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KOMATSU PC400LC-7L HYDRAULIC EXCAVATOR SHOP MANUAL SL NO PC400LC-7L A86001 & up ENGINE SAA6D125E-3 – PDF DOWNLOAD
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KOMATSU PC400LC-7L HYDRAULIC EXCAVATOR SHOP MANUAL
SERIAL NUMBERS:PC400LC-7L A86001 & up ENGINE SAA6D125E-3
PUBLICATION NUMBER:CEBM012503
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KOMATSU PC400LC-7L HYDRAULIC EXCAVATOR SHOP MANUAL SL NO PC400LC-7L A86001 & up ENGINE SAA6D125E-3
KOMATSU PC400LC-7L HYDRAULIC EXCAVATOR SHOP MANUAL SL NO PC400LC-7L A86001 & UP ENGINE SAA6D125E-3 – PDF DOWNLOAD:
SCREENSHOOTS OF THE MANUAL:
DESCRIPTION:
KOMATSU PC400LC-7L HYDRAULIC EXCAVATOR SHOP MANUAL SL NO PC400LC-7L A86001 & up ENGINE SAA6D125E-3
- 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, ADJUSTING AND TROUBLESHOOTING
- 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.
TABLE OF CONTENTS:
KOMATSU PC400LC-7L HYDRAULIC EXCAVATOR SHOP MANUAL SL NO PC400LC-7L A86001 & up ENGINE SAA6D125E-3
COVER........................................................................................ 1 CONTENTS..................................................................................... 2 FOREWORD..................................................................................... 13 SAFETY................................................................................... 13 SAFETY NOTICE........................................................................ 13 IMPORTANT SAFETY NOTICE.......................................................... 13 GENERAL PRECAUTIONS.............................................................. 13 PREPARATIONS FOR WORK............................................................ 13 PRECAUTIONS DURING WORK.......................................................... 14 GENERAL.................................................................................. 15 HOW TO READ THE SHOP MANUAL.............................................................. 16 VOLUMES.............................................................................. 16 DISTRIBUTION AND UPDATING............................................................ 16 FILING METHOD........................................................................ 16 REVISED EDITION MARK................................................................. 16 REVISIONS............................................................................ 16 SYMBOLS.............................................................................. 16 HOISTING INSTRUCTIONS.................................................................... 17 HOISTING............................................................................. 17 WIRE ROPES........................................................................... 17 COATING MATERIALS........................................................................ 18 STANDARD TIGHTENING TORQUE............................................................... 20 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS......................................... 20 TIGHTENING TORQUE OF HOSE NUTS....................................................... 21 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.............................................. 21 TIGHTENING TORQUE FOR FLARED NUTS.................................................... 21 ELECTRIC WIRE CODE....................................................................... 22 CLASSIFICATION BY THICKNESS.......................................................... 22 CLASSIFICATION BY COLOR AND CODE..................................................... 22 CONVERSION TABLES........................................................................ 23 METHOD OF USING THE CONVERSION TABLE................................................. 23 01 GENERAL................................................................................... 29 SPECIFICATIONS........................................................................... 30 WEIGHT TABLE............................................................................. 35 FUEL COOLANT AND LUBRICANTS.............................................................. 37 10 STRUCTURE AND FUNCTION.................................................................... 39 RADIATOR . OIL COOLER . AFTERCOOLER...................................................... 41 POWER TRAIN.............................................................................. 42 FINAL DRIVE.............................................................................. 43 SWING MACHINERY.......................................................................... 45 SWING CIRCLE............................................................................. 47 TRACK FRAME AND RECOIL SPRING............................................................ 48 IDLER.................................................................................... 50 CARRIER ROLLER........................................................................... 51 TRACK ROLLER............................................................................. 52 TRACK SHOE............................................................................... 54 TRIPLE GROUSER SHOE.................................................................. 57 HYDRAULIC SYSTEM......................................................................... 58 HYDRAULIC PIPING DRAWING............................................................. 58 HYDRAULIC TANK....................................................................... 60 HYDRAULIC PUMP....................................................................... 62 LS VALVE......................................................................... 67 PC VALVE......................................................................... 67 LS(PS)-EPC VALVE..................................................................... 79 VARIABLE VOLUME VALVE................................................................ 82 CONTROL VALVE........................................................................ 84 MAIN RELIEF VALVE.................................................................... 98 CLSS (CLOSED CENTER LOAD SENSING SYSTEM).............................................100 SELF PRESSURE REDUCING VALVE.........................................................103 SWING MOTOR..........................................................................106 RELIEF VALVE.....................................................................110 REVERSAL PREVENTION VALVE........................................................112 CENTER SWIVEL JOINT..................................................................114 TRAVEL MOTOR.........................................................................115 PARKING BRAKE....................................................................120 TRAVEL JUNCTION VALVE................................................................126 CONTROL VALVE........................................................................128 TRAVEL PPC SHUTTLE VALVE.............................................................130 WORK EQUIPMENT . SWING PPC VALVE.....................................................133 TRAVEL PPC VALVE.....................................................................138 SERVICE PPC VALVE....................................................................146 SOLENOID VALVE.......................................................................147 PPC