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KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:30001 & UP)(SN:10001 & UP) – PDF DOWNLOAD
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- KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER: SEBM006603
- SERIAL NUMBER:PC300-6 30001 and up
PC300LC-6 30001 and up
PC350-6 10001 and up
PC350LC-6 10001 and up
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Description
KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:30001 & UP)(SN:10001 & UP)
KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:30001 & UP)(SN:10001 & UP) – PDF DOWNLOAD:
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KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:30001 & UP)(SN:10001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding. the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to ‘Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when Inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:30001 & UP)(SN:10001 & UP)
COVER............................................................................................................................................................................................................ 1 CONTENTS......................................................................................................................................................................................................... 2 01 GENERAL....................................................................................................................................................................................................... 20 SPECIFICATION DRAWINGS....................................................................................................................................................................................... 21 SPECIFICATIONS............................................................................................................................................................................................... 23 WEIGHT TABLE................................................................................................................................................................................................. 27 FUEL, COOLANT AND LUBRICANTS................................................................................................................................................................................. 31 10 STRUCTURE AND FUNCTION........................................................................................................................................................................................ 33 PARTS RELATED TO ENGINE...................................................................................................................................................................................... 34 RADIATOR, OIL COOLER......................................................................................................................................................................................... 36 POWER TRAIN.................................................................................................................................................................................................. 37 FINAL DRIVE.................................................................................................................................................................................................. 38 SWING CIRCLE................................................................................................................................................................................................. 39 SWING MACHINERY.............................................................................................................................................................................................. 40 TRACK FRAME, RECOIL SPRING................................................................................................................................................................................... 41 TRACK SHOE................................................................................................................................................................................................... 42 HYDRAULIC PIPING DRAWING..................................................................................................................................................................................... 43 HYDRAULIC CIRCUIT DRAWING.................................................................................................................................................................................... 44 HYDRAULIC TANK, HYDRAULIC FILTER............................................................................................................................................................................. 45 HYDRAULIC PUMP............................................................................................................................................................................................... 46 CONTROL VALVE................................................................................................................................................................................................ 67 SUCTION SAFETY VALVE......................................................................................................................................................................................... 76 CLSS......................................................................................................................................................................................................... 77 SWING MOTOR..................................................................................................................................................................................................119 CENTER SWIVEL JOINT..........................................................................................................................................................................................123 TRAVEL MOTOR.................................................................................................................................................................................................124 VALVE CONTROL................................................................................................................................................................................................133 WORK EQUIPMENT, SWING PPC VALVE..............................................................................................................................................................................134 TRAVEL PPC VALVE.............................................................................................................................................................................................138 SERVICE PPC VALVE............................................................................................................................................................................................142 PPC SAFETY LOCK VALVE........................................................................................................................................................................................145 PPC ACCUMULATOR..............................................................................................................................................................................................145 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.....................................................................................................................................................................146 EPC SOLENOID VALVE...........................................................................................................................................................................................153 FOR LS SELECT, BOOM HI 2-STAGE SAFETY VALVE, MERGE/FLOW DIVIDER, TRAVEL SPEED, SWING BRAKE...............................................................................................................153 FOR LS VALVE CONTROL.....................................................................................................................................................................................155 BOOM HOLDING VALVE...........................................................................................................................................................................................158 HYDRAULIC CYLINDER...........................................................................................................................................................................................161 WORK EQUIPMENT...............................................................................................................................................................................................162 ACTUAL ELECTRIC WIRING DIAGRAM...............................................................................................................................................................................163 ELECTRIC CIRCUIT DIAGRAM.....................................................................................................................................................................................165 ENGINE CONTROL ..............................................................................................................................................................................................168 ELECTRONIC CONTROL SYSTEM....................................................................................................................................................................................174 MACHINE MONITOR SYSTEM.......................................................................................................................................................................................197 FRONT WINDOW AUTO PULL-UP SYSTEM.............................................................................................................................................................................204 20 TESTING AND ADJUSTING.........................................................................................................................................................................................206 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS................................................................................................................................................................207 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...............................................................................................................................................................208 STANDARD VALUE TABLE FOR ELECTRICAL PARTS....................................................................................................................................................................216 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING............................................................................................................................................................224 MEASURING ENGINE SPEED.......................................................................................................................................................................................225 MEASURING EXHAUST COLOR......................................................................................................................................................................................226 ADJUSTING VALVE CLEARANCE....................................................................................................................................................................................227 MEASURING COMPRESSION PRESSURE...............................................................................................................................................................................228 MEASURING BLOW-BY PRESSURE...................................................................................................................................................................................228 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................................................................................................................................229 MEASURING ENGINE OIL PRESSURE................................................................................................................................................................................230 TESTING AND ADJUSTING ALTERNATOR BELT TENSION................................................................................................................................................................231 TESTING AND ADJUSTING WATER PUMP BELT TENSION................................................................................................................................................................231 