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Komatsu PW160-7E0 Hydraulic Excavator Shop Manual (H55051 and up) PDF
Komatsu PW160-7E0 Hydraulic Excavator Shop Manual (H55051 and up)
FILE DETAILS:
Komatsu PW160-7E0 Hydraulic Excavator Shop Manual (H55051 and up)
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Product Code : VEBM395100
Total Pages : 1140
DESCRIPTION:
Komatsu PW160-7E0 Hydraulic Excavator Shop Manual (H55051 and up)
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters: these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
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 eachr 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 PW160-7E0 Hydraulic Excavator Shop Manual (H55051 and up)
VEBM395100 PW160-7E0........................................................................................................................... 1 SAFETY......................................................................................................................................... 3 SAFETY NOTICE.............................................................................................................................. 3 IMPORTANT SAFETY NOTICE................................................................................................................ 3 GENERAL PRECAUTIONS.................................................................................................................... 3 PRECAUTIONS DURING WORK................................................................................................................ 4 01 GENERAL..................................................................................................................................... 21 SPECIFICATION DIMENSION DRAWINGS........................................................................................................... 22 DIMENSIONS............................................................................................................................. 22 1 pIECE BOOM....................................................................................................................... 22 WORKING RANGES............................................................................................................................. 24 1 PIECE BOOM........................................................................................................................... 24 2 PIECE BOOM........................................................................................................................... 25 SPECIFICATIONS............................................................................................................................. 26 WEIGHT TABLE............................................................................................................................... 28 1 piece boom........................................................................................................................... 29 2 piece boom........................................................................................................................... 30 FUEL, COOLANT AND LUBRICANTS............................................................................................................... 31 10 STRUCTURE, FUNCTION AND..................................................................................................................... 33 ENGINE RELATED PARTS....................................................................................................................... 34 RADIATOR . OIL COOLER . CHARGE AIR COOLER.................................................................................................. 35 POWER TRAIN................................................................................................................................ 36 SWING CIRCLE............................................................................................................................... 38 SWING MACHINERY & MOTOR.................................................................................................................... 40 SWING MOTOR................................................................................................................................ 44 Operation of swing lock................................................................................................................ 48 RELIEF VALVE PORTION................................................................................................................... 49 Operation.............................................................................................................................. 49 UNDERCARRIAGE.............................................................................................................................. 50 TRANSMISSION............................................................................................................................... 52 ATT EPC VALVE ASSEMBLY..................................................................................................................... 55 QUICK COUPLER CONTROL VALVE................................................................................................................ 56 TRAVEL MOTOR............................................................................................................................... 58 OPERATION OF TRAVEL MOTOR.............................................................................................................. 60 CLUTCH CONTROL CIRCUIT..................................................................................................................... 62 AXLE....................................................................................................................................... 64 SUSPENSION LOCK CYLINDER................................................................................................................... 68 BRAKING SYSTEM............................................................................................................................. 70 BRAKE/STEER PUMP........................................................................................................................... 72 PRIORITY VALVE............................................................................................................................. 73 POWER BRAKE VALVE.......................................................................................................................... 74 SPECIFICATIONS......................................................................................................................... 74 FUNCTION............................................................................................................................... 75 ACCUMULATOR for brake system............................................................................................................... 76 STEERING SYSTEM............................................................................................................................ 78 STEERING COLUMN............................................................................................................................ 79 ORBITROL VALVE............................................................................................................................. 80 HYDRAULIC EQUIPMENT LAYOUT DRAWINGS........................................................................................................ 81 HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................. 84 HYDRAULIC TANK............................................................................................................................. 85 HYDRAULIC PUMP............................................................................................................................. 86 HPV125................................................................................................................................. 86 LS VALVE............................................................................................................................... 91 PC VALVE............................................................................................................................... 91 LS(pc)-EPC VALVE....................................................................................................................... 