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KOMATSU PC750SE-7K PC750LC-7K Service Repair Manual (UEBM002400) – PDF Download
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- KOMATSU PC750SE-7K PC750LC-7K Service Repair Manual
- PUBLICATION NUMBER:UEBM002400
- SERIAL NUMBER:PC750SE-7K 00 K40001 AND UP 00
PC750LC-7K 00 K40001 AND UP
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Description
KOMATSU PC750SE-7K PC750LC-7K Service Repair Manual (UEBM002400)
KOMATSU PC750SE-7K PC750LC-7K SERVICE REPAIR MANUAL (UEBM002400) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC750SE-7K PC750LC-7K Service Repair Manual (UEBM002400)
- 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-7K PC750LC-7K Service Repair Manual (UEBM002400)
Foreword.pdf.................................................................................................... 0 SAFETY...................................................................................................... 3 SAFETY NOTICE........................................................................................... 3 IMPORTANT SAFETY NOTICE............................................................................. 3 GENERAL PRECAUTIONS................................................................................. 3 PREPARATIONS FOR WORK............................................................................... 3 PRECAUTIONS DURING WORK............................................................................. 4 FOREWORD.................................................................................................... 5 GENERAL................................................................................................. 5 STRUCTURE AND FUNCTION.............................................................................. 5 TESTING AND ADJUSTING............................................................................... 5 DISASSEMBLY AND ASSEMBLY............................................................................ 5 MAINTENANCE STANDARD................................................................................ 5 OTHERS.............................................................................................. 5 HOW TO READ THE SHOP MANUAL............................................................................. 6 VOLUMES............................................................................................. 6 DISTRIBUTION AND UPDATING........................................................................... 6 FILING METHOD....................................................................................... 6 REVISED EDITION MARK................................................................................ 6 REVISIONS........................................................................................... 6 SYMBOLS............................................................................................. 6 HOISTING INSTRUCTIONS................................................................................... 7 HOISTING............................................................................................ 7 WIRE ROPES.......................................................................................... 7 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.............................................. 8 Disconnection....................................................................................... 8 Connection.......................................................................................... 8 COATING MATERIALS....................................................................................... 10 STANDARD TIGHTENING TORQUE.............................................................................. 12 STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)......................................... 12 TABLE OF TIGHTENING TORQUES FOR FLARED NUTS......................................................... 12 TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS.................................................. 13 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS........................................... 13 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS................................................... 13 TIGHTENING TORQUE FOR 102 ENGINE SERIES (BOLT AND NUTS)............................................. 14 TIGHTENING TORQUE FOR 102 ENGINE SERIES (EYE JOINTS)................................................ 14 TIGHTENING TORQUE FOR 102 ENGINE SERIES (TAPERED SCREWS)............................................ 14 ELECTRIC WIRE CODE...................................................................................... 15 CLASSIFICATION BY THICKNESS......................................................................... 15 CLASSIFICATION BY COLOR AND CODE.................................................................... 15 CONVERSION TABLE........................................................................................ 16 METHOD OF USING THE CONVERSION TABLE................................................................ 16 EXAMPLE............................................................................................. 16 Millimeters to inches............................................................................... 16 Millimeters to Inches............................................................................... 17 Kilogram to Pound................................................................................... 17 Liter to U.S. Gallon................................................................................ 18 Liter to U.K. Gallon................................................................................ 18 kgm to ft. lb....................................................................................... 19 kg/cm2 to lb/in2.................................................................................... 20 Temperature......................................................................................... 21 UNITS................................................................................................... 22 Example:............................................................................................ 22 01.pdf.......................................................................................................... 0 01 GENERAL.................................................................................................. 23 SPECIFICATION DRAWINGS.................................................................................. 24 SPECIFICATIONS.......................................................................................... 26 WEIGHT TABLE............................................................................................ 31 FUEL, COOLANT AND LUBRICANTS............................................................................ 33 10.pdf.......................................................................................................... 0 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD............................................................. 35 PTO..................................................................................................... 36 PTO LUBRICATION SYSTEM.................................................................................. 37 POWER TRAIN............................................................................................. 38 SWING MACHINERY......................................................................................... 40 SWING CIRCLE............................................................................................ 42 FINAL DRIVE............................................................................................. 44 TRACK FRAME AND RECOIL SPRING........................................................................... 46 IDLER................................................................................................... 