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KOMATSU PC270LC-6LE HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 & UP) KOMATSU PC270LC-6LE
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- KOMATSU PC270LC-6LE HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:A83001 & UP
- PUBLICATION NUMBER:CEBD003001
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Description
KOMATSU PC270LC-6LE HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 & UP) KOMATSU PC270LC-6LE
KOMATSU PC270LC-6LE HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 & UP) KOMATSU PC270LC-6LE:
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KOMATSU PC270LC-6LE HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 & UP) KOMATSU PC270LC-6LE
- 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 sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU PC270LC-6LE HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:A83001 & UP) KOMATSU PC270LC-6LE
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 00 FOREWORD.................................................................................................................................. 9 SAFETY................................................................................................................................... 12 GENERAL.................................................................................................................................. 14 HOW TO READ THE SHOP MANUAL.............................................................................................................. 15 HOISTING INSTRUCTIONS.................................................................................................................... 16 COATING MATERIALS........................................................................................................................ 17 STANDARD TIGHTENING TORQUE............................................................................................................... 18 ELECTRIC WIRE CODE....................................................................................................................... 20 CONVERSION TABLES........................................................................................................................ 21 01 GENERAL................................................................................................................................... 27 GENERAL ASSEMBLY DRAWING ................................................................................................................ 28 SPECIFICATIONS....................................................................................................................... 29 WEIGHT TABLE............................................................................................................................. 32 FUEL, COOLANT AND LUBRICANTS............................................................................................................. 34 ENGINE OIL SPECIFICATIONS............................................................................................................ 35 NORMAL OPERATION................................................................................................................. 35 ARCTIC OPERATION................................................................................................................. 35 DAMPER CASE, SWING MACHINERY CASE, TRACK FRONT IDLERS, TRACK ROLLERS, TOP CARRIER ROLLERS AND HYDRAULIC SYSTEM OIL SPECIFICATION..... 36 FINAL DRIVE OIL SPECIFICATIONS....................................................................................................... 36 DIESEL FUEL SPECIFICATIONS........................................................................................................... 36 COOLANT SPECIFICATIONS............................................................................................................... 37 GENERAL.......................................................................................................................... 37 WATER............................................................................................................................ 37 ANTIFREEZE....................................................................................................................... 37 10 STRUCTURE AND FUNCTION.................................................................................................................... 39 ENGINE RELATED PARTS..................................................................................................................... 42 RADIATOR AND OIL COOLER.................................................................................................................. 43 POWER TRAIN.............................................................................................................................. 44 FINAL DRIVE.............................................................................................................................. 45 SWING CIRCLE............................................................................................................................. 47 SWING MACHINERY.......................................................................................................................... 49 TRACK FRAME AND RECOIL SPRING............................................................................................................ 50 TRACK SHOE............................................................................................................................... 51 HYDRAULIC PIPING DRAWING................................................................................................................. 53 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 55 HYDRAULIC TANK........................................................................................................................... 57 HYDRAULIC PUMP........................................................................................................................... 58 BASIC PUMP............................................................................................................................... 58 LS (LOADING SENSING) AND PC (POWER CONTROL) VALVE........................................................................................ 64 IN-LINE OIL FILTER....................................................................................................................... 76 CONTROL VALVE............................................................................................................................ 77 OUTLINE.............................................................................................................................. 77 NINE-SPOOL VALVE (STANDARD PLUS THREE SERVICE VALVES)................................................................................ 78 MAIN STRUCTURE................................................................................................................... 79 SIX-SPOOL VALVE (STANDARD)........................................................................................................... 82 SAFETY-SUCTION VALVE FOR SERVICE VALVE................................................................................................... 83 SELF-REDUCING PRESSURE VALVE............................................................................................................. 83 FUNCTION............................................................................................................................. 86 OPERATION............................................................................................................................ 86 CLSS..................................................................................................................................... 89 OUTLINE OF CLSS...................................................................................................................... 89 OPERATION OF EACH FUNCTION AND VALVE................................................................................................. 92 OPERATION OF CLSS SYSTEM AS A WHOLE..................................................................................................118 SWING MOTOR..............................................................................................................................134 BASIC MOTOR..........................................................................................................................134 SWING LOCK VALVE.....................................................................................................................136 RELIEF VALVE PORTION.................................................................................................................137 REVERSE PREVENTION VALVE (SWING DAMPENING)...........................................................................................138 CENTER SWIVEL JOINT......................................................................................................................140 TRAVEL MOTOR.............................................................................................................................141 VALVE CONTROL............................................................................................................................149 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................................150 OPERATION............................................................................................................................152 TRAVEL PPC VALVE.........................................................................................................................154 OPERATION............................................................................................................................156 SERVICE PPC VALVE........................................................................................................................158 OPERATION............................................................................................................................158 SAFETY LOCK