Komatsu Hydraulic Excavators PC400LC-LM, PC400HD-LM Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC400LC-6LM, PC400HD-6LM, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC400LC-6LM, PC400HD-6LM workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,157 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM008000 - Hydraulic Excavator PC400LC-6LM, PC400HD-6LM Operation & Maintenance Manual.pdf
CEBM005302 - Hydraulic Excavator PC400LC-6LM, PC400HD-6LM Shop Manual.pdf
MAIN SECTIONS
MAIN MENU...0
COVER...1
CONTENTS...2
SAFETY...13
SAFETY NOTICE...13
IMPORTANT SAFETY NOTICE...13
GENERAL PRECAUTIONS...13
PREPARATIONS FOR WORK...13
PRECAUTIONS DURING WORK...13
FOREWORD...15
GENERAL...15
HOW TO READ THE SHOP MANUAL...16
VOLUMES...16
DISTRIBUTION AND UPDATING...16
FILING METHOD...16
REVISED EDITION MARK...16
REVISIONS...16
SYMBOLS...16
HOISTING INSTRUCTIONS...17
HOISTING...17
WIRE ROPES...17
COATING MATERIALS...18
STANDARD TIGHTENING TORQUE...20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS...20
TIGHTENING TORQUE OF HOSE NUTS...21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS...21
TIGHTENING TORQUE FOR FLARED NUTS...21
ALTERNATIVE FASTENERS...22
BOLT IDENTIFICATION CHART...22
GRADE 5 AND 8 NON PHOSPHATE COATED HARDWARE...23
GRADE 8 PHOSPHATE COATED HARDWARE...24
STANDARD METRIC FASTENERS...24
HYDRAULIC TUBES AND FITTINGS...25
HOSE CLAMPS...25
SPLIT FLANGE CONNECTIONS...25
ELECTRIC WIRE CODE...26
CLASSIFICATION BY THICKNESS...26
CLASSIFICATION BY COLOR AND CODE...26
CONVERSION TABLES...27
METHOD OF USING THE CONVERSION TABLE...27
01 GENERAL...33
SPECIFICATION DRAWINGS...34
MACHINE...34
WORK EQUIPMENT...36
SPECIFICATIONS...38
WEIGHT TABLE...40
FUEL COOLANT AND LUBRICANTS...42
ENGINE OIL SPECIFICATIONS...43
NORMAL OPERATION...43
ARCTIC OPERATION...43
FINAL DRIVE OIL SPECIFICATIONS...44
COOLANT SPECIFICATIONS...45
10 STRUCTURE AND FUNCTION...51
PARTS RELATED TO ENGINE...52
RADIATOR, OIL COOLER...54
POWER TRAIN...55
FINAL DRIVE...56
SWING CIRCLE...57
SWING MACHINERY...58
TRACK FRAME, RECOIL SPRING...59
PC400LC-6LM...59
TRACK FRAME, RECOIL SPRING...60
PC400LC-6LM - Variable Gauge...60
TRACK FRAME, RECOIL SPRING...61
PC400HD-6LM...61
TRACK SHOE...62
HYDRAULIC PIPING DRAWING...63
HYDRAULIC CIRCUIT DIAGRAM...64
HYDRAULIC TANK, HYDRAULIC FILTER...65
HYDRAULIC PUMP...66
MAIN PUMP...67
TVC, LS VALVE...72
CONTROL VALVE...86
STANDARD AND 2 SERVICE VALVES...86
MAIN STRUCTURE OF 9 SPOOL VALVE (1/4)...87
MAIN STRUCTURE OF 9 SPOOL VALVE (2/4)...88
MAIN STRUCTURE OF 9 SPOOL VALVE (3/4)...89
MAIN STRUCTURE OF 9 SPOOL VALVE (4/4)...90
9 SPOOL VALVE - STD AND 2 SERVICE VALVES...92
8 SPOOL VALVE - STD AND 1 SERVICE VALVES...93
7 SPOOL VALVE - STD...94
SELF REDUCING PRESSURE VALVE...95
STRUCTURE...95
WHEN ENGINE IS STOPPED...97
AT NEUTRAL AND WHEN LOAD PRESSURE P2 IS LOW...98
WHEN LOAD PRESSURE P2 IS HIGH...98
WHEN THERE IS ABNORMAL HIGH PRESSURE...99
SUCTION SAFETY VALVE...100
FOR SERVICE VALVE...100
CLSS...101
OUTLINE OF CLSS...101
BASIC PRINCIPLE...102
CONTROL OF PUMP SWASH PLATE ANGLE...102
PRESSURE COMPENSATION...103
WHEN UNLOAD VALVE IS ACTUATED...107
CUT-OFF CONTROL ACTUATED...108
CUT-OFF CANCELED...108
INTRODUCTION OF LS PRESSURE...109
LS BYPASS VALVE...110
PRESSURE COMPENSATION VALVE...111
SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE...114
VARIABLE TYPE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE)...116
BOOM REGENERATION CIRCUIT...117
ARM REGENERATION CIRCUIT...119
MERGE FLOW DIVIDER VALVE...120
LS SELECT VALVE...122
2-STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD)...123
