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Komatsu PC350LL-7E0 LOGGINGROAD BUILDER EXCAVATOR Service Repair Manual – PDF DOWNLOAD
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Description
Komatsu PC350LL-7E0 LOGGINGROAD BUILDER EXCAVATOR Service Repair Manual
Screenshot of the Manual:
KOMATSU PC350LL-7E0 LOGGINGROAD BUILDER EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
Komatsu PC350LL-7E0 LOGGINGROAD BUILDER EXCAVATOR Service Repair Manual
- 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, FUNCTION AND MAINTENANCE STANDARD
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section gives the judgement standards when inspecting disassembled parts. - STANDARD VALUE TABLE
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in 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
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. - AIR CONDITIONING
This section explains the air conditioning system. The structure, function, maintenance standard, testing, adjusting, troubleshooting, servicing and some disassembly and assembly. - DIAGRAMS AND DRAWINGS
This section has the foldout drawings for the machine.
Table of Contents:
Komatsu PC350LL-7E0 LOGGINGROAD BUILDER EXCAVATOR Service Repair Manual
CEBM024301 - PC350LL-7E0 - s/n A50001 and up....................................................... 1 CONTENTS....................................................................................... 3 REVISED PAGES.................................................................................. 4 SAFETY......................................................................................... 12 Safety Notice.............................................................................. 12 General Precautions.................................................................... 12 Preparations For Work.................................................................. 12 Precautions During Work................................................................ 13 GENERAL........................................................................................ 14 HOW TO READ THE SHOP MANUAL.................................................................... 15 Volumes.................................................................................... 15 Distribution And Updating.................................................................. 15 Filing Method.............................................................................. 15 Revised Edition Mark....................................................................... 15 Revisions.................................................................................. 15 Symbols.................................................................................... 16 HOISTING INSTRUCTIONS.......................................................................... 17 Hoisting................................................................................... 17 Wire Ropes................................................................................. 17 PUSH PULL COUPLER.............................................................................. 19 Type 1..................................................................................... 19 Disconnection.......................................................................... 19 Connection............................................................................. 19 Type 2..................................................................................... 20 Disconnection.......................................................................... 20 Connection............................................................................. 20 Type 3..................................................................................... 21 Disconnection.......................................................................... 21 Connection............................................................................. 21 EXPLANATION OF MAINTENANCE STANDARD TERMS...................................................... 22 STANDARD TIGHTENING TORQUE..................................................................... 24 Bolts and Nuts............................................................................. 24 Tightening Torque of Hose Nuts............................................................. 25 Tightening Torque of Split Flange Bolts.................................................... 25 Tightening Torque for Flared Nuts.......................................................... 25 Tightening Torques for O-ring Boss Piping Joints........................................... 26 Table of Tightening Torques for O-ring Boss Plugs.......................................... 26 Torque Table for Hoses (Taper Seal Type and Face Seal Type)................................ 26 ELECTRIC WIRE CODE............................................................................. 27 Classification by Thickness................................................................ 27 Classification by Color And Code........................................................... 27 How to Read Electric Wire Code............................................................. 28 CONVERSION TABLES.............................................................................. 31 Method of using the Conversion Table....................................................... 31 COATING MATERIALS.............................................................................. 37 01 GENERAL......................................................................................... 39 SPECIFICATIONS................................................................................. 40 Dimensions................................................................................. 40 Road Builder........................................................................... 40 Log Loader - 42 Ft Komatsu Forest Front................................................ 40 Working Ranges............................................................................. 42 Road Builder........................................................................... 42 Log Loader - 42 Ft Komatsu Forest Front................................................ 44 WEIGHT TABLE................................................................................... 49 FUEL, COOLANT, AND LUBRICANTS.................................................................. 51 10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD..................................................... 53 ENGINE RELATED PARTS........................................................................... 56 RADIATOR . OIL COOLER . AFTERCOOLER............................................................ 57 POWER TRAIN.................................................................................... 58 FINAL DRIVE.................................................................................... 59 SPROCKET....................................................................................... 63 Sprocket Tool.............................................................................. 64 SWING MACHINERY................................................................................ 65 Swing Circle............................................................................... 69 TRACK FRAME . RECOIL SPRING.................................................................... 70 IDLER.......................................................................................... 72 TRACK ROLLER/CARRIER ROLLER.................................................................... 74 TRACK SHOE..................................................................................... 76 TRIPLE GROUSER SHOE............................................................................ 79 DOUBLE GROUSER SHOE............................................................................ 80 HYDRAULIC EQUIPMENT............................................................................ 