VALVE........................................................................................................................160 STRAIGHT-TRAVEL SYSTEM...................................................................................................................161 FUNCTION.............................................................................................................................161 EPC VALVE................................................................................................................................162 OPERATION............................................................................................................................163 BOOM LOCK VALVE..........................................................................................................................164 OPERATION............................................................................................................................165 ADDITIONAL FILTER FOR BREAKER............................................................................................................167 WORK EQUIPMENT...........................................................................................................................168 AIR CONDITIONER..........................................................................................................................169 BASIC INFORMATION ON AIR CONDITIONERS................................................................................................170 UNITS RELATED TO REFRIGERATION.......................................................................................................170 PRINCIPLE OF COOLING.................................................................................................................174 REFRIGERANTS.........................................................................................................................179 SAFETY PRECAUTIONS...................................................................................................................179 REFRIGERATOR OIL (LUBE OIL)..........................................................................................................179 AIR CONDITIONING CONDENSER...............................................................................................................181 FUNCTION.............................................................................................................................181 GENERAL DESCRIPTION..................................................................................................................181 AIR CONDITIONER COMPRESSOR...............................................................................................................184 RECEIVER WITH SIGHT GLASS................................................................................................................185 AIR CONDITIONER UNIT.....................................................................................................................187 OUTLINE..............................................................................................................................187 ELECTRICAL WIRING DIAGRAM................................................................................................................189 ELECTRICAL CIRCUIT DIAGRAM...............................................................................................................191 ENGINE CONTROL SYSTEM....................................................................................................................195 FUNCTION.............................................................................................................................195 OPERATION OF SYSTEM..................................................................................................................196 COMPONENTS OF SYSTEM.................................................................................................................197 ELECTRONIC CONTROL SYSTEM............................................................................................................201 TOTAL SYSTEM DIAGRAM.................................................................................................................202 PUMP AND ENGINE MUTUAL CONTROL FUNCTION..............................................................................................203 PUMP AND VALVE CONTROL FUNCTION......................................................................................................208 POWER MAXIMIZING AND SWIFT SLOW-DOWN FUNCTION........................................................................................211 AUTO-DECELERATION FUNCTION...........................................................................................................212 AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION.........................................................................214 SWING CONTROL FUNCTION...............................................................................................................216 TRAVEL CONTROL FUNCTIONACTIVE MODE FUNCTION..........................................................................................218 ACTIVE MODE FUNCTION.................................................................................................................220 COMPONENTS OF SYSTEM.................................................................................................................222 MACHINE MONITOR SYSTEM...................................................................................................................225 FUNCTION.............................................................................................................................225 MONITOR PANEL........................................................................................................................226 MONITOR DISPLAY......................................................................................................................227 OIL MAINTENANCE FUNCTION.............................................................................................................229 SWITCHES.............................................................................................................................231 SENSORS..................................................................................................................................232 COOLANT LEVEL SENSOR.................................................................................................................232 ENGINE OIL LEVEL SENSOR..............................................................................................................233 HYDRAULIC OIL SENSOR.................................................................................................................233 ENGINE OIL PRESSURE SENSOR...........................................................................................................233 COOLANT TEMPERATURE SENSOR...........................................................................................................234 FUEL LEVEL SENSOR....................................................................................................................234 AIR CLEANER CLOGGING SENSOR..........................................................................................................234 20 TESTING, ADJUSTING AND TROUBLESHOOTING....................................................................................................235 TESTING AND ADJUSTING....................................................................................................................240 STANDARD VALUES TABLE................................................................................................................241 FOR ENGINE - PC270LC-6LE.........................................................................................................241 FOR CHASSIS......................................................................................................................242 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.....................................................................................261 MEASURING ENGINE SPEED...............................................................................................................262 MEASURING EXHAUST GAS COLOR..........................................................................................................263 ADJUSTING VALVE CLEARANCE............................................................................................................264 MEASURING COMPRESSION PRESSURE.......................................................................................................265 MEASURING BLOW-BY PRESSURE...........................................................................................................266 TESTING AND ADJUSTING FUEL INJECTION TIMING..........................................................................................267 MEASURING ENGINE OIL PRESSURE........................................................................................................268 TESTING AND ADJUSTING FAN BELT TENSION...............................................................................................269 TESTING AND ADJUSTING A/C COMPRESSOR BELT TENSION....................................................................................270 ADJUSTING THE ENGINE SPEED SENSOR....................................................................................................271 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE....................................................................................272 MEASURING EQUIPMENT CYCLE TIMES......................................................................................................273 TESTING AND ADJUSTING PILOT OIL PRESSURE ............................................................................................274 TESTING AND ADJUSTING MAIN HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT...........................................276 TESTING SERVO PISTON