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Komatsu PC1000-1/PC1000LC-1/PC1000SE-SP1 Excavator Workshop Repair Service Manual SEBM021N0107 – PDF DOWNLOAD
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Description
Komatsu PC1000-1/PC1000LC-1/PC1000SE-SP1 Excavator Workshop Repair Service Manual
FILE DETAILS:
Komatsu PC1000-1/PC1000LC-1/PC1000SE-SP1 Excavator Workshop Repair Service Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC1000-1/PC1000LC-1/PC1000SE-SP1
Serial Number: 10001 and up
Book Code: SEBM0210107
Language: English
Pages: 750
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC1000-1/PC1000LC-1/PC1000SE-SP1 Excavator Workshop Repair Service Manual
FOREWORD:
GENERAL
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.
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” 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 PC1000-1/PC1000LC-1/PC1000SE-SP1 Excavator Workshop Repair Service Manual
MAIN MENU............................................................................................................................................. 0 CONTENTS.............................................................................................................................................. 2 LIST OF REVISED PAGES................................................................................................................................. 3 SAFETY NOTICE......................................................................................................................................... 8 FOREWORD.............................................................................................................................................. 10 HOW TO READ THE SHOP MANUAL....................................................................................................................... 11 HOISTING INSTRUCTIONS............................................................................................................................. 12 WIRE ROPES.................................................................................................................................... 12 COATING MATERIALS................................................................................................................................. 13 STANDARD TIGHTENING TORQUE........................................................................................................................ 15 STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS................................................................................................. 15 TIGHTENING TORQUE OF HOSE NUTS................................................................................................................ 15 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....................................................................................................... 15 TIGHTENING TORQUE OF O-RING BOSS CONNECTOR.................................................................................................... 16 TIGHTENING TORQUE OF O-RING BOSS CONNECTOR.................................................................................................... 16 TIGHTENING TORQUES OF FLARE NUT............................................................................................................... 16 TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)....................................................................................... 17 TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS).......................................................................................... 17 TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)...................................................................................... 17 ELECTRIC WIRE CODE................................................................................................................................ 18 CLASSIFICATION BY THICKNESS................................................................................................................... 18 CLASSIFICATION BY COLOR AND CODE.............................................................................................................. 18 CONVERSION TABLE.................................................................................................................................. 19 METHOD OF USING THE CONVERSION TABLE.......................................................................................................... 19 Millimeters to Inches..................................................................................................................... 20 Kilogram to Pound......................................................................................................................... 20 Liter to U.S. Gallon...................................................................................................................... 21 Liter to U.K. Gallon...................................................................................................................... 21 kgm to ft. lb............................................................................................................................. 22 kg/cm2 to lb/in2.......................................................................................................................... 23 Temperature............................................................................................................................... 24 10 ENGINE............................................................................................................................................. 28 11 STRUCTURE AND FUNCTION......................................................................................................................... 28 PTO (Power Take-Off).......................................................................................................................... 29 PTO LUBRICATION SYSTEM........................................................................................................................ 30 AUTO-DECELERATION SYSTEM...................................................................................................................... 31 OPERATION TABLE........................................................................................................................... 34 1. DECELERATOR CYLINDER................................................................................................................... 35 2. SOLENOID VALVE......................................................................................................................... 36 OPERATION................................................................................................................................. 37 1. SOL A excited (engine running, control levers at NEUTRAL).......................................................................... 37 2. SOL A, B deactivated (engine running, control levers at NEUTRAL)................................................................... 37 3. SOL B excited (engine running, control levers operated)............................................................................ 37 3. OIL PRESSURE SWITCH................................................................................................................ 38 4. AUTO-DECELERATOR SELECTOR SWITCH................................................................................................... 38 12 TESTING AND ADJUSTING.......................................................................................................................... 39 STANDARD FOR TESTING AND ADJUSTING............................................................................................................ 40 TESTING AND ADJUSTING TOOL LIST............................................................................................................... 42 ADJUSTING VALVE CLEARANCE..................................................................................................................... 43 MEASURING COMPRESSION PRESSURE................................................................................................................ 44 MEASURING BLOW-BY PRESSURE.................................................................................................................... 45 TESTING AND ADJUSTING FUEL INJECTION TIMING................................................................................................... 46 ADJUSTING FUEL CONTROL LEVER.................................................................................................................. 49 ADJUSTING AUTO-DECELERATION SYSTEM............................................................................................................ 52 MEASURING EXHAUST GAS COLOR................................................................................................................... 54 13 DISASSEMBLY AND ASSEMBLY....................................................................................................................... 55 STARTING MOTOR................................................................................................................................ 56 REMOVAL................................................................................................................................... 56 INSTALLATION.............................................................................................................................. 56 ALTERNATOR.................................................................................................................................... 56 REMOVAL................................................................................................................................... 56 INSTALLATION.............................................................................................................................. 56 ENGINE OIL COOLER............................................................................................................................. 58 REMOVAL................................................................................................................................... 58 INSTALLATION.............................................................................................................................. 58 WATER PUMP.................................................................................................................................... 58 REMOVAL................................................................................................................................... 58 INSTALLATION.............................................................................................................................. 58 FUEL INJECTION PUMP........................................................................................................................... 60 REMOVAL .................................................................................................................................. 60 INSTALLATION.............................................................................................................................. 60 NOZZLE HOLDER................................................................................................................................. 62 REMOVAL................................................................................................................................... 62 INSTALLATION.............................................................................................................................. 62 TURBOCHARGER.................................................................................................................................. 