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KOMATSU AVANCE PC400HD-6LK HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 and UP) – PDF DOWNLOAD
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- KOMATSU AVANCE PC400HD-6LK HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:CEBM002502
- SN:A83001 and UP
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Description
KOMATSU AVANCE PC400HD-6LK HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 and UP)
KOMATSU AVANCE PC400HD-6LK HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 AND UP) – PDF DOWNLOAD:
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KOMATSU AVANCE PC400HD-6LK HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 and UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING, ADJUSTING AND TROUBLESHOOTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU AVANCE PC400HD-6LK HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 and UP)
MAIN MENU......................................................................................................... 0 COVER............................................................................................................. 1 CONTENTS.......................................................................................................... 2 FOREWORD.......................................................................................................... 13 SAFETY........................................................................................................ 13 SAFETY NOTICE............................................................................................. 13 IMPORTANT SAFETY NOTICE............................................................................... 13 GENERAL PRECAUTIONS................................................................................... 13 PREPARATIONS FOR WORK................................................................................. 13 PRECAUTIONS DURING WORK............................................................................... 13 GENERAL....................................................................................................... 15 HOW TO READ THE SHOP MANUAL................................................................................... 16 VOLUMES................................................................................................... 16 DISTRIBUTION AND UPDATING................................................................................. 16 FILING METHOD............................................................................................. 16 REVISED EDITION MARK...................................................................................... 16 REVISIONS................................................................................................. 16 SYMBOLS................................................................................................... 16 HOISTING INSTRUCTIONS......................................................................................... 17 HOISTING.................................................................................................. 17 WIRE ROPES................................................................................................ 17 COATING MATERIALS............................................................................................. 18 STANDARD TIGHTENING TORQUE.................................................................................... 20 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.............................................................. 20 TIGHTENING TORQUE OF HOSE NUTS............................................................................ 21 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................................................... 21 TIGHTENING TORQUE FOR FLARED NUTS......................................................................... 21 ELECTRIC WIRE CODE............................................................................................ 22 CLASSIFICATION BY THICKNESS............................................................................... 22 CLASSIFICATION BY COLOR AND CODE.......................................................................... 22 CONVERSION TABLES............................................................................................. 23 METHOD OF USING THE CONVERSION TABLE...................................................................... 23 01 GENERAL........................................................................................................ 29 SPECIFICATION DRAWINGS........................................................................................ 30 MACHINE................................................................................................... 30 WORK EQUIPMENT............................................................................................ 32 SPECIFICATIONS................................................................................................ 34 WEIGHT TABLE.................................................................................................. 36 FUEL COOLANT AND LUBRICANTS................................................................................... 38 10 STRUCTURE AND FUNCTION......................................................................................... 39 PARTS RELATED TO ENGINE....................................................................................... 43 ENGINE MOUNT TORQUES...................................................................................... 45 RADIATOR, OIL COOLER.......................................................................................... 47 RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (1/4).................................................. 48 RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (2/4).................................................. 49 RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (3/4).................................................. 50 RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (4/4).................................................. 52 POWER TRAIN................................................................................................... 53 FINAL DRIVE................................................................................................... 55 FINAL DRIVE SPECIFICATIONS AND TORQUES.................................................................... 56 SWING CIRCLE.................................................................................................. 58 SWING CIRCLE SPECIFICATIONS AND TORQUES................................................................... 59 SWING MACHINERY............................................................................................... 61 SWING MACHINERY SPECIFICATIONS AND TORQUES................................................................ 62 TRACK FRAME, RECOIL SPRING.................................................................................... 64 PC400LC-6LK............................................................................................... 64 TRACK FRAME, RECOIL SPRING TORQUES PC400LC-6LK........................................................ 65 PC400LC-6LK - VARIABLE GAUGE.............................................................................. 66 TRACK FRAME, RECOIL SPRING TORQUES PC400LC-6LK - VARIABLE GAUGE....................................... 67 PC400HD-6LK............................................................................................... 68 TRACK FRAME, RECOIL SPRING TORQUES PC400HD-6LK........................................................ 69 TRACK SHOE.................................................................................................... 71 TRACK SHOE SPECIFICATIONS................................................................................. 74 CARRIER ROLLER................................................................................................ 75 IDLER......................................................................................................... 76 TRACK ROLLER.................................................................................................. 78 HYDRAULIC PIPING DRAWING...................................................................................... 80 HYDRAULIC CIRCUIT DIAGRAM..................................................................................... 82 HYDRAULIC TANK, HYDRAULIC FILTER.............................................................................. 83 HYDRAULIC PUMP................................................................................................ 84 HPV 160 + 160............................................................................................. 84 HYDRAULIC PUMP TORQUES.................................................................................... 87 TVC, LS VALVE............................................................................................. 91 LS VALVE - OPERATION.................................................................................. 94 TVC VALVE - OPERATION................................................................................. 