82 HYDRAULIC TANK AND FILTER...................................................................... 84 HYDRAULIC PUMP................................................................................. 86 HPV125 + 125............................................................................... 86 LS Valve................................................................................... 92 PC Valve................................................................................... 97 LS(PC)-EPC Valve........................................................................... 104 Variable Volume Valve...................................................................... 108 CONTROL VALVE.................................................................................. 110 CLSS........................................................................................... 122 VALVE FUNCTIONS AND OPERATION.................................................................. 126 UNLOADER VALVE................................................................................. 128 INTRODUCTION OF LS PRESSURE.................................................................... 130 LS BYPASS VALVE................................................................................ 131 PRESSURE COMPENSATION VALVE.................................................................... 132 Pressure Compensation Valve Inner Shuttle.................................................. 135 Boom Regeneration Circuit.................................................................. 137 Arm Regeneration Circuit................................................................... 139 MERGE-DIVIDER VALVE............................................................................ 141 LS SELECT VALVE................................................................................ 143 SELF PRESSURE REDUCING VALVE................................................................... 144 TRAVEL JUNCTION VALVE.......................................................................... 147 TRAVEL PPC SHUTTLE VALVE....................................................................... 149 BOOM DRIFT PREVENTION VALVE.................................................................... 151 ARM DRIFT PREVENTION VALVE..................................................................... 154 QUICK RETURN VALVE............................................................................. 158 LIFT CHECK VALVE............................................................................... 160 MAIN RELIEF VALVE.............................................................................. 161 2-STAGE SAFETY-SUCTION VALVE................................................................... 162 VARIABLE PRESSURE COMPENSATION VALVE........................................................... 164 CONTROL VALVE.................................................................................. 166 PPC VALVE...................................................................................... 167 Work Equipment and Swing PPC Valve......................................................... 167 Travel PPC Valve........................................................................... 173 PRESSURE REDUCING VALVE........................................................................ 176 Straight Travel PPC Valve.................................................................. 182 PPC Accumulator............................................................................ 184 SOLENOID VALVE................................................................................. 185 ATTACHMENT SOLENOID VALVE...................................................................... 186 CENTER SWIVEL JOINT............................................................................ 188 TRAVEL MOTOR................................................................................... 189 Type: KMV200ADT-2.......................................................................... 189 Operation of Motor......................................................................... 192 PARKING BRAKE.................................................................................. 194 Brake Valve Operation...................................................................... 196 SAFETY VALVE................................................................................... 198 SWING MOTOR.................................................................................... 201 Type: KMF230ABE-5.......................................................................... 201 Swing Holding Brake........................................................................ 204 Relief Valve Portion....................................................................... 205 REVERSE PREVENTION VALVE....................................................................... 206 Explanatory Drawing of Effects............................................................. 207 HYDRAULIC CYLINDERS - EXCAVATOR WORK EQUIPMENT................................................. 210 Boom Cylinder.............................................................................. 210 Arm Cylinder............................................................................... 210 Bucket Cylinder............................................................................ 211 WORK EQUIPMENT PIVOT POINT MEASUREMENTS........................................................ 212 Boss Bushing/Pins - Excavator Work Equipment............................................... 212 Dimension of Arm - Excavator Work Equipment................................................ 214 Dimension of Bucket........................................................................ 216 CAB AND ATTACHMENTS............................................................................ 218 Air Conditioner Piping..................................................................... 218 ELECTRICAL SYSTEM.............................................................................. 219 Engine Control............................................................................. 219 ELECTRONIC COMPONENTS.......................................................................... 221 Fuel Control Dial.......................................................................... 221 Engine Controller.......................................................................... 222 Coolant Temperature Sensor................................................................. 226 Oil Pressure Switch........................................................................ 226 Engine Speed Sensor........................................................................ 227 Boost Pressure and Temperature Sensor...................................................... 227 WIF (Water-in-fuel Detection) Sensor....................................................... 228 Engine Oil Level Sensor.................................................................... 228 ELECTRONIC CONTROL SYSTEM...................................................................... 229 Control Function........................................................................... 229 System Diagram......................................................................... 230 Engine and Pump Control Function........................................................... 232 Pump and Valve Control..................................................................... 236 LS Control Function.................................................................... 237 Cut-off Function....................................................................... 237 2-stage Relief Function................................................................ 237 Power Maximizing and Machine Push-up....................................................... 238 Auto-deceleration.......................................................................... 240 Auto-warm-up and Overheat Prevention....................................................... 