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KOMATSU PC1800-6 SERVICE REPAIR MANUAL (SN:10011, 11002 and up) – PDF DOWNLOAD
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- KOMATSU PC1800-6 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM027708
- SERIAL No.
PC1800-6 10011, 11002 and up
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Description
KOMATSU PC1800-6 SERVICE REPAIR MANUAL (SN:10011, 11002 and up)
KOMATSU PC1800-6 SERVICE REPAIR MANUAL (SN:10011, 11002 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC1800-6 SERVICE REPAIR MANUAL (SN:10011, 11002 and up)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following 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 (SN:10011, 11002 and up)
COVER....................................................................................................................................................... 1 CONTENTS.................................................................................................................................................... 2 01 GENERAL.................................................................................................................................................. 31 SPECIFICATION DRAWINGS.................................................................................................................................. 32 SPECIFICATIONS.......................................................................................................................................... 34 WEIGHT TABLE............................................................................................................................................ 38 FUEL, COOLANT AND LUBRICANTS............................................................................................................................ 42 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................................................................................. 44 PTO..................................................................................................................................................... 45 PTO LUBRICATION SYSTEM.................................................................................................................................. 47 POWER TRAIN............................................................................................................................................. 48 SWING MACHINERY......................................................................................................................................... 50 SWING CIRCLE............................................................................................................................................ 52 FINAL DRIVE............................................................................................................................................. 53 SPROCKET................................................................................................................................................ 55 IDLER................................................................................................................................................... 57 HIC SYSTEM.............................................................................................................................................. 59 TRACK ROLLER............................................................................................................................................ 61 CARRIER ROLLER.......................................................................................................................................... 62 TRACK SHOE.............................................................................................................................................. 63 HYDRAULIC COMPONENT LAYOUT.............................................................................................................................. 67 HYDRAULIC TANK.......................................................................................................................................... 69 HYDRAULIC PUMP.......................................................................................................................................... 70 SWING PUMP.............................................................................................................................................. 97 CONTROL AND PTO LUBRICATING PUMP........................................................................................................................102 LINE OIL FILTER.........................................................................................................................................104 PILOT OIL FILTER........................................................................................................................................104 RETURN OIL FILTER.......................................................................................................................................105 DRAIN OIL FILTER........................................................................................................................................106 ELECTRONIC OLSS.........................................................................................................................................107 CONTROL VALVE...........................................................................................................................................109 SWING CONTROL VALVE.....................................................................................................................................125 SWING MOTOR.............................................................................................................................................128 CENTER SWIVEL JOINT.....................................................................................................................................131 TRAVEL MOTOR............................................................................................................................................132 TRAVEL BRAKE VALVE......................................................................................................................................134 PILOT RELIEF VALVE......................................................................................................................................136 SAFETY LOCK VALVE.......................................................................................................................................138 ACCUMULATOR.............................................................................................................................................140 PPC VALVE...............................................................................................................................................141 SOLENOID VALVE..........................................................................................................................................147 HYDRAULIC CYLINDER......................................................................................................................................149 AIR SYSTEM..............................................................................................................................................153 AIR GOVERNOR............................................................................................................................................154 AIR TANK................................................................................................................................................154 AUTO-DRAIN VALVE........................................................................................................................................154 SAFETY VALVE............................................................................................................................................155 SOLENOID VALVE (FOR LUBRICATION, HORN)..................................................................................................................155 GREASE PUMP.............................................................................................................................................156 GREASING SYSTEM.........................................................................................................................................158 WORK EQUIPMENT..........................................................................................................................................165 