITH BUCKET….3934
PRECAUTIONS FOR MAINTENANCE….3935
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….3935
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….3939
OPERATION….3946
MACHINE VIEW ILLUSTRATIONS….3947
OVERALL MACHINE VIEW….3947
CONTROLS AND GAUGES….3948
DETAILED CONTROLS AND GAUGES….3950
MONITORING SYSTEM….3950
SWITCHES….4015
CONTROL LEVERS AND PEDALS….4020
SUN ROOF….4023
WINDSHIELD….4023
EMERGENCY ESCAPE HAMMER….4029
DOOR LOCK….4029
CAP WITH LOCK….4030
DRINK BOX….4031
MAGAZINE BOX….4031
ASHTRAY….4031
AIR CONDITIONER CONTROLS….4032
RADIO….4045
AUXILIARY ELECTRIC POWER….4050
FUSE….4051
SLOW BLOW FUSE….4052
CONTROLLER….4052
TOOL BOX….4052
GREASE PUMP HOLDER….4052
FIRE EXTINGUISHER….4053
MACHINE OPERATIONS AND CONTROLS….4054
BEFORE STARTING ENGINE….4054
STARTING ENGINE….4073
AFTER STARTING ENGINE….4078
STOPPING THE ENGINE….4089
MACHINE OPERATION….4090
STEERING THE MACHINE….4094
SWINGING….4096
WORK EQUIPMENT CONTROLS AND OPERATIONS….4097
WORKING MODE….4099
PROHIBITED OPERATIONS….4101
GENERAL OPERATION INFORMATION….4104
TRAVELING ON SLOPES….4106
ESCAPE FROM MUD….4108
RECOMMENDED APPLICATIONS….4109
BUCKET REPLACEMENT AND INVERSION….4111
PARKING MACHINE….4114
MACHINE INSPECTION AFTER DAILY WORK….4115
LOCKING….4116
ROAD LINERS….4117
TRANSPORTATION….4119
TRANSPORTATION PROCEDURE….4119
LOADING AND UNLOADING WITH TRAILER….4120
LIFTING MACHINE….4129
COLD WEATHER OPERATION….4132
COLD WEATHER OPERATION INFORMATION….4132
AFTER DAILY WORK COMPLETION….4134
AFTER COLD WEATHER SEASON….4134
LONG TERM STORAGE….4135
BEFORE STORAGE….4135
DURING STORAGE….4135
AFTER STORAGE….4136
STARTING MACHINE AFTER LONG-TERM STORAGE….4136
TROUBLES AND ACTIONS….4137
RUNNING OUT OF FUEL….4137
PHENOMENA THAT ARE NOT FAILURES….4137
TOWING THE MACHINE….4138
LIGHTWEIGHT TOWING HOLE….4139
SEVERE JOB CONDITION….4139
DISCHARGED BATTERY….4140
OTHER TROUBLE….4144
MAINTENANCE….4150
MAINTENANCE INFORMATION….4151
OUTLINE OF SERVICE….4153
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4153
ELECTRIC SYSTEM MAINTENANCE….4156
WEAR PARTS….4157
WEAR PARTS LIST….4157
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….4158
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….4160
TIGHTENING TORQUE SPECIFICATIONS….4161
TIGHTENING TORQUE LIST….4161
SAFETY CRITICAL PARTS….4162
SAFETY CRITICAL PARTS LIST….4163
MAINTENANCE SCHEDULE….4164
MAINTENANCE SCHEDULE CHART….4164
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….4166
MAINTENANCE PROCEDURE….4167
WHEN REQUIRED….4167
CHECK BEFORE STARTING….4196
EVERY 100 HOURS MAINTENANCE….4197
EVERY 250 HOURS MAINTENANCE….4199
EVERY 500 HOURS MAINTENANCE….4204
EVERY 1000 HOURS MAINTENANCE….4215
EVERY 2000 HOURS MAINTENANCE….4221
EVERY 4000 HOURS MAINTENANCE….4225
EVERY 5000 HOURS MAINTENANCE….4227
EVERY 8000 HOURS MAINTENANCE….4228
SPECIFICATIONS….4230
SPECIFICATIONS….4231
ATTACHMENTS, OPTIONS ….4234
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….4235
SAFETY FIRST….4235
ATTACHMENT INSTALLATION….4236
BUCKET WITH HOOK….4237
HOOK CONDITION….4237
PROHIBITED OPERATIONS….4237
MACHINE READY FOR ATTACHMENT….4238
LOCATIONS….4238
HYDRAULIC CIRCUIT….4242
ATTACHMENT REMOVAL AND INSTALLATION….4243
ATTACHMENT OPERATIONS….4247
LONG TERM STORAGE….4251
SPECIFICATIONS….4251
ATTACHMENT GUIDE….4252
ATTACHMENT COMBINATIONS….4253
TRACK SHOES SELECTION….4254
HANDLING OF RUBBER PAD SHOE AND ROAD LINER….4255
RECOMMENDED ATTACHMENT OPERATIONS….4257
HYDRAULIC BREAKER….4257
HANDLING MACHINES EQUIPPED WITH KOMTRAX….4262
BASIC PRECAUTIONS….4262
INDEX….4264