241 Swing Control.............................................................................. 243 Travel Control............................................................................. 245 Attachment Flow Control and Circuit Selector (If Equipped)................................. 247 SYSTEM COMPONENTS.............................................................................. 248 PPC Oil Pressure Switch.................................................................... 248 Oil Pressure Sensor........................................................................ 249 Pump Pressure Sensor (High Pressure)....................................................... 250 Pump Controller............................................................................ 251 MONITOR SYSTEM................................................................................. 255 Machine Monitor............................................................................ 256 MONITOR CONTROL AND DISPLAY.................................................................... 259 Monitor.................................................................................... 259 Display.................................................................................... 260 SWITCHES....................................................................................... 264 Brightness, Contrast Adjustment............................................................ 272 Service Meter Check Function............................................................... 273 Display Lcd Check Function................................................................. 273 User Code Display Function................................................................. 274 SENSOR......................................................................................... 276 Hydraulic Oil and Coolant Temperature Sensor............................................... 276 Fuel Level Sensor.......................................................................... 277 Air Cleaner Clogging Sensor................................................................ 277 KOMTRAX TERMINAL SYSTEM........................................................................ 278 Komtrax Terminal........................................................................... 279 20 STANDARD VALUE TABLES........................................................................... 281 STANDARD VALUE TABLES.......................................................................... 282 Engine Related............................................................................. 282 Chassis Related............................................................................ 283 30 TESTING AND ADJUSTING........................................................................... 291 SERVICE TOOLS.................................................................................. 293 Engine Service Tools....................................................................... 293 Chassis Service Tools...................................................................... 294 ENGINE......................................................................................... 295 Engine Speed............................................................................... 295 Air Boost Pressure......................................................................... 296 Exhaust Gas Color.......................................................................... 297 Valve Clearance............................................................................ 299 Compression Pressure....................................................................... 301 Blow-by Pressure........................................................................... 306 Engine Oil Pressure........................................................................ 307 Fuel Pressure.............................................................................. 308 Handling During Cylinder Cut-out Operation................................................. 313 Handling During No Injection Cranking Operation............................................ 313 Fuel Return Rate And Leakage............................................................... 314 Bleeding Air From Fuel Circuit............................................................. 317 Fuel Circuit For Leakage................................................................... 318 AIR COMPRESSOR BELT TENSION.................................................................... 319 FAN BELT....................................................................................... 320 ALTERNATOR BELT................................................................................ 321 ENGINE FUNCTIONS............................................................................... 322 Measure Engine Speed With Machine Monitor.................................................. 322 Preparation............................................................................ 322 Measuring Low Idle Speed............................................................... 322 Measuring High Idle Speed.............................................................. 322 Measuring the Engine Speed When 2-pumps are Relieved................................... 322 Measuring the Engine Speed At 2-pump Relief and Power Maximizing (Near Rated Speed).... 322 Measuring the Speed When Auto-deceleration Speed is in Operation....................... 322 Determining a Defective Cylinder........................................................... 323 Procedures............................................................................. 323 Determining Cylinder Group............................................................. 323 Isolating the Defective Cylinder....................................................... 323 Cylinder Cut-out Operation................................................................. 324 No Injection Cranking Operation............................................................ 324 REFRIGERANT COMPRESSOR BELT.................................................................... 325 Inspection................................................................................. 325 Adjustment................................................................................. 325 SWING CIRCLE BEARING CLEARANCE................................................................. 326 TRACK SHOE TENSION............................................................................. 327 Inspection................................................................................. 327 Adjustment................................................................................. 327 OIL PRESSURE IN WORK EQUIPMENT................................................................. 328 OIL PRESSURE IN SWING.......................................................................... 328 OIL PRESSURE IN TRAVEL CIRCUIT................................................................. 328 Measuring.................................................................................. 328 Adjusting.................................................................................. 330 CONTROL CIRCUIT OIL PRESSURE................................................................... 333 Measuring.................................................................................. 333 PUMP PC CONTROL CIRCUIT OIL PRESSURE........................................................... 334 Measuring.................................................................................. 334 Adjusting.................................................................................. 336 PUMP LS CONTROL CIRCUIT OIL PRESSURE........................................................... 337 Measuring.................................................................................. 337 Adjusting.................................................................................. 341 SOLENOID VALVE OUTPUT PRESSURE................................................................. 