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FAILURE CODE [CA144] ..............................................................................................................40-204
FAILURE CODE [CA145] ..............................................................................................................40-206
FAILURE CODE [CA153] ..............................................................................................................40-208
FAILURE CODE [CA154] ..............................................................................................................40-211
FAILURE CODE [CA187] ..............................................................................................................40-214
FAILURE CODE [CA221] ..............................................................................................................40-216
FAILURE CODE [CA222] ..............................................................................................................40-218
FAILURE CODE [CA227] ..............................................................................................................40-220
FAILURE CODE [CA234] ..............................................................................................................40-221
FAILURE CODE [CA238] ..............................................................................................................40-222
FAILURE CODE [CA239] ..............................................................................................................40-224
FAILURE CODE [CA249] ..............................................................................................................40-226
FAILURE CODE [CA256] ..............................................................................................................40-228
FAILURE CODE [CA271] ..............................................................................................................40-230
FAILURE CODE [CA272] ..............................................................................................................40-232
FAILURE CODE [CA322] ..............................................................................................................40-234
FAILURE CODE [CA324] ..............................................................................................................40-236
FAILURE CODE [CA331] ..............................................................................................................40-238
FAILURE CODE [CA332] ..............................................................................................................40-240
FAILURE CODE [CA343] ..............................................................................................................40-242
FAILURE CODE [CA351] ..............................................................................................................40-243
FAILURE CODE [CA352] ..............................................................................................................40-244
FAILURE CODE [CA356] ..............................................................................................................40-247
FAILURE CODE [CA357] ..............................................................................................................40-249
FAILURE CODE [CA386] ..............................................................................................................40-251
FAILURE CODE [CA435] ..............................................................................................................40-252
FAILURE CODE [CA441] ..............................................................................................................40-254
FAILURE CODE [CA442] ..............................................................................................................40-256
FAILURE CODE [CA449] ..............................................................................................................40-257
FAILURE CODE [CA451] ..............................................................................................................40-258
FAILURE CODE [CA452] ..............................................................................................................40-260
FAILURE CODE [CA515] ..............................................................................................................40-262
FAILURE CODE [CA516] ..............................................................................................................40-264
FAILURE CODE [CA553] ..............................................................................................................40-266
FAILURE CODE [CA555] ..............................................................................................................40-267
FAILURE CODE [CA556] ..............................................................................................................40-268
FAILURE CODE [CA559] ..............................................................................................................40-269
FAILURE CODE [CA689] ..............................................................................................................40-273
FAILURE CODE [CA691] ..............................................................................................................40-275
FAILURE CODE [CA692] ..............................................................................................................40-277
FAILURE CODE [CA697] ..............................................................................................................40-279
FAILURE CODE [CA698] ..............................................................................................................40-280
FAILURE CODE [CA731] ..............................................................................................................40-281
FAILURE CODE [CA778] ..............................................................................................................40-283
FAILURE CODE [CA1117] ............................................................................................................40-288
FAILURE CODE [CA1664] ............................................................................................................40-289
FAILURE CODE [CA1669] ............................................................................................................40-291
FAILURE CODE [CA1673] ............................................................................................................40-292
FAILURE CODE [CA1677] ............................................................................................................40-293
FAILURE CODE [CA1678] ............................................................................................................40-294
FAILURE CODE [CA1682] ............................................................................................................40-295
FAILURE CODE [CA1683] ............................................................................................................40-299
FAILURE CODE [CA1684] ............................................................................................................40-301
FAILURE CODE [CA1686] ............................................................................................................40-303
FAILURE CODE [CA1691] ............................................................................................................40-304
FAILURE CODE [CA1694] ............................................................................................................40-306
FAILURE CODE [CA1695] ............................................................................................................40-308
FAILURE CODE [CA1696] ............................................................................................................40-309

INDEX

00 INDEX AND FOREWORD

00-6

PC138USLC-11

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Summary of Contents for PC138USLC-11

Page 1: ...HYDRAULIC EXCAVATOR SEN06589 03 PC138USLC 11 SERIAL NUMBERS 50001 and up ...

Page 2: ...Find manuals at https best manuals com ...

Page 3: ...00 INDEX AND FOREWORD PC138USLC 11 00 1 Find manuals at https best manuals com ...

Page 4: ...OR WITH LOCK TO PULL 00 66 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 67 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 00 69 HOW TO READ ELECTRICAL WIRE CODE 00 70 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 74 STANDARD TIGHTENING TORQUE TABLE 00 77 CONVERSION TABLE 00 84 01 SPECIFICATIONS 01 1 CONTENTS 01 2 ABBREVIATION LIST 01 3 SPECIFI...