TEN00485-00 – Hydraulic Excavator PC130-8 Operation & Maintenance Manual….4268
COVER….4268
FOREWORD….4269
BEFORE READING THIS MANUAL….4270
SAFETY INFORMATION….4271
INTRODUCTION….4272
USE OF MACHINE….4272
DIRECTIONS OF MACHINE….4272
VISIBILITY FROM OPERATOR'S SEAT….4272
PROTECTIVE STRUCTURE….4272
PRODUCT INFORMATION….4273
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….4273
EPA REGULATIONS, ENGINE NUMBER PLATE….4273
SERVICE METER LOCATION….4274
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….4274
CONTENTS….4275
SAFETY….4279
SAFETY….4280
SAFETY LABELS….4283
LOCATION OF SAFETY LABELS….4284
SAFETY LABELS….4285
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….4291
PRECAUTIONS BEFORE STARTING OPERATION….4291
PREPARATIONS FOR SAFE OPERATION….4291
FIRE PREVENTION….4293
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….4294
DO NOT GET CAUGHT IN WORK EQUIPMENT….4296
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….4296
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….4297
UNAUTHORIZED MODIFICATION….4297
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….4297
PRECAUTIONS RELATED TO CAB GLASS….4297
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….4298
PRECAUTIONS FOR OPERATION….4299
PRECAUTIONS FOR JOBSITE….4299
STARTING ENGINE….4301
OPERATION….4303
TRANSPORTATION….4311
TOWING….4312
LIFTING OBJECTS WITH BUCKET….4313
PRECAUTIONS FOR MAINTENANCE….4314
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….4314
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….4318
OPERATION….4325
MACHINE VIEW ILLUSTRATIONS….4326
OVERALL MACHINE VIEW….4326
CONTROLS AND GAUGES….4327
DETAILED CONTROLS AND GAUGES….4329
MONITORING SYSTEM….4329
SWITCHES….4394
CONTROL LEVERS AND PEDALS….4399
SUN ROOF….4402
WINDSHIELD….4402
EMERGENCY ESCAPE HAMMER….4408
DOOR LOCK….4408
CAP WITH LOCK….4409
DRINK BOX….4410
MAGAZINE BOX….4410
ASHTRAY….4410
AIR CONDITIONER CONTROLS….4411
RADIO….4424
AUXILIARY ELECTRIC POWER….4429
FUSE….4430
SLOW BLOW FUSE….4431
CONTROLLER….4431
TOOL BOX….4431
GREASE PUMP HOLDER….4431
FIRE EXTINGUISHER….4432
MACHINE OPERATIONS AND CONTROLS….4433
BEFORE STARTING ENGINE….4433
STARTING ENGINE….4452
AFTER STARTING ENGINE….4457
STOPPING THE ENGINE….4468
MACHINE OPERATION….4469
STEERING THE MACHINE….4473
SWINGING….4475
WORK EQUIPMENT CONTROLS AND OPERATIONS….4476
WORKING MODE….4478
PROHIBITED OPERATIONS….4480
GENERAL OPERATION INFORMATION….4483
TRAVELING ON SLOPES….4485
ESCAPE FROM MUD….4487
RECOMMENDED APPLICATIONS….4488
BUCKET REPLACEMENT AND INVERSION….4490
PARKING MACHINE….4493
MACHINE INSPECTION AFTER DAILY WORK….4494
LOCKING….4495
ROAD LINERS….4496
TRANSPORTATION….4498
TRANSPORTATION PROCEDURE….4498
LOADING AND UNLOADING WITH TRAILER….4499
LIFTING MACHINE….4508
COLD WEATHER OPERATION….4511
COLD WEATHER OPERATION INFORMATION….4511
AFTER DAILY WORK COMPLETION….4513
AFTER COLD WEATHER SEASON….4513
LONG TERM STORAGE….4514
BEFORE STORAGE….4514
DURING STORAGE….4514
AFTER STORAGE….4515
STARTING MACHINE AFTER LONG-TERM STORAGE….4515
TROUBLES AND ACTIONS….4516
RUNNING OUT OF FUEL….4516
PHENOMENA THAT ARE NOT FAILURES….4516
TOWING THE MACHINE….4517
LIGHTWEIGHT TOWING HOLE….4518
SEVERE JOB CONDITION….4518
DISCHARGED BATTERY….4519
OTHER TROUBLE….4523
MAINTENANCE….4529
MAINTENANCE INFORMATION….4530
OUTLINE OF SERVICE….4532
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4532
ELECTRIC SYSTEM MAINTENANCE….4535
WEAR PARTS….4536
WEAR PARTS LIST….4536
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….4537
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….4538