64 REMOVAL................................................................................................................................... 64 INSTALLATION.............................................................................................................................. 64 CYLINDER HEAD................................................................................................................................. 66 REMOVAL................................................................................................................................... 66 INSTALLATION Serial No.: 10001 - 10371.................................................................................................... 77 INSTALLATION Serial No.: 10372 and up..................................................................................................... 83 HYDRAULIC OIL COOLER.......................................................................................................................... 89 REMOVAL................................................................................................................................... 89 INSTALLATION.............................................................................................................................. 89 RADIATOR...................................................................................................................................... 89 REMOVAL................................................................................................................................... 89 INSTALLATION.............................................................................................................................. 89 ENGINE, PTO, HYDRAULIC PUMP................................................................................................................... 91 REMOVAL................................................................................................................................... 91 INSTALLATION.............................................................................................................................. 93 PTO........................................................................................................................................... 99 REMOVAL................................................................................................................................... 99 INSTALLATION.............................................................................................................................. 99 DISASSEMBLY...............................................................................................................................101 ASSEMBLY..................................................................................................................................101 AUTO-DECELERATION CYLINDER....................................................................................................................105 REMOVAL Serial No.: 10001 - 10371.........................................................................................................105 INSTALLATION Serial No.: 10001 - 10371....................................................................................................105 REMOVAL Serial No.: 10372 and up..........................................................................................................105 INSTALLATION Serial No.: 10372 and up....................................................................................................105 14 MAINTENANCE STANDARD...........................................................................................................................107 PTO (Power Take-Off)..........................................................................................................................108 20 POWER TRAIN........................................................................................................................................109 21 STRUCTURE AND FUNCTION.........................................................................................................................109 POWER TRAIN...................................................................................................................................110 TRAVEL AND BRAKE SYSTEM.......................................................................................................................111 1. TRAVEL CONTROL CIRCUIT SCHEMATICS......................................................................................................111 2. TRAVEL CONTROL CIRCUIT.................................................................................................................112 3. STRAIGHT-TRAVEL SYSTEM.................................................................................................................113 4. CENTER SWIVEL JOINT....................................................................................................................118 5. TRAVEL MOTOR AND BRAKE VALVE...........................................................................................................119 6. FINAL DRIVE............................................................................................................................131 SWING SYSTEM..................................................................................................................................133 1. SWING HYDRAULIC CIRCUIT SCHEMATICS.....................................................................................................133 2. SWING HYDRAULIC CIRCUIT................................................................................................................134 3. SWING PUMP.............................................................................................................................135 4. SWING CONTROL VALVE....................................................................................................................138 5. SWING MOTOR (WITH MECHANICAL BRAKE) AND SAFETY VALVE...................................................................................140 6. SWING BRAKE (AUTOMATIC) AND SWING PARKING BRAKE (MANUAL)...............................................................................144 7. FREE SWING SYSTEM......................................................................................................................148 8. SWING MACHINERY........................................................................................................................151 9. SWING CIRCLE...........................................................................................................................153 23 DISASSEMBLY AND ASSEMBLY.......................................................................................................................154 CENTER SWIVEL JOINT ASSEMBLY..................................................................................................................155 REMOVAL...................................................................................................................................155 INSTALLATION..............................................................................................................................155 DISASSEMBLY...............................................................................................................................157 ASSEMBLY..................................................................................................................................157 TRAVEL MOTOR, BRAKE VALVE.....................................................................................................................159 REMOVAL...................................................................................................................................159 INSTALLATION..............................................................................................................................159 TRAVEL MOTOR..................................................................................................................................161 DISASSEMBLY...............................................................................................................................161 ASSEMBLY..................................................................................................................................167 ASSEMBLY OF END COVER ASSEMBLY........................................................................................................167 1. Servo piston assembly..........................................................................................................167 2. Valve plate....................................................................................................................167 ASSEMBLY OF BRAKE VALVE ASSEMBLY......................................................................................................167 3. Suction valve..................................................................................................................167 4. Safety valve assembly..........................................................................................................167 5. Counterbalance valve...........................................................................................................169 ASSEMBLY OF MOTOR.....................................................................................................................169 6. Bearing outer race.............................................................................................................169 7. Shaft assembly.................................................................................................................169 8. Disc, plate....................................................................................................................171 9. Piston, retainer...............................................................................................................171 10. Brake piston assembly.........................................................................................................173 11. Cylinder block................................................................................................................173 12. Spring........................................................................................................................173 13. Motor case....................................................................................................................173 14. End cover assembly............................................................................................................173 15. Block.........................................................................................................................173 16. Measuring rotation torque.....................................................................................................173 17. Measuring brake torque........................................................................................................175 FINAL DRIVE ASSEMBLY..........................................................................................................................177 REMOVAL...................................................................................................................................177 INSTALLATION..............................................................................................................................177 DISASSEMBLY...............................................................................................................................179 1. Case assembly......................................................................................................................179 2. Coupling, pinion