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KOMATSU GALEO PC400LC-7E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A87001 & UP) – PDF Download
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- KOMATSU GALEO PC400LC-7E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER: A87001 & UP
- Publication Number:CEBM016902
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Description
KOMATSU GALEO PC400LC-7E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A87001 & UP)
KOMATSU GALEO PC400LC-7E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A87001 & UP) – PDF DOWNLOAD:
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KOMATSU GALEO PC400LC-7E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A87001 & 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 GALEO PC400LC-7E0 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN A87001 & UP)
MAIN MENU................................................................................ 0 COVER.................................................................................... 1 CONTENTS................................................................................. 2 FOREWORD............................................................................. 3 SAFETY.......................................................................... 11 SAFETY NOTICE................................................................ 11 GENERAL.......................................................................... 13 HOW TO READ THE SHOP MANUAL..................................................... 14 HOISTING INSTRUCTIONS............................................................ 15 PUSH PULL COUPLER................................................................ 16 EXPLANATION OF MAINTENANCE STANDARD TERMS....................................... 19 STANDARD TIGHTENING TORQUE...................................................... 21 BOLTS AND NUTS............................................................... 21 TIGHTENING TORQUE OF HOSE NUTS.............................................. 22 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...................................... 22 TIGHTENING TORQUE FOR FLARED NUTS............................................ 22 TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS............................. 23 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS............................ 23 TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE).................. 23 HOW TO READ ELECTRIC WIRE CODE.................................................. 25 CONVERSION TABLES................................................................ 28 METHOD OF USING THE CONVERSION TABLE......................................... 28 Millimeters to Inches.................................................... 29 Kilogram to Pound........................................................ 29 Liter to U.S. Gallon..................................................... 30 Liter to U.K. Gallon..................................................... 30 kgm to ft. lb............................................................ 31 kg/cm2 to lb/in2......................................................... 32 Temperature................................................................. 33 COATING MATERIALS............................................................... 34 01 GENERAL............................................................................... 37 SPECIFICATIONS....................................................................... 38 DIMENSIONS....................................................................... 39 FIXED GAUGE SPECIFICATION.................................................... 39 VARIABLE GAUGE SPECIFICATION................................................. 39 WORKING RANGES............................................................... 39 WEIGHT TABLE......................................................................... 44 FUEL COOLANT AND LUBRICANTS.......................................................... 46 10 STRUCTURE AND FUNCTION................................................................ 49 ENGINE AND COOLING SYSTEM............................................................ 53 ENGINE RELATED PARTS............................................................. 53 RADIATOR, OIL COOLER AND AFTERCOOLER............................................. 54 POWER TRAIN.......................................................................... 55 POWER TRAIN...................................................................... 55 FINAL DRIVE...................................................................... 56 SPROCKET......................................................................... 58 SWING MACHINERY.................................................................. 60 SWING CIRCLE..................................................................... 62 UNDERCARRIAGE AND FRAME.............................................................. 64 TRACK FRAME AND RECOIL SPRING.................................................... 64 IDLER............................................................................ 66 CARRIER ROLLER................................................................... 68 TRACK ROLLER..................................................................... 70 TRACK SHOE....................................................................... 72 TRIPLE GROUSER SHOE.............................................................. 75 HYDRAULIC SYSTEM..................................................................... 76 HYDRAULIC PIPING DRAWING......................................................... 76 HYDRAULIC TANK AND FILTER........................................................ 78 HYDRAULIC PUMP................................................................... 80 LS VALVE..................................................................... 