Komatsu PC650-3, PC650LC-3, PC650SE-3 Hydraulic Excavator Service Repair Manual
Description:
Komatsu PC650-3, PC650LC-3, PC650SE-3 Hydraulic Excavator Service Repair Manual
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
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 this section.
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 PC650-3, PC650LC-3, PC650SE-3 Hydraulic Excavator Service Repair Manual
COVER.................................................................................................................................................................................................. 1 CONTENTS............................................................................................................................................................................................... 2 10 ENGINE.............................................................................................................................................................................................. 27 11 STRUCTURE AND FUNCTION.......................................................................................................................................................................... 27 ENGINE RELATED PARTS........................................................................................................................................................................... 28 PTO (POWER TAKE-OFF)........................................................................................................................................................................... 29 PTO LUBRICATION SYSTEM......................................................................................................................................................................... 30 RADIATOR AND OIL COOLER........................................................................................................................................................................ 31 FUEL TANK AND PIPING........................................................................................................................................................................... 32 ENGINE CONTROL SYSTEM.......................................................................................................................................................................... 33 AUTO-DECELERATION SYSTEM (IF EQUIPPED)......................................................................................................................................................... 34 12 TESTING AND ADJUSTING........................................................................................................................................................................... 42 STANDARD FOR TESTING AND ADJUSTING............................................................................................................................................................. 43 TESTING AND ADJUSTING TOOL LIST................................................................................................................................................................ 43 ADJUSTING VALVE CLEARANCE...................................................................................................................................................................... 44 MEASURING COMPRESSION PRESSURE................................................................................................................................................................. 45 ADJUSTING FUEL INJECTION TIMING................................................................................................................................................................ 46 MEASURING EXHAUST GAS COLOR.................................................................................................................................................................... 47 MEASURING BLOW-BY PRESSURE..................................................................................................................................................................... 48 TESTING AND ADJUSTING FAN BELT TENSION......................................................................................................................................................... 49 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.................................................................................................................................................. 49 ADJUSTING FUEL CONTROL LEVER................................................................................................................................................................... 50 ADJUSTING AUTO-DECELERATION SYSTEM............................................................................................................................................................. 53 13 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................ 54 STARTING MOTOR................................................................................................................................................................................. 55 REMOVAL.................................................................................................................................................................................... 55 INSTALLATION............................................................................................................................................................................... 55 ALTERNATOR..................................................................................................................................................................................... 55 REMOVAL.................................................................................................................................................................................... 55 INSTALLATION............................................................................................................................................................................... 55 ENGINE OIL COOLER.............................................................................................................................................................................. 55 REMOVAL.................................................................................................................................................................................... 55 INSTALLATION............................................................................................................................................................................... 55 FUEL INJECTION PUMP............................................................................................................................................................................ 57 REMOVAL.................................................................................................................................................................................... 57 INSTALLATION............................................................................................................................................................................... 57 WATER PUMP..................................................................................................................................................................................... 57 REMOVAL.................................................................................................................................................................................... 57 INSTALLATION............................................................................................................................................................................... 57 NOZZLE HOLDER.................................................................................................................................................................................. 59 REMOVAL.................................................................................................................................................................................... 59 INSTALLATION............................................................................................................................................................................... 59 TURBOCHARGER................................................................................................................................................................................... 59 REMOVAL.................................................................................................................................................................................... 59 INSTALLATION............................................................................................................................................................................... 59 CYLINDER HEAD.................................................................................................................................................................................. 61 REMOVAL.................................................................................................................................................................................... 61 INSTALLATION............................................................................................................................................................................... 65 HYDRAULIC OIL COOLER........................................................................................................................................................................... 69 REMOVAL.................................................................................................................................................................................... 69 INSTALLATION............................................................................................................................................................................... 69 RADIATOR....................................................................................................................................................................................... 69 REMOVAL.................................................................................................................................................................................... 69 INSTALLATION............................................................................................................................................................................... 69 ENGINE, PTO AND HYDRAULIC PUMP................................................................................................................................................................. 71 REMOVAL.................................................................................................................................................................................... 71 INSTALLATION............................................................................................................................................................................... 