DIMENSIONS OF WORK EQUIPMENT............................................................................................................................169 ENGINE CONTROL..........................................................................................................................................173 MACHINE CONTROL SYSTEM..................................................................................................................................179 ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM........................................................................................203 MONITOR SYSTEM..........................................................................................................................................209 20 TESTING AND ADJUSTING....................................................................................................................................225 STANDARD VALUE TABLE FOR ENGINE.........................................................................................................................226 STANDARD VALUE TABLE FOR CHASSIS........................................................................................................................227 TESTING AND ADJUSTING...................................................................................................................................235 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING....................................................................................................236 MEASUREMENT OF ENGINE SPEED.........................................................................................................................238 MEASUREMENT OF AIR BOOST PRESSURE (BOOST PRESSURE)..................................................................................................239 MEASUREMENT OF EXHAUST GAS TEMPERATURE..............................................................................................................240 MEASUREMENT OF EXHAUST GAS COLOR....................................................................................................................240 ADJUSTMENT OF VALVE CLEARANCE.......................................................................................................................242 MEASUREMENT OF COMPRESSION PRESSURE.................................................................................................................243 MEASUREMENT OF BLOW-BY PRESSURE.....................................................................................................................243 MEASUREMENT OF ENGINE OIL PRESSURE..................................................................................................................244 HANDLING OF FUEL SYSTEM EQUIPMENT...................................................................................................................245 REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT................................................................................................245 MEASUREMENT OF FUEL PRESSURE........................................................................................................................246 AIR BLEEDING FROM FUEL CIRCUIT......................................................................................................................247 INSPECTION OF LEAKAGE FROM FUEL SYSTEM..............................................................................................................249 ADJUSTMENT OF ENGINE SPEED SENSOR...................................................................................................................250 INSPECTION AND ADJUSTMENT OF FAN BELT TENSION.......................................................................................................251 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.......................................................................................................252 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION.......................................................................................253 INSPECTION OF SWING CIRCLE BEARING CLEARANCE........................................................................................................254 REMAINING PRESSURE RELIEF FROM HIC CIRCUIT..........................................................................................................255 GAS FILLING IN HIC CIRCUIT ACCUMULATOR..............................................................................................................255 BLEEDING AIR FROM AND FILLING PRESSURIZED OIL IN HIC CIRCUIT........................................................................................257 INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION.....................................................................................................258 INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT OIL PRESSURES.................................................................259 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE...........................................................................................264 INSPECTION AND ADJUSTMENT OF PISTON PUMP CONTROL OIL PRESSURE.......................................................................................265 INSPECTION OF SERVO PISTON STROKE...................................................................................................................272 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE............................................................................................................273 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.......................................................................................................275 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE....................................................................................................277 INSPECTION AND ADJUSTMENT OF TRAVEL DEIEATION.......................................................................................................278 INSPECTION OF WORK EQUIPMENT HYDRAULIC DRIFT CAUSE PORTION..........................................................................................280 INSPECTION OF OIL LEAKAGE...........................................................................................................................281 REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT....................................................................................................284 AIR BLEEDING FROM EACH COMPONENT....................................................................................................................285 TESTING AND ADJUSTING HYDRAULIC AUTO GREASE SYSTEM..................................................................................................290 SPECIAL FUNCTION OF MACHINE MONITOR.................................................................................................................294 FUNCTION AMD OPERATION OF CGC MONITOR...............................................................................................................314 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT.....................................................................................................349 INITIALIZATION PROCEDURES FOR VHMS CONTROLLER.......................................................................................................350 SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER....................................................................................................364 TESTING AND ADJUSTING DEVICES RELATED TO VHMS.......................................................................................................381 ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)............................................................................................384 TROUBLESHOOTING.........................................................................................................................................402 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................................403 SEQUENCE OF EVENTS IN TROUBLESHOOTING...............................................................................................................404 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....................................................................................................405 