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Komatsu PC250 6 PC250LC 6 Service Repair Workshop Manual Download
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Description
Komatsu PC250 6 PC250LC 6 Service Repair Workshop Manual Download
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Komatsu PC250 6 PC250LC 6 Service Repair Workshop Manual Download
LANGUAGE:ENGLISH
PAGES:757
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU PC250 6 PC250LC 6 SERVICE REPAIR WORKSHOP MANUAL DOWNLOAD:
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Komatsu PC250 6 PC250LC 6 Service Repair Workshop Manual Download
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.
TABLE OF CONTENTS:
Komatsu PC250 6 PC250LC 6 Service Repair Workshop Manual Download COVER............................................................................................................................................................................................. 1 CONTENTS.......................................................................................................................................................................................... 2 01 GENERAL........................................................................................................................................................................................ 23 SPECIFICATION DIMENSION DRAWINGS.............................................................................................................................................................. 24 SPECIFICATIONS................................................................................................................................................................................ 25 WEIGHT TABLE.................................................................................................................................................................................. 27 FUEL,COOLANT AND LUBRICANTS................................................................................................................................................................... 29 10 STRUCTURE AND FUNCTION......................................................................................................................................................................... 31 ENGINE RELATED PARTS.......................................................................................................................................................................... 32 REDIATOR...................................................................................................................................................................................... 33 RADIATOR・OIL COOLER・AFTERCOOLER............................................................................................................................................................... 33 POWER TRAIN................................................................................................................................................................................... 34 FINAL DRIVE................................................................................................................................................................................... 35 SWING CIRCLE.................................................................................................................................................................................. 36 SWING MACHINERY............................................................................................................................................................................... 37 TRACK FRAME,RECOIL SPRING..................................................................................................................................................................... 38 TRACK SHOE.................................................................................................................................................................................... 39 HYDRAULIC PIPING DRAWING...................................................................................................................................................................... 40 HYDRAULIC TANK................................................................................................................................................................................ 42 HYDRAULIC PUMP................................................................................................................................................................................ 43 LINE OIL FILTER............................................................................................................................................................................... 62 CONTROL VALVE................................................................................................................................................................................. 63 SELF-REDUCING PRESSURE VALVE.................................................................................................................................................................. 69 CLSS.......................................................................................................................................................................................... 74 SWING MOTOR...................................................................................................................................................................................119 CENTER SWIVEL JOINT...........................................................................................................................................................................125 TRAVEL MOTOR..................................................................................................................................................................................126 VALVE CONTROL.................................................................................................................................................................................135 WORK EQUIPMENT・SWING PPC VALVE................................................................................................................................................................136 TRAVEL PPC VALVE..............................................................................................................................................................................140 SERVICE PPC VALVE.............................................................................................................................................................................144 SAFETY LOCK VALVE.............................................................................................................................................................................147 PPC ACCUMULATOR...............................................................................................................................................................................147 STRAIGHT-TRAVEL SYSTEM........................................................................................................................................................................148 SOLENOID VALVE................................................................................................................................................................................149 BOOM HOLDING VALVE............................................................................................................................................................................151 ADDITIONAL FILTER FOR BREAKER.................................................................................................................................................................154 WORK EQUIPMENT................................................................................................................................................................................155 AIR CONDITIONER...............................................................................................................................................................................156 ACTUAL ELECTRIC WIRING DIAGRAM................................................................................................................................................................157 ENGINE CONTROL SYSTEM.........................................................................................................................................................................162 ELECTRONIC CONTROL SYSTEM.....................................................................................................................................................................168 MONITOR SYSTEM................................................................................................................................................................................199 SENSORS.......................................................................................................................................................................................207 FRONT WINDOW AUTO PULL-UP SYSTEM..............................................................................................................................................................210 20 TESTING AND ADJUSTING..........................................................................................................................................................................212 TABLE OF JUDGEMENT STANDARD VALUE ............................................................................................................................................................214 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.....................................................................................................................................................223 TESTING AND ADJUSTING.........................................................................................................................................................................232 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING...........................................................................................................................................233 MEASURING ENGINE SPEED ...................................................................................................................................................................234 MEASURING EXHAUST GAS COLOR...............................................................................................................................................................235 ADJUSTING VALVE CLEARANCE.................................................................................................................................................................236 MEASURING COMPRESSION PRESSURE............................................................................................................................................................237 MEASURING BLOW-BY PRESSURE................................................................................................................................................................237 TESTING AND ADJUSTING FUEL INJECTION TIMING...............................................................................................................................................238 MEASURING ENGINE OIL PRESSURE ............................................................................................................................................................239 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.............................................................................................................................................240 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.........................................................................................................................240 MEASURING SPEED SENSOR ...................................................................................................................................................................241 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE.........................................................................................................................................242 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EPUIPMENT,SWING,TRAVEL,CIRCUIT...........................................................................................................243 TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUIT PRESSURE).............................................................................................................246 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)AND LS DIFFERENTIAL PRESSURE..................................................................................248 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE........................................................................................................................................251 TESTING SOLENOID VALVE OUTPUT PRESSURE....................................................................................................................................................252 MEASURING PPC VALVE OUTPUT PRESSURE.......................................................................................................................................................254 ADJUSTING WORK EQUIPMENT・SWING PPC VALVE..................................................................................................................................................256 TESTING TRAVEL DEVIATION..................................................................................................................................................................257 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...............................................................................................................................258 MEASURING OIL LEAKAGE.....................................................................................................................................................................260 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.........................................................................................................................................262 TESTING CLEARANCE OF SWING CIRCLE BEARING.................................................................................................................................................263 TESTING AND ADJUSTING TRACK SHOE TENSION..................................................................................................................................................264 BLEEDING AIR..............................................................................................................................................................................265 TROUBLESHOOTING...............................................................................................................................................................................268 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................................................................269 SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................................................................................................270 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..........................................................................................................................................271 CHECKS BEFORE TROUBLESHOOTING.............................................................................................................................................................279 CONNECTOR TYPES AND MOUNTING LOCATIONS....................................................................................................................................................280 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................................................................................284 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....................................................................................................................................295 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.....................................................................................................................................296 METHOD OF USING JUDGEMENT TABLE...........................................................................................................................................................306 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................................................................308 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE..................................................................................................................................310 SERVICE CODE TABLE........................................................................................................................................................................315 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)..............................................................................................................................316 N-1 [E218] COMMUNICATIONS ABNORMALITY.................................................................................................................................................317 TROUBLESHOOTING OF ENGINE THROTTLE・PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE).....................................................................................................319 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE・PUMP CONTROLLER SYSTEM .......................................................................................320 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE............................................................................................................321 JUDGEMENT TABLE FOR ENGINE THROTTLE・PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS................................................................................325 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM..........................................................................................................................................327 E-1 ABNORMALITY IN ENGINE THROTTLE・PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...............................................................................................329 E-2 [E308]ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...................................................................................................................330 E-3 [E317]ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED..............................................................................................................331 E-4 [E318]ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED..............................................................................................................332 E-5 [E306]ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...................................................................................................................333 E-6 [E315]ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED.....................................................................................................334 E-7 [E316]ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED................................................................................................................................335 E-8 ENGINE DOES NOT START.............................................................................................................................................................336 E-9 ENGINE SPEED IS IRREGULAR ........................................................................................................................................................339 a) IDLING SPEED IS IRREGULAR......................................................................................................................................................339 b) THERE IS HUNTING ..............................................................................................................................................................341 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW).............................................................................................................................343 E-11 ENGINE DOES NOT STOP.............................................................................................................................................................345 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)...............................................................................................................347 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).................................................................................................................................................349 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................................350 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).........................................................................................................................354 S-2 ENGINE DOES NOT START.............................................................................................................................................................355 (1)ENGINE DOES NOT TURN ..........................................................................................................................................................355 (2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).......................................................................................................356 (3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).....................................................................................................357 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..............................................................................................................................358 S-4 ENGINE STOPS DURING OPERATIONS....................................................................................................................................................359 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).........................................................................................................................................360 S-6 ENGINE LACK OUTPUT (NO POWER).....................................................................................................................................................361 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....................................................................................................................................362 