ACCUMULATOR......................................................................149 RETURN OIL FILTER....................................................................150 BOOM HYDRAULIC DRIFT PREVENTION VALVE................................................152 ARM HYDRAULIC DRIFT PREVENTION VALVE.................................................157 QUICK RETURN VALVE...................................................................161 LIFT CHECK VALVE.....................................................................163 ATTACHMENT CIRCUIT SELECTOR VALVE....................................................164 HOLDING VALVE........................................................................166 HYDRAULIC CYLINDER...................................................................170 BOOM CYLINDER....................................................................170 ARM CYLINDER.....................................................................170 BUCKET CYLINDER..................................................................170 WORK EQUIPMENT...........................................................................172 DIMENSION ARM........................................................................174 DIMENSION OF BUCKET..................................................................176 AIR CONDITIONER..........................................................................178 AIR CONDITIONER PIPING...............................................................178 ENGINE CONTROL...........................................................................179 OPERATION OF SYSTEM..................................................................179 STARTING ENGINE..................................................................179 ENGINE SPEED CONTROL.............................................................179 STOPPING ENGINE..................................................................179 COMPONENTS OF SYSTEM.................................................................180 FUEL CONTROL DIAL................................................................180 ENGINE CONTROLLER................................................................181 ELECTRONIC CONTROL SYSTEM................................................................184 CONTROL FUNCTIONS....................................................................184 TOTAL SYSTEM DIAGRAM.................................................................186 ENGINE AND PUMP CONTROL FUNCTION.....................................................188 PUMP/VALVE CONTROL FUNCTION..........................................................193 ONE-TOUCH POWER MAXIMIZING/MACHINE PUSH-UP FUNCTION..................................196 AUTO-DECELERATION FUNCTION...........................................................198 AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION............................................200 SWING CONTROL FUNCTION...............................................................202 TRAVEL CONTROL FUNCTION..............................................................204 ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT)...........................206 SYSTEM COMPONENT PARTS...............................................................207 ENGINE REVOLUTION SENSOR.........................................................207 PPC OIL PRESSURE SWITCH..........................................................208 PUMP PRESSURE SENSOR.............................................................209 PUMP CONTROLLER..................................................................210 MONITOR SYSTEM...........................................................................213 MONITOR CONTROL, DISPLAY PORTION.....................................................216 MONITOR PORTION..................................................................216 MONITOR ITEMS AND DISPLAY........................................................217 SWITCHES.........................................................................221 SELECT MODE FUNCTION.............................................................224 MAINTENANCE FUNCTION.............................................................227 SERVICE METER CHECK FUNCTION.....................................................230 DISPLAY LCD CHECK FUNCTION.......................................................230 SENSOR...................................................................................232 ENGINE OIL LEVER SENSOR..............................................................232 ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)........................................232 COOLANT TEMPERATURE SENSOR...........................................................233 HYDRAULIC OIL TEMPERATURE SENSOR.....................................................233 FUEL LEVEL SENSOR....................................................................233 AIR CLEANER CLOGGING SENSOR..........................................................234 20 TESTING, ADJUSTING AND TROUBLESHOOTING....................................................235 STANDARD VALUE TABLE FOR ENGINE..........................................................236 STANDARD VALUE TABLE FOR CHASSIS.........................................................237 TESTING AND ADJUSTING....................................................................247 SERVICE TOOLS........................................................................248 MEASURING ENGINE SPEED...............................................................250 ENGINE...............................................................................251 FUEL.............................................................................251 BLEEDING AIR FROM FUEL CIRCUIT...............................................251 FUEL PRESSURE................................................................251 HANDLING FUEL SYSTEM DEVICES.................................................251 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE.......................................251 RELEASING RESIDUAL FUEL SYSTEM PRESSURE......................................251 ADJUSTING ENGINE SPEED SENSOR....................................................251 ADJUSTING VALVE CLEARANCE........................................................251 BLOW-BY PRESSURE.................................................................251 COMPRESSION PRESSURE.............................................................251 ENGINE OIL PRESSURE..............................................................251 ENGINE SPEED SENSOR..............................................................251 EXHAUST GAS COLOR................................................................251 EXHAUST TEMPERATURE..............................................................251 INTAKE AIR PRESSURE (BOOST PRESSURE).............................................251 FAN BELT AND ALTERNATOR BELT TENSION.................................................252 AIR CONDITIONER COMPRESSOR BELT TENSION..............................................253 SWING CIRCLE BEARING CLEARANCE.......................................................254 TRACK SHOE TENSION...................................................................255 WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS.......................................256 CONTROL CIRCUIT - BASIC PRESSURE.....................................................261 PUMP PC CONTROL CIRCUIT..............................................................262 