98 HYDRAUIC CYLINDER.............................................................................................106 BOOM, BUCKET CYLINDER - THREADED PISTON...................................................................106 BOOM, BUCKET CYLINDER - CLAMPED PISTON....................................................................106 ARM CYLINDER - THREADED PISTON............................................................................106 ARM CYLINDER - CLAMPED PISTON.............................................................................106 CONTROL VALVE.................................................................................................108 10 SPOOL VALVE - STD. AND 3 SERVICE VALVES................................................................108 9 SPOOL VALVE - STD AND 2 SERVICE VALVES..................................................................114 8 SPOOL VALVE - STD AND 1 SERVICE VALVES..................................................................115 7 SPOOL VALVE - STD.......................................................................................116 CONTROL VALVE SPECIFICATIONS AND TORQUES..................................................................118 10 SPOOL VALVE........................................................................................118 SELF REDUCING PRESSURE VALVE..................................................................................124 SELF REDUCING PRESSURE VALVE SPECIFICATIONS...............................................................124 SUCTION SAFETY VALVE..........................................................................................130 FOR SERVICE...............................................................................................130 SUCTION SAFETY VALVE SPECIFICATIONS AND TORQUES...........................................................131 CLSS..........................................................................................................132 OUTLINE OF CLSS...........................................................................................132 BASIC PRINCIPLE...........................................................................................133 CONTROL OF PUMP SWASH PLATE ANGLE.....................................................................133 PRESSURE COMPENSATION.................................................................................134 OPERATION FOR EACH FUNCTION OF CLSS.......................................................................135 SYSTEM DIAGRAM............................................................................................136 WHEN UNLOAD VALVE IS ACTUATED.............................................................................137 OPERATION OF RELIEF VALVE.................................................................................138 CUT-OFF CONTROL ACTUATED..............................................................................138 CUT-OFF CANCELED......................................................................................138 INTRODUCTION OF LS PRESSURE...............................................................................139 LS BYPASS VALVE...........................................................................................140 PRESSURE COMPENSATION VALVE...............................................................................141 SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE..........................................................144 VARIABLE TYPE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE).............................................146 VARIABLE PRESSURE COMPENSATION VALVE SPECIFICATIONS AND TORQUES...........................................147 BOOM REGENERATION CIRCUIT.................................................................................148 ARM REGENERATION CIRCUIT..................................................................................150 MERGE FLOW DIVIDER VALVE..................................................................................152 LS SELECT VALVE...........................................................................................154 2-STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD)....................................................155 OPERATION OF CLSS SYSTEM AS A WHOLE.......................................................................156 WHEN ALL WORK EQUIPMENT IS AT NEUTRAL.................................................................156 WHEN PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY.............................................157 WHEN PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY..............................................157 WHEN PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY..................................................157 WHEN PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY.................................................158 WHEN PUMP DIVIDED, TRAVEL OPERATED INDEPENDENTLY......................................................158 WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY....................................158 WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY.....................................159 WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY...................................159 WHEN PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY.......................................159 SWING MOTOR...................................................................................................160 SWING MOTOR SPECIFICATIONS AND TORQUES....................................................................162 SUCTION-SAFETY VALVE......................................................................................163 SWING BRAKE...............................................................................................164 CENTER SWIVAL JOINT...........................................................................................165 CENTER SWIVEL JOINT SPECIFICATIONS........................................................................166 TRAVEL MOTOR..................................................................................................168 MOTOR OPERATION...........................................................................................172 AT LOW SPEED..........................................................................................172 AT HIGH SPEED.........................................................................................173 PARKING BRAKE OPERATION...................................................................................174 BRAKE VALVE OPERATION.................................................................................174 SAFETY VALVE..............................................................................................176 VALVE CONTROL.................................................................................................179 WORK EQUIPMENT PPC VALVE......................................................................................180 OPERATION.................................................................................................182 AT NEUTRAL............................................................................................182 DURING FINE CONTROL (NEUTRAL Æ FINE CONTROL)..........................................................182 DURING FINE CONTROL (WHEN LEVER IS RETURNED)..........................................................183 AT FULL STROKE........................................................................................183 WORK EQUIPMENT AND SWING PPC VALVE SPECIFICATIONS AND TORQUES.............................................184 TRAVEL PPC VALVE..............................................................................................185 OPERATION.................................................................................................187 AT NEUTRAL............................................................................................187 FINE CONTROL (NEUTRAL --> FINE CONTROL)...............................................................187 FINE CONTROL (CONTROL LEVER RETURNED).................................................................188 AT FULL STROKE........................................................................................188 TRAVEL PPC VALVE SPECIFICATIONS AND TORQUE................................................................190 SERVICE PPC VALVE.............................................................................................192 SERVICE PPC VALVE SPECIFICATIONS AND TORQUES..............................................................194 PPC SAFETY LOCK VALVE.........................................................................................195 PPC ACCUMULATOR...............................................................................................196 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE......................................................................197 PPC SHUTTLE VALVE.........................................................................................198 TRAVEL JUNCTION VALVE.....................................................................................201 STRAIGHT-TRAVEL SYSTEM....................................................................................202 