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...........................................................................................................................363 S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................................................................................364 S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................................................................................365 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN............................................................................................................366 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................................................................367 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)..............................................................................................................................................368 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................................................................................................369 S-15 ABNORMAL NOISE IS MADE...........................................................................................................................................................370 S-16 VIBRATION IS EXCESSIVE...........................................................................................................................................................371 TROUBLESHOOTING OF ENGINE THROTTLE・PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE).........................................................................................................372 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM........................................................................................................................373 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE............................................................................................................374 JUDGEMENT TABLE FOR ENGINE THROTTLE・PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.................................................................................382 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE ................................................................................................................................................384 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF).............................................................................................................386 C-2 [E232]SHORT CIRCUIT IN PC-EPC SOLENOID SYSTEM IS DISPLAYED........................................................................................................................387 C-3 [E233]DISCONNECTION IN PC-EPC SOLENOID SYSTEM IS DISPLAYED........................................................................................................................388 C-4 [E203]SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................389 C-5 [E213]DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................391 C-6 [E204]SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED............................................................................................................393 C-7 [E214]DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED............................................................................................................394 C-8 [E207]SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................395 C-9 [E208]DISCONNCETION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED...................................................................................................................396 C-10 [E206]SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED.................................................................................................................397 C-11 [E216]DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED.................................................................................................................398 C-12 [E205]SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...............................................................................................................399 C-13 [E215]DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED...............................................................................................................400 C-14 [E217]MODEL SELECTION INPUT ERROR IS DISPLAYED...................................................................................................................................401 C-15 [E222]SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................403 C-16 [E223]DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................404 C-17 [E224]ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED..............................................................................................................405 C-18 [E225]ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...............................................................................................................406 C-19 [E226]ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED............................................................................................................407 C-20 [E227]ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED.....................................................................................................................408 C-21 [E302]SHORT CIRCUIT IN SWING STROKE LIMIT SOLENOID SYSTEM IS DISPLAYED...........................................................................................................409 C-22 [E303]DISCONNECTION IN SWING STROKE LIMIT SOLENOID SYSTEM IS DISPLAYED...........................................................................................................410 TROUBLESHOOTING OF ENGINE THROTTLE・PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).........................................................................................................411 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE.................................................................................................................................................412 F-1 BIT PATTERN 20-(1)SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................................................................414 F-2 BIT PATTERN 20-(2)TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP....................................................................................................................415 F-3 BIT PATTERN 20-(3)BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................................................................................416 F-4 BIT PATTERN 20-(4)BOOM RAISE OIL PRESSURE SWITCH DOSE NOT LIGHT UP................................................................................................................417 F-5 BIT PATTERN 20-(5)ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP....................................................................................................................418 F-6 BIT PATTERN 20-(6)ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...................................................................................................................419 F-7 BIT PATTERN 21-(1)BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................420 F-8 BIT PATTERN 21-(2)BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................421 F-9 BIT PATTERN 21-(3)SWING LOCK SWITCH DOES NOT LIGHT UP.............................................................................................................................422 F-10 BIT PATTERN 22-(5)KEROSENE MODE CONNECTION DOES NOT LIGHT UP.....................................................................................................................423 F-11 BIT PATTERN 22-(6)L.H.KNOB SWITCH DOES NOT LIGHT UP..............................................................................................................................424 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 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.......................................................................................................................................................437 H-8 ARM IS SLOW OR LACKS POWER........................................................................................................................................................439 H-9 BUCKET IS SLOW OR LACKS POWER.....................................................................................................................................................441 H-10 WORK EQUIPMENT (BOOM,ARM,BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).................................................................................................442 H-11 EXCESSIVE HYDRAULIC DRIFT........................................................................................................................................................442 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)........................................................................................................................................443 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED............................................................................................................................443 H-14 LACK OF POWER WHEN PRESSURE RISES................................................................................................................................................444 H-15 IN L/O,F/O MODES,WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED.............................................................................................................445 H-16 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGE LOAD IS SLOW....................................................................................................................445 H-17 IN SWING + BOOM RAISE,BOOM RAISE IS SLOW.........................................................................................................................................446 H-18 IN SWING + TRAVEL,TRAVEL SPEED DROPS EXCESSIVELY.................................................................................................................................446 H-19 TRAVEL DEVIATION ................................................................................................................................................................447 H-20 TRAVEL SPEED IS SLOW.............................................................................................................................................................448 H-21 STEERING DOES NOT TURN EASILY OR LACKS POWER.....................................................................................................................................450 H-22 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED...................................................................................................................452 H-23 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).............................................................................................................................................452 H-24 DOES NOT SWING...................................................................................................................................................................453 H-25 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW................................................................................................................................454 