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Komatsu PC228US-3, PC228USLC-3 Hydraulic Excavator Shop Manual SEBM023104 – PDF DOWNLOAD
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Komatsu PC228US-3, PC228USLC-3 Hydraulic Excavator Shop Manual
MACHINE MODEL SERIAL NUMBER
PC228US-3 20001 and up 00
PC228USLC-3 20001 and up
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Description
Komatsu PC228US-3, PC228USLC-3 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC228US-3, PC228USLC-3 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC228US-3, PC228USLC-3
Serial Number: 20001 and up
Book Code: SEBM023104
Language: English
Pages: 598
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC228US-3, PC228USLC-3 Hydraulic Excavator Shop Manual
FOREWORD:
General :
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accu- rate 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 work- shop. 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 under- standing 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 compo- nent, 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 PC228US-3, PC228USLC-3 Hydraulic Excavator Shop Manual
COVER............................................................................................................................................................................................... 1 CONTENTS........................................................................................................................................................................................ 2 LIST OF REVISED PAGES........................................................................................................................................................................... 3 SAFETY.......................................................................................................................................................................................... 7 SAFETY NOTICE............................................................................................................................................................................... 7 GENERAL PRECAUTIONS..................................................................................................................................................................... 7 PREPARATIONS FOR WORK................................................................................................................................................................... 7 PRECAUTIONS DURING WORK................................................................................................................................................................. 8 FOREWORD........................................................................................................................................................................................ 9 GENERAL..................................................................................................................................................................................... 9 HOW TO READ THE SHOP MANUAL................................................................................................................................................................. 10 HOISTING INSTRUCTIONS....................................................................................................................................................................... 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.................................................................................................................................. 12 COATING MATERIALS........................................................................................................................................................................... 14 STANDARD TIGHTENING TORQUE.................................................................................................................................................................. 16 ELECTRIC WIRE CODE.......................................................................................................................................................................... 19 CONVERSION TABLE............................................................................................................................................................................ 20 01 GENERAL.......................................................................................................................................................................................... 27 SPECIFICATION DIMENSION DRAWINGS................................................................................................................................................................ 28 SPECIFICATIONS.................................................................................................................................................................................. 30 WEIGHT TABLE.................................................................................................................................................................................... 34 FUEL, COOLANT, AND LUBRICANTS................................................................................................................................................................... 38 10 STRUCTURE AND FUNCTION........................................................................................................................................................................... 39 ENGINE RELATED PARTS............................................................................................................................................................................ 40 RADIATOR • OIL COOLER • AFTERCOOLER............................................................................................................................................................. 41 POWER TRAIN..................................................................................................................................................................................... 42 FINAL DRIVE..................................................................................................................................................................................... 44 SWING CIRCLE.................................................................................................................................................................................... 46 SWING MACHINERY................................................................................................................................................................................. 48 TRACK FRAME • RECOIL SPRING..................................................................................................................................................................... 50 IDLER....................................................................................................................................................................................... 52 CARRIER ROLLER.............................................................................................................................................................................. 54 TRACK ROLLER................................................................................................................................................................................ 55 TRACK SHOE...................................................................................................................................................................................... 56 TRIPLE GROUSER SHOE, ROAD LINER, SWAMP SHOE, FLAT SHOE...................................................................................................................................... 56 TRIPLE GROUSER SHOE......................................................................................................................................................................... 59 HYDRAULIC TANK.................................................................................................................................................................................. 60 HYDRAULIC PUMP.................................................................................................................................................................................. 62 HPV95 + 95.................................................................................................................................................................................. 62 LS VALVE.................................................................................................................................................................................... 67 PC VALVE.................................................................................................................................................................................... 67 LS-EPC VALVE................................................................................................................................................................................ 80 CONTROL VALVE................................................................................................................................................................................... 84 VARIABLE PRESSURE COMPENSATION VALVE........................................................................................................................................................ 94 CLSS............................................................................................................................................................................................ 96 OUTLINE OF CLSS............................................................................................................................................................................. 96 SELF PRESSURE REDUCING VALVE.................................................................................................................................................................... 