INPUT PRESSURE..................................................................................................280 TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE.......................................................................................282 TESTING AND ADJUSTING PC VALVE.......................................................................................................284 TESTING SOLENOID VALVE OUTPUT PRESSURES (LS-EPC, PC-EPC AND ON/OFF SOLENOID VALUES)..................................................286 MEASURING PPC VALVE OUTPUT PRESSURE..................................................................................................290 PRESSURE SWITCH PIPING DIAGRAM...................................................................................................291 ADJUSTING WORK EQUIPMENT * SWING PPC VALVE...........................................................................................292 TESTING TRAVEL DEVIATION.............................................................................................................293 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT..........................................................................294 MEASURING OIL LEAKAGE................................................................................................................296 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....................................................................................298 TESTING CLEARANCE OF SWING CIRCLE BEARING............................................................................................299 TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................................300 BLEEDING AIR.........................................................................................................................302 TROUBLESHOOTING..........................................................................................................................304 POINTS TO REMEMER WHEN TROUBLESHOOTING...............................................................................................305 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................306 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....................................................................................307 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT..............................................................................307 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS........................................................................312 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.............................................................................313 CHECKS BEFORE TROUBLESHOOTING........................................................................................................315 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................316 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................320 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...............................................................................330 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL................................................................................331 METHOD OF USING JUDGEMENT TABLE......................................................................................................340 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................342 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE.............................................................................344 SERVICE CODE TABLE...................................................................................................................349 TROUBLESHOOTING OF COMMUNICATION ABNOMALITY SYSTEM (N MODE)..........................................................................350 N-1 [E218] COMMUNICATIONS ABNORMALITY............................................................................................350 TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)(E MODE)..............................................353 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER SYSTEM.................................353 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.......................................................354 JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS.........................358 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM.....................................................................................360 E-1 ABNOMALITY IN ENGINE THROTTLE - PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF).........................................362 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED.............................................................363 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................364 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................365 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED.............................................................366 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...............................................367 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED..........................................................................368 E-8 ENGINE DOES NOT START........................................................................................................370 E-9 ENGINE SPEED IS IRREGULAR....................................................................................................374 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED TO LOW)............................................................................378 E-11 ENGINE DOES NOT STOP........................................................................................................380 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOE NOT STOP)...........................................................382 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................384 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................384 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................................................................388 S-2 ENGINE DOES NOT START........................................................................................................390 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).........................................................................393 S-4 ENGINE STOPS DURING OPERATIONS ..............................................................................................394 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................395 S-6 ENGINE LACKS OUTPUT (NO POWER)...............................................................................................396 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...............................................................................397 S-8 OIL COMSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)......................................................................398 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................399 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................400 S-11 OIL IS IN COOLANT, OR COLLANT SPURTS BACK, OR COOLANT LEVLE GOES DOWN.......................................................401 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................402 S-13 OIL LEVEL RISES (COOLANT, FUEL IN OIL)......................................................................................403 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..........................................................................404 S-15 ABNORMAL NOISE IS MADE.....................................................................................................405 S-16 VIBRATION IS EXCESSIVE......................................................................................................406 TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM)(C MODE)...................................................407 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...................................................................407 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.......................................................408 JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS..........................416 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE AND F MODE.................................................................................418 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)........................................................420 C-2 [E232] SHORT CIRCUIT IN PUMP EPC SOLENOID SYSTEM IS DISPLAYED................................................................422 C-3 [E233] DISCONNECTION IN PC-EPC SOLENOID SYSTEM IS DISPLAYED..................................................................424 C-4 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED.....................................................426 C-5 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED.....................................................428 C-6 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED......................................................430 C-7 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED......................................................431 C-8 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYEDPC270LC-6LE..................................................432 C-9 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED.............................................................433 C-10 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...........................................................434 C-11 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED..................................................435 C-12 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.........................................................436 C-13 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.........................................................437 