H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING............................................................................................................................................456 H-27 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY).........................................................................................................................457 H-28 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING.....................................................................................................................................457 H-29 EXCESSIVE HYDRAULIC DRIFT OF SWING...............................................................................................................................................458 H-30 SWING SPEED IS FASTER THAN SPECIFIED SPEED IN L/O,F/O MODES......................................................................................................................459 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)........................................................................................................................................460 ACTIOM TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.........................................................................................................462 ELECTRICAL CIRCUIT DIAGRAN FOR M MODE SYSTEM..........................................................................................................................................464 M-1 [E101]ABNORMALITY IN ERROR DATA IS DISPLAYED [E102]ERROR IN CLOCK DATA IS DISPLAYED...............................................................................................466 M-2 [E103]SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED......................................................................467 M-3 [E104]AIR CLEANER CLOGGING DETECTED IS DISPLAYED..................................................................................................................................468 M-4 [E108]ENGINE WATER TEMPERATURE 105゜C DETECTED IS DISPLAYED........................................................................................................................468 M-5 WHEN STARTING SWITCH IS TURNED ON,NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS...........................................................................................469 a) NONE OF LAMPS ON MONITOR PANEL LIGHT UP........................................................................................................................................469 b) SOME OF LAMPS ON MONITOR PANEL NOT LIGHT UP....................................................................................................................................469 M-6 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT.......................................................................................471 M-7 WHEN STARTING SWITCH IS TURNED ON,ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL).....................................................................471 M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),BASIC CHECK ITEMS FLASH........................................................................................................472 a) (COOLANT LEVEL) FLASHES........................................................................................................................................................472 b) (ENGINE OIL LEVEL) FLASHES.....................................................................................................................................................473 c) (HYDRAULIC OIL LEVEL) FLASHES..................................................................................................................................................474 M-9 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP...................................................................................................................475 M-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,BASIC CHECK ITEMS FLASH..................................................................................................476 a) ALTERNATOR SYSTEM..............................................................................................................................................................476 b) ENGINE OIL PRESSURE SYSTEM.....................................................................................................................................................477 M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CAUTION ITEMS,EMERGENCY ITEMS FLASH (BATTERY,ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP).......................................478 a) ALTERNATOR SYSTEM..............................................................................................................................................................478 b) ENGINE OIL PRESSURE SENSOR SYSTEM..............................................................................................................................................479 M-12 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)....480 a) (ENGINE OIL PRESSURE) FLASHES..................................................................................................................................................480 b) (COOLANT LEVEL) FLASHES........................................................................................................................................................480 c) (BATTERY CHARGE) FLASHES.......................................................................................................................................................480 d) (COOLANT TEMPERATURE) FLASHES..................................................................................................................................................481 e) (FUEL LEVEL) FLASHES...........................................................................................................................................................481 f) (AIR CLEANER CLOGGING) FLASHES.................................................................................................................................................482 M-13 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SECOND, CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND............................................483 M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS.........................................................................................................................483 M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL).............................................................................................484 M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE..........................................................................................................................................485 M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)..............................................................................485 M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL............................................................................................................................................486 M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...........................................................................................................................................486 M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP ................................................................................................487 M-21 SWING PROLIX SWITCH IS TURNED ON (PROLIX),BUT (SWING LOCK MONITOR) DOES NOT FLASH................................................................................................487 M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING...........................................................................................................................488 M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED,TIME AND SERVICE METER ARE NOT DISPLAYED...............................................................................488 M-24 DEFECTIVE FUEL LEVEL SENSOR SYSTEM...............................................................................................................................................489 M-25 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM......................................................................................................................................490 M-26 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM.........................................................................................................................................491 M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM............................................................................................................................................492 M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM......................................................................................................................................493 M-29 WIPER DOES NOT WORK,OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED ...........................................................................................................494 a) WIPER DOES NOT WORK............................................................................................................................................................494 b) WIPER SWITCH IS NOT BEING OPERATED BUT WIPER IS ACTUATED.......................................................................................................................497 M-30 WASHER MOTOR DOES NOT WORK,OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED..............................................................................................499 a) WASHER MOTOR DOES NOT WORK ....................................................................................................................................................499 b) SWITCH IS NOT BEING OPERATED BUT WASHER IS ACTUATED............................................................................................................................500 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................501 METHOD OF USING MANUAL........................................................................................................................................................................503 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................................................................504 SPECIAL TOOL LIST.............................................................................................................................................................................506 SKETCHES OF SPECIAL TOOLS.....................................................................................................................................................................512 STARTING MOTOR................................................................................................................................................................................515 REMOVAL AND INSTALLATION..................................................................................................................................................................515 ALTERNATOR ...................................................................................................................................................................................516 REMOVAL AND INSTALLATION..................................................................................................................................................................516 