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KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:33001 & UP)(SN:12001 & UP) – PDF DOWNLOAD
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- KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM014307
- SERIAL NUMBER
PC300-6 33001 and up
PC300LC-6 33001 and up
PC350-6 12001 and up
PC350LC-6 12001 and up
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Description
KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:33001 & UP)(SN:12001 & UP)
KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:33001 & UP)(SN:12001 & UP) – PDF DOWNLOAD:
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KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:33001 & UP)(SN:12001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. - MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts
TABLE OF CONTENTS:
KOMATSU PC300,300LC-6 PC350,350LC-6 SERVICE REPAIR MANUAL (SN:33001 & UP)(SN:12001 & UP)
MAIN MENU........................................................................................................................................ 0 COVER............................................................................................................................................ 1 CONTENTS......................................................................................................................................... 2 SAFETY........................................................................................................................................... 8 FOREWARD......................................................................................................................................... 10 HOW TO READ THE SHOP MANUAL.................................................................................................................. 11 HOISTING INSTRUCTIONS........................................................................................................................ 12 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................................................................................... 13 COATING MATERIALS............................................................................................................................ 15 STANDARD TIGHENING TORQUE.................................................................................................................... 17 ELECTRIC WIRE CODE........................................................................................................................... 20 COVERSION TABLE.............................................................................................................................. 21 01 GENERAL...................................................................................................................................... 28 SPECIFICATION DRAWINGS....................................................................................................................... 29 SPECIFICATIONS............................................................................................................................... 31 WEIGHT TABLE................................................................................................................................. 35 FUEL, COOLANT AND LUBRICANTS................................................................................................................. 39 10 STRUCTURE AND FUNCTION........................................................................................................................ 41 PARTS RELATED TO ENGINE...................................................................................................................... 42 RADIATOR, OIL COOLER......................................................................................................................... 44 POWER TRAIN.................................................................................................................................. 45 FINAL DRIVE.................................................................................................................................. 46 SWING CIRCLE................................................................................................................................. 47 SWING MACHINERY.............................................................................................................................. 49 TRACK FRAME, RECIOL SPRING................................................................................................................... 50 TRACK SHOE................................................................................................................................... 51 HYDRAULIC PIPING DRAWING..................................................................................................................... 52 HYDRAULIC CIRUIT DIAGRAM.................................................................................................................... 54 HYDRAULIC TANK, HYDRAULIC FILTER............................................................................................................. 55 HYDRAULIC PUMP............................................................................................................................... 56 CONTROL VALVE................................................................................................................................ 75 SELF-REDUCING PRESSURE VALVE................................................................................................................. 84 SUCTION SAFETY VALVE......................................................................................................................... 89 CLSS......................................................................................................................................... 90 SWING MOTOR..................................................................................................................................144 CENTER SWIVEL JOINT..........................................................................................................................150 TRAVEL MOTOR.................................................................................................................................152 VALVE CONTROL................................................................................................................................161 WORK EQUIPMENT - SWING PPC VALVE.............................................................................................................162 TRAVEL PPC VALVE.............................................................................................................................166 SERVICE PPC VALVE............................................................................................................................170 PPC SAFETY LOCK VALVE........................................................................................................................173 PPC ACCUMULATOR..............................................................................................................................173 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.....................................................................................................174 LS-EPC VALVE ................................................................................................................................181 SOLENOID VALVE...............................................................................................................................184 BOOM HOLDING VALVE...........................................................................................................................186 WORK EQUIPMENT...............................................................................................................................189 AIR CONDITIONER..............................................................................................................................190 ACTUAL ELECTRICAL WIRING DIAGRAM.............................................................................................................191 ELECTRIC CIRCUIT DIAGRAM.....................................................................................................................195 ENGINE CONTROL...............................................................................................................................201 ELECTRONIC CONTROL SYSTEM....................................................................................................................207 MACHINE MONITOR SYSTEM.......................................................................................................................232 FRONT WINDOW AUTO PULL-UP SYSTEM.............................................................................................................242 20 TESTING AND ADJUSTING........................................................................................................................244 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS................................................................................................246 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...............................................................................................247 STANDARD VALUE TABLE FOR ELECTRICAL PARTS....................................................................................................255 TESTING AND ADJUSTING........................................................................................................................263 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.........................................................................................263 MEASURING ENGINE