342 ATTACHMENT SOLENOID VALVE OUTPUT............................................................... 345 PPC VALVE OUTPUT............................................................................... 347 ATTACHMENT PPC VALVE OUTPUT.................................................................... 348 WORK EQUIPMENT AND SWING PPC VALVES............................................................ 349 Adjust Play................................................................................ 349 HYDRAULIC DRIFT IN WORK EQUIPMENT.............................................................. 350 Boom and Bucket Cylinders Inspection....................................................... 350 Arm Cylinder Inspection.................................................................... 350 Boom Lock Valve Inspection................................................................. 351 PPC Valve Inspection....................................................................... 351 RELEASE REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................ 352 Oil Leakage Amount......................................................................... 352 BLEEDING AIR FROM VARIOUS SYSTEMS.............................................................. 355 DIODE INSPECTION PROCEDURES.................................................................... 357 MACHINE MONITOR - SPECIAL FUNCTIONS............................................................ 358 Ordinary and Special Functions............................................................. 359 Operators Menu and Display (Outline)....................................................... 360 SERVICE MENU OPERATION AND DISPLAY............................................................. 368 Switching To Service Menu.................................................................. 368 Monitoring [01] Function................................................................... 369 Function Of Abnormality Record [02]........................................................ 374 Function of Maintenance Record [03]........................................................ 376 Function of Maintenance Mode Change [04]................................................... 377 Function of Phone Number Entry [05]........................................................ 379 Function of Default [06]................................................................... 380 Function of Adjustment [07]................................................................ 382 Function of Cylinder Cut Out Operation [08]................................................ 383 Function of No Injection Cranking [09]..................................................... 385 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER.................................................. 387 PROCEDURE FOR TURNING ON KOMTRAX TERMINAL...................................................... 388 KOMTRAX TERMINAL LAMP INDICATIONS.............................................................. 391 TROUBLESHOOTING ELECTRICAL SYSTEM.............................................................. 394 PM-CLINIC INSPECTION TABLE..................................................................... 397 40 TROUBLESHOOTING................................................................................. 403 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................ 407 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................... 409 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...................................................... 410 Precautions when Handling Electrical Equipment............................................. 410 Handling Electronic Control Unit........................................................... 414 Points to Remember when Troubleshooting Electrical Circuits................................ 415 Points to Remember when Handling Hydraulic Equipment....................................... 416 Checks Before Troubleshooting.............................................................. 419 Categories and Method of using Troubleshooting Charts...................................... 420 Troubleshooting Individual Electrical Circuits............................................. 421 Troubleshooting Individual Hydraulic Circuits.............................................. 425 POSSIBLE PROBLEMS WHEN TROUBLESHOOTING A MODE.................................................. 427 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................... 430 T-ADAPTER TABLE................................................................................ 451 CONNECTOR TYPES AND LOCATIONS.................................................................. 454 CONNECTOR LAYOUT DRAWINGS...................................................................... 460 TROUBLESHOOTING BY FAILURE CODE................................................................ 466 Before carrying out troubleshooting when failure code is displayed......................... 469 Location of Fuse Box and Fuse Numbers...................................................... 470 INFORMATION CONTAINED IN TESTING PROCEDURES.................................................... 472 FAILURE CODE (DISPLAY OF CODE)................................................................. 474 A000N1 - Engine Over Speed................................................................. 474 AA10NX - Air Cleaner Clog Sensor System.................................................... 476 AB00KE - Charge Voltage Is Low............................................................. 478 B@BAZG - Engine Oil Pressure Drop.......................................................... 480 B@BAZK - Engine Oil Level Drop............................................................. 482 B@BCNS - Coolant High Temperature Sensor Showing Overheat (NS)............................. 484 B@BCZK - Engine Coolant Level Drop......................................................... 486 B@HANS - Hydraulic Oil Overheat Condition.................................................. 488 CA111 - Critical Internal Failure.......................................................... 490 CA115 - Engine NE And Backup Speed Sensor Error............................................ 491 CA122 - Charge Air Pressure Sensor High Error.............................................. 492 CA123 - Charge Air Pressure Sensor Low Error............................................... 494 CA131 - Throttle Sensor High Error......................................................... 496 CA132 - Throttle Sensor Low Error.......................................................... 498 CA144 - Coolant Temperature (High) Sensor Out of Range (KX)................................ 500 CA145 - Coolant Temperature (Low) Sensor Out of Range (KX)................................. 502 CA153 - Charge Air Pressure Sensor High Error.............................................. 504 CA154 - Charge Air Pressure Sensor Low Error............................................... 506 CA187 - SEnsor Supply 2 Volt Low Error..................................................... 508 CA221 - Ambient Pressure Sensor High Error................................................. 510 CA222 - Ambient Pressure Sensor Low Error.................................................. 512 CA227 - Sensor Supply 2 Volt High Error.................................................... 514 CA234 - Engine Over Speed.................................................................. 516 CA238 - Speed Sensor Supply Volt Error..................................................... 517 CA271 - UMV/PCV1 Short Error............................................................... 518 CA272 - UMV/PCV1 Open Error................................................................ 520 CA322 - Open In No. 1 Injector Solenoid Valve.............................................. 522 CA323 - Open In No. 5 Injector Solenoid Valve.............................................. 524 CA324 - Open In No. 3 Injector Solenoid Valve.............................................. 