104 PILOT PRESSURE CONTROL (PPC) SYSTEM........................................................................................................ 107 CONTROL VALVE.............................................................................................................................. 108 PW160-7E0.............................................................................................................................. 108 CLSS....................................................................................................................................... 118 OUTLINE OF CLSS........................................................................................................................ 118 CENTre SWIVEL JOINT........................................................................................................................ 139 TRAVEL PPC PEDAL........................................................................................................................... 140 WORK EQUIPMENT . SWING PPC VALVE........................................................................................................... 142 SOLENOID VALVE MANIFOLD.................................................................................................................... 146 SOLENOID VALVE BLOCK................................................................................................................... 147 2 Position 3 way valve............................................................................................................. 147 2 Position 4 way valve............................................................................................................. 149 attachment epc valve................................................................................................................... 151 BOOM SAFETY VALVE.......................................................................................................................... 154 HYDRAULIC CYLINDER......................................................................................................................... 157 BOOM CYLINDER.......................................................................................................................... 157 ARM CYLINDER........................................................................................................................... 157 BUCKET CYLINDER........................................................................................................................ 157 ADJUST CYLINDER........................................................................................................................ 158 OUTRIGGER CYLINDER......................................................................................................................... 160 DOZER CYLINDER............................................................................................................................. 162 WORK EQUIPMENT............................................................................................................................. 164 Work Equipment......................................................................................................................... 165 1. DIMENSION OF ARM.................................................................................................................... 167 2. Dimension of bucket................................................................................................................. 168 AIR CONDITIONER............................................................................................................................ 169 air conditioner piping................................................................................................................. 169 ELECTRICAL WIRING DIAGRAM.................................................................................................................. 170 ELECTRICAL SYSTEM.......................................................................................................................... 171 Engine Control......................................................................................................................... 171 Engine controller...................................................................................................................... 173 CN-CE01 (*: Never connect to NC as malfunctions and errors occur)...................................................................... 174 CN-CE01 (*: Never connect to NC as malfunctions and errors occur)...................................................................... 174 CN-CE02 (*: Never connect to NC as malfunctions and errors occur)...................................................................... 175 CN-CE03(*: Never connect to NC as malfunctions and errors occur)....................................................................... 175 Engine throttle and pump controller.................................................................................................... 175 ELECTRONIC CONTROL SYSTEM.................................................................................................................. 178 machine control system diagram......................................................................................................... 179 MACHINE MONITOR SYSTEM..................................................................................................................... 202 MONITOR PANEL.......................................................................................................................... 204 LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH............................................................................................... 223 OVERLOAD WARNING DEVICE.................................................................................................................... 230 OUTLINE................................................................................................................................ 230 SENSOR..................................................................................................................................... 231 1st ATTACHMENT CIRCUIT HYDRAULIC PERFORMANCE (MAIN......................................................................................... 240 TRAVEL SYSTEM.............................................................................................................................. 242 TRAVEL CIRCUIT......................................................................................................................... 242 oPERATIONAL AND CONTROL FEATURES....................................................................................................... 243 Operator’s Input via travel mode switch................................................................................................ 243 OVERRUN PROTECTION. This is dealt with through the action of the counterbalance spool in the motor control block.When the machin....... 243 STEERING SYSTEM............................................................................................................................ 264 Operating principles................................................................................................................... 264 Dynamic Steering....................................................................................................................... 264 2 - stage principle.................................................................................................................... 264 SERVICE BRAKE AND SUSPENSION SYSTEM........................................................................................................ 277 bRAKING SYSTEM......................................................................................................................... 277 operation.............................................................................................................................. 280 KOMTRAX terminal system................................................................................................................ 282 KOMTRAX terminal................................................................................................................... 