PUMP LS CONTROL CIRCUIT..............................................................266 SOLENOID VALVE - OUTPUT PRESSURE.....................................................271 PPC VALVE - OUTPUT PRESSURE..........................................................274 WORK EQUIPMENT PPC VALVE - PLAY ADJUSTMENT...........................................276 SWING PPC VALVE - PLAY ADJUSTMENT....................................................276 WORK EQUIPMENT - HYDRAULIC DRIFT - CAUSE.............................................277 RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT........................................279 MEASURING OIL LEAKAGE................................................................280 BLEEDING AIR FROM EACH PART..........................................................283 DIODE TESTING PROCEDURE..............................................................286 MONITOR PANEL - SPECIAL FUNCTIONS....................................................287 HANDLING OF ENGINE CONTROLLER........................................................313 PREPARATION WORK FOR TROUBLESHOOTING.................................................314 PM CLINIC SERVICE....................................................................316 UNDERCARRIAGE INSPECTION.............................................................322 TROUBLESHOOTING GENERAL..................................................................323 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................325 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................327 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.....................................328 POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT..............................328 HANDLING WIRING HARNESSES AND CONNECTORS.....................................328 REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES.............330 HANDLING CONTROL BOX.........................................................333 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS........................334 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.............................334 CHECKS BEFORE TROUBLESHOOTING........................................................336 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.........................................337 CLASSIFICATION OF TROUBLESHOOTING................................................337 STEPS FOR TROUBLESHOOTING........................................................337 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NOS......................338 CONNECTOR ARRANGEMENT DRAWING........................................................341 CONNECTORS LIST..................................................................341 CONNECTOR LOCATION DIAGRAM.......................................................346 MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT).................................352 ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT)................................353 PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT)...............................354 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................355 T-BRANCH BOX AND T-BRANCH TABLE......................................................376 CONNECTION TABLE OF FUSE BOX.........................................................380 TROUBLESHOOTING ERROR CODES IN MONITOR SYSTEM............................................381 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM.......................................386 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF....................387 USER CODE MEMORY RETENTION FUNCTION..............................................387 INFORMATION CONTAINED IN TESTING PROCEDURES..........................................388 E101.................................................................................390 ERROR IN DATA HISTORY............................................................390 E112.................................................................................392 SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM........................................392 E113.................................................................................394 SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE...........................394 E114.................................................................................396 SHORT OR OPEN IN WINDOW WASHER SYSTEM............................................396 E115.................................................................................398 ABNORMAL WIPER MOTOR OPERATION...................................................398 E116.................................................................................400 ABNORMALITY IN PARKING WIPER ARM.................................................400 E117.................................................................................402 ENGINE CONTROLLER S-NET COMMUNICATION ERROR......................................402 E118.................................................................................404 PUMP CONTROLLER S-NET COMMUNICTION ERROR.........................................404 E128.................................................................................406 MONITOR COMMUNICATION ABNORMALITY................................................406 E201.................................................................................408 SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID....................................408 E203.................................................................................410 SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM............................410 E204.................................................................................412 SHORT IN MERGE/DIVIDE SOLENOID...................................................412 E205.................................................................................414 SHORT IN 2-STAGE RELIEF SOLENOID.................................................414 E206.................................................................................416 SHORT IN TRAVEL SPEED SHIFT SOLENOID.............................................416 E211.................................................................................418 OPEN IN TRAVEL INTERLOCKING SOLENOID.............................................418 E213.................................................................................420 OPEN IN SWING HOLDING BRAKE SOLENOID.............................................420 E214.................................................................................422 OPEN IN MERGE/DIVIDE SOLENOID....................................................422 E215.................................................................................424 OPEN IN 2-STAGE RELIEF SOLENOID..................................................424 E216.................................................................................426 OPEN IN TRAVEL SPEED SOLENOID....................................................426 E217.................................................................................428 ABNORMAL INPUT MODEL CODE........................................................428 E218.................................................................................430 OPEN IN S-NET COMMUNICATION SIGNAL...............................................430 E222.................................................................................432 