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Komatsu PW400MH-6 Wheeled Excavator Material Handler Shop Manual SN A84210 and up – PDF DOWNLOAD
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Komatsu PW400MH-6 Wheeled Excavator Material Handler Shop Manual
Book Code: CEBM005600
SERIAL NUMBERS PW400MH-6 A84210 AND UP
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Description
Komatsu PW400MH-6 Wheeled Excavator Material Handler Shop Manual
FILE DETAILS:
Komatsu PW400MH-6 Wheeled Excavator Material Handler Shop Manual
Brands: Komatsu
Equipment Type: Wheeled Excavator/Material Handler
Manuals Type: Shop Manual
Machine Model: PW400MH-6
Serial Number: A84210 and up
Book Code: CEBM005600
Language: English
Pages: 662
File Format: Portable Document Format (PDF)
KOMATSU PW400MH-6 WHEELED EXCAVATOR MATERIAL HANDLER SHOP MANUAL SN A84210 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu PW400MH-6 Wheeled Excavator Material Handler Shop 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 PW400MH-6 Wheeled Excavator Material Handler Shop Manual
MAIN MENU........................................................................................................... 0 COVER............................................................................................................... 1 CONTENTS............................................................................................................ 2 SAFETY.............................................................................................................. 5 SAFETY NOTICE................................................................................................... 5 IMPORTANT SAFETY NOTICE..................................................................................... 5 GENERAL PRECAUTIONS......................................................................................... 5 PREPARATIONS FOR WORK....................................................................................... 5 PRECAUTIONS DURING WORK..................................................................................... 5 FOREWORD............................................................................................................ 7 GENERAL......................................................................................................... 7 HOW TO READ THE SHOP MANUAL..................................................................................... 8 VOLUMES..................................................................................................... 8 DISTRIBUTION AND UPDATING................................................................................... 8 FILING METHOD............................................................................................... 8 REVISED EDITION MARK........................................................................................ 8 REVISIONS................................................................................................... 8 SYMBOLS..................................................................................................... 8 HOISTING INSTRUCTIONS........................................................................................... 9 HOISTING.................................................................................................... 9 WIRE ROPES.................................................................................................. 9 COATING MATERIALS............................................................................................... 10 STANDARD TIGHTENING TORQUE...................................................................................... 12 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS................................................................ 12 TIGHTENING TORQUE OF HOSE NUTS.............................................................................. 13 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS..................................................................... 13 TIGHTENING TORQUE FOR FLARED NUTS........................................................................... 13 ALTERNATIVE FASTENERS....................................................................................... 14 BOLT IDENTIFICATION CHART............................................................................... 14 GRADE 5 AND 8 NONPHOSPHATE COATED HARDWARE............................................................. 15 GRADE 8 PHOSPHATE COATED HARDWARE....................................................................... 16 STANDARD METRIC FASTENERS............................................................................... 16 HYDRAULIC TUBES AND FITTINGS............................................................................ 17 HOSE CLAMPS............................................................................................. 17 SPLIT FLANGE CONNECTIONS................................................................................ 17 ELECTRIC WIRE CODE.............................................................................................. 18 CLASSIFICATION BY THICKNESS................................................................................. 18 CLASSIFICATION BY COLOR AND CODE............................................................................ 18 CONVERSION TABLES............................................................................................... 19 METHOD OF USING THE CONVERSION TABLE........................................................................ 19 01 GENERAL.......................................................................................................... 25 SPECIFICATIONS AND DRAWING...................................................................................... 27 SPECIFICATIONS.............................................................................................. 28 LIFTING PERFORMANCE............................................................................................. 29 LIFTING CAPACITY................................................................................................ 30 TRANSPORTATION.................................................................................................. 31 MAIN CARRIER TRANSPORTATION DATA............................................................................ 32 FUEL COOLANT AND LUBRICANTS..................................................................................... 33 ENGINE OIL SPECIFICATIONS....................................................................................... 34 NORMAL OPERATION............................................................................................ 34 ARCTIC OPERATION........................................................................................ 34 FINAL DRIVE OIL SPECIFICATIONS.......................................................................... 35 DIESEL FUEL SPECIFICATIONS.............................................................................. 35 COOLANT SPECIFICATIONS.................................................................................. 36 10 STRUCTURE AND FUNCTION........................................................................................... 43 ENGINE COMPONENTS............................................................................................... 45 TURBO INTAKE PIPING AND ENGINE MOUNTS....................................................................... 45 DRIVE PLATES AND ENGINE MOUNTS.............................................................................. 46 RADIATOR AND OIL COOLER..................................................................................... 47 POWER TRAIN..................................................................................................... 48 DRIVE SYSTEM.................................................................................................... 49 FINAL DRIVE................................................................................................. 49 WHEEL FRAME................................................................................................. 49 TRAVEL MOTOR................................................................................................ 