Komatsu Hydraulic Excavators PC1250-7, PC1250LC-7, PC1250SP-7 workshop service repair manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC1250-7, PC1250LC-7, PC1250SP-7, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC1250-7, PC1250LC-7, PC1250SP-7 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: 3,732 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM027311 - Hydraulic Excavator PC1250-7, PC1250LC-7, PC1250SP-7 Shop Manual.pdf
SEN00889-17 - Hydraulic Excavator PC1250-8, PC1250LC-8, PC1250SP-8 Shop Manual.pdf
GEN00015-03 - Hydraulic Excavator PC1250-7, PC1250LC-7, PC1250SP-7 Field Assembly Instruction.pdf
GEN00055-08 - Hydraulic Excavator PC1250-8, PC1250LC-8, PC1250SP-8 Field Assembly Instruction.pdf
TEN00146-02 - Hydraulic Excavator PC1250-8, PC1250LC-8, PC1250SP-8 Operation & Maintenance Manual.pdf
TEN00223-03 - Hydraulic Excavator PC1250-8, PC1250LC-8, PC1250SP-8 Operation & Maintenance Manual.pdf
TEN00291-00 - Hydraulic Excavator PC1250-7, PC1250LC-7, PC1250SP-7 Operation & Maintenance Manual.pdf
TEN00362-01 - Hydraulic Excavator PC1250-8, PC1250LC-8, PC1250SP-8 Operation & Maintenance Manual.pdf
TEN00503-02- Hydraulic Excavator PC1250-8, PC1250LC-8, PC1250SP-8 Operation & Maintenance Manual.pdf
MAIN SECTIONS
GEN00016-01 - Hydraulic Excavator PC1800-6 Field Assembly Instruction...2
COVER...2
CONTENTS...3
GENERAL...6
1. SPECIFICATIONS...6
2. POINTS REGARDING LOCAL ASSEMBLY...7
3. BOLT TIGHTENING TORQUE AND BOLT TIGHTENING TOOLS...8
4. SEPARATE UNITS...11
5. LIST OF PARTS SENT INDIVIDUALLY...31
6. ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE...60
7. KIT LAYOUT DIAGRAM...61
8. TOOLS AND EQUIPMENT TO BE USED...63
COMPONENTS TO BE ASSEMBLED IN HARBOR...71
COOLING SUB ASS'Y...72
FUEL TANK SUB ASS'Y...82
HYDRAULIC TANK SUB ASS'Y...88
SUCTION TUBE SUB ASS'Y...94
OIL COOLER LINE...96
SWING MACHINERY SUB ASSY...102
HOOD (SMALL) SUB ASSY...108
RIGHT SIDE DOOR SUB ASSY...112
RIGHT SIDE DUCT SUB ASSY...118
PARTITION COVER...123
MUFFLER COVER...125
BATTERY CASE SUB ASSY...127
A. ASSEMBY OF CHASSIS...133
A-1: ASSEMBLY OF TRACK FRAME AND AXLE...134
A-2: TRAVEL MOTOR PIPING...137
A-3: IDLER CUSHION CYLINDER PIPING...139
A-4: INSTALLATION OF TRAVEL MOTOR GUARD...140
A-5: FILLING SWING CIRCLE WITH GREASE...142
A-6: ASSEMBLY OF REVOLVING FRAME ASSEMBLY AND AXLE ASSEMBLY...143
A-7: SWIVEL TRAVEL PIPING...145
A-8: SWING CIRCLE GREASE TUBE PIPING...147
A-9: INSTALLATION OF LEFT AND RIGHT LADDERS...155
A-10: INSTALLATION OF LEFT CATWALK (STD)...156
A-11: INSATLLATION OF RIGHT CATWALK...157
A-12: INSATLLATION OF CATWALK, HANDRAIL BESIDE OPERATOR'S CAB...158
A-13: INSTALLATION OF OPERATOR'S CAB LADDER...159
A-14: INSTALLSTION OF OPERATOR'S CAB HANDRAIL...160
A-16: INSTALLSTION OF HANDRAIL AT REAR OF OPERATOR'S CAB...161
A-18: OPERATOR'S CAB FRONT FRAME, HANDRAIL...162
A-20: RIGHT DECK HANDRAIL...163
A-21: INSTALLATION OF LADDER ON TOP OF HYDRAULIC TANK...164
A-22: INSTALLATION OF COUNTERWEIGHT...165
A-23: INSTALLATION OF COUNTERWEIGHT LADDERS (LEFT AND RIGHT)...166
A-24: INSTALLATION OF HANDRAIL ON TOP OF FUEL TANK, COUNTERWEIGHT...167
A-25: INSTALLATION OF FUEL TANK VIBRATION STOPPER BRACKET...168
A-26: INSTALLATION OF GREASE REEL, HOSE, BRACKET...169
A-27: INSTALLATION OF LEFT CAB BASE ASSEMBLY...170
A-28: INSTALLATION OF OPERATOR'S CAB ASSEMBLY...175
A-29: INSTALLATION OF WIPER MOTOR COVER INSIDE OPERATOR'S CAB...176
A-30: INSTALLATION OF UPPER HANDRAIL OF LEFT-HAND DOOR COVER...177
A-31: HANDRAILS ABOVE THE RH DOOR AND BAOVE THE HYDRAULIC OIL TANK...179
A-32: EMERGENCY STOP SWITCH, FUEL CUT LEVER...180
A-33: HANDRAIL ABOVE THE RADIATOR...182
A-34: CONNECTION OF HYDRAULIC PIPING OPERATOR'S CAB ASSEMBLY...183
A-35: CONNECTION OF WINDOW WASHER HOSE OF OPERATOR'S CAB ASSEMBLY...188
A-36: CONNECTION OF AIR PIPING OF LEFT CAB BASE ASSEMBLY...189
A-37: CONNECTION OF GREASE PIPING OF OPERATION'S CAB ASSEMBLY...190
A-38: CONNECTION OF WIRING HAMESS IN CAB BASE...194
A-39: PIPING OF AIR CONDITIONER DISCHARGE HOSE...195
A-40: INSTALLATION OF HEAD GUARD...200
A-41: INSTALLATION OF ORBCOMM ANTENNA...201
A-42: CONNECTION OF BATTERY CABLE...202
A-43: START ENGINE...203
A-44: FINAL TIGHTENING OF SWING CIRCLE MOUNTING BOLTS...211
A-45: PARTS TO BE TOUCHED UP AFTER FIELD ASSEMBLY...212
L-1: INSTALLATION OF LEFT-HAND CATWALK AND POWER-ASSISTED LADDER...213
C. PC1800 INSTALLATION OF BACKHOE WORK EQUIPMENT...217
C-1: INSTALLATION OF BOOM CYLINDER TO CHASSIS...218
C-2: INSTALLATION OF BOOM CYLINDER PIPING...220
C-3: BLEEDING AIR FROM BOOM CYLINDER...221
C-4: BOOM SUB-ASSEMBLY...222
C-5: INSTALLATION OF BOOM ASSEMBLY...226
C-6: INSTALLATION OF BOOM CYLINDER TOP PIN...229
C-7: CONNECTION OF ARM ASSEMBLY TO BOOM...231
C-8: INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS...234
C-9: INSATLLATION OF ARM CYLINDER TOP PIN...236
C-10: BLEEDING AIR FROM ARM CYLINDER...238
C-11: INSTALLATION OF HYDRAULIC HOSES BETWEEN BOOM AND ARM...239
C-12: CONNECTION OF GREASE PIPING...240
C-13: CONNECTION OF WIRING BETWEEN BOOM AND CHASSIS...245
C-14: INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS...246
C-16: CONNECTION OF BUCKET ASSEMBLY TO ARM...248
C-17: INSTALLATIPN OF BUCKET LINK...251
C-18: BLEEDING AIR FROM BUCKET CYLINDER...253
ASSEMBLY MANUAL FOR LOADING SHOVEL WORK EQUIPMENT...255
LS-1: INSTALLATION OF ARM CYLINDER TUBES AND HOSES...256
LS-2: INSTALLATION OF BUCKET HOSES...257
LS-3: INSTALLATION OF BOTTOM DUMP HOSES AND TUBES...258
LS-4: INSTALLATION OF PILOT SOLENOID VALVE...259
LS-5: INSTALLATION OF BOTTOM PRIORITY VALVE...260
LS-6: INSTALLATION OF ARM PILOT DRAIN CIRCUIT...262
LS-7: INSTALLATION OF CONTROL PARTS...264
LS-8: INSTALLATION OF HORN SWITCH...266
LS-9: CHANGE OF ARM PILOT PIPING...267
LS-10: REMOVAL OF BOOM FOOT HANDRAIL...268
LS-11: INSTALLATION OF ARM CYLINDER BOTTOM PARTS...269
LS-12: INSTALLATION OF BOOM CYLINDER TO MACHINE BODY...270
LS-13: INSTALLATION OF BOOM CYLINDER PIPING...272
LS-14: INSTALLATION OF BOOM ASSEMBLY...274
LS-15: INSTALLATION OF BOOM CYLINDER HEAD PINS...275
LS-16: INSTALLATION OF GREASE FEED HOSE BETWEEN MACHINE BODY AND BOOM...276
LS-17: INSTALLATION OF BUCKET CYLINDER ASSEMBLY...277
LS-18: INSTALLATION OF ARM ASSEMBLY...278
LS-19: INSTALLATION OF ARM CYLINDER ASSEMBLY...279
LS-20: INSTALLATION OF HOSES BETWEEN BOOM AND ARM...280
LS-21: INSATLLATION OF BUCKET CYLINDER HOSES...281
LS-22: INSTALLATION OF GREASE FEED HOSE OF BUCKET CYLINDER...282
LS-23: INSTALLATION OF BUCKET ASSEMBLY...284
LS-24: INSTALLATION OF BOTTOM DUMP HOSE AND GREASE FEED HOSE BETWEEN ARM AND BUCKET...285
M. INSPECTION AND SERVICING PROCEDURES AFTER FINNISHING ALL THE ASSEMBLY AND INSTALLATION WORKS...286
M-1: 1. INSPECTING THE OIL LEVEL AND WATER LEVEL IN RESPECTIVE SECTIONS AND REFILLING THEM...287
M-1: 2. SELECTION OF THE APPROPRIATE FUEL TYPE AND LUBRICATING OIL TYPE FITTING TO THE ATMOSPHERIC TEMPERATURE RANGE...287
M-2: FLUSHING OF HYDRAULIC CIRCUIT...290
M-3: RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT...291
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER...292
SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER...306
FIELD ASSEMBLY INSPECTION REPORT...323
SEAM022902 - Hydraulic Excavator PC1800-6 Operation & Maintenance Manual...375
COVER PAGE...375
1. FOREWORD...376
2. SAFETY INFORMATION...377
3. INTRODUCTION...378
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...379
5. CONTENTS...380
SAFETY...383
6. GENERAL PRECAUTIONS...384
7. PRECAUTIONS DURING OPERATION...391
7.1 BEFORE STARTING ENGINE...391
7.2 AFTER STARTING ENGINE...393
7.3 TRANSPORTATION...400
7.4 BATTERY...401
7.5 TOWING...403
7.6 LIFTING OPERATIONS...403
8. PRECAUTIONS FOR MAINTENANCE...404
8.1 BEFORE CARRYING OUT MAINTENANCE...404
8.2 DURING MAINTENANCE...408
9. POSITION FOR ATTACHING SAFETY LABELS...413
OPERATION...418
10. GENERAL VIEW...419
10.1 GENERAL VIEW OF MACHINE...419
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...420
11. EXPLANATION OF COMPONENTS...422
11.1 MACHINE MONITOR...422
11.2 SWITCHES...431
11.3 LAMP...438
11.4 CONTROL LEVERS, PEDALS...439
11.5 DOOR LOCK...442
11.6 POCKET...442
11.7 HANDLING AIR CONDITIONER...443
11.8 EMERGENCY ESCAPE HAMMER...446
11.9 EMERGENCY ESCAPE LADDER...447
11.10 CAP, COVER WITH LOCK...448
11.11 ASHTRAY...448
11.12 CAR RADIO...449
11.13 FUSE...454
11.14 CIRCUIT-BREAKER ...455
11.15 CONTROLLERS...455
11.16 TOOL BOX...455
11.17 GREASE PUMP...456
11.18 HANDLING GREASE PUMP...456
11.19 HANDLING ACCUMULATOR...458
11.20 HEALTH MONITOR...460
12. OPERATION...471
12.1 CHECK BEFORE STARTING ENGINE...471
12.2 STARTING ENGINE...485
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE...488
12.4 MOVING MACHINE OFF...494
12.5 STEERING MACHINE...497
12.6 STOPPING MACHINE...499
12.7 SWINGING...500
12.8 OPERATION OF WORK EQUIPMENT...501
12.9 HANDLING WORKING MODE...502
12.10 PROHIBITIONS FOR OPERATION...503
12.11 PRECAUTIONS FOR OPERATION...505
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS...506
12.13 HOW TO ESCAPE FROM MUD...508
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR...509
12.15 PHENOMENA THAT ARE NOT FAILURES...509
12.16 PARKING MACHINE...510
12.17 CHECK AFTER FINISHING WORK...511
12.18 STOPPING ENGINE...512
12.19 CHECK AFTER STOPPING ENGINE...515
12.20 LOCKING...515
13. TRANSPORTATION...516
13.1 PRECAUTIONS FOR TRANSPORTATION...516
13.2 PARTS FOR TRANSPORT...517
14. COLD WEATHER OPERATION...525
14.1 PRECAUTIONS FOR LOW TEMPERATURE...525
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...527
14.3 AFTER COLD WEATHER...527
15. LONG-TERM STORAGE...528
15.1 BEFORE STORAGE...528
15.2 DURING STORAGE...529
15.3 AFTER STORAGE...529
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE...529
16. TROUBLESHOOTING...530
16.1 WHEN FUEL RUNS OUT...530
16.2 PHENOMENA THAT ARE NOT FAILURES...530
16.3 METHOD OF TOWING MACHINE...530
16.4 PRECAUTIONS ON PARTICULAR JOBSITES...530
16.5 IF BATTERY IS DISCHARGED...531
16.6 OTHER TROUBLE...534
MAINTENANCE...539
17. GUIDES TO MAINTENANCE...540
18. OUTLINES OF SERVICE...544
18.1 OUTLINE OF OIL, FUEL, COOLANT...544
18.2 OUTLINE OF ELECTRICAL SYSTEM...547
18.3 OUTLINE OF HYDRAULIC SYSTEM...548
18.4 RELEASING PRESSURE...549
18.5 BLEEDING AIR FROM CIRCUIT...551
19. CONSUMABLE PARTS LIST...557
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...558
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS...562
21.1 INTRODUCTION OF NECESSARY TOOLS...562
21.2 TORQUE LIST...563
22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS...564
23. MAINTENANCE SHEDULE CHART...566
23.1 MAINTENANCE SCHEDULE CHART...566
24. SERVICE PROCEDURE...566
24.1 INITIAL 100 HOURS SERVICE (ONLY AFTER THE FIRST 100 HOURS)...570
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER...570
24.2 INITIAL 250 HOURS SERVICE...570
REPLACE FUEL FILTER CARTRIDGE...570
CHANGE OIL IN SWING MACHINERY CASE...570
CHANGE OIL IN PTO CASE...570
CHANGE OIL IN FINAL DRIVE CASE...570
CHECK ENGINE VALVE CLEARANCE, ADJUST...570
24.3 WHEN REQUIRED...571
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...571
CLEAN INSIDE OF COOLING SYSTEM...573
CHECK AND TIGHTEN TRACK SHOE BOLTS...577
CHECK AND ADJUST TRACK TENSION...578
CHECK ELECTRICAL INTAKE AIR HEATER...580
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE) (KOMATSU TOOTH)...581
ADJUST BUCKET CLEARANCE...582
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...583
CHECK AND ADJUST AIR CONDITIONER...584
CLEANING, REMOVING DIRT FROM LINE FILTER...585
REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER...586