SPEED...................................................................................................................264 MEASURING EXHAUST COLOR..................................................................................................................265 ADJUSTING VALVE CLEARANCE................................................................................................................266 MEASURING COMPRESSION PRESSURE...........................................................................................................267 MEASURING BLOW-BY PRESSURE...............................................................................................................267 TESTING AND ADJUSTING FUEL INJECTION TIMING..............................................................................................268 MEASURING ENGINE OIL PRESSURE............................................................................................................269 TESTING AND ADJUSTING ALTERNATOR BELT TENSION............................................................................................270 TESTING AND ADJUSTING WATER PUMP BELT TENSION............................................................................................270 TESTING AND AJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.........................................................................271 ADJUSTING ENGINE SPEED...................................................................................................................271 MEASURING AIR SUPPLY (BOOST PRESSURE)....................................................................................................272 TESTING AND AJUSTING GOVERNOR MOTOR LEVER STROKE.........................................................................................273 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT........................................................274 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)............................................................278 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE DIFFERENTIAL PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSU............281 TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF-PRESSURE IS REDUCED)........................................................286 TESTING SOLENOID VALVE OUTPUT PRESSURE...................................................................................................287 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE........................................................................290 ADJUSTING WORK EQUIPMENT, SWING PC VALVE.................................................................................................292 TESTING TRAVEL DEVIATION.................................................................................................................293 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT..............................................................................294 MEASURING OIL LEAKAGE....................................................................................................................296 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT......................................................................................298 TESTING CLEARENCE OF SWING CIRCLE BEARING................................................................................................299 TESTING WEAR OF SPROCKET.................................................................................................................300 TESTING AND ADJUSTING TRACK SHOE TENSION.................................................................................................301 BLEEDING AIR.............................................................................................................................302 TROUBLESHOOTING..............................................................................................................................304 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................................................................305 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................306 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.........................................................................................307 CHECKS BEFORE TROUBLESHOOTING............................................................................................................315 CONNECTOR TYPES AND MOUNTING LOCATIONS...................................................................................................316 CONNECTOR ARRANGEMENT DIAGRAM............................................................................................................318 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...............................................................................................321 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...................................................................................331 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL....................................................................................332 METHOD OF USING JUDGEMENT TABLE..........................................................................................................341 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................343 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE.................................................................................345 SERVICE CODE TABLE.......................................................................................................................350 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE).............................................................................351 N-1 [E218] COMMUNICATION ABNORMALITY.................................................................................................352 TROUBLESHOOTING OF OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE).......................................................354 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM.............................................355 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................356 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS.....................................360 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM.........................................................................................362 E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)................................................364 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALVE IS DISPLAYED.............................................................365 E-3 [E317] E-1 ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED....................................................366 E-4 [E318] E-1 ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED....................................................367 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED.............................................................368 E-6 [E315] ABNORMALITY (SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED)...............................................369 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED..........................................................................370 E-8 ENGINE DOES NOT START........................................................................................................371 E-9 ENGINE SPEED IS IRREGULAR....................................................................................................373 A) IDLING SPEED IS IRREGULAR.................................................................................................373 B) THERE IS HUNTING..........................................................................................................375 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)........................................................................377 E-11 ENGINE DOES NOT STOP........................................................................................................379 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)..........................................................381 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)................................................................................................383 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................384 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)........................................................................388 S-2 ENGINE DOES NOT START............................................................................................................389 1) ENGINE DOES NOT TURN..........................................................................................................389 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)......................................................390 3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...................................................391 S-3 ENGINE DOES NOT PICK UP SMOOTHLY.................................................................................................392 S-4 ENGINE STOPS DURING OPERATION....................................................................................................393 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................................................................394 S-6 ENGINE LACKS OUTPUT (NO POWER)...................................................................................................395 S-7 EXHAUST GAS IS BLACK.............................................................................................................396 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)............................................................................397 