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komatsu PC1800-6 Service Repair Manual – PDF Download
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- Komatsu PC1800-6 Service Repair Manual
- SERIAL NUMBER-10002 and up
- PUBLICATION NUMBER:SEBM019105
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Description
Komatsu PC1800-6 Service Repair Manual
KOMATSU PC1800-6 SERVICE REPAIR MANUAL – PDF DOWNLOAD:
SCREENSHOT OF THE MANUAL:
DESCRIPTION:
- komatsu PC1800-6 Service Repair Manual
- 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 PC1800-6 Service Repair Manual
MAIN MENU.................................................................................................................................... 0 COVER PAGE................................................................................................................................... 1 CONTENTS..................................................................................................................................... 2 00 FOREWARD.................................................................................................................................. 8 FOREWARD................................................................................................................................. 10 HOW TO READ THE SHOP MANUAL.............................................................................................................. 11 HOISTING INSTRUCTIONS.................................................................................................................... 12 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER............................................................................... 13 COATING MATERIALS........................................................................................................................ 15 STANDARD TIGHTENING TORQUE............................................................................................................... 17 ELECTRIC WIRE CODE....................................................................................................................... 20 CONVERSION TABLE......................................................................................................................... 21 UNITS.................................................................................................................................... 27 01 GENERAL.................................................................................................................................. 28 SPECIFICATION DRAWINGS................................................................................................................... 241 SPECIFICATIONS........................................................................................................................... 242 WEIGHT TABLE............................................................................................................................. 244 FUEL, COOLANT AND LUBRICANTS............................................................................................................. 246 10 STRUCTURE AND FUNCTION................................................................................................................... 248 PTO...................................................................................................................................... 249 PTO LUBRICATION SYSTEM................................................................................................................... 250 POWER TRAIN.............................................................................................................................. 251 SWING MACHINERY.......................................................................................................................... 253 FINAL DRIVE.............................................................................................................................. 254 HIC SYSTEM............................................................................................................................... 255 AIR SYSTEM............................................................................................................................... 257 AIR GOVERNOR............................................................................................................................. 258 AIR TANK................................................................................................................................. 258 AUTO-DRAIN VALVE......................................................................................................................... 258 SAFETY VALVE............................................................................................................................. 259 SOLENOID VALVE (FOR LUBRICATION, HORN)................................................................................................... 259 GREASE PUMP.............................................................................................................................. 260 GREASING SYSTEM.......................................................................................................................... 263 HYDRAULIC COMPONENT LAYOUT............................................................................................................... 270 HYDRAULIC TANK........................................................................................................................... 273 HYDRAULIC PUMP........................................................................................................................... 274 SWING PUMP............................................................................................................................... 301 LINE OIL FILTER.......................................................................................................................... 306 PILOT OIL FILTER......................................................................................................................... 306 RETURN OIL FILTER........................................................................................................................ 307 DRAIN OIL FILTER......................................................................................................................... 308 CONTROL AND PTO LUBRICATING PUMP......................................................................................................... 309 ELECTRONIC OLSS.......................................................................................................................... 310 CONTROL VALVE............................................................................................................................ 312 SWING CONTROL VALVE...................................................................................................................... 321 SWING MOTOR.............................................................................................................................. 323 CENTER SWIVEL JOINT...................................................................................................................... 325 TRAVEL MOTOR............................................................................................................................. 326 TRAVEL BRAKE VALVE....................................................................................................................... 328 PILOT RELIEF VALVE....................................................................................................................... 329 SAFETY LOCK VALVE........................................................................................................................ 330 ACCUMULATOR.............................................................................................................................. 332 PPC VALVE................................................................................................................................ 333 SOLENOID VALVE........................................................................................................................... 337 ENGINE CONTROL........................................................................................................................... 339 MACHINE CONTROL SYSTEM................................................................................................................... 346 ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM......................................................................... 369 MONITOR SYSTEM........................................................................................................................... 375 20 TESTING AND ADJUSTING..................................................................................................................... 413 STANDARD VALUE TABLE FOR ENGINE.......................................................................................................... 414 STANDARD VALUE TABLE FOR CHASSIS......................................................................................................... 