75 PTO............................................................................................................................................................................................ 79 REMOVAL.................................................................................................................................................................................... 79 INSTALLATION............................................................................................................................................................................... 79 DISASSEMBLY................................................................................................................................................................................ 81 ASSEMBLY................................................................................................................................................................................... 81 DECELERATOR CYLINDER (IF EQUIPPED)............................................................................................................................................................. 85 REMOVAL.................................................................................................................................................................................... 85 INSTALLATION............................................................................................................................................................................... 85 14 MAINTENANCE STANDARD............................................................................................................................................................................ 87 PTO............................................................................................................................................................................................ 88 20 POWER TRAIN......................................................................................................................................................................................... 89 21 STRUCTURE AND FUNCTION.......................................................................................................................................................................... 89 POWER TRAIN ................................................................................................................................................................................... 90 TRAVEL AND BRAKE SYSTEM........................................................................................................................................................................ 92 1. OUTLINE................................................................................................................................................................................. 92 2. TRAVEL CONTROL CIRCUIT SCHEMATICS....................................................................................................................................................... 94 3. TRAVEL CONTROL CIRCUIT.................................................................................................................................................................. 96 4. STRAIGHT-TRAVEL SYSTEM.................................................................................................................................................................. 98 5. CENTER SWIVEL JOINT.....................................................................................................................................................................104 6. TRAVEL MOTOR (WITH PARKING BRAKE) ASSEMBLY..............................................................................................................................................105 7. TRAVEL BRAKE VALVE......................................................................................................................................................................121 8. FINAL DRIVE.............................................................................................................................................................................124 SWING SYSTEM...................................................................................................................................................................................127 1. OUTLINE.................................................................................................................................................................................127 2. SWING HYDRAULIC CIRCUIT SCHEMATICS......................................................................................................................................................128 3. SWING HYDRAULIC CIRCUIT.................................................................................................................................................................129 4. SWING PUMP..............................................................................................................................................................................130 5. SWING CONTROL VALVE.....................................................................................................................................................................133 6. SWING MOTOR (WITH MECHANICAL BRAKE) AND SAFETY VALVE ASSEMBLY...........................................................................................................................137 7. SWING BRAKE (AUTOMATIC) AND SWING PARKING BRAKE (MANUAL)................................................................................................................................143 8. FREE SWING SYSTEM.......................................................................................................................................................................147 9. SWING MACHINERY.........................................................................................................................................................................152 10. SWING CIRCLE...........................................................................................................................................................................154 23 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................155 CENTER SWIVEL JOINT............................................................................................................................................................................156 REMOVAL....................................................................................................................................................................................156 INSTALLATION...............................................................................................................................................................................156 DISASSEMBLY................................................................................................................................................................................158 ASSEMBLY...................................................................................................................................................................................158 TRAVEL MOTOR (WITH FOUR TRAVEL MOTORS).........................................................................................................................................................160 REMOVAL....................................................................................................................................................................................160 INSTALLATION...............................................................................................................................................................................160 DISASSEMBLY................................................................................................................................................................................164 ASSEMBLY...................................................................................................................................................................................170 TRAVEL BRAKE VALVE (WITH FOUR TRAVEL MOTORS)...................................................................................................................................................160 REMOVAL....................................................................................................................................................................................160 INSTALLATION...............................................................................................................................................................................160 TRAVEL MOTOR (WITH TWO TRAVEL MOTORS)..........................................................................................................................................................162 REMOVAL....................................................................................................................................................................................162 INSTALLATION...............................................................................................................................................................................162 DISASSEMBLY................................................................................................................................................................................180 ASSEMBLY...................................................................................................................................................................................193 FINAL DRIVE....................................................................................................................................................................................209 REMOVAL (WITH FOUR TRAVEL MOTORS)..........................................................................................................................................................209 INSTALLATION (WITH FOUR TRAVEL MOTORS).....................................................................................................................................................209 REMOVAL (WITH TWO TRAVEL MOTORS)...........................................................................................................................................................211 INSTALLATION (WITH TWO TRAVEL MOTORS)......................................................................................................................................................211 DISASSEMBLY (WITH FOUR TRAVEL MOTORS)......................................................................................................................................................213 ASSEMBLY (WITH FOUR TRAVEL MOTORS).........................................................................................................................................................217 