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KOMATSU PC750-6 PC800-6 SERVICE REPAIR MANUAL (SEBM025305) KOMATSU PC750 6 – PDF DOWNLOAD
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- KOMATSU PC750-6 PC800-6 SERVICE REPAIR MANUAL
- PUBLICATION NUMBER:SEBM025305
- SERIAL NUMBER
PC750-6 11001 and up
PC750SE-6 11001 and up
PC750LC-6 11001 and up
PC800-6 31001 and up
PC800SE-6 31001 and up
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Description
KOMATSU PC750-6 PC800-6 SERVICE REPAIR MANUAL (SEBM025305) KOMATSU PC750 6
KOMATSU PC750-6 PC800-6 SERVICE REPAIR MANUAL (SEBM025305) KOMATSU PC750 6 – PDF DOWNLOAD:
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KOMATSU PC750-6 PC800-6 SERVICE REPAIR MANUAL (SEBM025305) KOMATSU PC750 6
- 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 PC750-6 PC800-6 SERVICE REPAIR MANUAL (SEBM025305) KOMATSU PC750 6
COVER...................................................................................................................................................... 1 CONTENTS................................................................................................................................................... 2 01 GENERAL................................................................................................................................................. 28 SPECIFICATION DRAWINGS................................................................................................................................. 29 SPECIFICATIONS......................................................................................................................................... 33 WEIGHT TABLE........................................................................................................................................... 41 FUEL, COOLANT AND LUBRICANTS........................................................................................................................... 45 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................................................................................ 46 PTO.................................................................................................................................................... 47 PTO LUBRICATION SYSTEM................................................................................................................................. 48 POWER TRAIN............................................................................................................................................ 49 SWING MACHINERY........................................................................................................................................ 51 SWING CIRCLE........................................................................................................................................... 53 FINAL DRIVE............................................................................................................................................ 54 TRACK FRAME AND RECOIL SPRING.......................................................................................................................... 56 IDLER.................................................................................................................................................. 58 CARRIER ROLLER......................................................................................................................................... 60 TRACK ROLLER........................................................................................................................................... 61 TRACK SHOE............................................................................................................................................. 62 MOTOR GREASE PUMP...................................................................................................................................... 67 HYDRAULIC TANK......................................................................................................................................... 68 HYDRAULIC PUMP......................................................................................................................................... 69 LINE OIL FILTER........................................................................................................................................ 98 PILOT OIL FILTER....................................................................................................................................... 98 DRAIN OIL FILTER....................................................................................................................................... 99 L.H. 5-SPOOL CONTROL VALVE.............................................................................................................................100 R.H. 4-SPOOL CONTROL VALVE.............................................................................................................................105 STRAIGHT-TRAVEL VALVE..................................................................................................................................110 SWING MOTOR............................................................................................................................................113 CENTER SWIVEL JOINT....................................................................................................................................118 TRAVEL MOTOR...........................................................................................................................................119 PPC CONTROL RELIEF VALVE...............................................................................................................................129 SAFETY LOCK VALVE......................................................................................................................................130 PPC ACCUMULATOR........................................................................................................................................131 VALVE CONTROL..........................................................................................................................................132 WORK EQUIPMENT, SWING PPC VALVE........................................................................................................................133 TRAVEL PPC VALVE.......................................................................................................................................138 SOLENOID VALVE.........................................................................................................................................142 HYDRAULIC CYLINDER.....................................................................................................................................147 WORK EQUIPMENT.........................................................................................................................................155 DIMENSIONS OF WORK EQUIPMENT...........................................................................................................................163 AIR CONDITIONER........................................................................................................................................167 ENGINE CONTROL.........................................................................................................................................168 MACHINE CONTROL SYSTEM.................................................................................................................................173 MONITOR SYSTEM.........................................................................................................................................201 SENSORS................................................................................................................................................208 20 TESTING AND ADJUSTING...................................................................................................................................211 STANDARD VALUE TABLE FOR ENGINE........................................................................................................................212 STANDARD VALUE TABLE FOR CHASSIS.......................................................................................................................213 STANDARD VALUE TABLE FOR ELECTRICAL PARTS..............................................................................................................222 