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KOMATSU PC78MR-6 SERVICE REPAIR MANUAL (SN:1001 & UP) – PDF DOWNLOAD
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- KOMATSU PC78MR-6 SERVICE REPAIR MANUAL
- SERIAL NUMBER:1001 & UP
- PUBLICATION NUMBER:SEBM030604
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Description
KOMATSU PC78MR-6 SERVICE REPAIR MANUAL (SN:1001 & UP)
KOMATSU PC78MR-6 SERVICE REPAIR MANUAL (SN:1001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC78MR-6 SERVICE REPAIR MANUAL (SN:1001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and makejudge- ments. 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 under- standing 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 com- ponent, as well as precautions for them. - MAINTENANCE STANDARD
This section gives thejudgment 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 PC78MR-6 SERVICE REPAIR MANUAL (SN:1001 & UP)
MAIN MENU......................................................................................................................................................................................................................... 0 COVER............................................................................................................................................................................................................................. 1 CONTENTS.......................................................................................................................................................................................................................... 2 SAFETY............................................................................................................................................................................................................................ 6 SAFETY NOTICE................................................................................................................................................................................................................. 6 FOREWARD.......................................................................................................................................................................................................................... 8 GENERAL....................................................................................................................................................................................................................... 8 HOW TO READ THE SHOP MANUAL................................................................................................................................................................................................... 9 HOISTING INSTRUCTIONS......................................................................................................................................................................................................... 10 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER.................................................................................................................................................................... 11 COATING MATERIALS............................................................................................................................................................................................................. 13 STANDARD TIGHTENING TORQUE.................................................................................................................................................................................................... 15 ELECTRIC WIRE CODE............................................................................................................................................................................................................ 18 CONVERSION TABLE.............................................................................................................................................................................................................. 19 UNITS......................................................................................................................................................................................................................... 25 01 GENERAL........................................................................................................................................................................................................................ 27 SPECIFICATION DIMENSIONS DRAWING.............................................................................................................................................................................................. 28 WORKING RANGE DRAWING......................................................................................................................................................................................................... 30 SPECIFICATIONS................................................................................................................................................................................................................ 31 WEIGHT TABLE.................................................................................................................................................................................................................. 34 LIST OF LUBRICANTS AND COOLANT................................................................................................................................................................................................ 36 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD................................................................................................................................................................................... 38 PTO .......................................................................................................................................................................................................................... 39 COOLING SYSTEM................................................................................................................................................................................................................ 40 POWER TRAIN SYSTEM............................................................................................................................................................................................................ 41 SWING CIRCLE.................................................................................................................................................................................................................. 42 SWING MACHINERY............................................................................................................................................................................................................... 43 TRACK FRAME AND IDLER CUSHION................................................................................................................................................................................................. 45 IDLER......................................................................................................................................................................................................................... 47 TRACK ROLLER.................................................................................................................................................................................................................. 48 CARRIER ROLLER................................................................................................................................................................................................................ 50 SPROCKET...................................................................................................................................................................................................................... 51 TRACK SHOE.................................................................................................................................................................................................................... 52 ARRANGEMENT OF HYDRAULIC COMPONENTS........................................................................................................................................................................................... 57 HYDRAULIC TANK AND OIL FILTER................................................................................................................................................................................................. 58 CENTER SWIVEL JOINT........................................................................................................................................................................................................... 59 TRAVEL MOTOR.................................................................................................................................................................................................................. 60 WORK EQUIPMENT CYLINDER....................................................................................................................................................................................................... 68 SOLENOID VALVE................................................................................................................................................................................................................ 72 SOLENOID VALVE (FOR EU SPEC.)................................................................................................................................................................................................. 80 ACCUMULATOR FOR PPC........................................................................................................................................................................................................... 84 MULTI-CONTROL VALVE........................................................................................................................................................................................................... 85 ACCUMULATOR FOR BRAKER........................................................................................................................................................................................................ 