SHORT IN LS-EPC SOLENOID.........................................................432 E223.................................................................................434 OPEN IN LS-EPC SOLENOID SYSTEM...................................................434 E224.................................................................................436 ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL...........................................436 E225.................................................................................438 ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL...........................................438 E226.................................................................................440 ABNORMAL PRESSURE SENSOR POWER SUPPLY............................................440 E227.................................................................................442 ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR......................................442 E228.................................................................................444 SHORT IN ATTACHMENT RETURN SWITCHING RELAY.......................................444 E232.................................................................................446 SHORT IN PC-EPC SOLENOID.........................................................446 E233.................................................................................448 OPEN IN PC-EPC SOLENOID..........................................................448 E238.................................................................................450 OPEN IN ATTACHMENT RETURN SWITCHING RELAY........................................450 E245.................................................................................452 SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM...........................452 E246.................................................................................454 OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM............................454 E247.................................................................................456 ABNORMALITY IN ARM IN PPC PRESSURE SENSOR........................................456 E248.................................................................................458 ABNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR...................................458 E257.................................................................................460 ABNORMALITY IN PUMP..............................................................460 E315.................................................................................462 SHORT IN BATTERY RELAY SYSTEM....................................................462 E91B.................................................................................464 ENGNE NE SENSOR PROBLEM..........................................................464 E91C.................................................................................466 ENGINE G SENSOR PROBLEM..........................................................466 E920.................................................................................468 ENGINE TYPE SELECTION ERROR......................................................468 E921.................................................................................470 ENGINE TYPE MISMATCH.............................................................470 E931.................................................................................472 FUEL DIAL SYSTEM ERROR...........................................................472 E934.................................................................................474 ENGINE COOLANT SENSOR HI ERROR...................................................474 E96A.................................................................................476 ENGINE COOLANT SENSOR LO ERROR...................................................476 E936.................................................................................478 ENGINE OIL PRESSURE SWITCH ERROR.................................................478 E93C.................................................................................480 ENGINE BOOST SENSOR ERROR........................................................480 E93D.................................................................................482 ENGINE FUEL TEMPERATURE SENSOR ERROR.............................................482 E953.................................................................................484 ENGINE COMMUNICATION ABNORMALITY.................................................484 E954.................................................................................486 SHORT IN ENGINE IGNITION SWITCH..................................................486 E955.................................................................................488 ENGINE S-NET ERROR...............................................................488 E956.................................................................................490 ENGINE POWER FAILURE (1).........................................................490 E957.................................................................................492 ENGINE POWER FAILURE (2).........................................................492 E95A.................................................................................494 ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR..........................................494 E970.................................................................................496 PCV1 OVER CURRENT................................................................496 E971.................................................................................498 PCV2 OVER CURRENT................................................................498 E974.................................................................................500 PCV1 LINE CUT....................................................................500 E975.................................................................................502 PCV2 LINE CUT....................................................................502 E977.................................................................................504 RAIL PRESSURE SENSOR ERROR.......................................................504 E979.................................................................................506 RAIL PRESSURE HIGH...............................................................506 E97A.................................................................................507 RAIL PRESSURE ABNORMAL HIGH......................................................507 E97B.................................................................................508 RAIL PRESSURE LOW................................................................508 E97C.................................................................................510 RAIL PRESSURE TOO LOW............................................................510 E97D.................................................................................511 RAIL PRESSURE OUT OF CONTROL.....................................................511 E980.................................................................................512 ENGINE CONTROLLER ABNORMALITY....................................................512 E981.................................................................................514 