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING......................................................................................................235 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE).........................................................................................................237 MEASURING EXHAUST TEMPERATURE..........................................................................................................................238 MEASURING EXHAUST COLOR................................................................................................................................239 ADJUSTING VALVE CLEARANCE..............................................................................................................................240 MEASURING BLOW-BY PRESSURE.............................................................................................................................241 MEASURING COMPRESSION PRESSURE.........................................................................................................................241 MEASURING ENGINE OIL PRESSURE..........................................................................................................................242 HANDLING EQUIPMENT IN FUEL CIRCUIT.....................................................................................................................243 RELEASING REMAINING PRESSURE IN FUEL SYSTEM............................................................................................................243 MEASURING FUEL PRESSURE................................................................................................................................244 REDUCED CYLINDER MODE OPERATION FOR ENGINE.............................................................................................................245 BLEEDING AIR FROM FUEL CIRCUIT.........................................................................................................................247 CHECKING FOR LEAKAGE IN FUEL CIRCUIT...................................................................................................................249 TESTING AND ADJUSTING ALTERNATOR BELT TENSION..........................................................................................................250 TESTING AND ADJUSTING FAN BELT TENSION.................................................................................................................251 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION....................................................................................252 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT........................................................................................................253 ADJUSTING ENGINE SPEED SENSOR..........................................................................................................................254 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT......................................................................255 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE................................................................................................258 TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE.....................................................................................................260 MEASURING SERVO PISTON STROKE..........................................................................................................................266 MEASURING PPC VALVE OUTPUT PRESSURE....................................................................................................................267 TESTING SOLENOID VALVE OUTPUT PRESSURE.................................................................................................................268 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE..............................................................................................................269 TESTING TRAVEL DEVIATION...............................................................................................................................270 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT............................................................................................273 MEASURING OIL LEAKAGE..................................................................................................................................274 TESTING CLEARANCE OF SWING CIRCLE BEARING..............................................................................................................279 TESTING AND ADJUSTING TRACK SHOE TENSION...............................................................................................................280 BLEEDING AIR...........................................................................................................................................281 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT......................................................................................................283 PROCEDURE FOR CHECKING DIODE...........................................................................................................................284 TROUBLESHOOTING........................................................................................................................................285 POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................286 SEQUENCE OF EVENTS IN TROUBLESHOOTING..............................................................................................................287 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...................................................................................................288 CHECKS BEFORE TROUBLESHOOTING......................................................................................................................296 CONNECTOR TYPES AND MOUNTING LOCATIONS.............................................................................................................297 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.........................................................................................................304 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM.............................................................................................327 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL..............................................................................................328 METHOD OF USING JUDGEMENT TABLE....................................................................................................................343 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................................................345 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...........................................................................................346 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE).......................................................................................350 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....................................................................351 ELECTRICAL CIRCUIT DIAGRAM FOR N MODE SYSTEM...................................................................................................353 N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY....................................................................354 N-2 [E117, E218 OCCUR AT SAME TIME] ENGINE CONTROLLER COMMUNICATION ABNORMALITY................................................................356 N-3 [E118, E955 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY..................................................................358 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE)...............................................................................................360 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED...............................................................361 JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS.................................................................................369 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM...................................................................................................371 E-1 [E91b] (ABNORMALITY IN ENGINE SPEED NE SENSOR SYSTEM) IS DISPLAYED.........................................................................373 E-2 [E91C] (ABNORMALITY IN ENGINE G ROTATION SENSOR SYSTEM) IS DISPLAYED.......................................................................374 E-3 [E920] (ABNORMALITY IN MODEL SELECTION SYSTEM) IS DISPLAYED................................................................................375 