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................................................398 S-10 FUEL CONSUMPTION IS EXCESSIVE...................................................................................................399 S-11 OIL IS COOLING WATER, OR WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..................................................400 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)......................................................................401 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)............................................................................................402 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................................................403 S-15 ABNORMAL NOISE IS MADE..........................................................................................................404 S-16 VIBRATION IS EXCESSIVE..........................................................................................................405 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)..............................................................406 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM.......................................................................407 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................408 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS......................................416 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE................................................................................................418 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)........................................................420 C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED..........................................................421 C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED..........................................................423 C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED...........................................................425 C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED ..........................................................427 C-6 [E207] SHORT CIRCUIT IN ACTION MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED......................................................429 C-7 [E208] DISCONNECTION IN ACTION MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED......................................................430 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................431 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................433 C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED.....................................................435 C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED.....................................................436 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...........................................................437 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...........................................................438 C-14 [E231] SHORT CIRCUIT IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED....................................................439 C-15 [E235] DISCONNECTION CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...................................................440 C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED.............................................................................441 C-17 [E222] SHORT CIRCUIT IN ACC-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED .................................443 C-18 [E223] DISCONNECTION IN ACC-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED .................................444 C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED........................................................445 C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.........................................................446 C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED......................................................447 C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...............................................................448 C-23 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)..................................................449 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)..............................................................451 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE................................................................................................452 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...................................................................454 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP..................................................................455 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................456 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................457 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP..................................................................458 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP.................................................................459 F-7 BIT PATTERN 20-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................460 F-8 BIT PATTERN 20-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................461 F-9 BIT PATTERN 20-(3) SWING LOCK SWITCH DOES NOT LIGHT UP...........................................................................462 F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP...................................................................463 F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP...........................................................................464 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).................................................................................465 PUMP MERGE/DIVIDER LOGIC, SOLENOID ACTUATION TABLE...................................................................................467 TABLE OF FAILURE MODES AND CAUSES....................................................................................................468 ALL WORK EQUIPMENT, TRAVEL, SWING................................................................................................472 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER......................................................472 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...............................................................474 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...................................................................................475 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)..................................................................................475 H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)........................................................476 H-6 FINE CONTROL ABILTY IS POOR RESPONSE IS POOR ............................................................................476 WORK EQUIPMENT...................................................................................................................477 H-7 BOOM IS SLOW OR LACKS POWER.............................................................................................477 H-8 ARM IS SLOW OR LACKS POWER..............................................................................................479 H-9 BUCKET IS SLOW OR LACKS POWER...........................................................................................481 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).....................................482 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)..........................................................................482 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)..............................................................................483 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED..................................................................483 H-14 IN L/O F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED..................................................484 H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION........................................................................484 COMPOUND OPERATIONS..............................................................................................................484 H-16 INCOMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW.........................................................484 H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW..............................................................................485 H-18 IN SWING + ARM, ARM IS SLOW...........................................................................................485 H-19 IN SWING + TRAVEL SPEED DROPS EXCESSIVELY..............................................................................485 TRAVEL SYSTEM....................................................................................................................486 H-20 TRAVEL DEVIATION.......................................................................................................486 A) WHEN THERE IS DEVIATION IN NORMAL TRAVEL..............................................................................486 B) EXCESSIVE TRAVEL DEVIATION WHEN STARTING..............................................................................486 H-21 TRAVEL SPEED IS SLOW...................................................................................................487 H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER...........................................................................489 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED.........................................................491 