415 STANDARD VALUE FOR ELECTRICAL PARTS...................................................................................................... 423 TESTING AND ADJUSTING.................................................................................................................... 431 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.................................................................................... 432 MEASURING ENGINE SPEED............................................................................................................... 433 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....................................................................................... 434 MEASURING EXHAUST TEMPERATURE........................................................................................................ 435 MEASURING EXHAUST COLOR.............................................................................................................. 436 ADJUSTING VALVE CLEARANCE............................................................................................................ 437 MEASURING COMPRESSION PRESSURE....................................................................................................... 438 MEASURING BLOW-BY PRESSURE........................................................................................................... 439 TESTING AND ADJUSTING FUEL INJECTION TIMING.......................................................................................... 440 MEASURING ENGINE OIL PRESSURE........................................................................................................ 441 TESTING AND ADJUSTING ALTERNATOR BELT TENSION........................................................................................ 442 TESTING AND ADJUSTING FAN BELT TENSION............................................................................................... 442 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.................................................................... 443 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE.................................................................................... 444 ADJUSTING ENGINE SPEED SENSOR........................................................................................................ 445 TESTING AND ADJUSTING MAIN RELIEF VALVE.............................................................................................. 446 TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE....................................................................................... 451 MEASURING SERVO PISTON STROKE........................................................................................................ 455 TESTING SOLENOID VALVE OUTPUT PRESSURE............................................................................................... 456 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE............................................................................................ 457 TESTING TRAVEL DEVIATION............................................................................................................. 458 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.......................................................................... 461 MEASURING OIL LEAKAGE................................................................................................................ 462 MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR.................................................................................... 464 TESTING OIL LEAK FROM SWIVEL JOINT................................................................................................... 465 TESTING CLEARANCE OF SWING CIRCLE BEARING............................................................................................ 467 AIR BLEEDING......................................................................................................................... 468 CHARGING ACCUMULATOR WITH GAS........................................................................................................ 473 TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK..................................................................................... 475 ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)............................................................................. 476 TROUBLESHOOTING.......................................................................................................................... 482 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................. 483 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................ 484 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................................... 485 CHECKS BEFORE TROUBLESHOOTING........................................................................................................ 493 CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................................................... 494 CONNECTOR ARRANGEMENT DIAGRAM........................................................................................................ 499 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................................... 505 EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM.................................................................. 516 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL................................................................................ 517 TROUBLE HISTORY DISPLAY ON MACHINE CONTROL MONITOR................................................................................... 530 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE............................................................................. 537 METHOD OF USING JUDGEMENT TABLE...................................................................................................... 542 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................... 544 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)......................................................................... 546 CONTROLLER RESPONSES AND SYMPTOMS ON MACHINE BODY IN FAILURE OCCURRENCES......................................................... 547 N-1 [CONCURRENT OCCURENCES OF E116, E117, AND E118] COMMUNICATIONS FAILURE ON MONITOR PANEL..................................... 549 N-2 [CONCURRENT OCCURENCES OF E117 AND E218] COMMUNICATIONS FAILURE ON REAR ENGINE GP CONTROLLER................................ 551 N-3 [CONCURRENT OCCURRENCES OF E118 AND E418] COMMUNICATIONS FAILURE ON FRONT ENGINE GP CONTROLLER.............................. 553 N-4 [CONCURRENT OCCURENCES OF E116, E218 AND E418] COMMUNICATIONS FAILURE ON VHMS CONTROLLER.................................... 555 N-5 [E828] NO DISPLAY [OF E116, E117, E118, E218, OR E418] ON MONITOR PANEL, WITH CODE DISPLAYED ONLY ON CGC................... 557 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM (GOVERNOR CONTROL SYSTEM) (E MODE)..................................... 558 JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS....................... 559 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLEHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM................................ 563 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS...................................................... 564 ELECTRICAL CIRCUIT DIAGRAM OF ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)...................................... 572 E-1 POWER SYSTEM ABNORMALITY OF FRONT ENGINE THROTTLE AND PUMP CONTROLLER....................................................... 574 E-2 [E308] ABNORMALITY IN FRONT ENGINE CONTROL DIAL INPUT VALUE IS DISPLAYED................................................... 575 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED...................................................... 576 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN FRONT ENGINE GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED ................................ 577 E-5 [E306] ABNORMALITY IN FRONT ENGINE FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED................................................ 578 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN FRONT ENGINE BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED.................................. 579 E-7 [E316] ABNORMALITY (STEP-OUT) IN FRONT ENGINE MOTOR IS DISPLAYED............................................................. 580 E-8 THE FRONT ENGINE DOES NOT START............................................................................................. 581 E-9 FRONT ENGINE IRREGULAR ROTATION............................................................................................. 584 a) IRREGULAR IDLING SPEED................................................................................................... 584 b) HUNTING.................................................................................................................. 