24.4 CHECK BEFORE STARTING...587
CHECK COOLANT LEVEL, ADD WATER...587
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...587
CHECK FUEL LEVEL...587
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...587
CHECK FOR CLOGGING OF AIR CLEANER...587
CHECK ELECTRICAL WIRING...587
CHECK FUNCTION OF HORN...587
CHECK OIL LEVEL IN PTO CASE, ADD OIL...587
DRAIN WATER, SEDIMENT FROM FUEL TANK...587
CHECK CENTRAL MONITOR...587
24.5 EVERY 10 HOURS SERVICE...588
LUBRICATING...588
ARM-BUCKET COUPLING PIN (2 POINTS)...588
ARM-LINK COUPLING PIN (2 POINTS)...588
BUCKET CYLINDER ROD END PIN (2 POINTS)...589
LINK COUPLING PIN (4 POINTS)...589
BUCKET-LINK COUPLING PIN (2 POINTS)...589
BOOM CYLINDER FOOT PIN...590
BOOM FOOT PIN...590
BOOM CYLINDER ROD END PIN...590
ARM CYLINDER FOOT PIN...590
BUCKET CYLINDER FOOT PIN...590
BOOM-ARM COUPLING PIN...590
ARM-LINK COUPLING PIN...590
SWING CIRCLE...590
24.6 EVERY 100 HOURS SERVICE...591
CHECK OIL LEVEL IN SWING MACHINERY CASE...591
24.7 EVERY 250 HOURS SERVICE...592
LUBRICATING...592
FAN PULLEY ASSEMBLY (2 POINTS)...592
TENSION AND PULLEY ASSEMBLY (2 POINTS)...592
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...592
CHANGE DRAIN FILTER CARTRIDGE...593
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE AND BYPASS FILTER CARTRIDGE (FRONT AND REAR ENGINE)...593
CHECK ALTERNATOR DRIVE BELT TENSION ADJUST...594
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITONER)...595
CHECK LEVEL OF BATTERY ELECTROLYTE...596
CHECK, CLEAN FUEL STRAINER...597
CHECK AND TIGHTEN TRACK SHOE BOLTS...597
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS...597
REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER...598
24.8 EVERY 500 HOURS SERVICE...599
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, AFTER COOLER FINS, CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR COND...599
CLEAN PILOT FILTER STRAINER...600
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER...600
REPLACE FUEL FILTER CARTRIDGE...601
CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)...602
CHECK FAN BELT...602
CHANGE HYDRAULIC FILTER ELEMENT...603
24.9 EVERY 1000 HOURS SERVICE...604
CHANGE OIL IN SWING MACHINERY CASE...604
CHECK TURBOCHARGER CLAMPING JOINT...604
CHANGE OIL IN PTO CASE...605
REPLACE CORROSION RESISTOR CARTRIDGE...605
CHECK INSPECTION OF WELDING STRUCTURE (COLOR CHECK)...605
24.10 EVERY 2000 HOURS SERVICE...606
CHANGE OIL IN FINAL DRIVE CASE...606
CLEAN, CHECK TURBOCHARGER...606
CHECK TURBOCHARGER ROTOR PLAY...607
CHECK SWING PINION GREASE LEVEL, ADD GREASE...607
CLEAN ENGINE BREATHER...607
CLEAN HYDRAULIC TANK STRAINER...608
CHECK ALTERNATOR, STARTING MOTOR...608
CHECK ENGINE VALVE CLEARANCE, ADJUST...608
24.11 EVERY 4000 HOURS SERVICE...609
CHECK WATER PUMP...609
CHECK VIBRATION DAMPER...609
CHECK FAN PULLEY AND TENSION PULLEY...609
CHECK AIR COMPRESSOR, ADJUST...609
24.12 EVERY 5000 HOURS SERVICE...610
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER...610
SPECIFICATIONS...611
25. SPECIFICATIONS...612
OPTIONS, ATTACHMENTS...614
26. GENERAL PRECAUTIONS...615
26.1 PRECAUTIONS RELATED TO SAFETY...615
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS...616
27. INTRODUCTION OF ATTACHMENTS...617
27.1 GUARD...617
28. AUTO-GREASER SYSTEM...618
SEAM022908T - Hydraulic Excavator GALEO PC1800-6 Operation & Maintenance Manual...623
COVER...623
FOREWORD...624
FOREWORD...625
SAFETY INFORMATION...628
INTRODUCTION...630
DIRECTIONS OF MACHINE...630
PRODUCT INFORMATION...631
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION...631
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...631
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION...632
SERVICE METER LOCATION...632
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...633
CONTENTS...634
SAFETY...638
SAFETY INFORMATION...639
POSITION FOR ATTACHING SAFETY LABELS...641
POSITION FOR ATTACHING SAFETY LABELS...642
SAFETY LABELS...643
SAFETY INFORMATION...647
SAFETY RULES...647
IF ABNORMALITIES ARE FOUND...647
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...647
FIRE EXTINGUISHER AND FIRST AID KIT...647
SAFETY EQUIPMENT...648
KEEP MACHINE CLEAN...648
KEEP OPERATOR'S COMPARTMENT CLEAN...648
LEAVING OPERATOR'S SEAT WITH LOCK...648
HANDRAILS AND STEPS...649
MOUNTING AND DISMOUNTING...650
NO PERSONS ON ATTACHMENTS...650
BURN PREVENTION...650
FIRE PREVENTION AND EXPLOSION PREVENTION...651
ACTION IF FIRE OCCURS...652
WINDSHIELD WASHER FLUID...652
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...652
ATTACHMENT INSTALLATION...652
ATTACHMENT COMBINATIONS...653
CAB WIDOW GLASSES...653
UNAUTHORIZED MODIFICATIONS...653
SAFETY AT JOBSITE...653
WORKING ON LOOSE GROUND...654
DISTANCE TO HIGH VOLTAGE CABLES...654
ENSURE GOOD VISIBILITY...654
VENTILATION FOR ENCLOSED AREA...655
SIGNALMANS SIGNAL AND SIGNS...655
EMERGENCY EXIT FROM OPERATORS CAB...655
ASBESTOS DUST HAZARD PREVENTION...655
SAFETY MACHINE OPERATION...656
STARTING ENGINE...656
CHECKS BEFORE STARTING ENGINE...656
SAFETY RULES FOR STARTING ENGINE...657
STARTING ENGINE IN COLD WEATHER...657
OPERATION...658
CHECKS AFTER STARTING ENGINE...658
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...658
SAFETY RULES FOR TRAVELING...659
TRAVELING ON SLOPES...660
OPERATIONS ON SLOPES...661
PROHIBITED OPERATIONS...661
OPERATIONS ON SNOW...663
PARKING MACHINE...663
TRANSPORTATION...664
SHIPPING THE MACHINE...664
BATTERY...665
BATTERY HAZARD PREVENTION...665
STARTING ENGINE WITH BOOSTER CABLES...666
TOWING...667
SAFETY RULES FOR TOWING...667
LIFTING OBJECTS WITH BUCKET...668
SAFETY RULES FOR LIFTING OBJECTS...668
SAFETY MAINTENANCE INFORMATION...669
WARNING TAG...669
KEEP WORK PLACE CLEAN AND TIDY...669
APPOINT LEADER WHEN WORKING WITH OTHERS...669
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...670
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...671
PROPER TOOLS...671
ACCUMULATOR...672
PERSONNEL...672
ATTACHMENTS...672
WORK UNDER THE MACHINE...672
NOISE...673
WHEN USING HAMMER...673
WELDING WORKS...673
REMOVING BATTERY TERMINALS...673
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...674
DO NOT DISASSEMBLE RECOIL SPRINGS...674
SAFETY RULES FOR HIGH-PRESSURE OIL...674
PRECAUTION FOR HIGH FUEL PRESSURE...675
SAFETY HANDLING HIGH-PRESSURE HOSES...675
PRECAUTION FOR HIGH VOLTAGE...675
WASTE MATERIALS...675
AIR CONDITIONER MAINTENANCE...676
COMPRESSED AIR...676
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...676
OPERATION...678
GENERAL VIEW...679
GENERAL VIEW OF MACHINE...679
GENERAL VIEW OF CONTROLS AND GAUGES...680
EXPLANATION OF COMPONENTS...682
MACHINE MONITOR...682
BASIC CHECK ITEMS...684
CAUTION ITEMS...686
EMERGENCY STOP ITEMS...688
METER DISPLAY PORTION...690
PILOT DISPLAY...690
GAUGES AND METER...691
MONITOR SWITCHES...694
CGC MONITOR...696
CGC MONITOR...696
CHANGES OF SCREEN AND CONTENT OF DISPLAY ON CGC MONITOR...697
EXPLANATION OF SCREENS...699
SWITCHES...734
STARTER SELECTOR SWITCH...735
STARTING SWITCH...735
PREHEATING SWITCH...735
FUEL CONTROL DIAL (FRONT ENGINE)...736
FUEL CONTROL DIAL (REAR ENGINE)...736
CIGARETTE LIGHTER...736
LAMP SWITCH...736
STEP LIGHT SWITCH...737
SWING LOCK SWITCH...737
ROOM LAMP SWITCH...738
MACHINE PUSH-UP SWITCH...738
FOG LAMP SWITCH...738
BOOM SHOCKLESS CONTROL SWITCH...739
ROTATING LAMP SWITCH...739
ALARM BUZZER STOP SWITCH...739
WINDSHIELD WIPER SWITCH...740
GREASING SWITCH...740
HORN SWITCH...740
TRUCK COUNTER SWITCH...741
ROOM LAMP SWITCH...742
ROOM LAMP SWITCH...742
ROOM LAMP SWITCH...743
PUMP DRIVE EMERGENCY SWITCH...743
SWING HOLDING BRAKE REPLEASE SWITCH...743
SPARE SOCKET...744
ENGINE EMERGENCY STOP SWITCH...744
LAMP...745
ENGINE EMERGENCY STOP LAMP...746
AUTO GREASING CAUTION LAMP...747
LADDER WARNING LAMP...747
TRUCK COUNTER LAMP...748
CONTROL LEVERS, PEDALS...749
SAFETY LOCK LEVER...750
TRAVEL LEVERS...751
WORK EQUIPMENT CONTROL LEVER...752
DOOR LOCK...753
POCKET...753
EMERGENCY ESCAPE HAMMER...753
EMERGENCY ESCAPE LADDER...754
FIRE EXTINGUISHER...754
CAP, COVER WITH LOCK...755
METHOD OF OPENING AND CLOSING CAP WITH LOCK...755
METHOD OF OPENING AND CLOSING COVER WITH LOCK...755
ASHTRAY...755
HANDLING AIR CONDITIONER...756
GENERAL LOCATIONS OF CONTROL PANEL...756
USE AIR CONDITIONER WITH CARE...763
CAR RADIO...764
EXPLANATION OF COMPONENTS...764
CONTROLS OF RADIO...767
AUXILIARY ELECTRIC POWER...769
FUSE...769
CIRCUIT BREAKER...770
CIRCUIT BREAKER (20A)...770
CIRCUIT-BREAKER (40A)...770
FUSE, CIRCUIT BREAKER CAPACITY AND NAME OF CIRCUIT...771
FUSE...772
CONTROLLER (COMPUTER)...773
TOOLBOX...774
HANDLING GREASE PUMP AND GREASE GUN...774
HANDLING ACCUMULATOR...778
METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR...778
ORBCOMM CONTROLLER...779
MACHINE OPERATIONS AND CONTROLS...780
BEFORE STARTING ENGINE...780
WALK-AROUND CHECKS...780
CHECKS BEFORE STARTING...781
ADJUST BEFORE OPERATION...793
SEAT BELT...796
OPERATIONS BEFORE STARTING ENGINE...798
STARTING ENGINE...801
NORMAL STARTING...801
STARTING ENGINE IN COLD WEATHER...803
AFTER STARTING ENGINE...806
BREAKING-IN THE NEW MACHINE...806
WARMING-UP OPERATION...807
IN COLD AREAS...810
STOPPING THE ENGINE...813
NORMAL STOPPING...813
STOPPING IN EMERGENCIES...813
CHECK AFTER SHUT OFF ENGINE...816
MACHINE OPERATION...817
PREPARATIONS FOR MOVING THE MACHINE OFF...817
MOVING MACHINE FORWARD...818
MOVING MACHINE BACKWARD...819
STOPPING MACHINE...820
STEERING THE MACHINE...821
STEERING...821
SWINGING...823
WORK EQUIPMENT CONTROLS AND OPERATIONS...824
HANDLING WORKING MODE...825
WORKING MODE...825
PROHIBITED OPERATIONS...826
OPERATIONS USING SWING FORCE...826
OPERATIONS USING TRAVEL FORCE...826
OPERATIONS USING HYDRAULIC CYLINDER STROKE ENDS...826
OPERATIONS USING BUCKET DROPPING FORCE...827
OPERATIONS USING MACHINE DROPPING FORCE...827
DIGGING HARD ROCKY GROUND...827
GENERAL OPERATION INFORMATION...828
TRAVELING...828
PERMISSIBLE WATER DEPTH...828
TRAVELING ON SLOPES...829
TRAVELING DOWNHILL...830
ENGINE STOPPED ON SLOPE...830
PRECAUTIONS ON SLOPES...830
ESCAPE FROM MUD...831
STUCK ONE SIDE OF TRACK...831
STUCK BOTH SIDES OF TRACKS...831
RECOMMENDED APPLICATIONS...832
BACKHOE WORK...832
LOADING WORK...832
REPLACEMENT AND INVERSION OF BUCKET...833
REPLACEMENT...833
PARKING MACHINE...835
CHECK AFTER FINISHING WORK...836
LOCKING...837
TRANSPORTATION...838
PRECAUTIONS FOR TRANSPORTATION...838
REMOVAL AND INSTALLATION OF MIRRORS...838
LIFTING MACHINE...839
PARTS FOR TRANSPORT...839
COLD WEATHER OPERATION...840
COLD WEATHER OPERATION INFORMATION...840
FUEL AND LUBRICANTS...840
COOLING SYSTEM COOLANT...840
BATTERY...841
AFTER DAILY WORK COMPLETION...842
AFTER COLD WEATHER SEASON...842
LONG TERM STORAGE...843
BEFORE STORAGE...843
DURING STORAGE...843
AFTER STORAGE...844
STARTING MACHINE AFTER LONG-TERM STORAGE...844
TROUBLESHOOTING...845
AFTER RUNNING OUT OF FUEL...845
PHENOMENA THAT ARE NOT FAILURES...846
TOWING THE MACHINE...847
PRECAUTIONS ON PARTICULAR JOBSITES...847
DISCHARGED BATTERY...848
REMOVAL AND INSTALLATION OF BATTERY...849
BATTERY CHARGES...849
STARTING ENGINE WITH BOOSTER CABLES...850
OTHER TROUBLE...852
ELECTRICAL SYSTEM...852
CHASSIS...853
ENGINE...854
ELECTRONIC CONTROL SYSTEM...856
MAINTENANCE...858
MAINTENANCE INFORMATION...859
SERVICE METER READING...859
KOMATSU GENUINE REPLACEMENT PARTS...859
KOMATSU GENUINE LUBRICANTS...859
WINDSHIELD WASHER FLUID...859
FRESH AND CLEAN LUBRICANTS...859
CHECK DRAINED OIL AND USED FILTER...859
FUEL STRAINER...859
WELDING INSTRUCTIONS...859
DO NOT DROP THINGS INSIDE MACHINE...860