E-4 [E922] (ENGINE OVERRUN) IS DISPLAYED.......................................................................................................376 E-5 [E924] (DROP IN ENGINE OIL PRESSURE) IS DISPLAYED..........................................................................................377 E-6 [E931] (ABNORMALITY IN FUEL CONTROL DIAL SENSOR SYSTEM) IS DISPLAYED.......................................................................378 E-7 [E934] (ABNORMALITY IN ENGINE WATER HIGH-TEMPERATURE SENSOR SYSTEM) IS DISPLAYED...........................................................379 E-8 [E936] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM) IS DISPLAYED.....................................................................380 E-9 [E93C] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED..........................................................................382 E-10 [E93d] (ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED.......................................................................383 E-11 [E954] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED...........................................................................384 E-12 [E955] (ABNORMALITY IN NETWORK SYSTEM) IS DISPLAYED.......................................................................................384 E-13 [E956] (POWER SOURCE SYSTEM ABNORMALITY 1) IS DISPLAYED...................................................................................385 E-14 [E957] (POWER SOURCE SYSTEM ABNORMALITY 2) IS DISPLAYED...................................................................................387 E-15 [E95A] (ABNORMALITY IN FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL) IS DISPLAYED.......................................................387 E-16 [E96A] (ABNORMALITY IN ENGINE WATER LOW-TEMPERATURE SENSOR SYSTEM) IS DISPLAYED...........................................................388 E-17 [E970] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED......................................................................389 E-18 [E971] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED......................................................................390 E-19 [E974] (DISCONNECTION IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED.......................................................................391 E-20 [E975] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED.......................................................................392 E-21 [E977] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED..............................................................393 E-22 [E979] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1) IS DISPLAYED, [E97A] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2) IS DISPLAYED....394 E-23 [E97b] (FUEL SUPPLY PUMP NON-FORCE FEED 1) IS DISPLAYED, [E97C] (FUEL SUPPLY PUMP NON-FORCE FEED 2) IS DISPLAYED..........................395 E-24 [E97d] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE) IS DISPLAYED............................................................................397 E-25 [E980] (DEFECTIVE ENGINE CONTROLLER) IS DISPLAYED.........................................................................................397 E-26 [E981] (DISCONNECTION IN NO. 1 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................398 E-27 [E982] (DISCONNECTION IN NO. 2 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................399 E-28 [E983] (DISCONNECTION IN NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................400 E-29 [E984] (DISCONNECTION IN NO. 4 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................401 E-30 [E985] (DISCONNECTION IN NO. 5 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................402 E-31 [E986] (DISCONNECTION IN NO. 6 FUEL INJECTOR SYSTEM) IS DISPLAYED.........................................................................403 E-32 [E98A] (SHORT CIRCUIT IN NO. 1, NO. 2, NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED...........................................................404 E-33 [E98b] (SHORT CIRCUIT IN NO. 3, NO. 4, NO. 5 FUEL INJECTOR SYSTEM) IS DISPLAYED...........................................................408 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE).................................................................................................412 POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM......................................................................................413 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....................................................................414 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS................................................................................422 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM...................................................................................................424 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)......................................................................426 C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED..............................................................................427 C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED..............................................................................429 C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED...................................................................431 C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED...................................................................433 C-6 [E201] SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED.............................................................................435 C-7 [E211] DISCONNECTION IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED.............................................................................436 C-8 [E202] SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED.......................................................................437 C-9 [E212] DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED.......................................................................438 C-10 [E204] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.......................................................................439 C-11 [E214] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.......................................................................440 C-12 [E205] SHORT CIRCUIT IN SWING PRIORITY SELECTOR SOLENOID SYSTEM IS DISPLAYED..............................................................441 C-13 [E211] DISCONNECTION IN SWING PRIORITY SELECTOR SOLENOID SYSTEM IS DISPLAYED..............................................................442 C-14 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED.........................................................................443 C-15 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED.........................................................................444 C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED...........................................................................................445 C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED.............................................................................447 C-18 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)................................................................448 C-19 ABNORMALITY IN SHOCKLESS BOOM SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED).................................................................450 C-20 [E207] SHORT CIRCUIT IN FLASH LIGHT RELAY DRIVE SYSTEM IS DISPLAYED.......................................................................453 C-21 FLASH LIGHT RELAY DOES NOT WORK...........................................................................................................454 C-22 [E231] ABNORMALITY (SHORT CIRCUIT) IN POWER SOURCE HOLDING RELAY OUTPUT SYSTEM FOR STEP LIGHT IS DISPLAYED................................455 C-23 STEP LIGHT SWITCH DOES NOT WORK...........................................................................................................456 C-24 [E302] SHORT CIRCUIT IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED........................................................................457 C-25 [303] DISCONNECTION IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED.........................................................................458 C-26 STEP LIGHT DOES NOT LIGHT UP..............................................................................................................459 C-27 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED........................................................................460 TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)................................................................461 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE SYSTEM...................................................................................................462 F-1 [BIT PATTERN 20-(1)] SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...........................................................................464 F-2 [BIT PATTERN 20-(2)] R.