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Komatsu PW170Es-6K Wheeled Excavator Service Repair Manual SN K32001, K34001 and up – PDF DOWNLOAD
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Komatsu PW170Es-6K Wheeled Excavator Service Repair Manual
Book Code: UEBM001001
MACHINE MODEL SERIAL NUMBER
PW170ES-6K – K32001 and up
PW170ES-6K – K34001 and up
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Description
Komatsu PW170Es-6K Wheeled Excavator Service Repair Manual
FILE DETAILS:
Komatsu PW170Es-6K Wheeled Excavator Service Repair Manual
Brands: Komatsu
Equipment Type: Wheeled Excavator
Manuals Type: Shop Manual
Machine Model: PW170ES-6K
Serial Number: K32001 and up, K34001 and up
Book Code: UEBM001001
Language: English
Pages: 667
File Format: Portable Document Format (PDF)
KOMATSU PW170ES-6K WHEELED EXCAVATOR SERVICE REPAIR MANUAL SN K32001, K34001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PW170Es-6K Wheeled Excavator Service Repair Manual
FOREWORD:
GENERAL:
- 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 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.
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” to “Causes” are also included in thissection.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PW170Es-6K Wheeled Excavator Service Repair Manual
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 01 GENERAL................................................................................................................................... 2 FOREWORD................................................................................................................................. 8 HOW TO READ THE SHOP MANUAL.............................................................................................................. 9 HOISTING INSTRUCTIONS.................................................................................................................... 10 COATING MATERIALS........................................................................................................................ 11 STANDARD TIGHTENING TORQUE............................................................................................................... 12 ELECTRIC WIRE CODE....................................................................................................................... 14 CONVERSION TABLE......................................................................................................................... 15 10 STRUCTURE AND FUNCTION.................................................................................................................... 22 ENGINE RELATED PARTS..................................................................................................................... 23 RADIATOR, OIL COOLER, AFTERCOOLER........................................................................................................ 24 POWER TRAIN.............................................................................................................................. 25 SWING CIRCLE............................................................................................................................. 26 SWING MACHINERY.......................................................................................................................... 27 UNDERCARRIAGE............................................................................................................................ 29 TRANSMISSION............................................................................................................................. 30 AXLE..................................................................................................................................... 33 SUSPENSION LOCK CYLINDER................................................................................................................. 37 BRAKING TRAIN............................................................................................................................ 39 BRAKE PEDAL.............................................................................................................................. 40 BRAKE VALVE.............................................................................................................................. 41 ACCUMULATOR FOR BRAKE SYSTEM............................................................................................................. 42 STEERING TRAIN........................................................................................................................... 43 STEERING COLUMN.......................................................................................................................... 45 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 46 HYDRAULIC TANK........................................................................................................................... 48 HYDRAULIC PUMP........................................................................................................................... 49 CONTROL VALVE............................................................................................................................ 68 CLSS..................................................................................................................................... 78 SWING MOTOR..............................................................................................................................113 CENTER SWIVEL JOINT......................................................................................................................116 TRAVEL MOTOR (FRONT, REAR)...............................................................................................................117 WORK EQUIPMENT, SWING PPC VALVE..........................................................................................................119 TRAVEL PPC PEDAL.........................................................................................................................123 SERVICE PPC VALVE........................................................................................................................124 SAFETY LOCK VALVE........................................................................................................................127 PPC ACCUMULATOR..........................................................................................................................127 PPC SHUTTLE VALVE, TRAVEL JOINT VALVE....................................................................................................128 EPC, SOLENOID VALVE......................................................................................................................132 BOOM HOLDING VALVE.......................................................................................................................146 HYDRAULIC CYLINDERS......................................................................................................................150 WORK EQUIPMENT...........................................................................................................................154 ELECTRICAL WIRING DIAGRAM................................................................................................................155 ELECTRICAL WIRING DIAGRAM................................................................................................................156 ELECTRICAL WIRING DIAGRAM................................................................................................................157 EUROPEAN SPECIFICATIONS..................................................................................................................158 TRAVEL ALARM FOR USA SPECIFICATIONS......................................................................................................159 ENGINE CONTROL SYSTEM....................................................................................................................160 ELECTRONIC CONTROL SYSTEM................................................................................................................166 MACHINE MONITOR SYSTEM...................................................................................................................189 REVERSE ALARM............................................................................................................................196 BREAKER MODE HYDRAULIC PERFORMANCE.......................................................................................................198 20 TESTING AND ADJUSTING.....................................................................................................................200 TABLE OF JUDGEMENT STANDARD VALUE........................................................................................................201 STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................211 CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSION......................................................................219 ADJUSTING ENGINE SPEED SENSOR............................................................................................................220 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE........................................................................................221 TESTING CLEARANCE OF SWING CIRCLE BEARING................................................................................................223 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT........................................................224 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)............................................................227 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE................................229 TESTING AND ADJUSTING PPC PRESSURE ......................................................................................................232 TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE........................................................................................234 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE........................................................................236 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE................................................................................................238 TESTING LOCATION CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...............................................................................239 MEASURING OIL LEAKAGE....................................................................................................................241 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT........................................................................................242 BLEEDING AIR.............................................................................................................................243 ACCUMULATORS.............................................................................................................................245 TROUBLESHOOTING..........................................................................................................................249 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................250 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................251 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................252 CHECKS BEFORE TROUBLESHOOTING........................................................................................................259 CONNECTOR