86 PC VALVE..................................................................... 91 LS(PC)-EPC VALVE............................................................. 98 VARIABLE VOLUME VALVE........................................................101 CONTROL VALVE....................................................................102 CLSS (CLOSED CENTER LOAD SENSING SYSTEM).........................................114 FUNCTIONS AND OPERATION BY VALVE.................................................118 UNLOAD VALVE.................................................................120 LS BYPASS VALVE..............................................................123 PRESSURE COMPENSATION VALVE..................................................124 PRESSURE COMPENSATION VALVE INNER SHUTTLE VALVE..............................127 BOOM REGENERATION CIRCUIT....................................................129 ARM REGENERATION CIRCUIT.....................................................131 MERGE-DIVIDER VALVE..........................................................133 LS SELECT VALVE..............................................................135 SELF PRESSURE REDUCING VALVE.................................................136 TRAVEL JUNCTION VALVE........................................................139 TRAVEL PPC SHUTTLE VALVE.....................................................141 BOOM DRIFT PREVENTIVE VALVE..................................................143 ARM DRIFT PREVENTIVE VALVE...................................................146 QUICK RETURN VALVE...........................................................150 LIFT CHECK VALVE.............................................................152 MAIN RELIEF VALVE............................................................153 2-STAGE SAFETY-SUCTION VALVE.................................................154 VARIABLE PRESSURE COMPENSATION VALVE.........................................156 ATTACHMENT CIRCUIT SELECTOR VALVE............................................162 VALVE CONTROL....................................................................160 PPC VALVE....................................................................162 TRAVEL PPC VALVE.............................................................167 SERVICE PPC VALVE............................................................177 SOLENOID VALVE...............................................................179 PPC ACCUMULATOR..............................................................181 RETURN OIL FILTER............................................................182 CENTER SWIVEL JOINT..........................................................183 TRAVEL MOTOR.................................................................185 BRAKE VALVE..................................................................193 SWING MOTOR..................................................................199 REVERSE PREVENTION VALVE.....................................................205 WORK EQUIPMENT.......................................................................211 WORK EQUIPMENT...................................................................211 DIMENSIONS OF COMPONENTS.........................................................213 DIMENSION OF ARM.............................................................213 DIMENSION OF BUCKET..........................................................215 AIR CONDITIONER PIPING...............................................................217 ELECTRICAL SYSTEM....................................................................218 ENGINE CONTROL...................................................................218 FUEL CONTROL DIAL............................................................219 ENGINE CONTROLLER............................................................221 SENSORS..........................................................................225 ROTATION SENSOR..............................................................225 OIL PRESSURE SWITCH..........................................................225 AMBIENT PRESSURE SENSOR......................................................226 BOOST PRESSURE SENSOR........................................................226 BOOST TEMPERATURE SENSOR.....................................................227 COOLANT TEMPERATURE SENSOR...................................................227 HYDRAULIC OIL TEMPERATURE SENSOR.............................................227 EGR VALVE STROKE SENSOR......................................................228 ENGINE OIL LEVEL SENSOR......................................................229 ELECTRONIC CONTROL SYSTEM............................................................230 ENGINE AND PUMP COMPOSITE CONTROL FUNCTION.......................................233 PUMP AND VALVE CONTROL FUNCTION..................................................238 POWER MAXIMIZING AND MACHINE PUSH-UP FUNCTION....................................240 AUTO-DECELERATION FUNCTION.......................................................242 AUTO-WARM-UP AND OVERHEAT PREVENTION FUNCTION....................................243 SWING CONTROL FUNCTION...........................................................245 TRAVEL CONTROL FUNCTION..........................................................247 ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR FUNCTION............................249 SYSTEM COMPONENT PARTS...........................................................250 PUMP PRESSURE SENSOR (HIGH PRESSURE).............................................252 PUMP CONTROLLER..................................................................253 MONITOR SYSTEM.......................................................................256 MACHINE MONITOR..................................................................257 