586 E-10 FRONT ENGINE INSUFFICIENT OUTPUT............................................................................................ 588 E-11 THE FRONT ENGINE DOES NOT STOP.............................................................................................. 590 E-12 DEFECTIVE OPERATION OF FRONT ENGINE BATTERY RELAY SYSTEM.................................................................... 592 E-13 POWER SYSTEM ABNORMALITY OF REAR ENGINE THROTTLE AND PUMP CONTROLLER........................................................ 594 E-14 [E508] ABNORMALITY IN REAR ENGINE FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED................................................ 595 E-15 [E517] ABNORMALITY (DISCONNECTION) IN REAR ENGINE MOTOR DRIVE SYSTEM IS DISPLAYED........................................... 596 E-16 [E518] ABNORMALITY (SHORT CIRCUIT) IN REAR ENGINE MOTOR DRIVE SYSTEM IS DISPLAYED........................................... 597 E-17 [E506] ABNORMALITY IN REAR ENGINE FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED................................................ 598 E-18 [E515] ABNORMALITY (SHORT CIRCUIT) IN REAR ENGINE BATTERY RELAY OUTPUT SYTEM IS DISPLAYED................................... 599 E-19 [E516] ABNORMALITY (STEP-OUT) IN FRONT ENGINE MOTOR IS DISPLAYED............................................................ 600 E-20 THE REAR ENGINE DOES NOT START.............................................................................................. 601 E-21 REAR ENGINE IRREGULAR ROTATION.............................................................................................. 604 a) IRREGULAR IDLING SPEED.................................................................................................... 604 b) HUNTING................................................................................................................... 606 E-22 REAR ENGINE INSUFFICIENT OUTPUT............................................................................................. 608 E-23 THE REAR ENGINE DOES NOT STOP............................................................................................... 610 E-24 DEFECTIVE OPERATION OF REAR ENGINE BATTERY RELAY SYSTEM..................................................................... 612 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM (PUMP CONTROL SYSTEM) (C MODE)......................................... 614 JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER AND HYDRAULIC RELATED PARTS.............................................. 615 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM................................................................... 618 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................... 619 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE............................................................................................ 625 C-1 DISPLAY OF ABNORMALITY OF FRONT ENGINE CONTROLLER POWER SUPPLY SYSTEM........................................................ 627 C-2 DISPLAY OF [E232] SHORT CIRCUIT OF FRONT PUMP TVC SOLENOID SYSTEM............................................................ 628 C-3 DISPLAY OF [E233] DISCONNECTION OF FRONT PUMP TVC SOLENOID SYSTEM............................................................ 630 C-4 DISPLAY OF [E203] SHORT CIRCUIT OF SWING HOLD BRAKE SOLENOID SYSTEM.......................................................... 632 C-5 DISPLAY OF [E213] DISCONNECTION OF SWING HOLD BRAKE SOLENOID SYSTEM.......................................................... 634 C-6 DISPLAY OF [E201] SHORT CIRCUIT OF CO CANCEL SOLENOID SYSTEM................................................................. 636 C-7 DISPLAY OF [E211] DISCONNECTION OF CO CANCEL SOLENOID SYSTEM................................................................. 637 C-8 DISPLAY OF [E202] SHORT CIRCUIT OF TRAVEL STRAIGHT SOLENOID SYSTEM.......................................................... 638 C-9 DISPLAY OF [E212] DISCONNECTION OF TRAVEL STRAIGHT SOLENOID SYSTEM........................................................... 639 C-10 DISPLAY OF [E204] SHORT CIRCUIT OF 2-STAGE RELIEF SOLENOID SYSTEM........................................................... 640 C-11 DISPLAY OF [E214] DISCONNECTION OF 2-STAGE RELIEF SOLENOID SYSTEM........................................................... 641 C-12 DISPLAY OF [E206] SHORT CIRCUIT OF TRAVEL ALARM OUTPUT SYSTEM............................................................... 642 C-13 DISPLAY OF [E216] DISCONNECTION OF TRAVEL ALARM OUPUT SYSTEM................................................................ 643 C-14 DISPLAY OF [E217] FRONT ENGINE CONTROLLER MODEL SELECTION INPUT ERROR....................................................... 644 C-15 DISPLAY OF [E227] ABNORMALITY OF FRONT ENGINE SPEED SENSOR SYSTEM........................................................... 646 C-16 DISPLAY OF ABNORMALITY OF MACHINE PUSHUP SOLENOID SYSTEM ( WITH NO DISPLAY OF SERVICE CODE)................................. 647 C-17 DISPLAY OF ABNORMALITY OF BOOM SHOCKLESS SOLENOID SYSTEM (WITH NO DISPLAY OF SERVICE CODE).................................. 649 C-18 DISPLAY OF [E221] ABNORMALITY OF GEAR PUMP PRESSURE SENSOR SYSTEM........................................................... 652 C-19 DISPLAY OF [E225] ABNORMALITY OF FRONT ENGINE OIL PRESSURE SENSOR SYSTEM.................................................... 653 C-20 DISPLAY OF [E226] ABNORMALITY OF FRONT ENGINE SENSOR POWER SUPPLY SYSTEM.................................................... 654 C-21 DISPLAY OF [E228] ABNORMALITY OF AUTO-DECEL OUTPUT SYSTEM................................................................... 655 C-22 DISPLAY OF ABNORMALITY OF REAR ENGINE CONTROLLER POWER SUPPLY SYSTEM........................................................ 656 C-23 DISPLAY OF [E-432] SHORT CIRCUIT OF REAR PUMP TVC SOLENOID SYSTEM........................................................... 657 C-24 DISPLAY OF [E433] DISCONNECTION OF REAR PUMP TVC SOLENOID SYSTEM............................................................ 659 C-25 DISPLAY OF [E417] REAR ENGINE CONTROLLER MODEL SELECTION INPUT ERROR........................................................ 661 C-26 DISPLAY OF [E427] ABNORMALITY OF REAR ENGINE SPEED SENSOR SYSTEM............................................................ 663 C-27 DISPLAY OF [E425] ABNORMALITY OF REAR ENGINE OIL PRESSURE SENSOR SYSTEM..................................................... 664 C-28 DISPLAY OF [E426] ABNORMALITY OF REAR ENGINE SENSOR POWER SUPPLY SYSTEM..................................................... 665 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTOLLER (INMPUT SIGNAL) SYSTEM (F MODE)................................................ 666 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE............................................................................................ 667 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP............................................................... 669 F-2 BIT PATTERN 20-(2) R.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................... 670 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP.......................................................... 671 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP.......................................................... 672 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................. 673 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP............................................................. 674 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................... 675 F-8 BIT PATTERN 21-(2) BUCKET DUMP, SERVICE OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................ 676 F-9 BIT PATTERN 21-(5) L.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................... 677 F-10 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP...................................................................... 678 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE).............................................................................. 679 TABLE OF FAILURE MODES AND CAUSES................................................................................................ 680 BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)................................................................. 682 ALL WORK EQUIPMENT, TRAVEL, SWING................................................................................................ 685 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER....................................................... 685 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS................................................................ 686 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE.................................................................................... 688 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)................................................................................... 690 H-5 AUTO-DECELERATION DOES NOT WORK ......................................................................................... 