49 TRAVEL CONTROL SYSTEM....................................................................................... 49 STRAIGHT-TRAVEL SYSTEM...................................................................................... 49 TRAVEL JUNCTION VALVE....................................................................................... 49 SWING CIRCLE.................................................................................................... 50 SWING MACHINERY................................................................................................. 51 HYDRAULIC PIPING DRAWING........................................................................................ 52 HYDRULIC PIPING SCHEMATIC....................................................................................... 53 HYDRAULIC TANK AND FILTER....................................................................................... 54 HYDRULIC PUMP................................................................................................... 55 MAIN PUMP................................................................................................... 56 TVC AND LS VALVE............................................................................................ 61 CONTROL VALVE................................................................................................... 74 MAIN STRUCTURE OF 9 SPOOL VALVE (1/4)....................................................................... 75 MAIN STRUCTURE OF 9 SPOOL VALVE (2/4)....................................................................... 76 MAIN STRUCTURE OF 9 SPOOL VALVE (3/4)....................................................................... 77 MAIN STRUCTURE OF 9 SPOOL VALVE (4/4)....................................................................... 78 SELF REDUCING PRESSURE VALVE.................................................................................... 80 STRUCTURE................................................................................................... 80 SUCTION SAFETY VALVE............................................................................................ 85 FOR SERVICE VALVE........................................................................................... 85 CLSS............................................................................................................ 86 CLSS HYDRAULICS............................................................................................. 89 SYSTEM DIAGRAM.............................................................................................. 90 WHEN UNLOAD VALVE IS ACTUATED............................................................................... 91 RELIEF VALVE................................................................................................ 92 CUT-OFF CONTROL ACTUATED................................................................................ 92 CUT-OFF CANCELED........................................................................................ 92 INTRODUCTION OF LS PRESSURE................................................................................. 93 LS BYPASS VALVE............................................................................................. 94 PRESSURE COMPENSATION VALVE................................................................................. 95 SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE............................................................ 98 VARIABLE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE.....................................................100 BOOM REGENERATION CIRCUIT...................................................................................101 ARM REGENERATION CIRCUIT....................................................................................103 MERGE FLOW DIVIDER VALVE....................................................................................104 LS SELECT VALVE.............................................................................................106 2-STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD)......................................................107 SWING SYSTEM....................................................................................................108 CENTER SWIVEL JOINT.........................................................................................108 COUNTERBALANCE VALVE........................................................................................108 SAFETY VALVE................................................................................................108 SWING MOTOR.................................................................................................109 PW400MH-6 APPLICATION...................................................................................109 SUCTION-SAFETY VALVE........................................................................................111 PARKING BRAKE...............................................................................................112 VALVE CONTROL...................................................................................................113 PPC VALVE.......................................................................................................114 SERVICE PPC VALVE...........................................................................................114 PPC SAFETY LOCK VALVE.......................................................................................114 TRAVEL PPC VALVE............................................................................................114 BOOM HOLDING VALVE..........................................................................................114 WORK EQUIPMENT..............................................................................................114 AUTO DECELERATION SYSTEM....................................................................................114 WORK EQUIPMENT PPC VALVE....................................................................................115 PPC ACCUMULATOR.................................................................................................117 PPC SHUTTLE VALVE VIEW..........................................................................................118 PPC SHUTTLE VALVE PORT LOCATIONS............................................................................119 LS-EPC VALVE....................................................................................................121 SOLENOID VALVE..................................................................................................124 AIR CONDITIONER.................................................................................................126 AIR CONDITIONER PIPING......................................................................................126 ACTUAL ELECTRICAL WIRING DIAGRAM................................................................................127 ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)..........................................................................130 ENGINE CONTROL..................................................................................................131 COMPONENTS OF SYSTEM........................................................................................133 ELECTRONIC CONTROL SYSTEM.......................................................................................137 CONTROL FUNCTION............................................................................................137 PUMP AND ENGINE MUTUAL CONTROL SYSTEM.......................................................................139 CONTROL METHOD IN EACH MODE.............................................................................140 PUMP AND VALVE CONTROL FUNCTION.............................................................................141 AUTOMATIC WARM-UP AND ENGINE OVERHEAT PROTECTION............................................................143 SWING CONTROL SYSTEM........................................................................................145 SWING LOCK AND SWING HOLDING BRAKE......................................................................146 COMPONENTS OF