gear..............................................................................................................179 3. Case, gear assembly................................................................................................................179 4. Carrier assembly (small)...........................................................................................................179 5. Ring gear (small)..................................................................................................................181 8. Carrier assembly (large)...........................................................................................................181 7. Shaft..............................................................................................................................181 8. Ring gear, housing assembly........................................................................................................181 9. Case assembly......................................................................................................................181 ASSEMBLY..................................................................................................................................183 1. Housing............................................................................................................................183 2. Case assembly......................................................................................................................183 3. Bearing............................................................................................................................183 4. Ring gear, housing assembly........................................................................................................183 5. Preload adjustment, retainer.......................................................................................................183 6. Shaft..............................................................................................................................185 7. Carrier assembly (large)...........................................................................................................185 8. Carrier assembly (small)...........................................................................................................187 9. Ring gear (small)..................................................................................................................187 10. Case and gear assembly............................................................................................................187 11. Pinion gear.......................................................................................................................189 12. Case assembly.....................................................................................................................189 SPROCKET......................................................................................................................................191 REMOVAL...................................................................................................................................191 INSTALLATION..............................................................................................................................191 SWING PUMP....................................................................................................................................193 REMOVAL...................................................................................................................................193 INSTALLATION..............................................................................................................................193 DISASSEMBLY...............................................................................................................................195 ASSEMBLY..................................................................................................................................199 ASSEMBLY OF PUMP SUBASSEMBLY..........................................................................................................199 1. Cradle, piston assembly........................................................................................................199 2. Cylinder block.................................................................................................................199 3. Shaft assembly.................................................................................................................201 4. Servo piston...................................................................................................................203 5. Pump subassembly...............................................................................................................205 6. Adjusting end play of bearing..................................................................................................205 7. End cap........................................................................................................................205 8. Servo piston cap...............................................................................................................205 9. Impeller.......................................................................................................................207 10. Servo and CO-NC valves........................................................................................................209 11. Rear pump assembly............................................................................................................209 CO-NC VALVE ASSEMBLY..........................................................................................................................211 REMOVAL...................................................................................................................................211 INSTALLATION..............................................................................................................................211 SERVO VALVE...................................................................................................................................211 REMOVAL...................................................................................................................................211 INSTALLATION..............................................................................................................................211 PPC VALVE.....................................................................................................................................213 REMOVAL...................................................................................................................................213 INSTALLATION..............................................................................................................................213 DISASSEMBLY...............................................................................................................................213 ASSEMBLY..................................................................................................................................213 SWING CONTROL VALVE...........................................................................................................................215 REMOVAL...................................................................................................................................215 INSTALLATION..............................................................................................................................215 MAIN RELIEF VALVE.............................................................................................................................215 REMOVAL...................................................................................................................................215 INSTALLATION..............................................................................................................................215 SWING CONTROL VALVE...........................................................................................................................219 DISASSEMBLY...............................................................................................................................217 ASSEMBLY..................................................................................................................................219 FRONT SWING MOTOR.............................................................................................................................221 REMOVAL...................................................................................................................................221 INSTALLATION..............................................................................................................................221 REAR SWING MOTOR..............................................................................................................................221 REMOVAL...................................................................................................................................221 INSTALLATION..............................................................................................................................221 SWING MOTOR ASSEMBLY..........................................................................................................................227 DISASSEMBLY...............................................................................................................................223 ASSEMBLY..................................................................................................................................227 1. Outer race.........................................................................................................................227 2. Shaft assembly.....................................................................................................................227 3. Belleville spring, spacer, bearing.................................................................................................227 4. Spacer.............................................................................................................................227 5. Cover..............................................................................................................................227 6. Plate, disc........................................................................................................................227 7. Brake piston.......................................................................................................................229 8. Piston, shaft......................................................................................................................229 9. Spring.............................................................................................................................229 10. Cylinder block....................................................................................................................229 11. Valve plate.......................................................................................................................229 12. Belleville spring.................................................................................................................229 13. Check valve.......................................................................................................................229 14. Relief valve......................................................................................................................229 15. Valve case assembly ..............................................................................................................229 16. Inspection of rotating