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE SPECIFICATIONS AND TORQUES.......................................204 LS-EPC VALVE..................................................................................................205 LS-EPC VALVE SPECIFICATIONS AND TORQUES...................................................................208 SOLENOID VALVE................................................................................................209 SOLENOID VALVE TORQUES....................................................................................211 BOOM HOLDING VALVE............................................................................................212 BOOM HOLDING VALVE SPECIFICATIONS AND TORQUES.............................................................215 WORK EQUIPMENT................................................................................................217 WORK EQUIPMENT SPECIFICATIONS.............................................................................218 DIMENSIONS OF WORK EQUIPMENT..............................................................................220 ARM...................................................................................................220 BUCKET................................................................................................222 AIR CONDITIONER...............................................................................................225 A/C PIPING................................................................................................225 A/C ELECTRICAL WIRING DIAGRAM.............................................................................226 ENGINE CONTROL................................................................................................230 OPERATION.................................................................................................231 STARTING ENGINE.......................................................................................231 ENGINE SPEED CONTROL..................................................................................231 STOPPING ENGINE.......................................................................................231 COMPONENTS................................................................................................232 FUEL CONTROL DIAL.....................................................................................232 GOVERNOR MOTOR........................................................................................234 GOVERNOR, PUMP CONTROLLER.............................................................................236 INPUT OUTPUT SIGNALS..................................................................................237 ELECTRONIC CONTROL SYSTEM.....................................................................................239 CONTROL FUNCTION..........................................................................................239 TOTAL SYSTEM DIAGRAM......................................................................................239 PUMP AND ENGINE CONTROL SYSTEM............................................................................240 PUMP AND VALVE CONTROL FUNCTION...........................................................................243 CUT-OFF FUNCTION......................................................................................244 CUT-OFF CANCEL FUNCTION...............................................................................244 FINE CONTROL MODE FUNCTION............................................................................245 POWER MAX. FUNCTION, SWIFT SLOW-DOWN FUNCTION.............................................................246 AUTO DECELERATION SYSTEM..................................................................................247 AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION..............................................249 SWING CONTROL SYSTEM......................................................................................252 TRAVEL CONTROL SYSTEM.....................................................................................254 ACTIVE MODE FUNCTION......................................................................................256 INCREASE IN ENGINE SPEED..................................................................................257 COMPONENTS OF SYSTEM......................................................................................258 ENGINE SPEED SENSOR...................................................................................258 PPC HYDRAULIC SWITCH..................................................................................258 PUMP PRESSURE SENSOR..................................................................................259 TVC PROLIX RESISTOR...................................................................................260 MACHINE MONITOR SYSTEM........................................................................................262 MONITOR PANEL.............................................................................................263 MONITOR DISPLAY...........................................................................................264 CONTENT OF DISPLAY....................................................................................265 OIL MAINTENANCE FUNCTION..................................................................................266 MODE SELECTION SWITCHES...................................................................................268 SWITCH ACTUATION TABLE................................................................................268 SENSORS...............................................................................................269 20 TESTING, ADJUSTING AND TROUBLESHOOTING.........................................................................273 STANDARD VALUE TABLES.........................................................................................275 ENGINE RELATED PARTS......................................................................................275 CHASSIS RELATED PARTS.....................................................................................276 ELECTRICAL PARTS..........................................................................................281 TESTING AND ADJUSTING.........................................................................................287 SERVICE TOOLS.............................................................................................289 ENGINE....................................................................................................290 BLOW BY PRESSURE......................................................................................290 BOOST PRESSURE........................................................................................290 COMPRESSION PRESSURE..................................................................................290 ENGINE OIL PRESSURE...................................................................................290 ENGINE SPEED SENSOR...................................................................................290 ENGINE SPEED (rpm)....................................................................................290 EXHAUST COLOR.........................................................................................290 FUEL INJECTION TIMING.................................................................................290 VALVE CLEARANCE.......................................................................................290 GOVERNOR MOTOR LEVER STROKE..............................................................................291 FAN BELT TENSION..........................................................................................292 A/C COMPRESSOR BELT.......................................................................................292 WORK EQUIPMENT, SWING, TRAVEL CIRCUIT.....................................................................293 TVC VALVE OUTPUT PRESSURE.................................................................................296 LS VALVE OUTPUT PRESSURE..................................................................................298 LS DIFFERENTIAL PRESSURE..................................................................................298 CONTROL CIRCUIT OIL PRESSURE..............................................................................301 SOLENOID VALVE OUTPUT PRESSURE............................................................................302 PPC VALVE OUTPUT PRESSURE.................................................................................305 PPC SHUTTLE VALVE.........................................................................................305 WORK EQUIPMENT, SWING PPC VALVE...........................................................................307 WORK EQUIPMENT............................................................................................309 HYDRAULIC DRIFT - LOCATIONS CAUSING...................................................................309 CYLINDER PACKING..................................................................................309 BOOM LOCK VALVE...................................................................................310 