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Komatsu Pc270-7 Hydraulic Excavator Service Repair Manual – PDF Download
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Description
Komatsu Pc270-7 Hydraulic Excavator Service Repair Manual
FILE DETAILS:
Komatsu Pc270-7 Hydraulic Excavator Service Repair Manual
LANGUAGE:ENGLISH
PAGES:758
DOWNLOADABLE:YES
FILE TYPE:PDF
KOMATSU PC270-7 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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DESCRIPTION:
Komatsu Pc270-7 Hydraulic Excavator Service Repair Manual
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
TABLE OF CONTENTS:
Komatsu Pc270-7 Hydraulic Excavator Service Repair Manual
COVER................................................................................................................................. 1
CONTENTS.............................................................................................................................. 2
01 GENERAL............................................................................................................................ 28
SPECIFICATION DIMENSION DRAWINGS.................................................................................................. 29
SPECIFICATIONS.................................................................................................................... 31
WEIGHT TABLE...................................................................................................................... 33
FUEL,COOLANT,AND LUBRICANTS....................................................................................................... 35
10 STRUCTURE,FUNCTION,AND MAINTENANCE STANDARD........................................................................................ 36
ENGINE RELATED PARTS.............................................................................................................. 37
RADIATOR・OIL COOLER・AFTERCOOLER................................................................................................... 38
POWER TRAIN....................................................................................................................... 39
FINAL DRIVE....................................................................................................................... 40
SWING MACHINERY................................................................................................................... 42
SWING CIRCLE...................................................................................................................... 44
TRACK FRAME・RECOIL SPRING......................................................................................................... 45
IDLER............................................................................................................................. 47
CARRIER ROLLER.................................................................................................................... 49
TRACK ROLLER...................................................................................................................... 50
TRACK SHOE........................................................................................................................ 51
HYDRAULIC EQUIPMENT LAYOUT DRAWING................................................................................................ 55
HYDRAULIC TANK.................................................................................................................... 57
HYDRAULIC PUMP.................................................................................................................... 58
CONTROL VALVE..................................................................................................................... 79
CLSS.............................................................................................................................. 94
SELF PRESSURE REDUCING VALVE...................................................................................................... 97
SWING MOTOR.......................................................................................................................100
REVERSE PREVENTION VALVE..........................................................................................................105
CENTER SWIVEL JOINT...............................................................................................................107
TRAVEL MOTOR......................................................................................................................108
TRAVEL JUNCTION VALVE.............................................................................................................118
TRAVEL PPC SHUTTLE VALVE..........................................................................................................120
VALVE CONTROL.....................................................................................................................122
WORK EQUIPMENT・SWING PPC VALVE....................................................................................................123
TRAVEL PPC VALVE..................................................................................................................127
SERVICE PPC VALVE.................................................................................................................136
SOLENOID VALVE....................................................................................................................139
PPC ACCUMULATOR...................................................................................................................141
RETURN OIL FILTER.................................................................................................................142
BOOM HYDRAULIC DRIFT PREVENTION VALVE.............................................................................................143
LIFT CHECK VALVE..................................................................................................................146
ATTACHMENT CIRCUIT SELECTOR VALVE.................................................................................................147
HYDRAULIC CYLINDER................................................................................................................149
WORK EQUIPMENT....................................................................................................................151
AIR CONDITIONER...................................................................................................................157
ENGINE CONTROL....................................................................................................................158
ELECTRONIC CONTROL SYSTEM.........................................................................................................164
MULTI MONITOR SYSTEM..............................................................................................................188
7-SEGMENT MONITOR SYSTEM..........................................................................................................208
SENSOR............................................................................................................................215
20 TESTING AND ADJUSTING..............................................................................................................218
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.....................................................................................219
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....................................................................................220
TESTING AND ADJUSTING.............................................................................................................227
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING..............................................................................228
INSPECTION AND ADJUSTMENT OF ENGINE RPM.......................................................................................230
MEASUREMENT OF EXHAUST GAS COLOR..............................................................................................232
ADJUSTMENT OF VALVE CLEARANCE.................................................................................................233