SYSTEM....................................................................................147 MACHINE MONITOR SYSTEM..........................................................................................150 MONITOR PANEL FRONT AND BACK VIEW...........................................................................151 MONITOR DISPLAY.............................................................................................152 CONTENT OF DISPLAY......................................................................................153 OIL MAINTENANCE FUNCTION....................................................................................154 MODE SELECTION SWITCHES.....................................................................................155 SENSORS.........................................................................................................156 COOLANT LEVEL SENSOR........................................................................................156 COOLANT TEMPERATURE SENSOR..................................................................................157 OIL PRESSURE AND LEVEL SENSOR...............................................................................158 FUEL LEVEL SENSOR...........................................................................................159 20 TESTING, ADJUSTING AND TROUBLESHOOTING...........................................................................161 STANDARD VALUE TABLE FOR ENGINE.................................................................................162 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS..................................................................163 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.......................................................................167 SERVICE TOOLS TABLE.............................................................................................172 ENGINE COMPONENTS...............................................................................................173 ADJUSTING ENGINE STOP LINKAGE...............................................................................173 ADJUSTING ENGINE STOP SOLONOID..............................................................................173 MEASURING AND ADJUSTING VALVE CLEARANCE.....................................................................173 MEASURING BLOW-BY PRESSURE..................................................................................173 MEASURING COMPRESSION PRESSURE..............................................................................173 MEASURING COOLANT TEMPERATURE...............................................................................173 MEASURING ENGINE LUBRICATING PRESSURE.......................................................................173 MEASURING ENGINE SPEEDS.....................................................................................173 MEASURING ENGINE EXHAUST SMOKE..............................................................................173 MEASURING EXHAUST GAS TEMPERATURE...........................................................................173 MEASURING FUEL FILTER INLET RESTRICTION.....................................................................173 TESTING AND ADJUSTING BELT TENSIONS.........................................................................173 TESTING AND ADJUSTING FUEL INJECTION TIMING.................................................................173 GOVERNOR MOTOR LEVER STROKE.....................................................................................174 WORK AND SWING EQUIPMENT........................................................................................175 TVC VALVE OUTPUT PRESSURE.......................................................................................178 LS VALVE OUTPUT AND DIFFERENTIAL PRESSURE.......................................................................180 CONTROL CIRCUIT OIL PRESSURE....................................................................................183 SOLENOID VALVE OUTPUT PRESSURE..................................................................................184 PPC VALVE OUTPUT PRESSURE AND SHUTTLE VALVE.....................................................................187 WORK EQUIPMENT, SWING PPC VALVE.................................................................................189 TRAVEL DEVIATION................................................................................................190 LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.............................................................191 MEASURING OIL LEAKAGE...........................................................................................193 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................195 TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................196 BLEEDING AIR....................................................................................................197 TROUBLESHOOTING - GENERAL.......................................................................................201 POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................203 SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................205 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...................................................................206 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT............................................................206 HANDLING CONTROL BOX....................................................................................211 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT....................................................212 CHECKS BEFORE TROUBLESHOOTING...............................................................................214 JUDGEMENT OF POWER TRAIN....................................................................................215 PRECAUTIONS WHEN TROUBLESHOOTING............................................................................216 SAFETY..................................................................................................216 METHODS FOR TROUBLESHOOTING.............................................................................216 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING.........218 PREVENTING RECURRENCE OF TROUBLE............................................................................219 HYDRAULIC EQUIPMENT.....................................................................................219 OIL CHECKS..........................................................................................219 CLEANING FRAGMENTS OFF DAMAGED PARTS................................................................219 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................220 CATEGORY OF TROUBLESHOOTING CODE NUMBER.................................................................220 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE.....................................220 METHOD OF USING MATRIX TROUBLESHOOTING TABLES...............................................................222 METHOD OF USING ENGINE RELATED CHARTS.......................................................................224 TROUBLESHOOTING ELECTRICAL CONNECTORS...........................................................................229 CONNECTOR TYPES AND MOUNTING LOCATIONS......................................................................230 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................233 CONTROL MECHANISM FOR ELECTRICAL SYSTEM.....................................................................243 MACHINE CONTROL FUNCTIONS...............................................................................243 DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL.....................................................244 DISPLAY ON MACHINE MONITOR..............................................................................244 RECORDING SERVICE CODES AND USER CODE...................................................................244 MACHINE DATA MONITORING FUNCTION........................................................................245 METHOD OF DISPLAYING MONITORING CODE................................................................246 