Page 5: ...EL SYSTEM 10 277 LAYOUT DRAWING OF TRAVEL SYSTEM 10 277 TRAVEL CONTROL SYSTEM DIAGRAM 10 279 COMPONENT PARTS OF TRAVEL SYSTEM 10 283 UNDERCARRIAGE AND FRAME 10 299 LAYOUT DRAWING OF UNDERCARRIAGE 10 299 IDLER CUSHION 10 300 WORK EQUIPMENT 10 301 STRUCTURE OF WORK EQUIPMENT 10 301 FUNCTION OF WORK EQUIPMENT 10 302 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10 303 BUCKET CLEARANCE ADJUSTMENT SHIM 10 3...

Page 6: ...WORK EQUIPMENT SWING TRAVEL AND BLADE CIR CUITS 30 105 TEST OIL PRESSURE OF CONTROL CIRCUIT 30 114 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30 116 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30 120 TEST OUTLET PRESSURE OF SOLENOID VALVE 30 126 TEST PPC VALVE OUTLET PRESSURE 30 131 ADJUST WORK EQUIPMENT AND SWING PPC VALVES 30 133 TEST AND ADJUST TRAVEL DEVIATION 30 134 T...

Page 7: ...CODE 879CKA 40 154 FAILURE CODE 879CKB 40 155 FAILURE CODE 879DKZ 40 156 FAILURE CODE 879EMC 40 158 FAILURE CODE 879FMC 40 159 FAILURE CODE 879GKX 40 160 FAILURE CODE 989L00 40 162 FAILURE CODE 989M00 40 163 FAILURE CODE 989N00 40 164 FAILURE CODE A1U0N3 40 165 FAILURE CODE A1U0N4 40 167 FAILURE CODE A900FR 40 169 FAILURE CODE A900N6 40 170 FAILURE CODE A900NY 40 171 FAILURE CODE AA10NX 40 172 FAI...

Page 8: ...FAILURE CODE CA442 40 256 FAILURE CODE CA449 40 257 FAILURE CODE CA451 40 258 FAILURE CODE CA452 40 260 FAILURE CODE CA515 40 262 FAILURE CODE CA516 40 264 FAILURE CODE CA553 40 266 FAILURE CODE CA555 40 267 FAILURE CODE CA556 40 268 FAILURE CODE CA559 40 269 FAILURE CODE CA689 40 273 FAILURE CODE CA691 40 275 FAILURE CODE CA692 40 277 FAILURE CODE CA697 40 279 FAILURE CODE CA698 40 280 FAILURE CO...

Page 9: ... 364 FAILURE CODE CA3142 40 366 FAILURE CODE CA3143 40 367 FAILURE CODE CA3144 40 368 FAILURE CODE CA3146 40 370 FAILURE CODE CA3147 40 371 FAILURE CODE CA3148 40 372 FAILURE CODE CA3151 40 374 FAILURE CODE CA3165 40 380 FAILURE CODE CA3229 40 382 FAILURE CODE CA3231 40 384 FAILURE CODE CA3232 40 386 FAILURE CODE CA3235 40 390 FAILURE CODE CA3239 40 392 FAILURE CODE CA3241 40 395 FAILURE CODE CA32...

Page 10: ... 508 FAIULER CODE CA3921 40 510 FAILURE CODE CA3928 40 511 FAILURE CODE CA3932 40 512 FAILURE CODE CA3933 40 514 FAILURE CODE CA3934 40 516 FAILURE CODE CA3935 40 519 FAILURE CODE CA3936 40 521 FAILURE CODE CA4152 40 523 FAILURE CODE CA4155 40 527 FAILURE CODE CA4156 40 530 FAILURE CODE CA4157 40 533 FAILURE CODE CA4159 40 535 FAILURE CODE CA4164 40 536 FAILURE CODE CA4165 40 538 FAILURE CODE CA41...

Page 11: ...LURE CODE D811MC 40 633 FAILURE CODE D862KA 40 634 FAILURE CODE D8ALKA 40 635 FAILURE CODE D8ALKB 40 637 FAILURE CODE D8AQKR 40 639 FAILURE CODE DA20MC 40 643 FAILURE CODE DA22KK 40 644 FAILURE CODE DA25KP 40 647 FAILURE CODE DA26KP 40 651 FAILURE CODE DA29KQ 40 653 FAILURE CODE DA2LKA 40 655 FAILURE CODE DA2LKB 40 657 FAILURE CODE DA2QKR 40 659 FAILURE CODE DA2RKR 40 664 FAILURE CODE DAF0MB 40 66...