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR............................................................................................................................................232 ADJUSTING ENGINE SPEED SENSOR................................................................................................................................................................................232 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...............................................................................................................................................................233 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE............................................................................................................................................................234 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT............................................................................................................................235 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)................................................................................................................................238 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE....................................................................................................240 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE......................................................................................................................................................243 TESTING SOLENOID VALVE OUTPUT PRESSURE.......................................................................................................................................................................245 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE............................................................................................................................................247 ADJUSTING WORK EQUIPMENT,SWING PPC VALVE.....................................................................................................................................................................249 TESTING TRAVEL DEVIATION.....................................................................................................................................................................................250 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT..................................................................................................................................................251 MEASURING OIL LEAKAGE........................................................................................................................................................................................253 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................................................................................................255 TESTING CLEARANCE OF SWING CIRCLE BEARING....................................................................................................................................................................256 TESTING AND ADJUSTING TRACK SHOE TENSION.....................................................................................................................................................................257 BLEEDING AIR.................................................................................................................................................................................................258 TROUBLESHOOTING..............................................................................................................................................................................................260 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................................................................................................261 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................................................................................262 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.........................................................................................................................................................263 CHECKS BEFORE TROUBLESHOOTING............................................................................................................................................................................271 CONNECTOR TYPES AND MOUNTING LOCATIONS...................................................................................................................................................................272 CONNECTOR ARRANGEMENT DIAGRAM............................................................................................................................................................................274 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...............................................................................................................................................................276 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...................................................................................................................................................286 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL....................................................................................................................................................287 METHOD OF USING JUDGEMENT TABLE..........................................................................................................................................................................295 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................................................................................297 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE.................................................................................................................................................299 SERVICE CODE TABLE.......................................................................................................................................................................................304 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE).............................................................................................................................................305 N-1 [E218] COMMUNICATION ABNORMALITY.................................................................................................................................................................306 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)..........................................................................................................................308 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM.............................................................................................................309 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................................................................................310 JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS.......................................................................................................314 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM.........................................................................................................................................................316 E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)................................................................................................................318 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED.............................................................................................................................319 E-3 [E317] ABNORMALITY (DISCONNECTION) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED...............................................................................................................320 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED...............................................................................................................321 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED.............................................................................................................................322 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...............................................................................................................323 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED..........................................................................................................................................324 E-8 ENGINE DOES NOT START........................................................................................................................................................................325 E-9 ENGINE SPEED IS IRREGULAR....................................................................................................................................................................327 a) IDLING SPEED IS IRREGULAR.................................................................................................................................................................327 b) THERE IS HUNTING..........................................................................................................................................................................329 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)........................................................................................................................................331 E-11 ENGINE DOES NOT STOP........................................................................................................................................................................333 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)..........................................................................................................................335 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................................................................................337 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................................................................................338 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................................................................................................................................342 S-2 ENGINE DOES NOT START........................................................................................................................................................................343 (1) ENGINE DOES NOT TURN.....................................................................................................................................................................343 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).................................................................................................................344 (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)..............................................................................................................345 S-3 ENGINE DOES NOT PICK UP SMOOTHLY.............................................................................................................................................................346 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................................................................................347 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................................................................................348 S-6 ENGINE LACKS OUTPUT (NO POWER)...............................................................................................................................................................349 S-7 EXHAUST SOMKE IS BLACK.......................................................................................................................................................................350 S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST SMOKE IS BLUE.......................................................................................................................................351 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................................................................................352 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................................................................................353 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN.......................................................................................................................354 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................................................................................355 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................................................................................356 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................................................................................357 