H-24 TRAVEL DOES MOVE (ONE SIDE ONLY).......................................................................................491 SWING SYSTEM.....................................................................................................................492 H-25 DOES NOT SWING.........................................................................................................492 A) DOES NOT SWING TO EITHER LEFT OR RIGHT................................................................................492 B) DOES NOT SWING IN ONE DIRECTION.......................................................................................492 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW (BLOW LEFT AND RIGHT, ONE DIRECTION ONLY)............................493 A) SWING ACCELERATIONS IS POOR...........................................................................................493 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING...................................................................................495 A) ONE DIRECTION ONLY....................................................................................................495 B) BOTH DIRECTIONS.......................................................................................................495 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)................................................................496 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING..................................................................................496 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING......................................................................................497 A) WHEN SWING HOLDING BRAKE IS RELEASED..................................................................................497 B) WHEN SWING HOLDING BRAKE IS APPLIED...................................................................................497 H-31 SWING SPEED IS FASTER THAN SPECIFIED SPEED..............................................................................498 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).......................................................................................499 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................501 ELECTRICAL CIRCUIT DIAGRAM M MODE SYSTEM ............................................................................................503 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED...............................................................................507 [E102] ERROR IN CLOCK DATA IS DISPLAYED......................................................................................507 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED ...............508 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED............................................................................509 M-4 [E106] DROP IN ENGINE OIL PRESSURE HI DETECTED IS DISPLAYED..................................................................509 M-5 [E108] ENGINE WATER TEMPERATURE 105 C DETECTED IS DISPLAYED..................................................................510 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS....................................511 A) NONE OF LAMP ON MONITOR PANEL LIGHT UP....................................................................................511 B) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP............................................................................511 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT................................513 M-8 WHEN STARTING WITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAl MACHINE (MODEL)...............513 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH.................................................514 A) (COOLANT LEVEL) FLASHES...................................................................................................514 B) (ENGINE OIL LEVEL) FLASHES................................................................................................515 C) (HYDRAULIC OIL LEVEL) FLASHES.............................................................................................516 M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP.............................................................517 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH............................................518 A) ALTERNATOR SYSTEM.........................................................................................................518 B) ENGINE OIL PRESSURE SYSTEM................................................................................................519 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH..............................520 A) ALTERNATOR SYSTEM.........................................................................................................520 B) ENGINE OIL PRESSURE SYSTEM................................................................................................521 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH.........................522 A) (ENGINE OIL PRESSURE) FLASHES.............................................................................................522 B) (COOLANT LEVEL) FLASHES...................................................................................................522 C) (BATTERY CHARGE) FLASHES..................................................................................................522 D) (COOLANT TEMPERATURE) FLASHES ............................................................................................523 E) (FUEL LEVEL) FLASHES......................................................................................................523 F) (AIR CLEANER CLOGGING) FLASHES............................................................................................524 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER ....525 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS....................................................................525 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)........................................526 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE.....................................................................................527 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY.........................................................................527 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.......................................................................................528 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY......................................................................................528 M-21 SWING LOCK SWITCH IS TURNED ON LOCK SWITCH IS TURNED ON ....................................................................529 M-22 SWING LOCK SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP.........................................529 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING......................................................................530 M-24 WHEN STARTING SWITCH IS OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED............................530 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM..........................................................................................531 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM.................................................................................532 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM....................................................................................533 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.......................................................................................534 M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM.................................................................................535 M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113)..................................536 A) WIPER DOES NOT WORK.......................................................................................................536 B) WIPER SWITCH IS NOT BEING OPERATED BUT WIPER IS ACTUATED..................................................................541 M-31 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114).........................542 A) WASHER MOTOR DOES NOT WORK................................................................................................542 B) SWITCH IS NOT BEING OPERATED BUT WASHER IS ACTUATED.......................................................................543 M-32 ELECTRIC GREASE GUN DOES NOT WORK...........................................................................................545 30 DISASSEMBLY AND ASSEMBLY......................................................................................................................546 METHOD OF USING MANUAL.......................................................................................................................548 PRECAUTIONS WHEN CARRYING OUT OPERATION......................................................................................................550 SPECIAL TOOL LIST............................................................................................................................552 SKETCHES OF SPECIAL TOOLS....................................................................................................................557 STARTING MOTOR ASSEMBLY......................................................................................................................562 REMOVAL AND INSTALLATION.................................................................................................................562 ALTERNATOR ASSEMBLY..........................................................................................................................563 