48 CARRIER ROLLER.......................................................................................... 50 TRACK ROLLER............................................................................................ 51 TRACK SHOE.............................................................................................. 52 MOTOR GREASE PUMP....................................................................................... 57 HYDRAULIC TANK.......................................................................................... 58 HYDRAULIC PUMP.......................................................................................... 60 RETURN OIL FILTER....................................................................................... 90 LINE OIL FILTER......................................................................................... 91 PILOT OIL FILTER........................................................................................ 91 DRAIN OIL FILTER........................................................................................ 92 L.H. 5-SPOOL CONTROL VALVE.............................................................................. 94 R.H. 4-SPOOL CONTROL VALVE..............................................................................100 STRAIGHT-TRAVEL VALVE...................................................................................106 SWING MOTOR.............................................................................................109 CENTER SWIVEL JOINT.....................................................................................114 TRAVEL MOTOR............................................................................................115 PPC CONTROL RELIEF VALVE................................................................................125 PPC ACCUMULATOR.........................................................................................126 VALVE CONTROL...........................................................................................127 WORK EQUIPMENT, SWING PPC VALVE.........................................................................128 TRAVEL PPC VALVE........................................................................................134 SOLENOID VALVE..........................................................................................138 HYDRAULIC CYLINDER......................................................................................144 WORK EQUIPMENT..........................................................................................146 DIMENSIONS OF WORK EQUIPMENT............................................................................148 AIR CONDITIONER.........................................................................................150 ENGINE CONTROL..........................................................................................151 MACHINE CONTROL SYSTEM..................................................................................157 MONITOR SYSTEM..........................................................................................186 SENSORS.................................................................................................201 20.pdf.......................................................................................................... 0 20 TESTING AND ADJUSTING....................................................................................205 STANDARD VALUE TABLE FOR ENGINE.........................................................................204 STANDARD VALUE TABLE FOR CHASSIS........................................................................207 20_101.pdf...................................................................................................... 0 TESTING AND ADJUSTING.......................................................................................217 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING........................................................ 36 MEASURING ENGINE SPEED..................................................................................220 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)..........................................................221 MEASUREMENT OF EXHAUST GAS TEMPERATURE..................................................................222 MEASUREMENT OF EXHAUST GAS COLOR........................................................................223 ADJUSTING VALVE CLEARANCE...............................................................................224 MEASURING COMPRESSION PRESSURE..........................................................................204 MEASURING BLOW-BY PRESSURE..............................................................................227 MEASURING ENGINE OIL PRESSURE...........................................................................228 HANDLING OF FUEL SYSTEM EQUIPMENT.......................................................................229 REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT....................................................229 MEASUREMENT OF FUEL PRESSURE............................................................................230 AIR BLEEDING FROM FUEL CIRCUIT..........................................................................231 INSPECTION OF LEAKAGE FROM FUEL SYSTEM..................................................................233 ADJUSTING ENGINE SPEED SENSOR...........................................................................214 TESTING AND ADJUSTING FAN BELT TENSION..................................................................235 TESTING AND ADJUSTING ALTERNATOR BELT TENSION...........................................................236 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT...................................................237 INSPECTION OF SWING CIRCLE BEARING CLEARANCE............................................................238 TESTING AND ADJUSTING TRACK SHOE TENSION................................................................239 TESTING AND ADJUSTING WORK EQUIPMENT, SWING, AND TRAVEL CIRCUIT OIL PRESSURES...........................240 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE......................................................245 TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE......................................................213 INSPECTION OF SERVO PISTON STROKE.......................................................................252 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE................................................................253 MEASURING OUTLET PRESSURES OF SOLENOID VALVE, SWING PPC SHUTTLE VALVE, AND SWING PRIORITY SELECTO.......256 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...............................................................261 TESTING AND ADJUSTING TRAVEL DEVIATION..................................................................262 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT............................................264 MEASURING OIL LEAKAGE...................................................................................265 RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT.....................................................269 BLEEDING AIR FROM EACH PART.............................................................................270 INSPECTION PROCEDURES FOR DIODE.........................................................................273 SPECIAL FUNCTION OF MONITOR PANEL.......................................................................274 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT.........................................................301 PREPARATION WORK........................................................................................302 20_101A.pdf..................................................................................................... 0 Pm-CLINIC SERVICE...........................................................................................304 