86 HYDRAULIC PUMP................................................................................................................................................................................................................ 87 CONTROL VALVE.................................................................................................................................................................................................................101 CLSS..........................................................................................................................................................................................................................113 SWING MOTOR...................................................................................................................................................................................................................145 WORK EQUIPMENT AND SWING PPC VALVE............................................................................................................................................................................................153 TRAVEL PPC VALVE..............................................................................................................................................................................................................159 BOOM SWING PPC VALVE, BLADE PPC VALVE.........................................................................................................................................................................................163 BOOM HYDRAULIC ANTI-BURST VALVE (FOR EU SPEC).................................................................................................................................................................................167 WORK EQUIPMENT................................................................................................................................................................................................................173 DIMENSIONS OF EACH PART OF WORK EQUIPMENT.....................................................................................................................................................................................175 AIR CONDITIONER PIPING (OPTIONAL).............................................................................................................................................................................................179 ELECTRIC CONTROL SYSTEM.......................................................................................................................................................................................................180 SYSTEM COMPONENTS.............................................................................................................................................................................................................200 MONITOR SYSTEM................................................................................................................................................................................................................209 SENSORS.......................................................................................................................................................................................................................214 20 TESTING AND ADJUSTING..........................................................................................................................................................................................................217 STANDARD VALUE TABLE FOR ENGINE...............................................................................................................................................................................................218 STANARD VALUE TABLE FOR CHASSIS...............................................................................................................................................................................................219 STANDARD VALUE TABLE FOR ELECTRIC PARTS.......................................................................................................................................................................................227 TESTING AND ADJUSTING.........................................................................................................................................................................................................233 LIST OF DEVICES FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...............................................................................................................................................................234 MEASURING ENGINE SPEED....................................................................................................................................................................................................235 MEASURING EXHAUST GAS COLOR...............................................................................................................................................................................................236 ADJUSTING VALVE CLEARANCE.................................................................................................................................................................................................237 MEASURING COMPRESSION PRESSURE............................................................................................................................................................................................238 MEASURING BLOW-BY PRESSURE................................................................................................................................................................................................239 TESTING AND ADJUSTING FUEL INJECTION TIMING...............................................................................................................................................................................240 MEASURING ENGINE OIL PRESSURE.............................................................................................................................................................................................244 ADJUSTING ENGINE STOP SOLENOID............................................................................................................................................................................................245 ADJUSTING FUEL CONTROL LINKAGE............................................................................................................................................................................................247 ADJUSTING ENGINE SPEED SENSOR.............................................................................................................................................................................................249 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS....................................................................................................................................250 MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE.................................................................................................................................................................253 ADJUSTING PC VALVE........................................................................................................................................................................................................255 TESTING TVC-EPC SOLENOID OUTPUT PRESSURE..................................................................................................................................................................................255 MEASURING CONTROL CIRCUIT PRESSURE........................................................................................................................................................................................256 MEASURING PPC VALVE OUTPUT PRESSURE.......................................................................................................................................................................................257 TESTING SOLENOID VALVE OUTPUT PRESSURE....................................................................................................................................................................................258 ADJUSTING WORK EQUIPMENT VALVE AND SWING PPC VALVE........................................................................................................................................................................260 TESTING TRAVEL DEVIATION..................................................................................................................................................................................................261 TESTING PARTS WHICH CAN CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT...........................................................................................................................................................263 MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTORS........................................................................................................................................................................264 RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT........................................................................................................................................................................265 TESTING CLEARANCE OF SWING CIRCLE BEARING.................................................................................................................................................................................266 TESTING AND ADJUSTING TRACK SHOE TENSION..................................................................................................................................................................................267 BLEEDING AIR FROM HYDRAULIC CIRCUIT.......................................................................................................................................................................................268 REPLACEMENT PROCEDURE OF POTENTIOMETERS...................................................................................................................................................................................270 PROCEDURE FOR TESTING DIODE...............................................................................................................................................................................................271 TROUBLESHOOTING...............................................................................................................................................................................................................273 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................................................................................................274 SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................................................................................................................................275 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..........................................................................................................................................................................276 