torque of drive shaft......................................................................................229 REVOLVING FRAME...............................................................................................................................231 REMOVAL...................................................................................................................................231 INSTALLATION..............................................................................................................................231 SWING CIRCLE..................................................................................................................................233 REMOVAL...................................................................................................................................233 INSTALLATION..............................................................................................................................233 FRONT SWING MACHINERY.........................................................................................................................235 REMOVAL...................................................................................................................................235 INSTALLATION..............................................................................................................................235 REAR SWING MACHINERY..........................................................................................................................237 REMOVAL...................................................................................................................................237 INSTALLATION..............................................................................................................................237 SWING MACHINERY...............................................................................................................................239 DISASSEMBLY...............................................................................................................................239 1. Cover..............................................................................................................................239 2. Coupling...........................................................................................................................239 3. Ring gear..........................................................................................................................239 4. Thrust washer......................................................................................................................239 5. Sungear............................................................................................................................239 6. Carrier assembly...................................................................................................................239 7. Thrust washer......................................................................................................................239 8. Bolt, plate........................................................................................................................239 9. Gear assembly......................................................................................................................239 10. Shaft.............................................................................................................................239 11. Spacer............................................................................................................................241 12. Snap ring, bearing................................................................................................................241 13. Oil seal..........................................................................................................................241 DISASSEMBLY OF CARRIER ASSEMBLY...........................................................................................................241 14. Shaft.............................................................................................................................241 15. Gear assembly.....................................................................................................................241 SWING MACHINERY ..............................................................................................................................243 DISASSEMBLY Serial No. 10001-10077........................................................................................................239 1. Cover..............................................................................................................................239 2. Coupling...........................................................................................................................239 3. Ring gear..........................................................................................................................239 4. Thrust washer......................................................................................................................239 5. Sungear............................................................................................................................239 6. Carrier assembly...................................................................................................................239 7. Thrust washer......................................................................................................................239 8. Bolt, plate........................................................................................................................239 9. Gear assembly......................................................................................................................239 10. Shaft.............................................................................................................................239 11. Spacer............................................................................................................................241 12. Snap ring, bearing................................................................................................................241 13. Oil seal..........................................................................................................................241 14. Shaft.............................................................................................................................241 15. Gear assembly.....................................................................................................................241 ASSEMBLY Serial No. 10001-10077...........................................................................................................243 1. Gear assembly......................................................................................................................243 2. Shaft..............................................................................................................................243 3. Oil seal...........................................................................................................................243 4. Bearing, snap ring.................................................................................................................243 6. Shaft..............................................................................................................................243 6. Spacer.............................................................................................................................243 7. Bearing............................................................................................................................245 8. Gear assembly......................................................................................................................245 9. Plate, bolt........................................................................................................................245 10. Thrust washer.....................................................................................................................245 11. Carrier assembly, sun gear........................................................................................................245 12. Thrust washer.....................................................................................................................247 13. Ring gear.........................................................................................................................247 14. Coupling..........................................................................................................................247 15. Cover.............................................................................................................................247 16. Refilling with oil................................................................................................................247 DISASSEMBLY Serial No. 10078 and up.......................................................................................................249 1. Oil filler.........................................................................................................................249 2. Cover..............................................................................................................................249 3. No. 1 sun gear.....................................................................................................................249 4. No. 1 carrier assembly.............................................................................................................249 5. Ring gear..........................................................................................................................250 6. No. 2 carrier assembly.............................................................................................................251 7. Swing pinion.......................................................................................................................252 8. Spacer.............................................................................................................................253 9. Oil seal, bearing..................................................................................................................253 10. Bearing...........................................................................................................................253 ASSEMBLY Serial No. 10078 and up..........................................................................................................254 1. Bearing, oil seal..................................................................................................................254 2. Swing pinion.......................................................................................................................254 3. Retainer...........................................................................................................................255 4. No. 2 carrier assembly.............................................................................................................255 5. Ring gear..........................................................................................................................257 6. No. 1 carrier assembly.............................................................................................................257 7. No. 1 sun gear.....................................................................................................................258 8. Cover..............................................................................................................................259 9. Oil filler.........................................................................................................................260 