REMOVAL AND INSTALLATION.................................................................................................................563 ENGINE OIL COOLER ASSEMBLY...................................................................................................................564 REMOVAL AND INSTALLATION.................................................................................................................564 FUEL INJECTION PUMP..........................................................................................................................565 REMOVAL..................................................................................................................................565 INSTALLATION.............................................................................................................................566 WATER PUMP ASSEMBLY..........................................................................................................................567 REMOVAL AND INSTALLATION.................................................................................................................567 NOZZLE HOLDER................................................................................................................................568 REMOVAL AND INSTALLATION.................................................................................................................568 TURBOCHARGER.................................................................................................................................569 REMOVAL AND INSTALLATION.................................................................................................................569 THERMOSTAT...................................................................................................................................570 REMOVAL AND INSTALLATION.................................................................................................................570 ENGINE FRONT SEAL............................................................................................................................571 REMOVAL .................................................................................................................................571 INSTALLATION.............................................................................................................................572 ENGINE REAR SEAL.............................................................................................................................573 REMOVAL..................................................................................................................................573 INSTALLATION.............................................................................................................................573 GOVERNOR MOTOR ASSEMBLY......................................................................................................................575 REMOVAL AND INSTALLATION.................................................................................................................575 CYLINDER HEAD ASSEMBLY.......................................................................................................................576 REMOVAL..................................................................................................................................576 INSTALLATION.............................................................................................................................578 AFTERCOOLER ASSEMBLY.........................................................................................................................581 REMOVAL AND INSTALLATION.................................................................................................................581 HYDRAULIC COOLER ASSEMBLY....................................................................................................................582 REMOVAL AND INSTALLATION.................................................................................................................582 RADIATOR, HYDRAULIC COOLER ASSEMBLY..........................................................................................................583 REMOVAL..................................................................................................................................583 INSTALLATION.............................................................................................................................584 ENGINE, MAIN PUMP ASSEMBLY...................................................................................................................585 REMOVAL.................................................................................................................................. 0 INSTALLATION ............................................................................................................................588 DAMPER ASSEMBLY..............................................................................................................................589 REMOVAL AND INSTALLATION.................................................................................................................589 FUEL TANK ASSEMBLY...........................................................................................................................590 REMOVAL AND INSTALLATION................................................................................................................590 CENTER SWIVEL JOINT ASSEMBLY.................................................................................................................591 REMOVAL AND INSTALLATION.................................................................................................................591 DISASSEMBLY AND ASSEMBLY.................................................................................................................594 FINAL DRIVE ASSEMBLY.........................................................................................................................595 REMOVAL AND INSTALLATION.................................................................................................................595 DISASSEMBLY..............................................................................................................................596 ASSEMBLY.................................................................................................................................600 TRAVEL MOTOR ASSEMBLY........................................................................................................................606 DISASSEMBLY .............................................................................................................................606 ASSEMBLY ................................................................................................................................611 SPROCKET.....................................................................................................................................620 REMOVAL AND INSTALLATION.................................................................................................................620 SWING MOTOR ASSEMBLY.........................................................................................................................621 REMOVAL AND INSTALLATION.................................................................................................................621 DISASSEMBLY..............................................................................................................................622 ASSEMBLY.................................................................................................................................625 SWING MACHINERY ASSEMBLY.....................................................................................................................632 REMOVAL AND INSTALLATION.................................................................................................................632 DISASSEMBLY..............................................................................................................................633 ASSEMBLY.................................................................................................................................637 REVOLVING FRAME ASSEMBLY.....................................................................................................................642 REMOVAL .................................................................................................................................642 INSTALLATION.............................................................................................................................643 SWING CIRCLE ASSEMBLY........................................................................................................................644 REMOVAL AND INSTALLATION.................................................................................................................644 IDLER, RECOIL SPRING.........................................................................................................................645 REMOVAL AND INSTALLATION.................................................................................................................645 IDER ASSEMBLY................................................................................................................................646 DISASSEMBLY..............................................................................................................................646 ASSEMBLY.................................................................................................................................647 RECOIL SPRING