CHECKS BEFORE TROUBLESHOOTING.............................................................................................................................................................................................284 TYPE AND LOCATION OF CONNECTORS...........................................................................................................................................................................................286 CONNECTOR ARRANGEMENT DIAGRAM.............................................................................................................................................................................................288 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................................................................................................................291 EXPLANATION OF FUNCTIONS OF ELECTRIC SYSTEM CONTROL MECHANISM.............................................................................................................................................................314 DISPLAY AND SPECIAL FUNCTIONS OF MONITOR PANEL............................................................................................................................................................................315 TVC VALVE CURRENT ADJUSTMENT TABLE........................................................................................................................................................................................326 METHOD OF USING JUDGEMENT TABLE...........................................................................................................................................................................................327 HOW TO READ FLOW OF TROUBLESHOOTING.......................................................................................................................................................................................329 CONTENTS AND PROCEDURE OF TROUBLESHOOTING.................................................................................................................................................................................331 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................................................................................................................................332 METHOD OF USING TROUBLESHOOTING CHART.................................................................................................................................................................................333 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).........................................................................................................................................................337 S-2 ENGINE DOES NOT START.............................................................................................................................................................................................339 1) ENGINE DOES NOT TURN...........................................................................................................................................................................................339 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).......................................................................................................................................340 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).....................................................................................................................................341 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)..............................................................................................................................................................342 S-4 ENGINE STOPS DURING OPERATIONS....................................................................................................................................................................................343 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).........................................................................................................................................................................344 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..............................................................................................................................................................................345 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....................................................................................................................................................................346 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...........................................................................................................................................................347 S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................................................................................................................348 S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................................................................................................................349 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..........................................................................................................................................350 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).......................................................................................................................................................351 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL).............................................................................................................................................................................352 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................................................................................................................................353 S-15 ABNORMAL NOISE IS MADE...........................................................................................................................................................................................354 S-16 VIBRATION IS EXCESSIVE...........................................................................................................................................................................................355 TROUBLESHOOTING OF COMMUNICATION SYSTEM (N MODE)..........................................................................................................................................................................356 N-1 DEFECTIVE COMMUNICATION...........................................................................................................................................................................................357 TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE).........................................................................................................................................................358 PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (GOVERNOR CONTROL SYSTEM)..............................................................................................................................................359 ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE................................................................................................................................................361 JUDGEMENT TABLE FOR CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE...................................................................................................................................................363 E-1 CONTROLLER POWER SUPPLY IS DEFECTIVE (LED OF CONTROLLER IS TURNED OFF)............................................................................................................................................365 E-2 [E323] (SHORT CIRCUIT IN ACCELERATOR RELAY SYSTEM) IS DISPLAYED...................................................................................................................................................366 E-3 [E325] (SHORT CIRCUIT IN DECELERATOR RELAY SYSTEM) IS DISPLAYED...................................................................................................................................................367 E-4 [E328] (STALL OF MOTOR) IS DISPLAYED..............................................................................................................................................................................368 E-5 [E227] (TROUBLE IN ENGINE SPEED SENSOR) IS DISPLAYED..............................................................................................................................................................370 E-6 ONE TOUCH SLOW DOWN MECHANISM DOES NOT WORK.......................................................................................................................................................................371 E-7 ENGINE DOES NOT START.............................................................................................................................................................................................372 a) [E304] SHORT CIRCUIT IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED.........................................................................................................................................372 b) [E314] DISCONNECTION IN ENGINE STOP SOLENOID RELAY SYSTEM IS DISPLAYED.........................................................................................................................................372 c) ENGINE STOP SOLENOID SYSTEM....................................................................................................................................................................................373 d) STARTING SYSTEM................................................................................................................................................................................................375 E-8 ENGINE DOES NOT STOP..............................................................................................................................................................................................379 TROUBLESHOOTING FOR CONTROLLER PUMP CONTROL SYSTEM (C MODE)...............................................................................................................................................................380 PRECAUTIONS FOR TROUBLESHOOTING FOR CONTROLLER (PUMP CONTROL SYSTEM)..................................................................................................................................................381 ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE................................................................................................................................................383 