DISASSEMBLY (WITH TWO TRAVEL MOTORS).......................................................................................................................................................225 ASSEMBLY (WITH TWO TRAVEL MOTORS)..........................................................................................................................................................229 SPROCKET.......................................................................................................................................................................................237 REMOVAL....................................................................................................................................................................................237 INSTALLATION...............................................................................................................................................................................237 SWING PUMP.....................................................................................................................................................................................239 REMOVAL....................................................................................................................................................................................239 INSTALLATION...............................................................................................................................................................................239 DISASSEMBLY................................................................................................................................................................................241 ASSEMBLY...................................................................................................................................................................................245 CO・NC VALVE (FOR SWING PUMP)...................................................................................................................................................................255 REMOVAL....................................................................................................................................................................................255 INSTALLATION...............................................................................................................................................................................255 SERVO VALVE (FOR SWING PUMP)...................................................................................................................................................................255 REMOVAL....................................................................................................................................................................................255 INSTALLATION...............................................................................................................................................................................255 SWING CONTROL VALVE............................................................................................................................................................................255 REMOVAL....................................................................................................................................................................................255 INSTALLATION...............................................................................................................................................................................255 DISASSEMBLY................................................................................................................................................................................257 ASSEMBLY...................................................................................................................................................................................257 MAIN RELIEF VALVE (FOR SWING CONTROL VALVE)....................................................................................................................................................257 REMOVAL....................................................................................................................................................................................257 INSTALLATION...............................................................................................................................................................................257 SWING MOTOR....................................................................................................................................................................................259 REMOVAL....................................................................................................................................................................................259 INSTALLATION...............................................................................................................................................................................259 DISASSEMBLY................................................................................................................................................................................261 ASSEMBLY...................................................................................................................................................................................265 REVOLVING FRAME................................................................................................................................................................................269 REMOVAL....................................................................................................................................................................................269 INSTALLATION...............................................................................................................................................................................269 SWING CIRCLE...................................................................................................................................................................................271 REMOVAL....................................................................................................................................................................................271 INSTALLATION...............................................................................................................................................................................271 SWING MACHINERY................................................................................................................................................................................273 REMOVAL....................................................................................................................................................................................273 INSTALLATION...............................................................................................................................................................................273 DISASSEMBLY................................................................................................................................................................................275 ASSEMBLY...................................................................................................................................................................................279 24 MAINTENANCE STANDARD............................................................................................................................................................................283 TRAVEL MOTOR...................................................................................................................................................................................284 TRAVEL SHUTTLE VALVE...........................................................................................................................................................................285 STRAIGHT-TRAVEL VALVE..........................................................................................................................................................................286 TRAVEL BRAKE VALVE.............................................................................................................................................................................287 FINAL DRIVE....................................................................................................................................................................................289 SWING CONTROL VALVE............................................................................................................................................................................293 JET SENSOR.....................................................................................................................................................................................295 SWING MOTOR....................................................................................................................................................................................296 SWING SHADOW VALVE (IF EQUIPPED)...............................................................................................................................................................297 CONNECTION VALVE (IF EQUIPPED).................................................................................................................................................................298 SWING MACHINERY................................................................................................................................................................................299 SWING CIRCLE...................................................................................................................................................................................301 30 UNDERCARRIAGE.......................................................................................................................................................................................302 31 STRUCTURE AND FUNCTION..........................................................................................................................................................................302 TRACK FRAME....................................................................................................................................................................................303 IDLER CUSHION..................................................................................................................................................................................305 IDLER..........................................................................................................................................................................................309 TRACK