Komatsu Excavator PC135F-10M0 service & repair manual

Description Komatsu Excavator PC135F-10M0 service & repair manual

Komatsu Hydraulic Excavator PC135F-10M0 pdf workshop service repair manual

Serial number J10001 and up

Technical data, specifications, maintenance, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
NDEX AND FOREWORD
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTIONS IF FIRE OCCURS
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE
ABBREVIATION LIST

SPECIFICATIONS
SPECIFICATION DRAWING
WORKING RANGE DRAWINGS
WEIGHT TABLE
FUEL, COOLANT, LUBRICANT

STRUCTURE AND FUNCTION
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH KOMTRAX TERMINAL)
LAYOUT DRAWING OF BOOT-UP SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)
SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE SYSTEM
ENGINE CONTROL SYSTEM
AUTO-DECELERATION SYSTEM
ENGINE AUTOMATIC WARM-UP SYSTEM
OVERHEAT PREVENTION SYSTEM
TURBOCHARGER PROTECTION SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH KOMTRAX TERMINAL)
LAYOUT DRAWING OF CONTROL SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)
MACHINE MONITOR SYSTEM
KOMTRAX SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC SYSTEM
CLSS
ENGINE AND PUMP COMBINED CONTROL SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
STRUCTURE OF VALVE CONTROL
PPC LOCK SYSTEM
ONE-TOUCH POWER MAXIMIZING SYSTEM
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
SWING SYSTEM
LAYOUT DRAWING OF SWING SYSTEM
SWING CONTROL SYSTEM DIAGRAM
COMPONENT PARTS OF SWING SYSTEM
TRAVEL SYSTEM
LAYOUT DRAWING OF TRAVEL SYSTEM
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM
COMPONENT PARTS OF TRAVEL SYSTEM
UNDERCARRIAGE AND FRAME
LAYOUT DRAWING OF UNDERCARRIAGE
IDLER CUSHION
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
BUCKET CLEARANCE ADJUSTMENT SHIM
CAB AND ITS ATTACHMENTS
ROPS CAB
CAB MOUNT
CAB TIPPING STOPPER

STANDARD VALUE TABLE
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR MACHINE
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE

TESTING AND ADJUSTING
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
TEST EXHAUST GAS COLOR
TEST AND ADJUST VALVE CLEARANCE
TEST COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
TEST FUEL PRESSURE
TEST FUEL RETURN RATE AND LEAKAGE
BLEED AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUT-OUT MODE OPERATION
HANDLE NO-INJECTION CRANKING OPERATION
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
TEST AND ADJUST FAN BELT TENSION
POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANCE
UNDERCARRIAGE AND FRAME
TEST AND ADJUST TRACK TENSION
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL, AND BLADE CIRCUITS
TEST OIL PRESSURE OF CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
TEST OUTLET PRESSURE OF SOLENOID VALVE
TEST OUTLET PRESSURE IN PPC VALVE
ADJUST WORK EQUIPMENT AND SWING PPC VALVES
TEST AND ADJUST TRAVEL DEVIATION
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
TEST OIL LEAKAGE
BLEED AIR FROM HYDRAULIC CIRCUIT
CAB RELATED PARTS
TEST CAB TIPPING STOPPER
ADJUST MIRRORS
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
START UP KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL)
STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL)
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER)
ADJUST REARVIEW CAMERA ANGLE
SET REGION OF Bluetooth® COMPATIBLE RADIO
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER
BATTERY DISCONNECT SWITCH (MACHINE WITH KOMTRAX TERMINAL)
BATTERY DISCONNECT SWITCH (MACHINE WITH GATEWAY FUNCTION CONTROLLER)
TEST DIODES
Pm-CLINIC
Pm CLINIC SERVICE

TROUBLESHOOTING
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOM AND TROUBLESHOOTING NUMBERS
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM
CONNECTOR LIST AND LAYOUT (MACHINES WITHOUT FUEL REFILL PUMP)
CONNECTOR CONTACT IDENTIFICATION
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)