MEASUREMENT OF COMPRESSION PRESSURE...........................................................................................235
MEASUREMENT OF BLOW-BY PRESSURE...............................................................................................236
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING............................................................................237
MEASUREMENT OF ENGINE OIL PRESSURE............................................................................................239
ADJUSTMENT OF ENGINE SPEED SENSOR.............................................................................................240
INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION......................................................................240
EMERGENT ESCAPE FROM FAILURE IN ENGINE CONTROL SYSTEM.........................................................................241
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS.............................................................................242
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION...............................................................................243
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT,SWING AND TRAVEL..................244
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE.....................................................................248
INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE.............................................................249
INSPECTION AND ADJUSTMENT OF PUMP LS CONTROL CIRCUIT OIL PRESSURE.............................................................252
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.................................................................................257
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE......................................................................................260
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE..............................................................................261
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT..................................................................262
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................263
MEASUREMENT OF OIL LEAKAGE AMOUNT.............................................................................................264
AIR BLEEDING OF VARIOUS PARTS.................................................................................................266
INSPECTION PROCEDURES FOR DIODE...............................................................................................268
SPECIAL FUNCTION OF MULTI-MONITOR PANEL.......................................................................................269
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL.................................................................................294
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM............................................................................311
PM-TUNE UP SERVICE............................................................................................................313
TROUBLESHOOTING...................................................................................................................317
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................318
SEQUENCE OF EVENTS IN TROUBLESHOOTING.........................................................................................319
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..............................................................................320
CHECKS BEFORE TROUBLESHOOTING.................................................................................................328
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING..................................................................................329
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM.............................................................333
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................367
TROUBLESHOOTING WHEN SERVICE CODE"ELECTRICAL SYSTEM"AND FAILURE CODE"MECHANICAL SYSTEM"ARE INDICATED..........................399
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ...........................................................................401
SERVICE CODE IN ELECTRICAL SYSTEM [E101] (ABNORMAL DATE IN ERROR HISTORY).................................................403
SERVICE CODE IN ELECTRICAL SYSTEM [E112] (SHORT-CIRCUITING IN NORMAL ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE......405
SERVICE CODE IN ELECTRICAL SYSTEM [E113] (SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....407
SERVICE CODE IN ELECTRICAL SYSTEM [E114] (SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................409
SERVICE CODE IN ELECTRICAL SYSTEM [E115] (ABNORMAL WINDSHIELD WIPER MOTION)...............................................413
SERVICE CODE IN ELECTRICAL SYSTEM [E116] (ABNORMALITY IN RETRACTING WINDSHIELD WIPER).....................................415
SERVICE CODE IN ELECTRICAL SYSTEM [E201] (SHORT-CIRCUITING IN TRAVEL INTERLOCKING SOLENOID)...............................417
SERVICE CODE IN ELECTRICAL SYSTEM [E203] (SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...............................421
SERVICE CODE IN ELECTRICAL SYSTEM [E204] (SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)......................................425
SERVICE CODE IN ELECTRICAL SYSTEM [E205] (SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)....................................429
SERVICE CODE IN ELECTRICAL SYSTEM [E206] (SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................433
SERVICE CODE IN ELECTRICAL SYSTEM [E211] (DISCONNECTION IN TRAVEL INTERLOCKING SOLENOID)..................................437
SERVICE CODE IN ELECTRICAL SYSTEM [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)..................................441
SERVICE CODE IN ELECTRICAL SYSTEM [E214] (DISCONNECTION OF MERGE/DIVIDE SOLENOID).........................................445
SERVICE CODE IN ELECTRICAL SYSTEM [E215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID).......................................449
SERVICE CODE IN ELECTRICAL SYSTEM [E216] (DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................453
SERVICE CODE IN ELECTRICAL SYSTEM [E217] (ABNORMALITY IN INPUTTING MODEL CODE)............................................457
SERVICE CODE IN ELECTRICAL SYSTEM [E218] (DISCONNECTION OF S-NET SIGNAL)..................................................459
SERVICE CODE IN ELECTRICAL SYSTEM [E222] (SHORT-CIRCUITING IN LS-EPC SOLENOID)............................................461
SERVICE CODE IN ELECTRICAL SYSTEM [E223] (DISCONNECTION IN LS-EPC SOLENOID SYSTEM)........................................462
SERVICE CODE IN ELECTRICAL SYSTEM [E224] (ABNORMALITY IN F PUMP PRESSURE SENSOR)..........................................463
SERVICE CODE IN ELECTRICAL SYSTEM [E225] (ABNORMALITY IN R PUMP PRESSURE SENSOR)..........................................465
SERVICE CODE IN ELECTRICAL SYSTEM [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE)....................................467
SERVICE CODE IN ELECTRICAL SYSTEM [E227] (ABNORMALITY IN ENGINE ROTATION SENSOR)..........................................469
SERVICE CODE IN ELECTRICAL SYSTEM [E228] (SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)..........................470
SERVICE CODE IN ELECTRICAL SYSTEM [E232] (SHORT-CIRCUITING IN PC-EPC SOLENOID)............................................471
SERVICE CODE IN ELECTRICAL SYSTEM [E233] (DISCONNECTION IN PC-EPC SOLENOID SYSTEM)........................................473
SERVICE CODE IN ELECTRICAL SYSTEM [E238] (DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY).............................475
SERVICE CODE IN ELECTRICAL EQUIPMENT [E245] (SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC)..................477
SERVICE CODE IN ELECTRICAL SYSTEM [E246] (DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC) .......................478
SERVICE CODE IN ELECTRICAL SYSTEM [E256] (INCORRECT NONVOLATILE MEMORY DATE)..............................................479
