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Komatsu PC1250-7 PC1250SP-7 PC1250LC-7 Hydraulic Excavator Service Shop Manual – PDF DOWNLOAD
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Komatsu PC1250-7 PC1250SP-7 PC1250LC-7 Hydraulic Excavator Service Shop Manual
- MACHINE MODEL:PC1250-7 , PC1250SP-7 , PC1250LC-7
- SERIAL No: 20001 and up ,20001 and up, 20001 and up
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Description
Komatsu PC1250-7 PC1250SP-7 PC1250LC-7 Hydraulic Excavator Service Shop Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:940
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU PC1250-7 PC1250SP-7 PC1250LC-7 HYDRAULIC EXCAVATOR SERVICE SHOP MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu PC1250-7 PC1250SP-7 PC1250LC-7 Hydraulic Excavator Service Shop 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu PC1250-7 PC1250SP-7 PC1250LC-7 Hydraulic Excavator Service Shop Manual
COVER................................................................................................................... 1 CONTENTS................................................................................................................ 2 01 GENERAL.............................................................................................................. 29 SPECIFICATION DIMENSION DRAWINGS.................................................................................... 30 SPECIFICATIONS...................................................................................................... 34 WEIGHT TABLE........................................................................................................ 38 FUEL, COOLANT AND LUBRICANTS........................................................................................ 42 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD......................................................................... 43 PTO................................................................................................................. 44 PTO LUBRICATION SYSTEM ............................................................................................. 46 RADIATOR, OIL COOLER, AFTERCOOLER AND FUEL COOLER .................................................................. 47 POWER TRAIN......................................................................................................... 49 SWING MACHINERY..................................................................................................... 51 SWING CIRCLE........................................................................................................ 53 FINAL DRIVE ........................................................................................................ 54 SPROCKET............................................................................................................ 57 TRACK FRAME......................................................................................................... 59 IDLER............................................................................................................... 61 CARRIER ROLLER ..................................................................................................... 63 TRACK ROLLER ....................................................................................................... 64 TRACK SHOE ......................................................................................................... 65 AIR PIPING DIAGRAM.................................................................................................. 69 AIR CIRCUIT DIAGRAM................................................................................................. 70 AIR GOVERNOR........................................................................................................ 71 AIR TANK ........................................................................................................... 71 SAFETY VALVE........................................................................................................ 72 HORN VALVE.......................................................................................................... 72 GREASE PUMP......................................................................................................... 73 HYDRAULIC EQUIPMENT LAYOUT DRAWING.................................................................................. 74 HYDRAULIC TANK ..................................................................................................... 79 HYDRAULIC PUMP...................................................................................................... 80 NO.1 PUMP........................................................................................................... 81 NO.2 PUMP...........................................................................................................104 NO.3 PUMP...........................................................................................................109 LINE OIL FILTER.....................................................................................................118 PILOT OIL FILTER....................................................................................................119 RETURN OIL FILTER...................................................................................................120 DRAIN OIL FILTER....................................................................................................121 L.H.5-SPOOL CONTROL VALVE...........................................................................................122 R.H.4-SPOOL CONTROL VALVE...........................................................................................126 SWING 4-SPOOL CONTROL VALVE.........................................................................................130 STRAIGHT-TRAVEL VALVE...............................................................................................135 SWING MOTOR.........................................................................................................138 CENTER SWIVEL JOINT.................................................................................................140 TRAVEL MOTOR........................................................................................................141 PPC CONTROL RELIEF VALVE............................................................................................151 ACCUMULATOR.........................................................................................................153 VALVE CONTROL.......................................................................................................154 WORK EQUIPMENT, SWING PPC VALVE ....................................................................................155 TRAVEL PPC VALVE....................................................................................................160 SOLENOID VALVE......................................................................................................164 HYDRAULIC CYLINDER..................................................................................................172 WORK EQUIPMENT......................................................................................................176 DIMENSIONS OF WORK EQUIPMENT........................................................................................180 AIR CONDITIONER.....................................................................................................184 ENGINE CONTROL......................................................................................................185 HPI ENGINE CONTROL SYSTEM...........................................................................................191 MACHINE CONTROL SYSTEM..............................................................................................193 MONITOR SYSTEM......................................................................................................221 