24 MAINTENANCE STANDARD...........................................................................................................................261 TRAVEL MOTOR AND BRAKE VALVE..................................................................................................................262 TRAVEL RELIEF VALVE...........................................................................................................................264 TRAVEL SHUTTLE VALVE..........................................................................................................................265 STRAIGHT-TRAVEL VALVE.........................................................................................................................266 FINAL DRIVE...................................................................................................................................267 SWING CONTROL VALVE...........................................................................................................................268 JET SENSOR....................................................................................................................................269 CONNECTION VALVE..............................................................................................................................270 SWING MOTOR...................................................................................................................................271 SWING MACHINERY...............................................................................................................................272 SWING CIRCLE..................................................................................................................................274 30 UNDERCARRIAGE......................................................................................................................................275 31 STRUCTURE AND FUNCTION.........................................................................................................................275 TRACK FRAME...................................................................................................................................276 IDLER CUSHION.................................................................................................................................279 IDLER.........................................................................................................................................283 TRACK ROLLER..................................................................................................................................284 CARRIER ROLLER................................................................................................................................284 TRACK SHOE....................................................................................................................................285 33 DISASSEMBLY AND ASSEMBLY.......................................................................................................................287 TRACK.........................................................................................................................................288 REMOVAL...................................................................................................................................288 INSTALLATION..............................................................................................................................288 IDLER.........................................................................................................................................290 REMOVAL...................................................................................................................................290 INSTALLATION..............................................................................................................................290 IDLER CUSHION.................................................................................................................................290 REMOVAL...................................................................................................................................290 INSTALLATION..............................................................................................................................290 DISASSEMBLY...............................................................................................................................292 ASSEMBLY..................................................................................................................................292 IDLER ADJUSTMENT CYLINDER.....................................................................................................................292 DISASSEMBLY...............................................................................................................................292 ASSEMBLY..................................................................................................................................292 TRACK ROLLER..................................................................................................................................294 REMOVAL...................................................................................................................................294 INSTALLATION..............................................................................................................................294 CARRIER ROLLER................................................................................................................................294 REMOVAL...................................................................................................................................294 INSTALLATION..............................................................................................................................294 34 MAINTENANCE STANDARD...........................................................................................................................296 TRACK FRAME...................................................................................................................................297 TRACK ROLLER..................................................................................................................................298 IDLER.........................................................................................................................................299 CARRIER ROLLER................................................................................................................................301 TRACK SHOE....................................................................................................................................302 50 AIR SYSTEM.........................................................................................................................................304 51 STRUCTURE AND FUNCTION.........................................................................................................................304 AIR PIPING....................................................................................................................................305 AIR CIRCUIT DIAGRAM...........................................................................................................................305 AIR GOVERNOR..................................................................................................................................306 AIR TANK......................................................................................................................................306 SAFETY VALVE..................................................................................................................................307 HORN VALVE....................................................................................................................................307 GREASE PUMP...................................................................................................................................308 60 HYDRAULIC SYSTEM...................................................................................................................................309 61 STRUCTURE AND FUNCTION.........................................................................................................................309 HYDRAULIC SYSTEM LOCATION.....................................................................................................................310 HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................................311 WORK EQUIPMENT CONTROL........................................................................................................................316 ELECTRONIC AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM............................................................................................335 HYDRAULIC TANK................................................................................................................................344 MAIN PUMP.....................................................................................................................................345 CHARGING AND PTO LUBRICATING PUMP.............................................................................................................362 HYDRAULIC OIL FILTER..........................................................................................................................363 2-STAGE AND 3-STAGE MODE SELECTOR OLSS (Open center Load Sensing System)......................................................................365 HYDRAULIC CONTROL VALVE.......................................................................................................................383 PPC VALVE.....................................................................................................................................390 PPC ACCUMULATOR...............................................................................................................................396 PPC SHUTTLE VALVE.............................................................................................................................397 PILOT RELIEF VALVE............................................................................................................................399 SAFETY LOCK VALVE.............................................................................................................................401 HYDRAULIC CYLINDER............................................................................................................................402 WORK EQUIPMENT................................................................................................................................409 62 TESTING AND ADJUSTING..........................................................................................................................410 TABLE OF JUDGEMENT STANDARD VALUE.............................................................................................................411 TABLE OF JUDGEMENT STANDARD VALVE (FOR MACHINES EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS).....................................................422 TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE..................................................................................................433 TESTING AND ADJUSTING TOOL LIST...............................................................................................................446 TESTING AND ADJUSTMENT OF RELIEF PRESSURE.....................................................................................................447 TESTING AND