FUEL INJECTOR 1 DISCONNECTION....................................................514 E982.................................................................................515 FUEL INJECTOR 2 DISCONNECTION....................................................515 E983.................................................................................516 FUEL INJECTOR 3 DISCONNECTION....................................................516 E984.................................................................................517 FUEL INJECTOR 4 DISCONNECTION....................................................517 E985.................................................................................518 FUEL INJECTOR 5 DISCONNECTION....................................................518 E986.................................................................................519 FUEL INJECTOR 6 DISCONNECTION....................................................519 E98A.................................................................................520 FUEL INJECTOR 1 - 3 S/C..........................................................520 E98B.................................................................................522 FUEL INJECTOR 4 - 6 S/C..........................................................522 A000N1...............................................................................524 ENGINE HIGH IDLELING SPEED OUT OF STANDARD.......................................524 A000N2...............................................................................525 ENGINE LOW IDLING SPEED OUT OF STANDARD..........................................525 AA10NX...............................................................................526 AIR CLEANER CLOGGED..............................................................526 AB00KE...............................................................................528 CHARGE VOLTAGE LOW...............................................................528 B@BAZG...............................................................................530 ENGINE OIL PRESSURE LOW..........................................................530 B@BAZK...............................................................................532 ENGINE OIL LEVEL LOW.............................................................532 B@BCNS...............................................................................534 ENGINE WATER OVERHEAT............................................................534 B@BCZK...............................................................................536 ENGINE WATER LEVEL LOW...........................................................536 B@HANS...............................................................................538 HYDRAULIC OIL OVERHEAT...........................................................538 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................541 BEFORE CARRYING OUT TROUBLESHOOTING..................................................543 CONNECTION TABLE OF FUSE BOX.....................................................543 POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM.......................................544 POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF....................545 USER CODE MEMORY RETENTION FUNCTION..............................................545 INFORMATION CONTAINED IN TESTING PROCEDURES..........................................546 E-1..................................................................................548 THE ENGINE DOES NOT CRANK........................................................548 E-2..................................................................................551 PREHEATER DOES NOT OPERATE.......................................................551 PREHEATING MONITOR DOES NOT LIGHT............................................551 HEATER UNIT DOES NOT WARM....................................................552 E-3..................................................................................554 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK.........................................554 E-4..................................................................................555 AUTO-DECELERATOR DOES NOT OPERATE................................................555 E-5..................................................................................556 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE..............................556 E-6..................................................................................558 ONE-TOUCH POWER MAX. FUNCTION DOES NOT OPERATE...................................558 E-7..................................................................................560 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY...............................560 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE....................................560 MACHINE PUSH-UP FUNCTION IS NOT TURNED OFF...................................561 E-8..................................................................................564 ATTACHMENT CIRCUIT DOES NOT CHANGE...............................................564 E-9..................................................................................566 NO DISPLAY IN MONITOR PANEL AT ALL...............................................566 E-10.................................................................................568 PART OF DISPLAY ON MONITOR PANEL IS MISSING......................................568 E-11.................................................................................568 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL..........................568 E-12.................................................................................569 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING....................569 E-13.................................................................................570 ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY........................570 E-14.................................................................................572 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.......................572 E-15.................................................................................574 FUEL GAUGE DOES NOT DISPLAY CORRECTLY............................................574 E-16.................................................................................576 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY....................................576 E-17.................................................................................578 WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED............................578 E-18.................................................................................580 WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK...................................580 WINDSHIELD WIPER DOES NOT WORK...............................................580 WINDSHIELD WASHER DOES NOT OPERATE...........................................582 E-19.................................................................................584 ALARM BUZZER CANNOT BE CANCELLED.................................................584 E-20.................................................................................586 “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................586 E-21.................................................................................588 “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................588 E-22.................................................................................590 “ARM IN” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION........................590 E-23.................................................................................591 “ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....................591 E-24.................................................................................593 “BUCKET CURL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION...................593 E-25.................................................................................594 “BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..................594 E-26.................................................................................596 “SWING” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION.........................596 E-27.................................................................................598 “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................598 E-28.................................................................................600 “TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION....600 E-29.................................................................................602 “SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.........................602 E-30.................................................................................604 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING............................604 E-32.................................................................................606 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM.......................................606 TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM.........................606 TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE.....................................606 E-32-E11 DISCONNECTION IN RECIRCULATED AIR SENSOR............................607 E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE.............................607 E-32-E15 DISCONNECTION IN WATER TEMPERATURE SENSOR...........................608 E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR...........................608 E-32-E18 SHORT IN DAYLIGHT SENSOR............................................609 E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER....................................609 E-32-E44 ABNORMALITY IN AIR MIX DAMPER.......................................610 E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER....................610 E-32 - TROUBLESHOOTING BY FAILURE PHENOMENON.................................612 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..............................617 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS....................................619 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.......................................621 H-1..................................................................................622 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW...............622 H-2..................................................................................623 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS......................................623 H-3..................................................................................624 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE..........................................624 H-4..................................................................................624 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...............................624 H-5..................................................................................625 AUTO-DECELERATOR DOES NOT WORK...................................................625 H-6..................................................................................625 FINE CONTROL MODE DOES NOT FUNCTION..............................................625 H-7..................................................................................626 BOOM MOVES SLOWLY OR LACKS POWER.................................................626 H-8..................................................................................627 ARM MOVES SLOWLY OR LACKS POWER..................................................627 H-9..................................................................................628 BUCKET MOVES SLOWLY OR LACKS POWER...............................................628 H-10.................................................................................628 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION.............................628 H-11.................................................................................629 WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST..........................................629 H-12.................................................................................630 WORK EQUIPMENT HAS BIG TIME LAG..................................................630 H-13.................................................................................630 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT.........................630 H-14.................................................................................630 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK......................................630 H-15.................................................................................631 MACHINE PUSH-UP FUNCTION DOES NOT WORK...........................................631 H-16.................................................................................631 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY..............631 H-17.................................................................................632 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY...............................632 H-18.................................................................................632 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY....................................632 H-19.................................................................................633 MACHINE SWERVES IN TRAVEL........................................................633 H-20.................................................................................634 MACHINE TRAVELS SLOWLY...........................................................634 H-21.................................................................................635 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER..................................635 H-22.................................................................................636 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED.........636 H-23.................................................................................636 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)......................................636 H-24.................................................................................637 MACHINE DOES NOT SWING...........................................................637 H-25.................................................................................638 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW...............................638 H-26.................................................................................639 EXCESSIVE OVERRUN WHEN STOPPING