PPC VALVE.........................................................................................310 OIL LEAKAGE...............................................................................................311 WORK EQUIPMENT CYLINDER...............................................................................311 SWING MOTOR...........................................................................................312 TRAVEL MOTOR..........................................................................................312 RELEASING REMAINING PRESSURE..............................................................................313 TESTING CLEARANCE OF SWING CIRCLE BEARING.................................................................314 SPROCKET WEAR.............................................................................................315 TRACK SHOE TENSION........................................................................................316 BLEEDING AIR..............................................................................................317 BLEEDING AIR FROM HYDRAULIC CYLINDERS.................................................................318 BLEEDING AIR FROM SWING MOTOR.........................................................................318 BLEEDING AIR FROM TRAVEL MOTOR........................................................................318 TROUBLESHOOTING GENERAL.......................................................................................319 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................321 SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................323 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..........................................................324 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT...................................................324 HANDLING WIRING HARNESSES AND CONNECTORS..........................................................324 REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES..................................326 HANDLING CONTROL BOX..............................................................................329 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS.............................................330 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT..................................................330 CHECKS BEFORE TROUBLESHOOTING.............................................................................332 CONNECTOR TYPES AND MOUNTING LOCATIONS....................................................................333 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................339 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....................................................349 EXPLANATION OF MACHINE CONTROL FUNCTIONS..............................................................349 DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL...............................................350 DISPLAY ON MACHINE MONITOR........................................................................350 RECORDING OF SERVICE CODES AND USER CODE DISPLAY FUNCTION.........................................350 METHOD OF DISPLAYING TROUBLE DATA.................................................................351 MACHINE DATA MONITORING FUNCTION..................................................................352 METHOD OF DISPLAYING MONITORING CODE..............................................................352 TABLE OF MACHINE MONITORING CODES.................................................................353 BIT PATTERN CHART.................................................................................354 GOVERNOR MOTOR ADJUSTMENT MODE....................................................................356 TIME ADJUSTMENT MODE..............................................................................356 WORKING MODE DEFAULT SETTING MODE.................................................................357 METHOD OF USING JUDGEMENT TABLE...........................................................................358 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................360 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE...................................360 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE..................................................364 PROCEDURE FOR CHECKING MONITOR PANEL OUTPUT SIGNAL....................................................366 CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER....................................................367 PUMP CONTROL SYSTEM...............................................................................367 GOVERNOR CONTROL SYSTEM...........................................................................370 SERVICE CODE TABLE........................................................................................371 TROUBLESHOOTING ELECTRICAL SYSTEM ON GOVERNOR PUMP CONTROLLER (C-MODE)........................................373 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM............................................................375 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF...........................................375 USER CODE MEMORY RETENTION FUNCTION...................................................................375 INFORMATION CONTAINED IN TESTING PROCEDURES...............................................................376 (C-1).....................................................................................................378 CONTROLLER POWER SOURCE (LED) IS OFF..................................................................378 (C-2).....................................................................................................380 SHORT IN FRONT PUMP (TVC) SOLENOID SYSTEM.............................................................380 (C-3).....................................................................................................382 OPEN IN FRONT PUMP (TVC) SOLENOID SYSTEM..............................................................382 (C-4).....................................................................................................384 SHORT IN REAR PUMP (TVC) SOLENOID SYSTEM..............................................................384 (C-5).....................................................................................................386 OPEN IN REAR PUMP (TVC) SOLENOID SYSTEM...............................................................386 (C-6).....................................................................................................388 SHORT IN (LS) SELECT SOLENOID SYSTEM..................................................................388 (C-7).....................................................................................................389 OPEN IN (LS) SELECT SOLENOID SYSTEM...................................................................389 (C-8).....................................................................................................390 SHORT IN SWING BRAKE SOLENOID SYSTEM..................................................................390 (C-9).....................................................................................................392 OPEN IN SWING BRAKE SOLENOID SYSTEM...................................................................392 (C-10)....................................................................................................394 SHORT IN PUMP MERGE DIVIDER SOLENOID SYSTEM...........................................................394 (C-11)....................................................................................................396 OPEN IN PUMP MERGE DIVIDER SOLENOID SYSTEM............................................................396 (C-12)....................................................................................................398 SHORT IN TRAVEL SPEED SOLENOID SYSTEM.................................................................398 (C-13)....................................................................................................400 OPEN IN TRAVEL SPEED SOLENOID SYSTEM..................................................................400 (C-14)....................................................................................................402 SHORT IN ACTIVE MODE, SWING, SOLENOID SYSTEM..........................................................402 (C-15)....................................................................................................404 OPEN IN ACTIVE MODE, SWING, SOLENOID SYSTEM...........................................................404 (C-16)....................................................................................................406 ABNORMAL INPUT FOR MODEL CODE.........................................................................406 (C-17)....................................................................................................408 SHORT IN (LS-EPC) SOLENOID SYSTEM.....................................................................408 (C-18)....................................................................................................409 OPEN IN (LS-EPC) SOLENOID