283 20 TESTING AND ADJUSTING....................................................................................................................... 285 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.............................................................................................. 286 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS............................................................................................. 287 Flow control characteristic of PC valve (STD).......................................................................................... 298 TESTING AND ADJUSTING...................................................................................................................... 299 Measuring engine speed................................................................................................................. 300 Measuring intake air pressure (boost pressure)......................................................................................... 302 MEASUREMENT OF EXHAUST GAS COLOUR...................................................................................................... 303 Adjusting valve clearance.............................................................................................................. 305 Measuring compression pressure......................................................................................................... 307 MEASUREMENT OF BLOW-BY PRESSURE........................................................................................................ 309 Measuring engine oil pressure.......................................................................................................... 310 CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 311 Replacing the fan belt................................................................................................................. 312 Handling fuel system parts............................................................................................................. 313 Releasing residual pressure from fuel system........................................................................................... 314 Measuring fuel pressure................................................................................................................ 315 Measuring fuel discharge, return and leakage........................................................................................... 317 Bleeding air from fuel circuit......................................................................................................... 321 Checking fuel circuit for leakage...................................................................................................... 322 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS...................................................................................... 323 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL.......................... 324 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE.............................................................................. 327 Procedure for pressure reducing adjustment............................................................................................. 328 INSPECTION AND ADJUSTMENT OF PUMP PC (Valve INLET) CONTROL OIL PRESSURE................................................................ 329 INSPECTION AND ADJUSTMENT OF PUMP LS valve CONTROL OIL PRESSURE........................................................................ 332 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.......................................................................................... 336 6 - Stage solenoid block........................................................................................................... 338 4 - Stage solenoid block........................................................................................................... 340 2 - Stage solenoid block........................................................................................................... 341 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE............................................................................................... 342 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE....................................................................................... 344 Measuring and adjusting quick coupler control valve output pressure.................................................................... 345 testing travel motor relief pressure................................................................................................... 346 adjusting travel motor relief pressure................................................................................................. 347 Testing propshaft speed................................................................................................................ 348 TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT............................................................................................ 349 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT........................................................................... 351 RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................................................. 353 MEASUREMENT OF OIL LEAKAGE AMOUNT...................................................................................................... 354 AIR BLEEDING OF VARIOUS PARTS.......................................................................................................... 356 INSPECTION PROCEDURES FOR DIODE........................................................................................................ 358 SPECIAL FUNCTION OF MONITOR PANEL...................................................................................................... 359 OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE).................................................................................. 361 TABLE FOR FAILURE CODE NO.......................................................................................................... 368 OPERATION AND DISPLAY OF SERVICE MENU.............................................................................................. 371 Way of switching to Service Menu............................................................................................... 371 Table for Monitoring Items......................................................................................................... 374 Procedure for turning on KOMTRAX terminal.......................................................................................... 391 KOMTRAX terminal lamp indications.................................................................................................. 394 Preparation work for troubleshooting of electrical system.......................................................................... 397 PM - Tune up service................................................................................................................... 399 TROUBLESHOOTING............................................................................................................................ 403 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................ 404 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................. 405 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....................................................................................... 406 CHECKS BEFORE TROUBLESHOOTING.......................................................................................................... 414 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING........................................................................................... 415 Failure-looking Phenomenon and Troubleshooting No.................................................................................. 416 How to read electric wire code..................................................................................................... 419 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM...................................................................... 422 CONNECTOR LOCATIONS................................................................................................................ 