690 WORK EQUIPMENT................................................................................................................... 691 H-6 WORK EQUIPMENT SPEED IS SLOW (BOOM, ARM, BUCKET)......................................................................... 691 H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)....................................... 692 H-8 EXCESSIVE HYDRAULIC DRIFT................................................................................................ 692 H-9 EXCESSIVE TIME LAG....................................................................................................... 693 H-10 EXCESSIVE SHOCK WHEN BOOM IS STOPPED (WHEN SHOCKLESS SWITCH IS ON)...................................................... 693 H-11 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION......................................................................... 693 H-12 BOOM RAISE SPEED IS SLOW OR LACKS POWER WHEN HEAVY LIFT SWITCH IS ON ................................................... 694 TRAVEL SYSTEM.................................................................................................................... 695 H-13 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS................................................................ 695 H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS......................................................... 696 H-15 DEVIATION IS EXCESSIVE WHEN STARTING.................................................................................... 699 H-16 TRAVEL SPEED IS SLOW.................................................................................................... 701 H-17 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).................................................................................... 701 SWING SYSTEM..................................................................................................................... 702 H-18 DOES NOT SWING.......................................................................................................... 702 H-19 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR....................................................................... 703 H-20 EXCESSIVE OVERRUN WHEN STOPPING SWING................................................................................... 704 H-21 EXCESSIVE SHOCK WHEN STOPPING SWING..................................................................................... 705 H-22 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING............................................................................ 705 H-23 EXCESSIVE HYDRAULIC DRIFT OF SWING...................................................................................... 706 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)................................................................................... 707 MONITOR PANEL INDICATIONS AND SYMPTOMS FOUND ON MACHINE IN FAILURE............................................................... 708 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM..................................................................................... 710 TROUBLESHOOTING FLOWCHART FOR EACH FAILURE MODE.................................................................................. 712 M-1 [E101] ERROR HISTORY DATA ERROR.............................................................................................. 712 [E102] CLOCK DATA ERROR...................................................................................................... 712 M-2 [E103] SHORT CIRCUIT IN THE BUZZER OUTPUT CIRCUIT............................................................................ 713 M-3 [E104] DETECTION OF CLOGGED FRONT ENGINE AIR CLEANER......................................................................... 714 M-4 [E105] DETECTION OF CLOGGED REAR ENGINE AIR CLEANER.......................................................................... 714 M-5 [E108] DETECTION OF FRONT ENGINE WATER TEMPERATURE OF 105°C................................................................. 715 M-6 [E111] DETECTION OF REAR ENGINE WATER TEMPERATURE OF 105°C .................................................................. 715 M-7 [115] DETECTION OF HYDRAULIC OIL TEMPERATURE OF 100°C ....................................................................... 715 M-8 THE LAMPS ON THE MONITOR PANEL FAILED TO COME ON FOR THREE SECONDS WHEN THE STARTING SWITCH WAS TURNED ON.................... 716 M-9 THE LAMPS ON THE MONITOR PANEL COME ON WHEN THE STARTING SWITCH IS TURNED ON, BUT DO NOT GO OFF.............................. 718 M-10 THE LAMP FOR A DIFFERENT MACHINE BODY (MODEL) COMES ON WHEN THE STARTING SWITCH IS TRUNED ON............................... 718 M-11 THE BASIC CHECK ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON .......................................................... 719 M-12 THE "ENGINE PRE-HEATING MONITOR" TURNS ON THOUGH PRE-HEATING OPERATION IS NOT PERFORMED..................................... 724 M-13 THE BASIC CHECK ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON AND THE ENGINE IS STARTED................................. 725 M-14 THE CAUTION AND EMERGENCY STOP ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON (THE ENGINE IS STOPPED), BUT THE BATTER.... 729 M-15 THE CAUTION AND EMERGENCY STOP ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON AND THE ENGINE IS STARTED, BUT NO ABNO.... 733 M-16 THE BUZZER DOES NOT SOUND FOR ONE SECOND WHEN THE STARTING SWITCH IS TURNED ON (THE ENGINE IS STOPPED). THE BUZZER DOES.... 741 M-17 THE BUZZER SOUNDS THOUGH THE MONITOR DISPLAYS NO FAILURE.................................................................... 741 M-18 THE NIGHTLIGHT ON THE MONITOR PANEL DOES NOT COME ON (THE LCD WORKS NORMAL)................................................. 742 M-19 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE HIGHER TEMPERTURES.......................................................... 743 M-20 THE COOLANT TEMPERATURE GAUGE DISPLAYS NOT A SINGLE LEVEL DURING OPERATION.................................................. 745 M-21 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE HIGHER TEMPERATURES................................................... 747 M-22 THE HYDRAULIC OIL TEMPERATURE GAUGE DISPLAYS NOT A SINGLE LEVEL DURING OPERATION............................................ 747 M-23 THE FUEL LEVEL GAUGE ALWAYS INDICATES FULL.................................................................................. 748 M-24 THE FUEL LEVEL GAUGE DISPLAYS NOTHING....................................................................................... 748 M-25 THE "SWING LOCK MONITOR" DOES NOT COME ON THOUGH THE SWING LOCK SWITCH IS TURNED ON (LOCK).................................. 749 M-26 EMERGENCY SWING SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH......................................... 749 M-27 THE SERVICE METER DOES NOT WORK WHILE THE ENGINE IS IN OPERATION. THE CLOCK IS NOT DISPLAYED THOUGH THE STARTING SWITCH.... 750 M-28 THE SERVICE METER DOES NOT WORK THOUGH THE CLOCK SWITCH IS PRESSED WITH THE STARTING SWITCH TURNED OFF...................... 750 M-29 DEFECTIVE FUEL LEVEL SENSOR................................................................................................. 751 M-30 DEFECTIVE TEMPERATURE SENSOR (ENGINE WATER TEMPERATURE, ENGINE OIL TEMPERATURE, PTO OIL TEMPERATURE, AND HYDRAULIC OIL T.... 752 M-31 DEFECTIVE ENGINE OIL LEVEL SENSOR........................................................................................... 753 M-32 DEFECTIVE COOLANT LEVEL SENSOR.............................................................................................. 754 M-33 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR........................................................................................ 755 TROUBLESHOOTING OF MACHINE CONTROL SYSTEM (V MODE)................................................................................... 756 CODES DISPLAYED IN FAILURE OCCURRENCES AND DESCRIPTIONS.......................................................................... 758 LIST OF WARNING ITEMS DISPLAYED ON CGC MONITOR................................................................................... 768 V MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM......................................................................................... 772 TROUBLESHOOTING BY FAILURE MODE.................................................................................................. 774 V-1 [E811] FAILURE IN VHMS CONTROLLER POWER SUPPLY SYSTEM........................................................................ 774 V-2 [E812] FAILURE ON VHMS SENSORE POWER SUPPLY (24 V)........................................................................... 775 V-3 [E813] FAILURE ON VHMS SENSOR POWER SUPPLY (12 V)........................................................................... 776 V-4 [E814] FAILURE ON VHMS SENSOR POWER SUPPLY (5 V)............................................................................. 