WHEN ALL WORK EQUIPMENT IS AT NEUTRAL (10-75)...124
WHEN PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY (10-76)...127
WHEN PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY (10-79)...128
WHEN PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY (10-80)...131
WHEN PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY (10-83)...132
WHEN PUMP DIVIDED, TRAVEL OPERATED INDEPENDENTLY (10-84)...135
WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY (10-87)...136
WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY (10-88)...139
WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY (10-91)...140
WHEN PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY (10-92)...143
SWING MOTOR...144
KMF160ABE-3...144
SUCTION-SAFETY VALVE...146
SWING BRAKE...147
CENTER SWIVEL JOINT...148
TRAVEL MOTOR...149
OPERATION OF MOTOR...151
AT LOW SPEED...151
AT HIGH SPEED...152
OPERATION OF PARKING BRAKE...153
COUNTERBALANCE VALVE, CHECK VALVE...154
SAFETY VALVE...155
VALVE CONTROL...158
WORK EQUIPMENT PPC VALVE...159
OPERATION...161
TRAVEL PPC VALVE...163
OPERATION...165
SERVICE PPC VALVE...167
PPC SAFETY LOCK VALVE...169
PPC ACCUMULATOR...170
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE...171
PPC SHUTTLE VALVE...172
TRAVEL JUNCTION VALVE...175
STRAIGHT-TRAVEL SYSTEM...176
LS-EPC VALVE...178
FUNCTION...179
OPERATION...179
SOLENOID VALVE...181
WHEN SOLENOID IS DEACTIVATED...182
WHEN SOLENOID IS EXCITED...182
BOOM HOLDING VALVE...183
OPERATION...184
BOOM LEVER AT HOLD...184
AT BOOM LOWER...185
WORK EQUIPMENT...186
AIR CONDITIONER...187
AIR CONDITIONER PIPING...187
ACTUAL ELECTRICAL WIRING DIAGRAM...188
ENGINE CONTROL...194
OPERATION OF SYSTEM...195
COMPONENTS OF SYSTEM...196
ELECTRONIC CONTROL SYSTEM...200
CONTROL FUNCTION...200
PUMP AND ENGINE MUTUAL CONTROL SYSTEM...202
CONTROL METHOD IN EACH MODE...203
PUMP AND VALVE CONTROL FUNCTION...205
FUNCTION...205
LS CONTROL FUNCTION...205
CUT-OFF FUNCTION...206
CUT-OFF CANCEL FUNCTION...206
FINE CONTROL MODE FUNCTION...207
POWER MAX. FUNCTION, SWIFT SLOW-DOWN FUNCTION...208
FUNCTION...208
POWER MAX. FUNCTION...208
SWIFT SLOW-DOWN FUNCTION...208
AUTO DECELERATION SYSTEM...209
FUNCTION...209
OPERATION...210
AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION...211
FUNCTION...211
ENGINE AUTOMATIC WARMING-UP FUNCTION...212
ENGINE OVERHEAT PREVENTION FUNCTION...212
SWING CONTROL SYSTEM...213
FUNCTION...213
SWING LOCK, SWING HOLDING BRAKE FUNCTION...214
HYDRAULIC OIL QUICK WARM-UP FUNCTION WHEN SWING LOCK SWITCH IS ON...214
TRAVEL CONTROL SYSTEM...215
FUNCTION...215
PUMP CONTROL FUNCTION WHEN TRAVELING...216
TRAVEL SPEED SELECTION FUNCTION...216
ACTIVE MODE FUNCTION...217
FUNCTION...217
INCREASE IN ENGINE SPEED...218
2-STAGE BOOM LOWERING SPEED...218
2-STAGE STROKE FOR SWING SPOOL...218
COMPONENTS OF SYSTEM...219
ENGINE SPEED SENSOR...219
PPC HYDRAULIC SWITCH...219
PUMP PRESSURE SENSOR...220
TVC PROLIX RESISTOR...221
MACHINE MONITOR SYSTEM...222
MONITOR PANEL...223
OUTLINE...223
INPUT AND OUTPUT SIGNALS...223
MONITOR DISPLAY...224
CONTENT OF DISPLAY...225
OIL MAINTENANCE FUNCTION...226
ELAPSED TIME RESET...227
DEMO MODE...227
MODE SELECTION SWITCHES...228
SWITCH ACTUATION TABLE...228
SENSORS...229
ENGINE OIL LEVEL SENSOR...230
HYDRAULIC OIL LEVEL SENSOR...230
ENGINE OIL PRESSURE SENSOR (BOTH LO AND HI)...230
COOLANT TEMPERATURE SENSOR...230
FUEL LEVEL SENSOR...231
AIR CLEANER CLOGGING SENSOR...231
20 TESTING, ADJUSTING AND TROUBLESHOOTING...233
STANDARD VALUE TABLE...234
FOR ENGINE...234
FOR CHASSIS RELATED PARTS...235
FOR ELECTRICAL PARTS...240
SERVICE TOOLS TABLE...245
MEASURING ENGINE SPEED...246
