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KOMATSU BR550JG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR550JG 1 – PDF DOWNLOAD
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- KOMATSU BR550JG-1 SERVICE REPAIR MANUAL
- SERIAL NUMBER:1001 & UP
- PUBLICATION NUMBER:SEBM022504
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Description
KOMATSU BR550JG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR550JG 1
KOMATSU BR550JG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR550JG 1 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU BR550JG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR550JG 1
- 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 chapters; these chapters are further divided into the each main group of components.
- 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
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” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU BR550JG-1 SERVICE REPAIR MANUAL (SN:1001 & UP) KOMATSU BR550JG 1
COVER............................................................................................................................................................................................. 1 CONTENTS.......................................................................................................................................................................................... 2 01 GENERAL........................................................................................................................................................................................ 27 SPECIFICATION DRAWINGS........................................................................................................................................................................ 28 SPECIFICATIONS................................................................................................................................................................................ 29 WEIGHT TABLE.................................................................................................................................................................................. 32 TABLE OF FUEL, COOLANT, AND LUBRICANTS........................................................................................................................................................ 33 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................................................................................................................... 35 ENGINE MOUNT AND DAMPER....................................................................................................................................................................... 36 RADIATOR, OIL, AND AFTERCOOLER................................................................................................................................................................ 38 POWER TRAIN................................................................................................................................................................................... 39 FINAL DRIVE................................................................................................................................................................................... 41 TRACK FRAME AND RECOIL SPRING................................................................................................................................................................. 43 IDLER......................................................................................................................................................................................... 44 CARRIER ROLLER................................................................................................................................................................................ 45 TRACK ROLLER.................................................................................................................................................................................. 46 TRACK SHOE.................................................................................................................................................................................... 47 HYDRAULIC PIPING DIAGRAM...................................................................................................................................................................... 50 HYDRAULIC TANK AND FILTER..................................................................................................................................................................... 51 HYDRAULIC PUMP................................................................................................................................................................................ 52 MAIN PUMP..................................................................................................................................................................................... 53 TCV, LC VALVE................................................................................................................................................................................. 58 FUNCTION.................................................................................................................................................................................. 60 OPERATION-LS VALVE........................................................................................................................................................................ 61 OPERATION-TVC VALVE....................................................................................................................................................................... 65 CONTROL VALVE................................................................................................................................................................................. 72 SELF-REDUCING PRESSURE VALVE.................................................................................................................................................................. 78 CLASS......................................................................................................................................................................................... 83 OUTLINE OF CLASS.......................................................................................................................................................................... 83 BASIC PRINCIPLE........................................................................................................................................................................... 84 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................. 86 WHEN UPLOAD VALVE IS ACTUATED............................................................................................................................................................. 89 INTRODUCTION OF LS PRESSURE............................................................................................................................................................... 91 LS BYPASS VALVE........................................................................................................................................................................... 92 PRESSURE COMPENSATION VALVE............................................................................................................................................................... 93 SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE.......................................................................................................................................... 95 MERGE FLOW DIVIDER VALVE.................................................................................................................................................................. 98 CRUSHER MOTOR.................................................................................................................................................................................100 GRIZZLY FEEDER MOTOR..........................................................................................................................................................................102 TRAVEL MOTOR (FIXED SWASH PLATE)..............................................................................................................................................................103 OPERATION OF PARKING BRAKE................................................................................................................................................................105 COUNTERBALANCE AND CHECK VALVE............................................................................................................................................................106 SAFETY VALVE..............................................................................................................................................................................107 TRAVEL PPC VALVE..............................................................................................................................................................................110 TRAVEL JUNCTION VALVE.........................................................................................................................................................................114 4-SPOOL SOLENOLD VALVE........................................................................................................................................................................117 8-SPOOL EPC VALVE.............................................................................................................................................................................119 EPC VALVE.....................................................................................................................................................................................120 LS-EPC