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Komatsu PC750SE-6K, PC750LC-6K Hydraulic Excavator Shop Manual K32001 and up – PDF DOWNLOAD
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Komatsu PC750SE-6K, PC750LC-6K Hydraulic Excavator Shop Manual
Book Code: UEBM001801
MACHINE MODEL SERIAL NUMBER
PC750SE-6 K32001 and up
PC750LC-6 K32001 and up
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Description
Komatsu PC750SE-6K, PC750LC-6K Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC750SE-6K, PC750LC-6K Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC750SE-6K, PC750LC-6K
Serial Number: K32001 and up
Book Code: UEBM001801
Language: English
Pages: 701
File Format: Portable Document Format (PDF)
KOMATSU PC750SE-6K, PC750LC-6K HYDRAULIC EXCAVATOR SHOP MANUAL K32001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PC750SE-6K, PC750LC-6K Hydraulic Excavator Shop Manual
FOREWORD:
GENERAL:
- 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 PC750SE-6K, PC750LC-6K Hydraulic Excavator Shop Manual
GENERAL .......................................................................................................................................................................................................................................................................... 29 SPECIFICATION DRAWINGS ....................................................................................................................................................................................................................................................... 30 FUEL, COOLANT AND LUBRICANTS ................................................................................................................................................................................................................................................. 38 PTO .............................................................................................................................................................................................................................................................................. 40 PTO LUBRICATION SYSTEM ........................................................................................................................................................................................................................................................... 41 POWER TRAIN SWING MACHINERY SWING CIRCLE ......................................................................................................................................................................................................................................... 46 FINAL DRIVE ...................................................................................................................................................................................................................................................................... 48 TRACK FRAME AND RECOIL SPRING .................................................................................................................................................................................................................................................... 50 IDLER CARRIER ROLLER ............................................................................................................................................................................................................................................................. 54 TRACK ROLLER ..................................................................................................................................................................................................................................................................... 55 TRACK SHOE ( 1/ 2) ............................................................................................................................................................................................................................................................... 56 ( 2/ 2) .......................................................................................................................................................................................................................................................................... 58 MOTOR GREASE PUMP ................................................................................................................................................................................................................................................................ 61 HYDRAULIC TANK ................................................................................................................................................................................................................................................................... 62 HYDRAULIC PUMP ................................................................................................................................................................................................................................................................... 64 LINE OIL FILTER .................................................................................................................................................................................................................................................................. 94 PILOT OIL FILTER ................................................................................................................................................................................................................................................................. 94 DRAIN OIL FILTER ................................................................................................................................................................................................................................................................. 95 L. H. 5- SPOOL CONTROL VALVE ..................................................................................................................................................................................................................................................... 96 R. H. 4- SPOOL CONTROL VALVE .....................................................................................................................................................................................................................................................102 STRAIGHT- TRAVEL VALVE ...........................................................................................................................................................................................................................................................108 SWING MOTOR ......................................................................................................................................................................................................................................................................111 CENTER SWIVEL JOINT ..............................................................................................................................................................................................................................................................116 TRAVEL MOTOR .....................................................................................................................................................................................................................................................................117 PPC CONTROL RELIEF VALVE .........................................................................................................................................................................................................................................................127 SAFETY LOCK VALVE ................................................................................................................................................................................................................................................................128 PPC ACCUMULATOR ..................................................................................................................................................................................................................................................................129 VALVE CONTROL ....................................................................................................................................................................................................................................................................130 WORK EQUIPMENT, SWING PPC VALVE ..................................................................................................................................................................................................................................................131 TRAVEL PPC VALVE .................................................................................................................................................................................................................................................................136 SOLENOID VALVE ...................................................................................................................................................................................................................................................................140 HYDRAULIC CYLINDER ...............................................................................................................................................................................................................................................................146 WORK EQUIPMENT ...................................................................................................................................................................................................................................................................150 DIMENSIONS OF WORK EQUIPMENT .....................................................................................................................................................................................................................................................154 AIR CONDITIONER ..................................................................................................................................................................................................................................................................158 ENGINE CONTROL ...................................................................................................................................................................................................................................................................159 MACHINE CONTROL SYSTEM ...........................................................................................................................................................................................................................................................164 MONITOR SYSTEM ...................................................................................................................................................................................................................................................................192 SENSORS ..........................................................................................................................................................................................................................................................................199 TESTING AND ADJUSTING ............................................................................................................................................................................................................................................................203 STANDARD VALUE TABLE FOR ENGINE ..............................................................................................................................................................................................................................................204 STANDARD VALUE TABLE FOR CHASSIS .............................................................................................................................................................................................................................................205 STANDARD VALUE TABLE FOR ELECTRICAL PARTS ........................................................................................................................................................................................................................................214 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ................................................................................................................................................................................................................................227 MEASURING AIR SUPPLY PRESSURE ( BOOST PRESSURE) ..................................................................................................................................................................................................................................230 MEASURING EXHAUST TEMPERATURE ....................................................................................................................................................................................................................................................231 MEASURING EXHAUST COLOR ..........................................................................................................................................................................................................................................................232 ADJUSTING VALVE CLEARANCE ........................................................................................................................................................................................................................................................233 MEASURING BLOW- BY PRESSURE ......................................................................................................................................................................................................................................................234 MEASURING COMPRESSION PRESSURE ...................................................................................................................................................................................................................................................234 MEASURING ENGINE OIL PRESSURE ....................................................................................................................................................................................................................................................235 HANDLING EQUIPMENT IN FUEL CIRCUIT ...............................................................................................................................................................................................................................................236 RELEASING REMAINING PRESSURE IN FUEL SYSTEM ......................................................................................................................................................................................................................................236 MEASURING FUEL PRESSURE ..........................................................................................................................................................................................................................................................237 REDUCED CYLINDER MODE OPERATION FOR ENGINE .......................................................................................................................................................................................................................................238 BLEEDING AIR FROM FUEL CIRCUIT ...................................................................................................................................................................................................................................................240 CHECKING FOR LEAKAGE IN FUEL CIRCUIT .............................................................................................................................................................................................................................................242 TESTING AND ADJUSTING ALTERNATOR BELT TENSION ....................................................................................................................................................................................................................................243 TESTING AND ADJUSTING FAN BELT TENSION ...........................................................................................................................................................................................................................................244 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR DRIVE BELT TENSION ..............................................................................................................................................................................................................245 HANDLING ENGINE CONTROL- LER HIGH VOLTAGE CIRCUIT ................................................................................................................................................................................................................................246 ADJUSTING ENGINE SPEED SENSOR ....................................................................................................................................................................................................................................................247 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT ................................................................................................................................................................................................248 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE ..........................................................................................................................................................................................................................251 TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE ...............................................................................................................................................................................................................................253 MEASURING SERVO PISTON STROKE ....................................................................................................................................................................................................................................................259 MEASURING PPC VALVE OUT- PUT PRESSURE ............................................................................................................................................................................................................................................260 TESTING SOLENOID VALVE OUTPUT PRESSURE ...........................................................................................................................................................................................................................................261 ADJUSTING WORK EQUIP- MENT, SWING PPC VALVE ......................................................................................................................................................................................................................................262 TESTING TRAVEL DEVIATION .........................................................................................................................................................................................................................................................263 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ......................................................................................................................................................................................................................266 MEASURING OIL LEAKAGE ............................................................................................................................................................................................................................................................267 TESTING CLEARANCE OF SWING CIRCLE BEARING ........................................................................................................................................................................................................................................272 TESTING AND ADJUSTING TRACK SHOE TENSION .........................................................................................................................................................................................................................................273 BLEEDING AIR .....................................................................................................................................................................................................................................................................274 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ................................................................................................................................................................................................................................276 PROCEDURE FOR CHECKING DIODE .....................................................................................................................................................................................................................................................277 POINTS TO REMEMBER WHEN TROUBLESHOOTING ..........................................................................................................................................................................................................................................280 SEQUENCE OF EVENTS IN TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE CHECKS BEFORE TROUBLESHOOTING .............................................................................................................................................................290 CONNECTOR TYPES AND MOUNTING LOCATIONS ...........................................................................................................................................................................................................................................291 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .......................................................................................................................................................................................................................................298 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM ...........................................................................................................................................................................................................................321 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL ............................................................................................................................................................................................................................322 METHOD OF USING JUDGEMENT TABLE ..................................................................................................................................................................................................................................................337 METHOD OF USING TROUBLESHOOTING CHARTS ...........................................................................................................................................................................................................................................339 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE .........................................................................................................................................................................................................................340 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE .......................................................................................................................................................................................................346 N- 1 [ E117, E118 occur at same time ] Monitor panel communication abnormality ...................................................................................................................................................................................................349 N- 2 [ E117, E218 occur at same time ] Engine controller communication abnormality ...............................................................................................................................................................................................351 N- 3 [ E118, E955 occur at same time ] Pump controller communication abnormality .................................................................................................................................................................................................353 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED .................................................................................................................................................................................................356 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED .................................................................................................................................................................................................356 E- 1 [ E91b ] ( Abnormality in engine speed Ne sensor system) is displayed .......................................................................................................................................................................................................368 E- 2 [ E91C ] ( Abnormality in engine G rotation sensor system) is displayed .....................................................................................................................................................................................................369 E- 3 [ E920 ] ( Abnormality in model selection system) is displayed ..............................................................................................................................................................................................................370 E- 4 [ E922 ] ( Engine overrun) is displayed .....................................................................................................................................................................................................................................371 E- 5 [ E924 ] ( Drop in engine oil pressure) is displayed ........................................................................................................................................................................................................................372 E- 6 [ E931 ] ( Abnormality in fuel control dial sensor system) is displayed .....................................................................................................................................................................................................373 E- 7 [ E934 ] ( Abnormality in engine water high- temperature sensor system) is displayed ........................................................................................................................................................................................374 E- 8 [ E936 ] ( Abnormality in engine oil pressure switch system) is displayed ...................................................................................................................................................................................................375 E- 9 [ E93C ] ( Abnormality in boost pressure sensor system) is displayed ........................................................................................................................................................................................................377 E- 10 [ E93d ] ( Abnormality in fuel temperature sensor system) is displayed .....................................................................................................................................................................................................378 E- 11 [ E954 ] ( Short circuit in starting switch C system) is displayed .........................................................................................................................................................................................................379 12 [ E955 ] ( Abnormality in network system) is displayed ........................................................................................................................................................................................................................379 E- 13 [ E956 ] ( Power source system abnormality 1) is displayed .................................................................................................................................................................................................................380 E- 14 [ E957 ] ( Power source system abnormality 2) is displayed .................................................................................................................................................................................................................382 15 [ E95A ] ( Abnormality in fuel injection amount adjustment switch signal) is displayed ........................................................................................................................................................................................382 E- 16 [ E96A ] ( Abnormality in engine water low- temperature sensor system) is displayed ........................................................................................................................................................................................383 E- 17 [ E970 ] ( Excess current in fuel supply pump PCV1 system) is displayed ....................................................................................................................................................................................................384 E- 18 [ E971 ] ( Excess current in fuel supply pump PCV2 system) is displayed ....................................................................................................................................................................................................385 E- 19 [ E974 ] ( Disconnection in fuel supply pump PCV1 system) is displayed .....................................................................................................................................................................................................386 E- 20 [ E975 ] ( Disconnection in fuel supply pump PCV2 system) is displayed .....................................................................................................................................................................................................387 E- 21 [ E977 ] ( Abnormality in common rail fuel pressure sensor system) is displayed ............................................................................................................................................................................................388 E- 22 [ E979 ] ( Common rail fuel high pressure abnormality 1) is displayed [ E97A ] ( Common rail fuel high pressure abnormality 2) is displayed ................................................................................................................................389 E- 23 [ E97b ] ( Fuel supply pump non- force feed 1) is displayed [ E97C ] ( Fuel supply pump non- force feed 2) is displayed ....................................................................................................................................................390 E- 24 [ E97d ] ( Abnormality in common rail fuel pressure) is displayed ..........................................................................................................................................................................................................392 E- 25 [ E980 ] ( Defective engine controller) is displayed .......................................................................................................................................................................................................................392 E- 26 [ E981 ] ( Disconnection in No. 1 fuel injector system) is displayed .......................................................................................................................................................................................................393 E- 27 [ E982 ] ( Disconnection in No. 2 fuel injector system) is displayed .......................................................................................................................................................................................................394 E- 28 [ E983 ] ( Disconnection in No. 3 fuel injector system) is displayed .......................................................................................................................................................................................................395 E- 29 [ E984 ] ( Disconnection in No. 4 fuel injector system) is displayed .......................................................................................................................................................................................................396 E- 30 [ E985 ] ( Disconnection in No. 5 fuel injector system) is displayed .......................................................................................................................................................................................................397 E- 31 [ E986 ] ( Disconnection in No. 6 fuel injector system) is displayed .......................................................................................................................................................................................................398 E- 32 [ E98A ] ( Short circuit in No. 1, No. 2, No. 3 fuel injector system) is displayed .........................................................................................................................................................................................399 E- 33 [ E98b ] ( Short circuit in No. 3, No. 4, No. 5 fuel injector system) is displayed .........................................................................................................................................................................................403 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM ( C MODE) ..............................................................................................................................................................................................................................407 POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM ....................................................................................................................................................................................................................408 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ...................................................................................................................................................................................................410 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS ..............................................................................................................................................................................................................418 POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM ........................................................................................................................................................................................................................408 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE .......................................................................................................................................................................................................410 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS ..................................................................................................................................................................................................................418 C- 1 Abnormality in controller power source system ( controller LED is OFF) ......................................................................................................................................................................................................422 C- 1 Related electrical circuit diagram ......................................................................................................................................................................................................................................422 TROUBLESHOOTING C- 2 .........................................................................................................................................................................................................................................................423 C- 2 [ E232 ] Short circuit in pump TVC solenoid system is displayed .............................................................................................................................................................................................................423 TROUBLESHOOTING C- 2 C- 2 Related electrical circuit diagram TROUBLESHOOTING C- 3 ............................................................................................................................................................................................425 C- 3 [ E233 ] Disconnection in pump TVC solenoid system is displayed .............................................................................................................................................................................................................425 TROUBLESHOOTING C- 3 C- 3 Related electrical circuit diagram TROUBLESHOOTING C- 4 ............................................................................................................................................................................................427 C- 4 [ E203 ] Short circuit in swing holding brake solenoid system is displayed ..................................................................................................................................................................................................427 TROUBLESHOOTING C- 4 C- 4 Related electrical circuit diagram TROUBLESHOOTING C- 5 ............................................................................................................................................................................................429 C- 5 [ E213 ] Disconnection in swing holding brake solenoid system is displayed ..................................................................................................................................................................................................429 TROUBLESHOOTING C- 5 C- 5 Related electrical circuit diagram TROUBLESHOOTING C- 6 ............................................................................................................................................................................................431 C- 6 [ E201 ] Short circuit in CO cancel solenoid system is displayed ............................................................................................................................................................................................................431 C- 6 Related electrical circuit diagram ......................................................................................................................................................................................................................................431 TROUBLESHOOTING C- 7 .........................................................................................................................................................................................................................................................432 C- 7 [ E211 ] Disconnection in CO cancel solenoid system is displayed ............................................................................................................................................................................................................432 C- 7 Related electrical circuit diagram ......................................................................................................................................................................................................................................432 TROUBLESHOOTING C- 8 .........................................................................................................................................................................................................................................................433 C- 8 [ E202 ] Short circuit in straight- travel solenoid system is displayed .....................................................................................................................................................................................................433 C- 8 Related electrical circuit diagram ......................................................................................................................................................................................................................................433 TROUBLESHOOTING C- 9 .........................................................................................................................................................................................................................................................434 C- 9 [ E212 ] Disconnection in straight- travel solenoid system is displayed .....................................................................................................................................................................................................434 C- 9 Related electrical circuit diagram ......................................................................................................................................................................................................................................434 TROUBLESHOOTING C- 10 ........................................................................................................................................................................................................................................................435 C- 10 [ E204 ] Short circuit in 2- stage relief solenoid system is displayed .....................................................................................................................................................................................................435 C- 10 Related electrical circuit diagram .....................................................................................................................................................................................................................................435 TROUBLESHOOTING C- 11 ........................................................................................................................................................................................................................................................436 C- 11 [ E214 ] Disconnection in 2- stage relief solenoid system is displayed .....................................................................................................................................................................................................436 