DUSTY JOBSITE...860
AVOID MIXING LUBRICANTS...860
LOCKING THE INSPECTION COVERS...860
HYDRAULIC SYSTEM AIR BLEEDING...860
HYDRAULIC HOSE INSTALLATION...860
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS...861
LUBRICANTS, COOLANT AND FILTERS...862
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...862
OIL...862
FUEL...862
COOLING SYSTEM COOLANT...863
GREASE...863
CARRYING OUT KOWA (Komatsu Oil Wear Analysis)...863
OIL AND FUEL STORAGE...864
FILTERS...865
ELECTRIC SYSTEM MAINTENANCE...865
WEAR PARTS LIST...866
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...867
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...867
TIGHTENING TORQUE SPECIFICATIONS...871
TIGHTENING TORQUE LIST...871
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...872
SAFETY CRITICAL PARTS...873
MAINTENANCE SCHEDULE...875
MAINTENANCE SCHEDULE CHART...875
Initial 100 Hours Maintenance (Only after the first 250 hours)...875
Initial 250 Hours Maintenance (Only after the first 250 hours)...875
When Required...875
Checks Before Starting...875
Every 10 Hours Maintenance...875
Every 100 Hours Maintenance...876
Every 250 Hours Maintenance...876
Every 500 Hours Maintenance...876
Every 1000 Hours Maintenance...876
Every 2000 Hours Maintenance...877
Every 4000 Hours Maintenance...877
Every 5000 Hours Maintenance...877
Every 8000 Hours Maintenance...877
MAINTENANCE PROCEDURE...878
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)...878
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...878
WHEN REQUIRED...879
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...879
CLEAN INSIDE OF COOLING SYSTEM...882
CHECK AND TIGHTEN TRACK SHOE BOLTS...886
CHECK AND ADJUST TRACK TENSION...887
CHECK ELECTRICAL INTAKE AIR HEATER...890
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...891
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...894
ADJUST BUCKET CLEARANCE...895
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...896
CHECK AND ADJUST AIR CONDITIONER...897
CLEANING, REMOVING DIRT FROM LINE FILTER...898
REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER...899
GREASE LADDER...900
INSPECT SEALANT AROUND ENGINE COOLING SYSTEM...901
CHECK FOR LOOSE AFTERCOOLER HOSE CLAMPS...902
PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT...902
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...910
CHECK BEFORE STARTING...912
EVERY 10 HOURS MAINTENANCE...913
LUBRICATING...913
EVERY 100 HOURS MAINTENANCE...917
CHECK OIL LEVEL IN SWING MACHINERY CASE...917
EVERY 250 HOURS MAINTENANCE...918
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...918
CHECK LEVEL OF BATTERY ELECTROLYTE...919
REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER...921
CHECK, WASH FUEL STRAINER...922
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS...923
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST...924
CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...926
EVERY 500 HOURS MAINTENANCE...928
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...928
REPLACE FUEL FILTER CARTRIDGE...931
CLEAN PILOT FILTER STRAINER...933
CLEAN HYDRAULIC FILTER STRAINER FOR AUTO GREASING DRIVE...933
CHANGE HYDRAULIC FILTER ELEMENT...934
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER FINS...935
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM...937
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER...939
CHECK, REPLACE, ADJUST FAN BELT...940
CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE...941
REPLACING SWING MOTOR DRAIN FILTER CARTRIDGE...942
REPLACING TRAVEL MOTOR DRAIN FILTER CARTRIDGE...943
EVERY 1000 HOURS MAINTENANCE...944
CHANGE OIL IN SWING MACHINERY CASE...944
CHANGE OIL IN PTO CASE...946
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...946
REPLACE CORROSION RESISTOR CARTRIDGE...947
INSPECTION OF WELDED STRUCTURE AFTER INITIAL 4000 HOURS SERVICE...947
GREASING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY...947
EVERY 2000 HOURS MAINTENANCE...948
CHANGE OIL IN FINAL DRIVE CASE...948
CHANGE OIL IN HYDRAULIC TANK, WASH STRAINER...949
CHECK SWING PINION GREASE LEVEL, ADD GREASE...952
CLEAN ENGINE BREATHER...952
CLEAN, CHECK TURBOCHARGER...952
CHECK ALTERNATOR AND STARTING MOTOR...952
CHECK ENGINE VALVE CLEARANCES, ADJUST...953
CHECK INJECTOR...953
EVERY 4000 HOURS MAINTENENCE...954
CHECK WATER PUMP...954
CHECK VIBRATION DAMPER...954
CHECK FAN PULLEY AND TENSION PULLEY...954
REPLACE INJECTOR NOZZLE ASSEMBLY...954
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER...955
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...956
CHECK, ADJUST AIR COMPRESSOR...956
CHECK WELDED STRUCTURE...957
EVERY 5000 HOURS MAINTENANCE...960
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER...960
EVERY 8000 HOURS MAINTENANCE...963
REPLACE HIGH-PRESSURE PIPING CLAMP...963
REPLACE FUEL SPRAY PREVENTION CAP...963
SPECIFICATIONS...964
SPECIFICATIONS...965
ATTACHMENTS AND OPTIONS...968
GENERAL PRECAUTIONS...969
PRECAUTIONS RELATED TO SAFETY...969
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...971
ATTACHMENT GUIDE...972
COMBINATIONS OF WORK EQUIPMENT...972
PROTECTIVE GUARD...973
AUTO GREASING SYSTEM...974
CONTROL DEVICES...975
LOADING SHOVEL...978
GENERAL VIEW...979
GENERAL VIEW OF MACHINE...979
GENERAL VIEW OF CONTROLS AND GAUGES...980
EXPLANATION OF COMPONENTS...981
SWITCHES...981
AUTOMATIC LEVEL CROWDING/BUCKET ANGLE COMPENSATION SWITCH...981
AUTOMATIC LEVEL CROWDING SWITCH...981
BUCKET ANGLE COMPENSATION SWITCH...981
BOTTOM DUMP SWITCH...982
HORN SWITCH...982
CONTROL BOX...982
OPERATIONS...983
OPERATION OF WORK EQUIPMENT...983
PRECAUTIONS DURING OPERATION...985
EXCAVATOR WORK...989
PRECAUTIONS WHEN DISASSEMBLING MACHINE...990
RELEASING PRESSURE...990
RELEASING PRESSURE FROM WORK EQUIPMENT CIRCUIT, SWING CIRCUIT, TRAVEL CIRCUIT...990
RELEASING PRESSURE IN ACCUMULATOR CIRCUIT...990
TROUBLESHOOTING...991
WORK EQUIPMENT AUTOMATIC CONTROL CONTROLLER...991
TRANSPORTATION...992
MACHINE CONFIGURATION FOR TRANSPORT...992
MAINTENANCE SCHEDULE...993
EVERY 10 HOURS MAINTENANCE...993
PREPARATIONS BEFORE LUBRICATION...993
LUBRICATION...996
SPECIFICATION...1002
COMBINATION OF WORK EQUIPMENT...1004
COMBINATION OF WORK EQUIPMENT...1004
INDEX...1006
SEAW002201 - Hydraulic Excavator PC1800-6 Field Assembly Manual...1010
COVER...1010
CONTENTS...1011
GENERAL...1014
1. SPECIFICATIONS...1014
2. POINTS REGARDING LOCAL ASSEMBLY ...1015
3. BOLT TIGHTENING TORQUE AND BOLT TIGHTENING...1016
4. SEPARATE UNITS...1019
TRANSPORTATION STYLE OF LOADING SHOVEL (WORK EQUIPMENT ONLY)...1032
5. LIST OF PARTS SENT INDIVIDUALLY...1033
6. ASSEMBLY PROCEDURE, ASSEMBLY EQUIPMENT AND SCHEDULE...1058
7. KIT LAYOUT DIAGRAM...1059
8. TOOLS AND EQUIPMENT TO BE USED...1060
A. ASSEMBLY OF CHASSIS...1066
A-1. ASSEMBLY OF TRUCK FRAME AND AXLE...1067
A-2. TRAVEL MOTOR PIPING...1070
A-3. IDLER CRUSHION CYLINDER PIPING...1072
A-4. INSTALLATION OF TRAVEL MOTOR GUARD AND TRACK FRAME UNDER COVER...1074
A-5. FILING SWING CIRCUIT WITH GREASE...1075
A-6. ASSEMBLY OF TRAVEL ...1076
A-7. SWIVEL TRAVEL PIPING...1078
A-8. SWING CIRCLE GREASE TUBE PIPNG...1080
A-9. INSTALLNG OF LEFT AND RIGHT LADDERS...1085
A-10. INSTALLATION OF LEFT CATWALK...1086
A-11. INSTALLATION OF RIGHT CATWALK...1087
A-12. INSTALLATION OF CATWALK, HANDRAIL BESIDE OPERATOR'S CAB...1088
A-13...1011
A-14. INSTALLATION OF HANDRAIL FOR GETTING IN AND OUT OF OPERATOR'S CAB...1089
A-15...1011
A-16. INSTALLATION OF HANDRAIL AT REAR OF OPERATOR'S CAB...1091
A-17...1011
A-18. OPERATOR'S CAB FRONT FRAME, HANDRAIL...1092
A-19. LEFT DECK HANDRAIL...1093
A-20. RIGHT DECK HANDRAIL...1094
A-21. INSTALLATION OF LADDER ON TOP OF HYDRAULIC TANK...1095
A-22. INSTALLATION OF COUNTERWEIGHT...1096
A-23. INSTALLATION OF COUNTERWEIGHT LADDER (LEFT AND RIGHT)...1097
A-24. INSTALLATION OF HANDRAIL ON TOP OF FUEL TANK, COUNTERWEIGHT...1098
A-25. INSTALLATION OF FUEL TANK VIBRATION STOPPER BRACKET...1099
A-26. INSTALLATION OF GREASE REEL, HOSE, BRACKET...1100
A-27. INSTALLATION OF LEFT CAB BASE ASSEMBLY...1101
A-28. INSTALLATION OF OPERATOR'S CAB ASSEMBLY ...1106
A-29. INSTALLATION OF WIPER MOTOR COVER INSIDER OPERATR'S CAB...1107
A-30. HANDRAIL ON BOOM FOOT AND LEFT PUMP...1108
A-31. HANDRAIL ABOVE THE RH DOOR AND ABOVE THE HYDRAULIC OIL TANK...1109
A-32. EMERGENCY STOP SWITCH, FUEL CUTTING...1110
A-33A. HANDRAIL ABOVE THE RADIATOR (OPTIONAL)...1112
A-33B. CONNECTION OF HYDRAULIC PIPING OPERATOR'S CAB ASSEMBLY ...1113
A-34. CONNECTION OF WINDOW WASHER HOSE OF OPERATOR/S CAB ASSEMBLY ...1116
A-35. CONNECTION OF AIR PIPING OF LEFT CAB ASSEMBLY...1117
A-36. CONNECTION OF GREASE PIPING OPERATOR'S CAB ASSEMBLY...1119
A-37. WIRE HARNESS (WASHER TANK, WORKING LAMP AND OPERATOR'S CAB BASE LIGHT)...1121
A-38. AIR CONDITIONER HOSE, HARNESS AND PIPING...1122
A-39. INSTALLATION OF COUNTERWEIGHT LAMP (OPERATION)...1127
A-40. START ENGINE...1128
A-41. FINAL TIGHENING OF SWING CIRCLE OF SWING CIRCLE MOUNTING BOLTS...1134
ASSEMBLY OF POWER-ASSISTED LADDER...1135
L-1 POWER-ASSISTED LADDER...1138
C. PC1800 INSTALLATION OF BACKHOE WORK EQUIPMENT...1142
C-1. INSTALLATION OF BOOM CYLINDER TO CHASSIS...1143
C-2. INSTALLATION OF BOOM CYLINDER PIPING...1145
C-3. BLEEDING AIR FROM BOOM CYLINDER...1146
C-4. BOOM SUB-ASSEMBLY...1147
C-5. INSTALLATION OF BOOM ASSEMBLY...1151
C-6. INSTALLATION OF BOOM CYLINDER TOP PIN...1154
C-7. CONNECTION OF ARM ASSEMBLY TO BOOM...1156
C-8. INSTALLATION OF HOSES BETWEEN BOOM AND CHASSIS...1159
C-9. INSTALLATION OF ARM CYLINDER PIN...1161
C-10. BLEEDING AIR FROM ARM CYLINDER...1163
C-11. INSTALLATION OF HYDRAULIC BETWEEN BOOM AND ARM...1164
C-12. CONNECTION OF GREASE PIPING FOR BOOM...1165
C-13. CONNECTION OF WIRING BETWEEN BOOM AND CHASSIS...1168
C-14. INSTALLATION OF HOSES BETWEEN BOOM AND SHASSIS...1169
C-15...1011
C-16. CONNECTION OF BUCKET ASSEMBLY TO ARM...1171
C-17. INSTALLATION OF BUCKET LINK...1174
C-18. BLEEDING AIR FROM BUCKET CYCLINDER...1176
ASSEMBLY MANUAL FOR LOADING SHOVEL WORK EQUIPMENT...1176
LS-1. INSTALLATION OF ARM CYLINDER TUBES AND HOSES...1178
LS-2. INSTALLATION OF BUCKET HOSES...1179
LS-3. INSTALLATION OF BOTTOM DUMP HOSES AND TUBES...1180
LS-4. INSTALLATION OF PILOT SOLENOID VALVE...1181
LS-5. INSTALLATION OF BOTTOM PRIORITY VALVE...1182
LS-6. INSTALLATION OF ARM PILOT DRAIN CIRCUIT...1184
LS-7. INSTALLATION OF CONTROL PARTS...1186
LS-8. INSTALLATION OF HORN SWITCH...1188
LS-9. CHANGE OF ARM PILOT PIPING...1189
LS-10. REMOVAL OF BOOM FOOT HANDRAIL...1190
LS-11. INSTALLATION OF ARM CYLINDER BOTTOM PARTS...1191
LS-12. INSTALLATION OF ARM CYLINDER BOTTOM PARTS...1192
LS-13. INSTALLATION OF BOOM CYLINDER PIPING...1194
LS-14. INSTALLATION OF BOOM ASSEMBLY...1196
LS-15. INSTALLATION OF BOOM CYLINDER HEAD PINS...1197
LS-16. INSTALLATION OF GREASE FEED HOSE BETWEEN MACHINE BODY AND BOOM...1198
LS-17. INSTALLATION OF BUCKET CYLINDER ASSEMBLY...1199
LS-18. INSTALLATION OF ARM ASSEMBLY...1200
LS-19. INSTALLATION OF ARM CYLINDER ASSEMBLY...1201
LS-20. INSTALLATION OF HOSES BETWEEN BOOM AND ARM...1202
LS-21. INSTALLATION OF BUCKET CYLINDER HOSES...1203
LS-22. INSTALLATION OF GREASE FEED HOSE OF BUCKET CYLINDER...1204
LS-23. INSTALLATION OF BUCKET ASSEMBLY...1206
LS-24. INSTALLATION OF BOTTOM DUMP HOSE AND GREASE FEED HOSE BETWEEN ARM AND BUCKET...1207
M. INSPECTION AND SERVICING PROCEDURES AFTER FINISHING ALL THE ASSEMBLY AND INSTALLATION WORKS...1208
M-1. INSPECTING THE OIL LEVEL AND WATER LEVEL IN RESPECTIVE SECTIONS AND REFILLING THEM...1209