VALVE..................................................................................................................................................................................123 ELECTROMAGNETIC SELECTOR VALVE................................................................................................................................................................126 ENGINE CONTROL SYSTEM.........................................................................................................................................................................128 OPERATION OF SYSTEM ......................................................................................................................................................................129 COMPONENTS OF SYSTEM......................................................................................................................................................................130 ENGINE THROTTLE - PUMP CONTROLLER.............................................................................................................................................................132 INPUT AND OUTPUT SIGNALS..................................................................................................................................................................133 LX CONTROLLER.................................................................................................................................................................................134 INPUT AND OUTPUT SIGNALS..................................................................................................................................................................135 TROUBLESHOOTING DISPLAY OF LX CONTROLLER..................................................................................................................................................137 ERROR CODES...............................................................................................................................................................................139 MACHINE MONITOR SYSTEM........................................................................................................................................................................141 MACHINE MONITOR...........................................................................................................................................................................142 MONITOR DISPLAY...........................................................................................................................................................................143 CONTENT OF DISPLAY........................................................................................................................................................................144 OIL MAINTENANCE FUNCTION..................................................................................................................................................................145 SENSORS...................................................................................................................................................................................147 ELECTRONIC CONTROL SYSTEM.....................................................................................................................................................................150 PUMP PRESSURE SENSOR......................................................................................................................................................................150 EMERGENCY PUMP DRIVE RESISTOR.............................................................................................................................................................151 ENGINE SPEED SENSOR.......................................................................................................................................................................152 GRIZZLY FEEDER SEMI-AUTO SYSTEM...............................................................................................................................................................153 SYSTEM DRAWING............................................................................................................................................................................154 ABNORMAL LOAD STOP SYSTEM.....................................................................................................................................................................155 CRUSHER LOAD SETTING DIAL.....................................................................................................................................................................156 PRIMARY CONVEYOR MACHINERY....................................................................................................................................................................158 PRIMARY CONVEYOR MOTOR....................................................................................................................................................................159 PRIMARY BELT CONVEYOR.....................................................................................................................................................................160 GRIZZLY FEEDER............................................................................................................................................................................161 CRUSHER.......................................................................................................................................................................................164 PRINCIPLE OF CRUSHING.....................................................................................................................................................................166 METHOD OF USING JAW CRUSHER...............................................................................................................................................................167 20 TESTING AND ADJUSTING..........................................................................................................................................................................170 STANDARD VALUE TABLE FOR ENGINE...............................................................................................................................................................171 STANDARD VALUE TABLE FOR CHASSIS..............................................................................................................................................................172 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.....................................................................................................................................................177 TESTING AND ADJUSTING.........................................................................................................................................................................181 SERVICE TOOLS TABLE.......................................................................................................................................................................182 MEASURING ENGINE SPEED....................................................................................................................................................................183 MEASURING EXHAUST COLOR...................................................................................................................................................................184 ADJUSTING VALVE CLEARANCE.................................................................................................................................................................185 MEASURING COMPRESSION PRESSURE............................................................................................................................................................186 MEASURING BLOW-BY PRESSURE................................................................................................................................................................187 FUEL INJECTION TIMING.....................................................................................................................................................................188 MEASURING ENGINE OIL PRESSURE.............................................................................................................................................................190 TESTING AND ADJUSTING FAN BELT TENSION....................................................................................................................................................191 ADJUSTING ENGINE SPEED SENSOR.............................................................................................................................................................192 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)............................................................................................................................................193 GOVERNOR MOTOR LEVER STROKE...............................................................................................................................................................194 WORK EQUIPMENT AND TRAVEL CIRCUIT.........................................................................................................................................................195 TVC VALVE OUTPUT PRESSURE.................................................................................................................................................................197 LS VALVE OUTPUT AND DIFFERENTIAL PRESSURE.................................................................................................................................................199 CONTROL CIRCUIT OIL PRESSURE..............................................................................................................................................................203 SOLENOID VALVE OUTPUT