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KOMATSU PC58UU-3 SERVICE REPAIR MANUAL (SN:20001 & UP) KOMATSU PC58UU 3 – PDF DOWNLOAD
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- KOMATSU PC58UU-3 SERVICE REPAIR MANUAL
- SERIAL NUMBER:20001 & UP
- PUBLICATION NUMBER:SEBM023909
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Description
KOMATSU PC58UU-3 SERVICE REPAIR MANUAL (SN:20001 & UP) KOMATSU PC58UU 3
KOMATSU PC58UU-3 SERVICE REPAIR MANUAL (SN:20001 & UP) KOMATSU PC58UU 3 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC58UU-3 SERVICE REPAIR MANUAL (SN:20001 & UP) KOMATSU PC58UU 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 chapters; these chapters are further divided into the each main group of components.
- STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU PC58UU-3 SERVICE REPAIR MANUAL (SN:20001 & UP) KOMATSU PC58UU 3
COVER......................................................................................................................................................................... 1 CONTENTS...................................................................................................................................................................... 2 01 GENERAL.................................................................................................................................................................... 27 GENERAL ASSEMBLY DRAWING.................................................................................................................................................. 28 WORK EQUIPMENT RANGE DRAWING.............................................................................................................................................. 29 SPECIFICATIONS............................................................................................................................................................ 30 WEIGHT TABLE.............................................................................................................................................................. 37 LIST OF LUBRICANTS AND COOLANT............................................................................................................................................ 40 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD................................................................................................................................ 41 PTO....................................................................................................................................................................... 42 COOLING SYSTEM............................................................................................................................................................ 43 POWER TRAIN............................................................................................................................................................... 44 SWING CIRCLE.............................................................................................................................................................. 45 SWING MACHINERY........................................................................................................................................................... 46 TRACK FRAME,IDLER CUSHION................................................................................................................................................. 48 IDLER..................................................................................................................................................................... 51 TRACK ROLLER.............................................................................................................................................................. 52 CARRIER ROLLER............................................................................................................................................................ 53 SPROCKET.................................................................................................................................................................. 54 TRACK SHOE................................................................................................................................................................ 55 HYDRAULIC EQUIPMENT LAYOUT DRAWING........................................................................................................................................ 62 HYDRAULIC TANK AND FILTER................................................................................................................................................. 63 HYDRAULIC PUMP............................................................................................................................................................ 64 CONTROL VALVE............................................................................................................................................................. 73 CLSS...................................................................................................................................................................... 81 CENTER SWIVEL JOINT.......................................................................................................................................................104 TRAVEL MOTOR..............................................................................................................................................................105 SWING MOTOR...............................................................................................................................................................113 TRAVEL PPC VALVE..........................................................................................................................................................120 PPC VALVE.................................................................................................................................................................124 HYDRAULIC CYLINDER........................................................................................................................................................133 SOLENOID VALVE............................................................................................................................................................136 MULTI CONTROL VALVE.......................................................................................................................................................142 WORK EQUIPMENT............................................................................................................................................................143 AIR CONDITIONING PIPING...................................................................................................................................................149 ENGINE CONTROL............................................................................................................................................................150 ELECTRICAL CONTROL SYSTEM ................................................................................................................................................152 