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Komatsu PC200, 200LC-6 PC220, 220LC-6 Shop Manual SEBD003405 – PDF DOWNLOAD
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Komatsu PC200, 200LC-6 PC220, 220LC-6 Shop Manual
MACHINE MODEL SERIAL NUMBER
PC200, 200LC-6 80001 and up
PC220, 220LC-6 50001 and up
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Description
Komatsu PC200, 200LC-6 PC220, 220LC-6 Shop Manual
FILE DETAILS:
Komatsu PC200, 200LC-6 PC220, 220LC-6 80001 50001 and up Shop Manual SEBD003405
Size: 55.9 MB
Fomat: PDF
Language: English
Brand: Komatsu
Type of Document: Shop Manual
Model: PC200, 200LC-6 PC220, 220LC-6
Serial: 80001 50001 and up
Number of Page: 990 Pages
KOMATSU PC200, 200LC-6 PC220, 220LC-6 SHOP MANUAL SEBD003405 – PDF DOWNLOAD:
DESCRIPTION:
Komatsu PC200, 200LC-6 PC220, 220LC-6 Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC200, 200LC-6 PC220, 220LC-6 Shop Manual
MAIN MENU......................................................................................................................... 0 COVER............................................................................................................................. 1 CONTENTS.......................................................................................................................... 2 00 FORWARD........................................................................................................................ 9 SAFETY........................................................................................................................ 9 FOREWARD...................................................................................................................... 11 HOISTING INSTRUCTIONS......................................................................................................... 13 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.................................................................... 14 COATING MATERIALS............................................................................................................. 16 STANDARD TIGHENING TORQUE..................................................................................................... 18 ELECTRIC WIRE CODE............................................................................................................ 21 CONVERSION TABLE.............................................................................................................. 22 UNITS......................................................................................................................... 28 01 GENERAL........................................................................................................................ 29 GENERAL ASSEMBLY DRAWING...................................................................................................... 30 SPECIFICATIONS................................................................................................................ 32 WEIGHT TABLE.................................................................................................................. 36 LIST OF LUBRICANT AND WATER................................................................................................... 40 10 STRUCTURE AND FUNCTION......................................................................................................... 41 ENGINE RELATED PARTS.......................................................................................................... 42 RADIATOR - OIL COOLER - AFTERCOOLER........................................................................................... 43 POWER TRAIN................................................................................................................... 45 FINAL DRIVE................................................................................................................... 46 SWING CIRCLE.................................................................................................................. 48 SWING MACHINERY............................................................................................................... 49 TRACK FRAME - RECOIL SPRING................................................................................................... 50 TRACK SHOE.................................................................................................................... 51 HYDRAULIC PIPING DRAWING...................................................................................................... 53 HYDRAULIC TANK................................................................................................................ 57 HYDRAULIC PUMP................................................................................................................ 58 LINE OIL FILTER............................................................................................................... 79 CONTROL VALVE................................................................................................................. 80 CLSS.......................................................................................................................... 97 SWING MOTOR...................................................................................................................153 CENTER SWIVEL JOINT...........................................................................................................156 TRAVEL MOTOR..................................................................................................................158 VALVE CONTROL.................................................................................................................169 WORK EQUIPMENT - SWING PPC VALVE..............................................................................................170 TRAVEL PPC VALVE..............................................................................................................174 SERVICE PPC VALVE.............................................................................................................180 SAFETY LOCK VALVE.............................................................................................................183 PPC ACCUMULATOR...............................................................................................................183 PPC SHUTTLE - TRAVEL JUNCTION VALVE...........................................................................................184 EPC - SOLENOID VALVE..........................................................................................................191 BOOM HOLDING VALVE............................................................................................................197 HYDRAULIC CYLINDER............................................................................................................200 ADDITIONAL FILTER FOR BREAKER.................................................................................................201 WORK EQUIPMENT................................................................................................................202 ELECTRICAL WIRING DIAGRAM.....................................................................................................203 ELECTRICAL CIRCUIT DIAGRAM....................................................................................................205 ENGINE CONTROL SYSTEM.........................................................................................................209 ELECTRONIC CONTROL SYSTEM.....................................................................................................216 MACHINE MONITOR SYSTEM........................................................................................................248 20 TESTING AND ADJUSTING..........................................................................................................260 TABLE OF JUDGEMENT STANDARD VALUE.............................................................................................261 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.....................................................................................273 