MEASURING EXHAUST COLOR...247
MEASURING WITH HANDY SMOKE CHECKER H1...247
MEASURING WITH SMOKE METER H2...247
VALVE CLEARANCE...248
COMPRESSION PRESSURE...249
BLOW BY PRESSURE...250
FUEL INJECTION TIMING...251
ADJUSTING...252
ENGINE OIL PRESSURE...253
FAN BELT TENSION...254
A/C COMPRESSOR BELT...255
ENGINE SPEED SENSOR...256
BOOST PRESSURE...257
GOVERNOR MOTOR LEVER STROKE...258
WORK, SWING, AND TRAVEL CIRCUIT...259
TVC VALVE OUTPUT PRESSURE...262
LS VALVE OUTPUT AND DIFFERENTIAL PRESSURE...264
CONTROL CIRCUIT OIL PRESSURE...267
SOLENOID VALVE OUTPUT PRESSURE...268
PPC VALVE OUTPUT PRESSURE AND SHUTTLE VALVE...271
WORK EQUIPMENT, SWING PPC VALVE...273
TRAVEL DEVIATION...274
LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...275
MEASURING OIL LEAKAGE...277
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...280
TESTING CLEARANCE OF SWING CIRCLE BEARING...281
WEAR OF SPROCKET...282
TRACK SHOE TENSION...283
BLEEDING AIR...284
TROUBLESHOOTING GENERAL...287
POINTS TO REMEMBER WHEN TROUBLESHOOTING...289
SEQUENCE OF EVENTS IN TROUBLESHOOTING...291
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...292
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT...292
HANDLING CONTROL BOX...297
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT...298
CHECKS BEFORE TROUBLESHOOTING...300
JUDGEMENT OF POWER TRAIN...301
PRECAUTIONS WHEN TROUBLESHOOTING...302
SAFETY...302
METHODS FOR TROUBLESHOOTING...302
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING...304
PREVENTING RECURRENCE OF TROUBLE...305
HYDRAULIC EQUIPMENT...305
OIL CHECKS...305
CLEANING FRAGMENTS OF DAMAGED PARTS...305
METHOD OF USING TROUBLESHOOTING CHARTS...306
CATEGORY OF TROUBLESHOOTING CODE NUMBER...306
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE...306
METHOD OF USING MATRIX TROUBLESHOOTING TABLES...308
METHOD OF USING ENGINE RELATED CHARTS...310
TROUBLESHOOTING...315
CONNECTOR TYPES AND MOUNTING LOCATIONS...316
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...319
CONTROL MECHANISM FOR ELECTRICAL SYSTEM...329
MACHINE CONTROL FUNCTIONS...329
MONITORING PANEL...330
DISPLAY ON MACHINE MONITOR...330
RECORDING OF SERVICE CODES AND USER CODE DISPLAY FUNCTION...330
MACHINE DATA MONITORING FUNCTION...332
METHOD OF DISPLAYING MONITORING CODE...332
TABLE OF MACHINE MONITORING CODES...333
BIT PATTERN CHART...334
GOVERNOR MOTOR ADJUSTMENT MODE...336
TIME ADJUSTMENT MODE...336
WORKING MODE DEFAULT SETTING MODE...337
METHOD OF USING JUDGEMENT TABLE...338
WHEN USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM] AND ENGINE REL....338
WHEN USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM] AND HYDRAULIC ....339
METHOD OF USING TROUBLESHOOTING CHARTS...340
CATEGORY OF TROUBLESHOOTING CODE NUMBER...340
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE...340
TROUBLESHOOTING CODE NUMBER AND PROBLEM...340
DISTINGUISHING CONDITIONS...340
METHOD OF FOLLOWING TROUBLESHOOTING CHART...340
GENERAL PRECAUTIONS...340
DETAILS OF TROUBLESHOOTING AND PROCEDURE...343
PROCEDURE FOR CHECKING MONITOR PANEL OUTPUT SIGNAL...345
CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER...346
SERVICE CODE TABLE...348
TROUBLSHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N-MODE)...349
N-1 [E218] Communication abnormality...350
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER, GOVERNOR CONTROL SYSTEM (E-MODE)...353
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM...354
ACTIONS TAKEN...355
JUDGEMENT TABLE...357
ELECTRICAL CIRCUIT DIAGRAM FOR MODE SYSTEM...358
E-1 Abnormality in governor, pump controller power source, controller LED is OFF...359