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….4539
TIGHTENING TORQUE SPECIFICATIONS….4540
TIGHTENING TORQUE LIST….4540
SAFETY CRITICAL PARTS….4541
SAFETY CRITICAL PARTS LIST….4542
MAINTENANCE SCHEDULE….4543
MAINTENANCE SCHEDULE CHART….4543
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….4545
MAINTENANCE PROCEDURE….4546
WHEN REQUIRED….4546
CHECK BEFORE STARTING….4574
EVERY 100 HOURS MAINTENANCE….4575
EVERY 250 HOURS MAINTENANCE….4577
EVERY 500 HOURS MAINTENANCE….4582
EVERY 1000 HOURS MAINTENANCE….4593
EVERY 2000 HOURS MAINTENANCE….4599
EVERY 4000 HOURS MAINTENANCE….4603
EVERY 5000 HOURS MAINTENANCE….4605
EVERY 8000 HOURS MAINTENANCE….4606
SPECIFICATIONS….4607
SPECIFICATIONS….4608
ATTACHMENTS, OPTIONS….4611
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….4612
SAFETY FIRST….4612
ATTACHMENT INSTALLATION….4613
BUCKET WITH HOOK….4614
HOOK CONDITION….4614
PROHIBITED OPERATIONS….4614
MACHINE READY FOR ATTACHMENT….4615
LOCATIONS….4615
HYDRAULIC CIRCUIT….4619
ATTACHMENT REMOVAL AND INSTALLATION….4620
ATTACHMENT OPERATIONS….4624
LONG TERM STORAGE….4628
SPECIFICATIONS….4628
ATTACHMENT GUIDE….4629
ATTACHMENT COMBINATIONS….4630
TRACK SHOES SELECTION….4631
HANDLING OF RUBBER PAD SHOE AND ROAD LINER….4632
RECOMMENDED ATTACHMENT OPERATIONS….4634
HYDRAULIC BREAKER….4634
HANDLING MACHINES EQUIPPED WITH KOMTRAX….4639
BASIC PRECAUTIONS….4639
INDEX….4641
TEN00510-00 – Hydraulic Excavator PC130-8 Operation & Maintenance Manual….4645
COVER….4645
FOREWORD….4646
BEFORE READING THIS MANUAL….4647
SAFETY INFORMATION….4648
INTRODUCTION….4649
USE OF MACHINE….4649
DIRECTIONS OF MACHINE….4649
VISIBILITY FROM OPERATOR'S SEAT….4649
PROTECTIVE STRUCTURE….4649
PRODUCT INFORMATION….4650
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….4650
EPA REGULATIONS, ENGINE NUMBER PLATE….4650
SERVICE METER LOCATION….4651
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….4651
CONTENTS….4652
SAFETY….4656
SAFETY….4657
SAFETY LABELS….4660
LOCATION OF SAFETY LABELS….4661
SAFETY LABELS….4662
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….4668
PRECAUTIONS BEFORE STARTING OPERATION….4668
PREPARATIONS FOR SAFE OPERATION….4668
FIRE PREVENTION….4670
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….4671
DO NOT GET CAUGHT IN WORK EQUIPMENT….4673
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….4673
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….4674
UNAUTHORIZED MODIFICATION….4674
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….4674
PRECAUTIONS RELATED TO CAB GLASS….4674
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….4675
PRECAUTIONS FOR OPERATION….4676
PRECAUTIONS FOR JOBSITE….4676
STARTING ENGINE….4678
OPERATION….4680
TRANSPORTATION….4688
TOWING….4689
LIFTING OBJECTS WITH BUCKET….4690
PRECAUTIONS FOR MAINTENANCE….4691
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….4691
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….4695
OPERATION….4702
MACHINE VIEW ILLUSTRATIONS….4703
OVERALL MACHINE VIEW….4703
CONTROLS AND GAUGES….4704
DETAILED CONTROLS AND GAUGES….4706
MONITORING SYSTEM….4706
SWITCHES….4771
CONTROL LEVERS AND PEDALS….4776
SUN ROOF….4779
WINDSHIELD….4779
EMERGENCY ESCAPE HAMMER….4785
DOOR LOCK….4785
CAP WITH LOCK….4786
DRINK BOX….4787
MAGAZINE BOX….4787
ASHTRAY….4787
AIR CONDITIONER CONTROLS….4788
RADIO….4801
AUXILIARY ELECTRIC POWER….4806
FUSE….4807
SLOW BLOW FUSE….4808
CONTROLLER….4808
TOOL BOX….4808
GREASE PUMP HOLDER….4808
FIRE EXTINGUISHER….4809
MACHINE OPERATIONS AND CONTROLS….4810
BEFORE STARTING ENGINE….4810