430 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................. 451 TROUBLESHOOTING WHEN FAILURE CODE IS INDICATED............................................................................................. 485 Before carrying out troubleshooting when failure code is displayed..................................................................... 487 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE......................................................................................... 488 Relative Electrical Circuit Diagram................................................................................................ 489 Failure code [CA111] EMC Critical Internal Failure................................................................................. 490 Failure code [CA115] Engine Neutral and Backup Speed Sensor Error.................................................................. 491 Failure code [CA122] Chg Air Press Sensor High Error............................................................................... 492 Failure code [CA123] Chg Air Press Sensor Low Error................................................................................ 494 Failure code [CA131] Throttle Sensor High Error.................................................................................... 496 Failure code [CA132] Throttle Sensor Low Error..................................................................................... 498 Failure code [CA144] Coolant Temp Sens High Error.................................................................................. 500 Failure code [CA145] Coolant Temp Sens Low Error................................................................................... 502 Failure code [CA153] Chg Air Temp Sensor High Error................................................................................ 504 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................. 506 Failure code [CA155] Chg Air Temp High Speed Derate................................................................................ 508 Failure code [CA187] Sens Supply 2 Volt Low Error.................................................................................. 510 Failure code [CA221] Ambient Press Sens High Error................................................................................. 512 Failure code [CA222] Ambient Press Sens Low Error.................................................................................. 514 Failure code [CA227] Sens Supply 2 Volt High Error................................................................................. 516 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................... 518 Failure code [CA271] IMV/PCV1 Short Error.......................................................................................... 520 Failure code [CA272] IMV/PCV1 Open Error........................................................................................... 522 Failure code [CA322] Inj #1 (L#1) Open/Short Error................................................................................. 524 Failure code [CA324] Inj #3 (L#3) Open/Short Error................................................................................. 527 Failure code [CA331] Inj #2 (L#2) Open/Short Error................................................................................. 530 Failure code [CA332] Inj #4 (L#4) Open/Short Error................................................................................. 533 Failure code [CA342] Calibration Code Incompatibility.............................................................................. 536 Failure code [CA351] Injectors Drive Circuit Error................................................................................. 537 Failure code [CA352] Sensor Supply 1 Volt Low Error................................................................................ 540 Failure code [CA386] Sens Supply 1 Volt High Error................................................................................. 542 Failure code [CA428] Water in Fuel Sensor High Error............................................................................... 544 Failure code [CA429] Water in Fuel Sensor Low Error................................................................................ 546 Failure code [CA435] Eng Oil Press Sw Error........................................................................................ 548 Failure code [CA441] Battery Voltage Low Error..................................................................................... 550 Failure code [CA442] Battery Voltage High Error.................................................................................... 553 Failure code [CA449] Rail Press Very High Error.................................................................................... 555 Failure code [CA451] Rail Press Sensor High Error.................................................................................. 556 Failure code [CA452] Rail Press Sensor Low Error................................................................................... 558 Failure code [CA488] Chg Air Temp High Torque Derate............................................................................... 560 Failure code [CA553] Rail Press High Error......................................................................................... 561 Failure code [CA559] Rail Press Low Error.......................................................................................... 562 Failure code [CA689] Eng Ne Speed Sensor Error..................................................................................... 564 Failure code [CA731] Eng Bkup Speed Sens Phase Error............................................................................... 567 Failure code [CA757] All Continuous Data Lost Error................................................................................ 568 Failure code [CA778] Eng G Speed Sensor Error...................................................................................... 570 Failure code [CA1633] KOMNET Datalink Timeout Error................................................................................ 574 Failure code [CA2185] Throttle Sensor Supply Voltage High Error.................................................................... 576 Failure code [CA2186] Throttle Sensor Supply Voltage Low Error..................................................................... 578 Failure code [CA2249] Rail Press Very Low Error.................................................................................... 580 Failure code [CA2311] IMV Solenoid Error........................................................................................... 582 Failure code [CA2555] Grid Htr Relay Volt High Error............................................................................... 584 Failure code [CA2556] Grid Heater Relay Volt Low Error............................................................................. 586 Failure Code [D110KB] (Short-circuiting in battery relay).......................................................................... 588 Failure code [D862KA] GPS Antenna Disconnection.................................................................................... 590 Configuration diagram of KOMTRAX system........................................................................................ 590 Failure Code [DA22KK] (Abnormality in pump pressure sensor)........................................................................ 592 Failure code [DA25KP] Press. Sensor Power Abnormality.............................................................................. 594 Failure code [DA2RMC] Pump Comm. Abnormality....................................................................................... 596 Failure Code [DA2SKQ] (Abnormality in inputting model code)........................................................................ 598 Failure Code [DA2SKQ] (Abnormality in inputting model code)........................................................................ 600 Failure code [DAFRMC] Monitor Comm. Abnormality.................................................................................... 602 Failure code [DDC3KZ] Outrigger Switch Select Abnormality.......................................................................... 