Positions to install measuring devices (Related to engine and PTO)......................................218 Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)...............307 Pm-CLINIC SERVICE PC750 (LC, SE)............................................................................310 Arm.....................................................................................................310 1. Arm cylinder bracket.................................................................................310 2. Arm foot.............................................................................................310 3. Arm top boss.........................................................................................310 Boom....................................................................................................310 4. Boom top bracket.....................................................................................310 5. Boom cylinder bracket................................................................................310 6. Arm cylinder bracket.................................................................................310 7. Boom lower plate.....................................................................................310 8. Boom foot............................................................................................310 Revolving frame.........................................................................................310 9. Boom bracket.........................................................................................310 Track frame.............................................................................................310 10. Circle bracket......................................................................................310 11. Track frame mounting section........................................................................310 Visual check of welded structures (For PC750SE-7).......................................................311 Arm.................................................................................................311 1. Arm cylinder bracket.............................................................................311 2. Arm foot.........................................................................................311 3. Arm top boss.....................................................................................311 Boom................................................................................................311 4. Boom top bracket.................................................................................311 5. Boom cylinder bracket............................................................................311 6. Arm cylinder bracket.............................................................................311 7. Boom lower plate.................................................................................311 8. Boom foot........................................................................................311 Revolving frame.....................................................................................311 9. Boom bracket.....................................................................................311 Track frame.........................................................................................311 10. Circle bracket..................................................................................311 11. Track frame mounting section....................................................................311 UNDERCARRIAGE INSPECTION....................................................................................312 (Program form No.: ***************).....................................................................312 20_201.pdf...................................................................................................... 0 TROUBLESHOOTING.............................................................................................217 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................314 SEQUENCE OF EVENTS IN TROUBLESHOOTING...................................................................310 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE........................................................316 CHECKS BEFORE TROUBLESHOOTING...........................................................................324 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING............................................................325 Classification of troubleshooting...................................................................281 Steps for troubleshooting...........................................................................281 Failure-looking Phenomenon and Troubleshooting No...................................................326 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM.......................................329 Connector table.....................................................................................329 Connector Location Stereogram.......................................................................334 Monitor Panel System Circuit Diagram (M Circuit)....................................................340 Engine Control System Circuit Diagram (E Ciruit)....................................................342 Pump Controller System Circuit Diagram (P Circuit)..................................................344 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..............................................................346 T-BRANCH BOX AND T-BRANCH TABLE.........................................................................368 20_301.pdf...................................................................................................... 0 TROUBLESHOOTING WHEN ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE DISP...........371 BEFORE CARRYING OUT TROUBLESHOOTING OF DISPLAYED CODE...................................................287 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................376 Error Code in Electrical System E112 (Wiper Drive (For) S/C)............................................378 Error Code in Electrical System E113 (Wiper Drive (Rev) S/C)............................................382 Error Code in Electrical System E114 (Washer Drive S/C).................................................384 Error Code in Electrical System E115 (Wiper Working Abnormality)........................................386 Error Code in Electrical System E116 (Wiper Parking Abnormality)........................................388 Error Code in Electrical System E117 (Eng. Controller S-NET Comm Err.)..................................392 Error Code in Electrical System E118 (Pump Controller S-NET Comm Err.)..................................394 Error Code in Electrical System E128 (Monitor Comm. Abnormality)........................................396 Error Code in Electrical System E201 (CO Cancel Sol. S/C)...............................................398 Error Code in Electrical System E202 (Travel Junction Sol. S/C).........................................400 Error Code in Electrical System E203 (Swing Brake Sol. S/C).............................................402 Error Code in Electrical System E204 (2-stage Relief Sol. S/C)..........................................404 Error Code in Electrical System E205 (Swing Priority Sol. S/C)..........................................406 Error Code in Electrical System E206 (Travel Speed Sol. S/C)............................................408 Error Code in Electrical System E207 (Flash Light Relay S/C)............................................410 Error Code in Electrical System E211 (CO Cancel Sol. Disc.).............................................412 Error Code in Electrical System E212 (Travel Junction Sol. Disc.).......................................414 Error Code in Electrical System E213 (Swing Brake Sol. Disc.)