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.............................................................................291 MEASURING ENGINE SPEED........................................................................................................292 MEASURING EXHAUST GAS COLOR...................................................................................................293 ADJUSTING VALVE CLEARANCE.....................................................................................................294 MEASURING COMPRESSION PRESSURE................................................................................................295 MEASURING BLOWBY PRESSURE.....................................................................................................295 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................................................296 MEASURING ENGINE OIL PRESSURE.................................................................................................297 TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION.............................................................................298 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.............................................................298 ADJUSTING ENGINE SPEED SENSOR.................................................................................................299 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE.............................................................................300 TESTING CLEARANCE OF SWING CIRCLE BEARING.....................................................................................301 TESTING AND ADJUSTING TRACK SHOE TENSION......................................................................................302 TESTING AND ADJUSTING TRACK SHOE TENSION......................................................................................302 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT.............................................303 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE).................................................310 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE.....................312 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE.......................................................................315 TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE.............................................................................317 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE.............................................................319 ADJUSTING WORK EQUIPMENT - SWING PPC VALVE....................................................................................321 ADJUSTING TRAVEL LEVER........................................................................................................322 TESTING TRAVEL DEVIATION......................................................................................................323 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...................................................................324 MEASURING OIL LEAKAGE.........................................................................................................326 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.............................................................................327 BLEEDING AIR..................................................................................................................328 TROUBLESHOOTING...............................................................................................................330 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................331 SEQUENCE ,OF EVENTS IN TROUBLESHOOTING....................................................................................332 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.................................................................................333 CHECKS BEFORE TROUBLESHOOTING.............................................................................................340 CONNECTOR TYPES AND MOUNTING LOCATIONS....................................................................................341 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................349 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....................................................................359 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.....................................................................362 METHOD OF USING JUDGEMENT TABLE...........................................................................................382 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................386 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE..................................................................390 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)..............................................................402 N-1 [E218] Communication abnormality..................................................................................403 TROUBLESHOOTING OF ENGINE THROTTLE PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE).....................................434 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE SHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER SYSTEM.....................435 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE............................................436 JUDGEMENT TABLE FOR ENGINE THROTTLE . PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS..............440 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM..........................................................................442 E-1 Abnormality in engine throttle - pump controller power source.....................................................444 E-2 [E308] Abnormality in fuel control dial input value is displayed..................................................445 E-3 [E317] Abnormality (disconnection) in motor drive system is displayed.............................................446 E-4 [E318] Abnormality (short circuit) in motor drive system is displayed.............................................447 E-5 [E306] Abnormality in feedback potentiometer system is displayed..................................................448 E-6 [E315] Abnormality (short circuit) in battery relay output system is displayed....................................449 E-7 [E316] Abnormality (step-out) in motor is displayed...............................................................450 E-8 Engine does not start.............................................................................................451 E-9 Engine speed is irregular.........................................................................................453 a) Idling speed is irregular......................................................................................453 b) There is hunting...............................................................................................455 E-10 Lack of output (engine high idling speed is too low).............................................................457 E-11 Engine does not stop.............................................................................................459 E-12 Defective operation of battery relay system (engine does not stop)...............................................461 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).................................................................................463 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................464 S-1 Starting performance is poor (starting always takes time).........................................................468 S-2 Engine does not start.............................................................................................469 (1) Engine does not turn..........................................................................................469 (2) Engine turns but no exhaust smoke comes out (fuel is not being injected)......................................470 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)....................................471 S-3 Engine does not pick up smoothly (follow-up is