STARTING ENGINE….4829
AFTER STARTING ENGINE….4834
STOPPING THE ENGINE….4845
MACHINE OPERATION….4846
STEERING THE MACHINE….4850
SWINGING….4852
WORK EQUIPMENT CONTROLS AND OPERATIONS….4853
WORKING MODE….4855
PROHIBITED OPERATIONS….4857
GENERAL OPERATION INFORMATION….4860
TRAVELING ON SLOPES….4862
ESCAPE FROM MUD….4864
RECOMMENDED APPLICATIONS….4865
BUCKET REPLACEMENT AND INVERSION….4867
PARKING MACHINE….4870
MACHINE INSPECTION AFTER DAILY WORK….4871
LOCKING….4872
ROAD LINERS….4873
TRANSPORTATION….4875
TRANSPORTATION PROCEDURE….4875
LOADING AND UNLOADING WITH TRAILER….4876
LIFTING MACHINE….4885
COLD WEATHER OPERATION….4888
COLD WEATHER OPERATION INFORMATION….4888
AFTER DAILY WORK COMPLETION….4890
AFTER COLD WEATHER SEASON….4890
LONG TERM STORAGE….4891
BEFORE STORAGE….4891
DURING STORAGE….4891
AFTER STORAGE….4892
STARTING MACHINE AFTER LONG-TERM STORAGE….4892
TROUBLES AND ACTIONS….4893
RUNNING OUT OF FUEL….4893
PHENOMENA THAT ARE NOT FAILURES….4893
TOWING THE MACHINE….4894
LIGHTWEIGHT TOWING HOLE….4895
SEVERE JOB CONDITION….4895
DISCHARGED BATTERY….4896
OTHER TROUBLE….4900
MAINTENANCE….4906
MAINTENANCE INFORMATION….4907
OUTLINE OF SERVICE….4909
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….4909
ELECTRIC SYSTEM MAINTENANCE….4912
WEAR PARTS….4913
WEAR PARTS LIST….4913
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….4914
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….4915
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….4916
TIGHTENING TORQUE SPECIFICATIONS….4917
TIGHTENING TORQUE LIST….4917
SAFETY CRITICAL PARTS….4918
SAFETY CRITICAL PARTS LIST….4919
MAINTENANCE SCHEDULE….4920
MAINTENANCE SCHEDULE CHART….4920
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….4922
MAINTENANCE PROCEDURE….4923
WHEN REQUIRED….4923
CHECK BEFORE STARTING….4951
EVERY 100 HOURS MAINTENANCE….4952
EVERY 250 HOURS MAINTENANCE….4954
EVERY 500 HOURS MAINTENANCE….4959
EVERY 1000 HOURS MAINTENANCE….4970
EVERY 2000 HOURS MAINTENANCE….4976
EVERY 4000 HOURS MAINTENANCE….4980
EVERY 5000 HOURS MAINTENANCE….4982
EVERY 8000 HOURS MAINTENANCE….4983
SPECIFICATIONS….4984
SPECIFICATIONS….4985
ATTACHMENTS, OPTIONS….4988
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….4989
SAFETY FIRST….4989
ATTACHMENT INSTALLATION….4990
BUCKET WITH HOOK….4991
HOOK CONDITION….4991
PROHIBITED OPERATIONS….4991
MACHINE READY FOR ATTACHMENT….4992
LOCATIONS….4992
HYDRAULIC CIRCUIT….4996
ATTACHMENT REMOVAL AND INSTALLATION….4997
ATTACHMENT OPERATIONS….5001
LONG TERM STORAGE….5005
SPECIFICATIONS….5005
ATTACHMENT GUIDE….5006
ATTACHMENT COMBINATIONS….5007
TRACK SHOES SELECTION….5008
HANDLING OF RUBBER PAD SHOE AND ROAD LINER….5009
RECOMMENDED ATTACHMENT OPERATIONS….5011
HYDRAULIC BREAKER….5011
HANDLING MACHINES EQUIPPED WITH KOMTRAX….5016
BASIC PRECAUTIONS….5016
INDEX….5018
TEN00526-00 – Hydraulic Excavator PC130-8 Operation & Maintenance Manual….5022
COVER….5022
FOREWORD….5023
BEFORE READING THIS MANUAL….5024
SAFETY INFORMATION….5025
INTRODUCTION….5026
USE OF MACHINE….5026
DIRECTIONS OF MACHINE….5026
VISIBILITY FROM OPERATOR'S SEAT….5026
PROTECTIVE STRUCTURE….5026
PRODUCT INFORMATION….5027
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….5027
EPA REGULATIONS, ENGINE NUMBER PLATE….5027
SERVICE METER LOCATION….5028
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….5028
CONTENTS….5029
SAFETY….5033
SAFETY….5034
SAFETY LABELS….5037
LOCATION OF SAFETY LABELS….5038
SAFETY LABELS….5039
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE….5045
PRECAUTIONS BEFORE STARTING OPERATION….5045