C- 11 Related electrical circuit diagram .....................................................................................................................................................................................................................................436 TROUBLESHOOTING C- 12 ........................................................................................................................................................................................................................................................437 C- 12 [ E205 ] Short circuit in swing priority selector solenoid system is displayed .............................................................................................................................................................................................437 C- 12 Related electrical circuit diagram .....................................................................................................................................................................................................................................437 TROUBLESHOOTING C- 13 ........................................................................................................................................................................................................................................................438 C- 13 [ E211 ] Disconnection in swing priority selector solenoid system is displayed .............................................................................................................................................................................................438 C- 13 Related electrical circuit diagram .....................................................................................................................................................................................................................................438 TROUBLESHOOTING C- 14 ........................................................................................................................................................................................................................................................439 C- 14 [ E206 ] Short circuit in travel speed solenoid system is displayed ........................................................................................................................................................................................................439 C- 14 Related electrical circuit diagram .....................................................................................................................................................................................................................................439 TROUBLESHOOTING C- 15 ........................................................................................................................................................................................................................................................440 C- 15 [ E216 ] Disconnection in travel speed solenoid system is displayed ........................................................................................................................................................................................................440 C- 15 Related electric circuit diagram .......................................................................................................................................................................................................................................440 TROUBLESHOOTING C- 16 ........................................................................................................................................................................................................................................................441 C- 16 [ E217 ] Model selection input error is displayed ..........................................................................................................................................................................................................................441 TROUBLESHOOTING C- 16 C- 16 Related electrical circuit diagram TROUBLESHOOTING C- 17 .........................................................................................................................................................................................443 C- 17 [ E227 ] Abnormality in engine speed sensor system is displayed ............................................................................................................................................................................................................443 C- 17 Related electrical circuit diagram .....................................................................................................................................................................................................................................443 TROUBLESHOOTING C- 18 ........................................................................................................................................................................................................................................................444 C- 18 Abnormality in machine push- up solenoid system ( no service code displayed) ...............................................................................................................................................................................................444 a) Even when machine push- up switch is set to low pressure, solenoid is not switched ON .....................................................................................................................................................................................444 C- 19 Related electrical circuit diagram .....................................................................................................................................................................................................................................444 TROUBLESHOOTING C- 18 b) Even when machine push- up switch is set to high pressure, solenoid is not switched OFF .............................................................................................................................................................445 C- 18 Related electrical circuit diagram .....................................................................................................................................................................................................................................445 TROUBLESHOOTING C- 19 ........................................................................................................................................................................................................................................................446 C- 19 Abnormality in shockless boom solenoid system ( no service code displayed) .................................................................................................................................................................................................446 a) Shockless mode cannot be canceled ( solenoid is not switched ON) ..........................................................................................................................................................................................................446 TROUBLESHOOTING C- 19 C- 19 Related electrical circuit diagram ...............................................................................................................................................................................................................447 TROUBLESHOOTING C- 19 ........................................................................................................................................................................................................................................................448 b) Shockless mode is not actuated ............................................................................................................................................................................................................................................448 C- 19 Related electric circuit diagram TROUBLESHOOTING C- 20 C- 20 Related electrical circuit diagram ........................................................................................................................................................................449 C- 20 [ E207 ] Short circuit in flash light relay drive system is displayed ......................................................................................................................................................................................................449 TROUBLESHOOTING C- 21 ........................................................................................................................................................................................................................................................450 C- 21 Flash light relay does not work ............................................................................................................................................................................................................................................450 C- 21 Related electrical circuit diagram .....................................................................................................................................................................................................................................450 TROUBLESHOOTING C- 22 ........................................................................................................................................................................................................................................................451 C- 22 [ E231 ] Abnormality ( short circuit) in power source holding relay output system for step light is displayed ..............................................................................................................................................................451 C- 22 Related electrical circuit diagram .....................................................................................................................................................................................................................................451 TROUBLESHOOTING C- 23 ........................................................................................................................................................................................................................................................452 C- 23 Step light switch does not work ............................................................................................................................................................................................................................................452 C- 23 Related electrical circuit diagram .....................................................................................................................................................................................................................................452 TROUBLESHOOTING C- 24 ........................................................................................................................................................................................................................................................453 C- 24 [ E302 ] Short circuit in step light relay drive system is displayed .......................................................................................................................................................................................................453 C- 24 Related electrical circuit diagram .....................................................................................................................................................................................................................................453 TROUBLESHOOTING C- 25 ........................................................................................................................................................................................................................................................454 C- 25 [ 303 ] Disconnection in step light relay drive system is displayed ........................................................................................................................................................................................................454 C- 25 Related electrical circuit diagram .....................................................................................................................................................................................................................................454 TROUBLESHOOTING C- 26 ........................................................................................................................................................................................................................................................455 C- 26 Step light does not light up ...............................................................................................................................................................................................................................................455 C- 26 Related electrical circuit diagram .....................................................................................................................................................................................................................................455 TROUBLESHOOTING C- 27 ........................................................................................................................................................................................................................................................456 C- 27 [ E228 ] Abnormality in auto- deceleration output system is displayed ......................................................................................................................................................................................................456 C- 27 Related electrical circuit diagram .....................................................................................................................................................................................................................................456 TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER ( INPUT SIGNAL SYSTEM) ( F MODE) ............................................................................................................................................................................................457 F- 1 [ Bit pattern 20- ( 1) ] Swing oil pressure switch does not light up ........................................................................................................................................................................................................460 TROUBLESHOOTING F- 2 F- 2 Related electrical circuit diagram .................................................................................................................................................................................................................461 F- 2 [ Bit pattern 20- ( 2) ] R. H. travel oil pressure switch does not light up .................................................................................................................................................................................................461 F- 3 Related electrical circuit diagram TROUBLESHOOTING F- 3 .................................................................................................................................................................................................................462 F- 3 [ Bit pattern 20- ( 3) ] Boom LOWER oil pressure switch does not light up ...................................................................................................................................................................................................462 TROUBLESHOOTING F- 4 F- 4 Related electrical circuit diagram .................................................................................................................................................................................................................463 F- 4 [ Bit pattern 20- ( 4) ] Boom RAISE oil pressure switch does not light up ...................................................................................................................................................................................................463 F- 5 Related electrical circuit diagram TROUBLESHOOTING F- 5 .................................................................................................................................................................................................................464 F- 5 [ Bit pattern 20- ( 5) ] Arm IN oil pressure switch does not light up .......................................................................................................................................................................................................464 TROUBLESHOOTING F- 6 F- 6 Related electrical circuit diagram .................................................................................................................................................................................................................465 F- 6 [ Bit pattern 20- ( 6) ] Arm OUT oil pressure switch does not light up ......................................................................................................................................................................................................465 F- 7 Related electrical circuit diagram TROUBLESHOOTING F- 7 .................................................................................................................................................................................................................466 F- 7 [ Bit pattern 21- ( 1) ] Bucket CURL oil pressure switch does not light up ..................................................................................................................................................................................................466 TROUBLESHOOTING F- 8 F- 8 Related electrical circuit diagram .................................................................................................................................................................................................................467 F- 8 [ Bit pattern 21- ( 2) ] Bucket DUMP oil pressure switch does not light up ..................................................................................................................................................................................................467 F- 9 Related electrical circuit diagram TROUBLESHOOTING F- 9 .................................................................................................................................................................................................................468 F- 9 [ Bit pattern 20- ( 5) ] L. H. travel oil pressure switch does not light up .................................................................................................................................................................................................468 TROUBLESHOOTING F- 10 F- 10 Related electrical circuit diagram ...............................................................................................................................................................................................................469 F- 10 [ Bit pattern 21- ( 4) ] Service oil pressure switch does not light up .....................................................................................................................................................................................................469 F- 11 Related electrical circuit diagram TROUBLESHOOTING F- 11 ...............................................................................................................................................................................................................470 F- 11 [ Bit pattern 21- ( 3) ] Swing lock switch does not light up ...............................................................................................................................................................................................................470 TROUBLESHOOTING F- 12 F- 12 Related electrical circuit diagram ...............................................................................................................................................................................................................471 F- 12 [ Bit pattern 24- ( 1) ] When step light switch is ON, it does not go out ..................................................................................................................................................................................................471 F- 13 Related electrical circuit diagram TROUBLESHOOTING F- 13 ...............................................................................................................................................................................................................472 F- 13 [ Bit pattern 24- ( 2) ] When horn switch is ON, it does not go out ........................................................................................................................................................................................................472 TABLE OF FAILURE MODES AND CAUSES ................................................................................................................................................................................................................................................474 TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES ............................................................................................................................................................................................................................475 BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM ( H MODE) ................................................................................................................................................................................................................476 1. Actuation and combination of main pumps ...................................................................................................................................................................................................................................476 2. Judgement procedure .......................................................................................................................................................................................................................................................476 BEFORE CARRYING OUT TROUBLESHOOTING TROUBLESHOOTING OF HYDRAULIC SYSTEM ( H MODE) ............................................................................................................................................................................................476 BEFORE CARRYING OUT TROUBLESHOOTING TROUBLESHOOTING OF HYDRAULIC SYSTEM ( H MODE) TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM ( H MODE) Hydraulic circuit diagram after interchanging hoses Method of interchanging hoses TROUBLESHOOTING ....479 TROUBLESHOOTING H- 2 .........................................................................................................................................................................................................................................................480 TROUBLESHOOTING H- 2 .........................................................................................................................................................................................................................................................481 TROUBLESHOOTING H- 3 .........................................................................................................................................................................................................................................................482 H- 3 Related circuit diagram .................................................................................................................................................................................................................................................482 TROUBLESHOOTING H- 4, H- 5 ...................................................................................................................................................................................................................................................483 TROUBLESHOOTING H- 6 .........................................................................................................................................................................................................................................................484 a) If work equipment speed ( boom, arm, bucket) is slow or lacks power in normal mode ........................................................................................................................................................................................484 TROUBLESHOOTING H- 6 b) If boom RAISE speed is slow or lacks power in heavy lift mode ........................................................................................................................................................................................485 c) If boom LOWER speed is slow or lacks power when machine push- up is ON TROUBLESHOOTING H- 7, H- 8 .........................................................................................................................................................................486 TROUBLESHOOTING H- 9, H- 10, H- 11 ...........................................................................................................................................................................................................................................487 TROUBLESHOOTING H- 12 ........................................................................................................................................................................................................................................................488 TROUBLESHOOTING H- 13 ........................................................................................................................................................................................................................................................489 a) Direction of deviation is same in FORWARD and REVERSE .....................................................................................................................................................................................................................489 TROUBLESHOOTING H- 13 b) Direction of deviation is different in FORWARD and REVERSE ..........................................................................................................................................................................................490 TROUBLESHOOTING H- 14 ........................................................................................................................................................................................................................................................491 TROUBLESHOOTING H- 14, H- 15 .................................................................................................................................................................................................................................................492 TROUBLESHOOTING H- 16, H- 17 .................................................................................................................................................................................................................................................493 TROUBLESHOOTING H- 18 ........................................................................................................................................................................................................................................................494 TROUBLESHOOTING H- 18 ........................................................................................................................................................................................................................................................495 TROUBLESHOOTING H- 19 ........................................................................................................................................................................................................................................................496 TROUBLESHOOTING H- 19, H- 20 .................................................................................................................................................................................................................................................497 TROUBLESHOOTING H- 21 ........................................................................................................................................................................................................................................................498 TROUBLESHOOTING H- 22 ........................................................................................................................................................................................................................................................499 