C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED.............................................................................438 C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.................................................................440 C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.................................................................441 C-17 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED........................................................442 C-18 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.........................................................443 C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED......................................................444 C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...............................................................445 TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (INPUT SIGNAL SYSTEM (F MODE)...................................................447 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................447 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................448 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................449 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................450 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................451 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................452 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP.........................................................453 F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP ........................................................454 F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP.......................................................................455 F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP...............................................................456 F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP.......................................................................457 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..........................................................................458 TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM............................................................458 PUMP MERGE/DIVIDER LOGIC.........................................................................................................462 SOLENOID ACTUATION TABLE.........................................................................................................463 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW.........................................................................464 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS....................................................................466 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE........................................................................................466 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).......................................................................................467 H-5 AUTO-DECELERATION DOES NOT WORK (PPC SHUTTLE VALVE IS EQUIPPED ONLY IN TRAVEL PPC VALVE).....................................467 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR.............................................................................468 H-7 BOOM IS SLOW OR LACKS POWER..................................................................................................470 H-8 ARM IS SLOW OR LACKS POWER...................................................................................................472 H-9 BUCKET IS SLOW OR LACKS POWER................................................................................................474 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)..........................................475 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...............................................................................475 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...................................................................................476 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.......................................................................476 H-14 LACK OF POWER WHEN PRESSURE RISES...........................................................................................477 H-15 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED .....................................................478 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGE LOAD IS SLOW..............................................................478 H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...................................................................................479 H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY...........................................................................479 H-19 TRAVEL DEVIATION............................................................................................................479 H-20 TRAVEL SPEED IS SLOW........................................................................................................480 H-21 STEERING DOES NOT TURN EASILY OR LACKS POWER................................................................................482 H-22 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED..............................................................484 H-23 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)........................................................................................484 H-24 DOES NOT SWING..............................................................................................................485 H-25 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW...........................................................................486 H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING.......................................................................................488 H-27 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)....................................................................488 H-28 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING................................................................................489 H-29 EXCESSIVE HYDRAULIC DRIFT OF SWING..........................................................................................489 H-30 SWING SPEED IS FASTER THAN SPECIFIED SPEED IN L/O AND F/O MODES.............................................................490 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M CODE)..................................................................................492 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................492 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM.....................................................................................494 M-1 [E101] ABNORMALITY IN ERRO DATA IS DISPLAYED; [E102] ERROR IN CLOCK DATA IS DISPLAYED........................................496 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED................497 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED............................................................................498 M-4 [E108] ENGINE COOLANT TEMPERATURE 105 C (221F) DETECTED IS DISPLAYED.........................................................498 M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS.................................500 M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT.....................................502 M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE MODEL.....................502 M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH..................................................504 M-9 PREHEATING IS NOT BEING USED BUT PREHEATING MONITOR LIGHTS UP................................................................507 M-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH............................................508 M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE L....510 M-12 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMAL....512 M-13 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR SECOND. CAUTION ITEM FLASHES BUT BUZZER D....516 M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS....................................................................516 M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)........................................517 M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE.....................................................................................518 M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF THE GAUGE LAMPS LIGHT UP DURING OPERATION).....................519 M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.......................................................................................520 M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY......................................................................................520 M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT SWING LOCK MONITOR DOES NOT LIGHT UP..............................................521 M-21 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH............................................522 M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING......................................................................523 M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED.........................523 M-24 DEFECTIVE FUEL LEVER SENSOR SYSTEM..........................................................................................524 M-25 DEFECTIVE COOLANT TEMPERATUER SENSOR SYSTEM.................................................................................525 M-26 DEFECTIVE ENGINE OIL SENSOR SYSTEM..........................................................................................526 M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.......................................................................................527 M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM.................................................................................528 