SELECTION OF THE APPROPRIATE FUEL TYPE FITTING TO THE ATMOSPHERIC TEMPERATURE RANGE...1209
M-2. FLUSHING OF HYDRAULIC CIRCUIT...1211
M-3. RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT...1212
SEBM019105 - Hydraulic Excavator PC1800-6 Shop Manual...1239
COVER PAGE...1239
CONTENTS...1240
00 FOREWARD...1246
FOREWARD...1248
HOW TO READ THE SHOP MANUAL...1249
HOISTING INSTRUCTIONS...1250
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER...1251
COATING MATERIALS...1253
STANDARD TIGHTENING TORQUE...1255
ELECTRIC WIRE CODE...1258
CONVERSION TABLE...1259
UNITS...1265
01 GENERAL...1266
SPECIFICATION DRAWINGS...1479
SPECIFICATIONS...1480
WEIGHT TABLE...1482
FUEL, COOLANT AND LUBRICANTS...1484
10 STRUCTURE AND FUNCTION...1486
PTO...1487
PTO LUBRICATION SYSTEM...1488
POWER TRAIN...1489
SWING MACHINERY...1491
FINAL DRIVE...1492
HIC SYSTEM...1493
AIR SYSTEM...1495
AIR GOVERNOR...1496
AIR TANK...1496
AUTO-DRAIN VALVE...1496
SAFETY VALVE...1497
SOLENOID VALVE (FOR LUBRICATION, HORN)...1497
GREASE PUMP...1498
GREASING SYSTEM...1501
HYDRAULIC COMPONENT LAYOUT...1508
HYDRAULIC TANK...1511
HYDRAULIC PUMP...1512
SWING PUMP...1539
LINE OIL FILTER...1544
PILOT OIL FILTER...1544
RETURN OIL FILTER...1545
DRAIN OIL FILTER...1546
CONTROL AND PTO LUBRICATING PUMP...1547
ELECTRONIC OLSS...1548
CONTROL VALVE...1550
SWING CONTROL VALVE...1559
SWING MOTOR...1561
CENTER SWIVEL JOINT...1563
TRAVEL MOTOR...1564
TRAVEL BRAKE VALVE...1566
PILOT RELIEF VALVE...1567
SAFETY LOCK VALVE...1568
ACCUMULATOR...1570
PPC VALVE...1571
SOLENOID VALVE...1575
ENGINE CONTROL...1577
MACHINE CONTROL SYSTEM...1584
ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM...1607
MONITOR SYSTEM...1613
20 TESTING AND ADJUSTING...1651
STANDARD VALUE TABLE FOR ENGINE...1652
STANDARD VALUE TABLE FOR CHASSIS...1653
STANDARD VALUE FOR ELECTRICAL PARTS...1661
TESTING AND ADJUSTING...1669
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...1670
MEASURING ENGINE SPEED...1671
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...1672
MEASURING EXHAUST TEMPERATURE...1673
MEASURING EXHAUST COLOR...1674
ADJUSTING VALVE CLEARANCE...1675
MEASURING COMPRESSION PRESSURE...1676
MEASURING BLOW-BY PRESSURE...1677
TESTING AND ADJUSTING FUEL INJECTION TIMING...1678
MEASURING ENGINE OIL PRESSURE...1679
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...1680
TESTING AND ADJUSTING FAN BELT TENSION...1680
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...1681
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE...1682
ADJUSTING ENGINE SPEED SENSOR...1683
TESTING AND ADJUSTING MAIN RELIEF VALVE...1684
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE...1689
MEASURING SERVO PISTON STROKE...1693
TESTING SOLENOID VALVE OUTPUT PRESSURE...1694
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE...1695
TESTING TRAVEL DEVIATION...1696
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...1699
MEASURING OIL LEAKAGE...1700
MEASURING OIL LEAKAGE FROM SWING AND TRAVEL MOTOR...1702
TESTING OIL LEAK FROM SWIVEL JOINT...1703
TESTING CLEARANCE OF SWING CIRCLE BEARING...1705
AIR BLEEDING...1706
CHARGING ACCUMULATOR WITH GAS...1711
TESTING METHOD USING VISUAL AND FUNCTIONAL CHECK...1713
ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)...1714
TROUBLESHOOTING...1720
POINTS TO REMEMBER WHEN TROUBLESHOOTING...1721
SEQUENCE OF EVENTS IN TROUBLESHOOTING...1722
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...1723
CHECKS BEFORE TROUBLESHOOTING...1731
CONNECTOR TYPES AND MOUNTING LOCATIONS...1732
CONNECTOR ARRANGEMENT DIAGRAM...1737
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...1743
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM...1754
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL...1755
TROUBLE HISTORY DISPLAY ON MACHINE CONTROL MONITOR...1768
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE...1775
METHOD OF USING JUDGEMENT TABLE...1780
METHOD OF USING TROUBLESHOOTING CHARTS...1782
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)...1784
CONTROLLER RESPONSES AND SYMPTOMS ON MACHINE BODY IN FAILURE OCCURRENCES...1785
N-1 [CONCURRENT OCCURENCES OF E116, E117, AND E118] COMMUNICATIONS FAILURE ON MONITOR PANEL...1787
N-2 [CONCURRENT OCCURENCES OF E117 AND E218] COMMUNICATIONS FAILURE ON REAR ENGINE GP CONTROLLER...1789
N-3 [CONCURRENT OCCURRENCES OF E118 AND E418] COMMUNICATIONS FAILURE ON FRONT ENGINE GP CONTROLLER...1791
N-4 [CONCURRENT OCCURENCES OF E116, E218 AND E418] COMMUNICATIONS FAILURE ON VHMS CONTROLLER...1793
N-5 [E828] NO DISPLAY [OF E116, E117, E118, E218, OR E418] ON MONITOR PANEL, WITH CODE DISPLAYED ONLY ON CGC...1795
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM (GOVERNOR CONTROL SYSTEM) (E MODE)...1796
JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS...1797
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLEHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM...1801
ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS...1802
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE THROTTLE AND PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)...1810
E-1 POWER SYSTEM ABNORMALITY OF FRONT ENGINE THROTTLE AND PUMP CONTROLLER...1812
E-2 [E308] ABNORMALITY IN FRONT ENGINE CONTROL DIAL INPUT VALUE IS DISPLAYED...1813
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED...1814
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN FRONT ENGINE GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED ...1815
E-5 [E306] ABNORMALITY IN FRONT ENGINE FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...1816
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN FRONT ENGINE BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED...1817
E-7 [E316] ABNORMALITY (STEP-OUT) IN FRONT ENGINE MOTOR IS DISPLAYED...1818
E-8 THE FRONT ENGINE DOES NOT START...1819
E-9 FRONT ENGINE IRREGULAR ROTATION...1822
a) IRREGULAR IDLING SPEED...1822
b) HUNTING...1824
E-10 FRONT ENGINE INSUFFICIENT OUTPUT...1826
E-11 THE FRONT ENGINE DOES NOT STOP...1828
E-12 DEFECTIVE OPERATION OF FRONT ENGINE BATTERY RELAY SYSTEM...1830
E-13 POWER SYSTEM ABNORMALITY OF REAR ENGINE THROTTLE AND PUMP CONTROLLER...1832
E-14 [E508] ABNORMALITY IN REAR ENGINE FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED...1833
E-15 [E517] ABNORMALITY (DISCONNECTION) IN REAR ENGINE MOTOR DRIVE SYSTEM IS DISPLAYED...1834
E-16 [E518] ABNORMALITY (SHORT CIRCUIT) IN REAR ENGINE MOTOR DRIVE SYSTEM IS DISPLAYED...1835
E-17 [E506] ABNORMALITY IN REAR ENGINE FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED...1836
E-18 [E515] ABNORMALITY (SHORT CIRCUIT) IN REAR ENGINE BATTERY RELAY OUTPUT SYTEM IS DISPLAYED...1837
E-19 [E516] ABNORMALITY (STEP-OUT) IN FRONT ENGINE MOTOR IS DISPLAYED...1838
E-20 THE REAR ENGINE DOES NOT START...1839
E-21 REAR ENGINE IRREGULAR ROTATION...1842
a) IRREGULAR IDLING SPEED...1842
b) HUNTING...1844
E-22 REAR ENGINE INSUFFICIENT OUTPUT...1846
E-23 THE REAR ENGINE DOES NOT STOP...1848
E-24 DEFECTIVE OPERATION OF REAR ENGINE BATTERY RELAY SYSTEM...1850
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTROLLER SYSTEM (PUMP CONTROL SYSTEM) (C MODE)...1852
JUDGEMENT TABLE FOR ENGINE THROTTLE AND PUMP CONTROLLER AND HYDRAULIC RELATED PARTS...1853
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...1856
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...1857
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE...1863
C-1 DISPLAY OF ABNORMALITY OF FRONT ENGINE CONTROLLER POWER SUPPLY SYSTEM...1865
C-2 DISPLAY OF [E232] SHORT CIRCUIT OF FRONT PUMP TVC SOLENOID SYSTEM...1866
C-3 DISPLAY OF [E233] DISCONNECTION OF FRONT PUMP TVC SOLENOID SYSTEM...1868
C-4 DISPLAY OF [E203] SHORT CIRCUIT OF SWING HOLD BRAKE SOLENOID SYSTEM...1870
C-5 DISPLAY OF [E213] DISCONNECTION OF SWING HOLD BRAKE SOLENOID SYSTEM...1872
C-6 DISPLAY OF [E201] SHORT CIRCUIT OF CO CANCEL SOLENOID SYSTEM...1874
C-7 DISPLAY OF [E211] DISCONNECTION OF CO CANCEL SOLENOID SYSTEM...1875
C-8 DISPLAY OF [E202] SHORT CIRCUIT OF TRAVEL STRAIGHT SOLENOID SYSTEM...1876
C-9 DISPLAY OF [E212] DISCONNECTION OF TRAVEL STRAIGHT SOLENOID SYSTEM...1877
C-10 DISPLAY OF [E204] SHORT CIRCUIT OF 2-STAGE RELIEF SOLENOID SYSTEM...1878
C-11 DISPLAY OF [E214] DISCONNECTION OF 2-STAGE RELIEF SOLENOID SYSTEM...1879
C-12 DISPLAY OF [E206] SHORT CIRCUIT OF TRAVEL ALARM OUTPUT SYSTEM...1880
C-13 DISPLAY OF [E216] DISCONNECTION OF TRAVEL ALARM OUPUT SYSTEM...1881
C-14 DISPLAY OF [E217] FRONT ENGINE CONTROLLER MODEL SELECTION INPUT ERROR...1882
C-15 DISPLAY OF [E227] ABNORMALITY OF FRONT ENGINE SPEED SENSOR SYSTEM...1884
C-16 DISPLAY OF ABNORMALITY OF MACHINE PUSHUP SOLENOID SYSTEM ( WITH NO DISPLAY OF SERVICE CODE)...1885
C-17 DISPLAY OF ABNORMALITY OF BOOM SHOCKLESS SOLENOID SYSTEM (WITH NO DISPLAY OF SERVICE CODE)...1887
C-18 DISPLAY OF [E221] ABNORMALITY OF GEAR PUMP PRESSURE SENSOR SYSTEM...1890
C-19 DISPLAY OF [E225] ABNORMALITY OF FRONT ENGINE OIL PRESSURE SENSOR SYSTEM...1891
C-20 DISPLAY OF [E226] ABNORMALITY OF FRONT ENGINE SENSOR POWER SUPPLY SYSTEM...1892
C-21 DISPLAY OF [E228] ABNORMALITY OF AUTO-DECEL OUTPUT SYSTEM...1893
C-22 DISPLAY OF ABNORMALITY OF REAR ENGINE CONTROLLER POWER SUPPLY SYSTEM...1894
C-23 DISPLAY OF [E-432] SHORT CIRCUIT OF REAR PUMP TVC SOLENOID SYSTEM...1895
C-24 DISPLAY OF [E433] DISCONNECTION OF REAR PUMP TVC SOLENOID SYSTEM...1897
C-25 DISPLAY OF [E417] REAR ENGINE CONTROLLER MODEL SELECTION INPUT ERROR...1899
C-26 DISPLAY OF [E427] ABNORMALITY OF REAR ENGINE SPEED SENSOR SYSTEM...1901
C-27 DISPLAY OF [E425] ABNORMALITY OF REAR ENGINE OIL PRESSURE SENSOR SYSTEM...1902
C-28 DISPLAY OF [E426] ABNORMALITY OF REAR ENGINE SENSOR POWER SUPPLY SYSTEM...1903
TROUBLESHOOTING OF ENGINE THROTTLE AND PUMP CONTOLLER (INMPUT SIGNAL) SYSTEM (F MODE)...1904
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...1905
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...1907
F-2 BIT PATTERN 20-(2) R.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP...1908
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP...1909
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP...1910
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP...1911
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...1912
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...1913
F-8 BIT PATTERN 21-(2) BUCKET DUMP, SERVICE OIL PRESSURE SWITCH DOES NOT LIGHT UP...1914
F-9 BIT PATTERN 21-(5) L.H. TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP...1915
F-10 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP...1916
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)...1917
TABLE OF FAILURE MODES AND CAUSES...1918
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)...1920
ALL WORK EQUIPMENT, TRAVEL, SWING...1923
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...1923
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...1924
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...1926
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...1928
H-5 AUTO-DECELERATION DOES NOT WORK ...1928
WORK EQUIPMENT...1929
H-6 WORK EQUIPMENT SPEED IS SLOW (BOOM, ARM, BUCKET)...1929
H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)...1930
H-8 EXCESSIVE HYDRAULIC DRIFT...1930
H-9 EXCESSIVE TIME LAG...1931
H-10 EXCESSIVE SHOCK WHEN BOOM IS STOPPED (WHEN SHOCKLESS SWITCH IS ON)...1931
H-11 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION...1931
H-12 BOOM RAISE SPEED IS SLOW OR LACKS POWER WHEN HEAVY LIFT SWITCH IS ON ...1932
TRAVEL SYSTEM...1933