JUDGEMENT TABLE FOR CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC EQUIPMENT..........................................................................................................................................387 ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR STD. SPEC).............................................................................................................................................................389 ELECTRIC CIRCUIT DIAGRAM OF C MODE SYSTEM (FOR EU SPEC)...............................................................................................................................................................391 C-1 [E232], C-2 [E233] TROUBLE IN TVC-EPC SOLENOID SYSTEM.............................................................................................................................................................393 C-3 [E203], C-4 [E213] TROUBLE IN SWING HOLDING BRAKE SOLENOID SYSTEM.................................................................................................................................................394 C-5 [E206], C-6 [E216] TROUBLE IN 2ND TRAVEL SPEED SELECTION SOLENOID SYSTEM..........................................................................................................................................395 C-7 [E411] TROUBLE IN BOOM SWING ANGLE SENSOR CORRECTION..............................................................................................................................................................396 C-8 [E251] TROUBLE IN BOOM BOTTOM PRESSURE SENSOR (OVERLOAD SENSOR) SYSTEM (FOR EU SPEC)..............................................................................................................................397 C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR EU SPEC)............................................................................................................................................397 C-9 [E258] SHORT CIRCUIT IN 5V SYSTEM OF SENSOR POWER SUPPLY (FOR STD SPEC)...........................................................................................................................................398 C-10 [E412], C-11 [E413] TROUBLE IN BOOM SWING ANGLE SENSOR SYSTEM....................................................................................................................................................399 C-12 [E451] SHORT CIRCUIT IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED....................................................................................................................................400 C-13 [E452] DISCONNECTION IN BOOM SWING LEFT STOP EPC SOLENOID SYSTEM IS DISPLAYED....................................................................................................................................401 C-14 [E453] SHORT CIRCUIT IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED...................................................................................................................................402 C-15 [E454] DISCONNECTION IN BOOM SWING RIGHT STOP EPC SOLENOID SYSTEM IS DISPLAYED...................................................................................................................................403 C-16 BOOM SWING LEFTT END CUSHION DOES NOT WORK AT ALL OR NORMALLY....................................................................................................................................................404 C-17 BOOM SWING RIGHT END CUSHION DOES NOT WORK AT ALL OR NORMALLY....................................................................................................................................................406 C-18 WORK EQUIPMENT STILL MOVES AFTER WORK EQUIPMENT LOCK LEVER IS SET TO LOCK........................................................................................................................................408 C-19 MACHINE DOES NOT SWING...........................................................................................................................................................................................409 C-20 TRAVEL SPEED DOES NOT RISE.......................................................................................................................................................................................410 C-21 TROUBLE IN CONTROLLER POWER SUPPLY (LED OF CONTROLLER IS TURNED OFF).............................................................................................................................................410 TROUBLESHOOTING FOR CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).............................................................................................................................................................411 F-1 BIT PATTERN 1023-(4) SWING PRESSURE SWITCH DOES NOT LIGHT UP......................................................................................................................................................412 F-2 BIT PATTERN 1023-(3) TRAVEL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................................................................................................413 F-3 BIT PATTERN 1023-(6) BOOM RAISE PRESSURE SWITCH DOES NOT LIGHT UP.................................................................................................................................................414 F-4 BIT PATTERN 1023-(5) ARM IN PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................................................................................................415 F-5 BIT PATTERN 1026-(1) DECELERATION SWITCH OF LEFT KNOB DOES NOT LIGHT UP...........................................................................................................................................416 F-6 BIT PATTERN 1026-(4) 2ND TRAVEL SPEED SELECTION SWITCH (PEDAL) DOES NOT LIGHT UP..................................................................................................................................417 F-7 BIT PATTERN 1021-(3) COMPRESSOR SIGNAL DOES NOT LIGHT UP..........................................................................................................................................................418 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).............................................................................................................................................................419 TABLE OF HYDRAULIC FAILURE MODES AND THEIR CAUSES.....................................................................................................................................................................422 H-1 SPEED OR POWER OF 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET) TRAVEL, SWING, AND BLADE IS LOW.........................................................................................................424 a) SPEED OR POWER OF WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS IS LOW...........................................................................................................................424 b) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL IS LOW.......................................................................................................................................425 c) SPEED OR POWER OF SWING AND BLADE IS LOW.......................................................................................................................................................................425 d) SPEED OR POWER OF TRAVEL AND BLADE IS LOW......................................................................................................................................................................426 e) SPEED OR POWER OF ALL WORK EQUIPMENT (EXCLUDING BLADE) IS LOW..................................................................................................................................................426 f) SPEED OR POWER OF TRAVEL AND SWING IS LOW......................................................................................................................................................................426 H-2 ENGINE SPEED LOWERS EXTREMELY OR ENGINE STALLS....................................................................................................................................................................427 H-3 2 OR MORE SYSTEMS OF WORK EQUIPMENT (BOOM, ARM, BUCKET), TRAVEL, SWING, AND BLADE DO NOT MOVE.....................................................................................................................429 a) ALL WORK EQUIPMENT (INCLUDING BLADE), TRAVEL, AND SWING SYSTEMS DO NOT MOVE....................................................................................................................................429 b) ALL WORK EQUIPMENT (EXCLUDING BLADE) AND TRAVEL SYSTEMS DO NOT MOVE............................................................................................................................................430 c) SWING AND BLADE SYSTEMS DO NOT MOVE............................................................................................................................................................................430 d) TRAVEL AND BLADE SYSTEMS DO NOT MOVE...........................................................................................................................................................................431 e) ALL WORK EQUIPMENT (EXCLUDING BLADE) DOES NOT MOVE.............................................................................................................................................................431 H-4 ABNORMAL SOUND COMES OUT (FROM AROUND PUMP).......................................................................................................................................................................432 H-5 FINE CONTROLLABILITY OR RESPONSE IS LOW...........................................................................................................................................................................433 H-6 HYDRAULIC DRIFT IS LARGE (ALL WORK EQUIPMENT AND BLADE)...........................................................................................................................................................434 H-7 BOOM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL).......................................................................................................................................................435 a) BOOM RAISE SPEED OR POWER IS LOW...............................................................................................................................................................................435 b) BOOM LOWER SPEED OR POWER IS LOW...............................................................................................................................................................................436 