ELECTRICAL SYSTEM.........................................................................................................................................................158 MONITOR SYSTEM............................................................................................................................................................176 20 TESTING AND ADJUSTING......................................................................................................................................................181 STANDARD VALUE TABLUE FOR ENGING..........................................................................................................................................182 STANDARD VALUE TABLE FOR CHASSIS..........................................................................................................................................184 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.................................................................................................................................192 TESTING AND ADJUSTING.....................................................................................................................................................197 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.....................................................................................................................198 MEASURING ENGINE SPEED................................................................................................................................................199 MEASURING ENGINE OIL PRESSURE.........................................................................................................................................199 MEASURING COMPRESSING PRESSURE........................................................................................................................................200 AD JUSTING VALVE CLEARANCE............................................................................................................................................201 TESTING AND ADJUSTING FUEL INJECTION TIMING...........................................................................................................................202 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.........................................................................................................................205 ADJUSTING FUEL CONTROL LINKAGE........................................................................................................................................206 MEASURING EXHAUST COLOR...............................................................................................................................................207 TESTING CLEARANCE OF SWING CIRCLE BEARING.............................................................................................................................208 CHECKING WEAR OF SPROCKET.............................................................................................................................................209 TESTING AND ADJUSTING TRACK SHOE TENSION..............................................................................................................................210 ADJUSTING BRADE CONTROL LEVER.........................................................................................................................................211 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS................................................................................212 TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE........................................................................................................................214 ADJUSTING PC VALVE....................................................................................................................................................215 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN CONTROL PUMP CIRCUIT......................................................................................................216 MEASURING SOLENOID VALVE OUTPUT PRESSURE..............................................................................................................................217 MEASURING PPC VALVE OUTPUT PRESSURE...................................................................................................................................219 ADJUSTING PPC VALVE...................................................................................................................................................221 TESTING SWING HOLDING BRAKE INLET PRESSURE............................................................................................................................221 TESTING AND ADJUSTING TRAVEL DEVIATION................................................................................................................................222 MEASURING OIL LEAKAGE FROM WORK EQUIPMENT CYLINDER....................................................................................................................224 BLEEDING AIR FROM EACH PART...........................................................................................................................................226 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT....................................................................................................................228 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC TANK.......................................................................................................................228 PRESSURIZING HYDRAULIC TANK...........................................................................................................................................228 RESETTING PROCEDURE OF ELECTRIC SYSTEM AND CHECK OF ITS OPERATION.....................................................................................................229 PROCEDURE FOR REPLACING POTENTIOMETER.................................................................................................................................242 PROCEDURE FOR TESTING DIODE...........................................................................................................................................243 TROUBLESHOOTING...........................................................................................................................................................244 TROUBLESHOOTING POINTS TO REMEMBER....................................................................................................................................245 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................................................246 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................................................247 CHECKS BEFORE TROUBLESHOOTING.........................................................................................................................................255 CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................................................256 CONNECTOR ARRANGEMENT DIAGRAM.........................................................................................................................................260 