TROUBLESHOOTING H- 23 ........................................................................................................................................................................................................................................................500 TROUBLESHOOTING H- 24 ........................................................................................................................................................................................................................................................501 TROUBLESHOOTING H- 25 ........................................................................................................................................................................................................................................................502 a) When swing holding brake is released ......................................................................................................................................................................................................................................502 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ....................................................................................................................................................................................................504 M- 1 [ E101 ] ( Abnormality in error data) or [ E102 ] ( Abnormality in clock data) is displayed .............................................................................................................................................................................508 M- 2 [ E103 ] ( Short circuit in buzzer output system) is displayed ..........................................................................................................................................................................................................509 M- 3 [ E104 ] ( Air cleaner clogging detection) is displayed .................................................................................................................................................................................................................510 M- 4 [ E108 ] ( Engine water temperature 105 .................................................................................................................................................................................................................................510 C) is displayed ..............................................................................................................................................................................................................................................................510 M- 5 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds ................................................................................................................................................................................511 M- 6 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out ............................................................................................................................................................................513 M- 7 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine ..................................................................................................................................................................513 M- 8 When starting switch is turned ON ( engine stopped) , basic check items flash ...........................................................................................................................................................................................514 M- 9 Preheating is not being used but preheating display motor lamp lights up ................................................................................................................................................................................................517 M- 10 When engine is started, basic check items flash ........................................................................................................................................................................................................................518 M- 11 When starting switch is turned ON ( engine stopped) , CAUTION items and EMERGENCY STOP items flash .....................................................................................................................................................................519 M- 12 When engine is started, CAUTION items and EMERGENCY STOP items flash ...................................................................................................................................................................................................520 M- 13 Operation of alarm buzzer is not normal ................................................................................................................................................................................................................................524 M- 14 Night lighting on monitor panel does not light up ......................................................................................................................................................................................................................526 M- 15 Engine water temperature display is not normal .........................................................................................................................................................................................................................527 M- 16 Fuel level gauge display is not normal .................................................................................................................................................................................................................................528 M- 17 Swing lock switch is turned ON but swing lock monitor lamp does not light up ...........................................................................................................................................................................................530 M- 18 When swing brake release switch is set to RELEASE ( EMERGENCY) , swing lock monitor lamp does not flash ................................................................................................................................................................531 M- 19 Service meter does not give normal display .............................................................................................................................................................................................................................532 M- 20 Defective fuel level sensor system .....................................................................................................................................................................................................................................533 M- 21 Defective engine oil level sensor system ...............................................................................................................................................................................................................................534 M- 22 Defective coolant level sensor system ..................................................................................................................................................................................................................................535 M- 23 Defective hydraulic oil level sensor system ............................................................................................................................................................................................................................536 M- 24 Wiper is not actuated when wiper switch is operated or wiper is actuated when wiper switch is not operated .............................................................................................................................................................537 M- 25 Window washer is not actuated when wiper switch is operated or window washer is actuated when switch is not operated ...................................................................................................................................................542 M- 26 Electric grease gun does not work ( machines equipped with electric grease gun) ........................................................................................................................................................................................545 METHOD OF USING MANUAL ...........................................................................................................................................................................................................................................................548 1. When removing or installing unit assemblies ...............................................................................................................................................................................................................................548 2. ...........................................................................................................................................................................................................................................................................548 3. Listing of special tools ..................................................................................................................................................................................................................................................548 A1 ...........................................................................................................................................................................................................................................................................548 DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL ..............................................................................................................................................................................................................................549 6. Tightening torque of split flange bolts ...................................................................................................................................................................................................................................549 5. Tightening torque of hose nuts ............................................................................................................................................................................................................................................549 4. Standard tightening torques of bolts and nuts DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL .............................................................................................................................................................................550 7. Tightening torque of O- ring boss connector ...............................................................................................................................................................................................................................550 8. Tightening torque of O- ring boss connector ...............................................................................................................................................................................................................................550 DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION .............................................................................................................................................................................................................551 PRECAUTIONS WHEN CARRYING OUT OPERATION ..........................................................................................................................................................................................................................................551 1. Precautions when carrying out removal work ................................................................................................................................................................................................................................551 SPECIAL TOOL LIST ................................................................................................................................................................................................................................................................553 SKETCHES OF SPECIAL TOOLS ........................................................................................................................................................................................................................................................560 REMOVAL OF AFTERCOOLER CORE ......................................................................................................................................................................................................................................................562 INSTALLATION OF AFTERCOOLER CORE .................................................................................................................................................................................................................................................562 REMOVAL OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY .................................................................................................................................................................................................................563 INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY ............................................................................................................................................................................................................565 Water Filling ..............................................................................................................................................................................................................................................................565 Filling ( Hydraulic Tank) with Oil .........................................................................................................................................................................................................................................565 Filling of Air Conditioner Gas .............................................................................................................................................................................................................................................565 