AIR CONDITIONER COMPRESSOR ...................................................................................................................................................................517 REMOVAL AND INSTALLATION..................................................................................................................................................................517 AIR CONDITIONER CONDENSER ....................................................................................................................................................................518 REMOVAL AND INSTALLATION..................................................................................................................................................................518 DRY RECEIVER .................................................................................................................................................................................519 REMOVAL AND INSTALLATION..................................................................................................................................................................519 ENGINE OIL COOLER CORE .......................................................................................................................................................................520 REMOVAL AND INSTALLATION..................................................................................................................................................................520 FUEL INJECTION PUMP...........................................................................................................................................................................521 REMOVAL ..................................................................................................................................................................................521 INSTALLATION..............................................................................................................................................................................524 WATER PUMP ...................................................................................................................................................................................526 REMOVAL ..................................................................................................................................................................................526 INSTALLATION..............................................................................................................................................................................527 NOZZLE HOLDER.................................................................................................................................................................................528 REMOVAL AND INSTALLATION..................................................................................................................................................................528 TURBOCHARGER..................................................................................................................................................................................529 REMOVAL AND INSTALLATION..................................................................................................................................................................529 THERMOSTAT....................................................................................................................................................................................530 REMOVAL ..................................................................................................................................................................................530 INSTALLATION..............................................................................................................................................................................531 GOVERNOR MOTOR................................................................................................................................................................................532 REMOVAL AND INSTALLATION..................................................................................................................................................................532 CYLINDER HEAD ................................................................................................................................................................................533 REMOVAL ..................................................................................................................................................................................533 INSTALLATION..............................................................................................................................................................................538 HYDRAULIC OIL COOLER..........................................................................................................................................................................541 REMOVAL AND INSTALLATION..................................................................................................................................................................541 RADIATOR,HYDRAULIC OIL COOLER.................................................................................................................................................................542 REMOVAL ..................................................................................................................................................................................542 INSTALLATION..............................................................................................................................................................................544 ENGINE,MAIN PUMP..............................................................................................................................................................................545 REMOVAL ..................................................................................................................................................................................545 INSTALLATION..............................................................................................................................................................................549 DAMPER........................................................................................................................................................................................550 REMOVAL AND INSTALLATION..................................................................................................................................................................550 FUEL TANK.....................................................................................................................................................................................551 REMOVAL AND INSTALLATION..................................................................................................................................................................551 CENTER SWIVEL JOINT...........................................................................................................................................................................552 REMOVAL ..................................................................................................................................................................................552 INSTALLATION..............................................................................................................................................................................553 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................554 FINAL DRIVE...................................................................................................................................................................................555 REMOVAL AND INSTALLATION..................................................................................................................................................................555 DISASSEMBLY...............................................................................................................................................................................556 ASSEMBLY..................................................................................................................................................................................560 TRAVEL MOTOR..................................................................................................................................................................................566 DISASSEMBLY...............................................................................................................................................................................566 ASSEMBLY..................................................................................................................................................................................571 SPROCKET......................................................................................................................................................................................580 REMOVAL AND INSTALLATION..................................................................................................................................................................580 SWING MOTOR AND SWING MACHINERY...............................................................................................................................................................581 REMOVAL ..................................................................................................................................................................................581 INSTALLATION..............................................................................................................................................................................582 SWING MACHINERY ............................................................................................................................................................................583 DISASSEMBLY...............................................................................................................................................................................583 ASSEMBLY..................................................................................................................................................................................587 SWING MOTOR ..................................................................................................................................................................................592 DISASSEMBLY...............................................................................................................................................................................592 ASSEMBLY..................................................................................................................................................................................596 REVOLVING FRAME...............................................................................................................................................................................603 REMOVAL ..................................................................................................................................................................................603 INSTALLATION..............................................................................................................................................................................604 SWING CIRCLE..................................................................................................................................................................................605 REMOVAL AND INSTALLATION..................................................................................................................................................................605 IDLER,RECOIL SPRING...........................................................................................................................................................................606 REMOVAL AND INSTALLATION..................................................................................................................................................................606 IDLER .......................................................................................................................................................................................607 DISASSEMBLY...............................................................................................................................................................................607 ASSEMBLY..................................................................................................................................................................................608 RECOIL SPRING.................................................................................................................................................................................610 DISASSEMBLY...............................................................................................................................................................................610 ASSEMBLY..................................................................................................................................................................................611 TRACK ROLLER..................................................................................................................................................................................612 REMOVAL AND INSTALLATION..................................................................................................................................................................612 DISASSEMBLY...............................................................................................................................................................................613 ASSEMBLY..................................................................................................................................................................................614 CARRIER ROLLER................................................................................................................................................................................616 REMOVAL AND INSTALLATION..................................................................................................................................................................616 DISASSEMBLY...............................................................................................................................................................................617 ASSEMBLY..................................................................................................................................................................................619 TRACK SHOE ...................................................................................................................................................................................621 REMOVAL AND INSTALLATION..................................................................................................................................................................621 HYDRAULIC TANK................................................................................................................................................................................622 REMOVAL ..................................................................................................................................................................................622 INSTALLATION..............................................................................................................................................................................623 MAIN PUMP.....................................................................................................................................................................................624 REMOVAL ..................................................................................................................................................................................624 INSTALLATION..............................................................................................................................................................................626 DISASSEMBLY...............................................................................................................................................................................627 ASSEMBLY..................................................................................................................................................................................640 MAIN PUMP INPUT SHAFT OIL SEAL................................................................................................................................................................656 REMOVAL AND INSTALLATION..................................................................................................................................................................656 CONTROL VALVE.................................................................................................................................................................................657 REMOVAL ..................................................................................................................................................................................657 INSTALLATION..............................................................................................................................................................................659 DISASSEMBLY...............................................................................................................................................................................660 ASSEMBLY..................................................................................................................................................................................665 PUMP MERGE-DIVIDER VALVE......................................................................................................................................................................671 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................671 MAIN RELIEF VALVE.............................................................................................................................................................................672 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................672 PC VALVE......................................................................................................................................................................................673 REMOVAL ..................................................................................................................................................................................673 INSTALLATION..............................................................................................................................................................................674 LS VALVE......................................................................................................................................................................................675 REMOVAL AND INSTALLATION..................................................................................................................................................................675 PC, LS-EPC VALVE..............................................................................................................................................................................676 REMOVAL AND INSTALLATION..................................................................................................................................................................676 SOLENOID VALVE................................................................................................................................................................................677 REMOVAL AND INSTALLATION..................................................................................................................................................................677 WORK EQUIPMENT・SWING PPC VALVE................................................................................................................................................................678 REMOVAL AND INSTALLATION..................................................................................................................................................................678 DISASSEMBLY...............................................................................................................................................................................679 ASSEMBLY..................................................................................................................................................................................680 TEAVEL PPC VALVE..............................................................................................................................................................................681 REMOVAL AND INSTALLATION..................................................................................................................................................................681 DISASSEMBLY...............................................................................................................................................................................682 BOOM LOCK VALVE...............................................................................................................................................................................684 REMOVAL AND INSTALLATION..................................................................................................................................................................684 BOOM CYLINDER.................................................................................................................................................................................685 REMOVAL ..................................................................................................................................................................................685 INSTALLATION..............................................................................................................................................................................686 ARM CYLINDER..................................................................................................................................................................................687 REMOVAL ..................................................................................................................................................................................687 INSTALLATION..............................................................................................................................................................................688 BUCKET CYLINDER...............................................................................................................................................................................689 REMOVAL ..................................................................................................................................................................................689 INSTALLATION..............................................................................................................................................................................690 HYDRAULIC CYLINDER............................................................................................................................................................................691 DISASSEMBLY...............................................................................................................................................................................691 ASSEMBLY..................................................................................................................................................................................694 WORK EQUIPMENT ..............................................................................................................................................................................698 REMOVAL ..................................................................................................................................................................................698 INSTALLATION..............................................................................................................................................................................699 BUCKET ......................................................................................................................................................................................700 REMOVAL ..................................................................................................................................................................................700 INSTALLATION..............................................................................................................................................................................701 ARM .........................................................................................................................................................................................702 REMOVAL ..................................................................................................................................................................................702 INSTALLATION..............................................................................................................................................................................703 BUCKET・ARM....................................................................................................................................................................................704 REMOVAL ..................................................................................................................................................................................704 INSTALLATION..............................................................................................................................................................................705 BOOM..........................................................................................................................................................................................706 REMOVAL ..................................................................................................................................................................................706 INSTALLATION..............................................................................................................................................................................707 OPERATOR'S CAB................................................................................................................................................................................708 REMOVAL ..................................................................................................................................................................................708 INSTALLATION..............................................................................................................................................................................709 COUNTERWEIGHT.................................................................................................................................................................................710 REMOVAL AND INSTALLATION..................................................................................................................................................................710 ENGINE THROTTLE・PUMP CONTROLLER...............................................................................................................................................................711 REMOVAL AND INSTALLATION..................................................................................................................................................................711 CONTROL STAND CASE............................................................................................................................................................................712 REMOVAL ..................................................................................................................................................................................712 INSTALLATION..............................................................................................................................................................................713 MONITOR.......................................................................................................................................................................................714 REMOVAL AND INSTALLATION..................................................................................................................................................................714 40 MAINTENANCE STANDARD...........................................................................................................................................................................715 SWING MACHINERY...............................................................................................................................................................................716 FINAL DRIVE ..................................................................................................................................................................................718 SWING CIRCLE..................................................................................................................................................................................720 TRACK FRAME AND RECOIL SPRING.................................................................................................................................................................721 IDLER.........................................................................................................................................................................................722 CARRIER ROLLER................................................................................................................................................................................724 TRACK ROLLER..................................................................................................................................................................................725 TRACK SHOE....................................................................................................................................................................................726 HYDRAULIC PUMP................................................................................................................................................................................730 CONTROL VALVE.................................................................................................................................................................................731 SELF-REDUCING PRESSURE VALVE..................................................................................................................................................................739 SWING MOTOR...................................................................................................................................................................................740 TRAVEL MOTOR..................................................................................................................................................................................741 WORK EQUIPMENT・SWING PPC VALVE................................................................................................................................................................742 TRAVEL PPC VALVE..............................................................................................................................................................................743 SERVICE PPC VALVE.............................................................................................................................................................................744 CENTER SWIVEL JOINT ..........................................................................................................................................................................745 BOOM HOLDING VALVE............................................................................................................................................................................746 HYDRAULIC CYLINDER............................................................................................................................................................................747 WORK EQUIPMENT ..............................................................................................................................................................................749 DIMENSION OF WORK EQUIPMENT...................................................................................................................................................................751 90 OTHERS.........................................................................................................................................................................................754 HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................................................................................755 ELECTRICAL CIRCUIT DIAGRAM (1/2)..............................................................................................................................................................756 ELECTRICAL CIRCUIT DIAGRAM (2/2)..............................................................................................................................................................
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