604 Failure Code [DDP4KX] (Abnormality in travel PPC pressure switch).................................................................. 606 Failure Code [DDWCKZ] (Abnormality in travel direction control switch)............................................................. 608 Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality......................................................................... 610 Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality......................................................................... 613 Failure code [DFB3L8] Service Lever 1 Potentio Error............................................................................... 616 Failure code [DFB4L8] Service Lever 2 Potentio Error............................................................................... 617 Failure code [DGH2KB] Hydr Oil Sensor Short........................................................................................ 619 Failure Code [DH1OKS] (Abnormality in Pressure sensor power source)................................................................ 620 Failure code [DHPAMA] F Pump Press Sensor Abnormality.............................................................................. 622 Failure Code [DHS5KX] (Abnormality in travel PPC sensor)........................................................................... 624 Failure Code [DHX1MA] (Abnormality in overload caution sensor)..................................................................... 626 Failure Code [DLT4KA] (Disconnection in transmission speed sensor in pump controller system)....................................... 628 Failure Code [DW27KA] (Disconnection in Transmission Clutch solenoid).............................................................. 630 Failure Code [DW27KB] (Short-circuiting in Transmission Clutch solenoid)........................................................... 632 Failure Code DW4AKA (Disconnection in suspension lock solenoid).................................................................... 634 Failure Code [DW4AKB] (Short circuiting in suspension lock solenoid)............................................................... 636 Failure Code [DW4CKA] (Disconnection in PPC lock solenoid)......................................................................... 638 Failure code [DW4CKB] PPC Lock Sol. S/C............................................................................................ 640 Failure Code [DW4MKA] (Disconnection in Creep solenoid)............................................................................ 642 Failure Code [DW4MKB] (Short-circuiting in Creep solenoid)......................................................................... 644 Failure Code [DW44KA] (Disconnection of Travel F/R solenoid)....................................................................... 646 Failure Code [DW44KB] (Short-circuiting of Travel F/R solenoid).................................................................... 648 Failure Code [DW45KA] (Disconnection in Swing Parking Brake solenoid).............................................................. 650 Failure code [DW45KB] Swing Brake Sol. S/C......................................................................................... 654 Failure Code [DW91KA] (Disconnection in Travel Neutral solenoid)................................................................... 656 Failure Code [DW91KB] (Short-circuiting in Travel Neutral Solenoid)................................................................ 658 Failure Code [DWK0KA] (Disconnection in 2-stage Relief solenoid)................................................................... 660 Failure Code [DWK0KB] (Short-circuiting in 2-Stage Relief Solenoid)................................................................ 662 Failure Code [DWK2KA] (Disconnection in 2-stage Back Pressure solenoid)............................................................ 664 Failure Code [DWK2KB] (Short circuiting in 2-stage back pressure solenoid)......................................................... 666 Failure Code [DXA0KA] (Disconnection in PC-EPC solenoid system).................................................................... 668 Failure Code [DXA0KB] (Short-circuiting in PC-EPC solenoid)........................................................................ 670 Failure Code [DXE0KA] (Disconnection in LS-EPC solenoid system).................................................................... 672 Failure Code [DXE0KB] (Short-circuiting in LS-EPC solenoid)........................................................................ 674 Failure code [DXE4KA] Service Current EPC1 Discon.................................................................................. 676 Failure code [DXE4KB] Service Current EPC1 Short................................................................................... 678 Failure code [DXE7KA] Service Current EPC2 Discon.................................................................................. 680 Failure code [DXE7KB] Service Current EPC2 Short................................................................................... 682 Failure code [DXE8KA] Service Current EPC3 Discon.................................................................................. 684 Failure code [DXE8KB] Service Current EPC3 Short................................................................................... 686 Failure code [DXE9KA] Service Current EPC4 Discon.................................................................................. 688 Failure code [DXE9KB] Service Current EPC4 Short................................................................................... 690 Failure code [DY20KA] Wiper Working Abnormality.................................................................................... 692 Failure code [DY20MA] Wiper Parking Abnormality.................................................................................... 694 Failure code [DY2CKB] Washer Drive S/C............................................................................................. 696 Failure code [DY2DKB] Wiper Drive (For) S/C........................................................................................ 698 Failure code [DY2EKB] Wiper Drive (Rev) S/C........................................................................................ 700 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).............................................................................................. 703 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE......................................................................................... 704 E-1 Engine does not start (Engine does not rotate)................................................................................. 706 E-5 Auto-decelerator does not work................................................................................................. 711 E-6 Auto engine warm-up device does not work....................................................................................... 713 E-7 Preheater does not operate..................................................................................................... 714 E-8 All work equipment, swing and travel do not move............................................................................... 716 E-9 One-touch Power Max Switch does not work....................................................................................... 718 E-10 No display in monitor panel at all............................................................................................ 719 E-11 Part of display on monitor panel is missing................................................................................... 720 E-12 Monitor panel displays contents irrelevant to the model....................................................................... 720 E-13 Fuel level monitor red lamp lights up while engine is running................................................................. 721 E-14 Engine coolant temperature gauge does not indicate normally................................................................... 722 E-15 Hydraulic oil temperature gauge does not display correctly.................................................................... 724 E-16 Fuel gauge does not display correctly......................................................................................... 