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Komatsu PW180-7E0 Hydraulic Excavator Shop Manual - PDF DOWNLOAD
Komatsu PW180-7E0 Hydraulic Excavator Shop ManualFILE DETAILS:
Komatsu PW180-7E0 Hydraulic Excavator Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : VEBM400100
Total Pages : 1148
DESCRIPTION:
Komatsu PW180-7E0 Hydraulic Excavator Shop Manual
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.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
TABLE OF CONTENTS:
Komatsu PW180-7E0 Hydraulic Excavator Shop Manual
VEBM400100 PW180-E0.................................................................................................. 1 SAFETY............................................................................................................... 3 SAFETY NOTICE.................................................................................................... 3 01 GENERAL........................................................................................................... 11 SPECIFICATION DIMENSION DRAWINGS................................................................................. 28 DIMENSIONS................................................................................................... 28 WORKING RANGES................................................................................................... 32 1 PIECE BOOM................................................................................................. 32 2 PIECE BOOM................................................................................................. 33 SPECIFICATIONS................................................................................................... 34 FUEL, COOLANT AND LUBRICANTS..................................................................................... 39 WEIGHT TABLE..................................................................................................... 36 1 PIECE BOOM................................................................................................. 37 2 PIECE BOOM................................................................................................. 38 HOISTING INSTRUCTIONS............................................................................................ 13 HOW TO READ THE SHOP MANUAL...................................................................................... 12 COATING MATERIALS................................................................................................ 14 STANDARD TIGHTENING TORQUE....................................................................................... 16 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS................................................................. 16 TIGHTENING TORQUE OF HOSE NUTS............................................................................... 17 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...................................................................... 17 TIGHTENING TORQUES FOR HOSES (Taper seal type and face seal type)............................................ 17 TIGHTENING TORQUE FOR 107 ENGINE SERIES (BOLTS AND NUTS)..................................................... 18 TIGHTENING TORQUE FOR 107 ENGINE SERIES (EYE JOINTS)......................................................... 18 TIGHTENING TORQUE FOR 107 ENGINE SERIES (TAPERED SCREWS)..................................................... 18 ELECTRIC WIRE CODE............................................................................................... 19 CLASSIFICATION BY THICKNESS.................................................................................. 19 CLASSIFICATION BY COLOR AND CODE............................................................................. 19 CONVERSION TABLES................................................................................................ 20 METHOD OF USING THE CONVERSION TABLE......................................................................... 20 UNITS............................................................................................................ 26 DIMENSIONS................................................................................................... 30 2 PIECE BOOM................................................................................................. 30 10 STRUCTURE, FUNCTION AND MAINTENANCE .............................................................................. 41 ENGINE RELATED PARTS............................................................................................. 42 RADIATOR . OIL COOLER . CHARGE AIR COOLER........................................................................ 43 POWER TRAIN...................................................................................................... 44 SWING CIRCLE..................................................................................................... 46 SWING MACHINERY & MOTOR.......................................................................................... 47 SWING MOTOR...................................................................................................... 50 Operation of swing lock...................................................................................... 54 RELIEF VALVE PORTION......................................................................................... 55 UNDERCARRIAGE.................................................................................................... 56 TRANSMISSION..................................................................................................... 58 TRAVEL MOTOR..................................................................................................... 62 OPERATION OF TRAVEL MOTOR.................................................................................... 64 CLUTCH CONTROL CIRCUIT........................................................................................... 66 AXLE............................................................................................................. 68 SUSPENSION LOCK CYLINDER......................................................................................... 72 BRAKING SYSTEM................................................................................................... 74 BRAKE/STEER PUMP................................................................................................. 76 PRIORITY VALVE................................................................................................... 77 POWER BRAKE VALVE................................................................................................ 78 ACCUMULATOR FOR BRAKE VALVE...................................................................................... 80 STEERING SYSTEM.................................................................................................. 81 STEERING COLUMN.................................................................................................. 82 ORBITROL VALVE................................................................................................... 83 HYDRAULIC EQUIPMENT LAYOUT DRAWINGS.............................................................................. 84 HYDRAULIC CIRCUIT DIAGRAM........................................................................................ 