H-13 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS...1933
H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS...1934
H-15 DEVIATION IS EXCESSIVE WHEN STARTING...1937
H-16 TRAVEL SPEED IS SLOW...1939
H-17 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...1939
SWING SYSTEM...1940
H-18 DOES NOT SWING...1940
H-19 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR...1941
H-20 EXCESSIVE OVERRUN WHEN STOPPING SWING...1942
H-21 EXCESSIVE SHOCK WHEN STOPPING SWING...1943
H-22 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...1943
H-23 EXCESSIVE HYDRAULIC DRIFT OF SWING...1944
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...1945
MONITOR PANEL INDICATIONS AND SYMPTOMS FOUND ON MACHINE IN FAILURE...1946
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM...1948
TROUBLESHOOTING FLOWCHART FOR EACH FAILURE MODE...1950
M-1 [E101] ERROR HISTORY DATA ERROR...1950
[E102] CLOCK DATA ERROR...1950
M-2 [E103] SHORT CIRCUIT IN THE BUZZER OUTPUT CIRCUIT...1951
M-3 [E104] DETECTION OF CLOGGED FRONT ENGINE AIR CLEANER...1952
M-4 [E105] DETECTION OF CLOGGED REAR ENGINE AIR CLEANER...1952
M-5 [E108] DETECTION OF FRONT ENGINE WATER TEMPERATURE OF 105C...1953
M-6 [E111] DETECTION OF REAR ENGINE WATER TEMPERATURE OF 105C ...1953
M-7 [115] DETECTION OF HYDRAULIC OIL TEMPERATURE OF 100C ...1953
M-8 THE LAMPS ON THE MONITOR PANEL FAILED TO COME ON FOR THREE SECONDS WHEN THE STARTING SWITCH WAS TURNED ON...1954
M-9 THE LAMPS ON THE MONITOR PANEL COME ON WHEN THE STARTING SWITCH IS TURNED ON, BUT DO NOT GO OFF...1956
M-10 THE LAMP FOR A DIFFERENT MACHINE BODY (MODEL) COMES ON WHEN THE STARTING SWITCH IS TRUNED ON...1956
M-11 THE BASIC CHECK ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON ...1957
M-12 THE "ENGINE PRE-HEATING MONITOR" TURNS ON THOUGH PRE-HEATING OPERATION IS NOT PERFORMED...1962
M-13 THE BASIC CHECK ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON AND THE ENGINE IS STARTED...1963
M-14 THE CAUTION AND EMERGENCY STOP ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON (THE ENGINE IS STOPPED), BUT THE BATTER...1967
M-15 THE CAUTION AND EMERGENCY STOP ITEMS FLASH WHEN THE STARTING SWITCH IS TURNED ON AND THE ENGINE IS STARTED, BUT NO ABNO...1971
M-16 THE BUZZER DOES NOT SOUND FOR ONE SECOND WHEN THE STARTING SWITCH IS TURNED ON (THE ENGINE IS STOPPED). THE BUZZER DOES...1979
M-17 THE BUZZER SOUNDS THOUGH THE MONITOR DISPLAYS NO FAILURE...1979
M-18 THE NIGHTLIGHT ON THE MONITOR PANEL DOES NOT COME ON (THE LCD WORKS NORMAL)...1980
M-19 THE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE HIGHER TEMPERTURES...1981
M-20 THE COOLANT TEMPERATURE GAUGE DISPLAYS NOT A SINGLE LEVEL DURING OPERATION...1983
M-21 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE HIGHER TEMPERATURES...1985
M-22 THE HYDRAULIC OIL TEMPERATURE GAUGE DISPLAYS NOT A SINGLE LEVEL DURING OPERATION...1985
M-23 THE FUEL LEVEL GAUGE ALWAYS INDICATES FULL...1986
M-24 THE FUEL LEVEL GAUGE DISPLAYS NOTHING...1986
M-25 THE "SWING LOCK MONITOR" DOES NOT COME ON THOUGH THE SWING LOCK SWITCH IS TURNED ON (LOCK)...1987
M-26 EMERGENCY SWING SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH...1987
M-27 THE SERVICE METER DOES NOT WORK WHILE THE ENGINE IS IN OPERATION. THE CLOCK IS NOT DISPLAYED THOUGH THE STARTING SWITCH...1988
M-28 THE SERVICE METER DOES NOT WORK THOUGH THE CLOCK SWITCH IS PRESSED WITH THE STARTING SWITCH TURNED OFF...1988
M-29 DEFECTIVE FUEL LEVEL SENSOR...1989
M-30 DEFECTIVE TEMPERATURE SENSOR (ENGINE WATER TEMPERATURE, ENGINE OIL TEMPERATURE, PTO OIL TEMPERATURE, AND HYDRAULIC OIL T...1990
M-31 DEFECTIVE ENGINE OIL LEVEL SENSOR...1991
M-32 DEFECTIVE COOLANT LEVEL SENSOR...1992
M-33 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR...1993
TROUBLESHOOTING OF MACHINE CONTROL SYSTEM (V MODE)...1994
CODES DISPLAYED IN FAILURE OCCURRENCES AND DESCRIPTIONS...1996
LIST OF WARNING ITEMS DISPLAYED ON CGC MONITOR...2006
V MODE SYSTEM ELECTRICAL CIRCUIT DIAGRAM...2010
TROUBLESHOOTING BY FAILURE MODE...2012
V-1 [E811] FAILURE IN VHMS CONTROLLER POWER SUPPLY SYSTEM...2012
V-2 [E812] FAILURE ON VHMS SENSORE POWER SUPPLY (24 V)...2013
V-3 [E813] FAILURE ON VHMS SENSOR POWER SUPPLY (12 V)...2014
V-4 [E814] FAILURE ON VHMS SENSOR POWER SUPPLY (5 V)...2015
V-5 [E817] VHMS MODEL SELECTION INPUT ERROR...2016
V-6 [E818] VHMS CONNECTORS CONNECTION ERROR...2017
V-7 [E821] VHMS FIRM SYSTEM FAILURE...2018
V-8 [E828] DISCONNECTION ON S-NET BETWEEN VHMS AND MAIN MONITOR...2018
V-9 [E831] VHMS APPLICATION SYSTEM FAILURE...2018
[E832] VHMS LANGUAGE FAILURE...2018
V-10 [E857] FAILURE IN FRONT ENGINE SPEED SENSOR SYSTEM...2019
V-11 [E858] FAILURE IN REAR ENGINE SPEED SENSOR SYSTEM...2020
V-12 [E861] FAILURE IN FRONT ENGINE OIL TEMPERATURE SENSOR SYSTEM...2021
V-13 [E862] FAILURE IN REAR ENGINE OIL TEMPERATURE SENSOR SYSTEM ...2022
V-14 [E863] FAILURE IN FRONT PTO OIL TEMPERATURE SENSOR SYSTEM...2023
V-15 [E864] FAILURE IN REAR PTO OIL TEMPERATURE SENSOR SYSTEM...2024
V-16 [E865] FAILURE IN NOS. 1& 2 FRONT PUMPS PRESSURE SENSOR SYSTEM...2025
V-17 [E866] FAILURE IN NOS. 1 & 2 REAR PUMPS PRESSURE SENSOR SYSTEM...2026
V-18 [E867] FAILURE IN NOS. 3 & 4 FRONT PUMPS PRESSURE SENSOR SYSTEM...2027
V-19 [E868] FAILURE IN NOS. 3 & 4 REAR BUMPS PRESSURE SENSOR SYSTEM...2028
V-20 [E871] FAILURE IN FRONT ENGINE WATER TEMPERATURE SENSOR SYSTEM...2029
V-21 [E872] FAILURE IN REAR ENGINE WATER TEMPERATURE SENSOR SYSTEM...2029
V-22 [E873] FAILURE IN HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM...2030
V-23 [E876] ABNORMAL FRONT ENGINE EXHAUST TEMPERATURE SENSOR SYSTEM...2031
V-24 THE VALUE DISPLAYED ON THE FRONT ENGINE EXHAUST TEMPERATURE REAL-TIME MONITOR DOES NOT CORRESPOND WHEN THE TEMPERATURE R...2032
V-25 [E877] ABNORMAL REAR ENGINE EXHAUST TEMPERATURE SENSOR SYSTEM...2033
V-26 THE VALUE DISPLAYED ON THE REAR ENGINE EXHAUST TEMPERATURE REAL-TIME MONITOR DOES NOT CORRESPOND WHEN THE TEMPERATURE RI...2034
V-27 [E878] FAILURE IN SWING PUMP PRESSURE SENSOR SYSTEM...2035
V-28 ABNORMAL ENGINE OIL TEMPERATURE...2036
V-29 [E881] DISPLAY INDICATES DETECTION OF THE FRONT ENGINE OIL TEMPERATURE AT 125C ...2038
[E882] DISPLAY INDICATES DETECTION OF THE REAR ENGINE OIL TEMPERATURE AT 125C ...2038
V-30 [E883] FRONT ENGINE OIL PRESSURE DROP...2039
V-31 [E884] REAR ENGINE OIL PRESSURE DROP...2039
V-32 ABNORMAL PTO OIL TEMPERATURE...2040
V-33 [E885] DISPLAY INDICATES DETECTION OF THE FRONT ENGINE PTO OIL TEMPERATURE AT 125C...2042
[E886] DISPLAY INDICATES DETECTION OF THE REAR ENGINE PTO OIL TEMPERATURE AT 125C ...2042
V-34 ABNORMAL GEAR PUMP PRESSURE IS DISPLAYED...2043
V-35 [E887] ABNORMAL GEAR PUMP PRESSURE IS DISPLAYED...2043
V-36 [E888] EXCESSIVE EXHAUST GAS TEMPERATURE OF FRONT ENGINE ...2044
V-37 [E898] EXCESSIVE EXHAUST GAS TEMPERATURE OF REAR ENGINE...2044
V-38 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 FRONT PUMPS...2045
V-39 [E891] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 & 2 FRONT PUMPS...2045
V-40 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 REAR PUMPS...2046
V-41 [E892] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 1 AND 2 REAR PUMPS...2046
V-42 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 FRONT PUMPS...2047
V-43 [E893] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 FRONT PUMPS...2047
V-44 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 REAR PUMPS...2048
V-45 [E894] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR NOS. 3 AND 4 REAR PUMPS...2048
V-46 ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR THE SWING PUMP...2049
V-47 [E895] ABNORMAL RELIEF PRESSURE IS DISPLAYED FOR THE SWING PUMP...2049
V-48 FAILURE IN GEAR PUMP PRESSURE SENSOR SYSTEM...2050
V-49 FAILURE IN PRESSURE SENSOR SYSTEM FOR NOS. 1,2,3, & 4 PUMPS AND SWING PUMP...2051
TROUBLESHOOTING OF BOTTOM CYLINDER CONTROL SYSTEM (LE, LH MODE) [LOADING SHOVEL SPECIFICATION]...2052
LE-1 DEFECTIVE OPERATION OF BOTTOM CYLINDER...2053
A) BOTTOM CLOSING SIDE...2053
B) BOTTOM OPENING SIDE...2053
LH-1 DEFECTIVE OPERATION OF BOTTOM CYLINDER...2055
TROUBLESHOOTING OF WORK EQUIPMENT AUTOMATIC CONTROL SYSTEM (W, L MODE) [LOADING SHOVEL SPECIFICATION]...2056
ABNORMALITY JUDGEMENT STANDARDS FOR SELF-DIAGNOSTIC SYSTEM...2057
TROUBLESHOOTING...2058
W-1 IN ARC DIGGING MODE (AUTO LEVEL DIGGING SWITCH OFF), HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IS CARRIED OUT...2061
W-2 IN HORIZONTAL DIGGING MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING...2062
A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"...2062
B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"...2066
W-3 IN HORIZONTAL DIGGING MODE (BUCKET ANGLE REVISE SWITCH OFF), BUCKET ANGLE COMPENSATION IS CARRIED OUT...2067
W-4 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGL...2068
A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"...2068
B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"...2069
W-5 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORI...2071
A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"...2071
B) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "NORMAL DISPLAY"...2071
W-6 IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATIO MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION...2072
A) WHEN SELF-DIAGNOSTIC DISPLAY IS GIVING "ABNORMAL DISPLAY"...2072
L-1 IMPOSSIBLE TO CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION...2076
30 DISASSEMBLY AND ASSEMBLY...2077
METHOD OF USING MANUAL...2079
PRECAUTIONS WHEN CARRYING OUT OPERATION...2081
SPECIAL TOOL LIST...2083
FUEL INJECTION PUMP ASSEMBLY...2088
REMOVAL AND INSTALLATION...2088
NOZZLE HOLDER ASSEMBLY...2089
REMOVAL...2089
INSTALLATION...2090
TURBOCHARGER ASSEMBLY...2091
REMOVAL AND INSTALLATION...2091
CYLINDER HEAD ASSEMBLY...2092
REMOVAL...2092
INSTALLATION...2096
HYDRAULIC COOLER, AFTERCOOLER ASSEMBLY...2099
REMOVAL AND INSTALLATION...2099
FAN GUARD, RADIATOR, HYDRAULIC COOLER ASSEMBLY...2100
REMOVAL...2100
INSTALLATION...2101
AFTERCOOLER CORE...2102
REMOVAL AND INSTALLATION...2102
ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY...2103
REMOVAL...2103
INSTALLATION...2107
PTO ASSEMBLY...2108
REMOVAL...2108
INSTALLATION...2111
DISASSEMBLY...2112
ASSEMBLY...2113
CENTER SWIVEL JOINT ASSEMBLY...2116
REMOVAL AND INSTALLATION...2116
DISASSEMBLY AND ASSEMBLY...2117
TRAVEL MOTOR ASSEMBLY...2118
REMOVAL AND INSTALLATION...2118
TRAVEL MOTOR BRAKE VALVE ASSEMBLY...2119
REMOVAL AND INSTALLATION...2119
TRAVEL MOTOR ASSEMBLY...2120
DISASSEMBLY...2120
ASSEMBLY...2124
FINAL DRIVE ASSEMBLY...2130
DISASSEMBLY...2130
ASSEMBLY...2134
SWING MOTOR ASSEMBLY...2141
REMOVAL AND INSTALLATION...2141
DISASSEMBLY...2142
ASSEMBLY...2145
REVOLVING FRAME ASSEMBLY...2150
REMOVAL AND INSTALLATION...2150
SWING CIRCLE ASSEMBLY...2151
REMOVAL AND INSTALLATION...2151
SWING MACHINERY ASSEMBLY...2152
REMOVAL AND INSTALLATION...2152
DISASSEMBLY ...2153
ASSEMBLY...2158
IDLER CUSHION CYLINDER ASSEMBLY...2163
REMOVAL AND INSTALLATION...2163
DISASSEMBLY AND ASSEMBLY...2164
IDLER ADJUSTMENT CYLINDER ASSEMBLY...2165
DISASSEMBLY AND ASSEMBLY...2165
TRACK ROLLER ASSEMBLY...2166
REMOVAL AND INSTALLATION...2166
CARRIER ROLLER ASSEMBLY...2167
REMOVAL AND INSTALLATION...2167
TRACK SHOE ASSEMBLY...2168
REMOVAL...2168
INSTALLLATION...2169
CONTROL, PTO LUBRICATION PUMP ASSEMBLY...2170
REMOVAL AND INSTALLATION...2170
SWING PUMP ASSEMBLY...2171
REMOVAL AND INSTALLATION...2171
DISASSEMBLY...2172
ASSEMBLY...2179
NO. 1, 3 PUMP ASSEMBLY...2191
REMOVAL AND INSTALLATION...2191
NO. 2, 4 PUMP ASSEMBLY...2192