M-29 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED......................................................530 M-30 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED........................................536 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................539 METHOD OF USING MANUAL...................................................................................................................544 WHEN REMOVING OR INSTALLING UNIT ASSEMBLIES..........................................................................................544 GENERAL PRECAUTIONS..................................................................................................................544 LISTING OF SPECIAL TOOLS.............................................................................................................544 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................545 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...........................................................................................545 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK......................................................................................546 PRECAUTIONS WHEN COMPLETING OPERATIONS...............................................................................................546 SPECIAL TOOLS LIST.......................................................................................................................547 SPECIAL TOOL SKETCH......................................................................................................................551 STARTER MOTOR............................................................................................................................553 REMOVAL..............................................................................................................................553 INSTALLATION.........................................................................................................................553 ALTERNATOR...............................................................................................................................554 REMOVAL..............................................................................................................................554 INSTALLATION.........................................................................................................................554 AIR CONDITIONER COMPRESSOR...............................................................................................................555 REMOVAL..............................................................................................................................555 INSTALLATION.........................................................................................................................555 AIR CONDITIONER CONDENSER................................................................................................................556 REMOVAL..............................................................................................................................556 INSTALLATION.........................................................................................................................556 RECEIVER DRIER...........................................................................................................................557 REMOVAL..............................................................................................................................557 INSTALLATION.........................................................................................................................557 FUEL INJECTION PUMP......................................................................................................................558 REMOVAL..............................................................................................................................558 INSTALLATION.........................................................................................................................559 WATER PUMP...............................................................................................................................560 REMOVAL..............................................................................................................................560 INSTALLATION.........................................................................................................................561 NOZZLE HOLDER............................................................................................................................562 REMOVAL..............................................................................................................................562 INSTALLATION.........................................................................................................................562 TURBOCHARGER.............................................................................................................................563 REMOVAL..............................................................................................................................563 INSTALLATION.........................................................................................................................563 THERMOSTAT...............................................................................................................................564 REMOVAL..............................................................................................................................564 INSTALLATION.........................................................................................................................564 GOVERNOR MOTOR...........................................................................................................................565 REMOVAL..............................................................................................................................565 INSTALLATION.........................................................................................................................565 CYLINDER HEAD ASSEMBLY...................................................................................................................566 REMOVAL..............................................................................................................................566 INSTALLATION.........................................................................................................................568 RADIATOR - HYDRAULIC OIL COOLER..........................................................................................................570 REMOVAL..............................................................................................................................570 INSTALLATION.........................................................................................................................571 ENGINE, MAIN PUMP........................................................................................................................572 REMOVAL..............................................................................................................................572 INSTALLATION.........................................................................................................................575 DAMPER...................................................................................................................................576 REMOVAL..............................................................................................................................576 INSTALLATION.........................................................................................................................576 FUEL TANK................................................................................................................................577 REMOVAL..............................................................................................................................577 INSTALLATION.........................................................................................................................577 CENTER SWIVEL JOINT......................................................................................................................578 REMOVAL..............................................................................................................................578 INSTALLATION.........................................................................................................................579 DISASSEMBLY..........................................................................................................................580 ASSEMBLY.............................................................................................................................580 FINAL DRIVE..............................................................................................................................582 REMOVAL..............................................................................................................................582 INSTALLATION.........................................................................................................................582 DISASSEMBLY..........................................................................................................................583 ASSEMBLY.............................................................................................................................586 SPROCKET.................................................................................................................................590 REMOVAL..............................................................................................................................590 INSTALLATION.........................................................................................................................590 SWING MOTOR AND MACHINERY................................................................................................................592 