PREPARATIONS FOR SAFE OPERATION….5045
FIRE PREVENTION….5047
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE….5048
DO NOT GET CAUGHT IN WORK EQUIPMENT….5050
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES….5050
PROTECTION AGAINST FALLING, FLYING, INTRUDING OBJECTS….5051
UNAUTHORIZED MODIFICATION….5051
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS….5051
PRECAUTIONS RELATED TO CAB GLASS….5051
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING….5052
PRECAUTIONS FOR OPERATION….5053
PRECAUTIONS FOR JOBSITE….5053
STARTING ENGINE….5055
OPERATION….5057
TRANSPORTATION….5065
TOWING….5066
LIFTING OBJECTS WITH BUCKET….5067
PRECAUTIONS FOR MAINTENANCE….5068
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE….5068
PRECAUTIONS FOR INSPECTION AND MAINTENANCE….5072
OPERATION….5079
MACHINE VIEW ILLUSTRATIONS….5080
OVERALL MACHINE VIEW….5080
CONTROLS AND GAUGES….5081
DETAILED CONTROLS AND GAUGES….5083
MONITORING SYSTEM….5083
SWITCHES….5148
CONTROL LEVERS AND PEDALS….5153
SUN ROOF….5156
WINDSHIELD….5156
EMERGENCY ESCAPE HAMMER….5162
DOOR LOCK….5162
CAP WITH LOCK….5163
DRINK BOX….5164
MAGAZINE BOX….5164
ASHTRAY….5164
AIR CONDITIONER CONTROLS….5165
RADIO….5178
AUXILIARY ELECTRIC POWER….5183
FUSE….5184
SLOW BLOW FUSE….5185
CONTROLLER….5185
TOOL BOX….5185
GREASE PUMP HOLDER….5185
FIRE EXTINGUISHER….5186
MACHINE OPERATIONS AND CONTROLS….5187
BEFORE STARTING ENGINE….5187
STARTING ENGINE….5206
AFTER STARTING ENGINE….5211
STOPPING THE ENGINE….5222
MACHINE OPERATION….5223
STEERING THE MACHINE….5227
SWINGING….5229
WORK EQUIPMENT CONTROLS AND OPERATIONS….5230
WORKING MODE….5232
PROHIBITED OPERATIONS….5234
GENERAL OPERATION INFORMATION….5237
TRAVELING ON SLOPES….5239
ESCAPE FROM MUD….5241
RECOMMENDED APPLICATIONS….5242
BUCKET REPLACEMENT AND INVERSION….5244
PARKING MACHINE….5247
MACHINE INSPECTION AFTER DAILY WORK….5248
LOCKING….5249
ROAD LINERS….5250
TRANSPORTATION….5252
TRANSPORTATION PROCEDURE….5252
LOADING AND UNLOADING WITH TRAILER….5253
LIFTING MACHINE….5262
COLD WEATHER OPERATION….5265
COLD WEATHER OPERATION INFORMATION….5265
AFTER DAILY WORK COMPLETION….5267
AFTER COLD WEATHER SEASON….5267
LONG TERM STORAGE….5268
BEFORE STORAGE….5268
DURING STORAGE….5268
AFTER STORAGE….5269
STARTING MACHINE AFTER LONG-TERM STORAGE….5269
TROUBLES AND ACTIONS….5270
RUNNING OUT OF FUEL….5270
PHENOMENA THAT ARE NOT FAILURES….5270
TOWING THE MACHINE….5271
LIGHTWEIGHT TOWING HOLE….5272
SEVERE JOB CONDITION….5272
DISCHARGED BATTERY….5273
OTHER TROUBLE….5277
MAINTENANCE….5283
MAINTENANCE INFORMATION….5284
OUTLINE OF SERVICE….5286
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….5286
ELECTRIC SYSTEM MAINTENANCE….5289
WEAR PARTS….5290
WEAR PARTS LIST….5290
RECOMMENDED FUEL, COOLANT, AND LUBRICANT….5291
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE….5292
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL….5293
TIGHTENING TORQUE SPECIFICATIONS….5294
TIGHTENING TORQUE LIST….5294
SAFETY CRITICAL PARTS….5295
SAFETY CRITICAL PARTS LIST….5296
MAINTENANCE SCHEDULE….5297
MAINTENANCE SCHEDULE CHART….5297
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….5299
MAINTENANCE PROCEDURE….5300
WHEN REQUIRED….5300
CHECK BEFORE STARTING….5328
EVERY 100 HOURS MAINTENANCE….5329
EVERY 250 HOURS MAINTENANCE….5331
EVERY 500 HOURS MAINTENANCE….5336
EVERY 1000 HOURS MAINTENANCE….5347
EVERY 2000 HOURS MAINTENANCE….5353
EVERY 4000 HOURS MAINTENANCE….5357
EVERY 5000 HOURS MAINTENANCE….5359
EVERY 8000 HOURS MAINTENANCE….5360
SPECIFICATIONS….5361
SPECIFICATIONS….5362
ATTACHMENTS, OPTIONS….5365