poor)..............................................................472 S-4 Engine stops during operations....................................................................................473 S-5 Engine does not rotate smoothly (hunting).........................................................................474 S-6 Engine lacks output (no power)....................................................................................475 S-7 Exhaust smoke is black (incomplete combustion)....................................................................476 S-8 Oil consumption is excessive (or exhaust smoke is blue)...........................................................477 S-9 Oil becomes contaminated quickly..................................................................................478 S-10 Fuel consumption is excessive....................................................................................479 S-11 Oil is in cooling water, or water spurts back, or water level goes down..........................................480 S-12 Oil pressure caution lamp lights up (drop in oil pressure).......................................................481 S-13 Oil level rises (water, fuel in oil).............................................................................482 S-14 Water temperature becomes too high (overheating).................................................................483 S-15 Abnormal noise is made...........................................................................................484 S-16 Vibration is excessive...........................................................................................485 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)........................................................................486 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM........................................................487 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE............................................488 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS.......................................................492 PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM................................................................................493 C-1 Abnormality in pump controller power source system................................................................494 C-2 [E2:32] Short circuit in front pump TVC solenoid system is displayed..............................................495 C-3 [E2:33} Disconnection in front pump TVC solenoid system is displayed..............................................497 C-4 [E2:03] Short circuit in swing brake solenoid system is displayed.................................................499 C-5 [E2:13] Disconnection in swing brake solenoid system is displayed.................................................501 C-6 [E2:02] Short circuit in LS select solenoid system is displayed...................................................503 C-7 [E2:12] Disconnection in LS select solenoid system is displayed...................................................505 C-8 [E2:17] Model selection input error is displayed..................................................................507 C-9 [E2:18] Network response overtime error is displayed..............................................................508 C-10 [E2:22] Short circuit in LS control EPC solenoid system is displayed.............................................510 C-11 [E2:23] Disconnection in LS control EPC solenoid system is displayed.............................................511 C-12 [E2:24] Abnormality in front pump pressure sensor system is displayed............................................512 C-13 [E2:26] Abnormality in pump pressure sensor power source system is displayed.....................................514 C-14 [E2:27] Abnormality in engine speed sensor system is displayed...................................................515 C-15 [E2:28] Abnormality in auto-deceleration output system is displayed..............................................516 TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE).......................................517 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM........................................................518 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE............................................519 JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...............527 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE.................................................................................529 C-1 Abnormality in controller power source system (controller LED is OFF).............................................531 C-2 [E232] Short circuit in front pump TVC solenoid system is displayed...............................................532 C-3 [E233] Disconnection in front pump TVC solenoid system is displayed...............................................534 C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed................................................536 C-5 [E237] Disconnection in rear pump TVC solenoid system is displayed................................................538 C-6 [E2031 Short circuit in swing brake solenoid system is displayed..................................................540 C-7 [E213] Disconnection in swing brake solenoid system is displayed..................................................542 C-8 [E204] Short circuit in pump merge/divider solenoid system is displayed...........................................544 C-9 [E214] Disconnection in pump merge/divider solenoid system is displayed...........................................545 C-10 [E207] Short circuit in active mode solenoid system is displayed.................................................546 C-11 [E208] Disconnection in active mode solenoid system is displayed.................................................547 C-12 [E206] Short circuit in travel speed solenoid system is displayed................................................548 C-13 [E2161 Disconnection in travel speed selector solenoid system is displayed.......................................549 C-14 [E2051 Short circuit in 2-stage relief solenoid system is displayed..............................................550 C-15 [E215] Disconnection in 2-stage relief solenoid system is displayed..............................................551 C-16 [E217] Model selection input error is displayed..................................................................552 C-17 [E2221 Short circuit in LS-EPC solenoid system is displayed......................................................554 C-18 [E223] Disconnection in LS-EPC solenoid system is displayed......................................................555 C-19 [E224] Abnormality in front pump pressure sensor system is displayed.............................................556 C-20 [E225] Abnormality in rear pump pressure sensor system is displayed..............................................557 C-21 [E226] Abnormality in pressure sensor power source system is displayed...........................................558 C-22 [E227] Abnormality in engine speed sensor system is displayed....................................................559 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)...........................................................560 F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up....................................................561 F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up...................................................562 F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up...............................................563 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up...............................................564 F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up...................................................565 F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up..................................................566 F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up..............................................567 F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up..............................................568 F-9 Bit pattern 