CHECKS BEFORE TROUBLESHOOTING.......................................................................................................................413 CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING.....................................................................................................414 CONNECTOR ARRANGMENT DIAGRAM AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM.........................................................................418 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................................................................................................446 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE.............................................................................................................481 TROUBLESHOOTING AT DISPLAY OF FAILURE CODE OR ERROR CODE [CODE DISPLAY MODE]........................................................................485 INFORMATION IN TROUBLESHOOTING TABLE............................................................................................................488 FAILURE CODE [6014NX]...........................................................................................................................490 FAILURE CODE [7@HAKA]...........................................................................................................................492 FAILURE CODE [7@HAKB]...........................................................................................................................493 FAILURE CODE [7@HAZL]...........................................................................................................................494 FAILURE CODE [7@HBKA]...........................................................................................................................495 FAILURE CODE [7@HBKB]...........................................................................................................................496 FAILURE CODE [7@HBZL]...........................................................................................................................497 FAILURE CODE [7@HCKA]...........................................................................................................................498 FAILURE CODE [7@HCKB]...........................................................................................................................499 FAILURE CODE [7@HCZL]...........................................................................................................................500 FAILURE CODE [7@HDKA]...........................................................................................................................501 FAILURE CODE [7@HDKB]...........................................................................................................................502 FAILURE CODE [7@HDZL]...........................................................................................................................503 FAILURE CODE [A000N1] OR ERROR CODE [E922]......................................................................................................504 FAILURE CODE [a000N1] OR ERROR CODE [EA22]......................................................................................................505 FAILURE CODE [AA10NX] OR ERROR CODE [104].......................................................................................................506 FAILURE CODE [aA10NX] OR ERROR CODE [105].......................................................................................................507 FAILURE CODE [ABOOKE]...........................................................................................................................508 FAILURE CODE [aBOOKE]...........................................................................................................................509 FAILURE CODE [ADOOL2] OR ERROR CODE [E979]......................................................................................................510 FAILURE CODE [aD00L2] OR ERROR CODE [EA79]......................................................................................................511 FAILURE CODE [AD00MA] OR ERROR CODE [E97A]......................................................................................................512 FAILURE CODE [aD00MA] OR ERROR CODE [EA7A]......................................................................................................512 FAILURE CODE [AD10L3] OR ERROR CODE [E97b]......................................................................................................513 FAILURE CODE [aD10L3] OR ERROR CODE [EA7b]......................................................................................................515 FAILURE CODE [AD10MA] OR ERROR CODE [E97d]......................................................................................................517 FAILURE CODE [aD10MA] OR ERROR CODE [EA7d]......................................................................................................517 FAILURE CODE [AD10MB] OR ERROR CODE [E97C]......................................................................................................518 FAILURE CODE [aD10MB] OR ERROR CODE [EA7C]......................................................................................................518 FAILURE CODE [AD11KA] OR ERROR CODE [E974]......................................................................................................519 FAILURE CODE [aD11KA] OR ERROR CODE [EA74]......................................................................................................520 FAILURE CODE [AD11KB] OR ERROR CODE [E970]......................................................................................................521 FAILURE CODE [aD11KB] OR ERROR CODE [EA70]......................................................................................................522 FAILURE CODE [AD51KA] OR ERROR CODE [E975]......................................................................................................523 FAILURE CODE [aD51KA] OR ERROR CODE [EA75]......................................................................................................524 FAILURE CODE [AD51KB] OR ERROR CODE [E971]......................................................................................................525 FAILURE CODE [aD51KB] OR ERROR CODE [EA71]......................................................................................................526 FAILURE CODE [ADA1KA] OR ERROR CODE [E981]......................................................................................................527 FAILURE CODE [aDA1KA] OR ERROR CODE [EA81]......................................................................................................528 FAILURE CODE [ADAZKB] OR ERROR CODE [E98A]......................................................................................................529 FAILURE CODE [aDAZKB] OR ERROR CODE [EA8A]......................................................................................................531 FAILURE CODE [ADB1KA] OR ERROR CODE [E982]......................................................................................................533 FAILURE CODE [aDB1KA] OR ERROR CODE [EA82]......................................................................................................534 FAILURE CODE [ADC1KA] OR ERROR CODE [E983]......................................................................................................535 FAILURE CODE [aDC1KA] OR ERROR CODE [EA83]......................................................................................................536 FAILURE CODE [ADD1KA] OR ERROR CODE [E984]......................................................................................................537 FAILURE CODE [aDD1KA] OR ERROR CODE [EA84]......................................................................................................538 FAILURE CODE [ADDZKB] OR ERROR CODE [E98b]......................................................................................................539 FAILURE CODE [aDDZKB] OR ERROR CODE [EA8b]......................................................................................................541 FAILURE CODE [ADE1KA] OR ERROR CODE [E985]......................................................................................................543 FAILURE CODE [aDE1KA] OR ERROR CODE [EA85]......................................................................................................544 