ADJUSTMENT OF CONTROL CIRCUIT PRESSURE............................................................................................449 BLEEDING AIR AND RELEASING PRESSURE...........................................................................................................452 CHARGING ACCUMULATOR WITH GAS.................................................................................................................456 CHECKING SWIVEL JOINT.........................................................................................................................457 TESTING AND ADJUSTING OF TRAVEL CONTROL LEVER AND ROD.........................................................................................459 ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER (LOADING SHOVEL)...................................................................................460 ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX (LOADING SHOVEL).....................................................................................461 TROUBLESHOOTING...............................................................................................................................466 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................467 3-STAGE MODE SELECTOR ELECTRONIC OLSS.................................................................................................468 SWING PARKING BRAKE AND SWING BRAKE SYSTEM............................................................................................469 TRAVEL SPEED SELECTOR SYSTEM..........................................................................................................469 ELECTRONIC AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM....................................................................................472 CNE9 (Engine potentiometer).......................................................................................................473 CN5 (Intermediate connector)......................................................................................................474 CN 13 (WC solenoid)...............................................................................................................475 CN23 (Intermediate connector).....................................................................................................476 CN36 (Prolix circuit switch)......................................................................................................477 CN46 (Auto-deceleration solenoid B)...............................................................................................478 CN62 (Hydraulic pressure switch for ARM IN, BUCKET CURL and DUMP).................................................................479 OLSS control box..................................................................................................................480 POSITION OF CONNECTORS FOR TROUBLESHOOTING................................................................................................470 CONNECTION TABLE FOR CONNECTOR PINS.......................................................................................................481 TROUBLESHOOTING PROCEDURE.................................................................................................................485 CHECKS BEFORE TROUBLESHOOTING.............................................................................................................486 E. H MODE TROUBLESHOOTING.................................................................................................................489 ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY.............................................................................490 TROUBLESHOOTING.......................................................................................................................491 E-1 Machine deviates excessively (always deviates)................................................................................495 a) Self-testing display shows abnormality.....................................................................................496 b) If cause is removed when switching to prolix circuit (when self-testing display shows normal)..............................498 E-2 Work equipment, swing, travel speeds extremely slow, or lack of power.........................................................499 a) Self-testing display shows abnormality.....................................................................................499 b) If cause is removed when switching to prolix circuit (when self-testing display shows normal)..............................501 E-3 Engine stalls during operations, or engine speed drops........................................................................504 a) Self-testing display shows abnormality.....................................................................................504 b) If cause is removed when switching to prolix circuit (when self-testing display shows normal)..............................506 E-4 No change in output when mode switch is operated..............................................................................507 a) Self-testing display shows abnormality.....................................................................................508 b) If cause is removed when switching to prolix circuit (when self-testing display shows normal)..............................508 E-5 Auto-deceleration does not work...............................................................................................513 a) Self-testing display shows abnormality.....................................................................................513 b) Self-testing display shows normality.......................................................................................517 E-6 Swing does not work...........................................................................................................519 E-7 Excessive hydraulic drift of swing............................................................................................521 E-8 Travel speed does not switch..................................................................................................522 a) Speed does not increase when placed in Hi (does not switch to Hi)..........................................................522 b) Speed does not decrease when placed in Lo..................................................................................522 H-1 Machine deviates excessively (deviates more than standard when only travel system is used, travel lever at FULL position).....528 H-2 Excessive deviation in travel during simultaneous operations..................................................................530 H-3 Machine deviates excessively when starting....................................................................................532 H-4 Control levers are extremely heavy............................................................................................534 a) If travel lever is heavy...................................................................................................534 b) If work equipment levers are heavy.........................................................................................534 H-5 Work equipment, travel, and swing start suddenly during fine control operations...............................................535 H-6 Speeds for work equipment, swing, and travel are all extremely slow, or there is no power.....................................536 a) Machine hardly moves.......................................................................................................536 b) Abnormality in some part (abnormality on one side).........................................................................538 c) Individual symptoms........................................................................................................538 d) If work equipment speed on either side is slow.............................................................................539 e) For failures except for those in (a), (b), (c) and (d). (Auto-deceleration is normal.).....................................540 H-7 Engine stalls or engine speed drops during operations.........................................................................542 H-8 No change in output when mode selector switch is operated.....................................................................543 H-9 Auto-deceleration does not come on, or does not not go off....................................................................543 H-10 Abnormal noise comes from around pump........................................................................................544 H-11 Swing speed is slow, or overrun when stopping swing is excessive.............................................................545 H-12 Upper structure does not swing...............................................................................................547 H-13 Excessive hydraulic drift....................................................................................................549 H-16 Excessive time lag for work equipment........................................................................................549 H-17 Troubleshooting Chart........................................................................................................550 FAILURE MODE AND COMPONENTS.......................................................................................................551 W. L MODE TROUBLESHOOTING.................................................................................................................552 ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY.............................................................................553 TROUBLESHOOTING.......................................................................................................................554 W-1 In arc digging mode, work equipment carries out horizontal digging, or there is bucket angle......................................556 W-2 In horizontal digging mode, work equipment does not carry out horizontal digging..................................................557 a) Self-testing display does not show abnormality.................................................................................557 b) Self-testing display shows abnormality.........................................................................................559 W-3 In horizontal digging mode, there is bucket angle compensation....................................................................565 W-4 In horizontal digging + bucket angle compensation mode, work equipment carries out horizontal digging, but there is no............566 a) Self-testing display does not show abnormality.................................................................................566 b) Self-testing display shows abnormality.........................................................................................568 W-5 In horizontal digging + bucket angle compensation mode, there is bucket angle compensation, but work equipment does not...........570 a) Self-testing display does not show abnormality.................................................................................570 b) Self-testing display shows abnormality.........................................................................................570 W-6 In horizontal digging + bucket angle compensation mode, work equipment does not carry out horizontal digging, and there...........572 a) Self-testing display does not show abnormality.................................................................................572 b) Self-testing display shows abnormality.........................................................................................573 L-1 