E-2 [E308] Abnormality in fuel control dial input value is displayed...360
E-3 [E317] Abnormality, disconnection in motor drive system is displayed...361
E-4 [E318] Abnormality, short circuit in motor drive system is displayed...362
E-5 [E306] Abnormality in feedback potentiometer system is displayed...363
E-6 [E315] Abnormality, short circuit in battery relay output system is displayed...364
E-7 [E316] Abnormality, step out in motor displayed...365
E-8 Engine does not start...366
E-9 Engine does not start...369
E-10 Lack of output, engine high idle speed too low...370
E-11 Engine does not stop...371
E-12 Faulty operation of battery relay system, engine does not stop...372
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)...375
METHOD OF USING ENGINE RELATED CHARTS...376
S-1 Starting performance is poor (Starting always take time)...381
S-2 Engine does not start...382
S-3 Engine does not pick up smoothly (Follow-up is poor)...385
S-4 Engine stops during operation...386
S-5 Engine does not run smoothly (Hunting)...387
S-6 Engine lacks output (No power)...388
S-7 Exhaust gas is black (Incomplete Combustion)...389
S-8 Oil consumption is excessive (or exhaust gas is blue)...390
S-9 Oil becomes contaminated quickly...391
S-10 Fuel consumption is excessive...392
S-11 Oil in coolant, or coolant spurts back, or coolant level goes down...393
S-12 Oil pressure lamp lights up (Drop in oil pressure)...394
S-13 Oil level rises...395
S-14 Coolant Temperature becomes too high (Overheating)...396
S-15 Abnormal noise is made...397
S-16 Vibration is excessive...398
TROUBLESHOOTING OF GOVERNOR PUMP CONTROLLER, PUMP CONTROL SYSTEM (C-MODE)...399
POINTS TO REMEMBER WHEN TROUBLESHOOTING CONTROLLER SYSTEM...400
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...401
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS...405
ELECTRIC CIRCUIT DIAGRAM FOR C MODE...406
C-1 Abnormality in controller power source system, controller LED is OFF...408
C-2 [E232] Short circuit in front pump TVC solenoid system is displayed...409
C-3 [E233] Disconnection in front pump TVC solenoid system is displayed...410
C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed...411
C-5 [E237] Disconnection in rear pump TVC solenoid system is displayed...412
C-6 [E207] Short circuit in LS select solenoid system is displayed...413
C-7 [E208] Disconnection in active mode, boom, solenoid system is displayed...415
C-8 [E203] Short circuit in swing brake solenoid system is displayed...416
C-9 [E213] Disconnection in swing brake solenoid system is displayed...417
C-10 [E204] Short circuit in pump merge divider solenoid system is displayed...418
C-11 [E214] Disconnection in pump merge divider solenoid system is displayed...419
C-12 [E206] Short circuit in travel speed solenoid system is displayed...420
C-13 [E216] Disconnection in travel speed selector solenoid system is displayed...421
C-14 [E217] Short circuit in active mode, swing, solenoid system is displayed...422
C-15 [E235] Disconnection in active mode, swing, solenoid system is displayed...423
C16 [E217] Model selection input error is displayed...424
C-17 [E222] Short circuit in LS-EPC solenoid system is displayed...426
C-18 [E224] Disconnection in LS-EPC solenoid system is displayed...427
C-19 [E224] Abnormality in front pump pressure sensor system is displayed...428
C-20 [E225] Abnormality in rear pump pressure sensor system is displayed...429
C-21 [E226] Abnormality in i pressure sensor power source system is displayed...430
C-22 [E227] Abnormality in engine speed sensor system is displayed...431