SENSOR..............................................................................................................243 20 TESTING AND ADJUSTING................................................................................................246 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.......................................................................247 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS......................................................................251 TESTING AND ADJUSTING...............................................................................................270 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING................................................................271 MEASURING ENGINE SPEED..........................................................................................274 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)..................................................................275 MEASURING EXHAUST TEMPERATURE...................................................................................276 TROUBLESHOOTING FOR INJECTOR....................................................................................277 MEASURING EXHAUST COLOR.........................................................................................278 ADJUSTING VALVE CLEARANCE.......................................................................................279 ADJUSTING INJECTOR SET LOAD.....................................................................................280 MEASURING COMPRESSION PRESSURE..................................................................................282 MEASURING BLOW-BY PRESSURE......................................................................................284 MEASURING ENGINE OIL PRESSURE...................................................................................285 HANDLING EQUIPMENT IN FUEL SYSTEM...............................................................................286 MEASURING FUEL CIRCUIT PRESSURE.................................................................................287 VISUAL INSPECTION OF RETURN FUEL................................................................................289 ARRANGEMENT OF CONTROL DEVICES FOR HPI..........................................................................290 BLEEDING AIR FROM FUEL CIRCUIT..................................................................................292 ADJUSTING ENGINE SPEED SENSOR...................................................................................294 REPLACING AND ADJUSTING FAN BELT ...............................................................................295 TESTING AND ADJUSTING ALTERNATOR AND AIR COMPRESSOR BELT TENSION................................................296 TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................298 MEASURING WEAR OF SPROCKET......................................................................................299 TESTING AND ADJUSTING TRACK SHOE TENSION .......................................................................300 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................301 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE..............................................................307 TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE..............................................................308 TESTING SERVO PISTON STROKE ....................................................................................315 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING SWING PPC SHUTTLE VALVE.........................................316 MEASURING SOLENOID VALVE OUTPUT PRESSURE........................................................................320 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.......................................................................322 TESTING TRAVEL DEVIATION........................................................................................323 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................324 MEASURING OIL LEAKAGE...........................................................................................325 MEASURING FAN SPEED.............................................................................................329 MEASURING FAN CIRCUIT OIL PRESSURE..............................................................................329 BLEEDING AIR ...................................................................................................331 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................333 INSPECTION PROCEDURES FOR DIODE.................................................................................334 SPECIAL FUNCTION OF MONITOR PANEL...............................................................................335 INITIALIZATION PROCEDURES FOR VHMS CONTROLLER...................................................................365 SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER................................................................378 TESTING AND ADJUSTING DEVICES RELATED TO VHMS ..................................................................393 PM-CLINIC SERVICE...............................................................................................396 TROUBLESHOOTING.....................................................................................................410 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................................................411 SEQUENCE OF EVENTS IN TROUBLESHOOTING...........................................................................412 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................413 CHECKS BEFORE TROUBLESHOOTING...................................................................................421 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING....................................................................422 CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM.....................................426 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS......................................................................448 T-BRANCH BOX AND T-BRANCH TABLE.................................................................................471 TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (1/2)....473 INFORMATION IN TROUBLESHOOTING TABLE........................................................................474 ERROR CODE IN ELECTRICAL SYSTEM [C111] (ECM MICROPROCESSOR).................................................476 ERROR CODE IN ELECTRICAL SYSTEM [C112] (TIMING ACTUATOR STUCK)..............................................476 ERROR CODE IN ELECTRICAL SYSTEM [C113] (TIMING ACTUATOR CURRENT)............................................477 ERROR CODE IN ELECTRICAL SYSTEM [C115] (ENGINE SPEED SENSOR (2))............................................478 ERROR CODE IN ELECTRICAL SYSTEM [C116] (TIMING RAIL P. SENSOR)..............................................480 ERROR CODE IN ELECTRICAL SYSTEM [C117] (TIMING RAIL P. SENSOR)..............................................481 ERROR CODE IN ELECTRICAL SYSTEM [C118] (FUEL PUMP P. SENSOR)................................................482 ERROR CODE IN ELECTRICAL SYSTEM [C119] (FUEL PUMP P. SENSOR)................................................484 ERROR CODE IN ELECTRICAL SYSTEM [C121] (ENGINE SPEED SENSOR (1))............................................484 ERROR CODE IN ELECTRICAL SYSTEM [C122] (BOOST P. SENSOR)....................................................485 ERROR CODE IN ELECTRICAL SYSTEM [C123] (BOOST P. SENSOR)....................................................486 ERROR CODE IN ELECTRICAL SYSTEM [C131] (THROTTLE SENSOR)....................................................487 ERROR CODE IN ELECTRICAL SYSTEM [C132] (THROTTLE