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................465 F-3 [BIT PATTERN 20-(3)] BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................................466 F-4 [BIT PATTERN 20-(4)] BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................................467 F-5 [BIT PATTERN 20-(5)] ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................................468 F-6 [BIT PATTERN 20-(6)] ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP.........................................................................469 F-7 [BIT PATTERN 21-(1)] BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................470 F-8 [BIT PATTERN 21-(2)] BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................471 F-9 [BIT PATTERN 20-(5)] L.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................472 F-10 [BIT PATTERN 21-(4)] SERVICE OIL PRESSURE SWITCH DOES NOT LIGHT UP........................................................................473 F-11 [BIT PATTERN 21-(3)] SWING LOCK SWITCH DOES NOT LIGHT UP..................................................................................474 F-12 [BIT PATTERN 24-(1)] WHEN STEP LIGHT SWITCH IS ON, IT DOES NOT GO OUT.....................................................................475 F-13 [BIT PATTERN 24-(2)] WHEN HORN SWITCH IS ON, IT DOES NOT GO OUT...........................................................................476 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)...........................................................................................477 TABLE OF FAILURE MODES AND CAUSES..............................................................................................................478 BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)...............................................................................480 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER.........................................................................483 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS..................................................................................484 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE......................................................................................................486 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).....................................................................................................487 H-5 AUTO-DECELERATION DOES NOT WORK............................................................................................................487 H-6 WORK EQUIPMENT SPEED IS SLOW (BOOM, ARM, BUCKET)...........................................................................................488 H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).........................................................490 H-8 EXCESSIVE HYDRAULIC DRIFT..................................................................................................................490 H-9 EXCESSIVE TIME LAG.........................................................................................................................491 H-10 EXCESSIVE SHOCK WHEN BOOM IS STOPPED......................................................................................................491 H-11 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION...........................................................................................491 H-12 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS..................................................................................492 H-13 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS...........................................................................493 H-14 DEVIATION IS EXCESSIVE WHEN STARTING......................................................................................................495 H-15 TRAVEL SPEED IS SLOW......................................................................................................................496 H-16 TRAVEL SPEED DOES NOT SWITCH..............................................................................................................497 H-17 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)......................................................................................................497 H-18 DOES NOT SWING............................................................................................................................498 H-19 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR.........................................................................................500 H-20 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR DURING COMPOUND OPERATIONS WITH ARM, BUCKET.............................................501 H-21 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR DURING COMPOUND OPERATIONS WITH BOOM RAISE WHEN SWING PRIORITY IS ON....................502 H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING.....................................................................................................503 H-23 EXCESSIVE SHOCK WHEN STOPPING SWING.......................................................................................................504 H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..............................................................................................505 H-25 EXCESSIVE HYDRAULIC DRIFT OF SWING........................................................................................................506 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).................................................................................................507 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..................................................................508 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM...................................................................................................510 M-1 [E101] (ABNORMALITY IN ERROR DATA) OR [E102] (ABNORMALITY IN CLOCK DATA) IS DISPLAYED......................................................512 M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT SYSTEM) IS DISPLAYED................................................................................513 M-3 [E104] (AIR CLEANER CLOGGING DETECTION) IS DISPLAYED.......................................................................................514 M-4 [E108] (ENGINE WATER TEMPERATURE 105℃) IS DISPLAYED........................................................................................514 M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS...................................................515 M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT...............................................517 M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE.....................................517 M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH................................................................518 M-9 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY MOTOR LAMP LIGHTS UP...................................................................521 M-10 WHEN ENGINE IS STARTED, BASIC CHECK ITEMS FLASH...........................................................................................522 M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH..........................................523 M-12 WHEN ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH......................................................................524 M-13 OPERATION OF ALARM BUZZER IS NOT NORMAL...................................................................................................528 M-14 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP.........................................................................................530 M-15 ENGINE WATER TEMPERATURE DISPLAY IS NOT NORMAL............................................................................................531 M-16 FUEL LEVEL GAUGE DISPLAY IS NOT