Page 12: ...LURE CODE DUMBKA 40 762 FAILURE CODE DUMBKB 40 764 FAILURE CODE DV20KB 40 766 FAILURE CODE DW43KA 40 768 FAILURE CODE DW43KB 40 770 FAILURE CODE DW43KY 40 772 FAILURE CODE DW45KA 40 773 FAILURE CODE DW45KB 40 776 FAILURE CODE DW45KY 40 779 FAILURE CODE DW4CKY 40 781 FAILURE CODE DW91KA 40 783 FAILURE CODE DW91KB 40 785 FAILURE CODE DW91KY 40 787 FAILURE CODE DWA2KA 40 789 FAILURE CODE DWA2KB 40 79...

Page 13: ...GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40 863 E 16 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOL ANT TEMPERATURE 40 864 E 17 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 40 865 E 18 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEM PERATURE 40 867 E 19 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 40...

Page 14: ...MONITORING FUNCTION 40 910 E 52 BLADE RAISE ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 40 913 E 53 BLADE LOWER ON IS NOT DISPLAYED CORRECTLY WITH MONITORING 40 914 E 54 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 40 915 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS H MODE 40 916 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE H MODE 40 916 FAILURE MODE AND CAUSE TABLE 40 917 H 1 ALL WORK EQU...

Page 15: ... INFORMATION MENTIONED IN TROUBLESHOOTING TABLE S MODE 40 978 S 1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 40 979 S 2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 40 980 S 3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START MISFIRING ENGINE CRANKS BUT DOES NOT START 40 981 S 4 ENGINE STARTABILITY IS POOR 40 982 S 5 ENGINE DOES NOT PICK UP SMOOTHLY 40 984 S 6 ENGINE STOPS...

Page 16: ...K STRAINER 50 236 REMOVE AND INSTALL SCR ASSEMBLY 50 237 REMOVE AND INSTALL KDOC AND SCR ASSEMBLY BRACKET 50 246 REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 50 254 REMOVE AND INSTALL KCCV ASSEMBLY 50 262 REMOVE AND INSTALL EXHAUST THROTTLE VALVE 50 265 REMOVE AND INSTALL AdBlue DEF MIXING TUBE 50 277 REMOVE AND INSTALL AdBlue DEF INJECTOR 50 287 REMOVE AND INSTALL AdBlue DEF PUMP 50 295 REMOVE AND IN...

Page 17: ...MBLY 50 592 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 50 595 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 50 601 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 50 604 REMOVE AND INSTALL SCR TEMPERATURE SENSOR 50 609 REMOVE AND INSTALL REARVIEW CAMERA 50 611 REMOVE AND INSTALL KomVision CAMERA 50 614 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 50 619 60 MAINTENANCE STANDARD 60 1 CO...

Page 18: ... AIR CONDITIONER 80 13 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 80 14 OUTLINE OF REFRIGERATION CYCLE 80 15 COMPONENT PARTS OF AIR CONDITIONER SYSTEM 80 17 AIR CONDITIONER UNIT 80 17 COMPONENT PARTS OF AIR CONDITIONER UNIT 80 20 AIR CONDITIONER CONTROLLER 80 24 COMPRESSOR 80 25 CONDENSER 80 26 SENSORS FOR AIR CONDITIONER SYSTEM 80 28 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING...

Page 19: ...CHANGEOVER 80 83 TROUBLESHOOTING USING GAUGE PRESSURE 80 85 CONNECTION OF SERVICE TOOL 80 87 METHOD FOR CONNECTING SERVICE TOOL 80 87 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION ER PIPINGS 80 89 HANDLE COMPRESSOR OIL 80 91 METHOD FOR REPLACING DESICCANT 80 93 90 CIRCUIT DIAGRAMS 90 1 CONTENTS 90 2 ABBREVIATION LIST 90 3 HYDRAULIC CIRCUIT DIAGRAM 90 9 SYMBOLS USED ...

Page 20: ...on auto matically applies the retarder with a constant braking force HD HM ARSC Automatic Retarder Speed Control Travel and brake When the accelerator pedal is released while the machine is traveling downhill this function auto matically applies the retarder to ensure that the machine speed does not accelerate above the speed set by the operator HD HM ASR Automatic Spin Regula tor Travel and brake...