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................................................266 T-ADAPTER-BOXES AND T-ADAPTER TABLE...................................................................................................................................290 EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM................................................................................................................293 METHOD OF USING JUDGEMENT TABLE.......................................................................................................................................309 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................................................310 TROUBLESHOOTING OF CONTROLLER AND ELECTRIC SYSTEM(E-MODE).............................................................................................................312 ACTIONS OF SELF-DIAGNOSIS FUNCTION AND PROBLEMS IN MACHINE........................................................................................................313 JUDGMENT TABLE FOR MACHINE CONTROL................................................................................................................................319 E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM.........................................................................................................................321 PUMP CONTROLLER...................................................................................................................................................322 ENGINE CONTROLLER.................................................................................................................................................323 PRECAUTIONS FOR TROUBLESHOOTING CONTROLLER SYSTEM.................................................................................................................325 PRECAUTIONS FOR OPERATING SYSTEM RESET SWITCH WHEN ERROR CODE IS DISPLAYED AND WORK EQUIPMENT STOPS...............................................................327 E-1 ERROR CODE [24](TROUBLE IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED...........................................................................................328 E-2 ERROR CODE [31](TROUBLE IN BOOM POTENTIOMETER SYSTEM) IS DISLAYED.............................................................................................329 E-3 ERROR CODE [32](TROUBLE IN ARM POTENTIOMETER SYSTEM) IS DISPLAYED.............................................................................................330 E-4 ERROR CODE [34](TROUBLE IN OFFSET POTENTIOMETER SYSTEM) IS DISPLAYED..........................................................................................331 E-5 ERROR CODE [41](TROUBLE IN PPC LOCK SOLENOID SYSTEM) IS DISPLAYED.............................................................................................332 E-6 ERROR CODE [42](TROUBLE IN LEFT OFFSET STOP SOLENOID SYSTEM) IS DISPLAYED.....................................................................................333 E-7 ERROR CODE [48](TROUBLE IN TRAVELING ACCELERATOR SOLENOID SYSTEM) IS DISPLAYED................................................................................334 E-8 ERROR CODE [51](TROUBLE IN BOOM RAISE STOP SOLENOID SYSTEM) IS DISPLAYED......................................................................................335 E-9 ERROR CODE [52](TROUBLE IN ARM IN STOP SOLENOID SYSTEM) IS DISPLAYED .........................................................................................336 E-10 ERROR CODE [54](TROUBLE IN TVC-EPC SOLENOID SYSTEM) IS DISPLAYED.............................................................................................337 E-11 ERROR CODE [62](TROUBLE IN CONTROLLER POWER SOURCE SYSTEM) IS DISPLAYED......................................................................................338 E-12 ERROR CODE [64](TROUBLE IN SENSOR POWER SOURCE SYSTEM) IS DISPLAYED..........................................................................................339 E-13 ERROR CODE [71](MOTOR DRIVE RELAY(ACCELERATOR) IS DISPLAYED..................................................................................................340 E-14 ERROR CODE [72](MOTOR DRIVE RELAY(DECELERATOR)) IS DISPLAYED.................................................................................................341 E-15 ERROR CODE [74](MOTOR DRIVE RELAY(DECELERATOR)) IS DISPLAYED.................................................................................................342 E-16 ERROR CODE [78](ABNORMALITY IN MOTOR STALL SYSTEM)IS DISPLAYED...............................................................................................343 E-17 ERROR CODE [EE](FAULT IN CONTROLLER) IS DISPLAYED............................................................................................................345 a) WHEN CONTROLLER HAS FAULT IN IT............................................................................................................................345 b) WHEN COMMUNICATION SYSTEM BETWEEN CONTROLLER AND MONITOR PANEL IS TROUBLED.................................................................................346 E-18 DEFECTIVE ENGINE CONTROL SYSTEM..............................................................................................................................347 a) ENGINE CONTROL SYSTEM DOES NOT OPERATE AT ALL OR IT OPERATES FOR A MOMENT AND DOSE NOT OPERATE ANY MORE....................................................347 b) ENGINE CONTROL SYSTEM DOES NOT OPERATE AT ALL OR IT OPERATES FOR A MOMENT AND DOES NOT OPERATE ANY MORE(ABNORMAL SPEED OR INSUFFICIENT STROKE OF CABLE)....349 c) ONE-TOUCH DECELERATOR DOES NOT OPERATE.....................................................................................................................350 d) ENGINE CONTROL SYSTEM OPERATES NEAR IDING SPEED BUT DOES NOT OPERATE TO FULL(HIGH-LOAD RANGE)..............................................................350 E-19 WHEN STARTING SWITCH IS TURNED TO START POSITION,ENGINE DOES NOT START.......................................................................................351 a) STARTING SYSTEM............................................................................................................................................351 b) ENGINE STOP SOLENOID SYSTEM................................................................................................................................357 E-20 WHEN STARTING SWITCH IS TURNED TO OFF POSITION,ENGINE DOES NOT STOP..........................................................................................359 E-21 WHEN TRAVELING ACCELERATOR PEDAL IS PRESSED,TRAVEL SPEED DOES NOT RISE.......................................................................................361 E-22 WHEN TRAVELING ACCELERATOR PEDAL IS RELEASED,TRAVEL SPEED DOES NOT LOWER FROM RAISED LEVEL...................................................................362 E-23 WHEN WORK EQUIPMENT LOCK LEVER IS SET TO FREE POSITION, WORK EQUIPMENT DOES NOT MOVE.........................................................................363 E-24 AFTER WORK EQUIPMENT LOCK LEVER IS LOCKED, WORK EQUIPMENT STILL