S-15 ABNORMAL NOISE IS MADE......................................................................................................................................................................358 S-16 VIBRATION IS EXCESSIVE......................................................................................................................................................................359 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)..........................................................................................................................360 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...................................................................................................................................361 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.......................................................................................................................362 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS..................................................................................................368 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE............................................................................................................................................................370 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)....................................................................................................................372 C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED......................................................................................................................373 C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED......................................................................................................................375 C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................377 C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................379 C-6 [E202] SHORT CIRCUIT IN LS SELECT SOLENOID SYSTEM IS DISPLAYED...........................................................................................................................381 C-7 [E212] DISCONNECTION IN LS SELECT SOLENOID SYSTEM IS DISPLAYED...........................................................................................................................382 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.........................................................................................................................383 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.........................................................................................................................385 C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED.................................................................................................................387 C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED.................................................................................................................388 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IN DISPLAYED.......................................................................................................................389 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED..............................................................................................................390 C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED.........................................................................................................................................391 C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.............................................................................................................................393 C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.............................................................................................................................394 C-17 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED....................................................................................................................395 C-18 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.....................................................................................................................396 C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED.........................................................................................................................397 C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...........................................................................................................................398 C-21 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)..............................................................................................................399 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)..........................................................................................................................401 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE............................................................................................................................................................402 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................................404 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................................................................................405 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................................................................................406 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................................................................................407 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................................................................................408 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................................................................................409 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP.........................................................................................................................410 F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP.........................................................................................................................411 F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP.......................................................................................................................................412 F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP...............................................................................................................................413 F-11 BIT PATTERN 22-(6) L. H. KNOB SWITCH DOES NOT LIGHT UP......................................................................................................................................414 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).............................................................................................................................................415 PUMP MERGE/DIVIDER LOGIC, LS SELECT LOGIC, SOLENOID ACTUATION TABLE..............................................................................................................................416 TABLE OF FAILURE MODES AND CAUSES................................................................................................................................................................417 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...........................................................................................................................421 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS....................................................................................................................................423 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE........................................................................................................................................................424 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).......................................................................................................................................................424 H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)............................................................................................................................425 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR.............................................................................................................................................425 H-7 BOOM IS SLOW OR LACKS POWER..................................................................................................................................................................426 H-8 ARM IS SLOW OR LACKS POWER...................................................................................................................................................................428 H-9 BUCKET IS SLOW OR LACKS POWER................................................................................................................................................................430 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)..........................................................................................................431 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...............................................................................................................................................431 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...................................................................................................................................................432 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.......................................................................................................................................432 H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED......................................................................................................................433 H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION.............................................................................................................................................433 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW.............................................................................................................................433 H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...................................................................................................................................................434 H-18 IN SWING + ARM, ARM IS SLOW.................................................................................................................................................................434 H-19 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY...........................................................................................................................................434 H-20 TRAVEL DEVIATION............................................................................................................................................................................435 H-21 TRAVEL SPEED IS SLOW........................................................................................................................................................................436 H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER................................................................................................................................................438 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SET SPEED....................................................................................................................................440 H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)........................................................................................................................................................440 H-25 DOES NOT SWING..............................................................................................................................................................................441 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW...........................................................................................................................................442 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING.......................................................................................................................................................444 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)....................................................................................................................................445 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING................................................................................................................................................445 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING..........................................................................................................................................................446 H-31 SWING SPEED IS FASTER THAN SPECIFIED SPEED..................................................................................................................................................447 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...................................................................................................................................................448 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................................................................450 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM.....................................................................................................................................................452 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED.[E102] ERROR IN CLOCK DATA IS DISPLAYED....................................................................................................454 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED............................................................................455 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED........................................................................................................................................456 M-4 [E106] DROP IN ENGINE OIL PRESSURE HI PRESSURE DETECTED IS DISPLAYED.....................................................................................................................456 M-5 [E108] ENGINE WATER TEMPERATURE 105℃ DETECTED IS DISPLAYED...............................................................................................................................457 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS.................................................................................................458 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT.............................................................................................460 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)...........................................................................460 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES............................................................................................................461 M-10 PREHEATING IS NOT BEING USED BUT PREHEATING MONITOR LIGHTS UP...........................................................................................................................464 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH........................................................................................................465 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY,ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)...........................................467 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)....469 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPER), BUZZER DOES NOT SOUND FOR 1 SECOND.CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND...................................................472 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS................................................................................................................................472 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)....................................................................................................473 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE.................................................................................................................................................474 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION).....................................................................................474 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL...................................................................................................................................................475 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY..................................................................................................................................................475 M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT SWING LOCK MONITOR DOES NOT LIGHT UP..........................................................................................................476 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH........................................................................................................476 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING .................................................................................................................................477 M-24 WHEN STARING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED......................................................................................477 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM......................................................................................................................................................478 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM.............................................................................................................................................479 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM................................................................................................................................................480 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM...................................................................................................................................................481 M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM.............................................................................................................................................482 M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED...................................................................................................................483 M-31 ELECTRIC GREASE GUN DOES NOT WORK.......................................................................................................................................................487 30 DISASSEMBLY AND ASSEMBLY......................................................................................................................................................................................488 METHOD OF USING MANUAL.......................................................................................................................................................................................490 PRECAUTIONS WHEN CARRYING OUT OPERATION......................................................................................................................................................................492 SPECIAL TOOL LIST............................................................................................................................................................................................494 SKETCHES OF SPECIAL TOOLS....................................................................................................................................................................................499 STARTING MOTOR ASSEMBLY......................................................................................................................................................................................504 REMOVAL AND INSTALLATION.................................................................................................................................................................................504 ALTERNATOR ASSEMBLY..........................................................................................................................................................................................505 REMOVAL AND INSTALLATION.................................................................................................................................................................................505 ENGINE OIL COOLER ASSEMBLY...................................................................................................................................................................................506 REMOVAL AND INSTALLATION.................................................................................................................................................................................506 FUEL INJECTION PUMP ASSEMBLY.................................................................................................................................................................................507 REMOVAL..................................................................................................................................................................................................507 INSTALLATION.............................................................................................................................................................................................508 WATER PUMP ASSEMBLY..........................................................................................................................................................................................509 REMOVAL AND INSTALLATION.................................................................................................................................................................................509 NOZZLE HOLDER ASSEMBLY.......................................................................................................................................................................................510 REMOVAL AND INSTALLATION.................................................................................................................................................................................510 TURBOCHARGER ASSEMBLY........................................................................................................................................................................................511 REMOVAL AND INSTALLATION.................................................................................................................................................................................511 THERMOSTAT ASSEMBLY..........................................................................................................................................................................................512 REMOVAL AND INSTALLATION.................................................................................................................................................................................512 ENGINE FRONT SEAL............................................................................................................................................................................................513 REMOVAL..................................................................................................................................................................................................513 INSTALLATION.............................................................................................................................................................................................514 GOVERNOR MOTOR ASSEMBLY......................................................................................................................................................................................515 REMOVAL AND INSTALLATION.................................................................................................................................................................................515 CYLINDER HEAD ASSEMBLY.......................................................................................................................................................................................516 REMOVAL..................................................................................................................................................................................................516 INSTALLATION.............................................................................................................................................................................................518 AFTERCOOLER ASSEMBLY.........................................................................................................................................................................................521 REMOVAL AND INSTALLATION.................................................................................................................................................................................521 HYDRAULIC COOLER ASSEMBLY....................................................................................................................................................................................522 REMOVAL AND