86 HYDRAULIC TANK................................................................................................... 87 HYDRAULIC PUMP................................................................................................... 89 LS VALVE..................................................................................................... 94 PC VALVE..................................................................................................... 95 LS(PC)-EPC VALVE............................................................................................. 109 PILOT PRESSURE CONTROL (PPC) SYSTEM.............................................................................. 113 CONTROL VALVE.................................................................................................... 115 PW180-7E0.................................................................................................... 115 CLSS............................................................................................................. 126 OUTLINE OF CLSS.............................................................................................. 126 BASIC PRINCIPLE.............................................................................................. 127 OPERATION FOR EACH FUNCTION AND VALVE........................................................................ 129 1. Unload valve.............................................................................................. 131 2. Introduction of LS pressure............................................................................... 134 3. LS Bypass plug............................................................................................ 135 4. Pressure compensation valve............................................................................... 137 5. Area ratio of pressure compensation valve................................................................. 139 6. Boom regeneration circuit................................................................................. 141 7. Arm regeneration circuit.................................................................................. 143 8. Swing bleeding valve...................................................................................... 145 9. Variable type pressure compensation valve (for service)................................................... 146 10. LS select valve.......................................................................................... 147 CENTRE SWIVEL JOINT.............................................................................................. 148 TRAVEL PPC PEDAL................................................................................................. 149 WORK EQUIPMENT . SWING PPC VALVE................................................................................. 151 SOLENOID VALVE BLOCK............................................................................................. 157 SOLENOID VALVE BLOCK......................................................................................... 159 BOOM SAFETY VALVE................................................................................................ 166 HYDRAULIC CYLINDER............................................................................................... 168 OUTRIGGER CYLINDER............................................................................................... 170 DOZER CYLINDER................................................................................................... 172 WORK EQUIPMENT................................................................................................... 174 Work Equipment............................................................................................... 175 1. DIMENSION OF ARM.......................................................................................... 176 AIR CONDITIONER.................................................................................................. 180 AIR CONDITIONER PIPING....................................................................................... 180 ELECTRICAL WIRING DIAGRAM........................................................................................ 181 ELECTRICAL SYSTEM................................................................................................ 182 ELECTRONIC CONTROL SYSTEM........................................................................................ 188 MACHINE CONTROL SYSTEM DIAGRAM............................................................................... 189 MACHINE MONITOR SYSTEM........................................................................................... 213 OVERLOAD WARNING DEVICE.......................................................................................... 241 OUTLINE...................................................................................................... 241 SENSOR........................................................................................................... 242 1st ATTACHMENT CIRCUIT HYDRAULIC PERFORMANCE (MAIN VALVE BYPASSED)............................................... 251 TRAVEL SYSTEM.................................................................................................... 252 TRAVEL CIRCUIT............................................................................................... 252 OPERATIONAL AND CONTROL FEATURES............................................................................. 253 STEERING SYSTEM.................................................................................................. 271 OPERATING PRINCIPLES......................................................................................... 271 SERVICE BRAKE AND SUSPENSION SYSTEM.............................................................................. 284 BRAKING SYSTEM............................................................................................... 284 OPERATION.................................................................................................... 287 20 TESTING AND ADJUSTING............................................................................................. 289 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.................................................................... 290 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS................................................................... 291 Flow control characteristic of PC valve (STD)................................................................ 303 MEASURING ENGINE SPEED........................................................................................... 306 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................... 307 MEASUREMENT OF EXHAUST GAS COLOUR................................................................................ 308 ADJUSTING VALVE CLEARANCE........................................................................................ 310 MEASURING COMPRESSION PRESSURE................................................................................... 312 MEASURING BLOW-BY PRESSURE....................................................................................... 314 MEASURING ENGINE OIL PRESSURE.................................................................................... 