MOVES........................................................................................365 E-25 SYSTEM CANNOT BE INITIALIZED.................................................................................................................................366 E-26 DEPTH CANNOT BE SET TO 0 OR HEIGHT CANNOT BE SET.............................................................................................................368 TROUBLESHOOTING FOR CONTROLLER INPUT SIGNAL SYSTEM(F-MODE)............................................................................................................369 F-1 CONTROLLER DOES NOT DISPLAY [26 (2)] (ONE-TOUCH DECELERATION).................................................................................................370 F-2 CONTROLLER DOES NOT DISPLAY[26(3)](TRAVELING ACCELERATOR SWITCH)..............................................................................................371 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS(H-MODE)..........................................................................................................372 TABLE OF FAILURE MODES AND CAUSES.................................................................................................................................374 H-1 SPEED OR POWER OF TWO OR MORE OF WORK EQUIPMENT (BOOM,ARM,BUCKET,AND OFFSET),TRAVEL,SWING,AND BLADE SYSTEMS IS LOW........................................376 a) SPEED OR POWER OF WORK EQUIPMENT (INCLUDING BLADE),TRAVEL,AND SWING SYSTEMS IS LOW.....................................................................376 b) SPEED OR POWER OF WORK EQUIPMENT(EXCLUDING BLADE),TRAVEL,AND SWING SYSTEMS IS LOW......................................................................377 c) SPEED OR POWER OF WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL SYSTEM IS LOW............................................................................377 d) SPEED OR POWER OF SWING AND BLADE SYSTEM IS LOW........................................................................................................378 e) SPEED OR POWER OF TRAVEL AND BLADE SYSTEMS IS LOW......................................................................................................378 f) SPEED OR POWER OF WORK EQUIPMENT (EXCLUDING BLADE) IS LOW..............................................................................................379 g) SPEED OR POWER OF TRAVEL AND SWING SYSTEMS IS LOW......................................................................................................379 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED OR ENGINE STALLS..................................................................................................380 H-3 TWO OR MORE OF WORK EQUIPMENT (BOOM,ARM,BUCKET,AND OFFSET),TRAVEL,SWING,AND BLADE SYSTEMS DO NOT MOVE.....................................................382 a) WORK EQUIPMENT(INCLUDING BLADE),TRAVEL,AND SWING SYSTEMS DO NOT MOVE...................................................................................382 b) WORK EQUIPMENT(EXCLUDING BLADE),TRAVEL,AND SWING SYSTEMS DO NOT MOVE...................................................................................383 c) WORK EQUIPMENT(EXCLUDING BLADE) AND TRAVEL SYSTEMS DO NOT MOVE.........................................................................................383 d) AWING AND BLADE SYSTEMS DO NOT MOVE....................................................................................................................383 e) TRAVEL AND BLADE SYSTEMS DO NOT MOVE...................................................................................................................384 f) WORK EQUIPMENT (EXCLUDING BLADE) SYSTEM DOES NOT MOVE..................................................................................................384 H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)...............................................................................................................385 H-5 FINE CONTROLLABILITY IS POOR OR RESPONSE IS LOW (TWO OR MORE SYSTEMS HAVE POOR FINE CONTROLLABILITY OR LOW RESPONSE SIMULTANEOUSLY........................386 H-6 BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)...............................................................................................387 a) BOOM RAISE SPEED OR POWER IS LOW.......................................................................................................................387 b) BOOM LOWER SPEED OR POWER IS LOW.......................................................................................................................388 H-7 ARM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)................................................................................................389 a) ARM IN SPEED OR POWER IS LOW...........................................................................................................................389 b) ARM OUT SPEED OR POWER IS LOW..........................................................................................................................390 H-8 BUCKET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL).............................................................................................391 a) BUCKET CURL SPEED OR POWER IS LOW......................................................................................................................391 b) BUCKET DUMP SPEED OR POWER IS LOW......................................................................................................................392 H-9 OFFSET BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)........................................................................................393 a) OFFSET LEFT SPEED OR POWER IS LOW......................................................................................................................393 b) OFFSET RIGHT SPEED OR POWER IS LOW.....................................................................................................................394 H-10 BOOM DOES NOT MOVE.......................................................................................................................................395 a) BOOM DOES NOT RAISE....................................................................................................................................395 b) BOOM DOES NOT LOWER....................................................................................................................................396 H-11 ARM DOES NOT MOVE........................................................................................................................................397 a) ARM DOES NOT MOVE IN...................................................................................................................................397 b) ARM DOES NOT MOVE OUT..................................................................................................................................398 H-12 BUCKET DOES NOT MOVE.....................................................................................................................................399 a) BUCKET DOES NOT CURL...................................................................................................................................399 b) BUCKET DOES NOT