TABLE OF MACHINE MONITORING CODES...................................................................247 BIT PATTERN CHART...................................................................................248 GOVERNOR MOTOR ADJUSTMENT MODE......................................................................250 TIME ADJUSTMENT MODE................................................................................250 WORKING MODE DEFAULT SETTING MODE...................................................................251 METHOD OF USING JUDGEMENT TABLE.............................................................................252 WHEN USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYS-TEM] AND ENGINE RE.......252 EXAMPLE TABLE.......................................................................................252 USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM] AND HYDRAULIC RELAT.......254 EXAMPLE TABLE.......................................................................................254 METHOD OF USING TROUBLESHOOTING CHARTS......................................................................256 CATEGORY OF TROUBLESHOOTING CODE NUMBER.................................................................256 GENERAL PRECAUTIONS.................................................................................256 DETAILS OF TROUBLESHOOTING AND PROCEDURE....................................................................259 PROCEDURE FOR CHECKING MONITOR PANEL OUTPUT SIGNAL......................................................261 CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER......................................................262 SERVICE CODE TABLE..........................................................................................264 TROUBLESHOOTING COMMUNICATION SYSTEM (N-MODE)...................................................................265 N-1 [E218] COMMUNICATION ABNORMALITY........................................................................266 TROUBLESHOTING GOVERNOR PUMP CONTROLLER AND SYSTEM (E-MODE).....................................................269 POINTS TO REMEMBER WHEN TROUBLESHOOTING GOVERNOR, PUMP CONTROLLER SYSTEM....................................270 E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE, (CONTROLLER LED IS OFF)..........................275 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT (VALUE IS DISPLAYED)......................................276 E-3 [E317] ABNORMALITY, DISCONNECTION IN MOTOR DRIVE SYSTEM IS DISPLAYED....................................277 E-4 [E318] ABNORMALITY, SHORT CIRCUIT IN MOTOR DRIVE SYSTEM IS DISPLAYED....................................278 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED........................................279 E-6 [E315] SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED........................................280 E-7 [E316] ABNORMALITY, STEP OUT IN MOTOR DISPLAYED.........................................................282 E-8 ENGINE DOES NOT START...................................................................................283 (A) IDLE SPEED IS IRRERGULAR................................................................................285 (B) ENGINE SPEED HUNTING....................................................................................286 E-10 LACK OF OUTPUT, ENGINE HIGH IDLE SPEED IS LOW..........................................................287 E-11 ENGINE DOES NOT STOP...................................................................................288 E-12 FAULTY OPERATION OF BATTERY RELAY SYSTEM, (ENGINE DOES NOT STOP).......................................289 TROUBLESHOOTING ENGINE SYSTEM (S-MODE)..........................................................................292 METHOD OF USING ENGINE CHARTS...............................................................................293 S-1 ENGINE STARTING PERFORMANCE IS POOR.....................................................................298 S-2 ENGINE DOES NOT START...................................................................................299 S-3 ENGINE STARTS ROUGH.....................................................................................302 S-4 ENGINE QUITS DURING OPERATION...........................................................................303 S-5 ENGINE SPEED IS HUNTING.................................................................................304 S-6 ENGINE POWER OUTPUT IS POOR.............................................................................305 S-7 EXHAUST GAS IS BLACK (POOR COMBUSTION)..................................................................306 S-8 ENGINE OIL CONSUMPTION IS EXCESSIVE (EXHAUST GAS IS BLUE)...............................................307 S-9 ENGINE OIL BECOMES CONTAMINATED QUICKLY.................................................................308 S-10 EXCESS FUEL CONSUMPTION................................................................................309 S-11 OIL IN COOLANT, COOLANT BLOWS OUT OF SYSTEM DURING OPERATION...........................................310 S-12 OIL PRESSURE LIGHT STAYS ON (OIL PRESSURE LOW).........................................................311 S-13 OIL LEVEL RISES OR OIL LOOKS ABNORMAL..................................................................312 S-14 HIGH COOLANT TEMPERATURES (OVERHEATING)................................................................313 S-15 ABNORMAL NOISES COMING FROM ENGINE COMPARTMENT.........................................................314 S-16 EXCESSIVE ENGINE VIBRATION.............................................................................315 TROUBLESHOOTING GOVERNOR PUMP AND CONTROL SYSTEM (C-MODE).......................................................317 IMPORTANT POINTS WHEN TROUBLESHOOTING CONTROLLER SYSTEM.....................................................318 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.................................319 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.............323 ELECTRIC CIRCUIT DIAGRAM FOR (C MODE).......................................................................324 C1 ABNORMALITY IN CONTROLLER POWER SOURCE, LED IS OFF.......................................................326 C-2 [232] SHORT CIRCUIT IN FRONT PUMP TVC SOLONOID IS DISPLAYED.............................................327 C-3 [E233] DISCONECTION IN FRONT PUMP TVC SOLENOID IS DISPLAYED.............................................328 C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID IS DISPLAYED.............................................329 C-5 [E237] DISCONECT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED..........................................330 C-6 [E207] SHORT CIRCUIT IN LS SELECT SOLENOID SYSTEM IS DISPLAYED..........................................331 BLANK FAULT CODES...........................................................................................332 C-7 [E208]..............................................................................................332 C-12 [E206].............................................................................................332 C-13 [E216].............................................................................................332 C-14 [E217].............................................................................................332 C-15 [E235].............................................................................................332 C23.....................................................................................................332 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED........................................333 C-9 [E213] DISCONECT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED............................................334 C-10 [E204] SHORT CIRCUIT IN PUMP MERGE DIVIDER SOLENOID IS DISPLAYED.......................................335 C-11 [E214] DISCONECT IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED....................................336 C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED........................................................337 C-16 RELATED ELECTRIC CIRCUIT