DISASSEMBLY AND ASSEMBLY
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
PREPARATION
DRAIN AND ADD COOLANT
DRAIN AND ADD HYDRAULIC OIL
DRAIN AND ADD FUEL
COLLECT AND REFILL REFRIGERANT
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY
REMOVE AND INSTALL FAN BELT
REMOVE AND INSTALL RADIATOR ASSEMBLY
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY
UNDERCARRIAGE AND FRAME
SEPARATE AND INSTALL TRACK ASSEMBLY
REMOVE AND INSTALL SPROCKET
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY
HYDRAULIC SYSTEM
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
REMOVE AND INSTALL MAIN PUMP ASSEMBLY
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL BLADE ASSEMBLY
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY
DISASSEMBLE AND ASSEMBLE BUCKET CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE BOOM CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE ARM CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE BLADE CYLINDER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OIL PASSAGE INTEGRATED CYLINDER ASSEMBLY
CAB RELATED PARTS
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL) 
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER)
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH KOMTRAX TERMINAL)
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY (MACHINE WITH GATEWAY FUNCTION CONTROLLER)
REMOVE AND INSTALL OPERATOR SEAT
REMOVE AND INSTALL SEATBELT
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY
REMOVE AND INSTALL FRONT WIPER ASSEMBLY
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS
REMOVE AND INSTALL COMMUNICATION TERMINAL

MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF PTO
MAINTENANCE STANDARD OF COOLING SYSTEM
POWER TRAIN
MAINTENANCE STANDARD OF SWING CIRCLE
MAINTENANCE STANDARD OF SWING MACHINERY
MAINTENANCE STANDARD OF SPROCKET
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION
MAINTENANCE STANDARD OF IDLER
MAINTENANCE STANDARD OF TRACK ROLLER
MAINTENANCE STANDARD OF CARRIER ROLLER
MAINTENANCE STANDARD OF TRACK SHOE
MAINTENANCE STANDARD OF TRIPLE SHOE
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK
MAINTENANCE STANDARD OF MAIN PUMP
MAINTENANCE STANDARD OF PC-EPC VALVE
MAINTENANCE STANDARD OF SWING MOTOR
MAINTENANCE STANDARD OF TRAVEL MOTOR
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE
MAINTENANCE STANDARD OF BLADE PPC VALVE
MAINTENANCE STANDARD OF TRAVEL PPC VALVE
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)
MAINTENANCE STANDARD OF SOLENOID VALVE
MAINTENANCE STANDARD OF VARIABLE BACK PRESSURE SOLENOID VALVE
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)
MAINTENANCE STANDARD FOR ATTACHMENT CIRCUIT ACCUMULATOR (FOR LOW PRESSURE CIRCUIT)
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT
WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE
MAINTENANCE STANDARD OF BOOM CYLINDER
MAINTENANCE STANDARD OF ARM CYLINDER
MAINTENANCE STANDARD OF BUCKET CYLINDER
MAINTENANCE STANDARD OF BLADE CYLINDER
CAB AND ITS ATTACHMENTS
MAINTENANCE STANDARD OF CAB MOUNT

OTHERS
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER
SPECIFICATIONS OF AIR CONDITIONER
CONFIGURATION OF REFRIGERATION CYCLE
FUNCTION OF REFRIGERATION CYCLE
SYSTEM DIAGRAM OF AIR CONDITIONER
COMPONENT PARTS OF AIR CONDITIONER SYSTEM
AIR CONDITIONER UNIT
AIR CONDITIONER CONTROLLER
COMPRESSOR
CONDENSER
AIR CONDITIONER RELATED SENSORS
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
TEST AIR LEAKAGE (DUCT CONNECTION)
TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION
TEST VENT (MODE) CHANGEOVER
TEST FRESH/RECIRC AIR CHANGEOVER
TEST SUNLIGHT SENSOR
TEST DUAL PRESSURE SWITCH
TEST RELAY
SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS
PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER
INFORMATION DESCRIBED IN TROUBLESHOOTING
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
CONNECT SERVICE TOOL
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING
HANDLE COMPRESSOR OIL
REPLACE DESICCANT

CIRCUIT DIAGRAMS
HOW TO READ THE CODES FOR ELECTRIC CABLE
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM

Engine SAA4D95LE-5 workshop service manual