315 HANDLING FUEL SYSTEM PARTS....................................................................................... 316 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM..................................................................... 317 MEASURING FUEL PRESSURE.......................................................................................... 318 MEASURING FUEL RETURN RATE AND LEAKAGE........................................................................... 320 BLEEDING AIR FROM FUEL CIRCUIT................................................................................... 322 Checking fuel circuit for leakage............................................................................ 324 CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................................... 325 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS................................................................ 326 INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL.... 327 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE........................................................ 330 INSPECTION AND ADJUSTMENT OF PUMP PC (VALVE INLET) CONTROL OIL PRESSURE.......................................... 332 INSPECTION AND ADJUSTMENT OF PUMP LS VALVE CONTROL OIL PRESSURE.................................................. 335 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.................................................................... 339 Solenoid valve block......................................................................................... 341 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE......................................................................... 344 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE................................................................. 346 TESTING TRAVEL MOTOR RELIEF PRESSURE............................................................................. 347 ADJUSTING TRAVEL MOTOR RELIEF PRESSURE........................................................................... 348 TESTING PROPSHAFT SPEED...................................................................................... 349 TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT...................................................................... 350 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT..................................................... 352 RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT........................................................... 354 MEASUREMENT OF OIL LEAKAGE....................................................................................... 355 AIR BLEEDING OF VARIOUS PARTS.................................................................................... 358 INSPECTION PROCEDURES FOR DIODE.................................................................................. 361 SPECIAL FUNCTION OF MONITOR PANEL................................................................................ 363 OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE)............................................................ 365 TABLE FOR FAILURE CODE NO.................................................................................... 372 OPERATION AND DISPLAY OF SERVICE MENU........................................................................ 375 Way of switching to Service Menu......................................................................... 375 Table for Monitoring Items............................................................................... 378 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM............................................................... 395 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 398 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................ 399 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE................................................................. 400 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING..................................................................... 410 Classification of troubleshooting............................................................................ 410 Steps for troubleshooting................................................................................ 410 Failure-looking Phenomenon and Troubleshooting No............................................................ 411 How to read electric wire code............................................................................... 414 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM................................................ 417 CONNECTOR LOCATIONS.......................................................................................... 424 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................... 446 T-boxes and T-adapters table................................................................................. 474 Before carrying out troubleshooting when failure code is displayed........................................... 481 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................................................................... 482 Relative Electrical Circuit Diagram.......................................................................... 483 Failure Code [6B2JMA] (Abnormality in travel PPC switch hydraulics).......................................... 484 Failure code [989L00] Engine Controller Lock Caution 1....................................................... 485 Failure code [989M00] Engine Controller Lock Caution 2....................................................... 485 Failure code [989N00] Engine Controller Lock Caution 3....................................................... 486 Failure code [AA10NX] Air Cleaner Clogging................................................................... 486 Failure code [AB00KE] Charge Voltage Low..................................................................... 487 Failure code [B@BAZG] Eng Oil Press. Low..................................................................... 488 Failure code [B@BAZK] Eng Oil Level Low...................................................................... 488 Failure code [B@BCNS] Eng Water Overheat..................................................................... 489 Failure code [B@BCZK] Eng Water Level Low.................................................................... 489 Failure code [B@HANS] Hydr Oil Overheat...................................................................... 490 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 [CA234] Eng Overspeed........................................................................... 517 Failure code [CA238] Ne Speed Sens Supply Volt Error......................................................... 518 Failure code [CA271] IMV/PCV1 Short Error.................................................................... 519 Failure code [CA272] IMV/PCV1 Open Error..................................................................... 520 Failure code [CA322] Inj #1 (L#1) Open/Short Error........................................................... 522 Failure code [CA323] Inj #5 (L#5) Open/Short Error........................................................... 