ASSEMBLY.......................................................................................................................649 DISASSEMBLY..............................................................................................................................649 ASSEMBLY.................................................................................................................................650 TRACK ROLLER ASSEMBLY........................................................................................................................651 REMOVAL AND INSTALLATION.................................................................................................................651 DISASSEMBLY..............................................................................................................................652 ASSEMBLY.................................................................................................................................653 CARRIER ROLLER...............................................................................................................................655 REMOVAL AND INSTALLATION.................................................................................................................655 DISASSEMBLY .............................................................................................................................656 ASSEMBLY.................................................................................................................................658 TRACK SHOE ASSEMBLY..........................................................................................................................660 REMOVAL AND INSTALLATION.................................................................................................................660 HYDRAULIC TANK ASSEMBLY......................................................................................................................661 REMOVAL .................................................................................................................................661 INSTALLATION.............................................................................................................................662 MAIN PUMP ASSEMBLY...........................................................................................................................663 REMOVAL .................................................................................................................................663 INSTALLATION.............................................................................................................................665 DISASSEMBLY..............................................................................................................................666 ASSEMBLY.................................................................................................................................672 MAIN PUMP INPUT SHAFT OIL SEAL...............................................................................................................685 REMOVAL AND INSTALLATION.................................................................................................................685 CONTROL VALVE ASSEMBLY.......................................................................................................................686 REMOVAL .................................................................................................................................686 INSTALLATION.............................................................................................................................688 DISASSEMBLY..............................................................................................................................689 ASSEMBLY.................................................................................................................................695 PUMP MERGE/DIVIDER VALVE ASSEMBLY............................................................................................................702 REMOVAL AND INSTALLATION.................................................................................................................702 PRESSURE COMPENSATION VALVE..................................................................................................................703 DISASSEMBLY AND ASSEMBLY.................................................................................................................703 SERVO VALVE ASSEMBLY FOR FRONT PUMP..........................................................................................................704 REMOVAL AND INSTALLATION.................................................................................................................704 SERVO VALVE ASSEMBLY FOR REAR PUMP...........................................................................................................705 REMOVAL AND INSTALLATION.................................................................................................................705 LS-EPC SOLENOID VALVE ASSEMBLY...............................................................................................................706 REMOVAL AND INSTALLATION.................................................................................................................706 SOLENOID VALVE ASSEMBLY......................................................................................................................707 REMOVAL AND INSTALLATION.................................................................................................................707 WORK EQUIPMENT PPC VALVE ASSEMBLY............................................................................................................708 REMOVAL AND INSTALLATION.................................................................................................................708 DISASSEMBLY..............................................................................................................................709 ASSEMBLY.................................................................................................................................710 TRAVEL PPC VALVE ASSEMBLY....................................................................................................................711 REMOVAL AND INSTALLATION.................................................................................................................711 DISASSEMBLY..............................................................................................................................713 ASSEMBLY.................................................................................................................................713 PPC SHUTTLE VALVE ASSEMBLY...................................................................................................................714 REMOVAL..................................................................................................................................714 INSTALLATION.............................................................................................................................715 DIASSEMBLY...............................................................................................................................716 ASSEMBLY.................................................................................................................................717 BOOM LOCK VALVE ASSEMBLY.....................................................................................................................718 REMOVAL AND INSTALLATION.................................................................................................................718 DISASSEMBLY AND ASSEMBLY.................................................................................................................719 BOOM CYLINDER ASSEMBLY.......................................................................................................................720 REMOVAL..................................................................................................................................720 INSTALLATION.............................................................................................................................721 ARM CYLINDER ASSEMBLY........................................................................................................................722 REMOVAL .................................................................................................................................722 INSTALLATION.............................................................................................................................723 BUCKET CYLINDER ASSEMBLY.....................................................................................................................724 REMOVAL .................................................................................................................................724 INSTALLATION.............................................................................................................................725 HYDRAULIC CYLINDER ASSEMBLY..................................................................................................................726 DISASSEMBLY..............................................................................................................................726 ASSEMBLY.................................................................................................................................729 WORK EQUIPMENT ASSEMBLY......................................................................................................................733 REMOVAL .................................................................................................................................733 