SWING............................................639 H-27.................................................................................640 THERE IS BIG SHOCK WHEN STOPPING SWING...........................................640 H-28.................................................................................640 THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING...........................640 H-29.................................................................................641 SWING NATURAL DRIFT IS TOO BIG...................................................641 H-30.................................................................................642 ATTACHMENT CIRCUIT DOES NOT CHANGE...............................................642 H-31.................................................................................642 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED...............................642 30 DISASSEMBLY AND ASSEMBLY..................................................................643 HOW TO READ THIS MANUAL..................................................................647 REMOVAL AND INSTALLATION OF ASSEMBLIES...............................................647 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES...............................................647 PRECAUTIONS DURING OPERATION.............................................................649 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK...........................................649 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK......................................650 PRECAUTIONS WHEN COMPLETING THE OPERATIONS...........................................651 OTHER PRECAUTIONS....................................................................651 SPECIAL TOOL LIST........................................................................652 SKETCHES OF SPECIAL TOOLS............................................................657 CONNECTOR REPAIR PROCEDURES..............................................................659 CONTACT TERMINAL REMOVAL (HD30 TYPE).................................................659 STRIPING INSULATION..................................................................660 CRIMPING CONTACT TERMINAL (HD30 TYPE)................................................661 INSERTION OF CONTACT TERMINAL (HD30 TYPE)............................................662 CONTACT TERMINAL REMOVAL (DT TYPE)...................................................663 STRIPING INSULATION..................................................................664 CRIMPING CONTACT TERMINAL (DT TYPE)..................................................665 INSERTION OF CONTACT TERMINAL (DT TYPE)..............................................666 ENGINE...................................................................................667 AFTERCOOLER..........................................................................667 ALTERNATOR...........................................................................667 CYLINDER HEAD........................................................................667 ENGINE FRONT SEAL....................................................................667 ENGINE OIL COOLER....................................................................667 ENGINE REAR SEAL.....................................................................667 FUEL INJECTION PUMP..................................................................667 NOZZLE HOLDER........................................................................667 NOZZLE TIP...........................................................................667 STARTING MOTOR.......................................................................667 THERMOSTAT...........................................................................667 TURBOCHARGER.........................................................................667 WATER PUMP...........................................................................667 RADIATOR.................................................................................668 REMOVAL..............................................................................668 INSTALLATION.........................................................................670 HYDRAULIC OIL COOLER.....................................................................671 REMOVAL..............................................................................671 INSTALLATION.........................................................................672 ENGINE AND HYDRAULIC PUMP................................................................673 REMOVAL..............................................................................673 INSTALLATION.........................................................................678 SWING CIRCLE.............................................................................679 REMOVAL..............................................................................679 INSTALLATION.........................................................................679 SWING MOTOR AND SWING MACHINERY..........................................................680 REMOVAL..............................................................................680 INSTALLATION.........................................................................681 DISASSEMBLY..........................................................................682 ASSEMBLY.............................................................................686 SPROCKET.................................................................................692 REMOVAL..............................................................................692 INSTALLATION.........................................................................692 TRAVEL MOTOR AND FINAL DRIVE.............................................................693 REMOVAL..............................................................................693 INSTALLATION.........................................................................693 FINAL DRIVE..............................................................................694 DISASSEMBLY..........................................................................694 ASSEMBLY.............................................................................699 CARRIER ROLLER...........................................................................704 ASSEMBLY.............................................................................704 TRACK ROLLER.............................................................................706 ASSEMBLY.............................................................................706 IDLER....................................................................................707 DISASSEMBLY..........................................................................707 ASSEMBLY.............................................................................708 RECOIL SPRING............................................................................711 DISASSEMBLY..........................................................................711 ASSEMBLY.............................................................................712 TRACK SHOE...............................................................................713 EXPANSION............................................................................713 INSTALLATION.........................................................................714 AIR CONDITIONER