524 Failure code [CA324] Inj #3 (L#3) Open/Short Error........................................................... 526 Failure code [CA325] Inj #6 (L#6) Open/Short Error....................................................... 528 Failure code [CA331] Inj #2 (L#2) Open/Short Error........................................................... 530 Failure code [CA332] Inj #4 (L#4) Open/Short Error........................................................... 532 Failure code [CA342] Calibration Code Incompatibility........................................................ 534 Failure code [CA351] Injectors Drive Circuit Error....................................................... 536 Failure code [CA352] Sens Supply 1 Volt Low Error............................................................ 538 Failure code [CA386] Sens Supply 1 Volt High Error........................................................... 540 Failure code [CA428] Water in Fuel Sensor High Error......................................................... 542 Failure code [CA429] Water in Fuel Sensor Low Error...................................................... 544 Failure code [CA435] Eng Oil Press Sw Error.................................................................. 546 Failure code [CA441] Battery Voltage Low Error............................................................... 547 Failure code [CA442] Battery Voltage High Error.............................................................. 550 Failure code [CA449] Rail Press Very High Error.............................................................. 552 Failure code [CA451] Rail Press Sensor High Error............................................................ 554 Failure code [CA452] Rail Press Sensor Low Error............................................................. 556 Failure code [CA488] Chg Air Temp High Torque Derate......................................................... 558 Failure code [CA553] Rail Press High Error................................................................... 558 Failure code [CA559] Rail Press Low Error.................................................................... 559 Failure code [CA689] Eng Ne Speed Sensor Error............................................................... 562 Failure code [CA731] Eng Bkup Speed Sens Phase Error......................................................... 564 Failure code [CA757] All Continuous Data Lost Error.......................................................... 566 Failure code [CA778] Eng G Speed Sensor Error................................................................ 568 Failure code [CA1633] KOMNET Datalink Timeout Error.......................................................... 570 Failure code [CA2185] Throttle Sensor Supply Voltage High Error.............................................. 572 Failure code [CA2186] Throttle Sensor Supply Voltage Low Error............................................... 573 Failure code [CA2249] Rail Press Very Low Error.............................................................. 574 Failure code [CA2311] IMV Solenoid Error..................................................................... 576 Failure code [CA2555] Grid Htr Relay Volt High Error......................................................... 578 Failure code [CA2556] Grid Heater Relay Volt Low Error....................................................... 580 Failure Code [D110KB] (Short-circuiting in battery relay).................................................... 582 Failure code [D19JKZ] Personal Code Relay Abnormality........................................................ 584 Failure code [DA25KP] Press. Sensor Power Abnormality........................................................ 586 Failure code [DA2RMC] Pump Comm. Abnormality................................................................. 588 Failure Code [DA2SKQ] (Abnormality in inputting model code).................................................. 590 Failure Code [DA2SKQ] (Abnormality in inputting model code).................................................. 592 Failure code [DAFRMC] Monitor Comm. Abnormality.............................................................. 594 Failure Code [DDHPAKP] (Abnormality in pump pressure sensor)................................................. 596 Failure Code [DDP4KX] (Abnormality in travel PPC pressure switch)............................................ 598 Failure Code [DDWCKZ] (Abnormality in travel direction control switch)....................................... 599 Electrical Circuit Diagram for Travel PPC Switch......................................................... 599 Failure Code [DH1OKS] (Abnormality in Pressure sensor power source).......................................... 600 Failure code [DHPAMA] F Pump Press Sensor Abnormality........................................................ 602 Failure Code [DHS5KX] (Abnormality in travel PPC sensor)..................................................... 604 Failure Code [DHX1MA] (Abnormality in overload caution sensor)............................................... 606 Failure Code [DLT4KA] (Disconnection in transmission speed sensor in pump controller system)................. 608 Failure Code [DW27KA] (Disconnection in Transmission Clutch solenoid)........................................ 610 Failure Code [DW27KB] (Short-circuiting in Transmission Clutch solenoid)..................................... 612 Failure Code DW4AKA (Disconnection in suspension lock solenoid).............................................. 614 Failure Code [DW4AKB] (Short circuiting in suspension lock solenoid)......................................... 616 Failure Code [DW4CKA] (Disconnection in PPC lock solenoid)................................................... 618 Failure code [DW4CKB] PPC Lock Sol. S/C...................................................................... 620 Failure Code [DW4MKA] (Disconnection in Creep solenoid)...................................................... 622 Electrical Circuit Diagram for Creep Solenoid in Pump Controller......................................... 623 Failure Code [DW4MKB] (Short-circuiting in Creep solenoid)................................................... 624 Electrical Circuit Diagram for Creep Solenoid in Pump Controller......................................... 625 Failure Code [DW44KA] (Disconnection of Travel F/R solenoid)................................................. 626 Failure Code [DW44KB] (Short-circuiting of Travel F/R solenoid).............................................. 628 Failure Code [DW45KA] (Disconnection in Swing Parking Brake solenoid)........................................ 630 Failure code [DW45KB] Swing Brake Sol. S/C................................................................... 632 Failure Code [DW91KA] (Disconnection in Travel Neutral solenoid)............................................. 634 Failure Code [DW91KB] (Short-circuiting in Travel Neutral Solenoid).......................................... 636 Failure Code [DWK0KB] (Short-circuiting in 2-Stage Relief Solenoid).......................................... 640 Failure Code [DWK2KA] (Disconnection in 2-stage Back Pressure solenoid)...................................... 642 Failure Code [DWK2KB] (Short circuiting in 2-stage back pressure solenoid)................................... 