DIAGRAM.......................................................................338 C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED............................................339 C-18 [E224] DISCONECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.............................................340 C-19 [E224] ABNORMALITY IN FRONT FUMP PRESSURE SENSOR SYSTEM IS DISPLAYED...................................341 C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED....................................342 C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED........................................343 C-22 [E227] ABNORMALITY IN ENGINE SPEED SYSTEM IS DISPLAYED.................................................344 TROUBLESHOOTING GOVERNOR PUMP CONTROLLER INPUT SIGNAL (F-MODE)..................................................346 ELECTRIC CIRCUIT DIAGRAM FOR (F MODE).......................................................................348 F1 BIT PATTERN 20-[1] SWING OIL PRESSURE SWITCH LIGHT INNOPERATIVE..........................................349 F-2 BIT PATTERN 20-[2] NOT USED.............................................................................350 F-3 BIT PATTERN 20-[3] BOOM LOWER OIL PRESSURE SWITCH LIGHT INNOPERATIVE....................................351 F-4 BIT PATTERN 20-[4] BOOM RAISE OIL PRESSURE SWITCH LIGHT INNOPERATIVE....................................352 F-5 BIT PATTERN 20-[5] ARM IN OIL PRESSURE SWITCH LIGHT INNOPERATVE.........................................353 F-6 BIT PATTERN 20-[60] ARM OUT OIL PRESSURE SWITCH LIGHT INNOPERATIVE......................................354 F-7 BIT PATTERN 12-[1] GRAPPLE OPEN OIL PRESSURE SWITCH LIGHT INNOPERATIVE..................................355 F-8 BIT PATTERN 12-[2] GRAPPLE CLOSED OIL PRESSURE LIGHT INNOPERATIVE.......................................356 F-9 BIT PATTERN 21-[3] SWING LOCK OIL PRESSURE SWITCH LIGHT INNOPERATIVE....................................357 F-10 BIT PATTERN 22-[5] MODE CONNECTION LIGHT INNOPERATIVE..................................................358 F-11 BIT PATTERN 22-[6] NOT USED............................................................................359 TROUBLESHOOTING MACHINE MECHANICAL SYSTEM (H-MODE)..............................................................361 PUMP MERGE DIVIDER LOGIC....................................................................................362 SOLENOID ACTUATION TABLE....................................................................................362 TABLE OF FAILURE MODES AND CAUSES...........................................................................363 H-1 SPEEDS OF WORK EQUIPMENT ARE SLOW OR LACK POWER.........................................................365 H-2 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS........................................................366 H-3 NO WORK EQUIPMENT OR SWING MOVEMENT.....................................................................366 H-4 ABNORMAL NOISE GENERATED AROUNG PUMPS...................................................................367 BLANK FAULT CODES...........................................................................................368 H-5.....................................................................................................368 H-6.....................................................................................................368 H-9.....................................................................................................368 H-10....................................................................................................368 H-14....................................................................................................368 H-15....................................................................................................368 H-16....................................................................................................368 H-17....................................................................................................368 H-19....................................................................................................368 H-20....................................................................................................368 H_21....................................................................................................368 H-23....................................................................................................368 H-24....................................................................................................368 H-7 BOOM IS SLOW OR LACKS POWER.............................................................................369 H-8 ARM IS SLOW OR LACKS POWER..............................................................................370 H-11 EXCESSIVE HYDRAULIC DRIFT..............................................................................371 1) EXCESSIVE HYDRAULIC DRIFT OF BOOM....................................................................371 2) EXCESSIVE HYDRAULIC DRIFT OF ARM.....................................................................371 H-12 EXCESSIVE TIME LAG (ENGINE AT IDLE)....................................................................372 H-13 OTHER EQUIPMENT MOVES WHEN SIGNAL CIRCUIT IS RELIEVED..................................................372 H-25 DOES NOT SWING.........................................................................................373 H-26 SWING ACCELERATION IS POOR OR SLOW.....................................................................374 H-27 EXCESSIVE OVERRUN WHEN STIPPING SWING MOTION...........................................................375 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)...............................................376 H-29 ABNORMAL NOISE WHEN STOPPING SWING.....................................................................376 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING.....................................................................377 H-31 SWING SPEED FASTER THAN SPECIFIED SWING SPEED..........................................................377 TROUBLESHOOTING MACHINE MONITOR SYSTEM (M-MODE).................................................................378 ACTIONS TAKEN BY MONITOR PANEL..............................................................................380 ELECTRIC CIRCUIT DIAGRAM FOR M MODE.........................................................................381 M-1 [E101] ABNORMALITY IN DATA OR IN CLOCK IS DISPLAYED.....................................................382 M-2 [E103] SHORT CIRCUIT IN BUZZER DISPLAYED................................................................383 M-3 [E104] AIR CLEANER RESTRICTION DETECTION DISPLAYED......................................................384 M-4 [E106] MAJOR DROP IN ENGINE OIL PRESSURE IS DISPLAYED...................................................384 M-5 [E108] 105° ENGINE COOLANT TEMPERATURE IS DISPLAYED.....................................................384 M-6 NO DISPLAY IN MONITOR PANEL WHEN IGNITION SWITCH IS IN THE "NO" POSITION................................385 M-7 WARNING LIGHTS ON MONITOR REMAIN ILLUMINATED WHILE MACHINE IS RUNNING...................................387 M-8 MONITOR PANEL DISPLAYS INCORRECT INFORMATION AFTER MACHINE IS RUNNING...................................387 M-9 WITH IGNITION SWITCH IN "ON" POSITION AND ENGINE OFF MONITOR PANEL DISPLAY FLASHES......................388 M-10 PREHEAT INDICATOR REMAINS ON AFTER ENGINE IS RUNNING...................................................391 M-11 WITH ENGINE RUNNING, MONITOR PANEL DISPLAY FLASHES.....................................................392 M-12 WITH IGNITION SRITCH IN THE "ON" POSITION, ENGINE SPEED, CAUTION AND EMERGENCY ITEMS FLASH W...........394 M-13 WITH ENGINE RUNNING, CAUTION AND EMERGENCY ITEMS FLASH DURING NORMAL OPERATION.........................396 M-14 WITH IGNITION SWITCH ON, AND ENGINE OFF, CAUTION ITEMS FLASH BUT DO NOT SOUND..........................399 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR PANEL BUT BUZZER SOUNDS.........................................400 M-16 DISPLAY ON MONITOR PANEL WORKS BUT NIGHT LIGHT ON PANEL DOES NOT ILLUMINATE............................401 