DUMP...................................................................................................................................400 H-13 OFFSET BOOM DOES NOT MOVE................................................................................................................................401 a) OFFSET BOOM DOES NOT MOVE TO LEFT......................................................................................................................401 b) OFFSET BOOM DOES NOT MOVE TO RIGHT.....................................................................................................................402 H-14 HYDRAULIC DRIFT OF BOOM IS LARGE.........................................................................................................................403 H-15 HYDRAULIC DRIFT OF ARM IS LARGE..........................................................................................................................403 H-16 HYDRAULIC DRIFT OF BUCKET IS LARGE.......................................................................................................................404 H-17 HYDRAULIC DRIFT OF OFFSET BOOM IS LARGE..................................................................................................................404 a) HYDRAULIC DRIFT OF OFFSET BOOM TO LEFT IS LARGE........................................................................................................404 b) HYDRAULIC DRIFT OF OFFSET BOOM TO RIGHT IS LARGE.......................................................................................................404 H-18 TIME LAG IS LARGE (ENGINE SPEED IS LOW)..................................................................................................................405 H-19 PART LOADED MORE MOVES SLOWER IN COMPOUND OPERATION OF WORK EQUIPMENT....................................................................................405 H-20 TRAVEL DEVIATION IS LARGE................................................................................................................................406 a) TRAVEL DEVIATION IS LARGE DURING ORDINARY TRAVEL.......................................................................................................406 b) TRAVEL DEVIATION IS LARGE WHEN MACHINE STARTING (BUT NORMAL DURING ORDINARY TRAVEL)....................................................................407 H-21 TRAVEL SPEED OR POWER IS LOW (WORK EQUIPMENT,SWING,AND BLADE OPERATIONS ARE NORMAL)......................................................................408 H-22 MACHINE CANNOT BE STEERED SHARPLY OR STEERING FORCE IS INSUFFICIENT......................................................................................409 H-23 TRAVEL SPEED DOES NOT CHANGE.............................................................................................................................410 H-24 MACHINE DOES NOT TRAVEL..................................................................................................................................411 H-25 OVERRUN OF TRAVEL IS LARGE...............................................................................................................................413 H-26 TRAVEL HYDRAULIC DRIFT IS LARGE..........................................................................................................................413 H-27 FINE CONTROLLABILITY OR RESPONSE IS LOW..................................................................................................................414 H-28 SWING SPEED OR POWER IS LOW (WORK EQUIPMENT,TRAVEL, AND BLADE OPERATIONS ARE NORMAL).....................................................................415 a) SWING SPEED OR POWER IS LOW IN BOTH DIRECTIONS.........................................................................................................415 b) SWING SPEED OR POWER IS LOW IN EITHER DIRECTION........................................................................................................417 H-29 MACHINE DOES NOT SWING (WORK EQUIPMENT,TRAVEL,AND BLADE OPERATIONS ARE NORMAL)...........................................................................418 a) MACHINE DOES NOT SWING IN EITHER DIRECTION.............................................................................................................418 b) MACHINE DOES NOT SWING IN BOTH DIRECTIONS..............................................................................................................420 H-30 SWING ACCELERATION IS LOW................................................................................................................................421 a) SWING ACCELERATION IS LOW IN BOTH DIRECTIONS...........................................................................................................421 b) SWING ACCELERATION IS LOW IN EITHER DIRECTION..........................................................................................................421 H-31 OVERRUN OF SWING IS LARGE................................................................................................................................422 a) OVERRUN OF SWING IS LARGE IN BOTH DIRECTIONS...........................................................................................................422 b) OVERRUN OF SWING IS LARGE IN EITHER DIRECTION..........................................................................................................422 H-32 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING..........................................................................................................423 H-33 LARGE ABNORMAL SOUND IS MADE WHEN MACHINE STOPS SWINGING.................................................................................................423 H-34 SWING HYDRAULIC DRIFT IS LARGE...........................................................................................................................423 H-35 FINE CONTROLLABILITY OR RESPONSE OF SWING IS LOW.........................................................................................................424 H-36 BLADE SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL,AND SWING OPERATIONS ARE NORMAL).....................................................................425 H-37 BLADE DOES NOT MOVE (WORK EQUIPMENT,TRAVEL,AND SWING OPERATIONS ARE NORMAL)..............................................................................426 a) BLADE DOES NOT RAISE...................................................................................................................................426 b) BLADE DOES NOT LOWER...................................................................................................................................427 H-38 HYDRAULIC DRIFT OF BLADE IS EXCESSIVE....................................................................................................................428 H-39 FINE CONTROLLABILITY IS POOR OR RESPONSE OF BLADE IS LOW.................................................................................................428 H-40 MONITOR PANEL DISPLAYS ERROR CODE [61] AND BOOM RAISE,ARM IN, AND LEFT OFFSET OPERATIONS STOP JUST BEFORE INTERFERENCE...................................429 H-41 MACHINE DOES NOT STOP BOOM RAISE,ARM IN,AND LEFT OFFSET OPERATIONS AUTOMATICALLY BUT INTERFERES..........................................................429 