PRESSURE............................................................................................................................................................204 TRAVEL DEVIATION..........................................................................................................................................................................205 MEASURING OIL LEAKAGE.....................................................................................................................................................................206 TESTING WEAR OF SPROCKET..................................................................................................................................................................207 TRACK SHOE TENSION........................................................................................................................................................................208 BLEEDING AIR..............................................................................................................................................................................209 JAW CRUSHER...............................................................................................................................................................................212 TENSION OF CRUSHER DRIVE BELT.............................................................................................................................................................218 PRIMARY BELT CONVEYOR.....................................................................................................................................................................219 REFERENCE (RADIO CONTROLLER SUPPORT POINT)................................................................................................................................................220 TROUBLESHOOTING...............................................................................................................................................................................221 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................................................................222 SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................................................................................................224 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.................................................................................................................................................225 CHECKS BEFORE TROUBLESHOOTING.............................................................................................................................................................233 CONNECTOR TYPES AND MOUNTING LOCATIONS....................................................................................................................................................234 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................................................................................250 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....................................................................................................................................267 DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL...................................................................................................................................270 METHOD OF USING JUDGEMENT TABLE...........................................................................................................................................................278 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................................................................280 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE..................................................................................................................................282 SERVICE CODE TABLE........................................................................................................................................................................285 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY (N MODE).....................................................................................................................................286 N-1 [E218] COMMUNICATION ABNORMALITY..................................................................................................................................................287 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE).................................................................................................289 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM....................................................................................290 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................................................................291 JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS............................................................................295 ELECTRICAL CIRCUIT DIAGRAM FOR E-MODE.................................................................................................................................................297 E-1 ABNORMALITY IN ENGINE THROTTLE AND PUMP CONTROLLER POWER SUPPLY- (CONTROLLER LED IS OFF)..........................................................................................299 E-2 [E308](ABNORMALITY IN INPUT VALUE FROM FUEL CONTROL DIAL) IS DISPLAYED............................................................................................................300 E-3 [E317](DISCONNECTION IN MOTOR DRIVE SYSTEM) IS DISPLAYED..........................................................................................................................301 E-4 [E318](SHORT CIRCUIT IN MOTOR DRIVE SYSTEM) IS DISPLAYED..........................................................................................................................302 E-5 [E306](ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM) IS DISPLAYED.................................................................................................................303 E-6 [E315](SHORT CIRCUIT IN OUTPUT SYSTEM TO BATTERY RELAY) IS DISPLAYED..............................................................................................................304 E-7 [E316](STEP-OUT IN MOTOR) IS DISPLAYED............................................................................................................................................305 E-8 ENGINE DOES NOT START.............................................................................................................................................................306 E-9 ENGINE SPEED IS IRREGULAR.........................................................................................................................................................309 E-10 LACK OF OUTPUT-ENGINE HIGH IDLING, SPEED IS TOO LOW..............................................................................................................................313 E-11 ENGINE DOES NOT STOP.............................................................................................................................................................315 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM, ENGINE DOES NOT STOP................................................................................................................317 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER (PUMP CONTROLLER SYSTEM)(C MODE)...................................................................................................319 POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM.............................................................................................................................320 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE............................................................................................................321 JUDGEMENT TABLE FOR ENGINE THROTTLE, PUMP CONTROLLER(PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.................................................................................329 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE.................................................................................................................................................331 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF).............................................................................................................333 C-2 [E232] (SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM) IS DISPLAYED.............................................................................................................334 C-3 [E233] (DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM) IS DISPLAYED.............................................................................................................336 C-4 [E236] (SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM) IS DISPLAYED..............................................................................................................338 C-5 [E237] (DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM) IS DISPLAYED .............................................................................................................340 C-6 [E207] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED.............................................................................................................................342 C-7 [E208] (DISCONNECTION IN DUMMY RESISTOR) IS DISPLAYED.............................................................................................................................343 C-8 [E203] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED.............................................................................................................................344 C-9 [E213] (DISCONNECTION IN DUMMY RESISTOR) IS DISPLAYED.............................................................................................................................345 C-10 [E204] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED............................................................................................................................346 C-11 [E214] (DISCONNECTION DUMMY RESISTOR) IS DISPLAYED...............................................................................................................................347 C-12 [E206] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED............................................................................................................................348 C-13 [E216] (DISCONNECTION IN DUMMY RESISTOR) IS DISPLAYED............................................................................................................................349 C-14 [E217] (SHORT CIRCUIT IN DUMMY RESISTOR) IS DISPLAYED............................................................................................................................350 C-15 [E235] (DISCONNECTION IN DUMMY RESISTOR) IS DISPLAYED............................................................................................................................351 C-16 [E217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED................................................................................................................................352 C-17 [E222] (SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM) IS DISPLAYED (DUMMY RESISTOR CIRCUIT)...........................................................................................353 C-18 [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM) IS DISPLAYED (DUMMY RESISTOR CIRCUIT)...........................................................................................354 C-19 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED...........................................................................................................355 C-20 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED............................................................................................................356 C-21 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SUPPLY SYSTEM) IS DISPLAYED.........................................................................................................357 C-22 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED..................................................................................................................358 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER(INPUT SIGNAL SYSTEM) (F MODE)......................................................................................................359 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE.................................................................................................................................................360 F-1 BIT PATTERN 20-[2] (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP.................................................................................................................362 F-2 BIT PATTERN 22-[5] (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP...................................................................................................................363 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)..................................................................................................................................364 SOLENOID VALVE OPERATION..............................................................................................................................................................365 TABLE OF FAILURE MODES AND CAUSES (1/2)...............................................................................................................................................366 TABLE OF FAILURE MODES AND CAUSES (2/2)...............................................................................................................................................368 H-1 SPEED OF ALL WORK EQUIPMENT, TRAVEL ARE SLOW OR LACK POWER........................................................................................................................370 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.........................................................................................................................372 H-3 NEITHER WORK EQUIPMENT, NOR TRAVEL MOVE...........................................................................................................................................372 H-4 ABNORMAL NOISE GENERATED AROUND PUMP..............................................................................................................................................373 H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR..................................................................................................................................373 H-6 CONVEYOR DOES NOT OPERATE.........................................................................................................................................................374 H-7 CONVEYOR SPEED IS LOW OR ITS POWER IS INSUFFICIENT................................................................................................................................375 H-8 CRUSHER DOES NOT OPERATE..........................................................................................................................................................376 H-9 CRUSHER SPEED IS LOW OR ITS POWER IS INSUFFICIENT.................................................................................................................................377 H-10 FEEDER DOES NOT FEED WELL (VIBRATION FREQUENCY IS LOW)...........................................................................................................................378 H-11 LOCK CYLINDER DOES NOT RETRACT OR DOES NOT EXTEND................................................................................................................................379 H-12 MUCK DISCHARGE CONVEYOR SPEED IS LOW OR ITS POWER IS INSUFFICIENT................................................................................................................380 H-13 MAGNETIC SEPARATOR BELT SPEED IS LOW.............................................................................................................................................381 H-14 MUCK DISCHARGE CONVEYOR DOES NOT MOVE UP OR DOES NOT MOVE DOWN CONVEYOR DOES NOT MOVE UP OR DOES NOT MOVE DOWN OPENING/CLOSING HOPPER DOES NOT OPERATE...........................382 H-15 MACHINE DOES NOT TRAVEL WHEN SWITCHES ON RADIO CONTROLLER ARE PRESSED(RIGHT REVERSE, RIGHT REVERSE, LEFT REVERSE, LEFT FORWARD)..................................................382 H-16 TRAVEL SPEED IS LOW..............................................................................................................................................................383 H-17 TRAVEL DEVIATION.................................................................................................................................................................385 H-18 STEERING DOES NOT TURN EASILY OR LACKS POWER.....................................................................................................................................386 H-19 TRAVEL DOES NOT MOVE ON ONE SIDE.................................................................................................................................................387 H-20 MACHINE DOES NOT TRAVEL (WHEN TRAVEL LEVER IS OPERATED)..........................................................................................................................387 TROUBLESHOOTING OF MONITOR SYSTEM (M MODE)................................................................................................................................................388 ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................................389 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE.................................................................................................................................................391 M-1 [E101] (ABNORMALITY IN ERROR DATA) IS DISPLAYED [E102] (ERROR IN CLOCK DATA) IS DISPLAYED.........................................................................................393 M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24 V WIRING HARNESS WITH BUZZER DRIVE) IS DISPLAYED..........................................................................394 M-3 [E104] (AIR CLEANER CLOGGING DETECTED) IS DISPLAYED...............................................................................................................................395 M-4 [E106] (DROP IN ENGINE OIL HI PRESSURE DETECTED) IS DISPLAYED.....................................................................................................................395 M-5 [E108] (ENGINE WATER TEMPERATURE 105℃ DETECTED) IS DISPLAYED......................................................................................................................396 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR THREE SECONDS......................................................................................397 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT......................................................................................399 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE(MODEL).....................................................................399 M-9 WHEN STARTING SWITCH IS TURNED ON, ENGINE STOPPED, BASIC CHECK ITEMS FLASH........................................................................................................400 M-10 PREHEATING IS NOT BEING USED, BUT PREHEATING MONITOR LIGHTS UP...................................................................................................................403 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH.................................................................................................404 M-12 WHEN STARTING SWITCH IS TURNED ON, ENGINE STOPPED,CAUTION ITEMS AND EMERGENCY ITEMS FLASH(BATTERY AND ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP).................................406 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS,EMERGENCY ITEMS FLASH(WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)....408 M-14 WHEN STARTING SWITCH IS TURNED ON,ENGINE STOPPED, BUZZER DOES NOT SOUND FOR ONE SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND ...........................................411 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS.........................................................................................................................411 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP(LIQUID CRYSTAL DISPLAY IS NORMAL)..............................................................................................412 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE..........................................................................................................................................413 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY(NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)...............................................................................414 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL............................................................................................................................................415 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...........................................................................................................................................416 M-21 WHEN MODE SELECTOR SWITCH IS TURNED ON(WORK,MAINTENANCE),TRAVEL LOCK MONITOR DOES NOT LIGHT UP...................................................................................417 M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING...........................................................................................................................419 M-23 WHEN START SWITCH IS AT OFF AND TIME SWITCH IS PRESSED,TIME AND SERVICE METER ARE NOT DISPLAYED..................................................................................419 M-24 FAULTY FUEL LEVEL SENSOR SYSTEM..................................................................................................................................................420 M-25 FAULTY COOLANT TEMPERATURE SENSOR SYSTEM.........................................................................................................................................421 M-26 FAULTY ENGINE OIL LEVEL SENSOR SYSTEM............................................................................................................................................422 M-27 FAULTY COOLANT LEVEL SENSOR SYSTEM...............................................................................................................................................423 M-28 FAULTY HYDRAULIC OIL LEVEL SENSOR SYSTEM.........................................................................................................................................424 TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE)..............................................................................................................................425 PRECAUTIONS FOR TROUBLESHOOTING WORK EQUIPMENT CONTROLLER SYSTEM......................................................................................................................427 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE............................................................................................................429 JUDGEMENT TABLE OF TROUBLES CONCERNED TO WORK EQUIPMENT CONTROL SYSTEM AND HYDRAULIC EQUIPMENT(1/2)...................................................................................443 JUDGEMENT TABLE OF TROUBLES CONCERNED TO WORK EQUIPMENT CONTROL SYSTEM AND HYDRAULIC EQUIPMENT(2/2)...................................................................................445 ELECTRICAL CIRCUIT DIAGRAM FOR W MODE.................................................................................................................................................447 HOW TO READ YES/NO TROUBLESHOOTING....................................................................................................................................................451 W-1 ABNORMALITY IN CONTROLLER POWER SUPPLY SYSTEM(CONTROLLER LED IS OFF)..............................................................................................................452 W-2 [E-10] DISCONNECTION IN EMERGENCY STOP SWITCH SYSTEM..............................................................................................................................453 W-3 [E-11] SHORT CIRCUIT IN CONVEYOR ON SWITCH SYSTEM.................................................................................................................................460 W-4 [E-12] DISCONNECTION IN CONVEYOR OFF SWITCH SYSTEM................................................................................................................................461 W-5 [E-13] SHORT CIRCUIT IN CRUSHER ON SWITCH SYSTEM..................................................................................................................................462 W-6 [E-14] DISCONNECTION IN CRUSHER OFF SWITCH SYSTEM.................................................................................................................................464 W-7 [E-15] SHORT CIRCUIT IN CRUSHER MANUAL FORWARD SWITCH SYSTEM......................................................................................................................466 W-8 [E-16] SHORT CIRCUIT IN CRUSHER MANUAL REVERSE SWITCH SYSTEM......................................................................................................................467 W-9 [E-17] SHORT CIRCUIT IN FEEDER ON SWITCH SYSTEM...................................................................................................................................468 W-10 [E-18] DISCONNECTION IN FEEDER OFF SWITCH SYSTEM.................................................................................................................................470 W-11 [E-19] SHORT CIRCUIT IN CRUSHER CLEARANCE EXTENSION SWITCH SYSTEM................................................................................................................472 W-12 [E-1A] SHORT CIRCUIT IN CRUSHER CLEARANCE RETRACTION SWITCH SYSTEM...............................................................................................................473 W-13 [E-1B] SHORT CIRCUIT IN MUCK CONVEYOR ON SWITCH SYSTEM...........................................................................................................................474 W-14 [E-1C] SHORT CIRCUIT IN MUCK CONVEYOR OFF SWITCH SYSTEM..........................................................................................................................475 W-15 [E-1D] SHORT CIRCUIT IN MAGNETIC SEPARATOR ON SWITCH SYSTEM......................................................................................................................476 W-16 [E-1E] SHORT CIRCUIT IN MAGNETIC SEPARATOR OFF SWITCH SYSTEM.....................................................................................................................477 W-17 [E-20] ABNORMALITY IN CRUSHER LOAD SETTING DIAL SYSTEM...........................................................................................................................478 W-18 [E-21] ABNORMALITY IN CRUSHER SPEED DIAL SYSTEM..................................................................................................................................479 W-19 [E-22] ABNORMALITY IN FEEDER SPEED DIAL SYSTEM...................................................................................................................................480 W-20 [E-23] SHORT CIRCUIT IN TRAVEL R.H. REVERSE SWITCH SYSTEM........................................................................................................................481 W-21 [E-24] SHORT CIRCUIT IN TRAVEL R.H. FORWARD SWITCH SYSTEM........................................................................................................................482 W-22 [E-25] SHORT CIRCUIT IN TRAVEL L.H. REVERSE SWITCH SYSTEM........................................................................................................................483 W-23 [E-26] SHORT CIRCUIT IN TRAVEL L.H. FORWARD SWITCH SYSTEM........................................................................................................................484 W-24 [E-27] SHORT CIRCUIT IN MUCK CONVEYOR RAISE OR LOWER SWITCH SYSTEM...............................................................................................................485 W-25 [E-28] SHORT CIRCUIT IN CONVEYOR RAISE OR LOWER SWITCH SYSTEM....................................................................................................................486 W-26 [E-2C] ABNORMALITY IN CONVEYOR PRESSURE SENSOR SYSTEM............................................................................................................................487 W-27 [E-2D] ABNORMALITY IN MUCK CONVEYOR PRESSURE SENSOR SYSTEM.......................................................................................................................489 W-28 [E-2E] ABNORMALITY IN CRUSHER PRESSURE SYSTEM....................................................................................................................................491 W-29 [E-2F] ABNORMALITY IN S-NET SYSTEM...............................................................................................................................................493 W-30a [E-30] Abnormality in model selection...........................................................................................................................................494 W-30b [E-31] Abnormality in crusher pressure sensor system (reverse rotation side)....................................................................................................495 W-31 [E-50] DISCONNECTION IN ACCESSORY EPC VALVE