ROLLER...................................................................................................................................................................................310 CARRIER ROLLER.................................................................................................................................................................................311 TRACK SHOE.....................................................................................................................................................................................312 33 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................314 IDLER..........................................................................................................................................................................................315 REMOVAL....................................................................................................................................................................................315 INSTALLATION...............................................................................................................................................................................315 IDLER CUSHION..................................................................................................................................................................................315 REMOVAL....................................................................................................................................................................................315 INSTALLATION...............................................................................................................................................................................315 DISASSEMBLY................................................................................................................................................................................317 ASSEMBLY...................................................................................................................................................................................317 IDLER ADJUSTMENT CYLINDER......................................................................................................................................................................317 DISASSEMBLY................................................................................................................................................................................317 ASSEMBLY...................................................................................................................................................................................317 TRACK ROLLER...................................................................................................................................................................................319 REMOVAL....................................................................................................................................................................................319 INSTALLATION...............................................................................................................................................................................319 CARRIER ROLLER.................................................................................................................................................................................319 REMOVAL....................................................................................................................................................................................319 INSTALLATION...............................................................................................................................................................................319 TRACK SHOE.....................................................................................................................................................................................321 REMOVAL....................................................................................................................................................................................321 INSTALLATION...............................................................................................................................................................................321 34 MAINTENANCE STANDARD............................................................................................................................................................................323 TRACK FRAME....................................................................................................................................................................................324 TRACK SHOE.....................................................................................................................................................................................325 IDLER..........................................................................................................................................................................................327 TRACK ROLLER...................................................................................................................................................................................329 CARRIER ROLLER.................................................................................................................................................................................331 50 AIR SYSTEM..........................................................................................................................................................................................332 51 STRUCTURE AND FUNCTION..........................................................................................................................................................................332 AIR PIPING.....................................................................................................................................................................................333 AIR CIRCUIT DIAGRAM............................................................................................................................................................................334 AIR GOVERNOR...................................................................................................................................................................................335 AIR TANK.......................................................................................................................................................................................335 SAFETY VALVE...................................................................................................................................................................................336 HORN VALVE.....................................................................................................................................................................................336 GREASE PUMP....................................................................................................................................................................................337 60 HYDRAULIC SYSTEM....................................................................................................................................................................................338 61 STRUCTURE AND FUNCTION..........................................................................................................................................................................338 HYDRAULIC PIPING...............................................................................................................................................................................339 HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................................................................343 WORK EQUIPMENT CONTROL.........................................................................................................................................................................347 ELECTRONIC AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM (IF EQUIPPED)...............................................................................................................................363 HYDRAULIC TANK.................................................................................................................................................................................372 MAIN PUMP......................................................................................................................................................................................373 HYDRAULIC OIL FILTER...........................................................................................................................................................................392 CHARGING AND PTO LUBRICATING PUMP..............................................................................................................................................................396 2-STAGE AND 3-STAGE MODE SELECTOR OLSS (OPEN CENTER LOAD SENSING SYSTEM).......................................................................................................................397 HYDRAULIC CONTROL VALVE........................................................................................................................................................................415 PPC VALVE......................................................................................................................................................................................422 PPC SHUTTLE VALVE..............................................................................................................................................................................428 ACCUMULATOR....................................................................................................................................................................................430 PILOT RELIEF VALVE.............................................................................................................................................................................431 SAFETY LOCK VALVE..............................................................................................................................................................................433 HYDRAULIC CYLINDER.............................................................................................................................................................................435 WORK EQUIPMENT.................................................................................................................................................................................442 62 TESTING AND ADJUSTING...........................................................................................................................................................................444 TABLE OF JUDGEMENT STANDARD