777 V-5 [E817] VHMS MODEL SELECTION INPUT ERROR...................................................................................... 778 V-6 [E818] VHMS CONNECTORS CONNECTION ERROR...................................................................................... 779 V-7 [E821] VHMS FIRM SYSTEM FAILURE.............................................................................................. 780 V-8 [E828] DISCONNECTION ON S-NET BETWEEN VHMS AND MAIN MONITOR.................................................................. 780 V-9 [E831] VHMS APPLICATION SYSTEM FAILURE...................................................................................... 780 [E832] VHMS LANGUAGE FAILURE................................................................................................. 780 V-10 [E857] FAILURE IN FRONT ENGINE SPEED SENSOR SYSTEM.......................................................................... 781 V-11 [E858] FAILURE IN REAR ENGINE SPEED SENSOR SYSTEM........................................................................... 782 V-12 [E861] FAILURE IN FRONT ENGINE OIL TEMPERATURE SENSOR SYSTEM................................................................ 783 V-13 [E862] FAILURE IN REAR ENGINE OIL TEMPERATURE SENSOR SYSTEM ................................................................ 784 V-14 [E863] FAILURE IN FRONT PTO OIL TEMPERATURE SENSOR SYSTEM................................................................... 785 V-15 [E864] FAILURE IN REAR PTO OIL TEMPERATURE SENSOR SYSTEM.................................................................... 786 V-16 [E865] FAILURE IN NOS. 1& 2 FRONT PUMPS PRESSURE SENSOR SYSTEM.............................................................. 787 V-17 [E866] FAILURE IN NOS. 1 & 2 REAR PUMPS PRESSURE SENSOR SYSTEM............................................................. 788 V-18 [E867] FAILURE IN NOS. 3 & 4 FRONT PUMPS PRESSURE SENSOR SYSTEM............................................................. 789 V-19 [E868] FAILURE IN NOS. 3 & 4 REAR BUMPS PRESSURE SENSOR SYSTEM.............................................................. 790 V-20 [E871] FAILURE IN FRONT ENGINE WATER TEMPERATURE SENSOR SYSTEM.............................................................. 791 V-21 [E872] FAILURE IN REAR ENGINE WATER TEMPERATURE SENSOR SYSTEM............................................................... 791 V-22 [E873] FAILURE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM................................................................... 792 V-23 [E876] ABNORMAL FRONT ENGINE EXHAUST TEMPERATURE SENSOR SYSTEM.............................................................. 793 V-24 THE VALUE DISPLAYED ON THE FRONT ENGINE EXHAUST TEMPERATURE REAL-TIME MONITOR DOES NOT CORRESPOND WHEN THE TEMPERATURE R.... 794 V-25 [E877] ABNORMAL REAR ENGINE EXHAUST TEMPERATURE SENSOR SYSTEM............................................................... 795 V-26 THE VALUE DISPLAYED ON THE REAR ENGINE EXHAUST TEMPERATURE REAL-TIME MONITOR DOES NOT CORRESPOND WHEN THE TEMPERATURE RI.... 796 V-27 [E878] FAILURE IN SWING PUMP PRESSURE SENSOR SYSTEM......................................................................... 797 V-28 ABNORMAL ENGINE OIL TEMPERATURE............................................................................................. 798 V-29 [E881] DISPLAY INDICATES DETECTION OF THE FRONT ENGINE OIL TEMPERATURE AT 125°C ............................................ 800 [E882] DISPLAY INDICATES DETECTION OF THE REAR ENGINE OIL TEMPERATURE AT 125°C .............................................. 800 V-30 [E883] FRONT ENGINE OIL PRESSURE DROP....................................................................................... 801 V-31 [E884] REAR ENGINE OIL PRESSURE DROP........................................................................................ 801 V-32 ABNORMAL PTO OIL TEMPERATURE................................................................................................ 802 V-33 [E885] DISPLAY INDICATES DETECTION OF THE FRONT ENGINE PTO OIL TEMPERATURE AT 125°C......................................... 804 [E886] DISPLAY INDICATES DETECTION OF THE REAR ENGINE PTO OIL TEMPERATURE AT 125°C .......................................... 804 V-34 ABNORMAL GEAR PUMP PRESSURE IS DISPLAYED.................................................................................... 805 V-35 [E887] ABNORMAL GEAR PUMP PRESSURE IS DISPLAYED............................................................................. 805 V-36 [E888] EXCESSIVE EXHAUST GAS TEMPERATURE OF FRONT ENGINE ................................................................... 806 V-37 [E898] EXCESSIVE EXHAUST GAS TEMPERATURE OF REAR ENGINE..................................................................... 806 V-38 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 FRONT PUMPS.......................................................... 807 V-39 [E891] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 & 2 FRONT PUMPS.................................................... 807 V-40 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 REAR PUMPS........................................................... 808 V-41 [E892] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 REAR PUMPS.................................................... 808 V-42 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 FRONT PUMPS.......................................................... 809 V-43 [E893] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 FRONT PUMPS.................................................. 809 V-44 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 REAR PUMPS........................................................... 810 V-45 [E894] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 REAR PUMPS.................................................... 810 V-46 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR THE SWING PUMP.................................................................... 811 V-47 [E895] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR THE SWING PUMP............................................................. 811 V-48 FAILURE IN GEAR PUMP PRESSURE SENSOR SYSTEM................................................................................. 812 V-49 FAILURE IN PRESSURE SENSOR SYSTEM FOR NOS. 1,2,3, & 4 PUMPS AND SWING PUMP.................................................. 813 TROUBLESHOOTING OF BOTTOM CYLINDER CONTROL SYSTEM (LE, LH MODE) [LOADING SHOVEL SPECIFICATION]....................................... 814 LE-1 DEFECTIVE OPERATION OF BOTTOM CYLINDER...................................................................................... 815 A) BOTTOM CLOSING SIDE....................................................................................................... 815 B) BOTTOM OPENING SIDE....................................................................................................... 815 LH-1 DEFECTIVE OPERATION OF BOTTOM CYLINDER...................................................................................... 817 TROUBLESHOOTING OF WORK EQUIPMENT AUTOMATIC CONTROL SYSTEM (W, L MODE) [LOADING SHOVEL SPECIFICATION]................................ 818 ABNORMALITY JUDGEMENT STANDARDS FOR SELF-DIAGNOSTIC SYSTEM....................................................................... 819 TROUBLESHOOTING.................................................................................................................. 820 W-1 IN ARC DIGGING MODE (AUTO LEVEL DIGGING SWITCH OFF), HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IS CARRIED OUT.......... 823 W-2 IN HORIZONTAL DIGGING MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING............................................................ 824 A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"................................................................. 824 B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"................................................................... 828 W-3 IN HORIZONTAL DIGGING MODE (BUCKET ANGLE REVISE SWITCH OFF), BUCKET ANGLE COMPENSATION IS CARRIED OUT........................ 829 W-4 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGL.... 830 A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"................................................................. 830 B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"................................................................... 831 W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORI.... 833 A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"................................................................. 833 B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"................................................................... 833 W-6 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATIO MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION.... 834 A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"................................................................. 834 L-1 IMPOSSIBLE TO CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION...................................................... 838 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................. 