SYSTEM......................................................................409 (C-19)....................................................................................................410 ABNORMAL FRONT PUMP PRESSURE SENSOR SIGNAL............................................................410 (C-20)....................................................................................................412 BINOMIAL REAR PUMP PRESSURE SENSOR SIGNAL.............................................................412 (C-21)....................................................................................................414 ABNORMAL PRESSURE SENSOR POWER SUPPLY.................................................................414 (C-22)....................................................................................................416 ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER................................................416 (C-23)....................................................................................................418 MACHINE PUSH-UP SOLENOID HAS NO RESPONSE..............................................................418 TROUBLESHOOTING ELECTRICAL SYSTEM ON GOVERNOR PUMP CONTROLLER (E-MODE)........................................421 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM............................................................423 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF...........................................423 USER CODE MEMORY RETENTION FUNCTION...................................................................423 INFORMATION CONTAINED IN TESTING PROCEDURES...............................................................424 (E-1).....................................................................................................426 CONTROLLER POWER SOURCE (LED) IS OFF..................................................................426 (E-2).....................................................................................................428 INCORRECT FUEL CONTROL DIAL VALUE DISPLAYED...........................................................428 (E-3).....................................................................................................430 OPEN IN MOTOR DRIVE SYSTEM............................................................................430 (E-4).....................................................................................................432 SHORT IN MOTOR DRIVE SYSTEM...........................................................................432 (E-5).....................................................................................................434 INCORRECT FEEDBACK IN POTENTIOMETER DISPLAYED.........................................................434 (E-6).....................................................................................................436 SHORT IN BATTERY RELAY OUTPUT SYSTEM..................................................................436 (E-7).....................................................................................................438 ABNORMALITY IN STEP OUT MOTOR SYSTEM..................................................................438 (E-8).....................................................................................................440 ENGINE WILL NOT CRANK.................................................................................440 (E-9).....................................................................................................442 ENGINE SPEED IRREGULAR................................................................................442 ENGINE SPEED IS HUNTING...............................................................................444 (E-10)....................................................................................................446 ENGINE OUTPUT IS LOW..................................................................................446 (E-11)....................................................................................................448 ENGINE WILL NOT SHUT DOWN.............................................................................448 (E-12)....................................................................................................450 FAULTY OPERATION OF RELAY OUTPUT SYSTEM...............................................................450 TROUBLSHOOTING GOVERNOR, PUMP CONTROLLER, INPUT SIGNAL (F-MODE)...............................................453 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM............................................................454 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF...........................................454 USER CODE MEMORY RETENTION FUNCTION...................................................................454 INFORMATION CONTAINED IN TESTING PROCEDURES...............................................................455 (F-1).....................................................................................................457 SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...........................................................457 (F-2).....................................................................................................458 TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................458 (F-3).....................................................................................................459 BOOM (LOWER) PRESSURE SWITCH DOES NOT LIGHT UP........................................................459 (F-4).....................................................................................................460 BOOM (RAISE) PRESSURE SWITCH DOES NOT LIGHT UP........................................................460 (F-5).....................................................................................................461 ARM (IN) PRESSURE SWITCH DOES NOT LIGHT UP............................................................461 (F-6).....................................................................................................462 ARM (OUT) PRESSURE SWITCH DOES NOT LIGHT UP...........................................................462 (F-7).....................................................................................................463 BUCKET (CURL) PRESSURE SWITCH DOES NOT LIGHT UP.......................................................463 (F-8).....................................................................................................464 BUCKET (DUMP) PRESSURE SWITCH DOES NOT LIGHT UP.......................................................464 (F-9).....................................................................................................465 SWING LOCK SWITCH DOES NOT LIGHT UP...................................................................465 (F-10)....................................................................................................466 MODE CONNECTION DOES NOT LIGHT UP.....................................................................466 (F-11)....................................................................................................468 LEFT KNOB SWITCH DOES NOT LIGHT UP....................................................................468 TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)......................................................471 PUMP MERGE DIVIDER LOGIC..................................................................................473 SOLENOID ACTUATION TABLE..................................................................................473 TABLE OF FAILURE MODES AND CAUSES.........................................................................474 H-1.......................................................................................................478 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER....................................478 H-2.......................................................................................................480 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.............................................480 H-3.......................................................................................................481 NO WORK EQUIPMENT, TRAVEL, SWING MOVEMENT.............................................................481 H-4.......................................................................................................482 ABNORMAL NOISE GENERATED AROUND PUMP..................................................................482 H-5.......................................................................................................483 AUTO DECELERATION DOES NOT WORK WHEN PPC SHUTTLE VALVE IS CAUSE.......................................483 H-6.......................................................................................................483 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR......................................................483 H-7.......................................................................................................484 BOOM IS SLOW OR LACKS POWER...........................................................................484 H-8.......................................................................................................486 ARM IS SLOW OR LACKS