MONITOR PORTION..............................................................259 SWITCHES.....................................................................264 MAINTENANCE FUNCTION.........................................................271 SENSOR...........................................................................277 HYDRAULIC OIL LEVEL SENSOR...................................................277 HYDRAULIC OIL TEMPERATURE SENSOR.............................................277 COOLANT TEMPERATURE SENSOR...................................................277 FUEL LEVEL SENSOR............................................................278 AIR CLEANER CLOGGING SENSOR..................................................278 KOMTRAX TERMINAL SYSTEM..........................................................280 KOMTRAX TERMINAL.............................................................281 20 TESTING, ADJUSTING AND TROUBLESHOOTING................................................283 STANDARD VALUE TABLES................................................................284 ENGINE RELATED...................................................................284 TESTING AND ADJUSTING................................................................293 SERVICE TOOLS...................................................................295 ENGINE SPEED.....................................................................297 ENGINE..........................................................................298 EXHAUST GAS COLOR................................................................299 FAN BELT AND ALTERNATOR BELT TENSION.............................................300 AIR CONDITIONER COMPRESSOR BELT TENSION.........................................301 SWING CIRCLE BEARING CLEARANCE...................................................302 TRACK SHOE TENSION...............................................................303 WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS...................................304 CONTROL CIRCUIT - BASIC PRESSURE.................................................309 PUMP PC CONTROL CIRCUIT..........................................................310 PUMP LS CONTROL CIRCUIT..........................................................314 SOLENOID VALVE - OUTPUT PRESSURE.................................................319 PPC VALVE - OUTPUT PRESSURE......................................................322 WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT.......................................324 SWING PPC VALVE - PLAY ADJUSTMENT............................................324 WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE.........................................325 RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT....................................327 MEASURING OIL LEAKAGE............................................................328 BLEEDING AIR FROM VARIOUS PARTS..................................................331 DIODE TESTING PROCEDURE..........................................................334 MONITOR PANEL - SPECIAL FUNCTIONS................................................335 OPERATOR’S MENU (OUTLINE)....................................................337 FAILURE CODES TABLE..........................................................343 SERVICE MENU.................................................................346 LIST OF MONITORING ITEMS.................................................349 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER....................................363 PROCEDURE FOR TURNING ON KOMTRAX TERMINAL........................................364 ELECTRICAL EQUIPMENT SYSTEM - PREPARATION WORK FOR TROUBLESHOOTING...............370 12 PM CLINIC SERVICE.........................................................372 TROUBLESHOOTING GENERAL..............................................................379 POINTS TO REMEMBER WHEN TROUBLESHOOTING..........................................381 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................383 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................384 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT..........................384 HANDLING WIRING HARNESSES AND CONNECTORS.................................384 12 REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES......386 HANDLING CONTROL BOX.....................................................389 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS................390 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.........................390 CHECKS BEFORE TROUBLESHOOTING....................................................392 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.....................................393 CLASSIFICATION OF TROUBLESHOOTING............................................393 STEPS FOR TROUBLESHOOTING....................................................393 POSSIBLE PROBLEMS AND TROUBLESHOOTING NO.....................................394 CONNECTOR ARRANGEMENT DIAGRAM....................................................397 ELECTRICAL CIRCUIT DIAGRAM......................................................408 See Section 90 for diagrams..................................................408 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.......................................409 12 T-BOXES AND T-ADAPTERS TABLE..................................................431 TROUBLESHOOTING ERROR CODES AND FAILURE CODES........................................435 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM...................................439 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF................440 USER CODE MEMORY RETENTION FUNCTION..........................................440 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................441 FAILURE CODES