NORMAL....................................................................................................532 M-17 SWING LOCK SWITCH IS TURNED ON BUT SWING LOCK MONITOR LAMP DOES NOT LIGHT UP..............................................................534 M-18 WHEN SWING BRAKE RELEASE SWITCH IS SET TO RELEASE (EMERGENCY), SWING LOCK MONITOR LAMP DOES NOT FLASH.....................................535 M-19 SERVICE METER DOES NOT GIVE NORMAL DISPLAY................................................................................................536 M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM........................................................................................................537 M-21 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM..................................................................................................538 M-22 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.....................................................................................................539 M-23 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM...............................................................................................540 M-24 WIPER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WIPER IS ACTUATED WHEN WIPER SWITCH IS NOT OPERATED................................541 M-25 WINDOW WASHER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WINDOW WASHER IS ACTUATED WHEN SWITCH IS NOT OPERATED......................546 M-26 ELECTRIC GREASE GUN DOES NOT WORK (MACHINES EQUIPPED WITH ELECTRIC GREASE GUN)............................................................549 30 DISASSEMBLY AND ASSEMBLY................................................................................................................................550 METHOD OF USING MANUAL.................................................................................................................................552 PRECAUTIONS WHEN CARRYING OUT OPERATION................................................................................................................555 SPECIAL TOOL LIST......................................................................................................................................557 SKETCHES OF SPECIAL TOOLS..............................................................................................................................564 FUEL SUPPLY PUMP.......................................................................................................................................567 REMOVAL............................................................................................................................................567 INSTALLATION.......................................................................................................................................569 FUEL INJECTOR..........................................................................................................................................570 REMOVAL............................................................................................................................................570 INSTALLATION.......................................................................................................................................572 NOZZLE TIP.............................................................................................................................................574 REMOVAL............................................................................................................................................574 INSTALLATION.......................................................................................................................................575 ENGINE FRONT SEAL......................................................................................................................................577 REMOVAL AND INSTALLATION...........................................................................................................................577 ENGINE REAR SEAL.......................................................................................................................................579 REMOVAL............................................................................................................................................579 INSTALLATION.......................................................................................................................................580 CYLINDER HEAD ASSEMBLY.................................................................................................................................584 REMOVAL............................................................................................................................................584 INSTALLATION.......................................................................................................................................587 AFTERCOOLER CORE.......................................................................................................................................591 REMOVAL, INSTALLATION..............................................................................................................................591 FAN GUARD, RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY.....................................................................................................592 REMOVAL............................................................................................................................................592 INSTALLATION.......................................................................................................................................594 FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY.....................................................................................................595 REMOVAL, INSTALLATION..............................................................................................................................595 FUEL TANK ASSEMBLY.....................................................................................................................................596 REMOVAL............................................................................................................................................596 INSTALLATION.......................................................................................................................................597 ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY................................................................................................................598 REMOVAL............................................................................................................................................598 INSTALLATION.......................................................................................................................................602 PTO ASSEMBLY...........................................................................................................................................603 REMOVAL............................................................................................................................................603 INSTALLATION.......................................................................................................................................604 PTO ASSEMBLY...........................................................................................................................................605 DISASSEMBLY........................................................................................................................................605 ASSEMBLY...........................................................................................................................................606 FINAL DRIVE ASSEMBLY...................................................................................................................................609 DISASSEMBLY........................................................................................................................................609 ASSEMBLY...........................................................................................................................................614 REVOLVING FRAME ASSEMBLY...............................................................................................................................622 REMOVAL............................................................................................................................................622 