839 METHOD OF USING MANUAL................................................................................................................... 841 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................. 843 SPECIAL TOOL LIST........................................................................................................................ 845 FUEL INJECTION PUMP ASSEMBLY............................................................................................................. 850 REMOVAL AND INSTALLATION............................................................................................................. 850 NOZZLE HOLDER ASSEMBLY................................................................................................................... 851 REMOVAL.............................................................................................................................. 851 INSTALLATION......................................................................................................................... 852 TURBOCHARGER ASSEMBLY.................................................................................................................... 853 REMOVAL AND INSTALLATION............................................................................................................. 853 CYLINDER HEAD ASSEMBLY................................................................................................................... 854 REMOVAL.............................................................................................................................. 854 INSTALLATION......................................................................................................................... 858 HYDRAULIC COOLER, AFTERCOOLER ASSEMBLY................................................................................................... 861 REMOVAL AND INSTALLATION............................................................................................................. 861 FAN GUARD, RADIATOR, HYDRAULIC COOLER ASSEMBLY........................................................................................... 862 REMOVAL.............................................................................................................................. 862 INSTALLATION......................................................................................................................... 863 AFTERCOOLER CORE......................................................................................................................... 864 REMOVAL AND INSTALLATION............................................................................................................. 864 ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY..................................................................................................... 865 REMOVAL.............................................................................................................................. 865 INSTALLATION......................................................................................................................... 869 PTO ASSEMBLY............................................................................................................................. 870 REMOVAL.............................................................................................................................. 870 INSTALLATION......................................................................................................................... 873 DISASSEMBLY.......................................................................................................................... 874 ASSEMBLY............................................................................................................................. 875 CENTER SWIVEL JOINT ASSEMBLY............................................................................................................. 878 REMOVAL AND INSTALLATION............................................................................................................. 878 DISASSEMBLY AND ASSEMBLY............................................................................................................. 879 TRAVEL MOTOR ASSEMBLY.................................................................................................................... 880 REMOVAL AND INSTALLATION............................................................................................................. 880 TRAVEL MOTOR BRAKE VALVE ASSEMBLY........................................................................................................ 881 REMOVAL AND INSTALLATION............................................................................................................. 881 TRAVEL MOTOR ASSEMBLY.................................................................................................................... 882 DISASSEMBLY.......................................................................................................................... 882 ASSEMBLY............................................................................................................................. 886 FINAL DRIVE ASSEMBLY..................................................................................................................... 892 DISASSEMBLY.......................................................................................................................... 892 ASSEMBLY............................................................................................................................. 896 SWING MOTOR ASSEMBLY..................................................................................................................... 903 REMOVAL AND INSTALLATION............................................................................................................. 903 DISASSEMBLY.......................................................................................................................... 904 ASSEMBLY............................................................................................................................. 907 REVOLVING FRAME ASSEMBLY................................................................................................................. 912 REMOVAL AND INSTALLATION............................................................................................................. 912 SWING CIRCLE ASSEMBLY.................................................................................................................... 913 REMOVAL AND INSTALLATION............................................................................................................. 913 SWING MACHINERY ASSEMBLY................................................................................................................. 914 REMOVAL AND INSTALLATION............................................................................................................. 914 DISASSEMBLY ......................................................................................................................... 915 ASSEMBLY............................................................................................................................. 920 IDLER CUSHION CYLINDER ASSEMBLY.......................................................................................................... 925 REMOVAL AND INSTALLATION............................................................................................................. 925 DISASSEMBLY AND ASSEMBLY............................................................................................................. 926 IDLER ADJUSTMENT CYLINDER ASSEMBLY....................................................................................................... 927 DISASSEMBLY AND ASSEMBLY............................................................................................................. 927 TRACK ROLLER ASSEMBLY.................................................................................................................... 928 REMOVAL AND INSTALLATION............................................................................................................. 928 CARRIER ROLLER ASSEMBLY.................................................................................................................. 929 REMOVAL AND INSTALLATION............................................................................................................. 929 TRACK SHOE ASSEMBLY...................................................................................................................... 930 REMOVAL.............................................................................................................................. 930 INSTALLLATION........................................................................................................................ 