526 CA325 - Open In No. 6 Injector Solenoid Valve.............................................. 528 CA331 - OPen In No. 2 Injector Solenoid Valve.............................................. 530 CA332 - Open In No. 4 Injector Solenoid Valve.............................................. 532 CA342 - Calibration Code Incompatibility................................................... 534 CA351 - Injector Drive Circuit Error....................................................... 536 CA352 - Ambient Pressure Sensor 1 Volt Low Error........................................... 538 CA386 - Ambient Pressure Sensor 1 Volt High Error.......................................... 540 CA428 - Water In Fuel Sensor High Error.................................................... 542 CA429 - Water In Fuel Sensor Low Error..................................................... 544 CA441 - Battery Voltage Low Error.......................................................... 546 CA442 - Battery Voltage High Error......................................................... 548 CA449 - Rail Pressure Very High............................................................ 550 CA451 - Rail Pressure Sensor High Error.................................................... 554 CA452 - Rail Pressure Sensor Low Error..................................................... 556 CA553 - Rail Pressure Error................................................................ 558 CA559 - Rail Pressure Very Low............................................................. 560 CA689 - Engine NE Speed Sensor Error....................................................... 562 CA731 - Engine Back-up Speed Sensor Phase Error............................................ 564 CA757 - Persistent Data Loss Error......................................................... 566 CA778 - Engine Bkup Speed Sensor Error..................................................... 568 CA1633 - (KOMNET) Datalink Has Time-out Error.............................................. 570 CA2185 - Throttle Sensor High Error........................................................ 572 CA2186 - Throttle Sensor Low Error......................................................... 574 CA2249 - Rail Pressure Very Low............................................................ 576 CA2265 - Electric Lift Pump High Error..................................................... 578 CA2266 - Electric Lift Pump Low Error...................................................... 580 CA2556 - Grid Heater Relay Volt Low Error.................................................. 582 CA2555 - Grid Heater Relay Volt High Error................................................. 584 D110KB - Battery Relay Drive S/C........................................................... 586 D196KA - Service Return Relay Error........................................................ 588 D196KB - Service Return Relay Error........................................................ 590 DA25KP - Sensor Power Error................................................................ 592 DA2RMC - Pump Communication Error.......................................................... 594 DA2SKQ - Model Selection Error............................................................. 596 DAFRMC - Monitor Communication Error....................................................... 598 DHPAMA - F Pump Pressure Sensor Error...................................................... 600 DHPBMA - R Pump Pressure Sensor Error...................................................... 602 DHS3MA - Arm Curl Pressure Sensor Error.................................................... 604 DHS4MA - Curl PPC Pressure Sensor Error.................................................... 606 DW43KA - Travel Speed Solenoid Error....................................................... 608 DW43KB - Travel Speed Solenoid Error....................................................... 610 DW45KA - Swing Brake Solenoid Error........................................................ 612 DW45KB - Swing Brake Solenoid Error........................................................ 615 DW91KA - Travel Junction Solenoid Error.................................................... 618 DW91KB - Travel Junction Solenoid Error.................................................... 620 DWJ0KA - Merge-divider Solenoid Error...................................................... 622 DWJ0KB - Merge-divider Solenoid Error...................................................... 624 DWK0KA - 2-Stage Relief Solenoid Error..................................................... 626 DWK0KB - 2-Stage Relief Solenoid Error..................................................... 628 DXA0KA - PC-EPC Solenoid Error............................................................. 630 DXA0KB - PC-EPC Solenoid Error............................................................. 632 DXE0KA - LS-EPC Solenoid Error............................................................. 634 DXE0KB - LS-EPC Solenoid Error............................................................. 636 DXE4KA - Service Current EPC Error......................................................... 638 DXE4KB - Service Current EPC Error......................................................... 640 DY20KA - Windshield Wiper Motor Drive Error................................................ 642 DY20MA - Windshield Wiper Motor Drive Error................................................ 644 DY2CKB - Windshield Washer Drive Error..................................................... 646 DY2DKB - Windshield Wiper Drive Error...................................................... 648 DY2EKB - Windshield Wiper Drive Error...................................................... 650 E-MODE (ELECTRICAL SYSTEM)..................................................................... 652 E-1 - Engine will not Crank................................................................ 652 E-2 - Auto Decelerator Does Not Work....................................................... 655 E-3 - Auto Engine Warm Up Device Does Not Work............................................. 656 E-4 - Cold Start Pre-heater Does Not Work.................................................. 658 E-5 - All Work Equipment, Swing And Travel Do Not Operate.................................. 660 E-6 - Power Maximizing Function Does Not Operate........................................... 662 E-7 - MACHINE MONITOR DOES NOT OPERATE..................................................... 664 E-8 - Machine Monitor Does Not Display Some Items.......................................... 666 E-9 - Machine Monitor Does Not Display Items Correctly..................................... 667 E-10 - Monitor Fuel Level Was Indicating Red While Engine Is Running....................... 668 E-11 - Coolant High Temperature Sensor Showing Overheat.................................... 670 E-12 - Hydraulic Oil Temperature Gauge Does Not Display Correctly.......................... 672 E-13 - Monitor Fuel Level Was Indicating Red While Engine Is Running....................... 674 E-14 - Swing Lock Monitor Does Not Display Correctly....................................... 676 E-15 - When the Monitor Switch is Operated, no Display Appears............................. 678 E-16 - Windshield Wiper and Washer do not Operate.......................................... 680 Windshield Washer Drive Error.......................................................... 682 E-17 - Machine Push-up Function Does Not Operate........................................... 684 E-18 - Boom Raise Not Correctly Displayed On Monitor....................................... 686 E-19 - Boom Lower Not Correctly Displayed On Monitor....................................... 688 E-20 - Arm In Not Correctly Displayed On Monitor........................................... 690 E-21 - Arm Out Not Correctly Displayed On Monitor.......................................... 692 E-22 - Bucket Curl Not Correctly Displayed On Monitor...................................... 