TABLE..........................................................441 BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED..........444 INFORMATION IN TROUBLESHOOTING TABLE.............................................448 A000N1 - ENG. HI OUT OF STD......................................................450 AA10NX - AIR CLEANER CLOGGING....................................................451 AB00KE - CHARGE VOLTAGE LOW......................................................452 B@BAZG - ENG OIL PRESS. LOW......................................................454 B@BAZK - ENG. OIL LEVEL LOW......................................................456 B@BCZK - ENG. WATER LVL LOW......................................................460 B@HANS - HYD. OIL OVERHEAT.......................................................461 CA111 - ECM CRITICAL INTERNAL FAILURE............................................462 CA115 - ENG NE AND BKUP SPEED SENS ERROR.........................................464 CA122 - CHG AIR PRESS SENSOR HIGH ERROR..........................................466 CA123 - CHG AIR PRESS SENSOR LOW ERROR...........................................468 CA131 - THROTTLE SENSOR HIGH ERROR...............................................470 CA132 - THROTTLE SENSOR LOW ERROR................................................471 CA135 - ENG OIL PRESS SENSOR HIGH ERROR..........................................472 CA141 - ENG OIL PRESS SENSOR LOW ERROR...........................................473 CA144 - COOLANT TEMP SENS HIGH ERROR.............................................474 CA145 - COOLANT TEMP SENS LOW ERROR..............................................475 CA153 - CHG AIR TEMP SENSOR HIGH ERROR...........................................476 CA154 - CHG AIR TEMP SENSOR LOW ERROR............................................478 CA187 - SENS SUPPLY 2 VOLT LOW ERROR.............................................479 CA221 - AMBIENT PRESS SENS HIGH ERROR............................................480 CA222 - AMBIENT PRESS SENS LOW ERROR.............................................482 CA227 - SENS SUPPLY 2 VOLT HIGH ERROR............................................484 CA234 - ENG OVERSPEED............................................................486 CA238 - NE SPEED SENS SUPPLY VOLT ERROR..........................................488 CA263 - FUEL TEMP SENSOR HIGH ERROR..............................................490 CA265 - FUEL TEMP SENSOR LOW ERROR...............................................492 CA271 - IMV/PCV1 SHORT ERROR.....................................................493 CA272 - IMV/PCV1 OPEN ERROR......................................................494 CA273 - PCV2 SHORT ERROR.........................................................496 CA274 - PCV2 OPEN ERROR..........................................................497 CA322 - INJ #1 (L#1) OPEN/SHORT ERROR............................................498 CA323 - INJ #5 (L#5) OPEN/SHORT ERROR............................................499 CA324 - INJ #3 (L#3) OPEN/SHORT ERROR............................................500 CA325 - INJ #6 (L#6) OPEN/SHORT ERROR............................................501 CA331 - INJ #2 (L#2) OPEN/SHORT ERROR............................................502 CA332 - INJ #4 (L#4) OPEN/SHORT ERROR............................................503 CA342 - CALIBRATION CODE INCOMPATIBILITY.........................................504 CA351 - INJECTORS DRIVE CIRCUIT ERROR............................................506 CA352 - SENS SUPPLY 1 VOLT LOW ERROR.............................................508 CA386 - SENS SUPPLY 1 VOLT HIGH ERROR............................................510 CA441 - BATTERY VOLTAGE LOW ERROR................................................512 CA442 - BATTERY VOLTAGE HIGH ERROR...............................................513 CA449 - RAIL PRESS VERY HIGH ERROR...............................................514 CA451 - RAIL PRESS SENSOR HIGH ERROR.............................................516 CA452 - RAIL PRESS SENSOR LOW ERROR..............................................518 CA553 - RAIL PRESS HIGH ERROR 1..................................................518 CA554 - RAIL PRESS SENSOR IN RANGE ERROR.........................................519 CA559 - RAIL PRESS LOW ERROR.....................................................520 CA689 - ENG NE SPEED SENSOR ERROR................................................524 CA731 - ENG BKUP SPEED SENS PHASE ERROR..........................................526 CA757 - ALL PERSISTENT DATA LOST ERROR...........................................527 CA778 - ENG BKUP SPEED SENSOR ERROR..............................................528 CA1228 - EGR VALVE SERVO ERROR 1.................................................530 CA1625 - EGR VALVE SERVO ERROR 2.................................................531 CA1633 - KOMNET DATALINK TIMEOUT ERROR...........................................532 CA2185 - THROT SENS SUP VOLT HIGH ERROR..........................................534 CA2186 - THROT SENS SUP VOLT LOW ERROR...........................................536 CA2249 - RAIL PRESS VERY LOW ERROR...............................................537 CA2271 - EGR VALVE LIFT SENS HIGH ERROR..........................................538 CA2272 - EGR VALVE LIFT SENS LOW ERROR...........................................540 CA2351 - EGR VALVE SOL CURRENT HIGH ERROR........................................542 CA2352 - EGR VALVE SOL CURRENT LOW ERROR.........................................544 CA2555 - GRID HTR RELAY VOLT LOW ERROR...........................................545 CA2556 - GRID HTR RELAY VOLT HIGH ERROR..........................................546 D110KB - BATTERY RELAY DRIVE S/C.................................................548 D196KA - SERVICE RETURN RELAY DISC...............................................550 D196KB - SERVICE RETURN RELAY