SENSOR)....................................................488 ERROR CODE IN ELECTRICAL SYSTEM [C135] (OIL P. SENSOR)......................................................489 ERROR CODE IN ELECTRICAL SYSTEM [C141] (OIL P. SENSOR)......................................................491 ERROR CODE IN ELECTRICAL SYSTEM [C143] (OIL P. LOW).........................................................491 ERROR CODE IN ELECTRICAL SYSTEM [C144] (COOLANT T. SENSOR)..................................................492 ERROR CODE IN ELECTRICAL SYSTEM [C145] (COOLANT T. SENSOR).................................................494 ERROR CODE IN ELECTRICAL SYSTEM [C151] (COOLANT T. HIGH)....................................................494 ERROR CODE IN ELECTRICAL SYSTEM [C153] (INTAKE MANIFOLD T. SENSOR)..........................................495 ERROR CODE IN ELECTRICAL SYSTEM [C154] (INTAKE MANIFOLD T. SENSOR)..........................................496 ERROR CODE IN ELECTRICAL SYSTEM [C221] (AMBIENT AIR P. SENSOR)..............................................497 ERROR CODE IN ELECTRICAL SYSTEM [C222] (AMBIENT AIR P. SENSOR)..............................................499 ERROR CODE IN ELECTRICAL SYSTEM [C234] (ENGINE OVERSPEED)...................................................499 ERROR CODE IN ELECTRICAL SYSTEM [C254] (FSOV CIRCUIT).......................................................500 ERROR CODE IN ELECTRICAL SYSTEM [C259] (FSOV CIRCUIT).......................................................501 ERROR CODE IN ELECTRICAL SYSTEM [C261] (FUEL T. HIGH).......................................................501 ERROR CODE IN ELECTRICAL SYSTEM [C263] (FUEL T. SENSOR).....................................................502 ERROR CODE IN ELECTRICAL SYSTEM [C265] (FUEL T. SENSOR).....................................................503 ERROR CODE IN ELECTRICAL SYSTEM [C316] (FUEL PUMP ACTUATOR CURRENT).........................................504 ERROR CODE IN ELECTRICAL SYSTEM [C318] (FUEL PUMP ACTUATOR STUCK)...........................................505 ERROR CODE IN ELECTRICAL SYSTEM [C346] (ECM POWERDOWN)......................................................506 ERROR CODE IN ELECTRICAL SYSTEM [C423] (TIMING RAIL P. IN RANGE ERROR)......................................508 ERROR CODE IN ELECTRICAL SYSTEM [C441] (BATTERY VOLTAGE)....................................................510 ERROR CODE IN ELECTRICAL SYSTEM [C442] (BATTERY VOLTAGE)....................................................510 ERROR CODE IN ELECTRICAL SYSTEM [C451] (FUEL RAIL P. SENSOR)................................................511 ERROR CODE IN ELECTRICAL SYSTEM [C452] (FUEL RAIL P. SENSOR)................................................512 ERROR CODE IN ELECTRICAL SYSTEM [C455] (FUEL RAIL ACTUATOR CURRENT).........................................513 ERROR CODE IN ELECTRICAL SYSTEM [C467] (TIMING ACTUATOR CONTROL)............................................514 ERROR CODE IN ELECTRICAL SYSTEM [C468] (RAIL ACTUATOR CONTROL)..............................................514 ERROR CODE IN ELECTRICAL SYSTEM [C514] (RAIL ACTUATOR STUCK)................................................515 ERROR CODE IN ELECTRICAL SYSTEM [C554] (FUEL RAIL P. IN RANGE ERROR)........................................516 TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (2/2)....518 ERROR CODE IN ELECTRICAL SYSTEM [E101] (ABNORMALITY ERROR RECORD)...........................................520 ERROR CODE IN ELECTRICAL SYSTEM [E112] (WIPER DRIVE (FOR) S/C)..............................................522 ERROR CODE IN ELECTRICAL SYSTEM [E113] (WIPER DRIVE (REV) S/C)..............................................526 ERROR CODE IN ELECTRICAL SYSTEM [E114] (WASHER DRIVE S/C)...................................................528 ERROR CODE IN ELECTRICAL SYSTEM [E115] (WIPER WORKING ABNORMALITY)..........................................530 ERROR CODE IN ELECTRICAL SYSTEM [E116] (WIPER PARKING ABNORMALITY)..........................................532 ERROR CODE IN ELECTRICAL SYSTEM [E201] (CO CANCEL SOL. S/C).................................................536 ERROR CODE IN ELECTRICAL SYSTEM [E202] (TRAVEL JUNCTION SOL. S/C)...........................................538 ERROR CODE IN ELECTRICAL SYSTEM [E203] (SWING BRAKE SOL. S/C)...............................................540 ERROR CODE IN ELECTRICAL SYSTEM [E204] (2-STAGE RELIEF SOL. S/C)............................................542 ERROR CODE IN ELECTRICAL SYSTEM [E205] (SWING PRIORITY SOL. S/C)............................................544 ERROR CODE IN ELECTRICAL SYSTEM [E206] (TRAVEL SPEED SOL. S/C)..............................................546 ERROR CODE IN ELECTRICAL SYSTEM [E207] (FLASH LIGHT RELAY S/C)..............................................548 ERROR CODE IN ELECTRICAL SYSTEM [E211] (CO CANCEL SOL. DISC.)...............................................550 ERROR CODE IN ELECTRICAL SYSTEM [E212] (TRAVEL JUNCTION SOL. DISC.).........................................552 ERROR CODE IN ELECTRICAL SYSTEM [E213] (SWING BRAKE SOL. DISC.).............................................554 ERROR CODE IN ELECTRICAL SYSTEM [E214] (2-STAGE RELIEF SOL. DISC.)..........................................556 ERROR CODE IN ELECTRICAL SYSTEM [E215] (SWING PRIORITY SOL. DISC.)..........................................558 ERROR CODE IN ELECTRICAL SYSTEM [E216] (TRAVEL SPEED SOL. DISC.)............................................560 ERROR CODE IN ELECTRICAL SYSTEM [E217] (MODEL SELECTION ABNORMALITY)........................................562 ERROR CODE IN ELECTRICAL SYSTEM [E218] (S-NET COMM. DISC.)..................................................564 ERROR CODE IN ELECTRICAL SYSTEM [E221] (J1939 COMM. ERROR)..................................................566 ERROR CODE IN ELECTRICAL SYSTEM [E222] (WORKING MODE OUTPUT S/C (1))........................................568 ERROR CODE IN ELECTRICAL SYSTEM [E223] (WORKING MODE OUTPUT DISC.(1)).......................................569 ERROR CODE IN ELECTRICAL SYSTEM [E224] (WORKING MODE OUTPUT S/C (2))........................................570 ERROR CODE IN ELECTRICAL SYSTEM [E225] (WORKING MODE OUTPUT DISC.(2)).......................................571 ERROR CODE IN ELECTRICAL SYSTEM [E226] (AUTO-DECELERATION OUTPUT DISC.).....................................572 ERROR CODE IN ELECTRICAL SYSTEM [E227] (ENGINE SPEED SENSOR ABNORMALITY)....................................573 ERROR CODE IN ELECTRICAL SYSTEM [E228] (AUTO-DECELERATION OUTPUT S/C).......................................574 ERROR CODE IN ELECTRICAL SYSTEM [E232] (TVC SOL. S/C).......................................................575 ERROR CODE IN ELECTRICAL SYSTEM [E233] (TVC SOL. DISC.).....................................................577 ERROR CODE IN ELECTRICAL SYSTEM [E234] (LEVER NEUTRAL OUTPUT S/C)...........................................579 ERROR CODE IN ELECTRICAL SYSTEM [E235] (LEVER NEUTRAL OUTPUT DISC.).........................................580 ERROR CODE IN ELECTRICAL SYSTEM [E241] (PRE. SENS VOLTAGE FAILURE)..........................................581 ERROR CODE IN ELECTRICAL SYSTEM [E242] (F PUMP PRE. SENS FAILURE)...........................................583 ERROR CODE IN ELECTRICAL SYSTEM [E243] (R PUMP PRE. SENS FAILURE)...........................................585 ERROR CODE IN ELECTRICAL SYSTEM [E244] (SWING PRE. SENS FAILURE)............................................587 ERROR CODE IN ELECTRICAL SYSTEM [E245] (HIGH RELIEF PRESS F PUMP)...........................................589 ERROR CODE IN ELECTRICAL SYSTEM [E246] (HIGH RELIEF PRESS R PUMP)...........................................590 ERROR CODE IN ELECTRICAL SYSTEM [E247] (HIGH RELIEF PRESS PUMP SWING).......................................591 ERROR CODE IN ELECTRICAL SYSTEM [E302] (STEP LIGHT RELAY S/C)...............................................592 ERROR CODE IN ELECTRICAL SYSTEM [E304] (STEP LIGHT POWER DRIVE