SERVICE CODE IN ELECTRICAL SYSTEM [E306] (ABNORMALITY IN GOVERNOR POTENTIOMETER)..........................................480
SERVICE CODE IN ELECTRICAL SYSTEM [E308] (ABNORMALITY IN FUEL DIAL).......................................................482
SERVICE CODE IN ELECTRICAL SYSTEM [E315] (SHORT-CIRCUITING IN BATTERY RELAY)..............................................484
SERVICE CODE IN ELECTRICAL SYSTEM [E316] (STEP-OUT IN GOVERNOR MOTOR).....................................................486
SERVICE CODE IN ELECTRICAL SYSTEM [E317] (DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)..................................487
SERVICE CODE IN ELECTRICAL SYSTEM [E318] (SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PHASE B).........................489
SERVICE CODE IN ELECTRICAL SYSTEM [E501] ("MODEL SELECTION" FUNCTION NOT PROVIDED YET)....................................491
SERVICE MODE IN ELECTRICAL SYSTEM [E502] (MODEL SELECTING SIGNAL FAULT)...................................................492
FAILURE CODE IN MECHANICAL SYSTEM [A000N1] (OUT-OF-RATE ENGINE ROTATION AT HIGH IDLING)...................................493
FAILURE CODE IN MECHANICAL SYSTEM [AA10NX] (AIR CLEANER CLOGGING).........................................................494
FAILURE CODE IN MECHANICAL SYSTEM [AB00KE] (ABNORMALLY LOWERED CHARGING VOLTAGE)..........................................495
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZG] (ABNORMALLY LOWERED ENGINE OIL PRESSURE).......................................498
FAILURE CODE IN MECHANICAL SYSTEM [B@BAZK] (ABNORMALLY LOWERED ENGINE OIL LEVEL)..........................................499
FAILURE CODE IN MECHANICAL SYSTEM [B@BCNS] (ENGINE COOLING WATER OVERHEATING).............................................500
FAILURE CODE IN MECHANICAL SYSTEM [B@BCZK] (ABNORMALLY LOWERED RADIATOR WATER LEVEL)......................................501
FAILURE CODE IN MECHANICAL SYSTEM [B@HANS] (HYDRAULIC OIL OVERHEATING)....................................................502
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E-MODE)..................................................................................503
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................................504
BEFORE CARRYING OUT TROUBLESHOOTING OF E MODE.............................................................................505
E-1 ENGINE DOES NOT START(ENGINE DOES NOT ROTATE).........................................................................506
E-2 ENGINE STOPS WHILE IN OPERATION.......................................................................................510
E-3 ENGINE SPEED IS IRREGULAR,OR THERE IS HUNTING.........................................................................511
E-4 ENGINE DOES NOT STOP..................................................................................................514
E-5 AUTO-DECELERATOR DOES NOT WORK........................................................................................517
E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK..............................................................................518
E-7 PREHEATER DOES NOT WORK...............................................................................................519
E-8 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE.......................................................................521
E-9 ONE-TOUCH POWER MAX SWITCH DOES NOT WORK..............................................................................523
E-10 NO DISPLAY IN MONITOR PANEL AT ALL...................................................................................524
E-11 PART OF DISPLAY ON MONITOR PANEL IS MISSING..........................................................................525
E-12 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL .............................................................525
E-13 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING........................................................526
E-14 ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY...................................................527
E-15 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY...........................................................528
E-16 FUEL GAUGE DOES NOT DISPLAY CORRECTLY................................................................................529
E-17 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY........................................................................530
E-18 WHEN THE MONITOR SWITCH IS OPERATED,NO DISPLAY APPEARS...............................................................532
E-19 WINDSHIELD WIPER DOES NOT WORK.......................................................................................533
E-20 ALARMING BUZZER CANNOT BE CANCELLED..................................................................................535
E-21 "BOOM RAISE"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION ..........................................................536
E-22 "BOOM LOWER"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...........................................................537
E-23 "ARM DIGGING"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................538
E-24 "ARM DUMPING"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................539
E-25 "BUCKET DIGGING"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................540
E-26 "BUCKET DUMPING"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.......................................................541
E-27 "SWING"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION................................................................542
E-28 "TRAVEL"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION...............................................................544
E-29 "TRAVEL DIFFERENTIAL PRESSURE"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.........................................546
E-30 "SERVICE"IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..............................................................548
E-31 AIR CONDITIONER DOES NOT WORK........................................................................................550
E-32 TRAVEL ALARM DOES NOT SOUND..........................................................................................562
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H-MODE)....................................................................563
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS.........................................................................564
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................................566
H-1 ALL WORK EQUIPMENT LACK POWER,OR TRAVEL AND SWING SPEEDS ARE SLOW.....................................................567
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS...........................................................................568
H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE................................................................................569
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP....................................................................569
H-5 AUTO-DECELERATOR DOES NOT WORK........................................................................................570
H-6 FINE CONTROL MODE DOES NOT FUNCTION...................................................................................570
H-7 BOOM MOVES SLOWLY OR LACKS POWER......................................................................................571
H-8 ARM MOVES SLOWLY OR LACKS POWER.......................................................................................572
H-9 BUCKET MOVES SLOWLY OR LACKS POWER....................................................................................573
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION.................................................................573
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT....................................................................574
H-12 WORK EQUIPMENT HAS BIG TIME LAG......................................................................................575
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT.............................................................575