S/C................................................552 DA25KP - PRESS. SENSOR POWER ABNORMALITY.........................................554 DA80MA - AUTO-LUBE ABNORMAL......................................................556 DA2RMC - PUMP COMM. ABNORMALITY..................................................558 DA2SKQ - MODEL SELECTION ABNORMALITY.............................................560 DAFRMC - MONITOR COMM. ABNORMALITY...............................................562 DHPAMA - F PUMP P. SENSOR ABNORMALITY............................................564 DHPBMA - R PUMP P. SENSOR ABNORMALITY............................................566 DHS3MA - ARM CURL PPC SEN. ABNORMALITY...........................................568 DHS4MA - BUCKET CURL PPC SEN. ABNORMALITY........................................570 DW43KA - TRAVEL SPEED SOL. DISC..................................................572 DW43KB - TRAVEL SPEED SOL. S/C...................................................574 DW45KA - SWING BRAKE SOL. DISC..................................................576 DW45KB - SWING BRAKE SOL. S/C....................................................578 DW91KA - TRAVEL JUNCTION SOL. DISC...............................................580 DW91KB - TRAVEL JUNCTION SOL. S/C................................................582 DWJ0KA - MERGE-DIVIDER SOL. DISC.................................................584 DWJ0KB - MERGE-DIVIDER SOL. S/C..................................................586 DWK0KA - 2-STAGE RELIEF SOL. DISC................................................588 DWK0KB - 2-STAGE RELIEF SOL. S/C.................................................590 DXA0KA - PC-EPC SOL. DISC........................................................592 DXA0KB - PC-EPC SOL. S/C.........................................................594 DXE0KA - LS-EPC SOL. DISC........................................................596 DXE0KB - LS-EPC SOL. S/C.........................................................598 DXE4KA - SERVICE CURRENT EPC DISC................................................600 DXE4KB - SERVICE CURRENT EPC S/C.................................................601 DY20KA - WIPER WORKING ABNORMALITY...............................................602 DY20MA - WIPER PARKING ABNORMALITY...............................................604 DY2CKB - WASHER DRIVE S/C........................................................606 DY2DKB - WIPER DRIVE (FOR) S/C...................................................608 DY2EKB - WIPER DRIVE (REV) S/C...................................................610 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)........................................613 BEFORE CARRYING OUT TROUBLESHOOTING..............................................614 CONNECTION TABLE OF FUSE BOX.................................................614 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...............................616 E-1 ENGINE DOES NOT START........................................................617 E-2 AUTO-DECELERATOR DOES NOT OPERATE............................................620 E-3 AUTOMATIC WARMING-UP DOES NOT OPERATE........................................621 E-4 PREHEATER DOES NOT OPERATE...................................................622 E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE..................624 E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE...................................626 E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL......................................627 E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS..................................628 E-9 DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE.............628 E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNING..................629 E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY.................630 E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY..................632 E-13 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY..................................633 E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY...............................634 E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHING...................636 E-16 WINDSHIELD WIPER DOES NOT OPERATE...........................................638 E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY..........................642 E-18 MONITORING FUNCTION FAILS TO DISPLAY “BOOM RAISE” NORMALLY..................644 E-19 MONITORING FUNCTION FAILS TO DISPLAY “BOOM LOWER" NORMALLY..................645 E-20 MONITORING FUNCTION FAILS TO DISPLAY “ARM IN” NORMALLY......................646 E-21 MONITORING FUNCTION FAILS TO DISPLAY “ARM OUT” NORMALLY.....................647 E-22 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET CURL" NORMALLY.................648 E-23 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET DUMP" NORMALLY.................649 E-24 MONITORING FUNCTION FAILS TO DISPLAY “SWING” NORMALLY.......................650 E-25 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL” NORMALLY......................652 E-26 MONITORING FAILS TO DISPLAY “TRAVEL DIFFERENTIAL PRESSURE" NORMALLY.........654 E-27 MONITORING FAILS TO DISPLAY “SERVICE” NORMALLY..............................656 E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY....................................658 E-29 AIR CONDITIONER DOES NOT OPERATE............................................660 E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING.......................662 E-31 HORN DOES NOT SOUND.........................................................664 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE).........................675 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS................................676 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................678 H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...........679 