ATTACHMENTS AND OPTIONS – GENERAL INFORMATION….5366
SAFETY FIRST….5366
ATTACHMENT INSTALLATION….5367
BUCKET WITH HOOK….5368
HOOK CONDITION….5368
PROHIBITED OPERATIONS….5368
MACHINE READY FOR ATTACHMENT….5369
LOCATIONS….5369
HYDRAULIC CIRCUIT….5373
ATTACHMENT REMOVAL AND INSTALLATION….5374
ATTACHMENT OPERATIONS….5378
LONG TERM STORAGE….5382
SPECIFICATIONS….5382
ATTACHMENT GUIDE….5383
ATTACHMENT COMBINATIONS….5384
TRACK SHOES SELECTION….5385
HANDLING OF RUBBER PAD SHOE AND ROAD LINER….5386
RECOMMENDED ATTACHMENT OPERATIONS….5388
HYDRAULIC BREAKER….5388
HANDLING MACHINES EQUIPPED WITH KOMTRAX….5393
BASIC PRECAUTIONS….5393
INDEX….5395
UEAM003604 – Hydraulic Excavator PC130-7 Operation & Maintenance Manual….5399
COVER….5399
FOREWORD….5401
FOREWORD….5402
SAFETY INFORMATION….5403
Noise emission levels….5405
Vibration levels….5405
Guide to Reduce Vibration Levels on Machine….5406
INTRODUCTION….5407
DIRECTIONS OF MACHINE….5407
BREAKING-IN THE NEW MACHINE….5407
PRODUCT INFORMATION….5408
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE….5408
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION….5408
SERVICE METER LOCATION….5409
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR….5409
MACHINE SERIAL NUMBER PLATE….5410
FOREWORD….5412
SAFETY….5412
OPERATION….5412
MAINTENANCE….5415
SPECIFICATIONS….5417
ATTACHMENTS AND OPTIONS….5417
INDEX….5419
COLOPHON….5419
SAFETY….5421
SAFETY INFORMATION….5422
SAFETY LABELS….5424
LOCATION OF SAFETY LABELS….5424
SAFETY LABELS….5425
SAFETY INFORMATION….5433
SAFETY MACHINE OPERATION….5443
STARTING ENGINE….5443
OPERATION….5445
TRANSPORTATION….5452
BATTERY….5453
TOWING….5455
LIFTING OBJECTS WITH BUCKET….5456
SAFETY MAINTENANCE INFORMATION….5458
OPERATION….5465
MACHINE VIEW ILLUSTRATIONS….5466
OVERALL MACHINE VIEW….5466
CONTROLS AND GAUGES….5467
DETAILED CONTROLS AND GAUGES….5468
MONITORING SYSTEM….5468
Basic Check Monitors….5469
Caution Monitors….5471
Emergency Monitors….5473
Meter Display Portion….5475
Monitor Switches Portion….5478
SWITCHES….5481
CONTROL LEVERS AND PEDALS….5487
SUN ROOF….5490
WINDSHIELD….5490
EMERGENCY EXIT FROM OPERATOR'S CAB….5495
DOOR LOCK….5495
CAP WITH LOCK….5496
HOT AND COOL BOX….5498
MAGAZINE BOX….5498
ASHTRAY….5498
AIR CONDITIONER CONTROLS….5499
Air Conditioner Control Panel….5499
Method of Operation….5504
Use Air Conditioner with Care….5510
Inspection and maintenance of Air Conditioner Equipped Machine….5510
Other Functions….5511
CAB RADIO CASSETTE….5512
Controls of Radio cassette….5512
Precautions when Using….5512
AUXILIARY ELECTRIC POWER….5513
24V power source….5513
12V power source….5513
FUSE….5514
FUSIBLE LINK….5515
CONTROLLERS….5515
TOOL BOX….5515
GREASE GUN HOLDER….5515
HANDLING GREASE GUN….5516
REFUELLING PUMP….5517
ACCUMULATOR….5519
Releasing Hydraulic Pressure with Accumulator….5519
MACHINE OPERATIONS AND CONTROLS….5520
BEFORE STARTING ENGINE….5520
Walk-around Checks….5520
Checks Before Starting….5522
Adjustment….5528
Seat Belt….5533
Operations Before Starting Engine….5534
STARTING ENGINE….5536
Normal Starting….5536
Starting Engine in Cold Weather….5538
AMBIENT TEMPERATURE RANGE FOR OPERATION….5540
AFTER STARTING ENGINE….5540
Warming-up Operation….5540
In Cold Weather Areas….5543
STOPPING THE ENGINE….5547
MACHINE OPERATION….5548
Preparations for Moving the Machine Off….5548
Moving Machine Forward….5549
Moving Machine Backward….5550
Stopping Machine….5551
STEERING THE MACHINE….5552
Steering….5552
SWINGING….5554
WORK EQUIPMENT CONTROLS AND OPERATIONS….5555
WORKING MODE….5557
PROHIBITED OPERATIONS….5558