SYSTEM...............................................................................................................................497 W-32 [E-51] SHORT CIRCUIT IN ACCESSORY EPC VALVE SYSTEM...............................................................................................................................498 W-33 [E-52] DISCONNECTION IN FEEDER EPC VALVE SYSTEM..................................................................................................................................499 W-34 [E-53] SHORT CIRCUIT IN FEEDER EPC VALVE SYSTEM..................................................................................................................................500 W-35 [E-54] DISCONNECTION IN CONVEYOR EPC VALVE SYSTEM................................................................................................................................501 W-36 [E-55] SHORT CIRCUIT IN CONVEYOR.................................................................................................................................................502 W-37 [E-56] DISCONNECTION IN TRAVEL LOCK EPC VALVE SYSTEM.............................................................................................................................503 W-38 SHORT CIRCUIT IN TRAVEL LOCK EPC VALVE SYSTEM....................................................................................................................................504 W-39 [E-58] DISCONNECTION IN CRUSHER FORWARD EPC VALVE SYSTEM.........................................................................................................................505 W-40 [E-59] SHORT CIRCUIT IN CRUSHER FORWARD EPC VALVE SYSTEM.........................................................................................................................506 W-41 [E-5A] DISCONNECTION IN CRUSHER REVERSE EPC VALVE SYSTEM.........................................................................................................................507 W-42 [E-5B] SHORT CIRCUIT IN CRUSHER REVERSE EPC VALVE SYSTEM.........................................................................................................................508 W-43 [E-5C] DISCONNECTION IN LOCK CYLINDER RETRACTION SOLENOID SYSTEM.................................................................................................................509 W-44 [E-5D] SHORT CIRCUIT IN LOCK CYLINDER RETRACTION SOLENOID SYSTEM.................................................................................................................510 W-45 [E-5E] DISCONNECTION IN LOCK CYLINDER EXTENSION SOLENOID SYSTEM..................................................................................................................511 W-46 [E-5F] SHORT CIRCUIT IN LOCK CYLINDER EXTENSION SOLENOID SYSTEM..................................................................................................................512 W-47 [E-60] DISCONNECTION IN MUCK DISCHARGE CONVEYOR SOLENOID SYSTEM..................................................................................................................513 W-48 [E-61] SHORT CIRCUIT IN MUCK DISCHARGE CONVEYER SOLENOID SYSTEM..................................................................................................................514 W-49 [E-62] DISCONNECTION IN MAGNETIC SEPARATOR SOLENOID SYSTEM.......................................................................................................................515 W-50 [E-63] SHORT CIRCUIT IN MAGNETIC SEPARATOR SOLENOID SYSTEM.......................................................................................................................516 W-51 [E-64] DISCONNECTION IN TRAVEL R.H. REVERSE SOLENOID SYSTEM......................................................................................................................517 W-52 [E-65] SHORT CIRCUIT IN TRAVEL R.H. REVERSE SOLENOID SYSTEM......................................................................................................................518 W-53 [E-66] DISCONNECTION IN TRAVEL L.H. REVERSE SOLENOID SYSTEM......................................................................................................................519 W-54 [E-67] SHORT CIRCUIT IN TRAVEL L.H. REVERSE SOLENOID SYSTEM......................................................................................................................520 W-55 [E-68] DISCONNECTION IN TRAVEL L.H. FORWARD SOLENOID SYSTEM......................................................................................................................521 W-56 [E-69] SHORT CIRCUIT IN TRAVEL L.H. FORWARD SOLENOID SYSTEM......................................................................................................................522 W-57 [E-6A] DISCONNECTION IN TRAVEL R.H. FORWARD SOLENOID SYSTEM......................................................................................................................523 W-58 [E-6B] SHORT CIRCUIT IN TRAVEL R.H. FORWARD SOLENOID SYSTEM......................................................................................................................524 W-59 [E-6D] SHORT CIRCUIT IN HORN RELAY COIL SYSTEM...................................................................................................................................525 W-60 [E-6E] SHORT CIRCUIT IN ROTARY LAMP RELAY SYSTEM.................................................................................................................................526 W-61 [E-70] DISCONNECTION IN LS EPC VALVE SYSTEM......................................................................................................................................527 W-62 [E-71] SHORT CIRCUIT IN LS EPC VALVE SYSTEM......................................................................................................................................528 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................529 METHOD OF USING MANUAL........................................................................................................................................................................530 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................................................................532 SPECIAL TOOL LIST.............................................................................................................................................................................535 FUEL INJECTION PUMP...........................................................................................................................................................................540 REMOVAL...................................................................................................................................................................................540 INSTALLATION..............................................................................................................................................................................541 NOZZLE HOLDER.................................................................................................................................................................................542 REMOVAL AND INSTALLATION..................................................................................................................................................................542 TURBOCHARGER..................................................................................................................................................................................543 REMOVAL AND INSTALLATION..................................................................................................................................................................543 CYLINDER HEAD.................................................................................................................................................................................544 REMOVAL...................................................................................................................................................................................544 INSTALLATION..............................................................................................................................................................................546 ENGINE FRONT SEAL.............................................................................................................................................................................549 REMOVAL AND INSTALLATION..................................................................................................................................................................549 ENGINE REAR SEAL..............................................................................................................................................................................550 REMOVAL AND INSTALLATION..................................................................................................................................................................550 ENGINE AFTERCOOLER............................................................................................................................................................................553 REMOVAL AND INSTALLATION..................................................................................................................................................................553 ENGINE, MAIN PUMP ............................................................................................................................................................................554 REMOVAL...................................................................................................................................................................................554 INSTALLATION..............................................................................................................................................................................556 DAMPER .......................................................................................................................................................................................557 REMOVAL AND INSTALLATION..................................................................................................................................................................557 RADIATOR, HYDRAULIC COOLER....................................................................................................................................................................558 REMOVAL...................................................................................................................................................................................558 INSTALLATION..............................................................................................................................................................................559 FUEL TANK.....................................................................................................................................................................................560 REMOVAL AND INSTALLATION..................................................................................................................................................................560 FINAL DRIVE ..................................................................................................................................................................................561 REMOVAL AND INSTALLATION..................................................................................................................................................................561 RECOIL SPRING.................................................................................................................................................................................569 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................569 IDLER.........................................................................................................................................................................................571 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................571 TRACK ROLLER..................................................................................................................................................................................574 DISASSEMBLY...............................................................................................................................................................................574 ASSEMBLY..................................................................................................................................................................................575 CARRIER ROLLER................................................................................................................................................................................577 DISASSEMBLY...............................................................................................................................................................................577 ASSEMBLY..................................................................................................................................................................................578 TRACK SHOE....................................................................................................................................................................................580 REMOVAL AND INSTALLATION..................................................................................................................................................................580 HYDRAULIC TANK................................................................................................................................................................................581 REMOVAL...................................................................................................................................................................................581 INSTALLATION..............................................................................................................................................................................582 MAIN PUMP.....................................................................................................................................................................................583 REMOVAL...................................................................................................................................................................................583 INSTALLATION..............................................................................................................................................................................584 PRESSURE REDUCING VALVE.......................................................................................................................................................................585 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................585 TRAVEL JUNCTION VALVE ........................................................................................................................................................................586 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................586 TRAVEL PPC VALVE..............................................................................................................................................................................587 DISASSEMBLY...............................................................................................................................................................................587 ASSEMBLY..................................................................................................................................................................................588 CONTROL VALVE.................................................................................................................................................................................589 REMOVAL...................................................................................................................................................................................589 INSTALLATION..............................................................................................................................................................................590 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................591 PRESSURE COMPENSATION VALVE...................................................................................................................................................................592 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................592 PUMP MERGE/DIVIDER VALVE......................................................................................................................................................................593 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................593 UNLOAD VALVE..................................................................................................................................................................................594 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................594 SUCTION, SAFETY VALVE.........................................................................................................................................................................595 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................595 MAIN RELIEF VALVE.............................................................................................................................................................................596 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................596 CRUSHER MOTOR.................................................................................................................................................................................597 REMOVAL AND INSTALLATION..................................................................................................................................................................597 FEEDER MOTOR .................................................................................................................................................................................598 REMOVAL AND INSTALLATION..................................................................................................................................................................598 CONVEYOR MOTOR, MACHINERY MOTOR...............................................................................................................................................................599 REMOVAL AND INSTALLATION..................................................................................................................................................................599 DISASSEMBLY...............................................................................................................................................................................600 ASSEMBLY..................................................................................................................................................................................602 MUCK DISCHARGE CONVEYOR MOTOR.................................................................................................................................................................605 REMOVAL AND INSTALLATION..................................................................................................................................................................605 MAGNETIC SEPARATOR MOTOR......................................................................................................................................................................606 REMOVAL AND INSTALLATION..................................................................................................................................................................606 