POWER............................................................................486 H-9.......................................................................................................488 BUCKET IS SLOW OR LACKS POWER.........................................................................488 H-10......................................................................................................490 WORK EQUIPMENT; BOOM, ARM, BUCKET, DOES NOT MOVE, BUT TRAVEL AND SWING ARE NORMAL.....................490 H-11......................................................................................................490 EXCESSIVE HYDRAULIC DRIFT, BOOM, ARM, BUCKET..........................................................490 EXCESSIVE HYDRAULIC DRIFT OF BOOM.................................................................490 EXCESSIVE HYDRAULIC DRIFT OF ARM OR BUCKET........................................................490 H-12......................................................................................................491 EXCESSIVE TIME LAG, ENGINE AT LOW IDLING..............................................................491 H-13......................................................................................................491 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.................................................491 H-14......................................................................................................492 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED................................492 H-15......................................................................................................492 MALFUNCTION OF MACHINE PUSH UP FUNCTION...............................................................492 H-16......................................................................................................492 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW.......................................492 H-17......................................................................................................493 IN SWING PLUS BOOM RAISE, BOOM RAISE IS SLOW..........................................................493 IN ACTIVE MODE....................................................................................493 IN OTHER MODE.....................................................................................493 H-18......................................................................................................493 IN SWING PLUS ARM, ARM IS SLOW........................................................................493 H-19......................................................................................................493 IN SWING PLUS TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY..................................................493 H-20......................................................................................................494 TRAVEL DEVIATION......................................................................................494 WHEN THERE IS A DEVIATION IN NORMAL TRAVEL........................................................494 EXCESSIVE DEVIATION WHEN STARTING.................................................................494 H-21......................................................................................................496 TRAVEL SPEED IS SLOW..................................................................................496 H-22......................................................................................................498 STEERING DOES NOT TURN EASILY OR LACKS POWER..........................................................498 H-23......................................................................................................500 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED........................................500 H-24......................................................................................................500 TRAVEL DOES NOT MOVE, ONE SIDE ONLY...................................................................500 H-25......................................................................................................501 DOES NOT SWING........................................................................................501 DOES NOT SWING TO EITHER LEFT OR RIGHT............................................................501 DOES NOT SWING IN ONE DIRECTION...................................................................501 H-26......................................................................................................502 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW.....................................................502 H-27......................................................................................................504 EXCESSIVE OVERRUN WHEN STOPPING SWING.................................................................504 ONE DIRECTION ONLY................................................................................504 BOTH DIRECTIONS...................................................................................504 H-28......................................................................................................505 EXCESSIVE SHOCK WHEN STOPPING SWING, ONE DIRECTION ONLY...............................................505 H-29......................................................................................................505 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..........................................................505 H-30......................................................................................................506 EXCESSIVE HYDRAULIC DRIFT OR SWING....................................................................506 WHEN SWING HOLDING BRAKE IS RELEASED..............................................................506 WHEN SWING HOLDING BRAKE IS APPLIED...............................................................506 H-31......................................................................................................507 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED......................................................507 TROUBLESHOOTING MACHINE MONITOR SYSTEM (M-MODE)...............................................................509 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM............................................................511 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF...........................................511 USER CODE MEMORY RETENTION FUNCTION...................................................................511 INFORMATION CONTAINED IN TESTING PROCEDURES...............................................................512 (M-1).....................................................................................................514 ERROR IN DATA HISTORY.................................................................................514 (M-2).....................................................................................................516 SHORT IN BUZZER OUTPUT DISPLAY........................................................................516 (M-3).....................................................................................................518 AIR CLEANER CLOG INDICATOR FAILURE....................................................................518 (M-4).....................................................................................................520 ABNORMAL ENGINE (HI) OIL PRESSURE.....................................................................520 (M-5).....................................................................................................522 ENGINE COOLANT INDICATING OVERHEAT CONDITION..........................................................522 (M-6).....................................................................................................524 THREE SECOND DELAY ON MONITOR WHEN IGNITION KEY IS TURNED “ON”........................................524 (M-7).....................................................................................................526 WHEN IGNITION SWITCH IS TURNED “ON” ALL PANEL LAMPS STAY ILLUMINATED..................................526 (M-8).....................................................................................................526 WHEN IGNITION SWITCH IS TURNED “ON” PANEL LIGHTS DO NOT MATCH THE MACHINE.............................526 (M-9).....................................................................................................528 ABNORMAL FLUID LEVEL INDICATIONS......................................................................528 ENGINE COOLANT LEVEL FLASHES......................................................................528 ENGINE OIL LEVEL FLASHES..........................................................................530 HYDRAULIC OIL LEVEL FLASHES.......................................................................531 (M-10)....................................................................................................532 PREHEATING INDICATION IS “ON” WHEN SYSTEM IS OFF......................................................532 (M-11)....................................................................................................534 