RELAY S/C)...................................594 ERROR CODE IN ELECTRICAL SYSTEM [E315] (BATTERY RELAY DRIVE S/C)............................................596 FAILURE CODE IN VHMS SYSTEM [A000N1] (ENGINE OVER SPEED)....................................................598 FAILURE CODE IN MECHANICAL SYSTEM [AA10NX] (AIRCLEANER CLOGGING)............................................599 FAILURE CODE IN MECHANICAL SYSTEM [AB00KE] (CHARGE VOLTAGE LOW).............................................601 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG] (ENG. OIL PRESS. LOW)............................................603 FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK] (ENG. OIL LEVEL LOW).............................................604 FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS] (ENG. WATER OVERHEAT)............................................605 FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK] (ENG. WATER LVL LOW).............................................606 FAILURE CODE IN VHMS SYSTEM [B@CBNS] (HIGH PTO TEMPERATURE).................................................608 FAILURE CODE IN MECHANICAL SYSTEM [B@HANS] (HYDR. OIL OVERHEAT).............................................609 FAILURE CODE IN VHMS SYSTEM [DBB0KK] (VHMS SOURCE VOLTAGE ERROR)............................................610 FAILURE CODE IN VHMS SYSTEM [DBB5KP] (VHMS 5V SOURCE SYS ERROR).............................................612 FAILURE CODE IN VHMS SYSTEM [DBB6KP] (VHMS 24V SOURCE SYS ERROR)............................................613 FAILURE CODE IN VHMS SYSTEM [DBBQKR] (KOM-NET/C ERROR)......................................................614 FAILURE CODE IN VHMS SYSTEM [DBBRKR] (CAN-NET SYS (J1939) ERROR)............................................616 FAILURE CODE IN VHMS SYSTEM [DGE1KB] (ENG OIL TEMP. SENSOR FAILURE).........................................618 FAILURE CODE IN VHMS SYSTEM [DGE1KY] (ENG OIL TEMP. SENSOR FAILURE).........................................620 FAILURE CODE IN VHMS SYSTEM [DGE5KX] (AMBIENT AIR TEMP SENSOR FAILURE)......................................622 FAILURE CODE IN VHMS SYSTEM [DGT3KZ] (PTO TEMP SENSOR FAILURE)..............................................624 FAILURE CODE IN VHMS SYSTEM [DGT4KA] (F EXHAUST TEMP. SENSOR FAILURE).......................................626 FAILURE CODE IN VHMS SYSTEM [DGT4KB] (F EXHAUST TEMP. SENSOR FAILURE).......................................628 FAILURE CODE IN VHMS SYSTEM [DGT5KA] (R EXHAUST TEMP. SENSOR FAILURE).......................................630 FAILURE CODE IN VHMS SYSTEM [DGT5KB] (R EXHAUST TEMP. SENSOR FAILURE).......................................632 FAILURE CODE IN VHMS SYSTEM [DHE5KB] (BLOWBY PRES. SENSOR FAILURE)..........................................634 FAILURE CODE IN VHMS SYSTEM [DHE5KY] (BLOWBY PRES. SENSOR FAILURE)..........................................636 FAILURE CODE IN VHMS SYSTEM [F@BBZL] (HIGH BLOWBY PRESSURE).................................................638 FAILURE CODE IN VHMS SYSTEM [F@BYNR] (HIGH F CYL. EXHAUST TEMP. 2)..........................................639 FAILURE CODE IN VHMS SYSTEM [F@BYNS] (HIGH F CYL. EXHAUST TEMP. 1)..........................................640 FAILURE CODE IN VHMS SYSTEM [F@BZNR] (HIGH R CYL. EXHAUST TEMP. 2)..........................................641 FAILURE CODE IN VHMS SYSTEM [F@BZNS] (HIGH R CYL. EXHAUST TEMP. 1)..........................................642 FAILURE CODE IN VHMS SYSTEM [J100KA] (CNT. PUMP PRE. SENS FAILURE)..........................................643 FAILURE CODE IN VHMS SYSTEM [J100KA] (FAN PUMP PRE. SENS FAILURE)...........................................645 FAILURE CODE IN VHMS SYSTEM [J100KB] (CNT. PUMP PRE. SENS FAILURE)..........................................647 FAILURE CODE IN VHMS SYSTEM [J100KB] (FAN PUMP PRE. SENS FAILURE)...........................................649 FAILURE CODE IN VHMS SYSTEM [J100L6](ABNOMAL CNT. GEAR PUMP PRESS)..........................................651 FAILURE CODE IN VHMS SYSTEM [J10016] (ABNOMAL FAN GEAR PUMP PRESS)..........................................653 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...................................................................655 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................656 E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)..........................................................657 E-2 AUTO-DECELERATOR DOES NOT WORK..........................................................................660 E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK................................................................661 E-4 PREHEATER DOES NOT WORK.................................................................................662 E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE........................................................664 E-6 MACHINE PUSH-UP CIRCUIT DOES NOT WORK...................................................................666 E-7 BOOM SHOCKLESS CIRCUIT CANNOT BE RESET..................................................................668 E-8 NO DISPLAY IN MONITOR PANEL AT ALL......................................................................670 E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING.............................................................671 E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL................................................671 E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING..........................................672 E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.............................................673 E-13 FUEL GAUGE DOES NOT DISPLAY CORRECTLY..................................................................674 E-14 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY..........................................................675 E-15 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS................................................676 E-16 WINDSHIELD WIPER DOES NOT WORK.........................................................................677 E-17 ALARMING BUZZER CANNOT BE CANCELLED....................................................................680 E-18 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION............................................681 E-19 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION............................................682 E-20 "ARM DIGGING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...........................................683 E-21 "ARM DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...........................................684 E-22 "BUCKET DIGGING " IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................685 E-23 "BUCKET DUMPING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION........................................686 E-24 "SWING" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.................................................687 E-25 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION................................................689 E-26 AIR CONDITIONER DOES NOT WORK..........................................................................691 E-27 TRAVEL ALARM DOES NOT SOUND............................................................................692 E-28 ANY OF PANEL LAMP, HEAD LAMP, WORKING LAMP (INCLUDING ADDITIONAL LAMP) DOES NOT LIGHT UP...............693 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)........................................................697 BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS.................................................698 INFORMATION IN TROUBLESHOOTING TABLE........................................................................703 H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW..........................................704 H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS.........................................................706 