HYDRAULIC CYLINDER............................................................................................................................................................................607 DISASSEMBLY...............................................................................................................................................................................607 ASSEMBLY..................................................................................................................................................................................608 CRUSHER.......................................................................................................................................................................................610 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................610 FLYWHEEL COVER ASSEMBLY.......................................................................................................................................................................611 REMOVAL AND INSTALLATION..................................................................................................................................................................611 V-SHEAVE COVER ASSEMBLY.......................................................................................................................................................................611 REMOVAL AND INSTALLATION..................................................................................................................................................................611 CHEEK PLATE...................................................................................................................................................................................612 FIXED JAW PLATE...............................................................................................................................................................................613 TOGGLE PLATE..................................................................................................................................................................................615 TOGGLE SEAT...................................................................................................................................................................................619 FLYWEEL AND V-SHEAVE..........................................................................................................................................................................621 REMOVAL AND INSTALLATION..................................................................................................................................................................621 SWING JAW ASSEMBLY............................................................................................................................................................................622 REMOVAL AND INSTALLATION..................................................................................................................................................................622 CRUSHER MAIN BEARING..........................................................................................................................................................................623 REMOVAL...................................................................................................................................................................................623 INSTALLATION..............................................................................................................................................................................626 CRUSHER ASSEMBLY..............................................................................................................................................................................629 REMOVAL...................................................................................................................................................................................629 INSTALLATION..............................................................................................................................................................................631 CRUSHER HOUSING...............................................................................................................................................................................632 FEEDER ASSEMBLY...............................................................................................................................................................................649 REMOVAL AND INSTALLATION..................................................................................................................................................................649 CONVEYOR BELT.................................................................................................................................................................................650 REMOVAL...................................................................................................................................................................................650 INSTALLATION..............................................................................................................................................................................651 CONVEYOR HEAD PULLEY..........................................................................................................................................................................652 REMOVAL AND INSTALLATION..................................................................................................................................................................652 CONVEYOR TAIL PULLEY..........................................................................................................................................................................653 REMOVAL AND INSTALLATION..................................................................................................................................................................653 MUCK DISCHARGE CONVERYOR BELT.................................................................................................................................................................654 REMOVAL...................................................................................................................................................................................654 INSTALLATION..............................................................................................................................................................................655 MUCK DISCHARGE CONVERYOR HEAD PULLEY..........................................................................................................................................................656 REMOVAL AND INSTALLATION..................................................................................................................................................................656 MUCK DISCHARGE CONVERYOR TAIL PULLEY..........................................................................................................................................................657 REMOVAL AND INSTALLATION..................................................................................................................................................................657 MAGNETIC SEPARATOR ASSEMBLY...................................................................................................................................................................658 REMOVAL...................................................................................................................................................................................658 INSTALLATION..............................................................................................................................................................................659 90 OTHERS.........................................................................................................................................................................................660 Electrical circuit diagram (1/3) Serial number 1001 - 1066....................................................................................................................................661 Electrical circuit diagram (2/3) Serial number 1001 - 1066....................................................................................................................................662 Electrical circuit diagram (3/3) Serial number 1001 - 1066....................................................................................................................................663 Electrical circuit diagram (1/3) Serial number 1067 and up....................................................................................................................................664 Electrical circuit diagram (2/3) Serial number 1067 and up....................................................................................................................................665 Electrical circuit diagram (3/3) Serial number 1067 and up....................................................................................................................................666 Hydraulic circuit diagram Serial number 1001 - 1066...........................................................................................................................................667 Hydraulic circuit diagram Serial number 1067 and up...........................................................................................................................................668
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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Zechariah Salvatore –
The books I ordered arrived in excellent condition and promptly.