WHEN ENGINE IS STARTED BASIC CHECK ITEMS FLASH........................................................534 ALTERNATOR SYSTEM.................................................................................534 ENGINE OIL PRESSURE...............................................................................536 (M-12)....................................................................................................538 WHEN ENGINE IS STARTED CAUTION ITEMS FLASH............................................................538 ALTERNATOR SYSTEM.................................................................................538 ENGINE OIL PRESSURE...............................................................................540 (M-13)....................................................................................................542 WHEN THE ENGINE IS STARTED CAUTION AND EMERGENCY ITEMS FLASH..........................................542 ENGINE OIL PRESSURE FLASHES.......................................................................542 COOLANT LEVEL FLASHES.............................................................................542 BATTERY CHARGE INDICATOR FLASHES..................................................................542 COOLANT TEMPERATURE FLASHES.......................................................................543 FUEL LEVEL FLASHES................................................................................544 AIR CLEANER CLOG INDICATOR FLASHES................................................................545 (M-14)....................................................................................................546 WARNINGS FLASH BUT BUZZER IS DELAYED..................................................................546 (M-15)....................................................................................................548 BUZZER SOUNDS CONTINUOUSLY............................................................................548 (M-16)....................................................................................................550 NIGHT LIGHT ON MONITOR PANEL DOES NOT LIGHT-UP........................................................550 (M-17)....................................................................................................552 ENGINE COOLANT TEMPERATURE DOES NOT RISE..............................................................552 (M-18)....................................................................................................554 ENGINE COOLANT TEMPERATURE GIVES NO DISPLAY...........................................................554 (M-19)....................................................................................................556 FUEL LEVEL GAUGE ALWAYS SHOWS “FULL”..................................................................556 (M-20)....................................................................................................557 FUEL LEVEL GAUGE DOES NOT DISPLAY.....................................................................557 (M-21)....................................................................................................558 SWING LOCK NOT INDICATED ON MONITOR WHEN “ON”.........................................................558 (M-22)....................................................................................................560 SWING PROLOX NOT INDICATED ON MONITOR.................................................................560 (M-23)....................................................................................................562 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING................................................562 (M-24)....................................................................................................563 WITH IGNITION SWITCH “OFF”, WHEN THE TIME SWITCH IS PRESSED THE TIME AND SERVICE ARE NOT DISPLAYED....563 (M-25)....................................................................................................564 FAULTY FUEL LEVER SENSOR SYSTEM.......................................................................564 (M-26)....................................................................................................565 COOLANT TEMPERATURE SENSOR SYSTEM.....................................................................565 (M-27)....................................................................................................566 FAULTY ENGINE OIL LEVEL SENSOR SYSTEM.................................................................566 (M-28)....................................................................................................568 FAULTY ENGINE COOLANT LEVEL SENSOR SYSTEM.............................................................568 (M-29)....................................................................................................570 FAULTY HYDRAULIC OIL LEVEL SENSOR SYSTEM..............................................................570 (M-30)....................................................................................................572 WIPER DOES NOT WORK, OR REMAINS “ON”..................................................................572 WIPER DOES NOT WORK...............................................................................572 WIPER SWITCH IS IN THE "OFF" POSITION BUT WIPERS REMAIN ON........................................575 (M-13)....................................................................................................578 WASHER MOTOR WORKS WHEN SWITCH IS NOT BEING USED OR WASHER MOTOR DOES NOT WORK........................578 TROUBLESHOOTING COMMUNICATION SYSTEM (N-MODE).................................................................581 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM............................................................582 POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF...........................................582 USER CODE MEMORY RETENTION FUNCTION...................................................................582 INFORMATION CONTAINED IN TESTING PROCEDURES...............................................................583 (N-1).....................................................................................................585 COMMUNICATION ABNORMALITY.............................................................................585 30 DISASSEMBLY AND ASSEMBLY.......................................................................................587 METHOD OF USING MANUAL........................................................................................589 PRECAUTIONS DURING OPERATION..................................................................................590 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK................................................................590 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...........................................................591 PRECAUTIONS WHEN COMPLETING THE OPERATIONS................................................................592 OTHER PRECAUTIONS.........................................................................................592 SPECIAL TOOL LIST.............................................................................................593 SKETCHES OF SPECIAL TOOLS.....................................................................................598 ENGINE........................................................................................................606 AFTERCOOLER...............................................................................................606 ALTERNATOR................................................................................................606 CYLINDER HEAD.............................................................................................606 ENGINE OIL COOLER.........................................................................................606 ENGINE REAR SEAL..........................................................................................606 FUEL INJECTION PUMP.......................................................................................606 NOZZLE HOLDER.............................................................................................606 STARTING MOTOR............................................................................................606 THERMOSTAT................................................................................................606 TURBOCHARGER..............................................................................................606 WATER PUMP................................................................................................606 GOVERNOR MOTOR................................................................................................607 OIL COOLER....................................................................................................608 RADIATOR, OIL COOLER..........................................................................................610 ENGINE, MAIN HYDRAULIC PUMP...................................................................................613 DAMPER........................................................................................................618 