REMOVAL..............................................................................................................................592 INSTALLATION.........................................................................................................................593 SWING MACHINERY..........................................................................................................................594 DISASSEMBLY..........................................................................................................................594 ASSEMBLY.............................................................................................................................597 REVOLVING FRAME..........................................................................................................................602 REMOVAL..............................................................................................................................602 INSTALLATION.........................................................................................................................603 SWING CIRCLE.............................................................................................................................604 REMOVAL..............................................................................................................................604 INSTALLATION.........................................................................................................................604 IDLER-RECOIL SPRING......................................................................................................................605 REMOVAL..............................................................................................................................605 INSTALLATION.........................................................................................................................605 IDLER RECOIL SPRING......................................................................................................................606 DISASSEMBLY..........................................................................................................................606 ASSEMBLY.............................................................................................................................607 IDLER....................................................................................................................................608 DISASSEMBLY..........................................................................................................................608 ASSEMBLY.............................................................................................................................609 TRACK ROLLER.............................................................................................................................612 REMOVAL..............................................................................................................................612 INSTALLATION.........................................................................................................................613 DISASSEMBLY..........................................................................................................................614 ASSEMBLY.............................................................................................................................615 CARRIER ROLLER...........................................................................................................................618 REMOVAL..............................................................................................................................618 INSTALLATION.........................................................................................................................618 DISASSEMBLY..........................................................................................................................619 ASSEMBLY.............................................................................................................................620 TRACK SHOE...............................................................................................................................622 REMOVAL..............................................................................................................................622 INSTALLATION.........................................................................................................................622 HYDRAULIC TANK...........................................................................................................................624 REMOVAL..............................................................................................................................624 INSTALLATION.........................................................................................................................625 MAIN PUMP................................................................................................................................626 REMOVAL..............................................................................................................................626 INSTALLATION.........................................................................................................................628 MAIN PUMP INPUT SHAFT OIL SEAL...........................................................................................................629 REMOVAL..............................................................................................................................629 INSTALLATION.........................................................................................................................629 CONTROL VALVE............................................................................................................................630 REMOVAL..............................................................................................................................630 INSTALLATION.........................................................................................................................632 DISASSEMBLY..........................................................................................................................633 ASSEMBLY.............................................................................................................................638 PUMP MERGER-DIVIDER VALVE................................................................................................................641 DISASSEMBLY..........................................................................................................................641 ASSEMBLY.............................................................................................................................641 MAIN RELIEF VALVE........................................................................................................................642 DISASSEMBLY..........................................................................................................................642 ASSEMBLY.............................................................................................................................642 PC VALVE.................................................................................................................................643 REMOVAL..............................................................................................................................643 INSTALLATION.........................................................................................................................643 LS VALVE.................................................................................................................................644 REMOVAL..............................................................................................................................644 INSTALLATION.........................................................................................................................644 PC-EPC, LS-EPC VALVES....................................................................................................................645 REMOVAL..............................................................................................................................645 INSTALLATION.........................................................................................................................645 SOLENOID VALVE...........................................................................................................................646 REMOVAL..............................................................................................................................646 INSTALLATION.........................................................................................................................646 WORK EQUIPMENT - SWING PPC VALVE.........................................................................................................648 REMOVAL..............................................................................................................................648 INSTALLATION.........................................................................................................................648 DISASSEMBLY .........................................................................................................................649 ASSEMBLY.............................................................................................................................650 TRAVEL PPC VALVE.........................................................................................................................652 REMOVAL..............................................................................................................................652 INSTALLATION.........................................................................................................................653 DISASSEMBLY..........................................................................................................................654 