H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK...............................................707 H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP................................................................708 H-5 SPEED OR POWER OF BOOM IS LOW...........................................................................709 H-6 SPEED OR POWER OF ARM IS LOW............................................................................711 H-7 SPEED OR POWER OF BUCKET IS LOW.........................................................................712 H-8 BOOM DOES NOT MOVE......................................................................................713 H-9 ARM DOES NOT MOVE.......................................................................................713 H-10 BUCKET DOES NOT MOVE...................................................................................713 H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE.............................................................714 H-12 TIME LAG OF WORK EQUIPMENT IS LARGE....................................................................715 H-13 BOOM SHOCKLESS FUNCTION CANNOT BE TURNED ON OR OFF.....................................................716 H-14 MACHINE DEVIATES IN ONE DIRECTION......................................................................716 H-15 MACHINE DEVIATES LARGELY AT START......................................................................718 H-16 MACHINE DEVIATES LARGELY DURING COMPOUND OPERATION.....................................................719 H-17 TRAVEL SPEED OR POWER IS LOW ..........................................................................719 H-18 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK)...............................................................720 H-19 TRAVEL SPEED DOES NOT CHANGE...........................................................................721 H-20 MACHINE DOES NOT SWING.................................................................................722 H-21 SWING SPEED OR ACCELERATION IS LOW.....................................................................723 H-22 SWING SPEED OR POWER IS LOW IN COMPOUND OPERATION OF TRAVEL AND BUCKET.................................724 H-23 SWING SPEED OR POWER IS LOW IN COMPOUND OPERATION OF TRAVEL AND BOOM IN SWING PRIORITY MODE............724 H-24 UPPER STRUCTURE OVERRUNS LARGELY.......................................................................725 H-25 LARGE SHOCKS ARE MADE WHEN UPPER STRUCTURE STOPS SWINGING..............................................726 H-26 LARGE ABNORMAL SOUNDS ARE MADE WHEN UPPER STRUCTURE STOPS SWINGING.....................................727 H-27 HYDRAULIC DRIFT OF SWING IS LARGE......................................................................727 TROUBLESHOOTING OF ENGINE BODY (S MODE).........................................................................728 POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................729 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................730 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...............................................733 S-2 ENGINE DOES NOT START...................................................................................735 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)....................................................740 S-4 ENGINE STOPS DURING OPERATIONS..........................................................................742 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...............................................................744 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)....................................................................746 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)..........................................................748 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................750 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................751 S-10 FUEL CONSUMPTION IS EXCESSIVE..........................................................................752 S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN..................................753 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).............................................754 S-13 OIL LEVEL RISES........................................................................................755 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....................................................756 S-15 ABNORMAL NOISE IS MADE.................................................................................757 S-16 VIBRATION IS EXCESSIVE.................................................................................758 30 DISASSEMBLY AND ASSEMBLY.............................................................................................759 HOW TO READ THIS MANUAL ............................................................................................762 REMOVAL AND INSTALLATION OF ASSEMBLIES..........................................................................762 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES..........................................................................763 PRECAUTIONS WHEN PERFORMING OPERATION...............................................................................764 SPECIAL TOOL LIST ..................................................................................................766 REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY......................................................................775 REMOVAL.........................................................................................................775 INSTALLATION....................................................................................................775 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL.......................................................................776 SPECIAL TOOLS...................................................................................................776 REMOVAL.........................................................................................................776 INSTALLATION....................................................................................................776 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL........................................................................778 SPECIAL TOOLS...................................................................................................778 REMOVAL.........................................................................................................778 INSTALLATION....................................................................................................778 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY..................................................................780 SPECIAL TOOLS...................................................................................................780 REMOVAL.........................................................................................................780 INSTALLATION....................................................................................................783 REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER ASSEMBLY................................................785 SPECIAL TOOLS...................................................................................................785 REMOVAL.........................................................................................................785 INSTALLATION....................................................................................................786 REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY....................................................................787 REMOVAL.........................................................................................................787 