21-(3) Swing lock switch does not light up............................................................569 F-10 Engine speed is not displayed in monitoring code 10 (abnormality in engine speed sensor system).................570 F-11 Bit pattern 22-(5) Kerosene mode connection does not light up....................................................571 F-12 Bit pattern 22-(6) L.H. knob switch does not light up............................................................572 TROUBLESHOOTING OF ENGINE THROTTLE PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).........................................573 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE.................................................................................574 F-1 Bit pattern 20-(1) Swing oil pressure switch does not light up....................................................576 F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up...................................................577 F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up...............................................578 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up...............................................579 F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up...................................................580 F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up..................................................581 F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch does not light up..............................................582 F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up..............................................583 F-9 Bit pattern 21-(3) Swing lock switch does not light up............................................................584 F-10 Bit pattern 22-(5) Kerosene mode connection does not light up....................................................585 F-11 Bit pattern 22-(6) L.H. knob switch does not light up............................................................586 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...............................................................587 TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM.................................................588 PUMP MERGE/DIVIDER LOGIC..............................................................................................592 SOLENOID ACTUATION TABLE..............................................................................................595 TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE.....................................................................596 ALL WORK EQUIPMENT, TRAVEL, SWING.................................................................................596 H-1 Speeds of all work equipment, swing, travel are slow or lack power........................................596 H-2 There is excessive drop in engine speed, or engine stalls.................................................600 H-3 No work equipment, travel, swing move.....................................................................601 H-4 Abnormal noise generated (around pump)....................................................................601 H-5 Auto-deceleration does not work (when PPC shuttle valve is cause).........................................602 H-6 Fine control ability is poor or response is poor..........................................................602 WORK EQUIPMENT....................................................................................................603 H-7 Boom is slow or lacks power...............................................................................603 H-8 Arm is slow or lacks power................................................................................605 H-9 Bucket is slow or lacks power.............................................................................607 H-10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal).......................608 H-11 Excessive hydraulic drift (boom, arm, bucket)............................................................608 H-12 Excessive time lag (engine at low idling)................................................................609 H-13 Other equipment moves when single circuit is relieved....................................................609 H-14 Lack of power when pressure rises........................................................................610 H-15 In L/O, F/O modes, work equipment speed is faster than specified speed...................................611 COMPOUND OPERATIONS...............................................................................................611 H-16 In compound operations, work equipment with larger load is slow..........................................611 H-17 In swing + boom RAISE, boom RAISE is slow................................................................612 H-18 In swing + arm OUT, arm OUT is slow......................................................................612 H-19 In swing + travel, travel speed drops excessively........................................................612 TRAVEL SYSTEM.....................................................................................................613 H-20 Travel deviation.........................................................................................613 H-21 Travel speed is slow.....................................................................................614 H-22 Steering does not turn easily or lacks power.............................................................616 H-23 Travel speed does not switch or is faster than specified speed...........................................618 H-24 Travel does not move (one side only).....................................................................618 SWING SYSTEM......................................................................................................619 H-25 Does not swing...........................................................................................619 H-26 Swing acceleration is poor or swing speed is slow (both left and right, one direction only)..............620 H-27 Excessive overrun when stopping swing....................................................................624 H-28 Excessive shock when stopping swing (one direction only).................................................625 H-29 Excessive abnormal noise when stopping swing.............................................................625 H-30 Excessive hydraulic drift of swing.......................................................................626 H-31 Swing speed is faster than specified speed in L/O and F/O modes..........................................627 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)........................................................................628 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCRS AND PROBLEMS ON MACHINE..........................................629 MACHINE MONITOR SYSTEM CIRCUIT DIAGRAM................................................................................630 M-1 [E1:01] Abnormality in error data is displayed....................................................................631 M-2 [E1:02] Error in clock data is displayed..........................................................................631 M-3 [E1:03] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed....631 M-4 When starting switch is turned on, none of lamps on monitor panel light up for 3 seconds..........................632 a) None of lamps on monitor panel light up........................................................................632 b) Some of lamps on monitor panel (gauge display, time display) do not light up...................................632 M-5 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out......................633 M-6 When starting switch is turned ON, items lighted up on monitor panel are different from machine model.............633 M-7 When starting switch is turned ON (engine stopped), CHECK items flash.............................................634 a) Coolant level flashes..........................................................................................634 b) Engine oil level