644 Failure Code [DXA0KA] (Disconnection in PC-EPC solenoid system).............................................. 646 Failure Code [DXA0KB] (Short-circuiting in PC-EPC solenoid).................................................. 648 Failure Code [DXE0KA] (Disconnection in LS-EPC solenoid system).............................................. 650 Failure Code [DXE0KB] (Short-circuiting in LS-EPC solenoid).................................................. 651 Failure Code [DXE4KA] (Disconnection in attachment oil flow rate adjusting EPC).............................. 652 1st Service EPC Solenoid (Left Hand)..................................................................... 652 1st Service EPC Solenoid (Right Hand).................................................................... 653 2nd Service EPC Solenoid (Left Hand)..................................................................... 654 2nd Service EPC Solenoid (Right Hand).................................................................... 655 Failure Code [DXE4KB] (Short-circuiting in attachment oil flow rate adjusting EPC)........................... 657 1st Service EPC Solenoid (Left Hand)..................................................................... 657 1st Service EPC Solenoid (Right Hand).................................................................... 658 2nd Service EPC Solenoid (Left Hand)..................................................................... 659 2nd Service EPC Solenoid (Right Hand).................................................................... 660 Failure code [DY20KA] Wiper Working Abnormality.............................................................. 662 Failure code [DY20MA] Wiper Parking Abnormality.............................................................. 664 Failure code [DY2CKB] Washer Drive S/C....................................................................... 666 Failure code [DY2DKB] Wiper Drive (For) S/C.................................................................. 668 Failure code [DY2EKB] Wiper Drive (Rev) S/C.................................................................. 670 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................................................................... 674 Relative Electrical Circuit Diagram.......................................................................... 675 E-1 Engine does not start (Engine does not rotate)........................................................... 676 Electrical Circuit Diagram for Engine Start, Stop and Battery Charging................................... 679 E-5 Auto-decelerator does not work........................................................................... 680 E-6 Auto engine warm-up device does not work................................................................. 682 E-7 Preheater does not operate............................................................................... 684 E-8 All work equipment, swing and travel do not move......................................................... 686 Electrical Circuit Diagram for PPC Lock Solenoid......................................................... 687 E-9 One-touch Power Max Switch does not work................................................................. 688 Electric Circuit Diagram for One-Touch Power Max. Switch................................................. 688 E-10 No display in monitor panel at all...................................................................... 689 Electrical Circuit Diagram for Power Source in Monitor Panel............................................. 689 E-11 Part of display on monitor panel is missing............................................................. 690 E-12 Monitor panel displays contents irrelevant to the model................................................. 690 E-13 Fuel level monitor red lamp lights up while engine is running........................................... 691 Electrical Circuit Diagram for Fuel Level Sensor......................................................... 691 E14 Engine coolant temperature gauge does not indicate normally.......................................... 692 E-15 Hydraulic oil temperature gauge does not display correctly.............................................. 694 Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor.......................................... 694 E-16 Fuel gauge does not display correctly................................................................... 695 Electrical Circuit Diagram for Fuel Level Sensor......................................................... 695 E-17 Swing lock monitor does not display correctly........................................................... 696 Electrical Circuit Diagram for Swing Lock Switch......................................................... 697 E-18 When the monitor switch is operated, no display appears................................................. 698 E-19 Windshield wiper and window washer do not operate....................................................... 700 E-20 Alarm buzzer cannot be stopped.......................................................................... 702 E-21 "Boom/Stabiliser RAISE" is not correctly displayed in monitor function.................................. 704 Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch........................................... 704 E-22 "Boom/Stabiliser LOWER" is not correctly displayed in monitor function.................................. 705 Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch........................................... 705 E-23 "Arm DIGGING" is not correctly displayed in monitor function............................................ 706 Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch.......................................... 706 E-24 "Arm DUMPING" is not correctly displayed in monitor function............................................ 707 Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch.......................................... 707 E-25 "Bucket DIGGING" is not correctly displayed in monitor function......................................... 708 Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch....................................... 708 E-26 "Bucket DUMPING" is not correctly displayed in monitor function......................................... 709 Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch....................................... 709 E-27 "SWING" is not correctly displayed in monitor function.................................................. 710 Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches............................... 711 E-28 "TRAVEL" is not correctly displayed in monitor function................................................. 712 Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm.............................. 713 E-29 "2 Piece Boom" is not correctly displayed in monitor function........................................... 714 Electrical Circuit Diagram for 2 Pice Boom PPC hydraulic Switch.......................................... 715 E-30 Air Conditioner does not work........................................................................... 716 Electrical Circuit Diagram for Air Conditioner........................................................... 717 E-31 Travel reverse alarm does not sound..................................................................... 