ASSEMBLY.............................................................................................................................655 BOOM LOCK VALVE..........................................................................................................................656 REMOVAL..............................................................................................................................656 INSTALLATION.........................................................................................................................656 BOOM CYLINDER............................................................................................................................658 REMOVAL..............................................................................................................................658 INSTALLATION.........................................................................................................................659 ARM CYLINDER.............................................................................................................................660 REMOVAL..............................................................................................................................660 INSTALLATION.........................................................................................................................661 BUCKET CYLINDER..........................................................................................................................662 REMOVAL..............................................................................................................................662 INSTALLATION.........................................................................................................................663 HYDRAULIC CYLINDER.......................................................................................................................664 DISASSEMBLY..........................................................................................................................664 ASSEMBLY.............................................................................................................................666 WORK EQUIPMENT...........................................................................................................................670 REMOVAL..............................................................................................................................670 INSTALLATION.........................................................................................................................671 BUCKET...................................................................................................................................672 REMOVAL..............................................................................................................................672 INSTALLATION.........................................................................................................................673 ARM......................................................................................................................................674 REMOVAL..............................................................................................................................674 INSTALLATION.........................................................................................................................675 BUCKET - ARM.............................................................................................................................676 REMOVAL..............................................................................................................................676 INSTALLATION.........................................................................................................................677 BOOM.....................................................................................................................................678 REMOVAL..............................................................................................................................678 INSTALLLATION........................................................................................................................679 OPERATOR'S CAB...........................................................................................................................680 REMOVAL..............................................................................................................................680 INSTALLATION.........................................................................................................................681 COUNTERWEIGHT............................................................................................................................682 REMOVAL..............................................................................................................................682 INSTALLATION.........................................................................................................................682 ENGINE THROTTLE - PUMP CONTROLLER........................................................................................................683 REMOVAL..............................................................................................................................683 INSTALLATION.........................................................................................................................683 CONTROL STAND CASE.......................................................................................................................684 REMOVAL..............................................................................................................................684 INSTALLATION.........................................................................................................................685 MONITOR..................................................................................................................................686 REMOVAL..............................................................................................................................686 INSTALLATION.........................................................................................................................686 40 MAINTENANCE STANDARD......................................................................................................................687 SWING MACHINERY..........................................................................................................................690 SWING CIRCLE.............................................................................................................................693 FINAL DRIVE..............................................................................................................................694 TRACK FRAME AND RECOIL SPRING............................................................................................................696 CARRIER ROLLER...........................................................................................................................697 IDLER....................................................................................................................................698 TRACK ROLLER.............................................................................................................................701 TRACK SHOE...............................................................................................................................702 HYDRAULIC PUMP...........................................................................................................................704 CONTROL VALVE............................................................................................................................705 VARIABLE PRESSURE COMPENSATION VALVE.....................................................................................................711 SAFETY-SUCTION VALVE FOR SERVICE VALVE...................................................................................................712 SELF-REDUCING PRESSURE VALVE.............................................................................................................713 SWING MOTOR..............................................................................................................................714 TRAVEL MOTOR.............................................................................................................................715 WORK EQUIPMENT AND SWING PPC VALVES......................................................................................................716 TRAVEL PPC VALVE.........................................................................................................................717 SERVICE PPC VALVE........................................................................................................................718 EPC SOLENOID VALVE.......................................................................................................................719 CENTER SWIVEL JOINT......................................................................................................................720 BOOM LOCK VALVE..........................................................................................................................721 HYDRAULIC CYLINDER.......................................................................................................................722 WORK EQUIPMENT...........................................................................................................................724 DIMENSION OF WORK EQUIPMENT..............................................................................................................726 ARM PORTION..........................................................................................................................726 BUCKET PORTION.......................................................................................................................728
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