INSTALLATION.................................................................................................................................................................................522 RADIATOR, HYDRAULIC COOLER ASSEMBLY..........................................................................................................................................................................523 REMOVAL..................................................................................................................................................................................................523 INSTALLATION.............................................................................................................................................................................................524 ENGINE, MAIN PUMP ASSEMBLY...................................................................................................................................................................................525 REMOVAL..................................................................................................................................................................................................525 INSTALLATION.............................................................................................................................................................................................527 DAMPER ASSEMBLY..............................................................................................................................................................................................528 REMOVAL AND INSTALLATION.................................................................................................................................................................................528 FUEL TANK ASSEMBLY...........................................................................................................................................................................................529 REMOVAL AND INSTALLATION.................................................................................................................................................................................529 CENTER SWIVEL JOINT ASSEMBLY.................................................................................................................................................................................530 REMOVAL AND INSTALLATION.................................................................................................................................................................................530 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................531 FINAL DRIVE ASSEMBLY.........................................................................................................................................................................................532 REMOVAL AND INSTALLATION.................................................................................................................................................................................532 DISASSEMBLY ............................................................................................................................................................................................533 ASSEMBLY.................................................................................................................................................................................................537 TRAVEL MOTOR ASSEMBLY........................................................................................................................................................................................543 DISASSEMBLY..............................................................................................................................................................................................543 ASSEMBLY.................................................................................................................................................................................................548 SPROCKET.....................................................................................................................................................................................................557 REMOVAL AND INSTALLATION.................................................................................................................................................................................557 SWING MOTOR ASSEMBLY.........................................................................................................................................................................................558 REMOVAL AND INSTALLATION.................................................................................................................................................................................558 DISASSEMBLY..............................................................................................................................................................................................559 ASSEMBLY.................................................................................................................................................................................................562 SWING MACHINERY ASSEMBLY.....................................................................................................................................................................................569 REMOVAL AND INSTALLATION.................................................................................................................................................................................569 DISASSEMBLY..............................................................................................................................................................................................570 ASSEMBLY.................................................................................................................................................................................................574 REVOLVING FRAME ASSEMBLY.....................................................................................................................................................................................579 REMOVAL..................................................................................................................................................................................................579 INSTALLATION.............................................................................................................................................................................................580 SWING CIRCLE ASSEMBLY........................................................................................................................................................................................581 REMOVAL AND INSTALLATION.................................................................................................................................................................................581 IDLER, RECOIL SPRING ASSEMBLY................................................................................................................................................................................582 REMOVAL AND INSTALLATION.................................................................................................................................................................................582 IDLER ASSEMBLY...............................................................................................................................................................................................583 DISASSEMBLY..............................................................................................................................................................................................583 ASSEMBLY.................................................................................................................................................................................................584 RECOIL SPRING ASSEMBLY.......................................................................................................................................................................................586 DISASSEMBLY..............................................................................................................................................................................................586 ASSEMBLY.................................................................................................................................................................................................587 TRACK ROLLER ASSEMBLY........................................................................................................................................................................................588 REMOVAL AND INSTALLATION.................................................................................................................................................................................588 DISASSEMBLY..............................................................................................................................................................................................589 ASSEMBLY.................................................................................................................................................................................................590 CARRIER ROLLER ASSEMBLY......................................................................................................................................................................................592 REMOVAL AND INSTALLATION.................................................................................................................................................................................592 DISASSEMBLY..............................................................................................................................................................................................593 ASSEMBLY.................................................................................................................................................................................................595 TRACK SHOE ASSEMBLY..........................................................................................................................................................................................597 REMOVAL AND INSTALLATION.................................................................................................................................................................................597 HYDRAULIC TANK ASSEMBLY......................................................................................................................................................................................598 REMOVAL..................................................................................................................................................................................................598 INSTALLATION.............................................................................................................................................................................................599 CONTROL PUMP ASSEMBLY........................................................................................................................................................................................600 REMOVAL AND INSTALLATION.................................................................................................................................................................................600 MAIN PUMP ASSEMBLY...........................................................................................................................................................................................601 REMOVAL..................................................................................................................................................................................................601 INSTALLATION.............................................................................................................................................................................................602 DISASSEMBLY..............................................................................................................................................................................................603 ASSEMBLY.................................................................................................................................................................................................609 MAIN PUMP INPUT SHAFT OIL SEAL...............................................................................................................................................................................623 REMOVAL AND