flashes.......................................................................................635 c) Hydraulic oil level flashes....................................................................................635 M-8 Preheating is not being used but preheating display lights up.....................................................636 M-9 When starting switch is turned ON and engine is started, CHECK items flash........................................637 a) Alternator system..............................................................................................637 b) Engine oil pressure system.....................................................................................638 M-10 When starting switch is turned ON (engine stopped), CAUTION items flash..........................................639 a) Alternator system..............................................................................................639 b) Engine oil pressure sensor system..............................................................................639 M-11 When starting switch is turned ON and engine is started, CAUTION items flash.....................................641 a) Engine oil pressure flashes....................................................................................641 b) Coolant level flashes..........................................................................................642 c) Coolant temperature flashes....................................................................................642 d) Battery charge flashes.........................................................................................643 e) Fuel level flashes.............................................................................................643 M-12 (a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second.......................644 M-12 (b) No abnormality is displayed on monitor but buzzer sounds.....................................................644 M-13 Liquid crystal night lighting on monitor panel does not light up.................................................645 M-14 Coolant temperature gauge does not rise..........................................................................646 M-15 Coolant temperature gauge does not give any display (none of gauge lamps light up during operation)..............647 M-16 Fuel level gauge always displays FULL............................................................................648 M-17 Fuel level gauge does not give display...........................................................................648 M-18 Swing lock switch is turned ON (LOCK) but monitor panel parking display does not light up........................649 M-19 Swing lock prolix switch is ON (prolix), but monitor panel parking display does not flash........................649 M-20 Defective fuel level sensor system...............................................................................650 M-21 Defective coolant temperature sensor system......................................................................651 M-22 Defective engine oil level sensor system.........................................................................652 M-23 Defective coolant level sensor system............................................................................653 M-24 Defective hydraulic oil level sensor system......................................................................654 M-25 Working light, panel lighting do not light up, or switch is not being used but lights light up...................655 M-26 Wiper does not work or switch is not being used but wiper is actuated............................................657 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)........................................................................661 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.........................................663 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM..........................................................................667 M-1 [E101] Abnormality in error data is displayed.....................................................................669 M-2 [El031 Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed.....670 M-3 [E104] Air cleaner clogging detected is displayed.................................................................671 M-4 [E106] Drop in engine oil Hi pressure detected is displayed.......................................................671 M-5 [El081 Engine water temperature 105°C detected is displayed.......................................................672 M-6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds..........................673 M-7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out......................675 M-8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine (model)....675 M-9 When starting switch is turned ON (engine stopped), basic check items flash.......................................676 M-10 Preheating is not being used but (preheating monitor) lights up..................................................679 M-11 When starting switch is turned ON and engine is started, basic check items flash.................................680 M-12 When starting switch is turned ON (engine stopped), caution items, emergency items flash ........................682 M-13 When starting switch is turned ON and engine is started, caution items, emergency items flash....................684 M-14 When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second...........................687 M-15 No abnormality is displayed on monitor but buzzer sounds.........................................................687 M-16 Night lighting on monitor panel does not light up................................................................688 M-17 Coolant temperature gauge does not rise..........................................................................689 M-18 Coolant temperature gauge does not give any display..............................................................689 M-19 Fuel level gauge always displays FULL............................................................................690 M-20 Fuel level gauge does not give display...........................................................................690 M-21 Swing lock switch is turned ON (LOCK) but (swing lock monitor) does not light up.................................691 M-22 Swing prolix switch is turned ON (prolix), but (swing lock monitor) does not flash...............................691 M-23 Service meter does not advance while engine is running...........................................................692 M-24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed..............692 M-25 Defective fuel level sensor system...............................................................................693 M-26 Defective coolant temperature sensor system......................................................................694 M-27 Defective engine oil level sensor system.........................................................................695 M-28 Defective coolant level sensor system............................................................................696 M-29 Defective hydraulic oil level sensor system......................................................................697 M-30 Wiper does not work, or switch is not being used but wiper is actuated...........................................698 M-31 Washer motor does not work, or switch is not being used but washer motor is actuated.............................703 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................705 METHOD OF USING MANUAL........................................................................................................707 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................708 SPECIAL TOOL LIST.............................................................................................................710 STARTING MOTOR................................................................................................................714 REMOVAL AND INSTALLATION..................................................................................................714 