C-23 [E225] Abnormality in machine push up solenoid system, no service code displayed...432
a) If solenoid is not actuated, turned on, when machine push up switch is set to low pressure setting...432
b) If solenoid is not canceled, turned off, when machine push up switch is set to high pressure setting...433
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER, INPUT SIGNAL SYSTEM (F-MODE)...435
ELECTRIC CIRCUIT DIAGRAM FOR F MODE...437
F-1 Bit pattern 20-[1] Swing oil pressure switch does not light up...438
F-2 Bit pattern 20-[2] Travel oil pressure switch does not light up...439
F-3 Bit pattern 20-[3] Boom LOWER oil pressure switch does not light up...440
F-4 Bit pattern 20-[4] Boom RAISE oil pressure switch does not light up...441
F-5 Bit pattern 20-[5] Arm IN oil pressure switch does not light up...442
F-6 Bit pattern 20-[6] Arm OUT oil pressure switch does not light up...443
F-7 Bit pattern 21-[1] Bucket CURL oil pressure switch does not light up...444
F-8 Bit pattern 21-[2] Bucket DUMP oil pressure switch does not light up...445
F-9 Bit pattern 21-[3] Swing lock oil pressure switch does not light up...446
F-10 Bit pattern 22-[5] Mode connection does not light up...447
F-11 Bit pattern 22-[6] Left knob switch does not light up...448
TROUBLESHOOTING OF MACHINE MECHANICAL MODE (H-MODE)...449
PUMP MERGE DIVIDER LOGIC...450
SOLENOID ACTUATION TABLE...450
TABLE OF FAILURE MODES AND CAUSES...451
H-1 Speeds of all work equipment swing, travel are slow or lack power...453
H-2 There is excessive drop in engine speed, or engine stalls...454
H-3 No work equipment, travel, swing movement...454
H-4 Abnormal noise generated around pump...455
H-5 Auto decel does not work when PPC shuttle valve is cause...455
H-6 Fine control ability is poor or response is poor...455
H-7 Boom is slow or lacks power...456
H-8 Arm is slow or lacks power...457
H-9 Bucket is slow or lacks power...458
H-10 Work Equipment; Boom, Arm, Bucket, Does Not Move, But Travel and Swing Are Normal...459
H-11 Excessive hydraulic drift, boom, arm, bucket ...459
1) Excessive hydraulic drift of boom...459
2) Excessive hydraulic drift of arm or bucket...459
H-12 Excessive time lag, engine at low idling...460
H-13 Other equipment moves when single circuit is relieved...460
H-14 In L/O, F3/O modes, work equipment speed is faster than specified speed...461
H-15 Malfunction of machine push up function...461
H-16 In compound operations, work equipment with larger load is slow...461
H-17 In swing plus boom RAISE, boom RAISE is slow...462
H-18 In swing plus arm, arm is slow...462
H-19 In swing plus travel, travel speed drops excessively...462
H-20 Travel deviation...463
H-21 Travel speed is slow...465
H-22 Steering does not turn easily or lacks power...466
H-23 Travel speed does not switch or is faster than specified speed...467
H-24 Travel does not move, one side only...467
H-25 Does not swing...468
H-26 Travel speed is slow...469
H-27 Excessive overrun when stopping swing...470
H-28 Excessive shock when stopping swing, one direction only...471
H-29 Excessive abnormal noise when stopping swing...471
H-30 Excessive hydraulic drift of swing...472
H-31 Swing speed is faster than specified swing speed...472
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M-MODE)...473
ACTIONS TAKEN BY MONITOR PANEL...475
ELECTRIC CIRCUIT DIAGRAM FOR M MODE...476
M-1 [E101] Abnormality in error data is displayed...477
[E102] Error in clock data is displayed...477
M-2 [E103] Short circuit in buzzer output or 24V wiring harness contact with buzzer harness is displayed...478
M-3 [E104] Air cleaner restriction detected is displayed...479