Work equipment does not carry out horizontal digging or bucket angle compensation.................................................579 63 DISASSEMBLY AND ASSEMBLY.......................................................................................................................580 CHARGING PUMP.................................................................................................................................581 REMOVAL...................................................................................................................................581 INSTALLATION..............................................................................................................................581 NO. 1 PUMP....................................................................................................................................583 REMOVAL...................................................................................................................................583 INSTALLATION..............................................................................................................................585 NO. 2 PUMP....................................................................................................................................587 REMOVAL...................................................................................................................................587 INSTALLATION..............................................................................................................................587 PISTON PUMP...................................................................................................................................589 DISASSEMBLY (HPV160 + 160)................................................................................................................589 DISASSEMBLY OF PUMP BODY..............................................................................................................589 DISASSEMBLY OF PUMP SUB-ASSEMBLY......................................................................................................591 ASSEMBLY (HPV160 + 160)..................................................................................................................593 ASSEMBLY OF PUMP SUBASSEMBLY..........................................................................................................593 ASSEMBLY OF PUMP BODY.................................................................................................................595 CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE....................................................601 CO•NC VALVE ASSEMBLY (for No. 1 front pump)...................................................................................................603 REMOVAL...................................................................................................................................603 INSTALLATION..............................................................................................................................603 CO•NC VALVE ASSEMBLY (for No. 1 rear pump with TVC valve)....................................................................................603 REMOVAL...................................................................................................................................603 INSTALLATION..............................................................................................................................603 TVC VALVE (for No. 1 rear pump)...............................................................................................................605 REMOVAL...................................................................................................................................605 INSTALLATION..............................................................................................................................605 SERVO VALVE (for No. 1 front pump)............................................................................................................607 REMOVAL...................................................................................................................................607 INSTALLATION..............................................................................................................................607 SERVO VALVE (for No; 1 rear pump).............................................................................................................607 REMOVAL...................................................................................................................................607 INSTALLATION..............................................................................................................................607 SERVO VALVE (for No. 2 front pump)............................................................................................................607 REMOVAL...................................................................................................................................607 INSTALLATION..............................................................................................................................607 SERVO VALVE (for No. 2 rear pump).............................................................................................................607 REMOVAL...................................................................................................................................607 INSTALLATION..............................................................................................................................607 L.H. 5-SPOOL CONTROL VALVE....................................................................................................................609 REMOVAL...................................................................................................................................609 INSTALLATION..............................................................................................................................611 R.H. 4-SPOOL CONTROL VALVE ASSEMBLY...........................................................................................................613 REMOVAL...................................................................................................................................613 INSTALLATION..............................................................................................................................615 CONTROL VALVE.................................................................................................................................617 DISASSEMBLY...............................................................................................................................617 ASSEMBLY..................................................................................................................................617 MAIN RELIEF VALVE (for 4-, 5-SPOOL CONTROL VALVE).............................................................................................619 REMOVAL, DISASSEMBLY......................................................................................................................619 INSTALLATION, ASSEMBLY....................................................................................................................619 PILOT RELIEF VALVE............................................................................................................................621 REMOVAL, DISASSEMBLY......................................................................................................................621 ASSEMBLY, INSTALLATION....................................................................................................................621 PPC VALVE ASSEMBLY (for work equipment and swing).............................................................................................621 DISASSEMBLY, ASSEMBLY.....................................................................................................................621 BOOM CYLINDER (BACKHOE).......................................................................................................................623 REMOVAL INSTALLATION......................................................................................................................623 ARM CYLINDER (BACKHOE)........................................................................................................................625 REMOVAL...................................................................................................................................625 INSTALLATION..............................................................................................................................625 BUCKET CYLINDER ASSEMBLY (BACKHOE)............................................................................................................627 REMOVAL...................................................................................................................................627 INSTALLATION..............................................................................................................................627 BOOM CYLINDER ASSEMBLY (LOADING SHOVEL).......................................................................................................629 REMOVAL...................................................................................................................................629 INSTALLATION..............................................................................................................................629 ARM CYLINDER ASSEMLBY (LOADING SHOVEL)........................................................................................................631 REMOVAL...................................................................................................................................631 INSTALLATION..............................................................................................................................631 BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL).....................................................................................................633 REMOVAL...................................................................................................................................633 INSTALLATION..............................................................................................................................633 BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL)................................................................................................635 REMOVAL...................................................................................................................................635 INSTALLATION..............................................................................................................................635 HYDRAULIC CYLINDER............................................................................................................................637 DISASSEMBLY...............................................................................................................................637 ASSEMBLY..................................................................................................................................641 BUCKET ASSEMBLY (BACKHOE).....................................................................................................................645 REMOVAL...................................................................................................................................645 INSTALLATION..............................................................................................................................645 ARM (BACKHOE).................................................................................................................................647 REMOVAL...................................................................................................................................647 INSTALLATION..............................................................................................................................647 BOOM (BACKHOE)................................................................................................................................649 REMOVAL...................................................................................................................................649 INSTALLATION..............................................................................................................................649 BUCKET AND ARM (BACKHOE)......................................................................................................................651 REMOVAL...................................................................................................................................651 INSTALLATION..............................................................................................................................651 WORK EQUIPMENT (BACKHOE)......................................................................................................................653 REMOVAL...................................................................................................................................653 INSTALLATION..............................................................................................................................653 BUCKET (LOADING SHOVEL).......................................................................................................................655 REMOVAL...................................................................................................................................655 INSTALLATION..............................................................................................................................655 ARM (LOADING SHOVEL)..........................................................................................................................657 REMOVAL...................................................................................................................................657 INSTALLATION..............................................................................................................................657 BOOM (LOADING SHOVEL).........................................................................................................................659 REMOVAL...................................................................................................................................659 INSTALLATION..............................................................................................................................661 WORK EQUIPMENT (LOADING SHOVEL)...............................................................................................................663 REMOVAL...................................................................................................................................663 INSTALLATION..............................................................................................................................663 POTENTIOMETER (LOADING SHOVEL)................................................................................................................665 DISASSEMBLY...............................................................................................................................665 ASSEMBLY..................................................................................................................................665 COUNTERWEIGHT.................................................................................................................................665 REMOVAL...................................................................................................................................665 INSTALLATION..............................................................................................................................665 64 MAINTENANCE STANDARD...........................................................................................................................667 CHARGING AND PTO LUBRICATION PUMP.............................................................................................................668 PILOT RELIEF VALE.............................................................................................................................669 L.H. 5-SPOOL CONTROL VALVE....................................................................................................................670 R.H. 4-SPOOL CONTROL VALVE....................................................................................................................672 PPC VALVE.....................................................................................................................................674 PPC SHUTTLE VALVE.............................................................................................................................675 WORK EQUIPMENT SAFETY VALVE...................................................................................................................677 HYDRAULIC CYLINDER............................................................................................................................680 WORK EQUIPMENT................................................................................................................................682 80 ELECTRIC AND ELECTRONIC SYSTEM.....................................................................................................................699 82 TESTING AND ADJUSTING..........................................................................................................................699 ELECTRICAL CIRCUIT DIAGRAM....................................................................................................................700 POSITION OF CONNECTORS FOR TROUBLESHOOTING....................................................................................................702 M MODE TROUBLESHOOTING........................................................................................................................712 M-1 When starting switch is turned ON, monitor panel display does not appear..............................................................713 M-2 When starting switch is turned ON, monitor panel display does not go out..............................................................713 M-3 When starting switch is turned ON (do not start engine), .............................................................................714 a) (coolant level) flashes............................................................................................................714 b) (engine oil level) flashes.........................................................................................................714 c) (hydraulic oil level) flashes......................................................................................................715 M-4 APS switch is not being used, but APS monitor lights up...............................................................................717 M-5 When starting switch is turned ON, (engine started), CHECK BEFORE STARTING items flash................................................718 a) Alternator system..................................................................................................................718 b) Engine oil pressure system.........................................................................................................718 M-6 When starting switch is turned ON, (do not start engine), CAUTION items flash.........................................................720 M-7 When starting switch is ON (engine started), caution items flash......................................................................721 a) (engine oil pressure) flashes......................................................................................................721 b) (coolant level) flashes............................................................................................................721 c) (coolant temperature gauge) flashes................................................................................................722 d) (charge level) flashes.............................................................................................................722 e) (hydraulic oil filter) flashes.....................................................................................................723 f) (hydraulic oil temperature) flashes................................................................................................723 M-8 When starting switch is turned ON (engine stopped) for 1 second, or when CAUTION items are flashing, warning buzzer does..............726 M-9 No abnormal display on monitor but warning buzzer sounds..............................................................................726 M-10 Monitor panel lamps do not light up (Indication on monitor panel is correct).........................................................728 M-11 When engine is started, service meter does not move..................................................................................729 a) Service meter does not move, when engine is started................................................................................729 b) Service meter does not stop moving, when engine is stopped.........................................................................729 M-12 Engine coolant temperature is high, but lowest level displayed.......................................................................731 M-13 Engine coolant temperature gauge gives no display....................................................................................731 M-14 Fuel tank is not full but display shows full tank....................................................................................733 M-15 No display is given for fuel level...................................................................................................733 P MODE TROUBLESHOOTING........................................................................................................................735 P-1 APS fuse (4) is blown.................................................................................................................736 P-2 Even when APS switch is turned ON, monitor lamp does not start to flash...............................................................739 P-3 When APS switch is turned ON, monitor lamp flashes, but time taken to change to ON is not 60 - 100 sec................................742 P-4 When APS switch is turned ON, flashing of monitor lamp changes to ON after approx. 80 sec. but engine does not start easily...........743 P-5 Engine can be started with APS, but when starting motor stops, engine immediately stalls..............................................746 P-6 Function of APS does not stop.........................................................................................................747 a) Function of APS is normal, but APS does not stop even when water temperature is more than 20°C.....................................747 b) APS is actuated even when APS switch on panel is not turned ON.....................................................................747 FAILURE MODE AND COMPONENTS...............................................................................................................749
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