H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS.................................680 H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE......................................681 H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...........................681 H-5 AUTO-DECELERATOR DOES NOT WORK...............................................682 H-6 FINE CONTROL MODE DOES NOT FUNCTION..........................................682 H-7 BOOM MOVES SLOWLY OR LACKS POWER.............................................683 H-8 ARM MOVES SLOWLY OR LACKS POWER..............................................684 H-9 BUCKET MOVES SLOWLY OR LACKS POWER..........................................685 H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION........................685 H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT...........................686 H-12 WORK EQUIPMENT HAS BIG TIME LAG.............................................687 H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT....................687 H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK.................................687 H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK......................................688 H-16 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY.........688 H-17 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY.........................689 H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY...............................689 H-19 MACHINE SWERVES IN TRAVEL...................................................690 H-20 MACHINE TRAVELS SLOWLY.....................................................691 H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER.............................692 H-22 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED....693 H-23 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY).................................693 H-24 MACHINE DOES NOT SWING.....................................................694 H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW..........................695 H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING......................................696 H-27 THERE IS BIG SHOCK WHEN STOPPING SWING......................................697 H-28 LARGE SOUND CAUSED WHEN STOPPING SWING......................................697 H-29 SWING NATURAL DRIFT IS TOO LARGE............................................698 H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE..........................................699 H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED..........................699 30 DISASSEMBLY AND ASSEMBLY..............................................................701 HOW TO READ THIS MANUAL..............................................................705 REMOVAL AND INSTALLATION OF PARTS................................................705 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...........................................707 PRECAUTIONS DURING OPERATION.........................................................709 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.......................................709 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK..................................710 PRECAUTIONS WHEN COMPLETING THE OPERATIONS.......................................711 OTHER PRECAUTIONS................................................................711 SPECIAL TOOL LIST....................................................................712 SKETCHES OF SPECIAL TOOLS........................................................716 CONNECTOR REPAIR PROCEDURES..........................................................718 CONTACT TERMINAL REMOVAL (HD30 TYPE).............................................718 STRIPPING INSULATION.............................................................719 CRIMPING CONTACT TERMINAL (HD30 TYPE)............................................720 INSERTION OF CONTACT TERMINAL (HD30 TYPE)........................................721 CONTACT TERMINAL REMOVAL (DT TYPE)...............................................722 CRIMPING CONTACT TERMINAL (DT TYPE)..............................................723 INSERTION OF CONTACT TERMINAL (DT TYPE)..........................................724 ENGINE...............................................................................725 AFTERCOOLER......................................................................725 ALTERNATOR.......................................................................725 CYLINDER HEAD....................................................................725 ENGINE FRONT SEAL................................................................725 ENGINE OIL COOLER................................................................725 ENGINE REAR SEAL.................................................................725 FUEL INJECTION PUMP..............................................................725 NOZZLE HOLDER....................................................................725 NOZZLE TIP.......................................................................725 STARTING MOTOR...................................................................725 THERMOSTAT.......................................................................725 TURBOCHARGER.....................................................................725 WATER PUMP.......................................................................725 RADIATOR ASSEMBLY....................................................................726 REMOVAL..........................................................................726 INSTALLATION.....................................................................727 HYDRAULIC OIL COOLER ASSEMBLY........................................................728 REMOVAL..........................................................................728 