INSTALLATION....................................................................................................787 REMOVAL AND INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY.....................................................788 REMOVAL.........................................................................................................788 INSTALLATION....................................................................................................789 REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY....................................................790 REMOVAL.........................................................................................................790 INSTALLATION....................................................................................................793 REMOVAL AND INSTALLATION OF PTO ASSEMBLY............................................................................794 REMOVAL.........................................................................................................794 INSTALLATION....................................................................................................795 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY............................................................................796 DISASSEMBLY.....................................................................................................796 ASSEMBLY........................................................................................................797 REMOVAL AND ASSEMBLY OF FUEL TANK ASSEMBLY..........................................................................800 REMOVAL.........................................................................................................800 INSTALLATION....................................................................................................800 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY....................................................................801 SPECIAL TOOLS ..................................................................................................801 DISASSEMBLY.....................................................................................................801 ASSEMBLY........................................................................................................805 SKETCHES OF SPECIAL TOOLS.......................................................................................811 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY................................................................812 REMOVAL.........................................................................................................812 INSTALLATION....................................................................................................812 REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY................................................................813 REMOVAL.........................................................................................................813 INSTALLATION....................................................................................................813 DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY................................................................814 SPECIAL TOOLS ..................................................................................................814 DISASSEMBLY.....................................................................................................814 ASSEMBLY........................................................................................................817 SKETCHES OF SPECIAL TOOLS.......................................................................................821 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY...................................................................823 REMOVAL.........................................................................................................823 INSTALLATION....................................................................................................823 REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY.....................................................................824 SPECIAL TOOLS ..................................................................................................824 REMOVAL.........................................................................................................824 INSTALLATION....................................................................................................825 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY..........................................................................826 REMOVAL.........................................................................................................826 INSTALLATION....................................................................................................826 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY..........................................................................827 SPECIAL TOOLS ..................................................................................................827 DISASSEMBLY.....................................................................................................827 ASSEMBLY........................................................................................................828 DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY......................................................830 DISASSEMBLY.....................................................................................................830 ASSEMBLY........................................................................................................830 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY..................................................................831 REMOVAL.........................................................................................................831 INSTALLATION....................................................................................................831 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY .................................................................833 SPECIAL TOOLS ..................................................................................................833 DISASSEMBLY.....................................................................................................833 INSTALLATION....................................................................................................834 SKETCHES OF SPECIAL TOOLS.......................................................................................835 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.................................................................836 REMOVAL.........................................................................................................836 INSTALLATION....................................................................................................836 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.................................................................837 SPECIAL TOOLS ..................................................................................................837 DISASSEMBLY.....................................................................................................837 ASSEMBLY........................................................................................................838 SKETCHES OF SPECIAL TOOLS.......................................................................................839 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY...................................................................840 SPECIAL TOOLS ..................................................................................................840 