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE................................................................402 M-18 COOLANT TEMPERATURE GAUGE DOES NOT WORK DURING NORMAL OPERATION........................................403 M-19 FUEL LEVEL GAUGE STUCK AT "FULL" INDICATION............................................................404 M-20 FUEL LEVEL GAUGE DOES NOT WORK.........................................................................405 M-12 SWING LOCK ON, BUT MONITOR PANEL DISPLAY DOES NOT WORK.................................................406 M-22 SWING PROLIX SEITCH IS ON, BUT MONITOR PANEL DISPLAY DOES NOT FLASH....................................407 M-23 HOUR METER DOES NOT WORK WHILE ENGINE IS RUNNING.......................................................408 M-24 WITH IGNITION SWITCH IN THE "OFF" POSITION, CLOCK AND HOUR METER ARE NOT DISPLAYED WHEN TIME...........408 M-25 FAULTY FUEL LEVER SENSOR SYSTEM........................................................................409 M-26 FAULTY COOLANT TEMPERATURE SENSOR SYSTEM...............................................................410 M-27 FAULTY OIL LEVEL SENSOR SYSTEM.........................................................................411 M-28 FAULTY COOLANT LEVEL SENSOR SYSTEM.....................................................................412 M-29 FAULTY HYDRAULIC OIL LEVEL SENSOR SYSTEM...............................................................413 M-30 [E112,113] WIPER OPERATION IS ABNORMAL WITH SWITCH IN THE "OFF" POSITION...............................414 M-31 WASHER WORKS, BUT WIPER DOES NOT WORK..................................................................418 30 DISASSEMBLY AND ASSEMBLY.........................................................................................420 SPECIAL TOOL LIST...............................................................................................424 SKETCHES OF SPECIAL TOOLS.......................................................................................428 ENGINE COMPONENTS...............................................................................................433 ALTERNATOR ASSEMBLY.........................................................................................433 AFTERCOOLER CORE ASSEMBLY...................................................................................433 CYLINDER HEAD ASSEMBLY......................................................................................433 CRANKSHAFT DAMPER AND PULLYASSEMBLY.........................................................................433 ENGINE OIL COOLER ASSEMBLY..................................................................................433 ENGINE OIL PUMP ASSEMBLY....................................................................................433 FUEL INJECTION PUMP ASSEMBLY................................................................................433 FUEL INJECTOR ASSEMBLY......................................................................................433 FRONT AND REAR ENGINE OIL SEAL ASSEMBLY.....................................................................433 GOVERNOR ASSEMBLY...........................................................................................433 STARTER MOTOR ASSEMBLY......................................................................................433 THERMOSTAT ASSEMBLY.........................................................................................433 TURBORCHARGER ASSEMBLY......................................................................................433 WATER PUMP ASSEMBLY.........................................................................................433 OIL COOLER......................................................................................................434 REMOVAL.....................................................................................................434 INSTALLATION................................................................................................435 RADIATOR, OIL COOLER AND AC CONDENSER...........................................................................436 REMOVAL.....................................................................................................436 INSTALLATION................................................................................................439 ENGINE WITH MAIN PUMP...........................................................................................440 REMOVAL.....................................................................................................440 INSTALLATION................................................................................................443 DAMPER..........................................................................................................445 REMOVAL.....................................................................................................445 INSTALLATION................................................................................................445 FUEL TANK.......................................................................................................446 REMOVAL.....................................................................................................446 INSTALLATION................................................................................................446 CENTER SWIVEL JOINT.............................................................................................447 REMOVAL.....................................................................................................447 INSTALLATION................................................................................................447 DISASSEMBLY.................................................................................................448 ASSEMBLY....................................................................................................448 SWING MOTOR.....................................................................................................449 REMOVAL.....................................................................................................449 INSTALLATION................................................................................................449 DISASSEMBLY.................................................................................................450 ASSEMBLY....................................................................................................452 SWING MACHINERY.................................................................................................458 REMOVAL.....................................................................................................458 INSTALLATION................................................................................................458 DISASSEMBLY.................................................................................................459 ASSEMBLY....................................................................................................462 REVOLVING FRAME.................................................................................................467 REMOVAL.....................................................................................................467 INSTALLATION................................................................................................468 SWING CIRCLE....................................................................................................469 REMOVAL.....................................................................................................469 INSTALLATION................................................................................................469 TRAVEL AND CARRIER SYSTEM.......................................................................................470 HYDRAULIC TANK AND PIPING...................................................................................470 TRAVEL SYSTEM HYDRAULICS....................................................................................470 TRAVEL MOTOR................................................................................................470 DRIVE AXLES REDUCTION BOXES.................................................................................470 STEERING SYSTEM.............................................................................................470 BRAKING SYSTEM..............................................................................................470 OUTRIGGER SYSTEM............................................................................................470 WORK SYSTEM.....................................................................................................471 ARM AND BOOM................................................................................................471 WORK EQUIPMENT..............................................................................................471 BOOM CYLINDER AND PIPING....................................................................................471 ARM CYLINDER AND PIPING.....................................................................................471 AUXILLURY PUMP SYSTEM.......................................................................................471 GENERATOR AND ELECTRICAL SYSTEM.............................................................................471 EQUIPMENT CONTROLS..........................................................................................471 MAIN PUMP.......................................................................................................472 REMOVAL.....................................................................................................472 INSTALLATION................................................................................................473 DISASSEMBLY.....................................................................................................474 PUMPS, FRONT AND REAR.......................................................................................474 FRONT PUMP TAIR DOWN....................................................................................474 REAR PUMP TAIR DOWN.....................................................................................479 ASSEMBLY........................................................................................................483 FRONT PUMP..................................................................................................483 MAIN PUMP OIL SEAL..............................................................................................502 REMOVAL.....................................................................................................502 INSTALLATION............................................................................................502 CONTROL VALVE...................................................................................................503 REMOVAL.....................................................................................................503 INSTALLATION................................................................................................505 DISASSEMBLY.................................................................................................506 (1/3)...................................................................................................506 (2/3)...................................................................................................507 (3/3)...................................................................................................508 ASSEMBLY....................................................................................................511 (1/3)...................................................................................................511 (2/3)...................................................................................................512 (3/3)...................................................................................................513 PUMP MERGE DIVIDER VALVE........................................................................................517 DISASSEMBLY.................................................................................................517 ASSEMBLY....................................................................................................517 PRESSURE COMPENSATION VALVE.....................................................................................518 DISASSEMBLY.................................................................................................518 ASSEMBLY....................................................................................................518 FRONT PUMP SERVO VALVE..........................................................................................519 REMOVAL.....................................................................................................519 INSTALLATION................................................................................................519 REAR PUMP SERVO VALVE...........................................................................................520 REMOVAL.....................................................................................................520 INSTALLATION................................................................................................520 LS-EPC SOLENOID VALVE...........................................................................................521 REMOVAL.....................................................................................................521 INSTALLATION................................................................................................521 SOLENOID VALVE..................................................................................................522 REMOVAL.....................................................................................................522 INSTALLATION................................................................................................522 WORK EQUIPMENT PPC VALVE........................................................................................523 REMOVAL.....................................................................................................523 INSTALLATION................................................................................................523 DISASSEMBLY.................................................................................................524 ASSEMBLY....................................................................................................524 PPC SHUTTLE VALVE...............................................................................................526 REMOVAL.....................................................................................................526 INSTALLATION................................................................................................527 DISASSEMBLY.................................................................................................527 ASSEMBLY....................................................................................................528 OPERATORS CAB...................................................................................................529 REMOVAL.....................................................................................................529 INSTALLATION................................................................................................530 COUNTERWEIGHT...................................................................................................531 REMOVAL.....................................................................................................531 INSTALLATION................................................................................................531 COMPRESSOR......................................................................................................532 REMOVAL.....................................................................................................532 INSTALLATION....................................................................................................532 CONDENSER.......................................................................................................533 REMOVAL.....................................................................................................533 INSTALLATION................................................................................................533 