H-8 ARM SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)........................................................................................................................................................437 a) ARM IN SPEED OR POWER IS LOW...................................................................................................................................................................................437 b) ARM OUT SPEED OR POWER IS LOW..................................................................................................................................................................................438 H-9 BUCKET SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL).....................................................................................................................................................439 a) BUCKET CURL SPEED OR POWER IS LOW..............................................................................................................................................................................439 b) BUCKET DUMP SPEED OR POWER IS LOW..............................................................................................................................................................................440 H-10 BOOM SWING SPEED OR POWER IS LOW (OTHER WORK EQUIPMENT IS NORMAL)................................................................................................................................................441 a) SWING LEFT SPEED OR POWER IS LOW...............................................................................................................................................................................441 b) SWING RIGHT SPEED OR POWER IS LOW..............................................................................................................................................................................442 H-11 BOOM DOES NOT MOVE...............................................................................................................................................................................................443 a) BOOM DOES NOT RISE.............................................................................................................................................................................................443 b) BOOM DOES NOT LOWER............................................................................................................................................................................................444 H-12 ARM DOES NOT MOVE................................................................................................................................................................................................445 a) ARM DOES NOT MOVE IN...........................................................................................................................................................................................445 b) ARM DOES NOT MOVE OUT..........................................................................................................................................................................................446 H-13 BUCKET DOES NOT MOVE.............................................................................................................................................................................................447 a) BUCKET DOES NOT CURL...........................................................................................................................................................................................447 b) BUCKET DOES NOT DUMP...........................................................................................................................................................................................448 H-14 BOOM SWING DOES NOT MOVE.........................................................................................................................................................................................449 a) BOOM SWING LEFT DOES NOT MOVE..................................................................................................................................................................................449 b) BOOM SWING RIGHT DOES NOT MOVE.................................................................................................................................................................................450 H-15 HYDRAULIC DRIFT OF BOOM IS LARGE.................................................................................................................................................................................451 H-16 HYDRAULIC DRIFT OF ARM IS LARGE..................................................................................................................................................................................451 H-17 HYDRAULIC DRIFT OF BUCKET IS LARGE...............................................................................................................................................................................452 H-18 HYDRAULIC DRIFT OF SWING IS LARGE................................................................................................................................................................................452 a) HYDRAULIC DRIFT OF SWING TO LEFT IS LARGE......................................................................................................................................................................452 b) HYDRAULIC DRIFT OF SWING TO RIGHT IS LARGE.....................................................................................................................................................................452 H-19 TIME LAG IS LARGE (WHEN ENGINE SPEED IS LOW).....................................................................................................................................................................453 H-20 PART LOADED MORE MOVES SLOWER IN COMPOUND OPERATION OF WORK EQUIPMENT............................................................................................................................................453 H-21 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING AND BOOM RAISE............................................................................................................................................454 H-22 TRAVEL SPEED LOWERS EXTREMELY IN COMPOUND OPERATION OF TRAVEL AND BOOM RAISE.....................................................................................................................................454 H-23 SPEED IS LOW IN COMPOUND OPERATION OF WORK EQUIPMENT RELIEF AND SWING, WORK EQUIPMENT RELIEF AND OTHER WORK EQUIPMENT............................................................................................454 H-24 TRAVEL DEVIATION IS LARGE........................................................................................................................................................................................455 a) TRAVEL DEVIATION IS LARGE DURING ORDINARY TRAVEL...............................................................................................................................................................455 b) TRAVEL DEVIATION IS LARGE WHEN MACHINE STARTS (BUT NORMAL DURING ORDINARY TRAVEL)..............................................................................................................................456 H-25 TRAVEL DEVIATION IS LARGE IN COMPOUND OERATION OF TRAVEL AND SWING, TRAVEL AND WORK EQUIPMENT....................................................................................................................457 H-26 TRAVEL SPEED OR POWER IS LOW (WORK EQUIPMENT, SWING, AND BLADE OPERATIONS ARE NORMAL)............................................................................................................................458 H-27 MACHINE CANNOT BE STEERED SHARPLY OR STEERING FORCE IS INSUFFICIENT..............................................................................................................................................460 H-28 TRAVEL SPEED DOES NOT CHANGE AT ALL OR DOES NOT CHANGE QUICKLY...................................................................................................................................................461 H-29 MACHINE DOES NOT TRAVEL..........................................................................................................................................................................................462 H-29 SUPPLEMENT.......................................................................................................................................................................................................463 H-30 OVERRUN OF TRAVEL IS LARGE.......................................................................................................................................................................................464 H-31 TRAVEL HYDRAULIC DRIFT IS LARGE..................................................................................................................................................................................464 H-32 FINE CONTROLLABILITY OR RESPONSE IS LOW..........................................................................................................................................................................465 H-33 SWING SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL)............................................................................................................................466 H-34 MACHINE DOES NOT SWING (WORK EQUIPMENT, TRAVEL, AND BLADE OPERATIONS ARE NORMAL).................................................................................................................................468 a) SWING SPEED OR POWER IS LOW IN BOTH DIRECTIONS.................................................................................................................................................................468 b) SWING SPEED OR POWER IS LOW IN EITHER DIRECTION................................................................................................................................................................469 H-35 SWING ACCELERATION IS LOW........................................................................................................................................................................................470 a) SWING ACCELERATION IS LOW IN BOTH DIRECTIONS...................................................................................................................................................................470 b) SWING ACCELERATION IS LOW IN EITHER DIRECTION..................................................................................................................................................................470 H-36 OVERRUN OF SWING IS