...........................................416 Error Code in Electrical System E214 (2-stage Relief Sol. Disc.)........................................418 Error Code in Electrical System E215 (Swing Priority Sol. Disc.)........................................420 Error Code in Electrical System E216 (Travel Speed Sol. Disc.)..........................................422 Error Code in Electrical System E217 (Model selection Abnormality)......................................424 Error Code in Electrical System E218 (S-Net Comm. Disc.)................................................426 Error Code in Electrical System E221 (Travel Alarm S/C).................................................428 Error Code in Electrical System E224 (F Pump P. Sensor Abnormality).....................................430 Error Code in Electrical System E225 (R Pump P. Sensor Abnormality).....................................432 Error Code in Electrical System E226 (Press. Sensor Power Abnormality)..................................434 Error Code in Electrical System E227 (Engine Speed Sensor Abnormality)..................................436 Error Code in Electrical System E232 (TVC Sol. S/C).....................................................438 Error Code in Electrical System E233 (TVC Sol. Disc.)...................................................440 Error Code in Electrical System E257 (Pump Comm. Abnormality)...........................................442 Error Code in Electrical System E302 (Step Light Relay S/C).............................................444 Error Code in Electrical System E304 (Step Light Power Hold Relay S/C)..................................446 Error Code in Electrical System E315 (Battery Relay Drive S/C)..........................................448 Error Code in Electrical System E91B (Engine Ne sensor problem).........................................450 Error Code in Electrical System E91C (Engine G sensor problem)..........................................451 Error Code in Electrical System E920 (Engine type selection error)......................................452 Error Code in Electrical System E921 (Engine type mismatch).............................................454 Error Code in Electrical System E931 (Fuel dial sys. error).............................................456 Error Code in Electrical System E934 (Engine coolant sensor Hi error)...................................458 Error Code in Electrical System E936 (Engine oil press. sw. error)......................................460 Error Code in Electrical System E93C (Engine boost sensor error)........................................462 Error Code in Electrical System E93D (Engine fuel temp. sensor error)...................................464 Error Code in Electrical System E953 (Engine Comm. Abnormality).........................................466 Error Code in Electrical System E954 (Short engine starter sw.).........................................468 Error Code in Electrical System E955 (Engine S-NET error)...............................................470 Error Code in Electrical System E956 (Engine power failure (1)).........................................472 Error Code in Electrical System E957 (Engine power failure (2)).........................................474 Error Code in Electrical System E95A (Engine Q-adj. sw. signal error)...................................476 Error Code in Electrical System E96A (Engine coolant sensor Lo error)...................................478 Error Code in Electrical System E970 (PCV1 over current)................................................480 Error Code in Electrical System E971 (PCV2 over current)................................................482 Error Code in Electrical System E974 (PCV1 line cut)....................................................484 Error Code in Electrical System E975 (PCV2 line cut)....................................................486 Error Code in Electrical System E977 (Rail press. sensor error).........................................488 Error Code in Electrical System E979 (Rail press. high).................................................490 Error Code in Electrical System E97A (Rail press. abnormal).............................................490 Error Code in Electrical System E97B (Rail press. low)..................................................491 Error Code in Electrical System E97C (Rail press. too low)..............................................493 Error Code in Electrical System E97D (Rail press. out of control).......................................493 Error Code in Electrical System E980 (Eng. Controller Abnormality)......................................494 Error Code in Electrical System E981 (Fuel Injector 1 Disc.)............................................496 Error Code in Electrical System E982 (Fuel Injector 2 Disc.)............................................497 Error Code in Electrical System E983 (Fuel Injector 3 Disc.)............................................498 Error Code in Electrical System E984 (Fuel Injector 4 Disc.)............................................499 Error Code in Electrical System E985 (Fuel Injector 5 Disc.)............................................500 Error Code in Electrical System E986 (Fuel Injector 6 Disc.)............................................501 Error Code in Electrical System E98A (Fuel Injector 1 – 3 S/C)..........................................502 Error Code in Electrical System E98B (Fuel Injector 4 – 6 S/C)..........................................504 Failure Code in Mechanical System A000N1 (Eng. Hi Out of Std)...........................................507 Failure Code in Mechanical System AA10NX (Aircleaner Clogging)..........................................508 Failure Code in Mechanical System AB00KE (Charge Voltage Low)...........................................510 Failure Code in Mechanical System B@BAZG (Eng. Oil Press. Low)..........................................512 Failure Code in Mechanical System B@BAZK (Eng. Oil Level Low)...........................................514 Failure Code in Mechanical System B@BCNS (Eng. Water Overheat)..........................................515 Failure Code in Mechanical System B@BCZK (Eng. Water Lvl Low)...........................................516 Failure Code in Mechanical System B@HANS (Hydr. Oil Overheat)...........................................518 Failure Code in Mechanical System DA80MA (Auto. Lub Abnormal.)..........................................520 20_501.pdf...................................................................................................... 0 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...............................................................371 BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)............................................................287 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..........................................................524 E-1 Engine does not start (Engine does not rotate)......................................................378 E-2 Preheater does not operate..........................................................................528 E-3 Auto engine warm-up device does not work............................................................530 E-4 Auto-decelerator does not operate...................................................................531 E-5 All work equipment, swing and travel do not move....................................................532 E-6 Machine push-up function does not operate normally..................................................534 E-7 Boom shockless function does not operate normally...................................................536 E-8 Any item is not displayed on monitor panel..........................................................538 E-9 Part of display on monitor panel is missing.........................................................539 E-10 Monitor panel displays contents irrelevant to the model............................................539 