99 TRAVEL JUNCTION VALVE...........................................................................................................................................................................102 BOOM HYDRAULIC DRIFT PREVENTION VALVE...........................................................................................................................................................104 TRAVEL PPC SHUTTLE VALVE........................................................................................................................................................................107 LIFT CHECK VALVE................................................................................................................................................................................109 HOLDING VALVE...................................................................................................................................................................................110 SWING MOTOR.....................................................................................................................................................................................116 REVERSE PREVENTION VALVE........................................................................................................................................................................121 CENTER SWIVEL JOINT.............................................................................................................................................................................123 TRAVEL MOTOR....................................................................................................................................................................................124 VALVE CONTROL...................................................................................................................................................................................133 WORK EQUIPMENT • SWING PPC VALVE................................................................................................................................................................134 TRAVEL PPC VALVE................................................................................................................................................................................138 SERVICE PPC VALVE...............................................................................................................................................................................148 PPC ACCUMULATOR.................................................................................................................................................................................151 SOLENOID VALVE..................................................................................................................................................................................152 HYDRAULIC CYLINDER..............................................................................................................................................................................154 BOOM CYLINDER...............................................................................................................................................................................154 ARM CYLINDER................................................................................................................................................................................154 BUCKET CYLINDER.............................................................................................................................................................................154 WORK EQUIPMENT..................................................................................................................................................................................156 DIMENSION OF ARM............................................................................................................................................................................158 DIMENSION OF BUCKET.........................................................................................................................................................................160 ENGINE CONTROL..................................................................................................................................................................................162 OPERATION OF SYSTEM.........................................................................................................................................................................164 Starting engine.........................................................................................................................................................................164 Engine speed control....................................................................................................................................................................164 Stopping engine.........................................................................................................................................................................164 COMPONENT...................................................................................................................................................................................165 Fuel control dial.......................................................................................................................................................................165 Governor motor..........................................................................................................................................................................166 Engine throttle and pump controller.....................................................................................................................................................168 ELECTRONIC CONTROL SYSTEM.......................................................................................................................................................................171 Engine and Pump control function............................................................................................................................................................174 Pump/Valve control function.................................................................................................................................................................180 One-touch power maximizing function.........................................................................................................................................................182 Auto-deceleration function..................................................................................................................................................................184 Auto-warm-up/Overheat prevention function...................................................................................................................................................186 Swing control function......................................................................................................................................................................188 Travel control function.....................................................................................................................................................................190 Boom stroke end electronic cushion function.................................................................................................................................................192 ATT PPC throttle function (Optional)........................................................................................................................................................194 System component parts......................................................................................................................................................................195 Engine revolution sensor................................................................................................................................................................195 PPC oil pressure switch.................................................................................................................................................................196 Pump pressure sensor....................................................................................................................................................................197 Potentiometer...........................................................................................................................................................................198 Resistor................................................................................................................................................................................199 MONITORING SYSTEM...............................................................................................................................................................................200 Monitor panel...............................................................................................................................................................................201 Display section of monitor..................................................................................................................................................................202 Mode selector switches......................................................................................................................................................................206 SENSOR..........................................................................................................................................................................................207 Engine oil level sensor.....................................................................................................................................................................208 Engine oil pressure sensor (For low pressure)...............................................................................................................................................208 Coolant temperature sensor..................................................................................................................................................................208 Fuel level sensor...........................................................................................................................................................................209 Air cleaner clogging sensor.................................................................................................................................................................209 20 TESTING, ADJUSTING,AND TROUBLESHOOTING...........................................................................................................................................................211 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................................................................212 STANDARD VALUE TABLE FOR CHASSIS................................................................................................................................................................213 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS...............................................................................................................................................223 TESTING AND ADJUSTING...........................................................................................................................................................................231 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...........................................................................................................................................232 MEASURING ENGINE SPEED......................................................................................................................................................................234 