694 E-23 - Bucket Dump Not Correctly Displayed On Monitor...................................... 696 E-24 - Swing Not Correctly Displayed On Monitor............................................ 698 E-25 - Travel Not Correctly Displayed On Monitor........................................... 700 E-26 - Travel Differential Not Correctly Displayed On Monitor.............................. 702 E-27 - Service Not Correctly Displayed On Monitor.......................................... 704 E-28 - KOMTRAX System Does Not Operate Normally............................................ 706 E-29 - Air Conditioner System Does Not Work................................................ 708 E-30 - Travel Alarm Does Not Sound......................................................... 710 E-31 - Horn Does Not Sound................................................................. 712 H-MODE (HYDRAULIC AND MECHANICAL SYSTEMS)...................................................... 714 System Chart for Hydraulic and Mechanical Systems.......................................... 714 Information Contained in Troubleshooting Table............................................. 716 H-1 - Work Equipment, Travel And Swing Speeds Are Slow..................................... 717 H-2 - Engine Speed Drops Sharply Or Engine Stalls.......................................... 718 H-3 - No Work Equipment, Travel Or Swing Movement.......................................... 719 H-4 - Abnormal Noise Is Heard From Hydraulic Pump.......................................... 719 H-5 - Auto-decelerator Does Not Work....................................................... 720 H-6 - Fine Control Mode Does Not Function.................................................. 720 H-7 - Boom Moves Slowly Or Lacks Power..................................................... 721 H-8 - Work Equipment Moves Slowly Or Lacks Power........................................... 723 H-9 - Bucket Moves Slowly Or Lacks Power................................................... 724 H-10 - Work Equipment Does Not Move In A Independent Operation............................. 724 H-11 - Work Equipment Has Excessive Hydraulic Drift........................................ 725 H-12 - Work Equipment Has Excessive Lag Time............................................... 726 H-13 - Other Work Equipment Moves When Relieving A Single Circuit.......................... 726 H-14 - One-touch Power Max. Switch Does Not Operate........................................ 726 H-15 - In A Compound Operation, Work Equipment With Larger Loads Moves Slowly.............. 727 H-16 - In Swing And Boom Raise Operation, Boom Moves Slowly................................ 727 H-17 - In Swing + Travel, Travel Speed Drops Sharply....................................... 727 H-18 - Machine Swerves When Traveling...................................................... 728 H-19 - Machine Travels Slowly.............................................................. 729 H-20 - Machine Cannot Be Steered Easily Or Lacks Power..................................... 730 H-21 - Travel Speed Does Not Shift, Or It Is Too Slow Or Fast During Shifting.............. 731 H-22 - Track Shoes Do Not Turn (On One Side Only).......................................... 731 H-23 - Machine Does Not Swing.............................................................. 732 H-24 - Swing Acceleration Is Poor, Or Swing Speed Is Slow.................................. 733 H-25 - Excessive Overrun When Stopping Swing............................................... 734 H-26 - There Is A Sudden Shock When Stopping Swing......................................... 735 H-27 - Abnormal Noise Caused When Stopping Swing........................................... 735 H-28 - Swing Natural Drift Is Excessive.................................................... 736 50 DISASSEMBLY AND ASSEMBLY........................................................................ 737 HOW TO READ THIS MANUAL........................................................................ 740 Removal and Installation of Assemblies..................................................... 740 Special Tools.......................................................................... 740 Removal................................................................................ 740 Installation........................................................................... 740 Disassembly and Assembly of Assemblies..................................................... 741 Special Tools.......................................................................... 741 Disassembly............................................................................ 741 Assembly............................................................................... 742 SPECIAL TOOLS LIST............................................................................. 743 CONNECTOR REPAIR PROCEDURES.................................................................... 746 Contact Terminal Removal (HD30 Type)....................................................... 746 Stripping Insulation....................................................................... 747 Crimping Contact Terminal (HD30 Type)...................................................... 748 Insertion of Contact Terminal (HD30 Type).................................................. 749 Contact Terminal Removal (DT Type)......................................................... 750 Stripping Insulation....................................................................... 751 Crimping Contact Terminal (DT Type)........................................................ 752 Insertion of Contact Terminal (DT Type).................................................... 753 ENGINE COMPONENTS.............................................................................. 754 Cylinder Head.............................................................................. 754 Engine Front Seal.......................................................................... 754 Engine Rear Seal........................................................................... 754 Fuel Supply Pump........................................................................... 754 Valves..................................................................................... 754 ENGINE AND COOLING SYSTEM...................................................................... 755 Radiator................................................................................... 755 Removal................................................................................ 755 Installation........................................................................... 756 Hydraulic Oil Cooler....................................................................... 757 Removal................................................................................ 757 Installation........................................................................... 758 Aftercooler................................................................................ 759 Removal................................................................................ 759 Installation........................................................................... 759 Engine and Hydraulic Pump.................................................................. 760 Removal................................................................................ 760 Installation........................................................................... 764 POWER TRAIN.................................................................................... 766 Final Drive................................................................................ 766 Removal................................................................................ 766 Installation........................................................................... 767 Disassembly............................................................................ 767 Assembly............................................................................... 