H-14 ONE-TOUCH POWER MAX.SWITCH DOES NOT OPERATE..........................................................................575
H-15 IN COMPOUND OPERATION,WORK EQUIPMENT WITH LARGER LOAD MOVERS SLOWLY..................................................576
H-16 IN SWING+BOOM RAISE OPERATION,BOOM MOVES SLOWLY......................................................................576
H-17 IN SWING+TRAVEL,TRAVEL SPEED DROPS SHARPLY...........................................................................576
H-18 MACHINE SWERVES IN TRAVEL............................................................................................577
H-19 MACHINE TRAVELS SLOWLY...............................................................................................578
H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER......................................................................579
H-21 TRAVEL SPEED DOES NOT SHIFT,OR IT IS TOO SLOW OR FAST................................................................580
H-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)..........................................................................581
H-23 MACHINE DOES NOT SWING...............................................................................................582
H-24 SWING ACCELERATION IS POOR,OR SWING SPEED IS SLOW....................................................................583
H-25 EXCESSIVE OVERRUN WHEN STOPPING SWING................................................................................584
H-26 THERE IS BIG SHOCK WHEN STOPPING SWING...............................................................................585
H-27 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING...............................................................585
H-28 SWING NATURAL DRIFT IS TOO BIG.......................................................................................586
TROUBLESHOOTING OF ENGINE(S-MODE).............................................................................................587
METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................588
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).............................................................592
S-2 ENGINE DOES NOT START.................................................................................................594
(1)ENGINE DOES NOT TURN...............................................................................................594
(2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...........................................595
(3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).........................................596
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..................................................................597
S-4 ENGINE STOPS DURING OPERATIONS........................................................................................598
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).............................................................................599
S-6 ENGINE LACKS OUTPUT(OR LACKS POWER)...................................................................................600
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)........................................................................601
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...............................................................602
S-9 OIL BECOMES CONTAMINATED QUICKLY......................................................................................603
S-10 FUEL CONSUMPTION IS EXCESSIVE .......................................................................................604
S-11 OIL IS COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN...................................................605
S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)................................................................606
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)..................................................................................607
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).....................................................................608
S-15 ABNORMAL NOISE IS MADE...............................................................................................609
S-16 VIBRATION IS EXCESSIVE...............................................................................................610
30 DISASSEMBLY AND ASSEMBLY...........................................................................................................611
HOW TO READ THIS MANUAL...........................................................................................................613
REMOVAL AND INSTALLATION OF ASSEMBLIES........................................................................................613
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES........................................................................................614
PRECAUTIONS WHEN PERFORMING OPERATION.............................................................................................615
SPECIAL TOOL LIST.................................................................................................................617
SKETCHES OF SPECIAL TOOLS.........................................................................................................621
STARTING MOTOR ASSEMBLY...........................................................................................................622
REMOVAL.......................................................................................................................622
INSTALLATION..................................................................................................................622
FUEL INJECTION PUMP ASSEMBLY......................................................................................................623
SPECIAL TOOLS.................................................................................................................623
REMOVAL.......................................................................................................................623
INSTALLATION..................................................................................................................625
ENGINE FRONT SEAL.................................................................................................................627
SPECIAL TOOLS.................................................................................................................627
REMOVAL.......................................................................................................................627
INSTALLATION..................................................................................................................627
ENGINE REAR SEAL..................................................................................................................629
REMOVAL.......................................................................................................................629
INSTALLATION..................................................................................................................630
CYLINDER HEAD ASSEMBLY............................................................................................................631
SPECIAL TOOLS.................................................................................................................631
REMOVAL.......................................................................................................................631
INSTALLATION .................................................................................................................634
RADIATOR ASSEMBLY.................................................................................................................637
REMOVAL.......................................................................................................................637
INSTALLATION..................................................................................................................638
HYDRAULIC OIL COOLER ASSEMBLY.....................................................................................................639
REMOVAL.......................................................................................................................639