725 E-17 Swing lock monitor does not display correctly................................................................................. 726 E-18 When the monitor switch is operated, no display appears....................................................................... 728 E-19 Windshield wiper and window washer do not operate............................................................................. 729 E-20 Alarm buzzer cannot be stopped................................................................................................ 731 E-21 "Boom/Stabiliser RAISE" is not correctly displayed in monitor function........................................................ 732 E-22 "Boom/Stabiliser LOWER" is not correctly displayed in monitor function........................................................ 733 E-23 "Arm DIGGING" is not correctly displayed in monitor function.................................................................. 734 E-24 "Arm DUMPING" is not correctly displayed in monitor function.................................................................. 735 E-25 "Bucket DIGGING" is not correctly displayed in monitor function............................................................... 736 E-26 "Bucket DUMPING" is not correctly displayed in monitor function............................................................... 737 E-27 "SWING" is not correctly displayed in monitor function........................................................................ 738 E-28 "TRAVEL" is not correctly displayed in monitor function....................................................................... 740 E-29 "2 Piece Boom" is not correctly displayed in monitor function................................................................. 742 E-30 Air Conditioner does not work................................................................................................. 744 E-31 Travel reverse alarm does not sound........................................................................................... 746 E-32 KOMTRAX system does not operate normally...................................................................................... 748 TROUBLESHOOTING OF ELECTRICAL SYSTEM (Error checking of items without Monitor codes)....................................................... 751 Relative Electrical Circuit Diagram.................................................................................................... 753 Radio Cassette & Telephone Socket...................................................................................................... 754 Electrical Circuit Diagram For Radio Cassette & Telephone Socket................................................................... 755 PPC Lock Circuit....................................................................................................................... 756 Circuit Diagram for PPC Lock Circuit............................................................................................... 757 Brake Light Circuit.................................................................................................................... 758 Circuit Diagram for Brake Light Circuit............................................................................................ 759 Undercarriage Attachments - Mode Selection............................................................................................. 760 Circuit Diagram for Undercarriage Attachments - Mode Selection..................................................................... 761 Undercarriage Attachments - Front Left Outrigger....................................................................................... 762 Circuit Diagram for Undercarriage Attachments - Front Left Outrigger............................................................... 763 Undercarriage Attachments - Front Right Outrigger...................................................................................... 764 Circuit Diagram for Undercarriage Attachments - Front Right Outrigger.............................................................. 765 Undercarriage Attachments - Rear Left Outrigger........................................................................................ 766 Undercarriage Attachments - Rear Right Outrigger....................................................................................... 768 Circuit Diagram for Undercarriage Attachments - Rear Right Outrigger............................................................... 769 Heated Seat Does Not Warm Up........................................................................................................... 770 Circuit Diagram for the Heated Seat................................................................................................ 771 Suspension Lock........................................................................................................................ 772 Circuit Diagram for Suspension Lock................................................................................................ 773 Lower Wiper Does Not Work (Optional Fitment)........................................................................................... 774 Circuit Diagram for Lower Wiper.................................................................................................... 775 Work Lights (Operator Cab Front Left).................................................................................................. 776 Work Lights (Operator Cab Front Right)................................................................................................. 777 Work Lights (Operator Cab Rear)........................................................................................................ 778 Circuit Diagram for Work Lights.................................................................................................... 779 Worklights (Boom, Arm & Counterweight)................................................................................................. 780 Circuit Diagram for Worklights (Boom & Counterweight).............................................................................. 781 Cab and Counterweight Beacon Light..................................................................................................... 782 Circuit Diagram for Cab & Counterweight Beacon Light............................................................................... 783 Air Seat Compressor (Option - Air Suspension Seat)..................................................................................... 784 Circuit Diagram for Air Seat Compressor (Option - Air Suspension Seat)............................................................. 785 Operator Cab Interior Light............................................................................................................ 786 Circuit Diagram for Operator Cab Interior Light.................................................................................... 787 Cigar Lighter.......................................................................................................................... 788 Circuit Diagram for Cigar Lighter.................................................................................................. 789 Park Brake (Not Activating)............................................................................................................ 790 Circuit Diagram for Park Brake..................................................................................................... 791 Park Brake (Displayed Symbol).......................................................................................................... 792 Circuit Diagram for Park Brake..................................................................................................... 793 RH PPC Lever Clamshell Roller Switch Pushed to the LH Position......................................................................... 794 Circuit Diagram for Clamshell Control.............................................................................................. 795 RH PPC Lever Clamshell Roller Switch Pushed to the RH Position......................................................................... 796 Circuit Diagram for Clamshell Control.............................................................................................. 