REMOVAL...2192
INSTALLATION...2193
HYDAULIC PUMP ASSEMBLY...2194
DISASSEMBLY...2194
ASSEMBLY...2204
PILOT RELIEF VALVE ASSEMBLY...2219
REMOVAL AND INSTALLATION...2219
DISASSEMBLY AND ASSEMBLY...2220
MAIN RELIEF VALVE ASSEMBLY (FOR SWING)...2221
DISASSEMBLY AND ASSEMBLY...2221
MAIN RELIEF VALVE ASSEMBLY (FOR WORK EQUIPMENT, TRAVEL)...2222
DISASSEMBLY AND ASSEMBLY...2222
SWING CONTROL VALVE ASSEMBLY...2223
REMOVAL AND INSTALLATION...2223
DISASSEMBLY AND ASSEMBLY...2224
V1, V3 CONTROL VALVE ASSEMBLY...2226
REMOVAL AND INSTALLATION...2226
V2, V4 CONTROL VALVE ASSEMBLY...2227
REMOVAL AND INSTALLATION...2227
CONTROL VALVE ASSEMBLY...2228
DISASSEMBLY...2228
ASSEMBLY...2230
CO, NC VALVE ASSEMBLY...2232
REMOVAL AND INSTALLATION...2232
SERVO VALVE ASSEMBLY...2233
REMOVAL AND INSTALLATION...2233
TVC VALVE ASSEMBLY...2234
REMOVAL AND INSTALLATION...2234
PPC VALVE ASSEMBLY (FOR TRAVEL)...2235
REMOVAL AND INSTALLATION...2235
DISASSEMBLY AND ASSEMBLY...2236
PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)...2237
REMOVAL AND INSTALLATION0...2237
DISASSEMBLY AND ASSEMBLY...2238
BOOM CYLINDER ASSEMBLY (BACKHOE)...2239
BACK HOE...2239
REMOVAL...2239
INSTALLATION...2240
LOADING SHOVEL...2241
REMOVAL...2241
INSTALLATION...2242
ARM CYLINDER ASSEMBLY ...2243
(BACK HOE)...2243
REMOVAL...2243
INSTALLATION...2244
(LOADING SHOVEL)...2245
REMOVAL...2245
INSTALLATION...2246
BUCKET CYLINDER ASSEMBLY ...2247
(BACK HOE)...2247
REMOVAL...2247
INSTALLATION...2248
(LOADING SHOVEL)...2249
REMOVAL...2249
INSTALLATION...2250
BOTTOM DUMP CYLINDER ASSEMBLY...2251
(LOADING SHOVEL)...2251
REMOVAL...2251
INSTALLATION...2252
HYDRAULIC CYLINDER ASSEMBLY ...2253
(BACK HOE)...2253
DISASSEMBLY...2253
ASSEMBLY...2259
(LOADING SHOVEL)...2263
DISASSEMBLY...2263
ASSEMBLY...2265
BUCKET ASSEMBLY ...2268
(BACK HOE)...2268
REMOVAL...2268
INSTALLATION...2269
(LOADING SHOVEL)...2270
REMOVAL...2270
INSTALLATION...2271
ARM ASSEMBLY ...2272
(BACK HOE)...2272
REMOVAL...2272
INSTALLATION...2273
(LOADING SHOVEL)...2274
REMOVAL...2274
INSTALLATION...2275
BOOM ASSEMBLY...2280
(BACKHOE)...2280
REMOVAL...2280
INSTALLATION...2281
(LOADING SHOVEL)...2282
REMOVAL...2282
INSTALLATION...2283
COUNTERWEIGHT ASSEMBLY...2284
REMOVAL AND INSTALLATION...2284
OPERATOR'S CAB ASSEMBLY...2285
REMOVAL...2285
INSTALLATION...2286
40 MAINTENANCE STANDARD...2287
PTO...2288
SWING MACHINERY...2289
FINAL DRIVE...2291
IDLER...2292
TRACK ROLLER...2294
CARRIER ROLLER...2295
TRACK SHOE...2296
HYDRAULIC PUMP...2300
SWING PUMP...2301
CONTROL AND PTO LUBRICATION PUMP...2302
CONTROL VALVE...2303
SWING CONTROL VALVE...2310
SWING MOTOR...2311
TRAVEL MOTOR...2312
TRAVEL BRAKE VALVE...2313
CENTER SWIVEL JOINT...2314
PILOT RELIEF VALVE...2315
PPC VALVE...2316
SOLENOID VALVE...2318
HYDRAULIC CYLINDER...2319
WORK EQUIPMENT...2323
DIMENSIONS OF WORK EQUIPMENT...2327
90 OTHERS...2331
HYDRAULIC CIRCUIT DIAGRAM (BACK HOE)...2332
HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)...2338
ELECTRIC CIRCUIT DIAGRAM (1/5)...2342
ELECTRIC CIRCUIT DIAGRAM (2/5)...2347
ELECTRIC CIRCUIT DIAGRAM (3/5)...2352
ELECTRIC CIRCUIT DIAGRAM (4/5)...2357
ELECTRIC CIRCUIT DIAGRAM (5/5)...2362
SEBM027708 - Hydraulic Excavator PC1800-6 Shop Manual...2368
COVER...2368
CONTENTS...2369
01 GENERAL...2398
SPECIFICATION DRAWINGS...2399
SPECIFICATIONS...2401
WEIGHT TABLE...2405
FUEL, COOLANT AND LUBRICANTS...2409
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD...2411
PTO...2412
PTO LUBRICATION SYSTEM...2414
POWER TRAIN...2415
SWING MACHINERY...2417
SWING CIRCLE...2419
FINAL DRIVE...2420
SPROCKET...2422
IDLER...2424
HIC SYSTEM...2426
TRACK ROLLER...2428
CARRIER ROLLER...2429
TRACK SHOE...2430
HYDRAULIC COMPONENT LAYOUT...2434
HYDRAULIC TANK...2436
HYDRAULIC PUMP...2437
SWING PUMP...2464
CONTROL AND PTO LUBRICATING PUMP...2469
LINE OIL FILTER...2471
PILOT OIL FILTER...2471
RETURN OIL FILTER...2472
DRAIN OIL FILTER...2473
ELECTRONIC OLSS...2474
CONTROL VALVE...2476
SWING CONTROL VALVE...2492
SWING MOTOR...2495
CENTER SWIVEL JOINT...2498
TRAVEL MOTOR...2499
TRAVEL BRAKE VALVE...2501
PILOT RELIEF VALVE...2503
SAFETY LOCK VALVE...2505
ACCUMULATOR...2507
PPC VALVE...2508
SOLENOID VALVE...2514
HYDRAULIC CYLINDER...2516
AIR SYSTEM...2520
AIR GOVERNOR...2521
AIR TANK...2521
AUTO-DRAIN VALVE...2521
SAFETY VALVE...2522
SOLENOID VALVE (FOR LUBRICATION, HORN)...2522
GREASE PUMP...2523
GREASING SYSTEM...2525
WORK EQUIPMENT...2532
DIMENSIONS OF WORK EQUIPMENT...2536
ENGINE CONTROL...2540
MACHINE CONTROL SYSTEM...2546
ELECTRONIC COMPONENTS OF AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM...2570
MONITOR SYSTEM...2576
20 TESTING AND ADJUSTING...2592
STANDARD VALUE TABLE FOR ENGINE...2593
STANDARD VALUE TABLE FOR CHASSIS...2594
TESTING AND ADJUSTING...2602
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING...2603
MEASUREMENT OF ENGINE SPEED...2605
MEASUREMENT OF AIR BOOST PRESSURE (BOOST PRESSURE)...2606
MEASUREMENT OF EXHAUST GAS TEMPERATURE...2607
MEASUREMENT OF EXHAUST GAS COLOR...2607
ADJUSTMENT OF VALVE CLEARANCE...2609
MEASUREMENT OF COMPRESSION PRESSURE...2610
MEASUREMENT OF BLOW-BY PRESSURE...2610
MEASUREMENT OF ENGINE OIL PRESSURE...2611
HANDLING OF FUEL SYSTEM EQUIPMENT...2612
REMAINING PRESSURE RELIEF FROM FUEL SYSTEM EQUIPMENT...2612
MEASUREMENT OF FUEL PRESSURE...2613
AIR BLEEDING FROM FUEL CIRCUIT...2614
INSPECTION OF LEAKAGE FROM FUEL SYSTEM...2616
ADJUSTMENT OF ENGINE SPEED SENSOR...2617
INSPECTION AND ADJUSTMENT OF FAN BELT TENSION...2618
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...2619
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...2620
INSPECTION OF SWING CIRCLE BEARING CLEARANCE...2621
REMAINING PRESSURE RELIEF FROM HIC CIRCUIT...2622
GAS FILLING IN HIC CIRCUIT ACCUMULATOR...2622
BLEEDING AIR FROM AND FILLING PRESSURIZED OIL IN HIC CIRCUIT...2624
INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION...2625
INSPECTION AND ADJUSTMENT OF WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT OIL PRESSURES...2626
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE...2631
INSPECTION AND ADJUSTMENT OF PISTON PUMP CONTROL OIL PRESSURE...2632
INSPECTION OF SERVO PISTON STROKE...2639
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE...2640
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE...2642
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE...2644
INSPECTION AND ADJUSTMENT OF TRAVEL DEIEATION...2645
INSPECTION OF WORK EQUIPMENT HYDRAULIC DRIFT CAUSE PORTION...2647
INSPECTION OF OIL LEAKAGE...2648
REMAINING PRESSURE RELIEF FROM HYDRAULIC CIRCUIT...2651
AIR BLEEDING FROM EACH COMPONENT...2652
TESTING AND ADJUSTING HYDRAULIC AUTO GREASE SYSTEM...2657
SPECIAL FUNCTION OF MACHINE MONITOR...2661
FUNCTION AMD OPERATION OF CGC MONITOR...2681
HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT...2716
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER...2717
SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER...2731
TESTING AND ADJUSTING DEVICES RELATED TO VHMS...2748
ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (LOADING SHOVEL)...2751
TROUBLESHOOTING...2769
POINTS TO REMEMBER WHEN TROUBLESHOOTING...2770
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2771
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...2772
CHECKS BEFORE TROUBLESHOOTING...2780
CLASSIFICATION AND PROCEDURE OF TROUBLESHOOTING...2781
CONNECTOR ARRANGMENT DIAGRAM AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM...2785
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...2813
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...2848
TROUBLESHOOTING AT DISPLAY OF FAILURE CODE OR ERROR CODE [CODE DISPLAY MODE]...2852
INFORMATION IN TROUBLESHOOTING TABLE...2855
FAILURE CODE [6014NX]...2857
FAILURE CODE [7@HAKA]...2859
FAILURE CODE [7@HAKB]...2860
FAILURE CODE [7@HAZL]...2861
FAILURE CODE [7@HBKA]...2862
FAILURE CODE [7@HBKB]...2863
FAILURE CODE [7@HBZL]...2864
FAILURE CODE [7@HCKA]...2865
FAILURE CODE [7@HCKB]...2866
FAILURE CODE [7@HCZL]...2867
FAILURE CODE [7@HDKA]...2868
FAILURE CODE [7@HDKB]...2869
FAILURE CODE [7@HDZL]...2870
FAILURE CODE [A000N1] OR ERROR CODE [E922]...2871
FAILURE CODE [a000N1] OR ERROR CODE [EA22]...2872
FAILURE CODE [AA10NX] OR ERROR CODE [104]...2873
FAILURE CODE [aA10NX] OR ERROR CODE [105]...2874
FAILURE CODE [ABOOKE]...2875
FAILURE CODE [aBOOKE]...2876
FAILURE CODE [ADOOL2] OR ERROR CODE [E979]...2877
FAILURE CODE [aD00L2] OR ERROR CODE [EA79]...2878
FAILURE CODE [AD00MA] OR ERROR CODE [E97A]...2879
FAILURE CODE [aD00MA] OR ERROR CODE [EA7A]...2879
FAILURE CODE [AD10L3] OR ERROR CODE [E97b]...2880
FAILURE CODE [aD10L3] OR ERROR CODE [EA7b]...2882
FAILURE CODE [AD10MA] OR ERROR CODE [E97d]...2884
FAILURE CODE [aD10MA] OR ERROR CODE [EA7d]...2884
FAILURE CODE [AD10MB] OR ERROR CODE [E97C]...2885
FAILURE CODE [aD10MB] OR ERROR CODE [EA7C]...2885
FAILURE CODE [AD11KA] OR ERROR CODE [E974]...2886
FAILURE CODE [aD11KA] OR ERROR CODE [EA74]...2887
FAILURE CODE [AD11KB] OR ERROR CODE [E970]...2888
FAILURE CODE [aD11KB] OR ERROR CODE [EA70]...2889
FAILURE CODE [AD51KA] OR ERROR CODE [E975]...2890
FAILURE CODE [aD51KA] OR ERROR CODE [EA75]...2891
FAILURE CODE [AD51KB] OR ERROR CODE [E971]...2892
FAILURE CODE [aD51KB] OR ERROR CODE [EA71]...2893
FAILURE CODE [ADA1KA] OR ERROR CODE [E981]...2894
FAILURE CODE [aDA1KA] OR ERROR CODE [EA81]...2895
FAILURE CODE [ADAZKB] OR ERROR CODE [E98A]...2896
FAILURE CODE [aDAZKB] OR ERROR CODE [EA8A]...2898
FAILURE CODE [ADB1KA] OR ERROR CODE [E982]...2900
FAILURE CODE [aDB1KA] OR ERROR CODE [EA82]...2901
FAILURE CODE [ADC1KA] OR ERROR CODE [E983]...2902
FAILURE CODE [aDC1KA] OR ERROR CODE [EA83]...2903
FAILURE CODE [ADD1KA] OR ERROR CODE [E984]...2904
FAILURE CODE [aDD1KA] OR ERROR CODE [EA84]...2905
FAILURE CODE [ADDZKB] OR ERROR CODE [E98b]...2906
FAILURE CODE [aDDZKB] OR ERROR CODE [EA8b]...2908
FAILURE CODE [ADE1KA] OR ERROR CODE [E985]...2910
FAILURE CODE [aDE1KA] OR ERROR CODE [EA85]...2911
FAILURE CODE [ADF1KA] OR ERROR CODE [E986]...2912
FAILURE CODE [aDF1KA] OR ERROR CODE [EA86]...2913
FAILURE CODE [B@BAZG] OR ERROR CODE [E924]...2914
FAILURE CODE [b@BAZG] OR ERROR CODE [EA24]...2915
FAILURE CODE [B@BAZK]...2916
FAILURE CODE [b@BAZK]...2917
FAILURE CODE [B@BCNS] OR ERROR CODE [108]...2918
FAILURE CODE [b@BCNS] OR ERROR CODE [111]...2919
FAILURE CODE [B@BCZK]...2920
FAILURE CODE [b@BCZK]...2922
FAILURE CODE [B@CBNS]...2924
FAILURE CODE [b@CBNS]...2925
FAILURE CODE [B@HANS] OR ERROR CODE [115]...2926
FAILURE CODE [B@HAZK]...2927
FAILURE CODE [D11OKB]...2928
FAILURE CODE [D163KB]...2929
FAILURE CODE [D194KZ]...2930
FAILURE CODE [D195KB]...2931
FAILURE CODE [D1D0KB] OR ERROR CODE [E957]...2932
FAILURE CODE [d1D0KB] OR ERROR CODE [EA57]...2934
FAILURE CODE [DA20KT] OR ERROR CODE [101]...2936
FAILURE CODE [DA2SKA]...2937
FAILURE CODE [DA2SKQ]...2939
FAILURE CODE [DA80MA]...2941
FAILURE CODE [DAB0KR] OR ERROR CODE [118]...2942
FAILURE CODE [DB20KT] OR ERROR CODE [E980]...2944
FAILURE CODE [dB20KT] OR ERROR CODE [EA80]...2945
FAILURE CODE [DB22KK] OR ERROR CODE [E956]...2946
FAILURE CODE [dB22KK] OR ERROR CODE [EA56]...2948
FAILURE CODE [DB29KQ] OR ERROR CODE [E920]...2950
FAILURE CODE [dB29KQ] OR ERROR CODE [EA20]...2951
FAILURE CODE [DB2AMA] OR ERROR CODE [E95A]...2952
FAILURE CODE [bB2AMA] OR ERROR CODE [EA5A]...2952
FAILURE CODE [DB2RMC] OR ERROR CODE [E935]...2953
FAILURE CODE [dB2RMC] OR ERROR CODE [EA35]...2955
FAILURE CODE [DB2SMC] OR ERROR CODE [E955]...2957
FAILURE CODE [dB2SMC] OR ERROR CODE [EA55]...2959