ALTERNATOR....................................................................................................................714 REMOVAL AND INSTALLATION..................................................................................................714 AIR CONDITIONER COMPRESSOR....................................................................................................715 REMOVAL AND INSTALLATION..................................................................................................715 CONDENSER.....................................................................................................................716 REMOVAL AND INSTALLATION..................................................................................................716 ENGINE OIL COOLER.............................................................................................................717 REMOVAL AND INSTALLATION..................................................................................................717 FUEL INJECTION PUMP...........................................................................................................718 REMOVAL...................................................................................................................718 INSTALLATION..............................................................................................................720 WATER PUMP....................................................................................................................721 REMOVAL AND INSTALLATION..................................................................................................721 NOZZLE HOLDER.................................................................................................................722 REMOVAL AND INSTALLATION..................................................................................................722 TURBOCHARGER..................................................................................................................723 REMOVAL AND INSTALLATION..................................................................................................723 THERMOSTAT....................................................................................................................724 REMOVAL AND INSTALLATION..................................................................................................724 ENGINE FRONT OIL SEAL........................................................................................................725 REMOVAL AND INSTALLATION..................................................................................................725 ENGINE REAR OIL SEAL.........................................................................................................726 REMOVAL AND INSTALLATION..................................................................................................726 GOVERNOR MOTOR................................................................................................................727 REMOVAL AND INSTALLATION..................................................................................................727 CYLINDER HEAD.................................................................................................................728 REMOVAL...................................................................................................................728 INSTALLATION..............................................................................................................730 AFTERCOOLER...................................................................................................................732 REMOVAL AND INSTALLATION..................................................................................................732 HYDRAULIC OIL COOLER..........................................................................................................733 REMOVAL AND INSTALLATION..................................................................................................733 RADIATOR - HYDRAULIC OIL COOLER...............................................................................................735 REMOVAL ..................................................................................................................735 INSTALLATION .............................................................................................................736 ENGINE - HYDRAULIC PUMP.......................................................................................................739 REMOVAL...................................................................................................................739 INSTALLATION..............................................................................................................742 DAMPER........................................................................................................................743 REMOVAL AND INSTALLATION..................................................................................................743 FUEL TANK.....................................................................................................................744 REMOVAL AND INSTALLATION..................................................................................................744 CENTER SWIVEL JOINT...........................................................................................................745 REMOVAL AND INSTALLATION..................................................................................................745 DISASSEMBLY AND ASSEMBLY..................................................................................................746 FINAL DRIVE ASSEMBLY..........................................................................................................747 REMOVAL AND INSTALLATION..................................................................................................747 DISASSEMBLY...............................................................................................................749 ASSEMBLY..................................................................................................................752 SPROCKET......................................................................................................................765 REMOVAL AND INSTALLATION..................................................................................................765 TRAVEL MOTOR..................................................................................................................766 DISASSEMBLY...............................................................................................................766 ASSEMBLY..................................................................................................................771 DISASSEMBLY...............................................................................................................779 ASSEMBLY..................................................................................................................785 SWING MOTOR...................................................................................................................793 REMOVAL AND INSTALLATION..................................................................................................793 DISASSEMBLY (KMF90AB-2)...................................................................................................794 ASSEMBLY (KMF90AB-2)......................................................................................................797 SWING MACHINERY...............................................................................................................802 REMOVAL AND INSTALLATION..................................................................................................802 DISASSEMBLY...............................................................................................................803 ASSEMBLY..................................................................................................................806 REVOLVING FRAME...............................................................................................................810 