TROUBLE SHOOTING FOR MACHINE MONITOR SYSTEM(M-MODE)...................................................................................................................430 ELECTRIC CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM................................................................................................................431 M-1 WHEN STARTING SWITCH IS TURNED TO THE ON POSITION,NOTHING IS DISPLAYED(SEGMENTS DO NOT LIGHT UP FOR 3 SECONDS)................................................433 M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION,ALL SEGMENTS LIGHT UP BUT DO NOT GO OFF AFTER 3 SECONDS.........................................................433 M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION,SOME ITEMS DO NOT LIGHT UP FOR ALL SEGMENT LIGHT-UP PERIOD OF 3 SECONDS.........................................434 a) GAUGES DO NOT LIGHT UP ....................................................................................................................................434 b) ELECTRIC SYSTEM CAUTION LAMP DOES NOT LIGHT UP.............................................................................................................434 c) CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP................................................................................................................434 d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP.........................................................................................................434 M-4 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED),CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP...............................................435 M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOOPED),ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP........................................436 M-6 ENGINE PREHEATING PILOT LAMP DOES NOT LIGHT UP WHILE ENGINE IS PREHEATED......................................................................................437 M-7 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)............................................................437 M-8 CHARGE LEVEL CAUTION LAMP LIGHTS UP WHILE ENGINE IS RUNNING...................................................................................................438 M-9 ENGINE WATER TEMPERATURE GAUGE (COOLANT TEMPERATURE GAUGE) INDICATES ABNORMALLY...............................................................................440 a) AFTER ENGINE IS STARTED,TEMPERATURE DOES NOT RISE AT ALL FROM LOWEST LEVEL.................................................................................440 b) AFTER ENGINE IS STARTED,TEMPERATURE RISES IMMEDIATELY......................................................................................................441 c) WATER TEMPERATURE GAUGE GOES OFF...........................................................................................................................441 M-10 FUEL LEVEL GAUGE INDICATES ABNORMALLY........................................................................................................................442 a) AL SEGMENTS OF FUEL LEVEL GAUGE GO OFF.....................................................................................................................442 b) FUEL LEVEL GAUGE KEEPS INDICATING FULL WHILE FUEL IS CONSUMED..............................................................................................442 c) FUEL LEVEL GAUGE DOES NOT INDICATE FULL WHILE FUEL TANK IS FULL............................................................................................443 M-11 ALARM BUZZER OPERATES ABNORMALLY.............................................................................................................................444 a) BUZZER DOES NOT SOUND......................................................................................................................................444 b) BUZZER KEEPS SOUNDING......................................................................................................................................444 M-12 ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRIC SYSTEM CAUTION LAMP BLINKS WHILE EMERGENCY WORK EQUIPMENT OPERATION SWITCH IS NOT TURNED ON...................445 M-13 SERVICE METER DOES NOT OPERATE WHILE ENGINE IS RUNNING ......................................................................................................446 a) WHEN CHARGE LEVEL CAUTION LAMP DOES NOT LIGHT UP...........................................................................................................446 b) WHEN CHARGE LEVEL CAUTION LAMP LIGHTS UP...................................................................................................................446 M-14 LAMPS FOR NIGHT WORK DO NOT LIGHT UP.........................................................................................................................448 a) LAMP FOR COOLANT TEMPERATURE GAUGE,FUEL LEVEL GAUGE,AND DEPTH INDICATOR DOES NOT LIGHT UP..................................................................448 b) LAMP FOR SERVICE METER DOES NOT LIGHT UP...................................................................................................................448 M-15 ELECTRIC SYSTEM CAUTION LAMP DOES NOT GO OFF(CONTROLLER DOES NOT DISPLAY ANY ERROR CODE AND OPERATION IS NORMAL).............................................449 M-16 HEATER DOES NOT OPERATE......................................................................................................................................450 a) HEATER DOES NOT OPERATE AT BOTH LO AND HI LEVELS...........................................................................................................450 b) HEATER DOES NOT OPERATE AT ONLY LO LEVEL...................................................................................................................450 c) HEATER DOES NOT OPERATE AT ONLY HI LEVEL...................................................................................................................450 M-17 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING........................................................................................................452 a) TRAVEL ALARM DOES NOT SOUND................................................................................................................................452 b) WHEN MACHINE STOPS,ALARM DOES NOT STOP.....................................................................................................................452 30 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................454 METHOD OF USING MANUAL....................................................................................................................................................455 PRECAUTIONS WHEN PERFORMING OPERATION.....................................................................................................................................456 SPECIAL TOOL LIST.........................................................................................................................................................459 ENGINE AND WORK EQUIPMENT PUMP ASSEMBLY...................................................................................................................................462 