772 Swing Motor and Swing Machinery............................................................ 778 Removal................................................................................ 778 Installation........................................................................... 779 Disassembly............................................................................ 780 Assembly............................................................................... 783 Swing Circle............................................................................... 789 Removal................................................................................ 789 Installation........................................................................... 789 UNDERCARRIAGE AND FRAME........................................................................ 790 Track Roller and Carrier Roller............................................................ 790 Disassembly............................................................................ 790 Assembly............................................................................... 790 Idler...................................................................................... 792 Disassembly............................................................................ 792 Assembly............................................................................... 793 Recoil Spring.............................................................................. 796 Disassembly............................................................................ 796 Assembly............................................................................... 797 Sprocket................................................................................... 799 Removal................................................................................ 799 Installation........................................................................... 799 Track Shoe................................................................................. 800 Expansion of Track Shoe................................................................ 800 Installation of Track Shoe............................................................. 801 Revolving Frame............................................................................ 802 Removal................................................................................ 802 Installation........................................................................... 804 Counterweight.............................................................................. 805 Removal................................................................................ 805 Installation........................................................................... 805 HYDRAULIC SYSTEM............................................................................... 806 Center Swivel Joint........................................................................ 806 Removal................................................................................ 806 Installation........................................................................... 807 Disassembly............................................................................ 808 Assembly............................................................................... 808 Hydraulic Tank............................................................................. 809 Removal................................................................................ 809 Installation........................................................................... 811 Control Valve.............................................................................. 812 Removal................................................................................ 812 Installation........................................................................... 815 Assembly............................................................................... 817 Main Relief Valve...................................................................... 818 Hydraulic Pump............................................................................. 819 Removal................................................................................ 819 Installation........................................................................... 821 Oil Seal in Hydraulic Pump Input Shaft..................................................... 822 Removal................................................................................ 822 Installation........................................................................... 822 Work Equipment PPC Valve................................................................... 823 Disassembly............................................................................ 823 Assembly............................................................................... 823 Travel PPC Valve........................................................................... 824 Disassembly............................................................................ 824 Assembly............................................................................... 824 Hydraulic Cylinder......................................................................... 825 Disassembly............................................................................ 825 Assembly............................................................................... 827 WORK EQUIPMENT................................................................................. 832 Work Equipment............................................................................. 832 Removal................................................................................ 832 Installation........................................................................... 833 CAB AND ITS ATTACHMENTS........................................................................ 835 Operator's Cab............................................................................. 835 Removal................................................................................ 835 Installation........................................................................... 837 Operator’s Cab Glass (Stuck Glass)......................................................... 838 Removal................................................................................ 839 Installation........................................................................... 840 Front Window............................................................................... 849 Removal................................................................................ 849 Installation........................................................................... 852 ELECTRICAL SYSTEM.............................................................................. 857 Work Equipment............................................................................. 857 Removal................................................................................ 857 Installation........................................................................... 858 Machine Monitor............................................................................ 859 Removal................................................................................ 859 Installation........................................................................... 859 Pump Controller............................................................................ 860 Removal................................................................................ 860 Installation........................................................................... 860 KOMTRAX Terminal........................................................................... 861 Removal................................................................................ 861 Installation........................................................................... 