All Komatsu Manuals

CONTENTS 
01 GENERAL 
SPECIFICATION DIMENSION DRAWINGS 
SPECIFICATIONS 
WEIGHT TABLE 
FUEL, COOLANT, AND LUBRICANTS 
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD 
ENGINE RELATED PARTS 
RADIATOR • OIL COOLER • AFTERCOOLER 
POWER TRAIN 
FINAL DRIVE 
SWING MACHINERY 
SWING CIRCLE 
TRACK FRAME. RECOIL SPRING 
IDLER 
CARRIER ROLLER 
TRACK ROLLER 
TRACK SHOE 
HYDRAULIC EQUIPMENT LAYOUT DRAWING 
HYDRAULIC TANK 
HYDRAULIC PUMP 
CONTROL VALVE 
SPECIFICATIONS 
WEIGHT TABLE 
FUEL, COOLANT, AND LUBRICANTS 
10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD 
ENGINE RELATED PARTS 
RADIATOR • OIL COOLER • AFTERCOOLER 
POWER TRAIN 
FINAL DRIVE 
SWING MACHINERY 
SWING CIRCLE 
TRACK FRAME. RECOIL SPRING 
IDLER 
CARRIER ROLLER 
TRACK ROLLER 
TRACK SHOE 
HYDRAULIC EQUIPMENT LAYOUT DRAWING 
HYDRAULIC TANK 
HYDRAULIC PUMP 
CONTROL VALVE 
CENTER SWIVEL JOINT 
TRAVEL MOTOR 
TRAVEL JUNCTION VALVE 
STROKE REGULATION WHEN TRAVELLING 
VALVE CONTROL 
WORK EQUIPMENT .SWING ppc VALVE 
TRAVEL ppc VALVE 
SERVICE ppc VALVE 
SOLENOID VALVE 
ppc ACCUMULATOR 
RETURN OIL FILTER 
BOOM HYDRAULIC DRIFT PREVENTION VALVE 
LIFT CHECK VALVE 
ATTACHMENT CIRCUIT SELECTOR VALVE 
HYDRAULIC CYLINDER 
WORK EQUIPMENT 
AIR CONDITIONER 
ENGINE CONTROL 
ELECTRONIC CONTROL SYSTEM 
MULTI MONITOR SYSTEM 
7-SEGMENT MONITOR SYSTEM 
SENSOR 
20 TESTING AND ADJUSTING 
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 
tÉSTlNG AND ADJUSTING 
PRE-SSOkE' 
MEASUREMENT OF BLOW-BY PRESSURE 
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING 
MEASUREMENT OF ENGINE OIL PRESSURE 
ADJUSTMENT OF ENGINE SPEED SENSOR 
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION 
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM 
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS 
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION 
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND 
TRAVEL 
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE 
INSPECTION AND ADJUSTMENT OF PUMP pc CONTROL CIRCUIT OIL PRESSURE 
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE 
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE 
MEASUREMENT OF ppc VALVE OUTPUT PRESSURE 
ADJUSTMENT OF WORK EQUIPMENT AND SWING ppc VALVE 
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT 
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT 
MEASUREMENT OF OIL LEAKAGE AMOUNT 
AIR BLEEDING OF VARIOUS PARTS 
INSPECTION PROCEDURES FOR DIODE 
SPECIAL FUNCTION OF MULTI MONITOR PANEL 
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL 
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM 
TROUBLESHOOTING 
POINTS TO REMEMBER WHEN TROUBLESHOOTING 
SEQUENCE OF EVENTS IN TROUBLESHOOTING 
9ölNTS TO REMEMBER WHEN CARRYINGO MAINTENANC 
BEFORE TROUBLESHOOTING FOR DISPLAYED CODE 
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED 
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 
SERVICE CODE IN ELECTRICAL SYSTEM IEIOII (ABNORMAL DATA IN ERROR HISTORY) 
SERVICE CODE IN ELECTRICAL SYSTEM (El 12) (SHORT-CIRCUITING IN NORMAL ROTATOIN SYSTEM OF WINDSHIELD WIPER 
MOTOR DRIVE) 
SERVICE CODE IN ELECTRICAL SYSTEM (El 13) (SHORT CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER 
MOTOR DRIVE) 
SERVICE CODE IN ELECTRICAL SYSTEM (El 14) (SHORT CIRCUITING IN WINDOW WASHER DRIVE SYSTEM) 
SERVICE CODE IN ELECTRICAL SYSTEM (El 15) (ABNORMAL WINDSHIELD WIPER MOTION) 
SERVICE CODE IN ELECTRICAL SYSTEM 16) (ABNORMALITY IN RETRACTING WINDSHIELD WIPER) 
SERVICE CODE IN ELECTRICAL SYSTEM IE201) (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM IE203) (SHORT CIRCUITING IN SWING HOLDING BRAKE SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM IE204) (SHORT-CIRCUITING IN MERGE / DIVIDE SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM IE205) (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM IE206) (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM IE211) (DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-213) (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM IE214) (DISCONNECTION OF MERGE / DIVIDE SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-215) (DISCONNECTION IN 2-STAGE RELIEF SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM IE216) (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-217) (ABNORMALITY IN INPUTTING MODEL CODE) 