797 RH PPC Lever Clamshell Roller Switched Pushed to the RH or LH.......................................................................... 798 Circuit Diagram for Clamshell Control.............................................................................................. 799 Horns.................................................................................................................................. 800 Circuit Diagram for Horn........................................................................................................... 801 Swing Lock - Normal Operation.......................................................................................................... 802 Circuit Diagram for Swing Lock..................................................................................................... 803 Swing Lock - Emergency Operation....................................................................................................... 804 Circuit Diagram for Swing Lock - Emergency Operation............................................................................... 805 Neutral Start (Engine)................................................................................................................. 806 Neutral Start (Engine) cont’d (A)...................................................................................................... 807 Neutral Start (Engine) cont’d (B)...................................................................................................... 808 Neutral Start (Engine) cont’d (C)...................................................................................................... 809 Circuit Diagram for Neutral Start (Engine)......................................................................................... 810 Emergency Travel Control - Forward..................................................................................................... 811 Circuit Diagram for Travel Direction Control....................................................................................... 812 Emergency Travel Control - Neutral..................................................................................................... 813 Circuit Diagram for Travel Direction Control....................................................................................... 814 Emergency Travel Control - Reverse..................................................................................................... 815 Emergency Travel Control - Reverse cont’d.............................................................................................. 816 Circuit Diagram for Travel Direction Control....................................................................................... 817 Driving Lights - Main Beam............................................................................................................. 818 Circuit Diagram for Driving Lights................................................................................................. 819 Driving Lights - Main Beam Flash....................................................................................................... 820 Circuit Diagram for Driving Lights................................................................................................. 821 Driving Lights - Main Beam Dipped...................................................................................................... 822 Circuit Diagram for Driving Lights................................................................................................. 823 Driving Lights - Position Lights....................................................................................................... 824 Circuit Diagram for Driving Lights................................................................................................. 825 Driving Lights - Position Lights cont’d (1) and (2).................................................................................... 826 Circuit Diagram for Driving Lights................................................................................................. 827 Indicators - Right Hand................................................................................................................ 828 Circuit Diagram for Indicators & Hazard Warning.................................................................................... 829 Indicators - Left Hand................................................................................................................. 830 Circuit Diagram for Indicators & Hazard Warning.................................................................................... 831 Hazard Warning Lights.................................................................................................................. 832 Circuit Diagram for Indicators & Hazard Warning.................................................................................... 833 Hazard Warning Lights cont’d (A)....................................................................................................... 834 Circuit Diagram for Indicators & Hazard Warning.................................................................................... 835 Swing Lock Proximity Switch............................................................................................................ 836 Brake and Swing Lock Proximity Switches............................................................................................ 837 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)................................................................................ 839 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS...................................................................................... 840 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE......................................................................................... 844 Quick coupler.......................................................................................................................... 863 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................... 865 HOW TO READ THIS MANUAL.................................................................................................................... 869 REMOVAL AND INSTALLATION OF ASSEMBLIES................................................................................................. 869 DisassemblY and assemblY OF assemblIES................................................................................................. 870 SPECIAL TOOLS.............................................................................................................................. 875 SKETCHES............................................................................................................................... 875 LIST OF TOOLS.......................................................................................................................... 876 PRECAUTIONS WHEN PERFORMING OPERATION...................................................................................................... 880 STARTING MOTOR ASSEMBLY.................................................................................................................... 882 FUEL Supply PUMP assembly.................................................................................................................. 883 FUEL INJECTOR ASSEMBLY..................................................................................................................... 886 FRONT OIL SEAL............................................................................................................................. 891 REAR OIL SEAL.............................................................................................................................. 893 CYLINDER HEAD ASSEMBLY..................................................................................................................... 896 COMBINATION COOLER......................................................................................................................... 906 FUEL COOLER ASSEMBLY....................................................................................................................... 