LARGE........................................................................................................................................................................................471 a) OVERRUN OF SWING IS LARGE IN BOTH DIRECTIONS...................................................................................................................................................................471 b) OVERRUN OF SWING IS LARGE IN EITHER DIRECTION..................................................................................................................................................................471 H-37 LARGE SHOCK IS MADE WHEN MACHINE STOPS SWINGING..................................................................................................................................................................472 H-38 LARGE ABNORMAL SOUND IS MADE WHEN MACHINE STOPS SWINGING.........................................................................................................................................................472 H-39 SWING HYDRAULIC DRIFT IS LARGE...................................................................................................................................................................................473 H-40 FINE CONTROLLABILITY OR RESPONSE OF SWING IS LOW.................................................................................................................................................................474 H-41 BLADE SPEED OR POWER IS LOW (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL)............................................................................................................................475 H-42 BLADE DOES NOT MOVE (WORK EQUIPMENT, TRAVEL, AND SWING OPERATIONS ARE NORMAL)....................................................................................................................................476 a) BLADE DOES NOT RISE............................................................................................................................................................................................476 b) BLADE DOES NOT LOWER...........................................................................................................................................................................................477 H-43 HYDRAULIC DRIFT OF BLADE IS LARGE................................................................................................................................................................................478 H-44 FINE CONTROLLABILITY OR RESPONSE OF BLADE IS LOW.................................................................................................................................................................479 TROUBLESHOOTING FOR MACHINE MONITOR SYSTEM (M MODE).......................................................................................................................................................................481 ACTION TAKEN BY CONTROLLER WHEN TROUBLE OCCURS AND PROBLEMS ON MACHINE................................................................................................................................................482 ELECTRIC CIRCUIT DIAGRAM OF M MODE SYSTEM.............................................................................................................................................................................484 M-1 [E101] (ERROR HISTORY DATA ARE ABNORMAL) IS DISPLAYED.............................................................................................................................................................486 M-2 [E108] (ENGINE COOLANT TEMPERATURE IS 105 DEGREES C) IS DISPLAYED.................................................................................................................................................487 M-3 [E112] (WIPER FORWARD OUTPUT IS SHORTED) IS DISPLAYED.............................................................................................................................................................487 M-4 [E113] (WIPER REVERSE OUTPUT IS SHORTED) IS DISPLAYED.............................................................................................................................................................487 M-5 [E114] (CONTACT WITH WASHER OUTPUT OF 24V) IS DISPLAYED...........................................................................................................................................................487 M-6 [E115] (WIPER DOES NOT START WIPING IN 10 SECONDS) IS DISPLAYED...................................................................................................................................................487 M-7 [E116] (WIPER IS NOT RETRACTED IN 10 SECONDS) IS DISPLAYED........................................................................................................................................................487 M-8 MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL FOR 3 SECONDS AFTER STARTING SWITCH IS TURNED ON....................................................................................................................488 a) MONITOR PANEL SEGMENTS DO NOT LIGHT UP AT ALL..................................................................................................................................................................488 b) SOME MONITOR PANEL SEGMENTS DO NOT LIGHT UP....................................................................................................................................................................488 M-9 WHEN STARTING SWITCH IS SET TO ON POSITION, ALL MONITOR PANEL SEGMENTS LIGHT UP BUT DO NOT GO OFF.................................................................................................................490 M-10 WHILE PREHEATING IS NOT EXECUTED, "PREHEATER MONITOR" LIGHTS UP..................................................................................................................................................490 M-11 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH........................................................................................................................491 a) ALTERNATOR SYSTEM..............................................................................................................................................................................................491 b) ENGINE OIL SYSTEM..............................................................................................................................................................................................492 M-12 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), CAUTION ITEMS (EXCLUDING BATTERY AND ENGINE OIL) FLASH.......................................................................................493 a) ALTERNATOR SYSTEM..............................................................................................................................................................................................493 b) ENGINE OIL PRESSURE SENSOR SYSTEM..............................................................................................................................................................................494 M-13 WHEN STARTING SWITCH IS SET TO ON POSITION AND ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH (WHEN THERE IS NOT ABNORMALITY IN INSPECTION ITEMS AND ENGINE BEFORE TROUBLESHOOTING, HOWEVER)....495 a) "ENGINE OIL" FLASHES...........................................................................................................................................................................................495 b) "CHARGE LEVEL" FLASHES.........................................................................................................................................................................................495 c) "COOLANT TEMPERATURE" FLASHES..................................................................................................................................................................................496 d) "FUEL LEVEL" FLASHES...........................................................................................................................................................................................497 M-14 WHEN STARTING SWITCH IS SET TO ON POSITION (BUT ENGINE IS STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND WHILE CAUTION ITEM IS FLASHING, BUZZER DOES NOT SOUND.....................................................498 M-15 MONITOR PLANE LAMP FOR NIGHTTIME IS NOT TURNED ON (LC DISPLAY IS NORMAL).........................................................................................................................................499 M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE..........................................................................................................................................................................500 M-17 COOLANT TEMPERATURE GAUGE IS NOT DISPLAYED (GAUGE DOES NOT RISE TO 1ST LINE DURING OPERATION)....................................................................................................................500 M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL............................................................................................................................................................................501 M-19 FUEL LEVEL GAUGE IS NOT DISPLAYED................................................................................................................................................................................501 M-20 WHILE ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE..........................................................................................................................................................502 M-21 TROUBLE IN FUEL LEVEL SENSOR.....................................................................................................................................................................................503 M-22 TROUBLE IN COOLANT TEMPERATURE SENSOR............................................................................................................................................................................504 M-23 WIPER DOES NOT OPERATE OR OPERATES WHILE WIPER SWITCH IS TURNED OFF..............................................................................................................................................505 a) WIPER DOES NOT OPERATE.........................................................................................................................................................................................505 b) WIPER OPERATES WHILE WIPER SWITCH IS TURNED OFF................................................................................................................................................................505 M-24 WASHER MOTOR DOES NOT OPERATE OR OPERATES WHILE