Page 21: ...draulic system This mechanism allows actuators to be operated in proportion to the current supplied FOPS Falling Object Protective Structure Cab and canopy This structure protects the operator s head from falling objects This performance is standardized as ISO 3449 F N R Forward Neutral Re verse Operation Forward Neutral Reverse GPS Global Positioning Sys tem Communication Global Positioning Syste...

Page 22: ... at the same time activates the in ter axle differential lock when the wheels idle while the machine travels on the soft ground road HM LCD Liquid Crystal Display Machine monitor Image display equipment such as a monitor which assembles in the liquid crystal element LED Light Emitting Diode Electronic parts It refers to semiconductor element that emits light when the voltage is applied in forward ...

Page 23: ...k equipment This function performs hydraulic control of the tilt and pitch of the bulldozer blade D ROPS Roll Over Protective Structure Cab and canopy Sturcture protects the operator who wear the seatbelt so that he will not be crushed by a ma chine when it is tipped Operator Protective structure when tipping Structure which is standardized as ISO 3471 or ISO 12117 2 SCR Selective Catalytic Re duc...

Page 24: ...e model D Bulldozer HD Dump truck HM Articulate dump truck PC Hydraulic excavator WA Wheel loader List of abbreviations used in the circuit diagrams Abbreviation Actual word spelled out A C Air Conditioner A D Analogue to Digital A M Air Mix Damper ACC Accessory ADD Additional AUX Auxiliary BR Battery Relay CW Clockwise CCW Counter Clockwise ECU Electronic Control Unit ECM Electronic Control Modul...

Page 25: ...Abbreviation Actual word spelled out SPEC Specification SW Switch TEMP Temperature T C Torque Converter T M Transmission 00 INDEX AND FOREWORD ABBREVIATION LIST PC138USLC 11 00 23 ...

Page 26: ... adjusting and troubleshooting Use the standard values table to check the standard values for testing and adjusting and judge troubles in troubleshooting 30 TESTING AND ADJUSTING This section describes the measuring tools and measuring methods for testing and adjusting as well as the ad justing method of each part The standard values and repair limit for TESTING AND ADJUSTING are described in STAN...

Page 27: ...ing posture for slinging work Tightening torque This signal indicates the tightening torque for portions which requires spe cial care in assembling work Coat This signal indicates a place to be coated with adhesive grease etc in assembling work Oil and coolant This signal indicates a place to supply oil coolant etc and the quantity Draining This signal indicates a place to drain oil coolant etc an...

Page 28: ...in good physical condition and good preparation Always be alert and careful General precautions k If the machine is handled incorrectly it is dangerous Read and understand what is described in the operation and maintenance manual before operation Read and understand what is described in this manual before operation Read and understand the meaning of all the safety labels stuck to the machine befor...

Page 29: ... levers and hang UNDER REPAIR warning tag on them When performing the disassembling or assembling work support the machine securely with blocks jacks or stands before starting the work Remove all mud and oil from the steps or other places for going up and down on the machine Always use the hand rails ladders or steps when for going up and down on the machine Never jump on or off the machine When t...

Page 30: ...caught in ro tating parts or moving parts When raising a heavy component heavier than 25 kg use a hoist or crane Before starting work check that the slings wire ropes webbing slings chains and hooks are free from damage Always use slings which have ample capacity and install them to proper places Operate the hoist or crane slowly to prevent the component from hitting any other part Do not work wit...

Page 31: ...workers must communicate with each other fre quently The appointed signaler must make specified signals clearly at a place where he is well seen from the operator s seat and where he can see the working condition easily The signaler must always stand in front of the load and guide the operator safely k Never stand under the load k Do not move a load over a person k Never step on the load k Do not ...

Page 32: ...ok is maximum at its central part Never use a wire rope which has breaks in strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Precautions for slinging up Wind in the crane slowly until wire ropes are stretched When settling the wire ropes with the hand do not grasp them but press them from above If you grasp them your fingers may be caug...

Page 33: ...o work and passage After operating the hoist do not swing the control switch Remember the position of the main switch so that you can turn off the power immediately in an emer gency If the hoist stops because of a power failure turn off the main switch When turning on a switch after it is turned off by the ground fault circuit interrupter check that the devices related to that switch are not in op...