M-4 [E106] Drop in engine oil Hi pressure detected is displayed...479
M-5 [E108] Engine coolant temperature 105 C detected is displayed...479
M-6 When start switch is turned ON, no lamps on monitor panel light up for three seconds...480
M-7 When start switch is turned ON, monitor panel lamps all stay illuminated and do not go out...482
M-8 When start switch is turned ON, items illuminated on monitor panel are different from actual machine...482
M-9 When start switch is turned ON, engine stopped, basic check items flash...483
M-10 Preheating is not used, but on monitor panel lights up...486
M-11 When start switch is turned ON and engine is started, basic check items flash...487
M-12 When start switch is turned ON, engine speed, caution items, emergency items flash. Battery, engine oil pressure lamps d...489
M-13 When start switch is turned ON and engine is started, caution items, emergency items flash, when there is no abnormality...491
M-14 When start switch is turned ON, engine stopped, buzzer does not sound for one second, Caution ite....494
M-15 No abnormality is displayed on monitor panel but buzzer sounds...495
M-16 Night light on monitor panel does not light up, liquid crystal display is normal...496
M-17 Coolant temperature gauge does not rise...497
M-18 Coolant temperature gauge does not give any display, no gauge lamps light up during operation...498
M-19 Fuel level gauge always displays FULL...499
M-20 Fuel level gauge does not give display...500
M-21 Swing lock switch is turned ON, but on monitor panel does not light...501
M-22 Swing prolix switch is turned ON, but on monitor panel does not flash...502
M-23 Service meter does not advance while engine is running...503
M-24 When start switch is at OFF and time switch is pressed, time and service meter are not displayed...503
M-25 Faulty fuel level sensor system...504
M-26 Faulty coolant temperature sensor system...505
M-27 Faulty engine oil level sensor system...506
M-28 Faulty coolant level sensor system...507
M-29 Faulty hydraulic oil level sensor system...508
M-30 [E112, E113] Wiper does not work or switch is not being used, but wiper is actuated...509
M-31 [E114] Wiper does not work or switch is not being used, but washer motor is not actuated...513
30 DISASSEMBLY AND ASSEMBLY...515
METHOD OF USING MANUAL...516
SPECIAL TOOL LIST...521
SKETCHES OF SPECIAL TOOLS...526
STARTING MOTOR...534
REMOVAL...534
INSTALLATION...534
ALTERNATOR...535
REMOVAL...535
INSTALLATION...535
ENGINE OIL COOLER...536
REMOVAL...536
INSTALLATION...536
FUEL INJECTION PUMP...537
REMOVAL...537
INSTALLATION...538
WATER PUMP...539
REMOVAL...539
INSTALLATION...539
NOZZLE HOLDER...540
REMOVAL...540
INSTALLATION...540
TURBOCHARGER...541
REMOVAL...541
INSTALLATION...541
THERMOSTAT...542
REMOVAL...542
INSTALLATION...542
FRONT ENGINE SEAL...543
REMOVAL...543
INSTALLATION...543
REAR ENGINE SEAL...544
REMOVAL...544
INSTALLATION...545
CYLINDER HEAD...547
REMOVAL...547
INSTALLATION...551
GOVERNOR MOTOR...554
REMOVAL...554
INSTALLATION...554
AFTERCOOLER CORE...555
REMOVAL...555
INSTALLATION...555
OIL COOLER...556
REMOVAL...556
INSTALLATION...557
RADIATOR, OIL COOLER...558
REMOVAL...558
INSTALLATION...560
ENGINE, MAIN PUMP...561
REMOVAL...561
INSTALLATION...565
DAMPER...567
REMOVAL...567
INSTALLATION...567
FUEL TANK...568
REMOVAL...568
INSTALLATION...568
CENTER SWIVEL JOINT...569
REMOVAL...569
INSTALLATION...569
DISASSEMBLY...570
ASSEMBLY...570
FINAL DRIVE...571
REMOVAL...571
INSTALLATION...571
DISASSEMBLY...572
ASSEMBLY...576
TRAVEL MOTOR...582
DISASSEMBLY...582
ASSEMBLY...586
SPROCKET...595