E-11 Fuel level monitor red lamp lights up while engine is running......................................540 E-12 Engine water thermometer does not display normally.................................................542 E-13 Hydraulic oil temperature gauge does not display correctly.........................................544 E-14 Fuel gauge does not display correctly..............................................................545 E-15 Swing lock monitor does not display correctly......................................................546 E-16 When monitor switch is operated, nothing is displayed..............................................548 E-17 Windshield wiper and window washer do not work.....................................................550 E-18 Alarming buzzer cannot be cancelled................................................................558 E-19 "Boom RAISE" is not correctly displayed in monitor function........................................559 E-20 "Boom LOWER" is not correctly displayed in monitor function........................................560 E-21 "Arm IN" is not correctly displayed in monitor function............................................561 E-22 "Arm OUT" is not correctly displayed in monitor function...........................................562 E-23 "Bucket CURL" is not correctly displayed in monitor function.......................................563 E-24 "Bucket DUMP" is not correctly displayed in monitor function.......................................564 E-25 "SWING" is not correctly displayed in monitor function.............................................566 E-26 "Left travel" is not displayed normally in monitoring function.....................................568 E-27 "Right travel" is not displayed normally in monitoring function....................................570 E-28 "Service" is not correctly displayed in monitor function...........................................572 E-29 Air conditioner does not work......................................................................574 E-30 Step light does not light up or go off.............................................................575 E-31 Electric grease gun does not operate...............................................................580 E-32 Travel alarm does not sound or does not stop sounding..............................................582 20_601.pdf...................................................................................................... 0 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).................................................371 BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)....................................586 INFORMATION IN TROUBLESHOOTING TABLE....................................................................591 H-1 Speed or power of all work equipment, travel, and swing is low......................................378 H-2 Engine speed lowers remarkably or engine stalls.....................................................594 H-3 All work equipment, travel, and swing systems do not work...........................................530 H-4 Abnormal sound is heard from around pump............................................................596 H-5 Boom speed or power is low..........................................................................531 H-6 Speed or power of arm is low........................................................................599 H-7 Speed or power of bucket is low.....................................................................600 H-8 Boom does not move..................................................................................601 H-9 Arm does not move...................................................................................601 H-10 Bucket does not move...............................................................................601 H-11 Hydraulic drift of work equipment is large.........................................................602 H-12 Time lag of work equipment is large................................................................604 H-13 Heavy lift function does not operate or stop.......................................................605 H-14 Machine push-up function does not operate or stop..................................................605 H-15 Boom shockless function cannot be turned ON or OFF.................................................605 H-16 Machine deviates in one direction..................................................................606 H-17 Machine deviates largely at start..................................................................608 H-18 Machine deviates largely during compound operation.................................................609 H-19 Travel speed or power is low.......................................................................609 H-20 Machine does not travel (only one track)...........................................................610 H-21 Travel speed does not change.......................................................................611 H-22 Upper structure does not swing.....................................................................612 H-23 Swing speed or acceleration is low.................................................................613 H-24 Swing speed or acceleration is low during compound operation of swing and work equipment...........614 H-25 Upper structure overruns excessively when it stops swinging........................................616 H-26 Large shock is made when upper structure stops swinging............................................617 H-27 Large abnormal sound is made when upper structure stops swinging...................................618 H-28 Hydraulic drift of swing is large..................................................................619 20_701.pdf...................................................................................................... 0 TROUBLESHOOTING OF ENGINE (S MODE)..........................................................................371 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................622 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................623 S-1 Starting performance is poor (starting always takes time)...........................................626 S-2 Engine does not start...............................................................................627 S-3 Engine does not pick up smoothly (follow-up is poor)................................................630 S-4 Engine stops during operations......................................................................631 S-5 Engine does not rotate smoothly (hunting)...........................................................632 S-6 Engine lacks output (or lacks power)................................................................633 S-7 Exhaust smoke is black (incomplete combustion)......................................................634 S-8 Oil consumption is excessive (or exhaust smoke is blue).............................................635 S-9 Oil becomes contaminated quickly....................................................................636 S-10 Fuel consumption is excessive......................................................................637 S-11 Oil is in cooling water (or water spurts back, or water level goes down)...........................638 S-12 Oil pressure caution lamp lights up (drop in oil pressure).........................................639 S-13 Oil level rises (water, fuel in oil)...............................................................640 S-14 Water temperature becomes too high (overheating)...................................................641 S-15 Abnormal noise is made.............................................................................642 S-16 Vibration is excessive.............................................................................643 30.pdf.......................................................................................................... 0 30 DISASSEMBLY