TYPES......................................................................................................................260 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................265 EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM................................................................................278 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL................................................................................279 METHOD OF USING JUDGEMENT TABLE......................................................................................................287 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................289 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE.............................................................................291 SERVICE CODE TABLE...................................................................................................................296 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE).........................................................................298 N-1 [E218] COMMUNICATION ABNORMALITY.............................................................................................299 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)(E MODE).......................................................301 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM.........................................302 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS......................................................303 JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS...................................307 ELECTRICAL CIRCUIT DIAGRAM OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)................................................309 E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)................................................311 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED.............................................................312 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................313 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................314 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED.............................................................315 E-6 [E315] ABNORMALTIY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...............................................316 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED..........................................................................317 E-8 ENGINE DOES NOT START........................................................................................................319 E-9 ENGINE SPEED IS IRREGULAR....................................................................................................321 A) IDLING SPEED IS IRREGULAR................................................................................................321 B) THERE IS HUNTING..........................................................................................................323 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)........................................................................325 E-11 ENGINE DOES NOT STOP........................................................................................................327 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)..........................................................329 TROUBLESHOOTING OF ENGINE (S MODE)...................................................................................................330 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................331 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................................................................335 S-2 ENGINE DOES NOT START........................................................................................................336 (1) ENGINE DOES NOT RUN......................................................................................................336 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).................................................337 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...............................................338 S-3 ENGINE DOES NOT PICK UP SMOOTHLY ............................................................................................339 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................340 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................341 S-6 ENGINE LACKS OUTPUT (NO POWER)...............................................................................................342 S-7 EXHAUST SMOKE IS BLACK ......................................................................................................343 S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST GAS IS BLUE.........................................................................344 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................345 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................346 S-11 OIL IS IN COOLING WATER.....................................................................................................347 S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)...................................................................348 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................349 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................350 S-15 ABNORMAL NOISE IS MADE......................................................................................................351 S-16 VIBRATION IS EXCESSIVE......................................................................................................352 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM (PUMP CONTROL SYSTEM) (C MODE)...................................................353 POINTS TO REMEMBER WHEN CARRYIN GOUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM...................................................354 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS......................................................355 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER AND HYDRAULIC RELATED PARTS........................................................361 ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEMS.....................................................................................363 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)........................................................365 C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED................................................................366 C-3 [E233] DISCONNECTION PUMP TVC SOLENOID SYSTEM IS DISPLAYED...................................................................368 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................370 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................372 C-10 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.........................................................374 C-11 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.........................................................375 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...........................................................376 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED..................................................377 C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED.............................................................................378 C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.................................................................379 C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS.....................................................................380 C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED..............................................................381 C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED......................................................382 C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...............................................................383 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)..........................................................384 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE............................................................................................385 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................387 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................388 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................389 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................390 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................391 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................392 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP ........................................................393 F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP.........................................................394 F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP.......................................................................395 F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP.......................................................................396 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).............................................................................398 TABLE OF FAILURE MODES AND CAUSES................................................................................................399 ALL WORK EQUIPMENT, TRAVEL, SWING................................................................................................403 H-1 SPEED OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER........................................................403 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS................................................................405 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE....................................................................................406 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...................................................................................406 H-5 AUTO-DECELERATION DOES NOT WORK .........................................................................................407 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR.........................................................................407 WORK EQUIPMENT...................................................................................................................409 H-7 BOOM IS SLOW OR LACK POWER...............................................................................................409 H-8 ARM IS SLOW OR LACKS POWER...............................................................................................411 H-9 BUCKET IS SLOW OR LACKS POWER............................................................................................413 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE .......................................................................414 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...........................................................................414 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...............................................................................415 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED...................................................................415 H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED.......................................................416 H-15 LACK OF POWER WHEN PRESSURE