RECEIVER DRYER..................................................................................................534 REMOVAL.....................................................................................................534 INSTALLATION................................................................................................534 AIR CONDITIONER UNIT............................................................................................535 REMOVAL.....................................................................................................535 INSTALLATION................................................................................................536 GOVERNOR, PUMP CONTROLLER.......................................................................................537 REMOVAL.....................................................................................................537 INSTALLATION................................................................................................537 MONITOR PANEL...................................................................................................538 REMOVAL.....................................................................................................538 INSTALLATION................................................................................................538 CONTROL STAND CASE..............................................................................................539 REMOVAL.....................................................................................................539 TRAY....................................................................................................539 BOOT....................................................................................................539 UPPER CASE..............................................................................................540 INSTALLATION................................................................................................540 40 MAINTENANCE STANDARD.............................................................................................542 ENGINE MOUNTS...................................................................................................544 RADIATOR AND OIL COOLER MOUNTINGS (1/2).........................................................................545 RADIATOR AND OIL COOLER MOUNTINGS (2/2).........................................................................546 SPECIFICATIONS FOR RADIATOR AND OIL COOLER MOUNTINGS........................................................547 SWING MACHINERY.................................................................................................548 SWING CIRCLE....................................................................................................550 HYDRAULIC PUMP..................................................................................................551 CONTROL VALVE...................................................................................................552 SELF REDUCING PRESSURE VALVE....................................................................................562 SUCTION SAFETY VALVE............................................................................................563 SWING MOTOR.....................................................................................................564 WORK EQUIPMENT • SWING PPC VALVE................................................................................565 LS-EPC VALVE....................................................................................................567 SOLENOID VALVE..................................................................................................568 CENTER SWIVEL JOINT.............................................................................................569 90 OTHERS...........................................................................................................571 HYDRAULIC PIPING DRAWING........................................................................................573 HYDRAULIC PIPING SCHEMATIC......................................................................................575 DETAILS OF TROUBLESHOOTING, AND TROUBLESHOOTING PROCEDURE.......................................................585 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART I).........................................587 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART II)........................................589 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER AND ENGINE RELATED PARTS..........................................591 ELECTRICAL CIRCUIT DIAGRAM FOR (E) MODE.........................................................................593 (E-8) ENGINE DOES NOT START.................................................................................595 (A) IDLE SPEED IS IRREGULAR.....................................................................................597 (B) ENGINE SPEED IS HUNTING.....................................................................................599 (E-10) LACK OF OUTPUT, ENGINE HIGH IDLE SPEED IS LOW........................................................601 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART I).........................................605 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART II)........................................607 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART III).......................................609 ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE ( PART IV).......................................611 (E-11) ENGINE DOES NOT STOP.................................................................................603 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.................613 ELECTRIC CIRCUIT DIAGRAM FOR (C) MODE...........................................................................615 C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....................................617 C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....................................619 C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED......................................621 C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED......................................623 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED........................................625 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED........................................627 C-11 [E214] DISCONNECTION IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED................................629 ELECTRIC CIRCUIT DIAGRAM FOR (F) MODE...........................................................................631 TABLE OF FAILURE MODES AND CAUSES (1/2).........................................................................633 TABLE OF FAILURE MODES AND CAUSES (2/2).........................................................................635 (H-1) SPEEDS OF ALL WORK EQUIPMENT, SWING, ARE SLOW OR LACK POWER...........................................637 (H-4) ABNORMAL NOISE GENERATED AROUND PUMP..................................................................639 (H-7) BOOM IS SLOW OR LACKS POWER...........................................................................641 (H-26) SWING ACCELERATION IS POOR OR SLOW...................................................................645 (H-8) ARM IS SLOW OR LACKS POWER............................................................................643 ACTIONS TAKEN BY MONITOR WHEN ABNORMALITY OCCURS ON MACHINE.....................................................647 ELECTRICAL CIRCUIT DIAGRAM FOR (M) MODE.........................................................................649 (M-30) WIPER OPERATION IS ABNORMAL WITH SWITCH NOT BEING USED [Include E112, E113]..........................651 (M-31) WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED [Include E114]..........655 RADIATOR AND OIL COOLER MOUNTINGS (1/2).........................................................................657 RADIATOR AND OIL COOLER MOUNTINGS (2/2).........................................................................659
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