MEASURING EXHAUST GAS COLOR.................................................................................................................................................................235 ADJUSTING VALVE CLEARANCE...................................................................................................................................................................236 MEASURING COMPRESSION PRESSURE..............................................................................................................................................................237 MEASURING BLOW-BY PRESSURE..................................................................................................................................................................237 FUEL INJECTION TIMING.......................................................................................................................................................................238 MEASURING ENGINE OIL PRESSURE...............................................................................................................................................................239 BELT TENSION FOR AIR CONDITIONER COMPRESSOR.................................................................................................................................................240 MEASURING SPEED SENSOR......................................................................................................................................................................240 GOVERNOR MOTOR LEVER STROKE.................................................................................................................................................................241 HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING TRAVEL CIRCUIT..................................................................................................................................242 PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)......................................................................................................................................245 LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE.........................................................................................................247 CONTROL CIRCUIT OIL PRESSURE................................................................................................................................................................250 MEASURING SOLENOID VALVE OUTPUT PRESSURE....................................................................................................................................................251 MEASURING PPC VALVE OUTPUT PRESSURE.........................................................................................................................................................254 ADJUSTING WORK EQUIPMENT• SWING PPC VALVE...................................................................................................................................................255 TESTING TRAVEL DEVIATION....................................................................................................................................................................256 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.................................................................................................................................257 MEASURING SWING, TRAVEL MOTOR OIL LEAKAGE...................................................................................................................................................258 TESTING CLEARANCE OF SWING CIRCLE BEARING...................................................................................................................................................259 TESTING WEAR OF SPROCKET....................................................................................................................................................................260 TRACK SHOE TENSION..........................................................................................................................................................................261 BLEEDING AIR................................................................................................................................................................................262 Bleeding air from pump..................................................................................................................................................................262 Bleeding air from hydraulic cylinders...................................................................................................................................................263 Bleeding air from swing motor...........................................................................................................................................................263 Bleeding air from travel motor..........................................................................................................................................................263 PROCEDURE FOR REPLACEMENT OF BOOM ANGLE POTENTIOMETER.......................................................................................................................................264 PROCEDURE FOR CHECKING DIODE................................................................................................................................................................265 TROUBLESHOOTING.................................................................................................................................................................................267 POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................................................................................................268 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................................................................................................269 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................................................................................270 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT............................................................................................................................................270 Points to remember when troubleshooting electric circuits...............................................................................................................................275 POINTS TO REMEMBER WHEN HANDLINGHYDRAULIC EQUIPMENT.....................................................................................................................................276 CHECKS BEFORE TROUBLESHOOTING...............................................................................................................................................................278 CONNECTOR TYPES AND MOUNTING LOCATIONS......................................................................................................................................................279 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................................................................................286 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM......................................................................................................................................301 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.......................................................................................................................................302 METHOD OF USING JUDGEMENT TABLE.............................................................................................................................................................318 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................................................................................................320 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE....................................................................................................................................322 TROUBLESHOOTING OF COMMUNICATIONS ABNORMALITY (N MODE)......................................................................................................................................327 N-1 [E218] Communications abnormality...................................................................................................................................................328 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)...................................................................................................329 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM......................................................................................330 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..............................................................................................................332 JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS..............................................................................336 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE...................................................................................................................................................338 E-1 Abnormality in engine throttle and pump controller power source (controller LED is OFF).............................................................................................340 E-2 [E308] Abnormality in fuel control dial input value is displayed....................................................................................................................341 E-3 [E317] Abnormality (disconnection) in governor drive system displayed...............................................................................................................342 E-4 [E318] Abnormality (short circuit) in motor drive system is displayed...............................................................................................................343 E-5 [E306] Abnormality in feedback potentiometer system is displayed....................................................................................................................344 E-6 [E315] Abnormality (short circuit) in battery relay output system is displayed......................................................................................................345 E-7 [E316] Abnormality (step-out) in governor motor is displayed........................................................................................................................346 E-8 Engine does not start...............................................................................................................................................................348 E-9 Engine speed is irregular...........................................................................................................................................................352 a) Idling speed is irregular........................................................................................................................................................352 