REMOVAL.........................................................................................................840 INSTALLATION....................................................................................................840 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY ..................................................................841 SPECIAL TOOLS ..................................................................................................841 DISASSEMBLY.....................................................................................................841 ASSEMBLY........................................................................................................842 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.................................................................844 REMOVAL.........................................................................................................844 INSTALLATION....................................................................................................845 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY.................................................................846 REMOVAL.........................................................................................................846 INSTALLATION....................................................................................................846 REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL..........................................................847 REMOVAL.........................................................................................................847 INSTALLATION....................................................................................................847 DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY..............................................................848 DISASSEMBLY.....................................................................................................848 ASSEMBLY........................................................................................................848 REMOVAL AND INSTALLATION OF 5-SPOOL CONTROL VALVE ASSEMBLY (NO. 1)..................................................849 REMOVAL.........................................................................................................849 INSTALLATION....................................................................................................850 REMOVAL AND INSTALLATION OF 4-SPOOL CONTROL VALVE ASSEMBLY (NO. 2)..................................................851 REMOVAL.........................................................................................................851 INSTALLATION....................................................................................................852 REMOVAL AND INSTALLATION OF 4-SPOOL CONTROL VALVE ASSEMBLY (NO. 3)..................................................853 REMOVAL.........................................................................................................853 INSTALLATION....................................................................................................854 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 1)..........................................................855 DISASSEMBLY.....................................................................................................855 ASSEMBLY........................................................................................................856 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 2)..........................................................858 DISASSEMBLY.....................................................................................................858 ASSEMBLY........................................................................................................859 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 3)..........................................................862 DISASSEMBLY.....................................................................................................862 ASSEMBLY........................................................................................................863 REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY....................................................................865 REMOVAL.........................................................................................................865 INSTALLATION....................................................................................................866 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY............................................................867 REMOVAL.........................................................................................................867 INSTALLATION....................................................................................................867 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY............................................................868 DISASSEMBLY.....................................................................................................868 ASSEMBLY........................................................................................................868 REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY...................................................................869 SPECIAL TOOLS ..................................................................................................869 REMOVAL.........................................................................................................869 INSTALLATION....................................................................................................869 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY.......................................................870 DISASSEMBLY.....................................................................................................870 ASSEMBLY........................................................................................................871 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...............................................................872 DISASSEMBLY.....................................................................................................872 ASSEMBLY........................................................................................................873 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (BACKHOE SPECIFICATION)........................................874 REMOVAL.........................................................................................................874 INSTALLATION....................................................................................................875 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL)...............................................876 REMOVAL.........................................................................................................876 INSTALLATION....................................................................................................877 REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL)..........................................878 REMOVAL.........................................................................................................878 INSTALLATION....................................................................................................879 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (BACKHOE SPECIFICATION )..........................................880 SPECIAL TOOLS ..................................................................................................880 REMOVAL.........................................................................................................880 INSTALLATION....................................................................................................881 SKETCHES OF SPECIAL TOOLS.......................................................................................882 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (LOADING SHOVEL)..................................................883 REMOVAL.........................................................................................................883 INSTALLATION....................................................................................................884 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (BACKHOE SPECIFICATION ).........................................885 SPECIAL TOOLS ..................................................................................................885 REMOVAL.........................................................................................................885 INSTALLATION....................................................................................................886 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (LOADING SHOVEL )................................................887 REMOVAL.........................................................................................................887 INSTALLATION....................................................................................................888 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (BACKHOE SPECIFICATION )....................................889 SPECIAL TOOLS ..................................................................................................889 DISASSEMBLY.....................................................................................................889 ASSEMBLY........................................................................................................893 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (BACKHOE SPECIFICATION).................................................897 REMOVAL.........................................................................................................897 INSTALLATION....................................................................................................898 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (LOADING SHOVEL)........................................................899 REMOVAL.........................................................................................................899 INSTALLATION....................................................................................................900 REMOVAL AND INSTALLATION OF ARM ASSEMBLY (BACKHOE SPECIFICATION)....................................................901 REMOVAL.........................................................................................................901 INSTALLATION....................................................................................................901 REMOVAL AND INSTALLATION OF ARM ASSEMBLY (LOADING SHOVEL)...........................................................902 REMOVAL.........................................................................................................902 INSTALLATION....................................................................................................903 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (BACKHOE SPECIFICATION)...................................................904 REMOVAL.........................................................................................................904 INSTALLATION....................................................................................................905 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (LOADING SHOVEL)..........................................................906 REMOVAL.........................................................................................................906 INSTALLATION....................................................................................................907 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.................................................................908 REMOVAL.........................................................................................................908 INSTALLATION....................................................................................................909 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)......................................................910 SPECIAL TOOLS ..................................................................................................911 REMOVAL.........................................................................................................911 INSTALLATION....................................................................................................912 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY...................................................................920 REMOVAL.........................................................................................................920 INSTALLATION....................................................................................................922 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY..................................................................926 REMOVAL.........................................................................................................926 INSTALLATION....................................................................................................926 REMOVAL AND INSTALLATION OF RECEIVER TANK ASSEMBLY..................................................................927 SPECIAL TOOLS ..................................................................................................927 REMOVAL.........................................................................................................927 INSTALLATION....................................................................................................927 REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................928 SPECIAL TOOLS ..................................................................................................928 REMOVAL.........................................................................................................928 INSTALLATION....................................................................................................928 REMOVAL AND INSTALLATION OF VHMS CONTROLLER.........................................................................929 REMOVAL.........................................................................................................929 INSTALLATION....................................................................................................929 90 OTHERS...............................................................................................................930 HYDRAULIC CIRCUIT DIAGRAM (1/3).....................................................................................931 HYDRAULIC CIRCUIT DIAGRAM (2/3).....................................................................................932 HYDRAULIC CIRCUIT DIAGRAM (3/3) ....................................................................................933 ELECTRICAL CIRCUIT DIAGRAM (1/7)....................................................................................934 ELECTRICAL CIRCUIT DIAGRAM (2/7)....................................................................................935 ELECTRICAL CIRCUIT DIAGRAM (3/7)....................................................................................936 ELECTRICAL CIRCUIT DIAGRAM (4/7)....................................................................................937 ELECTRICAL CIRCUIT DIAGRAM (5/7)....................................................................................938 ELECTRICAL CIRCUIT DIAGRAM (6/7)....................................................................................939 ELECTRICAL CIRCUIT DIAGRAM (7/7)....................................................................................940
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
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