718 Electrical Circuit Diagram for Travel Reverse Alarm System............................................... 719 E-32 KOMTRAX system does not operate normally................................................................ 720 TROUBLESHOOTING OF ELECTRICAL SYSTEM (Error checking of items without Monitor codes)............................. 723 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................... 724 Relative Electrical Circuit Diagram...................................................................... 725 Radio Cassette & Telephone Socket........................................................................ 726 Electrical Circuit Diagram For Radio Cassette & Telephone Socket..................................... 727 PPC Lock Circuit......................................................................................... 728 Circuit Diagram for PPC Lock Circuit................................................................. 729 Brake Light Circuit...................................................................................... 730 Circuit Diagram for Brake Light Circuit.............................................................. 731 Undercarriage Attachments - Mode Selection............................................................... 732 Circuit Diagram for Undercarriage Attachments - Mode Selection....................................... 733 Undercarriage Attachments - Front Left Outrigger......................................................... 734 Circuit Diagram for Undercarriage Attachments - Front Left Outrigger................................. 735 Undercarriage Attacments - Front Right Outrigger......................................................... 736 Circuit Diagram for Undercarriage Attachments - Front Right Outrigger................................ 737 Undercariage Attachments - Rear Left Outrigger........................................................... 738 Undercarriage Attachments - Rear Right Outrigger......................................................... 740 Circuit Diagram for Undercarriage Attachments - Rear Right Outrigger................................. 741 Heated Seat Does Not Warm Up............................................................................. 742 Circuit Diagram for the Heated Seat.................................................................. 743 Suspension Lock.......................................................................................... 744 Circuit Diagram for Suspension Lock.................................................................. 745 Lower Wiper Does Not Work (Optional Fitment)............................................................. 746 Circuit Diagram for Lower Wiper...................................................................... 747 Work Lights (Operator Cab Front Left).................................................................... 748 Work Lights (Operator Cab Front Right)................................................................... 749 Work Lights (Operator Cab Rear).......................................................................... 750 Circuit Diagram for Work Lights...................................................................... 751 Worklights (Boom, Arm & Counterweight)................................................................... 752 Circuit Diagram for Worklights (Boom & Counterweight)................................................ 753 Cab and Counterweight Beacon Light....................................................................... 754 Circuit Diagram for Cab & Counterweight Beacon Light................................................. 755 Air Seat Compressor (Option - Air Suspension Seat)....................................................... 756 Circuit Diagram for Air Seat Compressor (Option - Air Suspension Seat)............................... 757 Operator Cab Interior Light.............................................................................. 758 Circuit Diagram for Operator Cab Interior Light...................................................... 759 Cigar Lighter............................................................................................ 760 Circuit Diagram for Cigar Lighter.................................................................... 761 Park Brake (Not Activating).............................................................................. 762 Circuit Diagram for Park Brake....................................................................... 763 Park Brake (Displayed Symbol)............................................................................ 764 Circuit Diagram for Park Brake....................................................................... 765 RH PPC Lever Clamshell Roller Switch Pushed to the LH Position........................................... 766 Circuit Diagram for Clamshell Control................................................................ 767 RH PPC Lever Clamshell Roller Switch Pushed to the RH Position........................................... 768 Circuit Diagram for Clamshell Control................................................................ 769 RH PPC Lever Clamshell Roller Switched Pushed to the RH or LH............................................ 770 Circuit Diagram for Clamshell Control................................................................ 771 Horns.................................................................................................... 772 Circuit Diagram for Horn............................................................................. 773 Swing Lock - Normal Operation............................................................................ 774 Circuit Diagram for Swing Lock....................................................................... 775 Swing Lock - Emergency Operation......................................................................... 776 Circuit Diagram for Swing Lock - Emergency Operation................................................. 777 Neutral Start (Engine)................................................................................... 778 Neutral Start (Engine) cont’d (A)........................................................................ 779 Neutral Start (Engine) cont’d (B)........................................................................ 780 Neutral Start (Engine) cont’d (C)........................................................................ 781 Circuit Diagram for Neutral Start (Engine)........................................................... 782 Emergency Travel Control - Forward....................................................................... 784 Circuit Diagram for Travel Direction Control......................................................... 785 Emergency Travel Control - Neutral....................................................................... 786 Circuit Diagram for Travel Direction Control......................................................... 787 Emergency Travel Control - Reverse....................................................................... 788 Emergency Travel Control - Reverse cont’d................................................................ 789 Circuit Diagram for Travel Direction Control......................................................... 