REMOVAL...............................................................................................................................................................462 INSTALLATION..........................................................................................................................................................467 CENTER SWIVEL JOINT ASSEMBLY..............................................................................................................................................472 REMOVAL...............................................................................................................................................................472 INSTALLATION..........................................................................................................................................................476 SWING MOTOR AND SWING MACHINERY ASSEMBLY..................................................................................................................................480 REMOVAL...............................................................................................................................................................480 INSTALLATION..........................................................................................................................................................481 REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY...................................................................................................................................482 INSTALLATION OF REVOLVING FRAME ASSEMBLY..................................................................................................................................486 SWING CIRCLE ASSEMBLY ....................................................................................................................................................490 REMOVAL...............................................................................................................................................................490 INSTALLATION..........................................................................................................................................................490 RUBBER SHOE ASSEMBLY......................................................................................................................................................491 REMOVAL...............................................................................................................................................................491 INSTALLATION..........................................................................................................................................................491 ROAD LINER IRON SHOE ASSEMBLY.............................................................................................................................................492 REMOVAL...............................................................................................................................................................492 INSTALLATION..........................................................................................................................................................493 SWING MACHINERY ASSEMBLY..................................................................................................................................................494 DISASSEMBLY...........................................................................................................................................................494 ASSEMBLY..............................................................................................................................................................497 CENTER SWIVEL JOINT ASSEMBLY..............................................................................................................................................500 DISASSEMBLY...........................................................................................................................................................500 ASSEMBLY..............................................................................................................................................................501 IDLER CUSHION ASSEMBLY....................................................................................................................................................502 DISASSEMBLY...........................................................................................................................................................502 ASSEMBLY..............................................................................................................................................................503 INSTALLATION OF IDLER ASSEMBLY............................................................................................................................................504 INSTALLATION OF TRACK ROLLER ASSEMBLY.....................................................................................................................................506 INSTALLATION OF CARRIER ROLLER ASSEMBLY...................................................................................................................................507 INSTALLATION OF HYDRAULIC CYLINDER ASSEMBLY...............................................................................................................................508 ASSEMBLY OF WORK EQUIPMENT VALVE(NOTES)...................................................................................................................................510 90 OTHERS.....................................................................................................................................................................513 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................................................514 HYDRAULIC CIRCUIT DIAGRAM (ADDITIONAL ATTACHMENT CIRCUIT).................................................................................................................515 ELECTRICAL CIRCUIT DIAGRAM (1/2) SERIAL NO.:20001-20423...................................................................................................................516 ELECTRICAL CIRCUIT DIAGRAM (2/2) SERIAL NO.:20001-20423...................................................................................................................517 ELECTRICAL CIRCUIT DIAGRAM (1/2) SERIAL NO.:20424-22000...................................................................................................................518 ELECTRICAL CIRCUIT DIAGRAM (2/2) SERIAL NO.:20424-22000...................................................................................................................519 ELECTRICAL CIRCUIT DIAGRAM (1/2) SERIAL NO.:22001 AND UP..................................................................................................................520 ELECTRICAL CIRCUIT DIAGRAM (2/2) SERIAL NO.:22001 AND UP..................................................................................................................521
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
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