FAILURE CODE [ADF1KA] OR ERROR CODE [E986]......................................................................................................545 FAILURE CODE [aDF1KA] OR ERROR CODE [EA86]......................................................................................................546 FAILURE CODE [B@BAZG] OR ERROR CODE [E924]......................................................................................................547 FAILURE CODE [b@BAZG] OR ERROR CODE [EA24]......................................................................................................548 FAILURE CODE [B@BAZK]...........................................................................................................................549 FAILURE CODE [b@BAZK]...........................................................................................................................550 FAILURE CODE [B@BCNS] OR ERROR CODE [108].......................................................................................................551 FAILURE CODE [b@BCNS] OR ERROR CODE [111].......................................................................................................552 FAILURE CODE [B@BCZK]...........................................................................................................................553 FAILURE CODE [b@BCZK]...........................................................................................................................555 FAILURE CODE [B@CBNS]...........................................................................................................................557 FAILURE CODE [b@CBNS]...........................................................................................................................558 FAILURE CODE [B@HANS] OR ERROR CODE [115].......................................................................................................559 FAILURE CODE [B@HAZK]...........................................................................................................................560 FAILURE CODE [D11OKB]...........................................................................................................................561 FAILURE CODE [D163KB]...........................................................................................................................562 FAILURE CODE [D194KZ]...........................................................................................................................563 FAILURE CODE [D195KB]...........................................................................................................................564 FAILURE CODE [D1D0KB] OR ERROR CODE [E957]......................................................................................................565 FAILURE CODE [d1D0KB] OR ERROR CODE [EA57]......................................................................................................567 FAILURE CODE [DA20KT] OR ERROR CODE [101].......................................................................................................569 FAILURE CODE [DA2SKA]...........................................................................................................................570 FAILURE CODE [DA2SKQ]...........................................................................................................................572 FAILURE CODE [DA80MA]...........................................................................................................................574 FAILURE CODE [DAB0KR] OR ERROR CODE [118].......................................................................................................575 FAILURE CODE [DB20KT] OR ERROR CODE [E980]......................................................................................................577 FAILURE CODE [dB20KT] OR ERROR CODE [EA80]......................................................................................................578 FAILURE CODE [DB22KK] OR ERROR CODE [E956]......................................................................................................579 FAILURE CODE [dB22KK] OR ERROR CODE [EA56]......................................................................................................581 FAILURE CODE [DB29KQ] OR ERROR CODE [E920]......................................................................................................583 FAILURE CODE [dB29KQ] OR ERROR CODE [EA20]......................................................................................................584 FAILURE CODE [DB2AMA] OR ERROR CODE [E95A]......................................................................................................585 FAILURE CODE [bB2AMA] OR ERROR CODE [EA5A]......................................................................................................585 FAILURE CODE [DB2RMC] OR ERROR CODE [E935]......................................................................................................586 FAILURE CODE [dB2RMC] OR ERROR CODE [EA35]......................................................................................................588 FAILURE CODE [DB2SMC] OR ERROR CODE [E955]......................................................................................................590 FAILURE CODE [dB2SMC] OR ERROR CODE [EA55]......................................................................................................592 FAILURE CODE [DBB0KK]...........................................................................................................................594 FAILURE CODE [DBB0KM]...........................................................................................................................595 FAILURE CODE [DBB0KP]...........................................................................................................................596 FAILURE CODE [DBB0KQ]...........................................................................................................................598 FAILURE CODE [DBB0KR] OR ERROR CODE [116].......................................................................................................600 FAILURE CODE [DBB0KT]...........................................................................................................................602 FAILURE CODE [DBBQKR]...........................................................................................................................603 FAILURE CODE [DD11KB] OR ERROR CODE [E954]......................................................................................................605 FAILURE CODE [dD11KB] OR ERROR CODE [EA54]......................................................................................................607 FAILURE CODE [DDE2L6] OR ERROR CODE [E936]......................................................................................................609 FAILURE CODE [dDE2L6] OR ERROR CODE [EA36]......................................................................................................611 FAILURE CODE [DGE4KX] OR ERROR CODE [E93d]......................................................................................................613 FAILURE CODE [dGE4KX] OR ERROR CODE [EA3d]......................................................................................................614 FAILURE CODE [DGT4KA]...........................................................................................................................615 FAILURE CODE [dGT4KA]...........................................................................................................................617 FAILURE CODE [DGT4KB]...........................................................................................................................619 FAILURE CODE [dGT4KB]...........................................................................................................................621 FAILURE CODE [DGT5KA]...........................................................................................................................623 FAILURE CODE [dGT5KA]...........................................................................................................................625 FAILURE CODE [DGT5KB]...........................................................................................................................627 FAILURE CODE [dGT5KB]...........................................................................................................................629 FAILURE CODE [DH30KX] OR ERROR CODE [E93C]......................................................................................................631 FAILURE CODE [dH30KX] OR ERROR CODE [EA3C]......................................................................................................632 FAILURE CODE [DH40KX] OR ERROR CODE [E977]......................................................................................................633 FAILURE CODE [dH40KX] OR ERROR CODE [EA77]......................................................................................................634 FAILURE CODE [DHE4KB]...........................................................................................................................635 FAILURE CODE [dHE4KB]...........................................................................................................................636 FAILURE CODE [DHE4KY]...........................................................................................................................637 FAILURE CODE [dHE4KY]...........................................................................................................................638 FAILURE CODE [DHE5KB]...........................................................................................................................639 FAILURE CODE [dHE5KB]...........................................................................................................................640 FAILURE CODE [DHE5KY]...........................................................................................................................641 FAILURE CODE [dHE5KY]...........................................................................................................................642 FAILURE CODE [DK10KX] OR ERROR CODE [E931]......................................................................................................643 FAILURE CODE [dK10KX] OR ERROR CODE [EA31]......................................................................................................644 FAILURE CODE [DLE2MA]...........................................................................................................................645 FAILURE CODE [dLE2MA]...........................................................................................................................646 FAILURE CODE [DLE3LC] OR ERROR CODE [E91b]......................................................................................................647 FAILURE CODE [dLE3LC] OR ERROR CODE [EA1b]......................................................................................................648 FAILURE CODE [DLH1LC] OR ERROR CODE [E91C]......................................................................................................649 FAILURE CODE [dLH1LC] OR ERROR CODE [EA1C]......................................................................................................650 FAILURE CODE [DPA0KR]...........................................................................................................................651 FAILURE CODE [DV00KY] OR ERROR CODE [102].......................................................................................................652 FAILURE CODE [DV20KB]...........................................................................................................................653 FAILURE CODE [DW42KZ]...........................................................................................................................654 FAILURE CODE [DW45KA]...........................................................................................................................655 FAILURE CODE [DW45KB]...........................................................................................................................657 FAILURE CODE [DW48KA]...........................................................................................................................659 FAILURE CODE [DW48KB]...........................................................................................................................660 FAILURE CODE [DW91KA]...........................................................................................................................661 FAILURE CODE [DW91KB]...........................................................................................................................662 FAILURE CODE [DWK0KA]...........................................................................................................................663 FAILURE CODE [DWK0KB]...........................................................................................................................664 FAILURE CODE [DXA0KA]...........................................................................................................................665 FAILURE CODE [dXA0KA]...........................................................................................................................667 FAILURE CODE [DXA0KB]...........................................................................................................................669 FAILURE CODE [dXA0KB]...........................................................................................................................671 FAILURE CODE [F@BBZL]...........................................................................................................................673 FAILURE CODE [f@BBZL]...........................................................................................................................673 FAILURE CODE [F@BVL6]...........................................................................................................................674 FAILURE CODE [f@BVL6]...........................................................................................................................674 FAILURE CODE [F@BYNR]...........................................................................................................................675 FAILURE CODE [f@BYNR]...........................................................................................................................676 FAILURE CODE [F@BYNS]...........................................................................................................................677 FAILURE CODE [f@BYNS]...........................................................................................................................678 FAILURE CODE [F@BZNR]...........................................................................................................................679 FAILURE CODE [f@BZNR]...........................................................................................................................680 FAILURE CODE [F@BZNS]...........................................................................................................................681 FAILURE CODE [f@BZNS]...........................................................................................................................682 FAILURE CODE [F@HCKA]...........................................................................................................................683 FAILURE CODE [F@HCKB]...........................................................................................................................684 FAILURE CODE [F@HCZL]...........................................................................................................................685 FAILURE CODE [J100KA]...........................................................................................................................686 FAILURE CODE [J100KB]...........................................................................................................................687 FAILURE CODE [J100L6]...........................................................................................................................688 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................................689 INFORMATION CONTAINED IN THE TROUBLESHOOTING LIST...............................................................................................690 E-1 ENGINE DOESN'T START UP.....................................................................................................................691 E-2 PREHEATING DOES NOT WORK....................................................................................................................696 E-3 AUTOMATIC-DECELERATOR DOES NOT WORK.........................................................................................................699 