RISES.......................................................................................416 COMPUND OPERATIONS...............................................................................................................416 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW.........................................................416 H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...............................................................................417 TRAVEL SYSTEM....................................................................................................................419 H-21 TRAVEL SPEED IS SLOW....................................................................................................419 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED..........................................................421 SWING SYSTEM.....................................................................................................................422 H-25 DOES NOT SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY)................................................................422 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY).............................423 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY).........................................425 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)................................................................426 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING............................................................................426 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN BRAKE IS ON, WHEN BRAKE IS OFF)................................................427 H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED........................................................................428 TROUBLESHOOTING OF MACHINE PANEL SYSTEM (M MODE).....................................................................................430 ACTION TAKEN BY PANEL AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS...........................................................431 ELECTRICAL CIRCUIT DIAGRAM FROM MONITOR SYSTEM................................................................................... 0 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED [E102] ERROR IN CLOCK DATA IS DISPLAYED........................................435 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED................436 M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED....................................................................................437 M-4 [E106] DROP IN ENGINE OIL PRESSURE DETECTED IS DISPLAYED.....................................................................437 M-5 [E108] ENGINE WATER TEMPERATURE 105 C DETECTED IS DISPLAYED..................................................................438 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL LIGHT UP FOR THREE SECONDS.........................439 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NO GO OUT......................................441 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)...................441 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH..................................................442 M-10 PREHEATING IS NOT BEING USED BUT PREHEATING MONITOR LIGHTS UP...............................................................444 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH............................................445 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LA....447 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMAL....449 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR ONE SECOND. CAUTION ITEM FLASHES BUT BUZZE....452 M-15 NO ABNORMALTIY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS....................................................................452 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)........................................453 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE.....................................................................................454 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION).........................454 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.......................................................................................455 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY......................................................................................455 M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP............................................456 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH..........................................456 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING......................................................................457 M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED.........................457 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM..........................................................................................458 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM.................................................................................459 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM....................................................................................460 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.......................................................................................461 M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED.......................................................462 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................466 METHOD OF USING MANUAL...................................................................................................................468 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................470 SPECIAL TOOL LIST........................................................................................................................472 GOVERNOR MOTOR ASSEMBLY..................................................................................................................475 REMOVAL AND INSTALLATION.............................................................................................................475 HYDRAULIC COOLER ASSEMBLY................................................................................................................476 REMOVAL..............................................................................................................................476 RADIATOR, HYDRAULIC COOLER ASSEMBLY......................................................................................................477 REMOVAL..............................................................................................................................477 INSTALLATION.........................................................................................................................478 ENGINE, MAIN PUMP ASSEMBLY...............................................................................................................479 REMOVAL..............................................................................................................................479 INSTALLATION.........................................................................................................................482 DAMPER ASSEMBLY..........................................................................................................................483 REMOVAL AND INSTALLATION.............................................................................................................483 FUEL TANK ASSEMBLY.......................................................................................................................484 REMOVAL AND INSTALLATION.............................................................................................................484 CENTER SWIVEL JOINT ASSEMBLY.............................................................................................................485 REMOVAL AND INSTALLATION.............................................................................................................485 SWING MOTOR ASSEMBLY.....................................................................................................................486 REMOVAL AND INSTALLATION.............................................................................................................487 SWING MACHINERY ASSEMBLY.................................................................................................................487 REMOVAL AND INSTALLATION.............................................................................................................487 SWING MOTOR .............................................................................................................................489 DISASSEMBLY AND ASSEMBLY.............................................................................................................489 REVOLVING FRAME ASSEMBLY ................................................................................................................496 REMOVAL..............................................................................................................................496 INSTALLATION.........................................................................................................................498 SWING CIRCLE ASSEMBLY....................................................................................................................499 REMOVAL AND INSTALLATION.............................................................................................................499 HYDRAULIC TANK ASSEMBLY..................................................................................................................501 REMOVAL .............................................................................................................................501 INSTALLATION.........................................................................................................................502 MAIN PUMP ASSEMBLY.......................................................................................................................503 REMOVAL..............................................................................................................................503 INSTALLATION.........................................................................................................................504 CONTROL VALVE ASSEMBLY...................................................................................................................505 REMOVAL..............................................................................................................................505 INSTALLATION.........................................................................................................................506 DISASSEMBLY AND ASSEMBLY.............................................................................................................507 LS SELECT VALVE ASSEMBLY.................................................................................................................511 DISASSEMBLY AND ASSEMBLY.............................................................................................................511 LS SHUTTLE VALVE.........................................................................................................................512 DISASSEMBLY AND ASSEMBLY.............................................................................................................512 PRESSURE COMPENSATION VALVE