WASHER SWITCH IS TURNED OFF......................................................................................................................................508 a) WASHER MOTOR DOES NOT OPERATE..................................................................................................................................................................................508 b) WASHER OPERATES WHILE WIPER SWITCH IS TURNED OFF...............................................................................................................................................................508 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................................................................511 METHOD OF USING MANUAL........................................................................................................................................................................................................512 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................................................................................................................................513 SPECIAL TOOL LIST.............................................................................................................................................................................................................517 COUNTERWEIGHT ................................................................................................................................................................................................................523 REMOVAL AND INSTALLATION..................................................................................................................................................................................................523 INJECTION PUMP ...............................................................................................................................................................................................................524 REMOVAL...................................................................................................................................................................................................................524 INSTALLATION..............................................................................................................................................................................................................525 CYLINDER HEAD.................................................................................................................................................................................................................526 REMOVAL...................................................................................................................................................................................................................526 INSTALLATION..............................................................................................................................................................................................................529 MAIN PUMP.....................................................................................................................................................................................................................530 REMOVAL...................................................................................................................................................................................................................530 INSTALLATION..............................................................................................................................................................................................................531 CONTROL PUMP..................................................................................................................................................................................................................531 REMOVAL AND INSTALLATION..................................................................................................................................................................................................531 ENGINE AND MAIN PUMP..........................................................................................................................................................................................................532 REMOVAL...................................................................................................................................................................................................................532 INSTALLATION..............................................................................................................................................................................................................534 HYDRAULIC OIL COOLER..........................................................................................................................................................................................................535 REMOVAL AND INSTALLATION..................................................................................................................................................................................................535 RADIATOR .....................................................................................................................................................................................................................535 REMOVAL...................................................................................................................................................................................................................535 INSTALLATION..............................................................................................................................................................................................................536 SWING MOTOR AND SWING MACHINERY...............................................................................................................................................................................................537 REMOVAL AND INSTALLATION..................................................................................................................................................................................................537 SWING MACHINERY...............................................................................................................................................................................................................538 DISASSEMBLY...............................................................................................................................................................................................................538 ASSEMBLY..................................................................................................................................................................................................................540 SWING MOTOR ..................................................................................................................................................................................................................544 REMOVAL AND INSTALLATION..................................................................................................................................................................................................544 CENTER SWIVEL JOINT...........................................................................................................................................................................................................544 REMOVAL...................................................................................................................................................................................................................544 INSTALLATION..............................................................................................................................................................................................................545 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................................................546 CONTROL VALVE.................................................................................................................................................................................................................547 REMOVAL AND INSTALLATION..................................................................................................................................................................................................547 ASSEMBLY..................................................................................................................................................................................................................548 WORK EQUIPMENT PPC VALVE......................................................................................................................................................................................................549 ASSEMBLY..................................................................................................................................................................................................................549 TRAVEL PPC VALVE .............................................................................................................................................................................................................550 ASSEMBLY..................................................................................................................................................................................................................550 HYDRAULIC TANK ...............................................................................................................................................................................................................552 REMOVAL AND INSTALLATION..................................................................................................................................................................................................552 FUEL TANK.....................................................................................................................................................................................................................553 REMOVAL...................................................................................................................................................................................................................553 INSTALLATION..............................................................................................................................................................................................................554 