INSTALLATION.............................................................................................................................734 BUCKET ASSEMBLY..............................................................................................................................735 REMOVAL .................................................................................................................................735 INSTALLATION.............................................................................................................................736 ARM ASSEMBLY.................................................................................................................................737 REMOVAL .................................................................................................................................737 INSTALLATION.............................................................................................................................738 BUCKET, ARM ASSEMBLY.........................................................................................................................739 REMOVAL..................................................................................................................................739 INSTALLATION.............................................................................................................................740 BOOM ASSEMBLY................................................................................................................................741 REMOVAL..................................................................................................................................741 INSTALLATION.............................................................................................................................742 OPERATOR'S CAB...............................................................................................................................743 REMOVAL .................................................................................................................................743 INSTALLATION.............................................................................................................................744 COUNTERWEIGHT ...............................................................................................................................745 REMOVAL AND INSTALLATION.................................................................................................................745 AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................................................746 REMOVAL AND INSTALLATION.................................................................................................................746 AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................................................747 REMOVAL AND INSTALLATION.................................................................................................................747 RECEIVER TANK ASSEMBLY......................................................................................................................748 REMOVAL AND INSTALLATION.................................................................................................................748 AIR CONDITIONER UNIT ASSEMBLY................................................................................................................749 REMOVAL .................................................................................................................................749 INSTALLATION.............................................................................................................................750 GOVERNOR, PUMP CONTROLLER ASSEMBLY...........................................................................................................751 REMOVAL AND INSTALLATION.................................................................................................................751 MONITOR PANEL ASSEMBLY.......................................................................................................................752 REMOVAL AND INSTALLATION.................................................................................................................752 CONTROL STAND CASE...........................................................................................................................753 REMOVAL..................................................................................................................................753 INSTALLATION.............................................................................................................................754 40 MAINTENANCE STANDARD..........................................................................................................................755 ENGINE MOUNT.................................................................................................................................756 SWING MACHINERY..............................................................................................................................757 SWING CIRCLE.................................................................................................................................759 FINAL DRIVE..................................................................................................................................761 TRACK FRAME AND RECOIL SPRING................................................................................................................763 IDER.........................................................................................................................................764 CARRIER ROLLER...............................................................................................................................766 TRACK ROLLER.................................................................................................................................767 TRACK SHOE...................................................................................................................................768 HYDRAULIC PUMP...............................................................................................................................772 CONTROL VALVE................................................................................................................................773 SELF-REDUCING PRESSURE VALVE.................................................................................................................780 SUCTION-SAFETY VALVE.........................................................................................................................781 SWING MOTOR..................................................................................................................................782 TRAVEL MOTOR.................................................................................................................................783 WORK EQUIPMENT - SWING PPC VALVE.............................................................................................................784 TRAVEL PPC VALVE.............................................................................................................................785 SERVICE PPC VALVE............................................................................................................................786 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.....................................................................................................787 LS-EPC VALVE.................................................................................................................................788 SOLENOID VALVE...............................................................................................................................789 CENTER SWIVEL JOINT..........................................................................................................................790 BOOM HOLDING VALVE...........................................................................................................................792 HYDRAULIC CYLINDER...........................................................................................................................793 WORK EQUIPMENT...............................................................................................................................795 DIMENSION OF WORK EQUIPMENT..................................................................................................................797 90 OTHERS.......................................................................................................................................801 HYDRAULIC CIRCUIT DIAGRAM....................................................................................................................802 ELECTRIC CIRCUIT DIAGRAM (1/3) WITH POWER WINDOW............................................................................................803 ELECTRIC CIRCUIT DIAGRAM (2/3) WITH POWER WINDOW.............................................................................................804 ELECTRIC CIRCUIT DIAGRAM (3/3) WITH POWER WINDOW............................................................................................805 ELECTRIC CIRCUIT DIAGRAM (1/3) WITH POWER WINDOW............................................................................................806 ELECTRIC CIRCUIT DIAGRAM (2/3) WITH POWER WINDOW............................................................................................807 ELECTRIC CIRCUIT DIAGRAM (3/3) WITH POWER WINDOW............................................................................................808
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