Page 34: ...to use 2 wrenches use one wrench to fix and use the other one to loosen the nut Precautions for air conditioner piping When installing the air conditioner piping be careful so that dirt dusts and water do not enter the hose Check that the O rings are fitted to the joints when connecting the air conditioner piping Do not reuse an O ring because it is deformed and deteriorated if it is used once Whe...

Page 35: ...g An O ring is fitted to every joint of the air conditioner piping For tightening torques see THE OTHER INFORMATION Pre cautions for disconnection and connection of air conditioner piping 00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION PC138USLC 11 00 33 ...

Page 36: ... attached to or around the engine exhaust manifold muffler or battery or on the undercovers To prevent fires from being caught remove any flammable materials such as dry leaves chips pieces of paper coal dust or any other flammable materials accumulated around the cooling system radiator oil cooler or on the undercover Fire coming from electric wiring Short circuits in the electrical system can ca...

Page 37: ...ee the Operation and Maintenance Manual for the setting procedure Explosion caused by lighting equipment When checking fuel oil battery electrolyte or coolant always use lighting equipment with anti explosion specifications When taking the electrical power for the lighting equipment from the machine follow the instructions in the Operation and Maintenance Manual 00 INDEX AND FOREWORD PRECAUTIONS T...

Page 38: ...hen they are inhaled Do not breathe the fumes After a fire there may be harmful compounds left If they touch your skin they may have a bad influence on your body Be sure to wear rubber gloves when handling the materials left after the fire The material of the gloves which is recommended is polychloroprene Neoprene or polyvinyl chloride in the lower temperature environment When wearing cotton work ...

Page 39: ...or lakes Obey appropriate laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters batteries and DEF Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people When disposing of parts made of rubber or plastics hoses cables and harnesses always comply with the local regulations for disposing industrial waste products 00 I...

Page 40: ...Association of Germany DEF is the abbreviation for Diesel Exhaust Fluid Commercial DEF that is API approved and meets all the requirements defined in ISO 22241 1 This solution will be represented as DEF throughout this manual About DEF DEF is necessary for the urea SCR system DEF is a colorless transparent 32 5 aqueous urea solution Urea as main constituent is a material which is used for cosmetic...

Page 41: ... When opening the container perform it where there is good ventilation For storage see STORE AdBlue DEF Store AdBlue DEF avoiding direct sunlight Always use the original container at the time of purchase Do not exchange the container of AdBlue DEF with another one If AdBlue DEF is stored in an iron or aluminum con tainer toxic gas may develop and a chemical reaction may corrode the container PRECA...

Page 42: ...ax 10 C Up to 36 months Max 25 C Up to 18 months Max 30 C Up to 12 months Max 35 C Up to 6 months Do not store AdBlue DEF in the temperature of 35 C or above Handling AdBlue DEF in cold weather AdBlue DEF freezes at 11 C AdBlue DEF may freeze and expand to break the devices and parts in the tank The parts inside the tank may be affected Add AdBlue DEF to the specified amount for cold weather below...

Page 43: ...e remaining pressure from the hydraulic circuit always before performing the work In the field there is a risk of dust entering the component during disassembling or maintenance work and perform ance check is hardly performed Replacement of the as sembly is recommended Perform disassembling and maintenance work in the dust proof area Sealing of openings prevention of flowing out of oil Plug the op...

Page 44: ...ARK Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir cuit Avoid reusing the hydraulic oil and lubricating oil Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine If reused any foreign material may enter the hydraulic equipment and it may cause a failure Flushing operation Flushing is required to ...

Page 45: ...can remove the ultra fine approxi mately 3 μm particles that the filter built in the hydraulic equip ment cannot remove So it is very effective device 00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT PC138USLC 11 00 43 ...

Page 46: ...ckness and number of shims when storing shims When hoisting the components prepare the slings with sufficient strength When using forcing screws to remove any component tighten the forcing screws uniformly and alternately Before removing any component clean the surrounding area and cover the component to prevent any for eign material from entering after removal After disconnecting the piping or re...

Page 47: ...n of the split flange type hoses and tubes Nomi nal No Bolt pitch mm Hose side Tube side O ring 4 Bolt 5 Washer 6 a b Flange 1 Split flange 2 Sleeve head 3 04 38 1 17 5 07379 00400 07371 30400 07378 10400 07000 12021 01010 80825 01643 50823 05 42 9 19 8 07379 00500 07371 30500 07378 10500 07000 13022 01010 80830 01643 50823 06 47 6 22 2 07379 00640 07371 30640 07378 10600 07000 13025 07372 51035 0...