INSTALLATION.....................................................................729 AFTERCOOLER ASSEMBLY.................................................................730 REMOVAL..........................................................................730 INSTALLATION.....................................................................731 ENGINE AND HYDRAULIC OIL PUMP ASSEMBLY...............................................732 REMOVAL..........................................................................732 INSTALLATION.....................................................................740 FINAL DRIVE ASSEMBLY.................................................................741 DISASSEMBLY......................................................................743 REMOVAL..........................................................................741 INSTALLATION.....................................................................742 FINAL DRIVE ASSEMBLY.................................................................743 DISASSEMBLY......................................................................743 ASSEMBLY.........................................................................747 SWING MOTOR AND SWING MACHINERY......................................................753 DISASSEMBLY......................................................................755 REMOVAL..........................................................................753 INSTALLATION.....................................................................754 SWING MOTOR AND SWING MACHINERY......................................................755 DISASSEMBLY......................................................................755 ASSEMBLY.........................................................................758 SWING CIRCLE ASSEMBLY................................................................764 REMOVAL..........................................................................764 INSTALLATION.....................................................................764 UNDERCARRIAGE AND FRAME..............................................................765 ASSEMBLY.........................................................................765 TRACK ROLLER ASSEMBLY................................................................767 ASSEMBLY.........................................................................767 IDLER ASSEMBLY.......................................................................768 DISASSEMBLY......................................................................768 ASSEMBLY.........................................................................769 RECOIL SPRING ASSEMBLY...............................................................772 DISASSEMBLY......................................................................772 ASSEMBLY.........................................................................773 SPROCKET.............................................................................774 REMOVAL..........................................................................774 INSTALLATION.....................................................................774 TRACK SHOE ASSEMBLY..................................................................775 EXPANSION........................................................................775 INSTALLATION.....................................................................775 REVOLVING FRAME ASSEMBLY.............................................................777 REMOVAL..........................................................................777 INSTALLATION.....................................................................779 COUNTERWEIGHT ASSEMBLY...............................................................780 REMOVAL..........................................................................780 INSTALLATION.....................................................................780 CENTER SWIVEL JOINT ASSEMBLY.........................................................781 REMOVAL..........................................................................781 INSTALLATION.....................................................................782 DISASSEMBLY......................................................................782 ASSEMBLY.........................................................................783 HYDRAULIC TANK ASSEMBLY..............................................................784 REMOVAL..........................................................................784 INSTALLATION.....................................................................785 CONTROL VALVE ASSEMBLY...............................................................786 REMOVAL..........................................................................786 INSTALLATION.....................................................................789 DISASSEMBLY......................................................................789 REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL...................789 ASSEMBLY.........................................................................791 HYDRAULIC PUMP ASSEMBLY..............................................................794 REMOVAL..........................................................................794 INSTALLATION.....................................................................796 HYDRAULIC PUMP INPUT SHAFT...........................................................797 REMOVAL..........................................................................797 INSTALLATION.....................................................................797 WORK EQUIPMENT PPC VALVE ASSEMBLY....................................................798 ASSEMBLY.........................................................................798 TRAVEL PPC VALVE ASSEMBLY............................................................799 