ASSEMBLY.....................................................................................................513 DISASSEMBLY AND ASSEMBLY.............................................................................................................513 MAIN RELIEF VALVE ASSEMBLY...............................................................................................................515 DISASSEMBLY..........................................................................................................................515 ASSEMBLY.............................................................................................................................516 LS CONTROL EPC VALVE ASSEMBLY............................................................................................................517 REMOVAL AND INSTALLATION.............................................................................................................517 EPC SOLENOID VALVE ASSEMBLY..............................................................................................................518 REMOVAL AND INSTALLATION.............................................................................................................518 PPC SHUTTLE VALVE ASSEMBLY...............................................................................................................519 REMOVAL..............................................................................................................................519 INSTALLATION.........................................................................................................................520 DISASSEMBLY..........................................................................................................................521 ASSEMBLY.............................................................................................................................522 WORK EQUIPMENT PPC VALVE ASSEMBLY........................................................................................................523 REMOVAL AND INSTALLATION.............................................................................................................523 TRAVEL PPC VALVE ASSEMBLY................................................................................................................524 REMOVAL AND INSTALLATION.............................................................................................................524 BOOM CYLINDER ASSEMBLY...................................................................................................................525 REMOVAL..............................................................................................................................525 INSTALLATION.........................................................................................................................526 ARM CYLINDER ASSEMBLY....................................................................................................................527 REMOVAL..............................................................................................................................527 INSTALLATION.........................................................................................................................528 BUCKET CYLINDER ASSEMBLY.................................................................................................................529 REMOVAL..............................................................................................................................529 INSTALLATION.........................................................................................................................530 HYDRAULIC CYLINDER ASSEMBLY..............................................................................................................531 DISASSEMBLY..........................................................................................................................531 ASSEMBLY.............................................................................................................................533 WORK EQUIPMENT ASSEMBLY..................................................................................................................536 REMOVAL..............................................................................................................................536 INSTALLATION.........................................................................................................................537 BUCKET ASSEMBLY..........................................................................................................................538 REMOVAL .............................................................................................................................538 INSTALLATION.........................................................................................................................538 ARM ASSEMBLY.............................................................................................................................538 REMOVAL..............................................................................................................................538 INSTALLATION.........................................................................................................................538 BUCKET, ARM ASSEMBLY.....................................................................................................................540 REMOVAL..............................................................................................................................540 INSTALLATION.........................................................................................................................540 BOOM ASSEMBLY............................................................................................................................542 REMOVAL..............................................................................................................................542 INSTALLATION.........................................................................................................................543 OPERATOR'S CAB ASSEMBLY..................................................................................................................544 REMOVAL .............................................................................................................................544 INSTALLATION.........................................................................................................................546 COUNTERWEIGHT ASSEMBLY...................................................................................................................547 REMOVAL AND INSTALLATION.............................................................................................................547 GOVERNOR, PUMP CONTROLLER ASSEMBLY.......................................................................................................548 REMOVAL AND INSTALLATION.............................................................................................................548 MONITOR PANEL ASSEMBLY...................................................................................................................549 REMOVAL AND INSTALLATION.............................................................................................................549 SWING MACHINERY ASSEMBLY.................................................................................................................551 DISASSEMBLY..........................................................................................................................551 ASSEMBLY.............................................................................................................................566 (SPECIAL TOOLS FOR SWING MACHINERY)..................................................................................................587 TRANSMISSION.............................................................................................................................588 FRONT AXLE...............................................................................................................................595 REAR AXLE................................................................................................................................613 BUCKET ADAPTOR...........................................................................................................................627 WELDING INSTRUCTIONS.................................................................................................................627 OUT RIGGER + BLADE CYLINDER..............................................................................................................630 40 MAINTENANCE STANDARD......................................................................................................................632 ENGINE MOUNT.............................................................................................................................633 SWING MACHINERY..........................................................................................................................634 SWING CIRCLE.............................................................................................................................636 CONTROL VALVE............................................................................................................................637 SUCTION-SAFETY VALVE.....................................................................................................................645 SWING MOTOR..............................................................................................................................646 WORK EQUIPMENT, SWING PPC VALVE..........................................................................................................647 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.................................................................................................648 EPC SOLENOID VALVE.......................................................................................................................649 CENTER SWIVEL JOINT......................................................................................................................650 BOOM SAFETY VALVE (ARM SAFETY VALVE).....................................................................................................651 HYDRAULIC CYLINDER.......................................................................................................................652 WORK EQUIPMENT...........................................................................................................................653 DOZER BLADE, OUTRIGGER CYLINDERS.........................................................................................................661 OUTRIGGER BUSH PINS......................................................................................................................662 TRANSMISSION.............................................................................................................................663 FRONT AXLE...............................................................................................................................664 REAR AXLE................................................................................................................................665 ARM ROTATION CIRCLE......................................................................................................................666
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