SERVICE CODE IN ELECTRICAL SYSTEM IE218) (DISCONNECTION OF S-NET SIGNAL) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-222) (SHORT-CIRCUITING IN LS-EPC SOLENOID) 
SERVICE CODE IN ELECTRICAL SYSTEM IE223) (DISCONNECTION IN LS-EPC SOLENOID SYSTEM) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-224) (ABNORMALITY IN F PUMP PRESSURE SENSOR) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-225) (ABNORMALITY IN R PUMP PRESSURE SENSOR) 
SERVICE coöE IN ELECTRICALSYSTEM tE226) (ABNORMALITY IN PRESSURE SENSOR POWER söÜR 
SERVICE CODE IN ELECTRICAL SYSTEM (E-227) (ABNORMALITY IN ENGINE ROTATION SENSOR) 
set-ev'lt-t: cul_.'t IN It:d3öJ (L.'IY-UNNEL-I IUN IN Al I Act-trv1tNl ut-(lN 
SERVICE CODE IN ELECTRICAL SYSTEM (E-245) (SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPO 
SERVICE CODE IN ELECTRICAL SYSTEM IE246) (DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING 
MONITOR ONLY) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-256) (INCORRECT NONVOLATILE MEMORY DATA) 
SERVICE CODE IN ELECTRICAL SYSTEM 1806) (ABNORMALITY IN GOVERNOR POTENTIOMETER) 
SERVICE CODE IN ELECTRICAL SYSTEM (ABNORMALITY IN FULE DIAL) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-315) (SHORT-CIRCUITING IN BATTERY RELAY) 
SERVICE CODE IN ELECTRICAL SYSTEM 1816) (STEP OUT IN GOVERNOR MOTOR) 
SERVICE CODE IN ELECTRICAL SYSTEM (E-317) (DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B) 
SERVICE CODE IN ELECTRICAL SYSTEM 1818) (SHORT CIRCUITING IN GOVERNOR MOTOR PHASE A AND PRASE B) 
SERVICE CODE IN ELECTRICAL SYSTEM IE501) ("MODEL SELECTION" FUNCTION NOT PROVIDED YET) 
SERVICE CODE IN ELECTRICAL SYSTEM IE502) (MODEL SELECTING SIGNAL FAULT) 
FAILURE CODE IN MECHANICAL SYSTEM IAOOONI) (OUT OF-RATE ENGINE ROTATION AT HIGH IDLE) 
FAILURE CODE IN MECHANICAL SYSTEM IAOOON21 (OUT OF-RATE ENGINE ROTATION AT LOW IDLE) 
FAILURE CODE IN MECHANICAL SYSTEM IAAIONX) (AIR CLEANER CLOGGING) 
FAILURE CODE IN MECHANICAL SYSTEM IABOOKE) (ABNORMALLY LOWERED CHARGING VOLTAGE) 
FAILURE CODE IN MECHANICAL SYSTEM IB@BAZG) (ABNORMALLY LOWERED ENGINE OIL PRESSURE) 
FAILURE CODE IN MECHANICAL SYSTEM IB@BAZK) (ABNORMALLY LOWERED ENGINE OIL LEVEL) 
FAILURE CODE IN MECHANICAL SYSTEM IB@BCNS) (ENGINE COOLANT OVERHEATING) 
FAILURE CODE IN MECHANICAL SYSTEM IB@BCZK) (ABNORMALLY LOWERED RADIATOR COOLANT LEVEL) 
FAILURE CODE IN MECHANICAL SYSTEM IB@HANS) (HYDRAULIC OIL OVERHEATING) 
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 
BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE 
E-l ENGINE DOES NOT START (ENGINE DOES NOT ROTATE) 
E-2 ENGINE STOPS WHILE IN OPERATION 
E-3 ENGINE SPEED IS IRREGULAR, OR THERE IS HUNTING 
ENGINE DOES NOT STOP 
10 NO DISPLAY IN MONITOR PANEL AT ALL 
11 PART OF DISPLAY ON MONITOR PANEL IS MISSING 
12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL 
13 FULE LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING 
14 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY 
15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 
16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY 
17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY 
18 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS 
19 WINDSHIELD WIPER DOES NOT WORK 
20 ALARMING BUZZER CANNOT BE CANCELLED 
"BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"ARM DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"BUCKET DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
"SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 
31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM 
32 TRAVEL ALARM DOES NOT SOUND 
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 
1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW 
2 ENGINE SPEED SHARPLY DROPS OR ENGINE STA 
8 ARM MOVES SLOWLY OR LACKS POWER 
9 BUCKET MOVES SLOWLY OR LACKS POWER 
10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION 
11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT 
12 WORK EQUIPMENT HAS BIG TIME LAG 
13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT 
14 ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE 