FAILURE CODE [DBB0KK]...2961
FAILURE CODE [DBB0KM]...2962
FAILURE CODE [DBB0KP]...2963
FAILURE CODE [DBB0KQ]...2965
FAILURE CODE [DBB0KR] OR ERROR CODE [116]...2967
FAILURE CODE [DBB0KT]...2969
FAILURE CODE [DBBQKR]...2970
FAILURE CODE [DD11KB] OR ERROR CODE [E954]...2972
FAILURE CODE [dD11KB] OR ERROR CODE [EA54]...2974
FAILURE CODE [DDE2L6] OR ERROR CODE [E936]...2976
FAILURE CODE [dDE2L6] OR ERROR CODE [EA36]...2978
FAILURE CODE [DGE4KX] OR ERROR CODE [E93d]...2980
FAILURE CODE [dGE4KX] OR ERROR CODE [EA3d]...2981
FAILURE CODE [DGT4KA]...2982
FAILURE CODE [dGT4KA]...2984
FAILURE CODE [DGT4KB]...2986
FAILURE CODE [dGT4KB]...2988
FAILURE CODE [DGT5KA]...2990
FAILURE CODE [dGT5KA]...2992
FAILURE CODE [DGT5KB]...2994
FAILURE CODE [dGT5KB]...2996
FAILURE CODE [DH30KX] OR ERROR CODE [E93C]...2998
FAILURE CODE [dH30KX] OR ERROR CODE [EA3C]...2999
FAILURE CODE [DH40KX] OR ERROR CODE [E977]...3000
FAILURE CODE [dH40KX] OR ERROR CODE [EA77]...3001
FAILURE CODE [DHE4KB]...3002
FAILURE CODE [dHE4KB]...3003
FAILURE CODE [DHE4KY]...3004
FAILURE CODE [dHE4KY]...3005
FAILURE CODE [DHE5KB]...3006
FAILURE CODE [dHE5KB]...3007
FAILURE CODE [DHE5KY]...3008
FAILURE CODE [dHE5KY]...3009
FAILURE CODE [DK10KX] OR ERROR CODE [E931]...3010
FAILURE CODE [dK10KX] OR ERROR CODE [EA31]...3011
FAILURE CODE [DLE2MA]...3012
FAILURE CODE [dLE2MA]...3013
FAILURE CODE [DLE3LC] OR ERROR CODE [E91b]...3014
FAILURE CODE [dLE3LC] OR ERROR CODE [EA1b]...3015
FAILURE CODE [DLH1LC] OR ERROR CODE [E91C]...3016
FAILURE CODE [dLH1LC] OR ERROR CODE [EA1C]...3017
FAILURE CODE [DPA0KR]...3018
FAILURE CODE [DV00KY] OR ERROR CODE [102]...3019
FAILURE CODE [DV20KB]...3020
FAILURE CODE [DW42KZ]...3021
FAILURE CODE [DW45KA]...3022
FAILURE CODE [DW45KB]...3024
FAILURE CODE [DW48KA]...3026
FAILURE CODE [DW48KB]...3027
FAILURE CODE [DW91KA]...3028
FAILURE CODE [DW91KB]...3029
FAILURE CODE [DWK0KA]...3030
FAILURE CODE [DWK0KB]...3031
FAILURE CODE [DXA0KA]...3032
FAILURE CODE [dXA0KA]...3034
FAILURE CODE [DXA0KB]...3036
FAILURE CODE [dXA0KB]...3038
FAILURE CODE [F@BBZL]...3040
FAILURE CODE [f@BBZL]...3040
FAILURE CODE [F@BVL6]...3041
FAILURE CODE [f@BVL6]...3041
FAILURE CODE [F@BYNR]...3042
FAILURE CODE [f@BYNR]...3043
FAILURE CODE [F@BYNS]...3044
FAILURE CODE [f@BYNS]...3045
FAILURE CODE [F@BZNR]...3046
FAILURE CODE [f@BZNR]...3047
FAILURE CODE [F@BZNS]...3048
FAILURE CODE [f@BZNS]...3049
FAILURE CODE [F@HCKA]...3050
FAILURE CODE [F@HCKB]...3051
FAILURE CODE [F@HCZL]...3052
FAILURE CODE [J100KA]...3053
FAILURE CODE [J100KB]...3054
FAILURE CODE [J100L6]...3055
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...3056
INFORMATION CONTAINED IN THE TROUBLESHOOTING LIST...3057
E-1 ENGINE DOESN'T START UP...3058
E-2 PREHEATING DOES NOT WORK...3063
E-3 AUTOMATIC-DECELERATOR DOES NOT WORK...3066
E-4 BOOM SHOCK-LESS FUNCTION DOES NOT OPERATE NORMALLY...3067
E-5 MACHINE PUSHUP FUNCTION DOES NOT WORK NORMALLY...3070
E-6 TRAVEL ALARM IS NOT SOUNDED...3072
E-7 ALL THE MACHINE MONITOR LAMPS DO NOT COME ON FOR 3 SECONDS AFTER THE STARTING SWITCH IS TURNED ON...3073
E-8 WHEN THE STARTING SWITCH IS TURNED ON ,MACHINE MONITOR LAMPS ALL STAYED LIGHTED UP AND DO NOT GO OUT...3075
E-9 MACHINE MONITOR LAMPS WHICH IS LIGHTED UP WHEN THE STARTING SWITCH IS TURNED ON, DO NOT EXACTLY REPRESENT THE MACHINE OPERATING STATUS...3075
E-10 A BASIC CHECK ITEM FLASHES ON THE MACHINE MONITOR WHILE THE STARTING SWITCH IS TURNED ON...3076
E-11 WHILE THE ENGINE IS IN OPERATION, A CAUTION ITEM FLASHES ON THE MACHINE MONITOR...3077
E-12 WHILE THE ENGINE IS IN OPERATION, AN EMERGENCY STOP ITEM FLASHES ON THE MACHINE MONITOR...3079
E-13 WARM-UP MONITOR UNINTENDED COMES ON OR FLASHES ON THE MACHINE MONITOR THOUGH THE WARM-UP OPERATION IS NOT TURNED ON...3081
E-14 SWING LOCK MONITOR DOES NOT COME ON...3083
E-15 ENGINE WATER TEMPERATURE GAUGE IS NOT CORRECT...3085
E-16 DISPLAY OF THE MACHINE MONITOR'S HYDRAULIC OIL TEMPERATURE GAUGE IS NOT CORRECT...3087
E-17 DISPLAY OF FUEL GAUGE IS NOT CORRECT...3088
E-18 ALARM BUZZER OF THE MACHINE MONITOR DOES NOT WORK NORMALLY...3089
E-19 CLOCK AND SERVICE METER ARE NOT CORRECTLY DISPLAYED...3091
E-20 BIT DISPLAY FOR BOOM RAISE IS NOT CORRECTLY DISPLAYED...3092
E-21 BIT DISPLAY FOR BOOM LOWER IS NOT CORRECTLY DISPLAYED...3093
E-22 BIT DISPLAY FOR ARM IN IS NOT CORRECTLY DISPLAYED...3094
E-23 BIT DISPLAY FOR ARM OUT IS NOT CORRECTLY DISPLAYED...3095
E-24 BIT DISPLAY FOR BUCKET CURL IS NOT CORRECTLY DISPLAYED...3096
E-25 BIT DISPLAY FOR BUCKET DUMP IS NOT CORRECTLY DISPLAYED...3097
E-26 BIT DISPLAY FOR SWING IS NOT CORRECTLY DISPLAYED...3098
E-27 BIT DISPLAY FOR LH TRAVEL IS NOT CORRECTLY DISPLAYED...3100
E-28 BIT DISPLAY FOR RH TRAVEL IS NOT CORRECTLY DISPLAYED...3102
E-29 BIT DISPLAY FOR THE SERVICE IS NOT CORRECTLY DISPLAYED...3104
E-30 BIT DISPLAY FOR BOTTOM OPEN, CLOSE IS NOT CORRECTLY DISPLAYED...3105
E-31 AIR CONDITIONER DOES NOT WORK...3107
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...3109
TABLE OF FAILURE MODES AND CAUSES...3110
PREPARATIONS FOR TROUBLESHOOTING OF HYDRAULIC SYSTEM...3112
HOW TO READ THE TROUBLESHOOTING FLOW...3117
H-1. SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER...3118
H-2. THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...3119
H-3. NO WORK EQUIPMENT, TRAVEL, SWING MOVE...3121
H-4. ABNORMAL NOISE GENERATED (AROUND PUMP)...3123
H-5. WORK EQUIPMENT SPEED IS SLOW (BOOM, ARM, BUCKET)...3124
H-6. WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)...3125
H-7. EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...3125
H-8. EXCESSIVE TIME LAG...3126
H-9. EXCESSIVE SHOCK WHEN BOOM IS STOPPED (WHEN SHOCKLESS SWITCH IS ON)...3126
H-10. DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION...3126
H-11. WHEN HEAVY LIFT IS ON, BOOM RAISE SPEED IS SLOW OR LACKS POWER...3127
H-12. TRAVEL DEVIATION IS EXCESSIVE DRUING COMPOUND OPERATIONS...3128
H-13. MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS...3129
H-14. DEVIATION IS EXCESSIVE WHEN STARTING ...3132
H-15. TRAVEL SPEED IS SLOW...3134
H-16. TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...3134
H-17. DOES NOT SWING...3135
H-18. SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR...3136
H-19. EXCESSIVE OVERRUN WHEN STOPPING SWING...3137
H-20. EXCESSIVE SHOCK WHEN STOPPING SWING...3138
H-21. EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...3138
H-22. EXCESSIVE HYDRAULIC DRIFT OF SWING...3139
TROUBLESHOOTING OF WORK EQUIPMENT AUTOMATIC CONTROL SYSTEM (W-MODE) [LOADING SHOVEL]...3140
METHOD OF USING TROUBLESHOOTING FLOWCHART...3141
ABNORMALITY JUDGEMENT STANDARDS FOR SELF-DIAGNOSTIC SYSTEM...3142
TROUBLESHOOTING...3143
W-1. IN ARC DIGGING MODE (AUTO LEVEL DIGGING SWITCH OFF), HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION IS CARRIED OUT...3146
W-2. IN HORIZONTAL DIGGING MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING...3147
W-3. IN HORIZONTAL DIGGING MODE (BUCKET ANGLE REVISE SWITCH OFF),BUCKET ANGLE COMPENSATION IS CARRIED OUT...3154
W-4. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT HORIZONTAL DIGGING BUT DOES NOT CARRY OUT BUCKET ANGLE COMPENSATION...3155
W-5. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, CARRIES OUT BUCKET ANGLE COMPENSATION BUT DOES NOT CARRY OUT HORIZONTAL DIGGING...3158
W-6. IN HORIZONTAL DIGGING + BUCKET ANGLE COMPENSATION MODE, DOES NOT CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION...3160
W-7. IMPOSSIBLE TO CARRY OUT HORIZONTAL DIGGING OR BUCKET ANGLE COMPENSATION...3167
30 DISASSEMBLY AND ASSEMBLY...3168
METHOD OF USING MANUAL...3170
PRECAUTIONS WHEN CARRYING OUT OPERATION...3172
SPECIAL TOOL LIST...3174
SKETCHES OF SPECIAL TOOLS...3177
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP...3180
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY...3183
REMOVAL AND INSTALLATION OF NOZZLE TIP...3186
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL...3188
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...3190
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY...3195
REMOVAL AND INSTALLATION OF FUEL COOLER ASSEMBLY...3200
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY...3201
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...3202
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY...3203
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY...3204
REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY...3206
REMOVAL AND INSTALLATION OF PTO ASSEMBLY...3210
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY...3213
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY...3215
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY...3217
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY...3218
REMOVAL AND INSTALLATION OF TRAVEL MOTOR BRAKE VALVE ASSEMBLY...3219
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY...3220
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMLY...3228
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...3229
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY...3230
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY...3231
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY ...3232
REMOVAL AND INSTALLATION OF IDLER CUSHION CYLINDER ASSEMBLY...3240
DISASSEMBLY AND ASSEMBLY OF IDLER CUSHION CYLINDER ASSEMBLY...3241
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY...3242
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY...3243
REMOVAL AND INSTALLATION OF FRONT IDLER ASSEMBLY...3245
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY...3246
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY...3248
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY...3249
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY...3251
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY...3252
REMOVAL AND INSTALLATION OF CONTROLPTO LUBRICATION PUMP ASSEMBLY...3254
REMOVAL AND INSTALLATION OF SWING PUMP ASSEMBLY...3255
REMOVAL AND INSTALLATION OF NO.1, 3 PUMP ASSEMBLY...3256
REMOVAL AND INSTALLATION OF NO.2, 4 PUMP ASSEMBLY...3257
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY...3258
REMOVAL AND INSTALLATION OF PILOT RELIEF VALVE ASSEMBLY...3259
DISASSEMBLY AND ASSEMBLY OF PILOT RELIEF VALVE ASSEMBLY...3260
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (FOR SWING)...3261
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY (FOR WORK EQUIPMENT, TRAVEL)...3262
REMOVAL AND INSTALLATION OF SWING CONTROL VALVE ASSEMBLY...3263
DISASSEMBLY AND ASSEMBLY OF SWING CONTROL VALVE ASSEMBLY...3264
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY...3266
REMOVAL AND INSTALLATION OF CO, NC VALVE ASSEMBLY...3270
REMOVAL AND INSTALLATION OF SERVO VALVE ASSEMBLY...3271
REMOVAL AND INSTALLATION OF TVC VALVE ASSEMBLY...3272
REMOVAL AND INSTALLATION OF PPC VALVE ASSEMBLY (FOR TRAVEL)...3273
DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY (FOR TRAVEL)...3274
REMOVAL AND INSTALLATION OF PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)...3275
DISASSEMBLY AND ASSEMBLY OF PPC VALVE ASSEMBLY (FOR WORK EQUIPMENT, SWING)...3276
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY...3277
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY...3279
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY...3281
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY...3282
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY...3283
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY...3284
REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY...3285