b) There is hunting.................................................................................................................................................................354 E-10 Lack of power (engine high idling speed is too low)................................................................................................................................356 E-11 Engine does not stop...............................................................................................................................................................358 E-12 Defective operation of battery relay system (engine does not stop).................................................................................................................360 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE).......................................................................................................363 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM..........................................................................................................................364 ACTION TAKEN BY THE CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..........................................................................................................366 JUDGEMENT TABLE FOR ENGINE THROTTLE • PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.................................................................................376 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...................................................................................................................................................378 C-1 Abnormality in controller power source system (controller LED is off)...............................................................................................................380 C-2 ([E232] Short circuit in PC-EPC solenoid system) is displayed.......................................................................................................................381 C-3 ([E233] Disconnection in PC-EPC solenoid system) is displayed.......................................................................................................................382 C-4 ([E203] Short circuit in swing holding brake solenoid system) is displayed..........................................................................................................383 C-5 ([E213] Disconnection in swing holding brake solenoid system) is displayed..........................................................................................................385 C-6 ([E234] Short circuit in boom RAISE throttle EPC solenoid system) is displayed......................................................................................................387 C-7 ([E235] Disconnection in boom RAISE throttle EPC solenoid system) is displayed......................................................................................................388 C-8 ([E204] Short circuit in pump merge/divider solenoid system) is displayed...........................................................................................................389 C-9 ([E214] Disconnection in pump merge/divider solenoid system) is displayed...........................................................................................................390 C-10([E206] Short circuit in travel speed selector system) is displayed.................................................................................................................391 C-11 ([E216] Disconnection in travel speed solenoid system) is displayed................................................................................................................392 C-12 ([E205] Short circuit in 2-stage relief solenoid system) is displayed..............................................................................................................393 C-13 ([E205] Disconnection in 2-stage relief solenoid system) is displayed..............................................................................................................394 C-14 ([E217] Machine Model selection input error) is displayed..........................................................................................................................395 C-15 ([E222] Short circuit in LS-EPC solenoid system) is displayed......................................................................................................................396 C-16 ([E223] Disconnection in LS-EPC solenoid system) is displayed......................................................................................................................397 C-17 ([E223] Abnormality in front pump pressure sensor system) is displayed.............................................................................................................398 C-18 ([E225] Abnormality in rear pump pressure sensor system) is displayed..............................................................................................................399 C-19 ([E226] Abnormality in pressure sensor power system) is displayed..................................................................................................................400 C-20 ([E201] Short circuit in travel junction solenoid system) is displayed.............................................................................................................401 C-21 ([E211] Disconnection in travel junction solenoid system) is displayed.............................................................................................................402 C-22 ([E227] Abnormality in engine speed sensor) is displayed...........................................................................................................................403 C-23 ([E241] Abnormality in boom angle potentiometer system input value) is displayed...................................................................................................404 C-24 ([E255] Abnormality in boom angle potentiometer compensation value (outside compensation range) is displayed.......................................................................405 C-25 ([E256] Abnormality in check sum is displayed......................................................................................................................................405 C-26 ([E313] Abnormality in automatic greasing is displayed.............................................................................................................................405 C-27 [E313] Abnormality in ATT-EPC solenoid system......................................................................................................................................406 TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).......................................................................................................407 F - MODE ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................................................................408 F-1 Bit pattern 20-(1) Swing oil pressure switch ON display does not light up...........................................................................................................410 F-2 Bit pattern 20-(2) Travel pressure switch ON display does not light up..............................................................................................................411 F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch ON display does not light up......................................................................................................412 F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch ON display does not light up......................................................................................................413 F-5 Bit pattern 20-(5) Arm IN oil pressure switch ON display does not light up..........................................................................................................414 F-6 Bit pattern 20-(6) Arm OUT oil pressure switch ON display does not light up.........................................................................................................415 F-7 Bit pattern 21-(1) Bucket CURL oil pressure switch ON display does not light up.....................................................................................................416 F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch ON display does not light up.....................................................................................................417 F-9 Bit pattern 21-(4) Service pressure switch ON display does not light up.............................................................................................................418 F-10 Bit pattern 21-(5) Travel steering pressure ON display switch does not light up....................................................................................................419 F-11 Bit pattern 22-(3) L. H. knob switch ON display does not light up..................................................................................................................420 F-12 Bit pattern 22-(4) Emergency swing holding brake release switch ON display does not light up.......................................................................................421 F-13 Bit pattern 22-(5) Swing lock switch ON display does not light up..................................................................................................................422 F-14 Bit pattern 27-(6) Kerosene mode connection display does not light up..............................................................................................................423 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).................................................................................................................................425 TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM ..................................................................................................................426 PUMP MERGE/DIVIDER LOGIC................................................................................................................................................................430 ON/OFF SOLENOID ACTUATION TABLE.........................................................................................................................................................431 H-1 Speeds of all work equipment, swing, travel are slow or lack power..................................................................................................................432 H-2 There is excessive drop in engine speed, or engine stalls...........................................................................................................................434 H-3 No work equipment, travel, swing move...............................................................................................................................................435 H-4 Abnormal noise generated (around pump)..............................................................................................................................................435 H-5 Auto-deceleration does not work (PPC Shuttle valve is equipped