INSTALLATION.......................................................................................................................................623 SWING MACHINERY ASSEMBLY...............................................................................................................................624 REMOVAL, INSTALLATION..............................................................................................................................624 SWING MACHINERY ASSEMBLY...............................................................................................................................625 DISASSEMBLY........................................................................................................................................625 ASSEMBLY...........................................................................................................................................629 SWING CIRCLE ASSEMBLY..................................................................................................................................634 REMOVAL, INSTALLATION..............................................................................................................................634 TRACK SHOE ASSEMBLY....................................................................................................................................635 REMOVAL............................................................................................................................................635 INSTALLATION.......................................................................................................................................636 ONE LINK IN FIELD......................................................................................................................................637 DISASSEMBLY........................................................................................................................................637 ASSEMBLY...........................................................................................................................................639 IDLER ASSEMBLY.........................................................................................................................................641 REMOVAL, INSTALLATION..............................................................................................................................641 IDLER ASSEMBLY.........................................................................................................................................642 DISASSEMBLY........................................................................................................................................642 ASSEMBLY...........................................................................................................................................644 IDLER ADJUSTMENT CYLINDER ASSEMBLY.....................................................................................................................646 DISASSEMBLY, ASSEMBLY..............................................................................................................................646 RECOIL SPRING ASSEMBLY.................................................................................................................................647 REMOVAL, INSTALLATION..............................................................................................................................647 RECOIL SPRING ASSEMBLY.................................................................................................................................649 DISASSEMBLY........................................................................................................................................649 ASSEMBLY...........................................................................................................................................650 CARRIER ROLLER ASSEMBLY................................................................................................................................651 REMOVAL, INSTALLATION..............................................................................................................................651 CARRIER ROLLER ASSEMBLY................................................................................................................................652 DISASSEMBLY........................................................................................................................................652 ASSEMBLY...........................................................................................................................................653 TRACK ROLLER ASSEMBLY..................................................................................................................................654 REMOVAL, INSTALLATION..............................................................................................................................654 TRACK ROLLER ASSEMBLY..................................................................................................................................655 DISASSEMBLY........................................................................................................................................655 ASSEMBLY...........................................................................................................................................656 HYDRAULIC TANK ASSEMBLY................................................................................................................................658 REMOVAL............................................................................................................................................658 INSTALLATION.......................................................................................................................................660 MAIN PUMP (NO. 1 PUMP) ASSEMBLY........................................................................................................................661 REMOVAL............................................................................................................................................661 INSTALLATION.......................................................................................................................................662 MAIN PUMP (NO. 2 PUMP) ASSEMBLY........................................................................................................................663 REMOVAL............................................................................................................................................663 INSTALLATION.......................................................................................................................................664 MAIN PUMP INPUT SHAFT OIL SEAL.........................................................................................................................665 REMOVAL, INSTALLATION..............................................................................................................................665 CONTROL・PTO LUBRICATION PUMP ASSEMBLY..................................................................................................................666 REMOVAL, INSTALLATION..............................................................................................................................666 MAIN RELIEF VALVE ASSEMBLY.............................................................................................................................667 DISASSEMBLY, ASSEMBLY..............................................................................................................................667 CONTROL VALVE ASSEMBLY.................................................................................................................................668 REMOVAL............................................................................................................................................668 INSTALLATION.......................................................................................................................................670 DISASSEMBLY........................................................................................................................................671 ASSEMBLY...........................................................................................................................................673 SOLENOID VALVE ASSEMBLY................................................................................................................................675 