15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGE LOAD MOVES SLOWLY 
16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY 
17 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY 
18 MACHINE SWERVES IN TRAVEL 
19 MACHINE TRAVELS SLOWLY 
20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER 
21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST 
22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) 
23 MACHINE DOES NOT SWING 
24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW 
25 EXCESSIVE OVERRUN WHEN STOPPING SWING 
26 THERE IS BIG SHOCK WHEN STOPPING SWING 
27 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING 
28 SWING NATURAL DRIFT IS TOO BIG 
TROUBLESHOOTING OF ENGINE (S-MODE) 
METHOD OF USING TROUBLESHOOTING CHARTS 
1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 
2 ENGINE DOES NOT START 
(1) ENGINE DOES NOT TURN 
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 
EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL iS BEING INJECTED 
8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 
9 OIL BECOMES CONTAMINATED QUICKLY 
10 FUEL CONSUMPTION IS EXCESSIVE 
11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN 
12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE) 
13 OIL LEVEL RISES (COOLANT, FUEL IN OIL) 
14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 
15 ABNORMAL NOISE IS MADE 
16 VIBRATION IS EXCESSIVE 
30 DISASSEMBLY AND ASSEMBLY 
HOW TO READ THIS MANUAL 
COATING MATERIALS LIST 
SPECIAL TOOL LIST 
SKETCHES OF SPECIAL TOOLS 
REMOVAL AND INSTALLATION OF STARTING MOTOR ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 
SPECIAL TOOLS 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL 
SPECIAL TOOLS 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL 
REMOVAL 
ONSTALLATION 
REMOVAL AND INSTALLATION OF 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLIES 
SPECIAL TOOLS 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY 
REMOVAL 
INSTALLATION 
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY 
SPECIAL TOOLS 
DISASSEMBLY 
ASSEMBLY 
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 
REMOVAL 
INSTALLATION 
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 
SPECIAL TOOLS 
DISASSEMBLY 
ASSEMBLY 
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY 
SPECIAL TOOLS 
DISASSEMBLY 
ASSEMBLY 
ISASSEMBLY 
ASS€-I"IBLT-. 
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 
SPECIAL TOOLS 
DISASSEMBLY 
ASSEMBLY 
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY 
SPECIAL TOOLS 
DISASSEMBLY 
ASSEMBLY 
REMOVAL AND INSTALLATION OF SPROCKET 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY 
SPECIAL TOOLS 
REMOVAL AND EXPANSION OF TRACK SHOE ASSEMBLY (IRON) 
INSTALLATION 
REMOVAL AND EXPANSION OF ROAD LINERS 
INSTALLATION OF ROAD LINERS 
REMOVAL AND INSTALLATION OF SWING CIRCUIT ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF CENTER SWIVEL MONT ASSEMBLY 
REMOVAL 
INSTALLATION 
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY 
SPECIAL TOOLS 
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY 
REMOVAL 
INSTALLATION 
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY 
SPECIAL TOOLS 
ASSEMBLY 
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 
SPECIAL TOOLS 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT 
SPECIAL TOOLS 
REMOVAL 
INSTALLATION 
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT ppc VALVE ASSEMBLY 
DISASSEMBLY 
ASSEMBLY 
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT ppc VALVE ASSEMBLY 
DISASSEMBLY 
ASSEMBLY 
DISASSEMBLY AND ASSEMBLY OF TRAVEL ppc VALVE ASSEMBLY 
SPECIAL TOOLS 
ASSEMBLY 
DISASSEMBLY 
DISASSEMBLY AND ASSEMBLY OF TRAVEL ppc VALVE ASSEMBLY 
DISASSEMBLY 
SPECIAL TOOLS 
SPECIAL TOOLS 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS) 
SPECIAL TOOLS 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY 
REMOVAL 
INSTALLATION 
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY 
REMOVAL 
b8STALLATlON 
REMOVAL AND INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY 
REMOVAL 
INSTALLATION 
90 OTHERS 
HYDRAULIC CIRCUIT DIAGRAM 
FOR MULTI MONITOR 
FOR 7-SEGMENT MONITOR 
ÉLECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER