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Komatsu PC150-5 Hydraulic Excavator Shop Manual SN 6001 and up – PDF DOWNLOAD
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Komatsu PC150-5 Hydraulic Excavator Shop Manual
MACHINE MODEL SERlAL No.
- PC150-5 6001 and up
Book Code: SEBM021K0502
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Description
Komatsu PC150-5 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC150-5 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC150-5
Serial Number: 6001 and up
Book Code: SEBM021K0502
Language: English
Pages: 520
File Format: Portable Document Format (PDF)
KOMATSU PC150-5 HYDRAULIC EXCAVATOR SHOP MANUAL SN 6001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC150-5 Hydraulic Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen 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 thissection.
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 PC150-5 Hydraulic Excavator Shop Manual
COVER............................................................................................................................................................ 1 CONTENTS......................................................................................................................................................... 2 10 STRUCTURE AND FUNCTION........................................................................................................................................ 17 POWER TRAIN.................................................................................................................................................. 18 FINAL DRIVE.................................................................................................................................................. 19 SWING CIRCLE................................................................................................................................................. 20 SWING MACHINERY.............................................................................................................................................. 21 TRACK FRAME.................................................................................................................................................. 22 IDLER........................................................................................................................................................ 23 IDLER CUSHION................................................................................................................................................ 23 CARRIER ROLLER............................................................................................................................................... 24 TRACK ROLLER................................................................................................................................................. 24 TRACK SHOE................................................................................................................................................... 25 HYDRAULIC PIPING............................................................................................................................................. 27 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................................... 28 HYDRAULIC TANK............................................................................................................................................... 29 OLSS (OPEN CENTER LOAD SENSING SYSTEM)....................................................................................................................... 30 HYDRAULIC PUMP............................................................................................................................................... 32 L.H. 6-SPOOL CONTROL VALVE................................................................................................................................... 51 R.H. 5-SPOOL CONTROL VALVE................................................................................................................................... 54 SWING MOTOR.................................................................................................................................................. 57 CENTER SWIVEL JOINT.......................................................................................................................................... 60 TRAVEL MOTOR................................................................................................................................................. 61 VALVE CONTROL................................................................................................................................................ 68 PPC VALVE.................................................................................................................................................... 69 ACCUMULATOR.................................................................................................................................................. 73 SAFETY LOCK VALVE............................................................................................................................................ 73 SOLENOID VALVE............................................................................................................................................... 74 SHUTTLE VALVE................................................................................................................................................ 78 BOOM HOLDING VALVE........................................................................................................................................... 79 HYDRAULIC CYLINDER........................................................................................................................................... 82 ELECTRICAL WIRING DIAGRAM.................................................................................................................................... 84 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................................... 86 ENGINE CONTROL SYSTEM........................................................................................................................................ 88 PEMC SYSTEM.................................................................................................................................................. 99 EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)...............................................................................................................126 20 TESTING AND ADJUSTING.........................................................................................................................................133 TABLE OF JUDGEMENT STANDARD VALUE............................................................................................................................134 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...................................................................................................................146 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................................................157 ADJUSTING VALVE CLEARANCE....................................................................................................................................158 MEASURING COMPRESSION PRESSURE...............................................................................................................................159 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................................................................................160 ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER.....................................................................................................................161 ADJUSTING ENGINE SPEED SENSOR................................................................................................................................162 ADJUSTING TRAVEL LIMIT SWITCH................................................................................................................................162 INSPECTION OF SWING CIRCLE BEARING CLEARANCE.................................................................................................................163 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT............................................................................164 TESTING AND ADJUSTING CHARGING PUMP PRESSURE.................................................................................................................166 TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE.............................................................................................................168 MEASURING STROKE OF SERVO PISTON.............................................................................................................................175 TESTING AND ADJUSTING TRAVEL DEVIATION.......................................................................................................................176 MEASURING OUTPUT PRESSURE OF PPC VALVE.......................................................................................................................178 ADJUSTING PPC VALVE..........................................................................................................................................179 TESTING PPC SHUTTLE VALVE....................................................................................................................................180 MEASURING SOLENOID VALVE OUTLET PORT PRESSURE................................................................................................................181 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT..................................................................................................182 BLEEDING AIR.................................................................................................................................................184 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................................................186 TROUBLESHOOTING..............................................................................................................................................187 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................................................188 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................................189 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE................................................................................................................190 CHECKS BEFORE TROUBLESHOOTING............................................................................................................................197 ELECTRICAL CIRCUIT DIAGRAM...............................................................................................................................198 POSITION OF CONNECTORS FOR TROUBLESHOOTING...............................................................................................................201 CONNECTION TABLE FOR CONNECTOR...........................................................................................................................203 HANDLING CONNECTORS......................................................................................................................................211 EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM.......................................................................................212 DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER.........................................................................215 ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE...............................................................................................219 METHOD OF USING JUDGEMENT TABLE..........................................................................................................................222 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................................224 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)............................................................................................226 ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS................................................................................................227 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM............................................................228 E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)..................................................................229 E-2 [SHORT CIRCUIT IN GOVERNOR MOTOR] IS DISPLAYED...................................................................................................231 E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED......................................................................................................232 E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED.................................................................................233 E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED.............................................................................................234 E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED..................................................................................................236 E-7 [ABNORMALITY IN NO.2 THROTTLE SIGNAL] IS DISPLAYED...............................................................................................237 E-8 ENGINE DOES NOT START............................................................................................................................239 E-9 ENGINE ROTATION IS IRREGULAR.....................................................................................................................241 a) IDLING ROTATION IS IRREGULAR..................................................................................................................241 b) THERE IS HUNTING..............................................................................................................................243 E-10 LACK OF OUTPUT POWER (MAX. ENGINE SPEED IS TOO LOW).............................................................................................245 E-11 ENGINE DOES NOT STOP............................................................................................................................247 E-12 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE.....................................................................................................249 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE).......................................................................................................250 CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS..............................................................251 C-1 [OFF] SELF-DIAGNOSTIC DISPLAY OF CONTROLLER DOES NOT LIGHT UP....................................................................................252 C-2 [01] [SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED.............................................................................253 C-3 [03] [SHORT CIRCUIT IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED...............................................................................254 C-4 [04] [SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED.................................................................................255 C-5 [05] [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED................................................................................256 C-6 [07] [SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED...................................................................................257 C-7 [08] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (1) ] IS DISPLAYED....................................................................................258 C-8 [09] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (2) ] IS DISPLAYED....................................................................................259 C-9 [11] [DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED.............................................................................260 C-10 [13] [DISCONNECTION IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED..............................................................................261 C-11 [14] [DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED................................................................................262 C-12 [15] [DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED...............................................................................263 C-13 [17] [DISCONNECTION IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED..................................................................................264 C-14 [18] [DISCONNECTION IN TVC SOLENOID SYSTEM] IS DISPLAYED........................................................................................265 C-15 [21] [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM] IS DISPLAYED..................................................................................266 C-16 [22] [ABNORMALITY IN THROTTLE SIGNAL SYSTEM] IS DISPLAYED.......................................................................................267 C-17 [23] [ABNORMALITY IN PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED...........................................................................268 C-18 [25] [ABNORMALITY IN PUMP PRESSURE SENSOR POWER SOURCE SYSTEM] IS DISPLAYED.....................................................................270 C-19 [26] [ABNORMALITY DISCONNECTION IN WIRING IN ENGINE SPEED SENSOR SYSTEM] IS DISPLAYED...........................................................271 C-20 [28] [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT SYSTEM] IS DISPLAYED.......................................................................272 C-21 [29] [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM] IS DISPLAYED.......................................................................................273 C-22 [88] [CONTROLLER ABNORMAL SYSTEM] IS DISPLAYED..................................................................................................274 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)..........................................................................................275 F-1 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P1] [WORK EQUIPMENT OIL PRESSURE SWITCH]...............................................................276 F-2 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P2] [SWING OIL PRESSURE SWITCH]........................................................................277 F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P6] [TRAVEL LIMIT SWITCH]..............................................................................278 F-4 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [b5] [SWING LOCK SWITCH]................................................................................279 F-5 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Hi] OR [Lo] [TRAVEL SPEED SWITCH]......................................................................280 F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Ad] [AUTO-DECELERATION SWITCH].........................................................................281 F-7 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [88] [DECIMAL POINT OF ENGINE SPEED SENSOR].............................................................282 F-8 PUMP CONTROLLER WORKING MODE DISPLAY DOES NOT SWITCH.............................................................................................283 F-9 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH................................................................................................284 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..............................................................................................285 H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW..............................................................................................286 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS........................................................................................288 H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW............................................................................290 H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER.....................................................................................................292 H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH.......................................................................................................292 H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)......................................................................................................293 H-7 AUTO-DECELERATION DOES NOT ACTUATED..............................................................................................................293 H-8 BOOM, ARM SPEED IS EXTREMELY SLOW................................................................................................................294 H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW.................................................................................................295 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER..................................................................................................297 H-11 EXCESSIVE HYDRAULIC DRIFT.......................................................................................................................297 H-12 EXCESSIVE TIME LAG..............................................................................................................................299 H-13 DOES NOT ENTER FINISHING OPERATION (F.O) MODE...................................................................................................299 H-14 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE....................................................................................300 a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE........................................................................................300 b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE........................................................................................302 H-15 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS..................................................................................................303 H-16 EXCESSIVE DEVIATION WHEN STARTING...............................................................................................................304 H-17 TRAVEL LACKS POWER (OR SPEED IS SLOW)...........................................................................................................306 H-18 TRAVEL SPEED DOES NOT SWITCH....................................................................................................................306 H-19 MACHINE DOES NOT MOVE (ONE SIDE ONLY)...........................................................................................................307 H-20 TRAVEL LEVER IS HEAVY...........................................................................................................................307 H-21 DOES NOT SWING..................................................................................................................................308 H-22 SWING SPEED IS SLOW OR ACCELERATION IS POOR.....................................................................................................310 H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING...........................................................................................................311 H-24 EXCESSIVE SHOCK WHEN STOPPING SWING.............................................................................................................311 H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....................................................................................................312 H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING..............................................................................................................312 H-27 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW......................................................................................312 TABLE OF FAILURE MODES AND CAUSES....................................................................................................................313 TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)...............................................................................................................314 P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON..............................................................315 a) NO MONITOR PANEL LAMPS LIGHT UP...............................................................................................................315 b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP......................................................................................................315 P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT............................................................316 P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS SPECIFIED)..................................317 a) COOLANT LEVEL FLASHES.........................................................................................................................317 b) ENGINE OIL LEVEL FLASHES......................................................................................................................318 P-4 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY LIGHTS UP...................................................................................319 P-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH.......................................................................320 a) ALTERNATOR SYSTEM.............................................................................................................................320 b) ENGINE OIL PRESSURE SYSTEM....................................................................................................................320 P-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH..........................................................................321 P-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE).............322 a) ENGINE OIL PRESSURE FLASHES...................................................................................................................322 b) COOLANT LEVEL FLASHES.........................................................................................................................322 c) COOLANT TEMPERATURE FLASHES...................................................................................................................323 d) CHARGE FLASHES................................................................................................................................323 e) FUEL LEVEL FLASHES............................................................................................................................324 P-8..................................................................................................................................................325 (a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND....325 (b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS........................................................................325 P-9 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL).............................................................326 P-10 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE............................................................................................327 P-11 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING OPERATION,ON LEVEL OF GAUGE IS DISPLAYED)....................................................327 P-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL...........................................................................................................328 P-13 FUEL GAUGE GIVES NO DISPLAY.....................................................................................................................328 P-14.................................................................................................................................................329 (a) LAMPS DO NOT LIGHT UP........................................................................................................................329 (b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NO OPERATED..........................................................................................329 P-15 ................................................................................................................................................331 (a) WIPERS DO NOT WORK...........................................................................................................................331 (b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED...........................................................................................331 P-16.................................................................................................................................................333 (a) FAN DOES NOT WORK............................................................................................................................333 (b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED...............................................................................................333 P-17 WORKING MODE DOES NOT SWITCH....................................................................................................................335 P-18 POWER SET DOES NOT SWITCH.......................................................................................................................336 P-19 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION; AUTO-DECELERATION IS NOT CANCELED).........................................337 P-20 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO..................................................................................................338 P-21 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 30℃, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30℃.................339 P-22 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP.............................................340 P-23 FUEL LEVEL SENSOR SYSTEM DEFECTIVE..............................................................................................................341 P-24 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE.....................................................................................................342 P-25 ENGINE OIL LEVEL SENSOR SYSTEM DEFECTIVE........................................................................................................343 P-26 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE...........................................................................................................344 30 DISASSEMBLY AND ASSEMBLY......................................................................................................................................345 METHOD OF USING MANUAL.......................................................................................................................................347 PRECAUTIONS WHEN CARRYING OUT OPERATION......................................................................................................................348 SPECIAL TOOL LIST............................................................................................................................................350 WEIGHT TABLE.................................................................................................................................................353 TIGHTENING TORQUES AND STANDARD VALUES TABLE.................................................................................................................354 LUBRICANT AND COOLANT TABLE..................................................................................................................................360 STARTING MOTOR...............................................................................................................................................361 REMOVAL..................................................................................................................................................361 INSTALLATION.............................................................................................................................................361 ALTERNATOR...................................................................................................................................................361 REMOVAL..................................................................................................................................................361 INSTALLATION.............................................................................................................................................361 ENGINE OIL COOLER............................................................................................................................................363 REMOVAL..................................................................................................................................................363 INSTALLATION.............................................................................................................................................363 FUEL INJECTION PUMP..........................................................................................................................................363 REMOVAL..................................................................................................................................................363 INSTALLATION.............................................................................................................................................363 WATER PUMP...................................................................................................................................................365 REMOVAL..................................................................................................................................................365 INSTALLATION.............................................................................................................................................365 NOZZLE HOLDER................................................................................................................................................365 REMOVAL..................................................................................................................................................365 INSTALLATION.............................................................................................................................................365 TURBOCHARGER.................................................................................................................................................367 REMOVAL..................................................................................................................................................367 INSTALLATION.............................................................................................................................................367 THERMOSTAT...................................................................................................................................................367 REMOVAL..................................................................................................................................................367 INSTALLATION.............................................................................................................................................367 ENGINE FRONT SEAL............................................................................................................................................369 REMOVAL..................................................................................................................................................369 INSTALLATION.............................................................................................................................................369 ENGINE REAR SEAL.............................................................................................................................................369 REMOVAL..................................................................................................................................................369 INSTALLATION.............................................................................................................................................369 GOVERNOR MOTOR...............................................................................................................................................371 REMOVAL..................................................................................................................................................371 INSTALLATION.............................................................................................................................................371 CYLINDER HEAD................................................................................................................................................373 REMOVAL..................................................................................................................................................373 INSTALLATION.............................................................................................................................................373 HYDRAULIC COOLER.............................................................................................................................................375 REMOVAL..................................................................................................................................................375 INSTALLATION.............................................................................................................................................375 RADIATOR, HYDRAULIC COOLER...................................................................................................................................375 REMOVAL..................................................................................................................................................375 INSTALLATION.............................................................................................................................................375 ENGINE, HYDRAULIC PUMP.......................................................................................................................................377 REMOVAL..................................................................................................................................................377 INSTALLATION.............................................................................................................................................377 PTO..........................................................................................................................................................379 REMOVAL..................................................................................................................................................379 INSTALLATION.............................................................................................................................................379 DISASSEMBLY..............................................................................................................................................379 ASSEMBLY.................................................................................................................................................379 CENTER SWIVEL JOINT..........................................................................................................................................381 REMOVAL..................................................................................................................................................381 INSTALLATION.............................................................................................................................................381 DISASSEMBLY..............................................................................................................................................381 ASSEMBLY.................................................................................................................................................381 FINAL DRIVE..................................................................................................................................................383 REMOVAL..................................................................................................................................................383 INSTALLATION.............................................................................................................................................383 DISASSEMBLY..............................................................................................................................................385 ASSEMBLY.................................................................................................................................................387 TRAVEL MOTOR (HMV110ADT).....................................................................................................................................393 DISASSEMBLY..............................................................................................................................................393 ASSEMBLY.................................................................................................................................................398 SPROCKET.....................................................................................................................................................408 REMOVAL..................................................................................................................................................408 INSTALLATION.............................................................................................................................................408 SWING MOTOR..................................................................................................................................................410 REMOVAL..................................................................................................................................................410 INSTALLATION.............................................................................................................................................410 SWING MACHINERY..............................................................................................................................................410 REMOVAL..................................................................................................................................................410 INSTALLATION.............................................................................................................................................410 SWING MOTOR (KMF90-2 (AB))...................................................................................................................................412 DISASSEMBLY..............................................................................................................................................412 ASSEMBLY.................................................................................................................................................415 SWING MACHINERY..............................................................................................................................................420 DISASSEMBLY..............................................................................................................................................420 ASSEMBLY.................................................................................................................................................422 REVOLVING FRAME..............................................................................................................................................426 REMOVAL..................................................................................................................................................426 INSTALLATION.............................................................................................................................................426 SWING CIRCLE.................................................................................................................................................426 REMOVAL..................................................................................................................................................426 INSTALLATION.............................................................................................................................................426 IDLER, RECOIL SPRING.........................................................................................................................................428 REMOVAL..................................................................................................................................................428 INSTALLATION.............................................................................................................................................428 RECOIL SPRING................................................................................................................................................430 DISASSEMBLY..............................................................................................................................................430 ASSEMBLY.................................................................................................................................................430 TRACK ROLLER.................................................................................................................................................432 REMOVAL..................................................................................................................................................432 INSTALLATION.............................................................................................................................................432 CARRIER ROLLER...............................................................................................................................................432 REMOVAL..................................................................................................................................................432 INSTALLATION.............................................................................................................................................432 TRACK SHOE...................................................................................................................................................434 REMOVAL..................................................................................................................................................434 INSTALLATION.............................................................................................................................................434 CHARGING PUMP................................................................................................................................................434 REMOVAL..................................................................................................................................................434 INSTALLATION.............................................................................................................................................434 MAIN PUMP INPUT SHAFT........................................................................................................................................436 REMOVAL..................................................................................................................................................436 INSTALLATION.............................................................................................................................................436 HYDRAULIC PUMP...............................................................................................................................................436 REMOVAL..................................................................................................................................................436 INSTALLATION.............................................................................................................................................436 DISASSEMBLY..............................................................................................................................................438 ASSEMBLY.................................................................................................................................................443 CONTROL VALVE................................................................................................................................................455 REMOVAL..................................................................................................................................................455 INSTALLATION.............................................................................................................................................455 DISASSEMBLY..............................................................................................................................................457 ASSEMBLY.................................................................................................................................................457 MAIN RELIEF VALVE............................................................................................................................................459 REMOVAL..................................................................................................................................................459 INSTALLATION.............................................................................................................................................459 DISASSEMBLY..............................................................................................................................................459 ASSEMBLY.................................................................................................................................................459 TVC VALVE....................................................................................................................................................461 REMOVAL..................................................................................................................................................461 INSTALLATION.............................................................................................................................................461 CO,NC VALVE..................................................................................................................................................461 REMOVAL..................................................................................................................................................461 INSTALLATION.............................................................................................................................................461 SERVO VALVE..................................................................................................................................................461 REMOVAL..................................................................................................................................................461 INSTALLATION.............................................................................................................................................461 WORK EQUIPMENT PPC VALVE.....................................................................................................................................463 REMOVAL..................................................................................................................................................463 INSTALLATION.............................................................................................................................................463 DISASSEMBLY..............................................................................................................................................463 ASSEMBLY.................................................................................................................................................463 PPC SHUTTLE VALVE............................................................................................................................................465 REMOVAL..................................................................................................................................................465 INSTALLATION.............................................................................................................................................465 BOOM HOLDING VALVE...........................................................................................................................................467 REMOVAL..................................................................................................................................................467 INSTALLATION.............................................................................................................................................467 DISASSEMBLY..............................................................................................................................................467 ASSEMBLY.................................................................................................................................................467 BOOM CYLINDER................................................................................................................................................469 REMOVAL..................................................................................................................................................469 INSTALLATION.............................................................................................................................................469 ARM CYLINDER.................................................................................................................................................471 REMOVAL..................................................................................................................................................471 INSTALLATION.............................................................................................................................................471 BUCKET CYLINDER..............................................................................................................................................473 REMOVAL..................................................................................................................................................473 INSTALLATION.............................................................................................................................................473 HYDRAULIC CYLINDER...........................................................................................................................................475 DISASSEMBLY..............................................................................................................................................475 ASSEMBLY.................................................................................................................................................477 WORK EQUIPMENT...............................................................................................................................................479 REMOVAL..................................................................................................................................................479 INSTALLATION.............................................................................................................................................479 BUCKET.......................................................................................................................................................481 REMOVAL..................................................................................................................................................481 INSTALLATION.............................................................................................................................................481 ARM..........................................................................................................................................................481 REMOVAL..................................................................................................................................................481 INSTALLATION.............................................................................................................................................481 ARM, BUCKET..................................................................................................................................................483 REMOVAL..................................................................................................................................................483 INSTALLATION.............................................................................................................................................483 BOOM.........................................................................................................................................................485 REMOVAL..................................................................................................................................................485 INSTALLATION.............................................................................................................................................485 OPERATOR'S CAB...............................................................................................................................................487 REMOVAL..................................................................................................................................................487 INSTALLATION.............................................................................................................................................487 COUNTERWEIGHT................................................................................................................................................487 REMOVAL..................................................................................................................................................487 INSTALLATION.............................................................................................................................................487 ENGINE THROTTLE CONTROLLER...................................................................................................................................489 REMOVAL..................................................................................................................................................489 INSTALLATION.............................................................................................................................................489 PUMP CONTROLLER..............................................................................................................................................489 REMOVAL..................................................................................................................................................489 INSTALLATION.............................................................................................................................................489 MONITOR PANEL................................................................................................................................................491 REMOVAL..................................................................................................................................................491 INSTALLATION.............................................................................................................................................491 40 MAINTENANCE STANDARD..........................................................................................................................................493 FINAL DRIVE..................................................................................................................................................494 SWING CIRCLE.................................................................................................................................................496 SWING MACHINERY..............................................................................................................................................497 TRACK FRAME..................................................................................................................................................498 IDLER........................................................................................................................................................499 TRACK ROLLER.................................................................................................................................................501 CARRIER ROLLER...............................................................................................................................................502 TRACK SHOE...................................................................................................................................................503 HYDRAULIC PUMP...............................................................................................................................................505 CHARGING PUMP AND RELIEF VALVE...............................................................................................................................506 L.H. 6-SPOOL CONTROL VALVE...................................................................................................................................507 R.H. 5-SPOOL CONTROL VALVE...................................................................................................................................510 SWING MOTOR..................................................................................................................................................513 CENTER SWIVEL JOINT..........................................................................................................................................514 TRAVEL MOTOR.................................................................................................................................................515 PPC VALVE....................................................................................................................................................516 BOOM HOLDING VALVE...........................................................................................................................................517 HYDRAULIC CYLINDER...........................................................................................................................................518 WORK EQUIPMENT...............................................................................................................................................519
PLEASE NOTE:
- This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
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- Require some other service manual or have any queries: please WRITE to us at [email protected]
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