REMOVAL...595
INSTALLATION...595
SWING MOTOR...596
REMOVAL...596
INSTALLATION...596
DISASSEMBLY...597
ASSEMBLY...599
SWING MACHINERY...606
REMOVAL...606
INSTALLATION...606
DISASSEMBLY...607
ASSEMBLY...610
REVOLVING FRAME...615
REMOVAL...615
INSTALLATION...616
SWING CIRCLE...617
REMOVAL...617
INSTALLATION...617
IDLER AND RECOIL SPRING...618
REMOVAL...618
INSTALLATION...618
IDLER...619
DISASSEMBLY...619
ASSEMBLY...620
RECOIL SPRING...623
DISASSEMBLY...623
ASSEMBLY...624
TRACK ROLLER...625
REMOVAL...625
INSTALLATION...625
DISASSEMBLY...626
ASSEMBLY...627
CARRIER ROLLER...630
REMOVAL...630
INSTALLATION...630
DISASSEMBLY...631
ASSEMBLY...632
TRACK CHAIN...635
REMOVAL...635
INSTALLATION...635
HYDRAULIC TANK...636
REMOVAL...636
INSTALLATION...637
MAIN PUMP...638
REMOVAL...638
INSTALLATION...639
DISASSEMBLY...640
PUMP ASSEMBLY...640
FRONT PUMP...640
REAR PUMP...645
ASSEMBLY...648
FRONT PUMP...648
REAR PUMP...655
MAIN PUMP OIL SEAL...666
REMOVAL...666
INSTALLATION...666
CONTROL VALVE...667
REMOVAL...667
INSTALLATION...669
DISASSEMBLY...670
(1/3)...670
(2/3)...671
(3/3)...672
ASSEMBLY...675
(1/3)...675
(2/3)...676
(3/3)...677
PUMP MERGE DIVIDER VALVE...681
DISASSEMBLY...681
ASSEMBLY...681
PRESSURE COMPENSATION VALVE...682
DISASSEMBLY...682
ASSEMBLY...682
FRONT PUMP SERVO VALVE...683
REMOVAL...683
INSTALLATION...683
REAR PUMP SERVO VALVE...684
REMOVAL...684
INSTALLATION...684
LS-EPC SOLENOID VALVE...685
REMOVAL...685
INSTALLATION...685
SOLENOID VALVE...686
REMOVAL...686
INSTALLATION...686
WORK EQUIPMENT PPC VALVE...687
REMOVAL...687
INSTALLATION...687
DISASSEMBLY...688
ASSEMBLY...688
TRAVEL PPC VALVE...689
REMOVAL...689
INSTALLATION...689
DISASSEMBLY...690
ASSEMBLY...690
PPC SHUTTLE VALVE...691
REMOVAL...691
INSTALLATION...692
DISASSEMBLY...692
ASSEMBLY...693
BOOM LOCK VALVE...694
REMOVAL...694
INSTALLATION...694
DISASSEMBLY...695
ASSEMBLY...695
BOOM CYLINDER...696
REMOVAL...696
INSTALLATION...696
ARM CYLINDER...698
REMOVAL...698
INSTALLATION...698
BUCKET CYLINDER...699
REMOVAL...699
INSTALLATION...699
HYDRAULIC CYLINDER...701
THREADED STYLE PISTON...701
DISASSEMBLY...701
ASSEMBLY...703
WORK EQUIPMENT...707
REMOVAL...707
INSTALLATION...708
BUCKET...709
REMOVAL...709
INSTALLATION...710
ARM...711
REMOVAL...711
INSTALLATION...712
BUCKET AND ARM...713
REMOVAL...713
INSTALLATION...714
BOOM...715
REMOVAL...715
INSTALLATION...716
OPERATOR?S CAB...717
REMOVAL...717
INSTALLATION...718
COUNTERWEIGHT...719
REMOVAL...719
INSTALLATION...719
COMPRESSOR...720
REMOVAL...720
INSTALLATION...720
CONDENSER...721
REMOVAL...721
INSTALLATION...721
RECEIVER TANK...722
REMOVAL...722
INSTALLATION...722
AIR CONDITIONER UNIT...723
REMOVAL...723
INSTALLATION...724
GOVERNOR, PUMP CONTROLLER...725
REMOVAL...725
INSTALLATION...725
MONITOR PANEL...726
REMOVAL...726
INSTALLATION...726
CONTROL STAND CASE...727
REMOVAL...727
TRAY...727
BOOT...727
UPPER CASE...728
INSTALLATION...728
40 MAINTENANCE STANDARD...729
ENGINE MOUNT...730
RADIATOR AND OIL COOLER MOUNT...731
SWING MACHINERY...735
SWING CIRCLE...736
FINAL DRIVE...737
TRACK FRAME AND RECOIL SPRING...738
IDLER...742
CARRIER ROLLER...744
TRACK ROLLER...745
TRACK SHOE...746
TRACK SHOE...748
HYDRAULIC PUMP...749
CONTROL VALVE...750
SELF REDUCING PRESSURE VALVE...757
SUCTION SAFETY VALVE...758
SWING MOTOR...759
TRAVEL MOTOR...760
WORK EQUIPMENT ? SWING PPC VALVE...761
TRAVEL PPC VALVE...762
SERVICE PPC VALVE...763
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE...764
LS-EPC VALVE...765
SOLENOID VALVE...766
CENTER SWIVEL JOINT...767
BOOM HOLDING VALVE...768
HYDRAULIC CYLINDER...770
BOOM, BUCKET CYLINDER - THREADED PISTON...770