INSTALLATION.................................................................................................................................................................................623 CONTROL VALVE ASSEMBLY.......................................................................................................................................................................................624 REMOVAL..................................................................................................................................................................................................624 INSTALLATION.............................................................................................................................................................................................626 DISASSEMBLY..............................................................................................................................................................................................627 ASSEMBLY.................................................................................................................................................................................................631 PUMP MERGE/DIVIDER VALVE ASSEMBLY............................................................................................................................................................................636 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................636 PRESSURE COMPENSATION VALVE ASSEMBLY.........................................................................................................................................................................637 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................637 SERVO VALVE ASSEMBLY FOR FRONT PUMP..........................................................................................................................................................................638 REMOVAL AND INSTALLATION.................................................................................................................................................................................638 SERVO VALVE ASSEMBLY FOR REAR PUMP...........................................................................................................................................................................639 REMOVAL AND INSTALLATION.................................................................................................................................................................................639 LS-EPC SOLENOID VALVE ASSEMBLY...............................................................................................................................................................................640 REMOVAL AND INSTALLATION.................................................................................................................................................................................640 SOLENOID VALVE ASSEMBLY......................................................................................................................................................................................641 REMOVAL AND INSTALLATION.................................................................................................................................................................................641 WORK EQUIPMENT PPC VALVE ASSEMBLY............................................................................................................................................................................642 REMOVAL AND INSTALLATION.................................................................................................................................................................................642 DISASSEMBLY..............................................................................................................................................................................................643 ASSEMBLY.................................................................................................................................................................................................644 TRAVEL PPC VALVE ASSEMBLY....................................................................................................................................................................................645 REMOVAL AND INSTALLATION.................................................................................................................................................................................645 DISASSEMBLY..............................................................................................................................................................................................646 ASSEMBLY.................................................................................................................................................................................................647 PPC SHUTTLE VALVE ASSEMBLY...................................................................................................................................................................................648 REMOVAL .................................................................................................................................................................................................648 INSTALLATION.............................................................................................................................................................................................649 DISASSEMBLY..............................................................................................................................................................................................650 ASSEMBLY.................................................................................................................................................................................................651 BOOM LOCK VALVE ASSEMBLY.....................................................................................................................................................................................652 REMOVAL AND INSTALLATION.................................................................................................................................................................................652 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................653 BOOM CYLINDER ASSEMBLY.......................................................................................................................................................................................654 REMOVAL .................................................................................................................................................................................................654 INSTALLATION.............................................................................................................................................................................................655 ARM CYLINDER ASSEMBLY........................................................................................................................................................................................656 REMOVAL..................................................................................................................................................................................................656 INSTALLATION.............................................................................................................................................................................................657 BUCKET CYLINDER ASSEMBLY.....................................................................................................................................................................................658 REMOVAL..................................................................................................................................................................................................658 INSTALLATION.............................................................................................................................................................................................659 HYDRAULIC CYLINDER ASSEMBLY..................................................................................................................................................................................660 DISASSEMBLY..............................................................................................................................................................................................660 ASSEMBLY.................................................................................................................................................................................................662 WORK EQUIPMENT ASSEMBLY......................................................................................................................................................................................664 REMOVAL..................................................................................................................................................................................................664 INSTALLATION.............................................................................................................................................................................................665 BUCKET ASSEMBLY..............................................................................................................................................................................................666 REMOVAL..................................................................................................................................................................................................666 INSTALLATION.............................................................................................................................................................................................667 ARM ASSEMBLY.................................................................................................................................................................................................668 REMOVAL .................................................................................................................................................................................................668 INSTALLATION.............................................................................................................................................................................................669 BUCKET, ARM ASSEMBLY.........................................................................................................................................................................................670 REMOVAL .................................................................................................................................................................................................670 INSTALLATION.............................................................................................................................................................................................671 BOOM ASSEMBLY................................................................................................................................................................................................672 REMOVAL .................................................................................................................................................................................................672 INSTALLATION.............................................................................................................................................................................................673 OPERATOR'S CAB ASSEMBLY......................................................................................................................................................................................674 REMOVAL..................................................................................................................................................................................................674 INSTALLATION.............................................................................................................................................................................................675 COUNTERWEIGHT ASSEMBLY.......................................................................................................................................................................................676 REMOVAL AND INSTALLATION.................................................................................................................................................................................676 AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................................................................................................................677 REMOVAL AND