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Example of Komatsu excavator shop manual content
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