DISASSEMBLY......................................................................799 ASSEMBLY.........................................................................799 HYDRAULIC CYLINDER ASSEMBLY..........................................................800 DISASSEMBLY......................................................................800 ASSEMBLY.........................................................................802 WORK EQUIPMENT ASSEMBLY..............................................................806 REMOVAL..........................................................................806 INSTALLATION.....................................................................807 CAB..................................................................................809 REMOVAL..........................................................................809 INSTALLATION.....................................................................812 CAB GLASS (STUCK GLASS)..............................................................813 REMOVAL..........................................................................814 INSTALLATION.....................................................................814 WINDOW ASSEMBLY......................................................................824 REMOVAL..........................................................................824 INSTALLATION.....................................................................827 AIR CONDITIONER UNIT ASSEMBLY........................................................832 REMOVAL..........................................................................832 INSTALLATION.....................................................................834 KOMTRAX TERMINAL ASSEMBLY............................................................835 REMOVAL..........................................................................835 INSTALLATION.....................................................................835 MONITOR ASSEMBLY.....................................................................836 REMOVAL..........................................................................836 INSTALLATION.....................................................................836 PUMP CONTROLLER......................................................................837 REMOVAL..........................................................................837 INSTALLATION.....................................................................837 90 OTHERS................................................................................839 REMOVAL..............................................................................726 HYDRAULIC...........................................................................841 HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 1 OF 5...................................841 HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 2 OF 5...................................842 HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 3 OF 5...................................843 HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 4 OF 5...................................844 HYDRAULIC DIAGRAM - PAGE 1 OF 2 - SHEET 5 OF 5...................................845 HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 1 OF 6...................................846 HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 2 OF 6...................................847 HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 3 OF 6...................................848 HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 4 OF 6...................................849 HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 5 OF 6...................................850 HYDRAULIC DIAGRAM - PAGE 2 OF 2 - SHEET 6 OF 6...................................851 ELECTRICAL..........................................................................852 ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 1 OF 4..................................852 ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 2 OF 4..................................853 ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 3 OF 4.................................854 ELECTRICAL DIAGRAM - PAGE 1 OF 6 - SHEET 4 OF 4..................................855 ELECTRICAL DIAGRAM - PAGE 2 OF 6 - SHEET 1 OF 1.................................856 ELECTRICAL DIAGRAM - PAGE 3 OF 6 - SHEET 1 OF 2..................................857 ELECTRICAL DIAGRAM - PAGE 3 OF 6 - SHEET 2 OF 2..................................858 ELECTRICAL DIAGRAM - PAGE 4 OF 6 - SHEET 1 OF 2..................................859 ELECTRICAL DIAGRAM - PAGE 4 OF 6 - SHEET 2 OF 2..................................860 ELECTRICAL DIAGRAM - PAGE 5 OF 6 - SHEET 1 OF 2..................................861 ELECTRICAL DIAGRAM - PAGE 5 OF 6 - SHEET 2 OF 2..................................862 ELECTRICAL DIAGRAM - PAGE 6 OF 6 - SHEET 1 OF 2..................................863 ELECTRICAL DIAGRAM - PAGE 6 OF 6 - SHEET 2 OF 2..................................864 ELECTRICAL CONNECTORS LEGEND AND LOCATION - SHEET 1 OF 9.........................865 ELECTRICAL CONNECTORS - SHEET 2 OF 9.............................................866 ELECTRICAL CONNECTORS - SHEET 3 OF 9.............................................867 ELECTRICAL CONNECTORS - SHEET 4 OF 9.............................................868 ELECTRICAL CONNECTORS - SHEET 5 OF 9.............................................869 ELECTRICAL CONNECTORS - SHEET 6 OF 9.............................................870 ELECTRICAL CONNECTORS - SHEET 7 OF 9.............................................871 ELECTRICAL CONNECTORS - SHEET 8 OF 9.............................................872 ELECTRICAL CONNECTORS - SHEET 9 OF 9.............................................873
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