VALUE..............................................................................................................................................................445 TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE...................................................................................................................................................454 TESTING AND ADJUSTING TOOL LIST................................................................................................................................................................468 TESTING TRAVEL AND OPERATING FORCE.............................................................................................................................................................469 TESTING AND ADJUSTING MAIN RELIEF VALVE........................................................................................................................................................470 TESTING CONTROL CIRCUIT PRESSURE...............................................................................................................................................................472 MEASURING DISCHARGE OF MAIN PISTON PUMP........................................................................................................................................................475 CHECKING AND ADJUSTING TRAVEL MOTOR PERFORMANCE................................................................................................................................................476 MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR..............................................................................................................................................479 TESTING OIL LEAKAGE FROM SWIVEL JOINT..........................................................................................................................................................480 BLEEDING AIR...................................................................................................................................................................................482 CHARGING ACCUMULATOR WITH GAS..................................................................................................................................................................485 TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK...............................................................................................................................................487 ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER.....................................................................................................................................................488 ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX.......................................................................................................................................................489 TROUBLESHOOTING................................................................................................................................................................................494 ELECTRICAL CIRCUIT DIAGRAM.................................................................................................................................................................495 POSITION OF CONNECTORS FOR TROUBLESHOOTING ................................................................................................................................................499 CONNECTION TABLE FOR CONNECTOR PINS........................................................................................................................................................509 TROUBLESHOOTING PROCEDURE..................................................................................................................................................................513 CHECKS BEFORE TROUBLESHOOTING..............................................................................................................................................................514 E.H MODE TROUBLESHOOTING...................................................................................................................................................................517 ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY..............................................................................................................................518 TROUBLESHOOTING (EXCEPT TROUBLESHOOTING FOR MACHINE MONITOR)...........................................................................................................................519 E-1 MACHINE DEVIATES EXCESSIVELY.......................................................................................................................................................523 a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................524 b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................526 E-2 WORK EQUIPMENT, SWING, TRAVEL SPEEDS EXTREMELY SLOW, OR LACK OF POWER..............................................................................................................527 a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................527 b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................529 E-3 ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS.............................................................................................................................532 a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................532 b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................534 E-4 NO CHANGE IN OUTPUT WHEN MODE SWITCH IS OPERATED...................................................................................................................................535 a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................536 b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................536 E-5 AUTO-DECELERATION DOES NOT WORK....................................................................................................................................................541 a) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................541 b) IF CAUSE IS REMOVED WHEN SWITCHING TO PROLIX CIRCUIT (WHEN SELF-TESTING DISPLAY SHOWS NORMAL)...................................................................................545 E-6 SWING DOES NOT WORK................................................................................................................................................................547 E-7 EXCESSIVE HYDRAULIC DRIFT OF SWING ................................................................................................................................................549 E-8 TRAVEL SPEED DOES NOT SWITCH.......................................................................................................................................................550 a) SPEED DOES NOT INCREASE WHEN PLACED IN HI (DOES NOT SWITCH TO HI)...............................................................................................................550 b) SPEED DOES NOT DECREASE WHEN PLACED IN LO.......................................................................................................................................550 H-1 MACHINE DEVIATES EXCESSIVELY (DEVIATES MORE THAN STANDARD WHEN ONLY TRAVEL SYSTEM IS USED, TRAVEL LEVER AT FULL POSITION)..........................................................556 H-2 EXCESSIVE DEVIATION IN TRAVEL DURING SIMULTANEOUS OPERATIONS.......................................................................................................................560 H-3 MACHINE DEVIATES EXCESSIVELY WHEN STARTING.........................................................................................................................................562 H-4 CONTROL LEVERS ARE EXTREMELY HEAVY.................................................................................................................................................564 a) IF TRAVEL LEVER IS HEAVY........................................................................................................................................................564 b) IF WORK EQUIPMENT LEVERS ARE HEAVY..............................................................................................................................................564 H-5 WORK EQUIPMENT, TRAVEL, AND SWING START SUDDENLY DURING FINE CONTROL OPERATIONS....................................................................................................565 H-6 SPEEDS FOR WORK EQUIPMENT, SWING, AND TRAVEL ARE ALL EXTREMELY SLOW, OR THERE IS NO POWER..........................................................................................566 a) MACHINE HARDLY MOVES............................................................................................................................................................566 b) ABNORMALITY IN SOME PART (ABNORMALITY ON ONE SIDE)..............................................................................................................................568 H-7 ENGINE STALLS OR ENGINE SPEED DROPS DURING OPERATIONS..............................................................................................................................570 H-8 NO CHANGE IN OUTPUT WHEN MODE SELECTOR SWITCH IS OPERATED..........................................................................................................................571 H-9 AUTO-DECELERATION DOES NOT COME ON, OR DOES NOT GO OFF.............................................................................................................................572 H-10 ABNORMAL NOISE COMES FROM AROUND PUMP.............................................................................................................................................572 H-11 SWING SPEED IS SLOW, OR OVERRUN WHEN STOPPING SWING IS EXCESSIVE..................................................................................................................573 H-12 UPPER STRUCTURE DOES NOT SWING....................................................................................................................................................575 H-13 EXCESSIVE HYDRAULIC DRIFT.........................................................................................................................................................577 H-16 EXCESSIVE TIME LAG FOR WORK EQUIPMENT.............................................................................................................................................577 H-17 TRAVEL SPEED DOES NOT SWITCH......................................................................................................................................................578 a) SPEED DOES NOT INCREASE EVEN WHEN SELECTOR SWITCH IS PLACED IN HI...............................................................................................................578 b) SPEED DOES NOT DECREASE EVEN WHEN SELECTOR SWITCH IS PLACED IN LO...............................................................................................................578 FAILURE MODE AND