Alignment of Engine Pulley and Fan Pulley ..................................................................................................................................................................................................................................565 Filling ( Fuel Tank) with Diesel Fuel ......................................................................................................................................................................................................................................565 REMOVAL OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY ....................................................................................................................................................................................................................566 INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY ...............................................................................................................................................................................................................566 REMOVAL OF FUEL TANK ASSEMBLY ....................................................................................................................................................................................................................................................567 INSTALLATION OF FUEL TANK ASSEMBLY ...............................................................................................................................................................................................................................................568 REMOVAL OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY ...............................................................................................................................................................................................................................569 INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY ..........................................................................................................................................................................................................................573 Water Filling ..............................................................................................................................................................................................................................................................573 Air Bleeding ...............................................................................................................................................................................................................................................................573 REMOVAL OF PTO ASSEMBLY ..........................................................................................................................................................................................................................................................574 INSTALLATION OF PTO ASSEMBLY .....................................................................................................................................................................................................................................................575 DISASSEMBLY OF PTO ASSEMBLY ......................................................................................................................................................................................................................................................576 1. Cover .....................................................................................................................................................................................................................................................................576 2. Gear assembly .............................................................................................................................................................................................................................................................576 3. Removal of bearing ........................................................................................................................................................................................................................................................576 ASSEMBLY OF PTO ASSEMBLY .........................................................................................................................................................................................................................................................577 1. Bearings ..................................................................................................................................................................................................................................................................577 2. Outer race at case end ....................................................................................................................................................................................................................................................577 3. Nipples, plug .............................................................................................................................................................................................................................................................577 4. Gears .....................................................................................................................................................................................................................................................................577 DISASSEMBLY OF FINAL DRIVE ASSEMBLY ..............................................................................................................................................................................................................................................580 ASSEMBLY OF FINAL DRIVE ASSEMBLY .................................................................................................................................................................................................................................................585 REMOVAL OF REVOLVING FRAME ASSEMBLY ..............................................................................................................................................................................................................................................593 INSTALLATION OF REVOLVING FRAME ASSEMBLY .........................................................................................................................................................................................................................................594 REMOVAL OF SWING MACHINERY ASSEMBLY ..............................................................................................................................................................................................................................................595 INSTALLATION OF SWING MACHINERY ASSEMBLY .........................................................................................................................................................................................................................................595 DISASSEMBLY OF SWING MACHINERY ASSEMBLY ..........................................................................................................................................................................................................................................596 ASSEMBLY OF SWING MACHINERY ASSEMBLY .............................................................................................................................................................................................................................................600 REMOVAL OF SWING CIRCLE ASSEMBLY .................................................................................................................................................................................................................................................605 INSTALLATION OF SWING CIRCLE ASSEMBLY ............................................................................................................................................................................................................................................605 REMOVAL OF TRACK SHOE ASSEMBLY ...................................................................................................................................................................................................................................................606 INSTALLATION OF TRACK SHOE ASSEMBLY ..............................................................................................................................................................................................................................................607 DISASSEMBLY OF ONE LINK IN FIELD .................................................................................................................................................................................................................................................608 FIELD ASSEMBLY OF ONE LINK .......................................................................................................................................................................................................................................................610 REMOVAL OF IDLER ASSEMBLY ........................................................................................................................................................................................................................................................612 INSTALLATION OF IDLER ASSEMBLY ...................................................................................................................................................................................................................................................612 DISASSEMBLY OF IDLER ASSEMBLY ....................................................................................................................................................................................................................................................613 ASSEMBLY OF IDLER ASSEMBLY .......................................................................................................................................................................................................................................................615 DISASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY ................................................................................................................................................................................................................................617 ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY ...................................................................................................................................................................................................................................617 REMOVAL OF RECOIL SPRING ASSEMBLY ................................................................................................................................................................................................................................................618 INSTALLATION OF RECOIL SPRING ASSEMBLY ...........................................................................................................................................................................................................................................618 DISASSEMBLY OF RECOIL SPRING ASSEMBLY ............................................................................................................................................................................................................................................620 ASSEMBLY OF RECOIL SPRING ASSEMBLY ...............................................................................................................................................................................................................................................621 REMOVAL OF CARRIER ROLLER ASSEMBLY ...............................................................................................................................................................................................................................................622 INSTALLATION OF CARRIER ROLLER ASSEMBLY ..........................................................................................................................................................................................................................................622 DISASSEMBLY OF CARRIER ROLLER ASSEMBLY ...........................................................................................................................................................................................................................................623 ASSEMBLY OF CARRIER ROLLER ASSEMBLY ..............................................................................................................................................................................................................................................624 REMOVAL OF TRACK ROLLER ASSEMBLY .................................................................................................................................................................................................................................................625 INSTALLATION OF TRACK ROLLER ASSEMBLY ............................................................................................................................................................................................................................................625 DISASSEMBLY OF TRACK ROLLER ASSEMBLY .............................................................................................................................................................................................................................................626 ASSEMBLY OF TRACK ROLLER ASSEMBLY ................................................................................................................................................................................................................................................627 REMOVAL OF HYDRAULIC TANK ASSEMBLY ...............................................................................................................................................................................................................................................629 