909 ENGINE AND HYDRAULIC PUMP ASSEMBLIES....................................................................................................... 910 TRAVEL MOTOR ASSEMBLY...................................................................................................................... 917 TRAVEL MOTOR ASSEMBLY...................................................................................................................... 919 SWING MOTOR AND SWING MACHINERY ASSEMBLY................................................................................................... 923 SWING MACHINERY ASSEMBLY................................................................................................................... 924 SWING MOTOR ASSEMBLY....................................................................................................................... 932 FRONT AXLE ASSEMBLY........................................................................................................................ 941 FRONT AXLE ASSEMBLY........................................................................................................................ 943 REAR AXLE AND TRANSMISSION ASSEMBLY........................................................................................................ 992 REAR AXLE ASSEMBLY......................................................................................................................... 995 TRANSMISSION ASSEMBLY......................................................................................................................1025 PROPSHAFT ASSEMBLY.........................................................................................................................1054 WHEEL ASSEMBLY.............................................................................................................................1056 SUSPENSION LOCK CYLINDER ASSEMBLY..........................................................................................................1057 SUSPENSION LOCK CYLINDERS ASSEMBLY.........................................................................................................1058 OUTRIGGER ASSEMBLY.........................................................................................................................1059 OUTRIGGER ASSEMBLY.........................................................................................................................1060 DOZER BLADE................................................................................................................................1061 DOZER BLADE ASSEMBLY.......................................................................................................................1062 SWING CIRCLE ASSEMBLY......................................................................................................................1063 REVOLVING FRAME ASSEMBLY...................................................................................................................1064 CENTRE SWIVEL JOINT ASSEMBLY...............................................................................................................1067 CENTRE SWIVEL JOINT ASSEMBLY...............................................................................................................1070 HYDRAULIC TANK ASSEMBLY....................................................................................................................1072 FUEL TANK ASSEMBLY.........................................................................................................................1076 CONTROL VALVE ASSEMBLY.....................................................................................................................1078 LS SEPARATION VALVE ASSEMBLY...............................................................................................................1082 PRESSURE COMPENSATION VALVE ASSEMBLY.......................................................................................................1083 MAIN RELIEF VALVE ASSEMBLY.................................................................................................................1084 LS CONTROL EPC VALVE ASSEMBLY..............................................................................................................1085 EPC SOLENOID VALVE ASSEMBLY................................................................................................................1086 4 STATION PPC SOLENOID VALVE BLOCK ASSEMBLY................................................................................................1087 MANIFOLD BLOCK ASSEMBLY....................................................................................................................1089 OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT.....................................................................................................1090 WORK EQUIPMENT PPC VALVE ASSEMBLY..........................................................................................................1091 HYDRAULIC CYLINDER ASSEMBLY................................................................................................................1092 MONOBOOM WORK EQUIPMENT ASSEMBLY...........................................................................................................1098 2 PIECE BOOM WORK EQUIPMENT ASSEMBLY.......................................................................................................1101 AIR CONDITIONER UNIT ASSEMBLY..............................................................................................................1104 COUNTERWEIGHT ASSEMBLY.....................................................................................................................1108 OPERATOR CAB ASSEMBLY......................................................................................................................1110 MONITOR ASSEMBLY...........................................................................................................................1113 GOVERNOR / PUMP CONTROLLER ASSEMBLY........................................................................................................1114 KOMTRAX TERMINAL...........................................................................................................................1115 ENGINE CONTROLLER..........................................................................................................................1116 90 OTHERS......................................................................................................................................1117 Mono boom..................................................................................................................................1118 Two plece boom.............................................................................................................................1119 Hydraulic circuit diagram 1/3..............................................................................................................1121 Hydraulic circuit diagram 2/3..............................................................................................................1123 Hydraulic circuit diagram 3/3..............................................................................................................1125 Electrical circuit diagram 1/7.............................................................................................................1127 Electrical circuit diagram 2/7.............................................................................................................1129 Electrical circuit diagram 3/7.............................................................................................................1131 Electrical circuit diagram 4/7.............................................................................................................1133 Electrical circuit diagram 5/7.............................................................................................................1135 Electrical circuit diagram 6/7.............................................................................................................1137 Electrical circuit diagram 7/7.............................................................................................................1139
IMAGES PREVIEW OF THE MANUAL:
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