861 Engine Controller.......................................................................... 862 Removal................................................................................ 862 Installation........................................................................... 862 60 AIR CONDITIONER................................................................................. 863 STRUCTURE AND FUNCTION......................................................................... 866 Air Conditioner Component.................................................................. 866 Configuration and Function of Refrigerating cycle.......................................... 868 Outline of Refrigerating Cycle............................................................. 869 Air Conditioner Unit....................................................................... 872 Functions of Major Components in the Air Conditioner Unit.................................. 874 Control Plate.............................................................................. 876 Compressor................................................................................. 879 Condenser and Receiver Drier............................................................... 880 TESTING AND ADJUSTING.......................................................................... 881 Caution About Refrigerant.................................................................. 881 Troubleshooting Procedure.................................................................. 882 Block Diagram.............................................................................. 883 Circuit Diagram and Arrangement of Connector Pins.......................................... 884 Detail of Air Conditioner Unit............................................................. 886 Part and Connector Locations............................................................... 888 Testing Air Leakage (Ducts)................................................................ 892 Testing with Self-diagnosis Function....................................................... 894 Testing Temperature Control................................................................ 897 Testing Vent (Mode) Changeover............................................................. 900 Testing Recirc/Fresh Changeover............................................................ 904 Testing Inner Sensor....................................................................... 906 Testing Evaporator Temperature Sensor...................................................... 907 Testing Sunlight Sensor.................................................................... 909 Testing (Dual) Pressure Switch for Refrigerant............................................. 910 Testing Relays............................................................................. 912 TROUBLESHOOTING................................................................................ 914 Troubleshooting Chart 1.................................................................... 914 Troubleshooting Chart 2.................................................................... 915 Troubleshooting for Electrical System (E mode)............................................. 918 E-1 Power Supply System (Air Conditioner does not Operate)............................. 919 E-2 Compressor System (Air is Not Cooled).............................................. 923 E-3 Blower Motor System (No Air Comes Out or Air Flow is Abnormal)..................... 926 E-4 Temperature Cannot be Controlled................................................... 930 E-5 Vent (Mode) Cannot be Changed Over................................................. 933 E-6 Recirc/Fresh Air Cannot be Changed Over............................................ 936 Troubleshooting With Gauge Pressure........................................................ 939 Connection of Service Tool................................................................. 942 Precautions for connecting air conditioner piping.......................................... 944 Handling of Compressor Oil................................................................. 945 Control of Compressor Oil.............................................................. 945 Adding of Compressor Oil............................................................... 945 Compressor Replacement................................................................. 946 Applying Compressor Oil for O-ring..................................................... 946 Desiccant Replacement Procedure............................................................ 947 90 OTHERS.......................................................................................... 949 ELECTRICAL CIRCUIT DIAGRAMS.................................................................... 951 TO CABIN HARNESS........................................................................... 951 CABIN HARNESS VIEW 1....................................................................... 953 CABIN HARNESS VIEW 2....................................................................... 955 CONTROLLER (CR700) VIEW.................................................................... 957 FLOOR HARNESS VIEW......................................................................... 959 MONITOR AND RADIO HARNESS VIEW............................................................. 961 LEFT CONSOLE, FUSE PANEL AND KOMTRAX CONTROLLER............................................ 963 WARNING AND INDICATOR LAMPS................................................................ 965 ENGINE AND DRIVE SYSTEM SENSORS AND CONTROLLERS............................................ 967 ENGINE SENSORS AND CONTROLLERS............................................................. 969 FUEL INJECTOR SYSTEM VIEW.................................................................. 971 ELECTRICAL DIAGRAM - 1 OF 9................................................................ 973 ELECTRICAL DIAGRAM - 2 OF 9................................................................ 975 ELECTRICAL DIAGRAM - 3 OF 9................................................................ 977 ELECTRICAL DIAGRAM - 4 OF 9................................................................ 979 ELECTRICAL DIAGRAM - 5 OF 9................................................................ 981 ELECTRICAL DIAGRAM - 6 OF 9................................................................ 983 ELECTRICAL DIAGRAM - 7 OF 9................................................................ 985 ELECTRICAL DIAGRAM - 8 OF 9................................................................ 987 ELECTRICAL DIAGRAM - 9 OF 9................................................................ 989 HYDRAULIC CIRCUIT DIAGRAMS..................................................................... 991 VIEW "A" - 1 OF 11......................................................................... 991 VIEW "A" - 2 OF 11......................................................................... 993 VIEW "A" - 3 OF 11......................................................................... 995 VIEW "A" - 4 OF 11......................................................................... 997 VIEW "A" - 5 OF 11......................................................................... 999 VIEW "A" - 6 OF 11.........................................................................1001 VIEW "A" - 7 OF 11.........................................................................1003 VIEW "A" - 8 OF 11.........................................................................1005 VIEW "A" - 9 OF 11.........................................................................1007 VIEW "A" - 10 OF 11........................................................................1009 VIEW "A" - 11 OF 11........................................................................1011 VIEW "B" - 1 OF 1..........................................................................1013
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Zachariah Judson –