only in travel PPC valve)............................................................................................436 H-6 Fine control ability is poor or response is poor....................................................................................................................................436 H-7 Boom is slow or lacks power.........................................................................................................................................................438 H-8 Arm is slow or lacks power..........................................................................................................................................................440 H-9 Bucket is slow or lacks power.......................................................................................................................................................442 H-10 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal).................................................................................................443 H-11 Excessive hydraulic drift..........................................................................................................................................................443 H-12 Excessive time lag (engine at low idling)..........................................................................................................................................444 H-13 Other equipment moves when single circuit is relieved..............................................................................................................................444 H-14 Lack of power when pressure rises..................................................................................................................................................444 H-15 In compound operations, work equipment with larger load is slow....................................................................................................................445 H-16 In swing + boom RAISE, boom RAISE is slow..........................................................................................................................................445 H-17 In swing + travel, travel speed drops excessively..................................................................................................................................445 H-18 Travel deviation...................................................................................................................................................................446 H-19 Travel speed is slow...............................................................................................................................................................447 H-20 Steering is difficult to turn or lacks power.......................................................................................................................................448 H-21 Travel speed does not switch or is faster than specified speed.....................................................................................................................450 H-22 Travel does not move (one side only)...............................................................................................................................................450 H-23 Does not swing.....................................................................................................................................................................451 H-24 Swing acceleration is poor or swing speed is slow..................................................................................................................................452 H-25 Excessive overrun when stopping swing..............................................................................................................................................453 H-26 Excessive shock when stopping swing (one direction only)...........................................................................................................................453 H-27 Excessive abnormal noise when stopping swing.......................................................................................................................................454 H-28 Excessive hydraulic drift of swing.................................................................................................................................................455 TROUBLESHOOTING OF MONITOR PANEL SYSTEM (M MODE)............................................................................................................................................457 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITYOCCURS AND PROBLEMS ON MACHINE............................................................................................................458 M-MODE ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................................................................460 M-1 [E101] (Abnormality in error data history) is displayed.............................................................................................................................462 M-2 [E104] (Air cleaner clogging detected) is displayed.................................................................................................................................463 M-3 [E108] (Engine water temperature 105° detected) is not displayed....................................................................................................................463 M-4 [E114] (Short circuit in wiper motor normal rotation output) is displayed...........................................................................................................463 M-5 [E115] (Short circuit in wiper motor reverse rotation output) is displayed..........................................................................................................463 M-6 [E116] (Short circuit with power supply in washer output) is displayed..............................................................................................................463 M-7 [E117] (Wiping failure continues for 10 seconds) is displayed.......................................................................................................................463 M-8 [E118] (Storing wiper blade failure continues for 10 seconds) is displayed..........................................................................................................463 M-9 When starting switch is turned ON, none of the lamps on the monitor panel light up for 3 seconds....................................................................................464 M-10 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out.......................................................................................465 M-11 When starting switch is turned ON (engine stopped), basic check item flashes.......................................................................................................465 M-12 Preheating is not being used but (preheating monitor) lights up....................................................................................................................467 M-13 When starting switch is ON and engine is started, basic check item flashes.........................................................................................................468 M-14 When starting switch is turned ON (engine stopped), caution items, emergency items flash, engine oil pressure lamps do not light up................................................470 M-15 When starting switch is turned ON and engine is started, caution items, emergency items flash (when there is no abnormality in engine or items to check before troubleshooting)....472 M-16 When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second - Caution item lamp flashes but buzzer does not sound.......................................475 M-17 Night lighting on monitor panel does not light up (liquid crystal display is normal)...............................................................................................476 M-18 Coolant temperature gauge always displays low......................................................................................................................................477 M-19 Coolant temperature gauge does not give any display (none of gauge elements light up during operation).............................................................................477 M-20 Fuel level gauge always displays full..............................................................................................................................................478 M-21 Fuel level gauge does not give display.............................................................................................................................................478 M-22 Swing lock switch is turned ON (lock) but (swing lock monitor) does not light up...................................................................................................479 M-23 Service meter does not advance when engine is running..............................................................................................................................479 M-24 Defective fuel level sensor system.................................................................................................................................................480 M-25 Defective coolant temperature sensor system........................................................................................................................................481 M-26 Defective engine oil level sensor system...........................................................................................................................................482 M-27 Wiper does not work, or switch is not being used but wiper is actuated.............................................................................................................483 M-28 Washer motor does not work, or washer switch is not being used but washer motor is actuated........................................................................................486 30 DISASSEMBLY AND ASSEMBLY.........................................................................................................................................................................487 METHOD OF USING MANUAL..........................................................................................................................................................................489 PRECAUTIONS WHEN CARRYING OUT OPERATION.........................................................................................................................................................491 SPECIAL TOOL LIST...............................................................................................................................................................................494 SKETCHES OF SPECIAL TOOLS...................................................................................................................................................................497 ENGINE ASSEMBLY.................................................................................................................................................................................500 