CONTROLLER....................................................................................................................................................................................................................556 REMOVAL AND INSTALLATION..................................................................................................................................................................................................556 MONITOR PANEL.................................................................................................................................................................................................................557 REMOVAL AND INSTALLATION..................................................................................................................................................................................................557 AIR CONDITIONER UNIT..........................................................................................................................................................................................................557 REMOVAL...................................................................................................................................................................................................................557 INSTALLATION..............................................................................................................................................................................................................558 OPERATOR'S CAB................................................................................................................................................................................................................559 REMOVAL AND INSTALLATION..................................................................................................................................................................................................559 FLOOR FRAME ..................................................................................................................................................................................................................560 REMOVAL...................................................................................................................................................................................................................560 INSTALLATION..............................................................................................................................................................................................................561 REVOLVING FRAME...............................................................................................................................................................................................................562 REMOVAL AND INSTALLATION..................................................................................................................................................................................................562 SWING CIRCLE..................................................................................................................................................................................................................563 REMOVAL AND INSTALLATION..................................................................................................................................................................................................563 WORK EQUIPMENT ...............................................................................................................................................................................................................564 REMOVAL...................................................................................................................................................................................................................564 INSTALLATION..............................................................................................................................................................................................................565 SWING BRACKET.................................................................................................................................................................................................................566 REMOVAL...................................................................................................................................................................................................................566 INSTALLATION..............................................................................................................................................................................................................567 STEEL SHOE, RUBBER PAD SHOE, ROAD LINER.......................................................................................................................................................................................568 EXPANSION AND INSTALLATION................................................................................................................................................................................................568 RUBBER SHOE ..................................................................................................................................................................................................................569 REMOVAL AND INSTALLATION..................................................................................................................................................................................................569 FINAL DRIVE ..................................................................................................................................................................................................................569 REMOVAL...................................................................................................................................................................................................................569 INSTALLATION..............................................................................................................................................................................................................570 IDLER ........................................................................................................................................................................................................................570 ASSEMBLY..................................................................................................................................................................................................................570 RECOIL SPRING.................................................................................................................................................................................................................572 DISASSEMBLY...............................................................................................................................................................................................................572 ASSEMBLY..................................................................................................................................................................................................................573 TRACK ROLLER..................................................................................................................................................................................................................574 DISASSEMBLY...............................................................................................................................................................................................................574 ASSEMBLY..................................................................................................................................................................................................................575 HYDRAULIC CYLINDER............................................................................................................................................................................................................577 DISASSEMBLY...............................................................................................................................................................................................................577 ASSEMBLY..................................................................................................................................................................................................................579 90 OTHERS.........................................................................................................................................................................................................................581 HYDRAULIC CIRCUIT DIAGRAM (FOR STD SPEC)......................................................................................................................................................................................582 HYDRAULIC CIRCUIT DIAGRAM (FOR EU SPEC).......................................................................................................................................................................................583 ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC) (1/2)...............................................................................................................................................................................584 ELECTRICAL CIRCUIT DIAGRAM (FOR STD SPEC) (2/2)...............................................................................................................................................................................585 ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC) (1/2)................................................................................................................................................................................586 ELECTRICAL CIRCUIT DIAGRAM (FOR EU SPEC) (2/2)................................................................................................................................................................................587 ELECTRICAL CIRCUIT DIAGRAM (FOR NORWAY SPEC.) (1/2)...........................................................................................................................................................................588 ELECTRICAL CIRCUIT DIAGRAM (FOR NORWAY SPEC.) (2/2)...........................................................................................................................................................................589
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