COMPONENTS............................................................................................................................................................579 W.L MODE TROUBLESHOOTING ..................................................................................................................................................................580 ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY..............................................................................................................................581 TROUBLESHOOTING........................................................................................................................................................................582 W-1 IN ARC DIGGING MODE, WORK EQUIPMENT CARRIES OUT HORIZONTAL DIGGING, OR THERE IS BUCKET ANGLE COMPENSATION..........................................................................584 W-2 IN HORIZONTAL DIGGING MODE, WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING...................................................................................................585 a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY..................................................................................................................................585 b) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................587 W-3 IN HORIZONTAL DIGGING MODE, THERE IS BUCKET ANGLE COMPENSATION.....................................................................................................................593 W-4 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, WORK EQUIPMENT CARRIES OUT HORIZONTAL DIGGING, BUT THERE IS NO BUCKET ANGLE COMPENSATION...................................594 a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY..................................................................................................................................594 b) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................596 W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, THERE IS BUCKET ANGLE COMPENSATION, BUT WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING...............................598 a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY..................................................................................................................................598 b) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................598 W-6 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING, AND THERE IS NO BUCKET ANGLE COMPENSATION............................600 a) SELF-TESTING DISPLAY DOES NOT SHOW ABNORMALITY..................................................................................................................................600 b) SELF-TESTING DISPLAY SHOWS ABNORMALITY..........................................................................................................................................601 L-1 WORK EQUIPMENT DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION..................................................................................................607 63 DISASSEMBLY AND ASSEMBLY........................................................................................................................................................................608 CHARGING AND PTO LUBRICATION PUMP..............................................................................................................................................................609 REMOVAL AND INSTALLATION...................................................................................................................................................................609 NO.1 PUMP......................................................................................................................................................................................611 REMOVAL AND INSTALLATION...................................................................................................................................................................611 NO.2 PUMP......................................................................................................................................................................................613 REMOVAL AND INSTALLATION...................................................................................................................................................................613 MAIN PUMP......................................................................................................................................................................................615 DISASSEMBLY................................................................................................................................................................................615 ASSEMBLY...................................................................................................................................................................................619 SERVO VALVE (FOR NO.1 FRONT PUMP)..............................................................................................................................................................631 REMOVAL AND INSTALLATION...................................................................................................................................................................631 SERVO VALVE (FOR NO.1 REAR PUMP)...............................................................................................................................................................631 REMOVAL AND INSTALLATION...................................................................................................................................................................631 SERVO VALVE (FOR NO.2 FRONT PUMP)..............................................................................................................................................................631 REMOVAL AND INSTALLATION...................................................................................................................................................................631 SERVO VALVE (FOR NO.2 REAR PUMP)...............................................................................................................................................................631 REMOVAL AND INSTALLATION...................................................................................................................................................................631 CO・NC VALVE (FOR NO.1 FRONT PUMP)..............................................................................................................................................................633 REMOVAL AND INSTALLATION...................................................................................................................................................................633 CO・NC VALVE (FOR NO.1 REAR PUMP)...............................................................................................................................................................633 REMOVAL AND INSTALLATION...................................................................................................................................................................633 TVC VALVE......................................................................................................................................................................................635 REMOVAL AND INSTALLATION...................................................................................................................................................................635 L.H.5-SPOOL CONTROL VALVE......................................................................................................................................................................637 REMOVAL....................................................................................................................................................................................637 INSTALLATION...............................................................................................................................................................................639 R.H.4-SPOOL CONTROL VALVE......................................................................................................................................................................643 REMOVAL ...................................................................................................................................................................................643 INSTALLATION...............................................................................................................................................................................645 CONTROL VALVE..................................................................................................................................................................................649 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................649 MAIN RELIEF VALVE (FOR L.H.5-SPOOL,R.H.4-SPOOL VALVE)..........................................................................................................................................651 REMOVAL AND INSTALLATION...................................................................................................................................................................651 PILOT RELIEF VALVE.............................................................................................................................................................................651 REMOVAL AND INSTALLATION...................................................................................................................................................................651 PPC VALVE (FOR TRAVEL).........................................................................................................................................................................653 REMOVAL AND INSTALLATION...................................................................................................................................................................653 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................655 PPC VALVE (FOR WORK EQUIPMENT AND SWING).......................................................................................................................................................655 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................655 BOOM CYLINDER (BACK HOE).......................................................................................................................................................................657 REMOVAL AND INSTALLATION...................................................................................................................................................................657 ARM CYLINDER (BACK HOE)........................................................................................................................................................................659 