REMOVAL OF..................................................................................................................................................................................500 INSTALLATION OF.............................................................................................................................................................................502 ENGINE FRONT SEAL...............................................................................................................................................................................503 REMOVAL OF..................................................................................................................................................................................503 INSTALLATION OF.............................................................................................................................................................................503 ENGINE REAR SEAL................................................................................................................................................................................505 REMOVAL OF..................................................................................................................................................................................505 INSTALLATION OF.............................................................................................................................................................................506 RADIATOR ASSEMBLY...............................................................................................................................................................................507 REMOVAL OF..................................................................................................................................................................................507 INSTALLATION OF.............................................................................................................................................................................508 HYDRAULIC OIL COOLER ASSEMBLY...................................................................................................................................................................509 REMOVAL OF..................................................................................................................................................................................509 INSTALLATION OF.............................................................................................................................................................................510 AFTERCOOLER ASSEMBLY............................................................................................................................................................................511 REMOVAL OF..................................................................................................................................................................................511 INSTALLATION OF.............................................................................................................................................................................511 FUEL TANK ASSEMBLY..............................................................................................................................................................................512 REMOVAL OF..................................................................................................................................................................................512 INSTALLATION OF.............................................................................................................................................................................512 CENTER SWIVEL JOINT ASSEMBLY....................................................................................................................................................................513 REMOVAL OF..................................................................................................................................................................................513 INSTALLATION OF.............................................................................................................................................................................514 DISASSEMBLY OF..............................................................................................................................................................................515 ASSEMBLY OF.................................................................................................................................................................................515 FINAL DRIVE, TRAVEL MOTOR ASSEMBLY..............................................................................................................................................................516 REMOVAL OF..................................................................................................................................................................................516 INSTALLATION OF.............................................................................................................................................................................516 DISASSEMBLY OF..............................................................................................................................................................................517 ASSEMBLY OF.................................................................................................................................................................................520 SWING MOTOR AND SWING MACHINERY ASSEMBLY........................................................................................................................................................526 REMOVAL OF..................................................................................................................................................................................526 INSTALLATION OF.............................................................................................................................................................................526 SWING MACHINERY ASSEMBLY....................................................................................................................................................................527 DISASSEMBLY OF..........................................................................................................................................................................527 ASSEMBLY OF.............................................................................................................................................................................529 REVOLVING FRAME ASSEMBLY........................................................................................................................................................................535 REMOVAL OF..................................................................................................................................................................................535 INSTALLATION OF.............................................................................................................................................................................536 SWING CIRCLE ASSEMBLY...........................................................................................................................................................................536 REMOVAL OF..................................................................................................................................................................................536 INSTALLATION OF.............................................................................................................................................................................537 RECOIL SPRING ASSEMBLY..........................................................................................................................................................................538 DISASSEMBLY OF..............................................................................................................................................................................538 ASSEMBLY OF.................................................................................................................................................................................539 IDLER ASSEMBLY..................................................................................................................................................................................540 ASSEMBLY....................................................................................................................................................................................540 TRACK ROLLER ASSEMBLY...........................................................................................................................................................................542 ASSEMBLY OF.................................................................................................................................................................................542 TRACK SHOE ASSEMBLY.............................................................................................................................................................................544 STEEL SHOE..................................................................................................................................................................................544 EXPANSION OF............................................................................................................................................................................544 INSTALLATION OF.........................................................................................................................................................................544 ROAD LINER SHOE.............................................................................................................................................................................545 EXPANSION OF............................................................................................................................................................................545 INSTALLATION OF.........................................................................................................................................................................545 HYDRAULIC TANK ASSEMBLY.........................................................................................................................................................................546 REMOVAL OF..................................................................................................................................................................................546 INSTALLATION