931 CONTROL, PTO LUBRICATION PUMP ASSEMBLY................................................................................................... 932 REMOVAL AND INSTALLATION............................................................................................................. 932 SWING PUMP ASSEMBLY...................................................................................................................... 933 REMOVAL AND INSTALLATION............................................................................................................. 933 DISASSEMBLY.......................................................................................................................... 934 ASSEMBLY............................................................................................................................. 941 NO. 1, 3 PUMP ASSEMBLY................................................................................................................... 953 REMOVAL AND INSTALLATION............................................................................................................. 953 NO. 2, 4 PUMP ASSEMBLY................................................................................................................... 954 REMOVAL.............................................................................................................................. 954 INSTALLATION......................................................................................................................... 955 HYDAULIC PUMP ASSEMBLY................................................................................................................... 956 DISASSEMBLY.......................................................................................................................... 956 ASSEMBLY............................................................................................................................. 966 PILOT RELIEF VALVE ASSEMBLY.............................................................................................................. 981 REMOVAL AND INSTALLATION............................................................................................................. 981 DISASSEMBLY AND ASSEMBLY............................................................................................................. 982 MAIN RELIEF VALVE ASSEMBLY (FOR SWING)................................................................................................... 983 DISASSEMBLY AND ASSEMBLY............................................................................................................. 983 MAIN RELIEF VALVE ASSEMBLY (FOR WORK EQUIPMENT, TRAVEL).................................................................................. 984 DISASSEMBLY AND ASSEMBLY............................................................................................................. 984 SWING CONTROL VALVE ASSEMBLY............................................................................................................. 985 REMOVAL AND INSTALLATION............................................................................................................. 985 DISASSEMBLY AND ASSEMBLY............................................................................................................. 986 V1, V3 CONTROL VALVE ASSEMBLY............................................................................................................ 988 REMOVAL AND INSTALLATION............................................................................................................. 988 V2, V4 CONTROL VALVE ASSEMBLY............................................................................................................ 989 REMOVAL AND INSTALLATION............................................................................................................. 989 CONTROL VALVE ASSEMBLY................................................................................................................... 990 DISASSEMBLY.......................................................................................................................... 990 ASSEMBLY............................................................................................................................. 992 CO, NC VALVE ASSEMBLY.................................................................................................................... 994 REMOVAL AND INSTALLATION............................................................................................................. 994 SERVO VALVE ASSEMBLY..................................................................................................................... 995 REMOVAL AND INSTALLATION............................................................................................................. 995 TVC VALVE ASSEMBLY....................................................................................................................... 996 REMOVAL AND INSTALLATION............................................................................................................. 996 PPC VALVE ASSEMBLY (FOR TRAVEL).......................................................................................................... 997 REMOVAL AND INSTALLATION............................................................................................................. 997 DISASSEMBLY AND ASSEMBLY............................................................................................................. 998 PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)........................................................................................... 999 REMOVAL AND INSTALLATION0............................................................................................................ 999 DISASSEMBLY AND ASSEMBLY.............................................................................................................1000 BOOM CYLINDER ASSEMBLY (BACKHOE).........................................................................................................1001 BACK HOE.............................................................................................................................1001 REMOVAL..........................................................................................................................1001 INSTALLATION.....................................................................................................................1002 LOADING SHOVEL.......................................................................................................................1003 REMOVAL..........................................................................................................................1003 INSTALLATION.....................................................................................................................1004 ARM CYLINDER ASSEMBLY ...................................................................................................................1005 (BACK HOE)...........................................................................................................................1005 REMOVAL..........................................................................................................................1005 INSTALLATION.....................................................................................................................1006 (LOADING SHOVEL).....................................................................................................................1007 REMOVAL..........................................................................................................................1007 INSTALLATION.....................................................................................................................1008 BUCKET CYLINDER ASSEMBLY ................................................................................................................1009 (BACK HOE)...........................................................................................................................1009 REMOVAL..........................................................................................................................1009 INSTALLATION.....................................................................................................................1010 (LOADING SHOVEL).....................................................................................................................1011 REMOVAL..........................................................................................................................1011 INSTALLATION.....................................................................................................................1012 BOTTOM DUMP CYLINDER ASSEMBLY............................................................................................................1013 (LOADING SHOVEL).....................................................................................................................1013 REMOVAL..........................................................................................................................1013 