790 Driving Lights - Main Beam............................................................................... 792 Circuit Diagram for Driving Lights................................................................... 793 Driving Lights - Main Beam Flash......................................................................... 794 Circuit Diagram for Driving Lights................................................................... 795 Driving Lights - Main Beam Dipped........................................................................ 796 Circuit Diagram for Driving Lights................................................................... 797 Driving Lights - Position Lights......................................................................... 798 Circuit Diagram for Driving Lights................................................................... 799 Driving Lights - Position Lights cont’d (1) and (2)...................................................... 800 Circuit Diagram for Driving Lights................................................................... 801 Indicators - Right Hand.................................................................................. 802 Circuit Diagram for Indicators & Hazard Warning...................................................... 803 Indicators - Left Hand................................................................................... 804 Circuit Diagram for Indicators & Hazard Warning...................................................... 805 Hazard Warning Lights.................................................................................... 806 Circuit Diagram for Indicators & Hazard Warning...................................................... 807 Hazard Warning Lights cont’d (A)......................................................................... 808 Circuit Diagram for Indicators & Hazard Warning...................................................... 809 Swing Lock Proximity Switch.............................................................................. 810 Brake and Swing Lock Proximity Switches.............................................................. 811 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS............................................................ 815 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE............................................................... 819 H-1 All work equipment lacks power, or travel and swing speeds are slow.................................. 820 H-2 Engine speed sharply drops or engine stalls.......................................................... 821 H-3 No work equipment, travel or swing move.............................................................. 822 H-4 Abnormal noise is heard from around hydraulic pump................................................... 822 H-5 Auto-decelerator does not work....................................................................... 823 H-6 Fine control mode does not function.................................................................. 823 H-7 Boom moves slowly or lacks power..................................................................... 824 H-8 Arm moves slowly or lacks power...................................................................... 825 H-9 Bucket moves slowly or lacks power................................................................... 826 H-10 Work equipment does not move in its single operation................................................ 826 H-11 Work equipment hydraulic drift is too fast.......................................................... 827 H-12 Work equipment has big time lag..................................................................... 828 H-13 Other work equipment moves when relieving single circuit............................................ 828 H-14 One-touch power max. switch does not operate........................................................ 829 H-15 In compound operation, work equipment with larger load moves slowly................................. 829 H-16 In swing + boom RAISE operation, boom moves slowly.................................................. 829 H-17 In swing + travel, travel speed drops sharply....................................................... 830 H-18 Travel speed does not switch........................................................................ 831 H-19 Travel speed does not shift, or it is too slow or fast.............................................. 832 H-20 Machine does not swing.............................................................................. 833 H-21 Swing acceleration is poor, or swing speed is slow.................................................. 834 H-22 Excessive overrun when stopping swing............................................................... 835 H-23 There is big shock when stopping swing.............................................................. 836 H-24 There is loud abnormal noise caused when stopping swing............................................. 836 H-25 Swing natural drift is too big...................................................................... 837 H-26 Swing speed is faster than specified swing speed.................................................... 837 Troubleshooting of engine (S-mode)....................................................................... 838 Method of using troubleshooting chart................................................................ 838 S-1 Starting performance is poor......................................................................... 841 S-2 Engine does not start................................................................................ 842 S-3 Engine does not pick up smoothly..................................................................... 845 S-4 Engine stops during operations....................................................................... 846 S-5 Engine does not rotate smoothly...................................................................... 847 S-6 Engine lack output (or lacks power).................................................................. 848 S-7 Exhaust smoke is black (incomplete combustion)....................................................... 849 S-8 Oil consumption is excessive (or exhaust smoke is blue).............................................. 850 S-9 Oil becomes contaminated quickly..................................................................... 851 S-10 Fuel consumption is excessive....................................................................... 852 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)............................... 853 S-12 Oil pressure drops.................................................................................. 854 S-13 Oil level rises (Entry of coolant/fuel)............................................................. 855 S-14 Coolant temperature becomes too high (overheating).................................................. 856 S-15 Abnormal noise is made.............................................................................. 857 S-16 Vibration is excessive.............................................................................. 858 30 DISASSEMBLY AND ASSEMBLY.......................................................................................... 