OF.............................................................................................................................................................................546 HYDRAULIC PUMP ASSEMBLY.........................................................................................................................................................................547 REMOVAL OF..................................................................................................................................................................................547 INSTALLATION OF.............................................................................................................................................................................548 CONTROL VALVE ASSEMBLY..........................................................................................................................................................................549 REMOVAL OF..................................................................................................................................................................................549 INSTALLATION OF.............................................................................................................................................................................551 DISASSEMBLY OF..............................................................................................................................................................................552 ASSEMBLY OF.................................................................................................................................................................................558 PUMP MERGE-DIVIDER VALVE/SELF-PRESSURE REDUCING VALVE/TRAVEL JUNCTION VALVE ASSEMBLY............................................................................................................564 DISASSEMBLY OF..............................................................................................................................................................................564 ASSEMBLY OF.................................................................................................................................................................................565 MAIN RELIEF VALVE ASSEMBLY......................................................................................................................................................................566 DISASSEMBLY OF..............................................................................................................................................................................566 ASSEMBLY OF.................................................................................................................................................................................566 WORK EQUIPMENT PPC VALVE ASSEMBLY (PPC VALVE FOR BOOM, BUCKET, ARM, SWING CONTROL)..............................................................................................................567 DISASSEMBLY OF..............................................................................................................................................................................567 TRAVEL PPC VALVE ASSEMBLY.......................................................................................................................................................................568 DISASSEMBLY OF..............................................................................................................................................................................568 ASSEMBLY OF.................................................................................................................................................................................568 WORK EQUIPMENT ASSEMBLY.........................................................................................................................................................................569 REMOVAL OF..................................................................................................................................................................................569 INSTALLATION OF.............................................................................................................................................................................570 OPERATOR'S CAB ASSEMBLY.........................................................................................................................................................................571 REMOVAL OF..................................................................................................................................................................................571 INSTALLATION OF.............................................................................................................................................................................572 FLOOR FRAME ASSEMBLY............................................................................................................................................................................573 REMOVAL OF..................................................................................................................................................................................573 INSTALLATION OF.............................................................................................................................................................................574 AIR CONDITIONER COMPRESSOR ASSEMBLY.............................................................................................................................................................575 REMOVAL OF..................................................................................................................................................................................575 INSTALLATION OF.............................................................................................................................................................................575 AIR CONDITIONER CONDENSER ASSEMBLY..............................................................................................................................................................576 REMOVAL OF..................................................................................................................................................................................576 INSTALLATION OF.............................................................................................................................................................................576 AIR CONDITIONER UNIT ASSEMBLY...................................................................................................................................................................576 REMOVAL OF..................................................................................................................................................................................576 INSTALLATION OF.............................................................................................................................................................................578 COUNTERWEIGHT ASSEMBLY..........................................................................................................................................................................578 REMOVAL, INSTALLATION OF....................................................................................................................................................................578 Removal of maintenance counterweight assembly (above pump)..................................................................................................................................579 Installation of maintenance counterweight assembly (above pump).............................................................................................................................579 Removal of counterweight assembly (including central counterweight at rear of engine and counterweight above pump)..........................................................................579 Installation of counterweight assembly (including central counterweight at rear of engine and counterweight above pump).....................................................................579 MONITOR PANEL ASSEMBLY..........................................................................................................................................................................580 REMOVAL OF..................................................................................................................................................................................580 INSTALLATION OF.............................................................................................................................................................................580 90 OTHERS...........................................................................................................................................................................................581 HYDRAULIC CIRCUIT DIAGRAM.......................................................................................................................................................................583 STANDARD MACHINE............................................................................................................................................................................583 ARM CRANE TYPE MACHINE......................................................................................................................................................................585 ELECTRICAL CIRCUIT DIAGRAM......................................................................................................................................................................587 STANDARD MACHINE (1/5)......................................................................................................................................................................587 STANDARD MACHINE (2/5)......................................................................................................................................................................589 STANDARD MACHINE (3/5)......................................................................................................................................................................591 STANDARD MACHINE (4/5)......................................................................................................................................................................593 ARM CRANE TYPE MACHINE (5/5)................................................................................................................................................................595 ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER..............................................................................................................................................597
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