FUEL TANK.....................................................................................................619 CENTER SWIVEL JOINT...........................................................................................620 FINAL DRIVE...................................................................................................622 TRAVEL MOTOR..................................................................................................633 SPROCKET......................................................................................................647 SWING MOTOR...................................................................................................648 SWING MACHINERY...............................................................................................658 REVOLVING FRAME...............................................................................................667 SWING CIRCLE..................................................................................................669 IDLER AND RECOIL SPRING.......................................................................................670 IDLER.........................................................................................................671 RECOIL SPRING.................................................................................................675 TRACK ROLLER..................................................................................................677 CARRIER ROLLER................................................................................................683 TRACK CHAIN...................................................................................................688 HYDRAULIC TANK................................................................................................689 MAIN HYDRAULIC PUMP...........................................................................................691 DISASSEMBLY...............................................................................................693 PUMP ASSEMBLY.........................................................................................693 FRONT PUMP............................................................................................693 REAR PUMP.............................................................................................698 ASSEMBLY..................................................................................................701 FRONT PUMP............................................................................................701 REAR PUMP.............................................................................................709 MAIN PUMP OIL SEAL............................................................................................720 CONTROL VALVE.................................................................................................721 PUMP MERGE DIVIDER VALVE......................................................................................735 PRESSURE COMPENSATION VALVE...................................................................................736 FRONT PUMP SERVO VALVE........................................................................................737 REAR PUMP SERVO VALVE.........................................................................................738 LS-EPC SOLENOID VALVE.........................................................................................739 SOLENOID VALVE................................................................................................740 WORK EQUIPMENT PPC VALVE......................................................................................742 TRAVEL PPC VALVE..............................................................................................744 PPC SHUTTLE VALVE.............................................................................................747 BOOM LOCK VALVE...............................................................................................750 CYLINDER......................................................................................................752 BOOM......................................................................................................752 ARM.......................................................................................................754 BUCKET....................................................................................................756 HYDRAULIC.................................................................................................758 BOLT ON TYPE PISTON...................................................................................758 THREADED STYLE PISTON.................................................................................762 WORK EQUIPMENT................................................................................................768 BUCKET....................................................................................................770 ARM.......................................................................................................772 BUCKET AND ARM............................................................................................774 BOOM......................................................................................................776 OPERATORS CAB.................................................................................................778 COUNTERWEIGHT.................................................................................................780 AIR CONDITIONER...............................................................................................781 COMPRESSOR................................................................................................781 CONDENSER.................................................................................................782 RECEIVER TANK.............................................................................................783 AIR CONDITIONER UNIT......................................................................................784 GOVERNOR, PUMP CONTROLLER.....................................................................................786 MONITOR PANEL.................................................................................................787 CONTROL STAND CASE............................................................................................788 90 OTHERS.........................................................................................................791 ELECTRICAL....................................................................................................793 FOLDOUT 1 - CIRCUIT DIAGRAM SHEET 1 (Part 1 of 3).........................................................793 FOLDOUT 2 - CIRCUIT DIAGRAM SHEET 1 (Part 2 of 3).........................................................795 FOLDOUT 3 - CIRCUIT DIAGRAM SHEET 1 (Part 3 of 3).........................................................797 FOLDOUT 4 - CIRCUIT DIAGRAM SHEET 2 (Part 1 of 2).........................................................799 FOLDOUT 5 - CIRCUIT DIAGRAM SHEET 2 (Part 2 of 2).........................................................801 FOLDOUT 6 - CIRCUIT DIAGRAM SHEET 3 (Part 1 of 1).........................................................803 FOLDOUT 7 - ELECTRONIC CONTROL SYSTEM - TOTAL SYSTEM DIAGRAM..............................................805 HYDRAULIC.....................................................................................................807 FOLDOUT 8 - CIRCUIT DIAGRAM (Sheet 1 of 4)................................................................807 FOLDOUT 9 - CIRCUIT DIAGRAM (Sheet 2 of 4)................................................................809 FOLDOUT 10 - CIRCUIT DIAGRAM (Sheet 3 of 4)...............................................................811 FOLDOUT 11 - CIRCUIT DIAGRAM (Sheet 4 of 4)...............................................................813 CLSS OPERATION FOR EACH FUNCTION..........................................................................815 FOLDOUT 12 - HYDRAULIC CIRCUIT DIAGRAM................................................................815 FOLDOUT 13 - WHEN ALL WORK EQUIPMENT IS AT NEUTRAL....................................................817 FOLDOUT 14 - WHEN PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY................................819 FOLDOUT 15 - WHEN PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY.................................821 FOLDOUT 16 - WHEN PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY.....................................823 FOLDOUT 17 - WHEN PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY....................................825 FOLDOUT 18 - WHEN PUMP DIVIDED, TRAVEL OPERATED INDEPENDENTLY.........................................827 FOLDOUT 19 - WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY.......................829 FOLDOUT 20 - WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY........................831 FOLDOUT 21 - WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY......................833 FOLDOUT 22 - WHEN PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY..........................835
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