REMOVAL...................................................................................................................810 INSTALLATION..............................................................................................................811 SWING CIRCLE..................................................................................................................812 REMOVAL...................................................................................................................812 INSTALLATION..............................................................................................................813 IDLER - RECOIL SPRING.........................................................................................................814 REMOVAL AND INSTALLATION..................................................................................................814 RECOIL SPRING.................................................................................................................815 DISASSEMBLY...............................................................................................................815 ASSEMBLY..................................................................................................................816 IDLER.........................................................................................................................817 DISASSEMBLY...............................................................................................................817 ASSEMBLY..................................................................................................................818 TRACK ROLLER..................................................................................................................820 REMOVAL AND INSTALLATION..................................................................................................820 DISASSEMBLY...............................................................................................................821 ASSEMBLY..................................................................................................................822 CARRIER ROLLER................................................................................................................824 REMOVAL AND INSTALLATION..................................................................................................824 DISASSEMBLY...............................................................................................................825 ASSEMBLY..................................................................................................................826 TRACK SHOE....................................................................................................................828 REMOVAL AND INSTALLATION..................................................................................................828 HYDRAULIC TANK................................................................................................................829 REMOVAL...................................................................................................................829 INSTALLATION..............................................................................................................830 CONTROL PUMP..................................................................................................................831 REMOVAL AND INSTALLATION..................................................................................................831 MAIN PUMP.....................................................................................................................832 REMOVAL...................................................................................................................832 INSTALLATION..............................................................................................................833 DISASSEMBLY...............................................................................................................834 ASSEMBLY..................................................................................................................840 MAIN PUMP INPUT SHAFT OIL SEAL................................................................................................856 REMOVAL AND INSTALLATION..................................................................................................856 CONTROL VALVE.................................................................................................................857 REMOVAL...................................................................................................................857 INSTALLATION..............................................................................................................864 DISASSEMBLY...............................................................................................................865 ASSEMBLY..................................................................................................................874 PUMP MERGE-DIVIDER VALVE......................................................................................................880 DISASSEMBLY AND ASSEMBLY..................................................................................................880 PRESSURE COMPENSATION VALVE...................................................................................................881 DISASSEMBLY AND ASSEMBLY..................................................................................................881 MAIN RELIEF VALVE.............................................................................................................882 DISASSEMBLY...............................................................................................................882 ASSEMBLY..................................................................................................................885 TVC - LS VALVE ASSEMBLY FOR FRONT PUMP........................................................................................886 REMOVAL AND INSTALLATION..................................................................................................886 TVC - LS VALVE ASSEMBLY FOR REAR PUMP.........................................................................................887 REMOVAL AND INSTALLATION..................................................................................................887 LS CONTROL EPC VALVE..........................................................................................................888 REMOVAL AND INSTALLATION..................................................................................................888 SOLENOID VALVE................................................................................................................889 REMOVAL AND INSTALLATION..................................................................................................889 WORK EQUIPMENT - SWING PPC VALVE..............................................................................................892 REMOVAL AND INSTALLATION..................................................................................................892 DISASSEMBLY...............................................................................................................893 ASSEMBLY..................................................................................................................894 TRAVEL PPC VALVE..............................................................................................................895 REMOVAL AND INSTALLATION..................................................................................................895 DISASSEMBLY...............................................................................................................897 ASSEMBLY..................................................................................................................898 BOOM LOCK VALVE...............................................................................................................902 REMOVAL AND INSTALLATION..................................................................................................902 BOOM