REMOVAL AND INSTALLATION...................................................................................................................................................................659 BUCKET CYLINDER (BACK HOE).....................................................................................................................................................................661 REMOVAL AND INSTALLATION...................................................................................................................................................................661 BOOM CYLINDER (LOADING SHOVEL).................................................................................................................................................................663 REMOVAL AND INSTALLATION...................................................................................................................................................................663 ARM CYLINDER (LOADING SHOVEL)..................................................................................................................................................................665 REMOVAL AND INSTALLATION...................................................................................................................................................................665 BUCKET CYLINDER (LOADING SHOVEL)...............................................................................................................................................................667 REMOVAL AND INSTALLATION...................................................................................................................................................................667 BOTTOM DUMP CYLINDER (LOADING SHOVEL)..........................................................................................................................................................669 REMOVAL AND INSTALLATION...................................................................................................................................................................669 HYDRAULIC CYLINDER.............................................................................................................................................................................671 DISASSEMBLY................................................................................................................................................................................671 ASSEMBLY...................................................................................................................................................................................675 BUCKET (BACK HOE)..............................................................................................................................................................................679 REMOVAL AND INSTALLATION...................................................................................................................................................................679 ARM (BACK HOE).................................................................................................................................................................................681 REMOVAL AND INSTALLATION...................................................................................................................................................................681 BOOM (BACK HOE)................................................................................................................................................................................683 REMOVAL AND INSTALLATION...................................................................................................................................................................683 BUCKET AND ARM (BACK HOE)......................................................................................................................................................................685 REMOVAL AND INSTALLATION...................................................................................................................................................................685 WORK EQUIPMENT (BACK HOE)......................................................................................................................................................................687 REMOVAL AND INSTALLATION...................................................................................................................................................................687 BUCKET (LOADING SHOVEL)........................................................................................................................................................................689 REMOVAL AND INSTALLATION...................................................................................................................................................................689 ARM (LOADING SHOVEL)...........................................................................................................................................................................691 REMOVAL AND INSTALLATION...................................................................................................................................................................691 BOOM (LOADING SHOVEL)..........................................................................................................................................................................693 REMOVAL AND INSTALLATION...................................................................................................................................................................693 WORK EQUIPMENT (LOADING SHOVEL)................................................................................................................................................................695 REMOVAL AND INSTALLATION...................................................................................................................................................................695 POTENTIOMETER (LOADING SHOVEL).................................................................................................................................................................697 DISASSEMBLY AND ASSEMBLY...................................................................................................................................................................697 COUNTERWEIGHT .................................................................................................................................................................................697 REMOVAL AND INSTALLATION...................................................................................................................................................................697 64 MAINTENANCE STANDARD............................................................................................................................................................................699 CHARGING AND PTO LUBRICATION PUMP..............................................................................................................................................................700 PILOT RELIEF VALVE.............................................................................................................................................................................701 L.H. 5-SPOOL CONTROL VALVE.....................................................................................................................................................................702 R.H. 4-SPOOL CONTROL VALVE.....................................................................................................................................................................704 PPC VALVE......................................................................................................................................................................................706 PPC SHUTTLE VALVE..............................................................................................................................................................................707 HYDRAULIC CYLINDER.............................................................................................................................................................................708 WORK EQUIPMENT.................................................................................................................................................................................712 80 ELECTRIC AND ELECTRONIC SYSTEM......................................................................................................................................................................716 81 STRUCTURE AND FUNCTION..........................................................................................................................................................................716 ELECTRICAL WIRING DIAGRAM......................................................................................................................................................................717 ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................................................................................719 ELECTRONIC COMPONENTS OF 3-STAGE MODE SELECTOR OLSS............................................................................................................................................723 ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM...............................................................................................................................728 EVMS...........................................................................................................................................................................................732 82 TESTING AND ADJUSTING...........................................................................................................................................................................740 ELECTRICAL CIRCUIT DIAGRAM.....................................................................................................................................................................741 POSITION OF CONNECTORS FOR TROUBLESHOOTING ....................................................................................................................................................743 M MODE TROUBLESHOOTING.........................................................................................................................................................................753 SERIAL NO: 10501-10599.....................................................................................................................................................................755 M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR...........................................................................................................755 a) NO DISPLAY APPEARS ON MONITOR PANEL (GAUGES AND MONITOR ITEMS)..................................................................................................................755 