GENERAL OPERATION INFORMATION….5560
TRAVELING ON SLOPES….5561
ESCAPE FROM MUD….5563
Stuck One Side of Track….5563
Stuck Both Sides of Tracks….5563
RECOMMENDED APPLICATIONS….5564
Backhoe Work….5564
Shovel Work….5564
Ditching Work….5564
Loading Work….5565
BUCKET REPLACEMENT AND INVERSION….5566
Replacement….5566
Inversion….5567
PARKING MACHINE….5568
CHECK AFTER SHUT OFF ENGINE….5569
MACHINE INSPECTION AFTER DAILY WORK….5570
LOCKING….5570
OVERLOAD WARNING DEVICE….5570
TRANSPORTATION….5571
TRANSPORTATION PROCEDURE….5571
LOADING AND UNLOADING WITH TRAILER….5572
Loading….5573
Securing Machine….5575
Unloading….5578
LIFTING MACHINE….5580
COLD WEATHER OPERATION….5581
COLD WEATHER OPERATION INFORMATION….5581
Fuel and Lubricants….5581
Cooling System Coolant….5581
Battery….5582
AFTER DAILY WORK COMPLETION….5583
AFTER COLD WEATHER SEASON….5583
LONG TERM STORAGE….5584
BEFORE STORAGE….5584
DURING STORAGE….5584
AFTER STORAGE….5585
STARTING MACHINE AFTER LONG-TERM STORAGE….5585
TROUBLES AND ACTIONS….5586
RUNNING OUT OF FUEL….5586
PHENOMENA THAT ARE NOT FAILURES….5586
TOWING THE MACHINE….5587
LIGHTWEIGHT TOWING HOLE….5587
SEVERE JOB CONDITION….5588
DISCHARGED BATTERY….5589
Battery Removal and Installation….5589
Battery Charges….5590
Starting Engine with Booster Cables….5591
OTHER TROUBLE….5593
Electrical System….5593
Chassis….5594
Engine….5595
Electronic Control System….5596
MAINTENANCE….5597
MAINTENANCE INFORMATION….5598
LUBRICANTS, COOLANT AND FILTERS….5601
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC….5601
Oil….5601
Fuel….5601
Cooling System Coolant….5602
Grease….5602
Carrying Out KOWA (Komatsu Oil Wear Analysis)….5603
Oil and Fuel Storage….5604
Filters….5604
ELECTRIC SYSTEM MAINTENANCE….5604
WEAR PARTS….5605
WEAR PARTS LIST….5605
LUBRICANTS, FUEL AND COOLANT SPECIFICATIONS….5606
PROPER SELECTION….5606
TIGHTENING TORQUE SPECIFICATIONS….5610
TIGHTENING TORQUE LIST….5610
SAFETY CRITICAL PARTS….5611
SAFETY CRITICAL PARTS LIST….5611
MAINTENANCE SCHEDULE….5612
MAINTENANCE SCHEDULE CHART….5612
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER….5614
MAINTENANCE PROCEDURE….5615
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)….5615
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)….5615
WHEN REQUIRED….5616
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT….5616
CLEAN INSIDE OF COOLING SYSTEM….5621
CHECK AND TIGHTEN TRACK SHOE BOLTS….5624
CHECK AND ADJUST TRACK TENSION….5625
CHECK ELECTRICAL INTAKE AIR HEATER….5627
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)….5628
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)….5631
ADJUST BUCKET CLEARANCE….5632
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID….5633
CHECK AND ADJUST AIR CONDITIONER….5634
WASH WASHABLE FLOOR….5635
BLEEDING AIR FROM HYDRAULIC SYSTEM….5639
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT….5642
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (control circuit)….5642
CHECK BEFORE STARTING….5643
EVERY 100 HOURS MAINTENANCE….5644
LUBRICATING….5644
CHECK SWING MACHINERY CASE OIL, ADD OIL….5646
EVERY 250 HOURS MAINTENANCE….5647
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL….5647
CHECK LEVEL OF BATTERY ELECTROLYTE….5648
EVERY 500 HOURS MAINTENANCE….5651
REPLACE FUEL FILTER CARTRIDGE….5651
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE….5652
CHECK SWING PINION GREASE LEVEL, ADD GREASE….5653
LUBRICATE SWING CIRCLE….5653
Radiator Core and Fins – Check/Clean….5654
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS….5655