859 HOW TO READ THIS MANUAL.......................................................................................... 864 REMOVAL AND INSTALLATION OF ASSEMBLIES....................................................................... 864 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES....................................................................... 865 Coating materials list................................................................................... 866 Special tools list....................................................................................... 869 Sketches of special tools................................................................................ 872 LIST OF TOOLS............................................................................................ 873 PRECAUTIONS WHEN PERFORMING OPERATION........................................................................ 874 Removal and installation of fuel supply pump assembly........................................................ 876 Removal and installation of fuel injector assembly........................................................... 878 Removal and installation of engine front seal................................................................ 886 Removal and installation of engine rear seal............................................................. 888 Removal and installation of cylinder head assembly........................................................... 892 Removal and installation of combination cooler assembly...................................................... 904 Removal and installation of fuel cooler assembly............................................................. 907 Removal and installation of engine and hydraulic pump assemblies............................................. 908 Removal and installation of travel motor assembly............................................................ 914 Disassembly and assembly of travel motor assembly............................................................ 916 Removal and installation of swing motor and swing machinery.................................................. 920 Disassembly and assembly of swing machinery.................................................................. 922 Disassembly and assembly of swing motor assembly............................................................. 930 Removal and installation of front axle assembly.............................................................. 938 Disassembly and assembly of front axle....................................................................... 940 Removal and installation of rear axle and transmission....................................................... 994 Disassembly and assembly of rear axle assembly............................................................... 998 Disassembly and assembly of transmission.....................................................................1026 Removal and installation of propshaft assembly...............................................................1056 Removal and installation of wheel assembly...................................................................1058 Removal and installation of suspension lock cylinder assembly................................................1060 Disassembly and assembly of suspension lock cylinder.........................................................1061 Removal and installation of outrigger assembly...............................................................1062 Disassembly and assembly of outriggers.......................................................................1064 Removal and installation of dozer blade assembly.............................................................1066 Disassembly and assembly of dozer blade......................................................................1068 Removal and installation of swing circle assembly............................................................1070 Removal and installation of revolving frame assembly.........................................................1072 Removal and installation of centre swivel joint..............................................................1076 Disassembly and assembly of centre swivel joint assembly.....................................................1080 Removal and installation of fuel tank assembly...............................................................1082 Removal and installation of hydraulic tank assembly..........................................................1084 Removal and installation of control valve assembly...........................................................1088 Removal and installation of LS separation valve assembly.....................................................1092 Removal and installation of pressure compensation valve assembly.............................................1093 Removal and installation of main relief valve assembly.......................................................1094 Removal and installation of LS control EPC valve.............................................................1095 Removal and installation of EPC solenoid valve assembly......................................................1096 Removal and installation of PPC solenoid valve block assembly................................................1098 Removal and installation of oil seal in hydraulic pump input shaft...........................................1100 Disassembly and assembly of work equipment PPC valve.........................................................1101 Disassembly and assembly of hydraulic cylinder...............................................................1102 Removal and installation of monoboom work equipment..........................................................1108 Removal and installation of 2 piece boom work equipment......................................................1112 Removal and installation of air conditioner unit.............................................................1116 Removal and installation of counterweight....................................................................1120 Removal and installation of operator cab assembly............................................................1122 Removal and installation of monitor assembly.................................................................1126 Removal and installation of pump controller assembly.........................................................1128 90 DIAGRAMS..........................................................................................................1131 HYDRAULIC CIRCUIT DIAGRAM (1/3)..................................................................................1133 HYDRAULIC CIRCUIT DIAGRAM (2/3)..................................................................................1135 HYDRAULIC CIRCUIT DIAGRAM (3/3)..................................................................................1137 ELECTRICAL CIRCUIT DIAGRAM (1/3).................................................................................1139 ELECTRICAL CIRCUIT DIAGRAM (2/3).................................................................................1141 ELECTRICAL CIRCUIT DIAGRAM (3/3).................................................................................1143
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