UNIT.....................................................................715 REMOVAL..............................................................................715 INSTALLATION.........................................................................717 OPERATOR’S CAB...........................................................................718 REMOVAL..............................................................................718 INSTALLATION.........................................................................720 MONITOR..................................................................................721 REMOVAL..............................................................................721 INSTALLATION.........................................................................721 PUMP CONTROLLER..........................................................................722 REMOVAL..............................................................................722 INSTALLATION.........................................................................722 ENGINE CONTROLLER........................................................................723 REMOVAL..............................................................................723 INSTALLATION.........................................................................723 REVOLVING FRAME..........................................................................724 REMOVAL..............................................................................724 INSTALLATION.........................................................................726 COUNTERWEIGHT............................................................................727 REMOVAL..............................................................................727 INSTALLATION.........................................................................727 HYDRAULIC TANK...........................................................................728 REMOVAL..............................................................................728 INSTALLATION.........................................................................729 HYDRAULIC PUMP...........................................................................730 REMOVAL..............................................................................730 INSTALLATION.........................................................................732 OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT...................................................733 REMOVAL..............................................................................733 INSTALLATION.........................................................................733 CONTROL VALVE............................................................................734 REMOVAL..............................................................................734 INSTALLATION.........................................................................737 REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL...........................738 ASSEMBLY.............................................................................740 CENTER SWIVEL JOINT......................................................................743 REMOVAL..............................................................................743 INSTALLATION.........................................................................744 DISASSEMBLY..........................................................................745 ASSEMBLY.............................................................................745 WORK EQUIPMENT PPC VALVE.................................................................746 ASSEMBLY.............................................................................746 TRAVEL PPC VALVE.........................................................................747 DISASSEMBLY..........................................................................747 ASSEMBLY.............................................................................747 HYDRAULIC CYLINDER.......................................................................748 DISASSEMBLY..........................................................................748 ASSEMBLY.............................................................................751 WORK EQUIPMENT...........................................................................755 REMOVAL..............................................................................755 INSTALLATION.........................................................................757 OPERATOR’S CAB GLASS.....................................................................758 REMOVAL..............................................................................759 INSTALLATION.........................................................................760 FRONT WINDOW.............................................................................769 REMOVAL..............................................................................769 INSTALLATION.........................................................................772 90 OTHERS....................................................................................777 HYDRAULIC................................................................................779 HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1..................................779 HYDRAULIC DIAGRAM SHEET 1/2 (PART 2 OF 4) FOLDOUT 2..................................781 HYDRAULIC DIAGRAM SHEET 1/2 (PART 3 OF 4) FOLDOUT 3..................................783 HYDRAULIC DIAGRAM SHEET 1/2 (PART 4 OF 4) FOLDOUT 4..................................785 HYDRAULIC DIAGRAM SHEET 2/2 (PART 1 OF 4) FOLDOUT 5..................................787 HYDRAULIC DIAGRAM SHEET 2/2 (PART 2 OF 4) FOLDOUT 6..................................789 HYDRAULIC DIAGRAM SHEET 2/2 (PART 3 OF 4) FOLDOUT 7..................................791 HYDRAULIC DIAGRAM SHEET 2/2 (PART 4 OF 4) FOLDOUT 8..................................793 ELECTRICAL...............................................................................795 ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9.................................795 ELECTRICAL DIAGRAM SHEET 1/5 (PART 2 OF 2) FOLDOUT 10................................797 ELECTRICAL DIAGRAM SHEET 2/5 (PART 1 OF 1) FOLDOUT 11................................799 ELECTRICAL DIAGRAM SHEET 3/5 (PART 1 OF 1) FOLDOUT 12................................801 ELECTRICAL DIAGRAM SHEET 4/5 (PART 1 OF 2) FOLDOUT 13................................803 ELECTRICAL DIAGRAM SHEET 4/5 (PART 2 OF 2) FOLDOUT 14................................805 ELECTRICAL DIAGRAM SHEET 5/5 (PART 1 OF 2) FOLDOUT 15................................807 ELECTRICAL DIAGRAM SHEET 5/5 (PART 2 OF 2) FOLDOUT 16................................809 M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17....................811 M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18....................813 E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19...................815 E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20...................817 P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21..................819 P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 2 OF 4) FOLDOUT 22..................821 P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 3 OF 4) FOLDOUT 23..................823 P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 4 OF 4) FOLDOUT 24..................825
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