AND ASSEMBLY.................................................................................645 METHOD OF USING MANUAL..................................................................................647 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................649 SPECIAL TOOL LIST.......................................................................................651 REMOVAL AND INSTALLATION OF AFTERCOOLER CORE............................................................658 REMOVAL AND INSTALLATION OF FAN GUARD, RADIATOR AND HYDRAULIC OIL COOLER ASSEMBLY.......................659 REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER CONDENSER ASSEMBLY..........................662 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY..........................................................663 REMOVAL AND INSTALLATION OF ENGINE, PTO AND HYDRAULIC PUMP ASSEMBLY.....................................664 REMOVAL AND INSTALLATION OF PTO ASSEMBLY................................................................668 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY................................................................670 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY........................................................673 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY....................................................684 REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY....................................................685 DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY....................................................686 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY.......................................................693 REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY.........................................................694 DISASSEMBLY AND ASSEMBLY OF ONE LINK IN FIELD...........................................................696 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY..............................................................700 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY..............................................................701 DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY..........................................704 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY......................................................705 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY......................................................707 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY.....................................................709 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY.....................................................710 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY.......................................................713 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY.......................................................714 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY.....................................................717 REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 1 PUMP) ASSEMBLY.............................................719 REMOVAL AND INSTALLATION OF MAIN PUMP (NO. 2 PUMP)......................................................721 REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL..............................................723 REMOVAL AND INSTALLATION OF CONTROL AND PTO LUBRICATION PUMP ASSEMBLY...................................724 DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY..................................................725 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY......................................................726 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (WORK EQUIPMENT).....................................729 REMOVAL AND INSTALLATION OF SOLENOID VALVE ASSEMBLY.....................................................732 REMOVAL AND INSTALLATION OF BOOM DAMPING VALVE ASSEMBLY.................................................734 REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY........................................................735 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT.........................................................737 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY................................................738 REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY.......................................................740 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY...........................................741 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY...................................................743 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY....................................................745 REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY....................................................747 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY.......................................................749 REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY.......................................................751 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY......................................................753 REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY......................................................755 REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY...............................................757 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................758 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY.............................................................764 REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY.............................................................765 REMOVAL AND INSTALLATION OF ARM ASSEMBLY................................................................766 REMOVAL AND INSTALLATION OF ARM ASSEMBLY................................................................768 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY...............................................................770 REMOVAL AND INSTALLATION OF BOOM ASSEMBLY...............................................................772 REMOVAL AND INSTALLATION OF WORK EQUIPMENT..............................................................774 REMOVAL AND INSTALLATION OF WORK EQUIPMENT..............................................................776 REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY.....................................................778 REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)..........................................780 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY.......................................................790 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY......................................................796 90.pdf.......................................................................................................... 0 90 OTHERS................................................................................................... 23 90-01.pdf....................................................................................................... 0 HYDRAULIC CIRCUIT DIAGRAM...................................................................................801 ELECTRICAL CIRCUIT DIAGRAM (1/5)............................................................................803 ELECTRICAL CIRCUIT DIAGRAM (2/5)............................................................................805 ELECTRICAL CIRCUIT DIAGRAM (3/5)............................................................................807 ELECTRICAL CIRCUIT DIAGRAM (4/5)............................................................................809 ELECTRICAL CIRCUIT DIAGRAM (5/5)............................................................................811
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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Austin Brian –