E-4 BOOM SHOCK-LESS FUNCTION DOES NOT OPERATE NORMALLY..........................................................................................700 E-5 MACHINE PUSHUP FUNCTION DOES NOT WORK NORMALLY..............................................................................................703 E-6 TRAVEL ALARM IS NOT SOUNDED.................................................................................................................705 E-7 ALL THE MACHINE MONITOR LAMPS DO NOT COME ON FOR 3 SECONDS AFTER THE STARTING SWITCH IS TURNED ON...........................................706 E-8 WHEN THE STARTING SWITCH IS TURNED ON ,MACHINE MONITOR LAMPS ALL STAYED LIGHTED UP AND DO NOT GO OUT........................................708 E-9 MACHINE MONITOR LAMPS WHICH IS LIGHTED UP WHEN THE STARTING SWITCH IS TURNED ON, DO NOT EXACTLY REPRESENT THE MACHINE OPERATING STATUS......708 E-10 A BASIC CHECK ITEM FLASHES ON THE MACHINE MONITOR WHILE THE STARTING SWITCH IS TURNED ON...................................................709 E-11 WHILE THE ENGINE IS IN OPERATION, A CAUTION ITEM FLASHES ON THE MACHINE MONITOR............................................................710 E-12 WHILE THE ENGINE IS IN OPERATION, AN EMERGENCY STOP ITEM FLASHES ON THE MACHINE MONITOR....................................................712 E-13 WARM-UP MONITOR UNINTENDED COMES ON OR FLASHES ON THE MACHINE MONITOR THOUGH THE WARM-UP OPERATION IS NOT TURNED ON........................714 E-14 SWING LOCK MONITOR DOES NOT COME ON........................................................................................................716 E-15 ENGINE WATER TEMPERATURE GAUGE IS NOT CORRECT..............................................................................................718 E-16 DISPLAY OF THE MACHINE MONITOR'S HYDRAULIC OIL TEMPERATURE GAUGE IS NOT CORRECT............................................................720 E-17 DISPLAY OF FUEL GAUGE IS NOT CORRECT.......................................................................................................721 E-18 ALARM BUZZER OF THE MACHINE MONITOR DOES NOT WORK NORMALLY.................................................................................722 E-19 CLOCK AND SERVICE METER ARE NOT CORRECTLY DISPLAYED........................................................................................724 E-20 BIT DISPLAY FOR BOOM RAISE IS NOT CORRECTLY DISPLAYED......................................................................................725 E-21 BIT DISPLAY FOR BOOM LOWER IS NOT CORRECTLY DISPLAYED......................................................................................726 E-22 BIT DISPLAY FOR ARM IN IS NOT CORRECTLY DISPLAYED..........................................................................................727 E-23 BIT DISPLAY FOR ARM OUT IS NOT CORRECTLY DISPLAYED.........................................................................................728 E-24 BIT DISPLAY FOR BUCKET CURL IS NOT CORRECTLY DISPLAYED.....................................................................................729 E-25 BIT DISPLAY FOR BUCKET DUMP IS NOT CORRECTLY DISPLAYED.....................................................................................730 E-26 BIT DISPLAY FOR SWING IS NOT CORRECTLY DISPLAYED...........................................................................................731 E-27 BIT DISPLAY FOR LH TRAVEL IS NOT CORRECTLY DISPLAYED.......................................................................................733 E-28 BIT DISPLAY FOR RH TRAVEL IS NOT CORRECTLY DISPLAYED.......................................................................................735 E-29 BIT DISPLAY FOR THE SERVICE IS NOT CORRECTLY DISPLAYED.....................................................................................737 E-30 BIT DISPLAY FOR BOTTOM OPEN, CLOSE IS NOT CORRECTLY DISPLAYED..............................................................................738 E-31 AIR CONDITIONER DOES NOT WORK..............................................................................................................740 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE).........................................................................................742 TABLE OF FAILURE MODES AND CAUSES...............................................................................................................743 PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM............................................................................................745 HOW TO READ THE TROUBLESHOOTING FLOW............................................................................................................750 H-1. SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER.........................................................................751 H-2. THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS..................................................................................752 H-3. NO WORK EQUIPMENT, TRAVEL, SWING MOVE......................................................................................................754 H-4. ABNORMAL NOISE GENERATED (AROUND PUMP).....................................................................................................756 H-5. WORK EQUIPMENT SPEED IS SLOW (BOOM, ARM, BUCKET)...........................................................................................757 H-6. WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).........................................................758 H-7. EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)..............................................................................................758 H-8. EXCESSIVE TIME LAG.........................................................................................................................759 H-9. EXCESSIVE SHOCK WHEN BOOM IS STOPPED (WHEN SHOCKLESS SWITCH IS ON).........................................................................759 H-10. DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION...........................................................................................759 H-11. WHEN HEAVY LIFT IS ON, BOOM RAISE SPEED IS SLOW OR LACKS POWER............................................................................760 H-12. TRAVEL DEVIATION IS EXCESSIVE DRUING COMPOUND OPERATIONS..................................................................................761 H-13. MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS...........................................................................762 H-14. DEVIATION IS EXCESSIVE WHEN STARTING .....................................................................................................765 H-15. TRAVEL SPEED IS SLOW......................................................................................................................767 H-16. TRAVEL DOES NOT MOVE (ONE SIDE ONLY)......................................................................................................767 H-17. DOES NOT SWING............................................................................................................................768 H-18. SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR.........................................................................................769 H-19. EXCESSIVE OVERRUN WHEN STOPPING SWING.....................................................................................................770 H-20. EXCESSIVE SHOCK WHEN STOPPING SWING.......................................................................................................771 H-21. EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..............................................................................................771 H-22. EXCESSIVE HYDRAULIC DRIFT OF SWING........................................................................................................772 TROUBLESHOOTING OF WORK EQUIPMENT AUTOMATIC CONTROL SYSTEM (W-MODE) [LOADING SHOVEL]................................................................773 METHOD OF USING TROUBLESHOOTING FLOWCHART.......................................................................................................774 ABNORMALITY JUDGEMENT STANDARDS FOR SELF-DIAGNOSTIC SYSTEM......................................................................................775 TROUBLESHOOTING.................................................................................................................................776 W-1. IN ARC DIGGING MODE (AUTO LEVEL DIGGING SWITCH OFF), HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IS CARRIED OUT........................779 W-2. IN HORIZONTAL DIGGING MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING..........................................................................780 W-3. IN HORIZONTAL DIGGING MODE (BUCKET ANGLE REVISE SWITCH OFF),BUCKET ANGLE COMPENSATION IS CARRIED OUT.......................................787 W-4. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGLE COMPENSATION....788 W-5. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORIZONTAL DIGGING....791 W-6. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION.................793 W-7. IMPOSSIBLE TO CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION....................................................................800 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................................801 METHOD OF USING MANUAL..................................................................................................................................803 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................805 SPECIAL TOOL LIST.......................................................................................................................................807 SKETCHES OF SPECIAL TOOLS...............................................................................................................................810 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP............................................................................................................813 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY......................................................................................................816 REMOVAL AND INSTALLATION OF NOZZLE TIP..................................................................................................................819 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...........................................................................................................821 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL............................................................................................................823 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY......................................................................................................828 REMOVAL AND INSTALLATION OF FUEL COOLER ASSEMBLY........................................................................................................833 REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY........................................................................................................834 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...............................................................................................835 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...........................................................................................................836 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY..........................................................................................................837 REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY........................................................................................839 REMOVAL AND INSTALLATION OF PTO ASSEMBLY................................................................................................................843 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY................................................................................................................846 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY................................................................................................848 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY................................................................................................850 REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY.......................................................................................................851 REMOVAL AND INSTALLATION OF TRAVEL MOTOR BRAKE VALVE ASSEMBLY...........................................................................................852 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY........................................................................................................853 REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMLY.........................................................................................................861 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY....................................................................................................862 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY.......................................................................................................863 REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY....................................................................................................864 DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY ...................................................................................................865 REMOVAL AND INSTALLATION OF IDLER CUSHION CYLINDER ASSEMBLY.............................................................................................873 DISASSEMBLY AND ASSEMBLY OF IDLER CUSHION CYLINDER ASSEMBLY.............................................................................................874 DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY..........................................................................................875 REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY.........................................................................................................876 REMOVAL AND INSTALLATION OF FRONT IDLER ASSEMBLY........................................................................................................878 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY..............................................................................................................879 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.....................................................................................................881 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.....................................................................................................882 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY.......................................................................................................884 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY.......................................................................................................885 REMOVAL AND INSTALLATION OF CONTROL・PTO LUBRICATION PUMP ASSEMBLY.......................................................................................887 REMOVAL AND INSTALLATION OF SWING PUMP ASSEMBLY.........................................................................................................888 REMOVAL AND INSTALLATION OF NO.1, 3 PUMP ASSEMBLY.......................................................................................................889 REMOVAL AND INSTALLATION OF NO.2, 4 PUMP ASSEMBLY.......................................................................................................890 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.....................................................................................................891 REMOVAL AND INSTALLATION OF PILOT RELIEF VALVE ASSEMBLY.................................................................................................892 DISASSEMBLY AND ASSEMBLY OF PILOT RELIEF VALVE ASSEMBLY.................................................................................................893 DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (FOR SWING)......................................................................................894 DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (FOR WORK EQUIPMENT, TRAVEL).....................................................................895 REMOVAL AND INSTALLATION OF SWING CONTROL VALVE ASSEMBLY................................................................................................896 DISASSEMBLY AND ASSEMBLY OF SWING CONTROL VALVE ASSEMBLY................................................................................................897 