CYLINDER.................................................................................................................903 REMOVAL...................................................................................................................903 INSTALLATION..............................................................................................................904 ARM CYLINDER..................................................................................................................905 REMOVAL...................................................................................................................905 INSTALLATION..............................................................................................................906 BUCKET CYLINDER...............................................................................................................907 REMOVAL...................................................................................................................907 INSTALLATION..............................................................................................................908 HYDRAULIC CYLINDER............................................................................................................909 DISASSEMBLY...............................................................................................................909 ASSEMBLY..................................................................................................................911 WORK EQUIPMENT................................................................................................................914 REMOVAL...................................................................................................................914 INSTALLATION..............................................................................................................915 BUCKET........................................................................................................................916 REMOVAL...................................................................................................................916 INSTALLATION..............................................................................................................917 ARM...........................................................................................................................918 REMOVAL...................................................................................................................918 INSTALLATION..............................................................................................................919 BUCKET - ARM..................................................................................................................920 REMOVAL...................................................................................................................920 INSTALLATION..............................................................................................................921 BOOM..........................................................................................................................922 REMOVAL...................................................................................................................922 INSTALLATION..............................................................................................................923 OPERATOR’S CAB................................................................................................................924 REMOVAL...................................................................................................................924 INSTALLATION..............................................................................................................926 COUNTERWEIGHT.................................................................................................................929 REMOVAL AND INSTALLATION..................................................................................................929 ENGINE THROTTLE CONTROLLER....................................................................................................930 REMOVAL AND INSTALLATION..................................................................................................930 PUMP CONTROLLER...............................................................................................................931 REMOVAL AND INSTALLATION..................................................................................................931 ENGINE THROTTLE - PUMP CONTROLLER.............................................................................................932 INSTALLATION AND INSTALLATION.............................................................................................932 CONTROL STAND CASE............................................................................................................933 REMOVAL...................................................................................................................933 INSTALLATION..............................................................................................................934 MONITOR.......................................................................................................................935 REMOVAL AND INSTALLATION..................................................................................................935 40 MAINTENANCE STANDARD...........................................................................................................936 FINAL DRIVE...................................................................................................................937 SWING MACHINERY...............................................................................................................941 TRACK FRAME - RECOIL SPRING...................................................................................................944 IDLER.........................................................................................................................945 CARRIER ROLLER................................................................................................................947 TRACK ROLLER..................................................................................................................948 TRACK SHOE....................................................................................................................949 HYDRAULIC PUMP................................................................................................................951 CONTROL VALVE.................................................................................................................953 SWING MOTOR...................................................................................................................967 TRAVEL MOTOR..................................................................................................................968 WORK EQUIPMENT - SWING PPC VALVE..............................................................................................970 TRAVEL PPC VALVE..............................................................................................................971 SERVICE PPC VALVE.............................................................................................................973 PPC SHUTTLE - TRAVEL JUNCTION VALVE...........................................................................................974 EPC - SOLENOID VALVE..........................................................................................................976 CENTER SWIVEL JOINT...........................................................................................................977 BOOM HOLDING VALVE............................................................................................................979 HYDRAULIC CYLINDER............................................................................................................980 WORK EQUIPMENT................................................................................................................984
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