REPLACE HYDRAULIC OIL FILTER ELEMENT….5657
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK….5658
CHECK AND ADJUST COOLING FAN BELT TENSION….5659
CHECK, ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION….5660
EVERY 1000 HOURS MAINTENANCE….5661
CHANGE OIL IN SWING MACHINERY CASE….5661
CHANGE OIL IN FINAL DRIVE CASE….5662
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER….5662
CHECK PLAY TURBOCHARGER ROTOR….5662
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (for breaker)….5662
EVERY 2000 HOURS MAINTENANCE….5663
CHECK PTO GEAR CASE, ADD OIL….5663
CLEAN HYDRAULIC TANK STRAINER….5664
CLEAN, CHECK TURBOCHARGER….5664
CHECK ALTERNATOR, STARTING MOTOR….5664
CHECK ENGINE VALVE CLEARANCE, ADJUST….5664
EVERY 4000 HOURS MAINTENENCE….5665
CHECK WATER PUMP….5665
EVERY 5000 HOURS MAINTENANCE….5666
CHANGE OIL IN HYDRAULIC TANK….5666
SPECIFICATIONS….5667
SPECIFICATIONS….5668
EXPLANATION OF LIFTING CAPACITY CHART (PC130-7 1- PC BOOM)….5671
EXPLANATION OF LIFTING CAPACITY CHART (PC130-7 2-PC BOOM)….5673
ATTACHMENTS AND OPTIONS….5675
GENERAL PRECAUTIONS FOR SAFETY….5676
HYDRAULIC QUICK COUPLER PIPING….5676
LOCATIONS….5676
OPERATION….5677
PRECAUTIONS WHEN SELECTING….5679
READ THE INSTRUCTION MANUAL THOROUGHLY….5679
PRECAUTIONS WHEN REMOVING OR INSTALLING….5679
PRECAUTIONS WHEN USING….5680
BUCKET WITH HOOK….5681
HOOK CONDITION….5681
PROHIBITED OPERATIONS….5681
MACHINE READY FOR ATTACHMENT….5682
LOCATIONS….5682
HYDRAULIC CIRCUIT….5685
Hydraulic Circuit Connection….5685
ATTACHMENT REMOVAL AND INSTALLATION….5686
Attachment Removal….5686
Attachment Installation….5686
ATTACHMENT OPERATIONS….5688
When Using Breaker….5688
When Using General Attachment Such as Crusher….5689
CRUSHER CONTROL FOR ROTATION….5690
ACCUMULATOR….5691
Hydraulic System – Pressure Release….5691
LONG TERM STORAGE….5692
SPECIFICATIONS….5692
ATTACHMENT GUIDE….5693
OTHER ATTACHMENTS….5693
ATTACHMENT COMBINATIONS….5694
TRACK SHOES SELECTION….5695
BUCKET TEETH SELECTION….5696
Teeth Selection….5696
Selection Guide for Horizontal or Vertical Pin Type Tooth….5696
HANDLING OF RUBBER PAD SHOE AND ROAD LINER….5697
Working Environment….5697
Working Conditions….5697
Storage, Protection….5698
Extent of Damage to Rubber….5698
Check Road Liner….5698
Replace Road Liner….5698
RECOMMENDED ATTACHMENT OPERATIONS….5699
HYDRAULIC BREAKER….5699
2-PC BOOM….5703
FEATURES OF 2-PIECE BOOM & ARM….5703
OPERATION….5704
BEFORE STORAGE POSTURE WHEN LEAVING MACHINE….5705
TESTING AND ADJUSTING….5706
PERODIC MAINTENANCE….5706
TRANSPORTATION….5707
HANDLING MACHINES EQUIPPED WITH KOMTRAX….5708
BASIC PRECAUTIONS….5708
SUPER LONG FRONT BOOM AND ARM….5709
OPERATION INSTRUCTION….5709
WORKING MODES….5710
CHECKS BEFORE STARTING….5711
USING SUPER LONG FRONT….5712
METHOD OF WORK….5713
WHEN TRAVELLING….5713
CONTROL LEVERS, PEDALS….5714
SAFETY LOCK LEVER (1)….5714
TRAVEL LEVERS (WITH PEDAL, AUTO-DECELERATION MECHANISM) (2)….5715
LEFT WORK EQUIPMENT CONTROL LEVER (3)….5715
RIGHT WORK EQUIPMENT CONTROL LEVER (4)….5716
MACHINE OPERATION….5717
PRECAUTIONS FOR OPERATION OF SUPER LONG FRONT….5717
TRANSPORT & STORAGE OF SUPER LONG FRONT MACHINE….5718
INSTALLATION OF SUPPORTING LINK….5718
TRANSPORTATION OF SUPER LONG FRONT MACHINE….5718
WORKING RANGE OF SUPER LONG FRONT….5719
LIFTING CAPACITY PC130 SUPER LONG FRONT….5720
MAINTENANCE….5721
SPECIAL SERVICE REQUIREMENTS FOR SUPER LONG FRONT WORK EQUIPMENT….5721
LUBRICATING….5721
INDEX….5723
COLOPHON….5727

Komatsu Hydraulic Excavator PC130 Repair Service Manuals

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