INSTALLATION..................................................................................................................640
ENGINE AND HYDRAULIC PUMP ASSEMBLIES..............................................................................................641
SPECIAL TOOLS.................................................................................................................641
REMOVAL.......................................................................................................................641
INSTALLATION..................................................................................................................645
FINAL DRIVE ASSEMBLY..............................................................................................................647
REMOVAL.......................................................................................................................647
INSTALLATION..................................................................................................................647
FINAL DRIVE ASSEMBLY..............................................................................................................648
SPECIAL TOOLS.................................................................................................................648
DISASSEMBLY...................................................................................................................648
ASSEMBLY......................................................................................................................651
SWING MOTOR AND SWING MACHINERY ASSEMBLY..........................................................................................658
REMOVAL.......................................................................................................................658
INSTALLATION..................................................................................................................658
SWING MOTOR AND SWING MACHINERY ASSEMBLY .........................................................................................659
SPECIAL TOOLS.................................................................................................................659
DISASSEMBLY...................................................................................................................659
ASSEMBLY......................................................................................................................661
CARRIER ROLLER ASSEMBLY...........................................................................................................674
SPECIAL TOOLS.................................................................................................................674
ASSEMBLY......................................................................................................................674
TRACK ROLLER ASSEMBLY.............................................................................................................675
SPECIAL TOOLS.................................................................................................................675
ASSEMBLY......................................................................................................................675
IDLER ASSEMBLY....................................................................................................................676
SPECIAL TOOLS.................................................................................................................676
DISASSEMBLY...................................................................................................................676
ASSEMBLY......................................................................................................................677
RECOIL SPRING ASSEMBLY............................................................................................................679
SPECIAL TOOLS.................................................................................................................679
DISASSEMBLY...................................................................................................................679
ASSEMBLY......................................................................................................................680
SPROCKET..........................................................................................................................681
REMOVAL.......................................................................................................................681
INSTALLATION .................................................................................................................681
TRACK SHOE ASSEMBLY...............................................................................................................682
SPECIAL TOOLS.................................................................................................................682
EXPANSION OF TRACK SHOE.......................................................................................................682
ASSEMBLY......................................................................................................................683
SWING CIRCLE ASSEMBLY ............................................................................................................684
REMOVAL.......................................................................................................................684
INSTALLATION..................................................................................................................684
REVOLVING FRAME ASSEMBLY..........................................................................................................685
REMOVAL.......................................................................................................................685
INSTALLATION..................................................................................................................686
CENTER SWIVEL JOINT ASSEMBLY......................................................................................................687
REMOVAL.......................................................................................................................687
INSTALLATION..................................................................................................................688
CENTER SWIVEL JOINT ASSEMBLY......................................................................................................689
SPECIAL TOOLS.................................................................................................................689
DISASSEMBLY...................................................................................................................689
ASSEMBLY......................................................................................................................689
HYDRAULIC TANK ASSEMBLY...........................................................................................................690
REMOVAL.......................................................................................................................690
INSTALLATION..................................................................................................................691
CONTROL VALVE ASSEMBLY............................................................................................................692
REMOVAL.......................................................................................................................692
INSTALLATION..................................................................................................................694
CONTROL VALVE ASSEMBLY............................................................................................................695
SPECIAL TOOLS.................................................................................................................695
ASSEMBLY......................................................................................................................696
HYDRAULIC PUMP ASSEMBLY...........................................................................................................698