Page 48: ...1643 51232 30 106 4 62 07379 03010 07371 13010 07378 13000 07000 12085 07372 51650 01643 51645 34 120 6 69 8 07379 03411 07371 13411 07378 13400 07000 12100 07372 51650 01643 51645 40 130 2 77 8 07379 04012 07371 14012 07378 14000 07000 12110 07372 51650 01643 51645 50 152 4 92 07379 05011 07371 15011 07378 15000 07000 12135 07372 51655 01643 51645 Introduction of parts for the removal of O ring b...

Page 49: ...ps of adhesive to the threaded portion When applying liquid gasket clean and degrease the surface and apply it uniformly after making sure that the surface is free from dust or damage Clean all of the parts If there is any damage dents burrs or rust found on them repair it Apply engine oil to the rotating parts and sliding surface Apply molybdenum disulfide lubricant LM P to the surfaces of the pr...

Page 50: ...specified amount of grease to the work equipment parts When the coolant is drained be sure that the drain valve is securely tightened then refill the coolant reser voir with the coolant Komatsu recommends to the specified level Start the engine to circulate the coolant in the piping and add the coolant to the specified level again When the hydraulic components are removed and installed refill the ...

Page 51: ...s installation portion If there is any damage replace the part Check that there is no looseness on the exhaust equipment and mounting bolts nuts and clamps on the instal lation portion If there is any looseness retighten the part Check of function of muffler in exhaust system REMARK When an equipment is described as an muffler in exhaust system it is one of the followings The applications or compo...

Page 52: ...necessary to be extremely careful when handling and maintenance of the wiring harnesses If AdBlue DEF is spilled over wiring harness and connectors it may cause corrosion and defective contact Be careful not to spill it over electrical equipment wiring harness and connectors since AdBlue DEF is strongly corrosive to metal Main causes of failure in wiring harness Defective contact of connectors def...

Page 53: ...icity Entry of water dirt or dust when disconnecting a con nector If any water mud or dust is stuck to the outside surface of a connector it can enter inside the connector when the connector is disconnected Before disconnecting the connector wipe off any stuck water or dirt by using a dry cloth or blow it with compressed air Oil mud or dust stuck to connector If any oil or grease is stuck to the c...

Page 54: ...y pollute the environ ment Do not discard the oil inconsiderately Ask the customer for disposal or bring it back to dispose it appropriately How to clean parts when dirt is stuck If any dirt or dust sticks the parts of the fuel system clean it off thoroughly with clean fuel Precautions for replacing fuel filter cartridge Be sure to use the Komatsu genuine fuel filter cartridge NOTICE The machine e...

Page 55: ...en servicing the intake system Select an appropriate workplace Avoid the work of adding hydraulic oil replacing filters or repairing the machine in rainy or windy weather or in dusty environment Sealing the opening Plug the removed pipes and the openings of the removed components with the caps tapes plastic bags etc to prevent foreign material from entering NOTICE Do not expose the openings or stu...

Page 56: ...undness of machine in addition to KOMTRAX function described above These data can be used on per sonal computer screens How to make a full use of KOMTRAX Making use of KOMTRAX enables the following activities Quick response to a request for immediate repair 1 To check the displayed caution and failure code etc through KOMTRAX upon receiving a repair re quest from a user 2 To immediately arrange ne...

Page 57: ...connection 1 Hold adapter 1 and push hose joint 2 into mating adapter 3 REMARK Push it in approximately 3 5 mm Do not hold rubber cap portion 4 2 While having adapter 3 inserted into hose side joint 2 insert rubber cap 4 to adapter 3 side until it clicks 3 Hold hose adapter 1 or hose 5 and pull it out REMARK Provide an oil container to receive a quantity of hydraulic oil which may flow out Connect...

Page 58: ...isconnection 1 Hold the tightening adapter part and push body 2 straight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition of step 1 turn lever 3 to the right clockwise 3 While keeping the conditions of steps 1 and 2 pull out whole body 2 to disconnect it REMARK Provide an container to receive a quantity of hydraulic oil ...

Page 59: ...traight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition of step 1 push cover 3 straight until it contacts contact surface a of the hexago nal portion on the male side 3 While keeping the conditions of steps 1 and 2 pull out whole body 2 to disconnect it REMARK Provide an container to receive a quantity of hydraulic oil ...

Page 60: ...ning adapter part and push body 2 straight un til sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end DISCONNECT AND CONNECT PUSH PULL TYPE COUPLER 00 INDEX AND FOREWORD 00 58 PC138USLC 11 ...

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