INSTALLATION OF HYDRAULIC TANK ASSEMBLY ..........................................................................................................................................................................................................................................631 REMOVAL OF MAIN PUMP ( NO. 1 PUMP) ASSEMBLY ......................................................................................................................................................................................................................................632 INSTALLATION OF MAIN PUMP ( NO. 1 PUMP) ASSEMBLY .................................................................................................................................................................................................................................633 REMOVAL OF MAIN PUMP ( NO. 2 PUMP) ...............................................................................................................................................................................................................................................634 INSTALLATION OF MAIN PUMP ( NO. 2 PUMP) ASSEMBLY .................................................................................................................................................................................................................................635 REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL ........................................................................................................................................................................................................................................636 INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL ...................................................................................................................................................................................................................................636 REMOVAL OF CONTROL PTO LUBRICATION PUMP ASSEMBLY ...............................................................................................................................................................................................................................637 INSTALLATION OF CONTROL PTO LUBRICATION PUMP ASSEMBLY ..........................................................................................................................................................................................................................637 DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY ........................................................................................................................................................................................................................................638 ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY ...........................................................................................................................................................................................................................................638 REMOVAL OF CONTROL VALVE ASSEMBLY ................................................................................................................................................................................................................................................639 INSTALLATION OF CONTROL VALVE ASSEMBLY ...........................................................................................................................................................................................................................................641 DISASSEMBLY OF CONTROL VALVE ASSEMBLY ( WORK EQUIPMENT) ..........................................................................................................................................................................................................................643 ASSEMBLY OF CONTROL VALVE ASSEMBLY ( WORK EQUIPMENT) .............................................................................................................................................................................................................................645 REMOVAL OF SOLENOID VALVE ASSEMBLY ...............................................................................................................................................................................................................................................647 INSTALLATION OF SOLENOID VALVE ASSEMBLY ..........................................................................................................................................................................................................................................648 REMOVAL OF BOOM DAMPING VALVE ASSEMBLY ...........................................................................................................................................................................................................................................649 INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY ......................................................................................................................................................................................................................................649 REMOVAL OF SWING MOTOR ASSEMBLY ..................................................................................................................................................................................................................................................650 INSTALLATION OF SWING MOTOR ASSEMBLY .............................................................................................................................................................................................................................................650 REMOVAL OF CENTER SWIVEL JOINT ...................................................................................................................................................................................................................................................651 INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY .....................................................................................................................................................................................................................................651 DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY ......................................................................................................................................................................................................................................652 ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY .........................................................................................................................................................................................................................................652 REMOVAL OF TRAVEL MOTOR ASSEMBLY .................................................................................................................................................................................................................................................653 INSTALLATION OF TRAVEL MOTOR ASSEMBLY ............................................................................................................................................................................................................................................653 DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY .................................................................................................................................................................................................................................654 ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY ....................................................................................................................................................................................................................................655 DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY .........................................................................................................................................................................................................................................656 ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY ............................................................................................................................................................................................................................................657 REMOVAL OF BUCKET CYLINDER ASSEMBLY ..............................................................................................................................................................................................................................................658 INSTALLATION OF BUCKET CYLINDER ASSEMBLY .........................................................................................................................................................................................................................................660 REMOVAL OF ARM CYLINDER ASSEMBLY .................................................................................................................................................................................................................................................662 INSTALLATION OF ARM CYLINDER ASSEMBLY ............................................................................................................................................................................................................................................664 REMOVAL OF BOOM CYLINDER ASSEMBLY ................................................................................................................................................................................................................................................666 INSTALLATION OF BOOM CYLINDER ASSEMBLY ...........................................................................................................................................................................................................................................668 REMOVAL OF BOTTOM DUMP CYLINDER ASSEMBLY .........................................................................................................................................................................................................................................670 INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY ....................................................................................................................................................................................................................................671 DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY .......................................................................................................................................................................................................................................672 ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ..........................................................................................................................................................................................................................................674 REMOVAL OF BUCKET ASSEMBLY .......................................................................................................................................................................................................................................................677 INSTALLATION OF BUCKET ASSEMBLY ..................................................................................................................................................................................................................................................679 REMOVAL OF ARM ASSEMBLY ..........................................................................................................................................................................................................................................................681 INSTALLATION OF ARM ASSEMBLY .....................................................................................................................................................................................................................................................683 REMOVAL OF BOOM ASSEMBLY .........................................................................................................................................................................................................................................................685 INSTALLATION OF BOOM ASSEMBLY ....................................................................................................................................................................................................................................................687 REMOVAL OF WORK EQUIPMENT ........................................................................................................................................................................................................................................................689 INSTALLATION OF WORK EQUIPMENT ASSEMBLY ..........................................................................................................................................................................................................................................691 REMOVAL OF OPERATOR S CAB ASSEMBLY .............................................................................................................................................................................................................................................693 INSTALLATION OF OPERATOR S CAB ASSEMBLY ........................................................................................................................................................................................................................................694 REMOVAL OF COUNTERWEIGHT ASSEMBLY ................................................................................................................................................................................................................................................695 INSTALLATION OF COUNTERWEIGHT ASSEMBLY ...........................................................................................................................................................................................................................................695
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