INSTALLATION.................................................................................................................................................................................677 CONDENSER ASSEMBLY...........................................................................................................................................................................................678 REMOVAL AND INSTALLATION.................................................................................................................................................................................678 AIR CONDITIONER UNIT ASSEMBLY................................................................................................................................................................................679 REMOVAL..................................................................................................................................................................................................679 INSTALLATION.............................................................................................................................................................................................680 GOVERNOR, PUMP CONTROLLER ASSEMBLY...........................................................................................................................................................................681 REMOVAL AND INSTALLATION.................................................................................................................................................................................681 MONITOR PANEL ASSEMBLY.......................................................................................................................................................................................682 REMOVAL AND INSTALLATION.................................................................................................................................................................................682 CONTROL STAND CASE...........................................................................................................................................................................................683 REMOVAL..................................................................................................................................................................................................683 INSTALLATION.............................................................................................................................................................................................684 40 MAINTENANCE STANDARD..........................................................................................................................................................................................685 ENGINE MOUNT.................................................................................................................................................................................................686 SWING MACHINERY..............................................................................................................................................................................................687 SWING CIRCLE.................................................................................................................................................................................................689 FINAL DRIVE..................................................................................................................................................................................................690 TRACK FRAME AND RECOIL SPRING................................................................................................................................................................................692 IDLER........................................................................................................................................................................................................693 CARRIER ROLLER...............................................................................................................................................................................................695 TRACK ROLLER.................................................................................................................................................................................................696 TRACK........................................................................................................................................................................................................697 HYDRAULIC PUMP...............................................................................................................................................................................................699 CONTROL PUMP AND RELIEF VALVE................................................................................................................................................................................700 CONTROL VALVE................................................................................................................................................................................................701 SUCTION-SAFETY VALVE.........................................................................................................................................................................................707 SWING MOTOR..................................................................................................................................................................................................708 TRAVEL MOTOR.................................................................................................................................................................................................709 WORK EQUIPMENT, SWING PPC VALVE..............................................................................................................................................................................710 TRAVEL PPC VALVE.............................................................................................................................................................................................711 SERVICE PPC VALVE............................................................................................................................................................................................712 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.....................................................................................................................................................................713 EPC SOLENOID VALVE...........................................................................................................................................................................................714 CENTER SWIVEL JOINT .........................................................................................................................................................................................715 BOOM HOLDING VALVE...........................................................................................................................................................................................716 HYDRAULIC CYLINDER...........................................................................................................................................................................................717 WORK EQUIPMENT ..............................................................................................................................................................................................718 90 OTHERS........................................................................................................................................................................................................724 HYDRAULIC PIPING DIAGRAM (10-12).............................................................................................................................................................................725 HYDRAULIC CIRCUIT DIAGRAM (10-13)............................................................................................................................................................................726 CONTROL VALVE................................................................................................................................................................................................727 10-SPOOL VALVE (10-38)...................................................................................................................................................................................727 9-SPOOL VALVE (10-44)....................................................................................................................................................................................728 8-SPOOL VALVE (10-45)....................................................................................................................................................................................729 7-SPOOL VALVE (10-46)....................................................................................................................................................................................730 OPERATION FOR EACH FUNCTION OF CLSS (10-52)..................................................................................................................................................................731 OPERATION OF WHOLE CLSS SYSTEM...............................................................................................................................................................................732 1.WHEN ALL WORK EQUIPMENT IS AT NEUTRAL (10-72)..........................................................................................................................................................732 2.PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY (10-74)...........................................................................................................................................733 3.PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY (10-76)............................................................................................................................................734 4.PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY (10-78)................................................................................................................................................735 5.PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY (10-80)...............................................................................................................................................736 6.PUMP FLOW DIVIDED, TRAVEL OPERATED INDEPENDENTLY (10-82)...............................................................................................................................................737 7.PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY (10-84)..................................................................................................................................738 8.PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY (10-86)...................................................................................................................................739 9.PUMP FLOW DIVIDED (PUMP PRESSURE:19.6 MPa (200kg/cm2) OR ABOVE), TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY (10-88)...................................................................................740 10.PUMP FLOW DIVIDED (PUMP PRESSURE:19.6 MPa (200 kg/cm2) OR ABOVE), TRAVEL + ARM IN OPERATED SIMULTANEOUSLY (10-90).....................................................................................741 ACTUAL ELECTRIC WIRING DIAGRAM (10-138)..................................................................................................................................................................742 ACTUAL ELECTRIC WIRING DIAGRAM (10-139)..................................................................................................................................................................743 ELECTRIC CIRCUIT DIAGRAM (10-140)........................................................................................................................................................................744 ELECTRIC CIRCUIT DIAGRAM (10-141)........................................................................................................................................................................745 CONNECTOR ARRANGEMENT DIAGRAM (20-116)...................................................................................................................................................................746 CONTROL VALVE (40-20)....................................................................................................................................................................................747
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