SPECIAL TOOLS.................................................................................................................698
REMOVAL.......................................................................................................................698
INSTALLATION..................................................................................................................700
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT............................................................................................701
SPECIAL TOOLS ................................................................................................................701
REMOVAL.......................................................................................................................701
INSTALLATION..................................................................................................................701
WORK EQUIPMENT PPC VALVE ASSEMBLY.................................................................................................702
ASSEMBLY......................................................................................................................702
TRAVEL PPC VALVE ASSEMBLY.........................................................................................................703
ASSEMBLY......................................................................................................................703
HYDRAULIC CYLINDER ASSEMBLY.......................................................................................................704
SPECIAL TOOLS.................................................................................................................704
DISASSEMBLY...................................................................................................................704
ASSEMBLY......................................................................................................................706
EQUIPMENT ASSEMBLY................................................................................................................710
SPECIAL TOOLS.................................................................................................................710
REMOVAL.......................................................................................................................710
INSTALLATION..................................................................................................................711
AIR CONDITIONER UNIT ASSEMBLY.....................................................................................................713
SPECIAL TOOLS.................................................................................................................713
REMOVAL.......................................................................................................................713
INSTALLATION..................................................................................................................715
AIR CONDITIONER UNIT ASSEMBLY.....................................................................................................716
SPECIAL TOOLS.................................................................................................................716
REMOVAL.......................................................................................................................716
INSTALLATION..................................................................................................................717
COUNTERWEIGHT ASSEMBLY............................................................................................................718
REMOVAL.......................................................................................................................718
INSTALLATION..................................................................................................................718
OPERATOR'S CAB ASSEMBLY...........................................................................................................719
REMOVAL.......................................................................................................................719
INSTALLATION..................................................................................................................721
OPERATOR'S CAB CLASS(STUCK GLASS).................................................................................................725
SPECIAL TOOLS.................................................................................................................726
REMOVAL.......................................................................................................................726
INSTALLATION..................................................................................................................727
FRONT WINDOW ASSEMBLY.............................................................................................................735
REMOVAL.......................................................................................................................735
INSTALLATION..................................................................................................................737
MONITOR ASSEMBLY..................................................................................................................740
REMOVAL.......................................................................................................................740
INSTALLATION..................................................................................................................737
GOVERNOR,PUMP CONTROLLER ASSEMBLY.................................................................................................741
REMOVAL.......................................................................................................................741
INSTALLATION..................................................................................................................741
90 OTHERS.............................................................................................................................742
HYDRAULIC CIRCUIT DIAGRAM (SHEET 1 OF 3)..........................................................................................743
HYDRAULIC CIRCUIT DIAGRAM (SHEET 2 OF 3)..........................................................................................744
HYDRAULIC CIRCUIT DIAGRAM (SHEET 3 OF 3)..........................................................................................745
ELECTRICAL CIRCUIT DIAGRAM SHEET 1 (SHEET 1 OF 3).................................................................................746
ELECTRICAL CIRCUIT DIAGRAM SHEET 1 (SHEET 2 OF 3).................................................................................747
ELECTRICAL CIRCUIT DIAGRAM SHEET 1 (SHEET 3 OF 3).................................................................................748
ELECTRICAL CIRCUIT DIAGRAM SHEET 2 (SHEET 1 OF 1).................................................................................749
ELECTRICAL CIRCUIT DIAGRAM SHEET 3 (SHEET 1 OF 2).................................................................................750
ELECTRICAL CIRCUIT DIAGRAM SHEET 3 (SHEET 2 OF 2).................................................................................751
ELECTRICAL CIRCUIT DIAGRAM SHEET 4 (SHEET 1 OF 2).................................................................................752
ELECTRICAL CIRCUIT DIAGRAM SHEET 4 (SHEET 2 OF 2).................................................................................753
ELECTRICAL CIRCUIT DIABRAM (1/4)..................................................................................................754
ELECTRICAL CIRCUIT DIABRAM (2/4)..................................................................................................755
ELECTRICAL CIRCUIT DIABRAM (3/4)..................................................................................................756
ELECTRICAL CIRCUIT DIABRAM (4/4)..................................................................................................757
ELECTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER....................................................................................758
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