REMOVAL............................................................................................................................................675 INSTALLATION.......................................................................................................................................676 BOOM DAMPING VALVE ASSEMBLY............................................................................................................................677 REMOVAL, INSTALLATION..............................................................................................................................677 SWING MOTOR ASSEMBLY...................................................................................................................................678 REMOVAL, INSTALLATION..............................................................................................................................678 CENTER SWIVEL JOINT ASSEMBLY...........................................................................................................................679 REMOVAL, INSTALLATION..............................................................................................................................679 CENTER SWIVEL JOINT ASSEMBLY...........................................................................................................................680 DISASSEMBLY, ASSEMBLY..............................................................................................................................680 TRAVEL MOTOR ASSEMBLY..................................................................................................................................681 REMOVAL, INSTALLATION..............................................................................................................................681 WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................................................................682 DISASSEMBLY........................................................................................................................................682 ASSEMBLY...........................................................................................................................................683 TRAVEL PPC VAVEL ASSEMBLY..............................................................................................................................684 DISASSEMBLY........................................................................................................................................684 ASSEMBLY...........................................................................................................................................685 BUCKET CYLINDER ASSEMBLY...............................................................................................................................686 REMOVAL............................................................................................................................................686 INSTALLATION.......................................................................................................................................688 ARM CYLINDER ASSEMBLY..................................................................................................................................690 REMOVAL............................................................................................................................................690 INSTALLATION.......................................................................................................................................692 BOOM CYLINDER ASSEMBLY.................................................................................................................................694 REMOVAL............................................................................................................................................694 INSTALLATION.......................................................................................................................................696 BOTTOM DUMP CYLINDER ASSEMBLY..........................................................................................................................698 REMOVAL............................................................................................................................................698 INSTALLATION.......................................................................................................................................699 HYDRAULIC CYLINDER ASSEMBLY............................................................................................................................700 DISASSEMBLY........................................................................................................................................700 ASSEMBLY...........................................................................................................................................702 BUCKET ASSEMBLY........................................................................................................................................705 REMOVAL............................................................................................................................................705 INSTALLATION.......................................................................................................................................707 ARM ASSEMBLY...........................................................................................................................................709 REMOVAL............................................................................................................................................709 INSTALLATION.......................................................................................................................................711 BOOM ASSEMBLY..........................................................................................................................................713 REMOVAL............................................................................................................................................713 INSTALLATION.......................................................................................................................................715 WORK EQUIPMENT ASSEMBLY................................................................................................................................717 REMOVAL............................................................................................................................................717 INSTALLATION.......................................................................................................................................719 OPERATOR'S CAB ASSEMBLY................................................................................................................................721 REMOVAL............................................................................................................................................721 INSTALLATION.......................................................................................................................................722 COUNTERWEIGHT ASSEMBLY.................................................................................................................................723 REMOVAL, INSTALLATION..............................................................................................................................723 90 OTHERS..................................................................................................................................................724 HYDRAULIC CIRCUIT DRAWING (BACKHOE SPECIFICATION)......................................................................................................725 HYDRAULIC CIRCUIT DRAWING (LOADING SHOVEL SPECIFICATION)...............................................................................................726 ELECTRIC CIRCUIT DIAGRAM (1/4).........................................................................................................................727 ELECTRIC CIRCUIT DIAGRAM (2/4).........................................................................................................................728 ELECTRIC CIRCUIT DIAGRAM (3/4).........................................................................................................................729 ELECTRIC CIRCUIT DIAGRAM (4/4).........................................................................................................................730
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]