b) DISPLAY OF EITHER GAUGES OR MONITOR ITEMS DOES NOT APPEAR ON MONITOR PANEL......................................................................................................755 c) DISPLAY DOES NOT APPEAR ON PART OF MONITOR PANEL ASSEMBLY.......................................................................................................................756 M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT GO OUT...................................................................................................................756 M-3 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP.............................................................757 a) (COOLANT LEVEL) FLASHES.........................................................................................................................................................757 b) (ENGINE OIL LEVEL) FLASHES......................................................................................................................................................757 c) (HYDRAULIC OIL LEVEL) FLASHES...................................................................................................................................................758 d) (HEATER SIGNAL) FLASHES.........................................................................................................................................................758 M-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CHECK BEFORE STARTING ITEMS FLASH..............................................................................................760 a) ALTERNATOR SYSTEM...............................................................................................................................................................760 b) ENGINE OIL PRESSURE SYSTEM......................................................................................................................................................760 M-5 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CAUTION ITEMS FLASH......................................................................................................762 M-6 WHEN STARTING SWITCH IS ON (ENGINE STARTED), CAUTION ITEMS FLASH...................................................................................................................763 a) (ENGINE OIL PRESSURE) FLASHES...................................................................................................................................................763 b) (COOLANT LEVEL) FLASHES.........................................................................................................................................................763 c) (COOLANT TEMPERATURE GAUGE) FLASHES.............................................................................................................................................764 d) (CHARGE LEVEL) FLASHES..........................................................................................................................................................764 e) (HYDRAULIC OIL FILTER) FLASHES..................................................................................................................................................765 f) (HYDRAULIC OIL TEMPERATURE) FLASHES.............................................................................................................................................766 M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 2 SECONDS, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND................................................769 M-8 NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS...........................................................................................................................771 M-9 MONITOR PANEL LAMPS DO NOT LIGHT UP (INDICATION ON MONITOR PANEL IS CORRECT).......................................................................................................772 a) NO LAMPS ON PANEL LIGHT UP......................................................................................................................................................772 b) SOME LAMPS ON PANEL DO NOT LIGHT UP.............................................................................................................................................773 M-10 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE WHEN ENGINE IS STOPPED, SERVICE METER MOVES...................................................................................775 a) SERVICE METER DOES NOT MOVE.....................................................................................................................................................775 b) SERVICE METER DOES NOT STOP MOVING .............................................................................................................................................776 M-11 ENGINE COOLANT TEMPERATURE IS HIGH, BUT LOWEST LEVEL DISPLAYED....................................................................................................................777 M-12 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY.................................................................................................................................777 M-13 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK.................................................................................................................................779 M-14 NO DISPLAY IS GIVEN FOR FUEL LEVEL................................................................................................................................................779 SERIAL NO: 10600 AND UP....................................................................................................................................................................781 M-1 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR...........................................................................................................781 a) NO DISPLAY APPEARS ON MONITOR PANEL (GAUGE AND MONITOR ITEMS)...................................................................................................................781 b) DISPLAY DOES NOT APPEAR ON PART OF MONITOR PANEL ASSEMBLY.......................................................................................................................781 M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DOES NOT GO OUT...................................................................................................................781 M-3 WHEN STARTING SWITCH IS TURNED ON (DO NOT START ENGINE), CHECK BEFORE STARTING ITEM FLASH OR PREHEATING ITEM LIGHTS UP (FLUID LEVEL OF CHECK BEFORE STARTING ITEMS ARE CORRECT)....782 a) (COOLANT LEVEL) FLASHES.........................................................................................................................................................782 b) (ENGINE OIL LEVEL) FLASHES......................................................................................................................................................782 c) (HYDRAULIC OIL LEVEL) FLASHES...................................................................................................................................................783 M-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CHECK BEFORE STARTING ITEMS FLASH..............................................................................................785 a) ALTERNATOR SYSTEM...............................................................................................................................................................785 b) ENGINE OIL PRESSURE SYSTEM......................................................................................................................................................785 M-5 WHEN STARTING SWITCH IS TURNED ON, (DO NOT START ENGINE), CAUTION ITEMS FLASH......................................................................................................787 M-6 WHEN STARTING SWITCH IS ON (ENGINE STARTED), CAUTION ITEMS FLASH...................................................................................................................788 a) (ENGINE OIL PRESSURE) FLASHES...................................................................................................................................................788 b) (COOLANT LEVEL) FLASHES.........................................................................................................................................................788 c) (COOLANT TEMPERATURE GAUGE) FLASHES.............................................................................................................................................789 d) (CHARGE LEVEL) FLASHES..........................................................................................................................................................789 e) (HYDRAULIC OIL FILTER) FLASHES..................................................................................................................................................790 f) (HYDRAULIC OIL TEMPERATURE) FLASHES.............................................................................................................................................790 M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 1 SECOND, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND.................................................793 M-8 NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS...........................................................................................................................793 M-9 MONITOR PANEL LAMPS DO NOT LIGHT UP (INDICATION ON MONITOR PANEL IS CORRECT).......................................................................................................795 M-10 WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE WHEN ENGINE IS STOPPED, SERVICE METER MOVES...................................................................................796 a) SERVICE METER DOES NOT MOVE, WHEN ENGINE IS STARTED.............................................................................................................................796 b) SERVICE METER DOES NOT STOP MOVING, WHEN ENGINE IS STOPPED......................................................................................................................796 M-11 ENGINE COOLANT TEMPERATURE IS HIGH, BUT LOWEST LEVEL DISPLAYED....................................................................................................................798 M-12 ENGINE COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY.................................................................................................................................798 M-13 FUEL TANK IS NOT FULL BUT DISPLAY SHOWS FULL TANK.................................................................................................................................800 M-14 NO DISPLAY IS GIVEN FOR FUEL LEVEL................................................................................................................................................800
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