ARM CYLINDER - THREADED PISTON...770
WORK EQUIPMENT...772
DIMENSIONS OF WORK EQUIPMENT...774
BUCKET...776
90 OTHERS...779
Foldout 20-203 Connector types and mounting location...781
Foldout 20-229 Details of troubleshooting and troubleshooting procedures...783
Foldout 20-353 Actions taken by controller when abnormality occurs and problems on machine...785
Foldout 20-354 Action taken by controller when abnormality occurs and problems on machine...787
Foldout 20-355 Judgement table for governor pump controller and engine related parts...789
Foldout 20-356 Electrical circuit diagram for E mode...791
Foldout 20-365 E-8 Engine does not start...793
Foldout 20-366 E-9a Engine speed is irregular...795
Foldout 20-367 E-9b There is hunting...797
Foldout 20-368 E-10 Lack of output, engine high idle speed is low...799
Foldout 20-369 E-11 Engine does not stop...801
Foldout 20-453 Actions taken by controller when abnormality occurs and problems on machine...803
Foldout 20-454 Actions taken by controller when abnormality occurs and problemss...805
Foldout 20-455 Actions taken by controller when abnormality occurs and problems on machine...807
Foldout 20-456 Actions taken by controller when abnromality occurs and problems on machine...809
Foldout 20-457 Judgement table for governor, pump controller (pump control system) and hydraulic related parts...811
Foldout 20-458 Electric circuit diagram for C mode...813
Foldout 20-461 C-2 [E232] Short circuit in front pump TVC solenoid is displayed...815
Foldout 20-462 C-3 [E233] Disconnection in front pump TVC solenoid system is displayed...817
Foldout 20-463 C-4 [E236] Short circuit in rear pump TVC solenoid system is displayed...819
Foldout 20-464 C-5 [E237] Disconnection in rar pump TVC solenid system is displayed...821
Foldout 20-467 C-7 [E208] Disconnection in active mode, boom, solenoid system is displayed...823
Foldout 20-468 C-8 [E203] Short circuit in swing brake solenoid system is displayed...825
Foldout 20-469 C-9 [E213] Disconnection in swing brake solenoid system is displayed...827
Foldout 20-471 C-11 [E214] Disconnection in pump merge divider solenoid system is displayed...829
Foldout 20-473 C-13 [E216] Disconnection in travel speed selector solenoid system is displayed...831
Foldout 20-475 C-15 [E235] Disconnection in active mode, swlin solenoid system is displayed...833
Foldout 20-503 Electric circuit diagram for F mode...835
Foldout 20-553 Table of failure modes and causes (1/2)...837
Foldout 20-554 Table of fialure modes and causes (2/2)...839
Foldout 20-555 H-1 Speed of all work equipment, swing, travel are slow or lack power...841
Foldout 20-557 H-4 Abnormal noise generated around pump...843
Foldout 20-557 H-5 Auto decel does not work when PPC shuttle valve is cause...843
Foldout 20-557 H-6 Fine control ability is poor or response is poor...843
Foldout 20-558 H-7 Boom is slow or lacks power...845
Foldout 20-559 H-8 Arm is slow or lacks power...847
Foldout 20-560 H-9 Bucket is slow or lacks power...849
Foldout 20-567 H-21 Travel speed is slow...851
Foldout 20-568 H-22 Steering does not turn easily or lacks power...853
Foldout 20-571 H-26 Travel speed is slow...855
Foldout 20-603 Actions taken by controller when abnormality occurs and problems on machine...857
Foldout 20-604 Electric circuit diagram for M mode...859
Foldout 20-637 M-30 Wiper does not work or switch is not being used, but wiper is actuated [include E112, E113]...861
Foldout 20-638 M-30 (continued)...863
Foldout 20-641 M-31 Wiper does not work or switch is not being used, but washer motor is actuated (include E114)...865