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY......................................................................................................899 REMOVAL AND INSTALLATION OF CO, NC VALVE ASSEMBLY.......................................................................................................903 REMOVAL AND INSTALLATION OF SERVO VALVE ASSEMBLY........................................................................................................904 REMOVAL AND INSTALLATION OF TVC VALVE ASSEMBLY..........................................................................................................905 REMOVAL AND INSTALLATION OF PPC VALVE ASSEMBLY (FOR TRAVEL).............................................................................................906 DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY (FOR TRAVEL).............................................................................................907 REMOVAL AND INSTALLATION OF PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)..............................................................................908 DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)..............................................................................909 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY......................................................................................................910 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY......................................................................................................912 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY.......................................................................................................914 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY.......................................................................................................915 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY....................................................................................................916 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY....................................................................................................917 REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY...............................................................................................918 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................920 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................927 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY.............................................................................................................931 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY.............................................................................................................932 REMOVAL AND INSTALLATION OF ARM ASSEMBLY................................................................................................................934 REMOVAL AND INSTALLATION OF ARM ASSEMBLY................................................................................................................935 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY...............................................................................................................937 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY...............................................................................................................939 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY .....................................................................................................941 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY.....................................................................................................942 REMOVAL AND INSTALLATION OF VHMS CONTROLLER.............................................................................................................944 90 OTHERS...................................................................................................................................................946 LOCATIONS OF CONNECTORS (WHOLE MACHINE-1/12)............................................................................................................947 LOCATIONS OF CONNECTORS (WHOLE MACHINE-2/12)............................................................................................................948 LOCATIONS OF CONNECTORS (WHOLE MACHINE-3/12)............................................................................................................949 LOCATIONS OF CONNECTORS (WHOLE MACHINE-4/12)............................................................................................................950 LOCATIONS OF CONNECTORS (WHOLE MACHINE-5/12)............................................................................................................951 LOCATIONS OF CONNECTORS (WHOLE MACHINE-6/12)............................................................................................................952 LOCATIONS OF CONNECTORS (WHOLE MACHINE-7/12)............................................................................................................953 LOCATIONS OF CONNECTORS (WHOLE MACHINE-8/12)............................................................................................................954 LOCATIONS OF CONNECTORS (WHOLE MACHINE-9/12)............................................................................................................955 LOCATIONS OF CONNECTORS (WHOLE MACHINE-10/12)...........................................................................................................956 LOCATIONS OF CONNECTORS (WHOLE MACHINE-11/12)...........................................................................................................957 LOCATIONS OF CONNECTORS (WHOLE MACHINE-12/12)...........................................................................................................958 LOCATIONS OF CONNECTORS (AROUND CONTROL)................................................................................................................959 LOCATIONS OF CONNECTORS (OPERATOR'S CAB-1/2)............................................................................................................960 LOCATIONS OF CONNECTORS (OPERATOR'S CAB-2/2)............................................................................................................961 LOCATIONS OF CONNECTORS (AROUND LADDER).................................................................................................................962 LOCATIONS OF CONNECTORS (RELATED TO AUTO GREASE SYSTEM).................................................................................................963 LOCATIONS OF CONNECTORS (FRONT ENGINE)..................................................................................................................964 LOCATIONS OF CONNECTORS (REAR ENGINE)...................................................................................................................965 HYDRAULIC CIRCUIT DIAGRAM (BACK HOE)....................................................................................................................966 HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)..............................................................................................................968 ELECTRICAL CIRCUIT DIAGRAM (1/7).......................................................................................................................970 ELECTRICAL CIRCUIT DIAGRAM (2/7).......................................................................................................................971 ELECTRICAL CIRCUIT DIAGRAM (3/7).......................................................................................................................972 ELECTRICAL CIRCUIT DIAGRAM (4/7).......................................................................................................................973 ELECTRICAL CIRCUIT DIAGRAM (5/7).......................................................................................................................974 ELECTRICAL CIRCUIT DIAGRAM (6/7).......................................................................................................................975 ELECTRICAL CIRCUIT DIAGRAM (7/7).......................................................................................................................976
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
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