INSTALLATION.....................................................................................................................1014 HYDRAULIC CYLINDER ASSEMBLY .............................................................................................................1015 (BACK HOE)...........................................................................................................................1015 DISASSEMBLY......................................................................................................................1015 ASSEMBLY.........................................................................................................................1021 (LOADING SHOVEL).....................................................................................................................1025 DISASSEMBLY......................................................................................................................1025 ASSEMBLY.........................................................................................................................1027 BUCKET ASSEMBLY .........................................................................................................................1030 (BACK HOE)...........................................................................................................................1030 REMOVAL..........................................................................................................................1030 INSTALLATION.....................................................................................................................1031 (LOADING SHOVEL).....................................................................................................................1032 REMOVAL..........................................................................................................................1032 INSTALLATION.....................................................................................................................1033 ARM ASSEMBLY ............................................................................................................................1034 (BACK HOE)...........................................................................................................................1034 REMOVAL..........................................................................................................................1034 INSTALLATION.....................................................................................................................1035 (LOADING SHOVEL).....................................................................................................................1036 REMOVAL..........................................................................................................................1036 INSTALLATION.....................................................................................................................1037 BOOM ASSEMBLY............................................................................................................................1042 (BACKHOE)............................................................................................................................1042 REMOVAL..........................................................................................................................1042 INSTALLATION.....................................................................................................................1043 (LOADING SHOVEL).....................................................................................................................1044 REMOVAL..........................................................................................................................1044 INSTALLATION.....................................................................................................................1045 COUNTERWEIGHT ASSEMBLY...................................................................................................................1046 REMOVAL AND INSTALLATION.............................................................................................................1046 OPERATOR'S CAB ASSEMBLY..................................................................................................................1047 REMOVAL..............................................................................................................................1047 INSTALLATION.........................................................................................................................1048 40 MAINTENANCE STANDARD.....................................................................................................................1049 PTO......................................................................................................................................1050 SWING MACHINERY..........................................................................................................................1051 FINAL DRIVE..............................................................................................................................1053 IDLER....................................................................................................................................1054 TRACK ROLLER.............................................................................................................................1056 CARRIER ROLLER...........................................................................................................................1057 TRACK SHOE...............................................................................................................................1058 HYDRAULIC PUMP...........................................................................................................................1062 SWING PUMP...............................................................................................................................1063 CONTROL AND PTO LUBRICATION PUMP.........................................................................................................1064 CONTROL VALVE............................................................................................................................1065 SWING CONTROL VALVE......................................................................................................................1072 SWING MOTOR..............................................................................................................................1073 TRAVEL MOTOR.............................................................................................................................1074 TRAVEL BRAKE VALVE.......................................................................................................................1075 CENTER SWIVEL JOINT......................................................................................................................1076 PILOT RELIEF VALVE.......................................................................................................................1077 PPC VALVE................................................................................................................................1078 SOLENOID VALVE...........................................................................................................................1080 HYDRAULIC CYLINDER.......................................................................................................................1081 WORK EQUIPMENT...........................................................................................................................1085 DIMENSIONS OF WORK EQUIPMENT.............................................................................................................1089 90 OTHERS...................................................................................................................................1093 HYDRAULIC CIRCUIT DIAGRAM (BACK HOE).....................................................................................................1094 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)...............................................................................................1100 ELECTRIC CIRCUIT DIAGRAM (1/5)...........................................................................................................1104 ELECTRIC CIRCUIT DIAGRAM (2/5)...........................................................................................................1109 ELECTRIC CIRCUIT DIAGRAM (3/5)...........................................................................................................1114 ELECTRIC CIRCUIT DIAGRAM (4/5)...........................................................................................................1119 ELECTRIC CIRCUIT DIAGRAM (5/5)...........................................................................................................1124
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