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...3287
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...3294
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY...3298
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY...3299
REMOVAL AND INSTALLATION OF ARM ASSEMBLY...3301
REMOVAL AND INSTALLATION OF ARM ASSEMBLY...3302
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY...3304
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY...3306
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY ...3308
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...3309
REMOVAL AND INSTALLATION OF VHMS CONTROLLER...3311
90 OTHERS...3313
LOCATIONS OF CONNECTORS (WHOLE MACHINE-1/12)...3314
LOCATIONS OF CONNECTORS (WHOLE MACHINE-2/12)...3315
LOCATIONS OF CONNECTORS (WHOLE MACHINE-3/12)...3316
LOCATIONS OF CONNECTORS (WHOLE MACHINE-4/12)...3317
LOCATIONS OF CONNECTORS (WHOLE MACHINE-5/12)...3318
LOCATIONS OF CONNECTORS (WHOLE MACHINE-6/12)...3319
LOCATIONS OF CONNECTORS (WHOLE MACHINE-7/12)...3320
LOCATIONS OF CONNECTORS (WHOLE MACHINE-8/12)...3321
LOCATIONS OF CONNECTORS (WHOLE MACHINE-9/12)...3322
LOCATIONS OF CONNECTORS (WHOLE MACHINE-10/12)...3323
LOCATIONS OF CONNECTORS (WHOLE MACHINE-11/12)...3324
LOCATIONS OF CONNECTORS (WHOLE MACHINE-12/12)...3325
LOCATIONS OF CONNECTORS (AROUND CONTROL)...3326
LOCATIONS OF CONNECTORS (OPERATOR'S CAB-1/2)...3327
LOCATIONS OF CONNECTORS (OPERATOR'S CAB-2/2)...3328
LOCATIONS OF CONNECTORS (AROUND LADDER)...3329
LOCATIONS OF CONNECTORS (RELATED TO AUTO GREASE SYSTEM)...3330
LOCATIONS OF CONNECTORS (FRONT ENGINE)...3331
LOCATIONS OF CONNECTORS (REAR ENGINE)...3332
HYDRAULIC CIRCUIT DIAGRAM (BACK HOE)...3333
HYDRAULIC CIRCUIT DIAGRAM (LOADING SHOVEL)...3335
ELECTRICAL CIRCUIT DIAGRAM (1/7)...3337
ELECTRICAL CIRCUIT DIAGRAM (2/7)...3338
ELECTRICAL CIRCUIT DIAGRAM (3/7)...3339
ELECTRICAL CIRCUIT DIAGRAM (4/7)...3340
ELECTRICAL CIRCUIT DIAGRAM (5/7)...3341
ELECTRICAL CIRCUIT DIAGRAM (6/7)...3342
ELECTRICAL CIRCUIT DIAGRAM (7/7)...3343
TEN00051-00 - Hydraulic Excavator GALEO PC1800-6 Operation & Maintenance Manual...3344
COVER...3344
FOREWORD...3345
FOREWORD...3346
SAFETY INFORMATION...3349
INTRODUCTION...3351
DIRECTIONS OF MACHINE...3351
PRODUCT INFORMATION...3352
MACHINE SERIAL NUMBER PLATE AND ITS LOCATION...3352
ENGINE SERIAL NUMBER PLATE AND ITS LOCATION...3352
EMISSION CONTROL INFORMATION LABEL AND ITS LOCATION...3353
SERVICE METER LOCATION...3353
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR...3354
CONTENTS...3355
SAFETY...3359
SAFETY INFORMATION...3360
POSITION FOR ATTACHING SAFETY LABELS...3362
POSITION FOR ATTACHING SAFETY LABELS...3363
SAFETY LABELS...3364
SAFETY INFORMATION...3368
SAFETY RULES...3368
IF ABNORMALITIES ARE FOUND...3368
WORKING WEAR AND PERSONAL PROTECTIVE ITEMS...3368
FIRE EXTINGUISHER AND FIRST AID KIT...3368
SAFETY EQUIPMENT...3369
KEEP MACHINE CLEAN...3369
KEEP OPERATOR'S COMPARTMENT CLEAN...3369
LEAVING OPERATOR'S SEAT WITH LOCK...3369
HANDRAILS AND STEPS...3370
MOUNTING AND DISMOUNTING...3371
NO PERSONS ON ATTACHMENTS...3371
BURN PREVENTION...3371
FIRE PREVENTION AND EXPLOSION PREVENTION...3372
ACTION IF FIRE OCCURS...3373
WINDSHIELD WASHER FLUID...3373
FALLING OBJECTS, FLYING OBJECTS AND INTRUDING OBJECTS PREVENTION...3373
ATTACHMENT INSTALLATION...3373
ATTACHMENT COMBINATIONS...3374
CAB WINDOW GLASSES...3374
UNAUTHORIZED MODIFICATIONS...3374
SAFETY AT JOBSITE...3374
WORKING ON LOOSE GROUND...3375
DISTANCE TO HIGH VOLTAGE CABLES...3375
ENSURE GOOD VISIBILITY...3375
VENTILATION FOR ENCLOSED AREA...3376
SIGNALMANS SIGNAL AND SIGNS...3376
EMERGENCY EXIT FROM OPERATORS CAB...3376
ASBESTOS DUST HAZARD PREVENTION...3376
SAFETY MACHINE OPERATION...3377
STARTING ENGINE...3377
CHECKS BEFORE STARTING ENGINE...3377
SAFETY RULES FOR STARTING ENGINE...3378
STARTING ENGINE IN COLD WEATHER...3378
OPERATION...3379
CHECKS AFTER STARTING ENGINE...3379
SAFETY RULES FOR CHANGING MACHINE DIRECTIONS...3379
SAFETY RULES FOR TRAVELING...3380
TRAVELING ON SLOPES...3381
OPERATIONS ON SLOPES...3382
PROHIBITED OPERATIONS...3382
OPERATIONS ON SNOW...3384
PARKING MACHINE...3384
TRANSPORTATION...3385
SHIPPING THE MACHINE...3385
BATTERY...3386
BATTERY HAZARD PREVENTION...3386
STARTING ENGINE WITH BOOSTER CABLES...3387
TOWING...3388
SAFETY RULES FOR TOWING...3388
LIFTING OBJECTS WITH BUCKET...3389
SAFETY RULES FOR LIFTING OBJECTS...3389
SAFETY MAINTENANCE INFORMATION...3390
WARNING TAG...3390
KEEP WORK PLACE CLEAN AND TIDY...3390
APPOINT LEADER WHEN WORKING WITH OTHERS...3390
STOP ENGINE BEFORE CARRYING OUT MAINTENANCE...3391
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING...3392
PROPER TOOLS...3392
ACCUMULATOR...3393
PERSONNEL...3393
ATTACHMENTS...3393
WORK UNDER THE MACHINE...3393
NOISE...3394
WHEN USING HAMMER...3394
WELDING WORKS...3394
REMOVING BATTERY TERMINALS...3394
SAFETY FIRST WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION...3395
DO NOT DISASSEMBLE RECOIL SPRINGS...3395
SAFETY RULES FOR HIGH-PRESSURE OIL...3395
PRECAUTION FOR HIGH FUEL PRESSURE...3396
SAFETY HANDLING HIGH-PRESSURE HOSES...3396
PRECAUTION FOR HIGH VOLTAGE...3396
WASTE MATERIALS...3396
AIR CONDITIONER MAINTENANCE...3397
COMPRESSED AIR...3397
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...3397
OPERATION...3399
GENERAL VIEW...3400
GENERAL VIEW OF MACHINE...3400
GENERAL VIEW OF CONTROLS AND GAUGES...3401
EXPLANATION OF COMPONENTS...3403
MACHINE MONITOR...3403
CGC MONITOR...3417
SWITCHES...3455
LAMP...3466
CONTROL LEVERS, PEDALS...3470
DOOR LOCK...3474
POCKET...3474
EMERGENCY ESCAPE HAMMER...3474
EMERGENCY ESCAPE LADDER...3475
FIRE EXTINGUISHER...3475
CAP, COVER WITH LOCK...3476
ASHTRAY...3476
HANDLING AIR CONDITIONER...3477
RADIO...3485
FUSE...3489
CIRCUIT BREAKER...3490
CONTROLLER (COMPUTER)...3493
TOOLBOX...3494
HANDLING GREASE PUMP AND GREASE GUN...3494
HANDLING ACCUMULATOR...3498
ORBCOMM CONTROLLER...3499
MACHINE OPERATIONS AND CONTROLS...3500
BEFORE STARTING ENGINE...3500
STARTING ENGINE...3521
AFTER STARTING ENGINE...3526
IN COLD AREAS...3530
STOPPING THE ENGINE...3533
CHECK AFTER SHUT OFF ENGINE...3536
MACHINE OPERATION...3537
STEERING THE MACHINE...3541
SWINGING...3543
WORK EQUIPMENT CONTROLS AND OPERATIONS...3544
HANDLING WORKING MODE...3545
PROHIBITED OPERATIONS...3546
GENERAL OPERATION INFORMATION...3548
TRAVELING ON SLOPES...3549
ESCAPE FROM MUD...3551
RECOMMENDED APPLICATIONS...3552
REPLACEMENT AND INVERSION OF BUCKET...3553
PARKING MACHINE...3555
CHECK AFTER FINISHING WORK...3556
LOCKING...3557
TRANSPORTATION...3558
PRECAUTIONS FOR TRANSPORTATION...3558
LIFTING MACHINE...3559
PARTS FOR TRANSPORT...3559
COLD WEATHER OPERATION...3560
COLD WEATHER OPERATION INFORMATION...3560
AFTER DAILY WORK COMPLETION...3562
AFTER COLD WEATHER SEASON...3562
LONG TERM STORAGE...3563
BEFORE STORAGE...3563
DURING STORAGE...3563
AFTER STORAGE...3564
TROUBLESHOOTING...3565
RUNNING OUT OF FUEL...3565
PHENOMENA THAT ARE NOT FAILURES...3566
TOWING THE MACHINE...3567
PRECAUTIONS ON PARTICULAR JOBSITES...3567
DISCHARGED BATTERY...3568
OTHER TROUBLE...3572
MAINTENANCE...3577
MAINTENANCE INFORMATION...3578
LUBRICANTS, COOLANT AND FILTERS...3581
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC...3581
ELECTRIC SYSTEM MAINTENANCE...3584
WEAR PARTS LIST...3585
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...3586
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS...3586
TIGHTENING TORQUE SPECIFICATIONS...3590
TIGHTENING TORQUE LIST...3590
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...3591
SAFETY CRITICAL PARTS...3592
MAINTENANCE SCHEDULE...3594
MAINTENANCE SCHEDULE CHART...3594
MAINTENANCE PROCEDURE...3597
INITIAL 100 HOURS MAINTENANCE (ONLY AFTER THE FIRST 100 HOURS)...3597
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER...3658
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS)...3597
CHANGE OIL IN SWING MACHINERY CASE...3667
CHANGE OIL IN PTO CASE...3669
CHANGE OIL IN FINAL DRIVE CASE...3671
WHEN REQUIRED...3598
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT...3598
CLEAN INSIDE OF COOLING SYSTEM...3601
CHECK AND TIGHTEN TRACK SHOE BOLTS...3605
CHECK AND ADJUST TRACK TENSION...3606
CHECK ELECTRICAL INTAKE AIR HEATER...3609
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)...3610
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)...3613
ADJUST BUCKET CLEARANCE...3614
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID...3615
CHECK AND ADJUST AIR CONDITIONER...3616
CLEANING, REMOVING DIRT FROM LINE FILTER...3617
REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER...3618
GREASE LADDER...3619
INSPECT SEALANT AROUND ENGINE COOLING SYSTEM...3620
CHECK FOR LOOSE AFTERCOOLER HOSE CLAMPS...3621
PROCEDURE FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT...3621
METHOD FOR RELEASING INTERNAL PRESSURE IN HYDRAULIC CIRCUIT...3629
CHECK BEFORE STARTING...3631
EVERY 10 HOURS MAINTENANCE...3632
LUBRICATING...3632
EVERY 100 HOURS MAINTENANCE...3636
CHECK OIL LEVEL IN SWING MACHINERY CASE...3636
EVERY 250 HOURS MAINTENANCE...3637
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL...3637
CHECK LEVEL OF BATTERY ELECTROLYTE...3638
REPLACE FILTER ELEMENT OF HYDRAULIC TANK BREATHER...3640
CHECK, WASH FUEL STRAINER...3641
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS...3642
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST...3643
CHECK ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT...3645
EVERY 500 HOURS MAINTENANCE...3647
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE...3647
REPLACE FUEL FILTER CARTRIDGE...3650
CLEAN PILOT FILTER STRAINER...3652
CLEAN HYDRAULIC FILTER STRAINER FOR AUTO GREASING DRIVE...3652
CHANGE HYDRAULIC FILTER ELEMENT...3653
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS, FUEL COOLER AND AFTER COOLER FINS...3654
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM...3656
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER...3658
CHECK, REPLACE, ADJUST FAN BELT...3659
CHECK, REPLACE HYDRAULIC PUMP DRAIN FILTER CARTRIDGE...3660
REPLACING SWING MOTOR DRAIN FILTER CARTRIDGE...3661
REPLACING TRAVEL MOTOR DRAIN FILTER CARTRIDGE...3662
REPLACE ADDITIONAL FUEL FILTER CARTRIDGE...3663
EVERY 1000 HOURS MAINTENANCE...3665
REPLACE FUEL FILTER CARTRIDGE...3665
CHANGE OIL IN SWING MACHINERY CASE...3667
CHANGE OIL IN PTO CASE...3669
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER...3669
REPLACE CORROSION RESISTOR CARTRIDGE...3670
INSPECTION OF WELDED STRUCTURE AFTER INITIAL 4000 HOURS SERVICE...3670
GREASING FAN PULLEY ASSEMBLY, TENSION PULLEY ASSEMBLY...3670
EVERY 2000 HOURS MAINTENANCE...3671
CHANGE OIL IN FINAL DRIVE CASE...3671
CHANGE OIL IN HYDRAULIC TANK, WASH STRAINER...3672
CHECK SWING PINION GREASE LEVEL, ADD GREASE...3675
CLEAN ENGINE BREATHER...3675
CLEAN, CHECK TURBOCHARGER...3675
CHECK ALTERNATOR AND STARTING MOTOR...3675
CHECK ENGINE VALVE CLEARANCES, ADJUST...3676
CHECK INJECTOR...3676
EVERY 4000 HOURS MAINTENENCE...3677
CHECK WATER PUMP...3677
CHECK VIBRATION DAMPER...3677
CHECK FAN PULLEY AND TENSION PULLEY...3677
REPLACE INJECTOR NOZZLE ASSEMBLY...3677
CHECK FOR LOOSENESS OF HIGH-PRESSURE CLAMP, HARDENING OF RUBBER...3678
CHECK FOR MISSING FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER...3679
CHECK, ADJUST AIR COMPRESSOR...3679
CHECK WELDED STRUCTURE...3680
EVERY 5000 HOURS MAINTENANCE...3683
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER...3683
EVERY 8000 HOURS MAINTENANCE...3686
REPLACE HIGH-PRESSURE PIPING CLAMP...3686
REPLACE FUEL SPRAY PREVENTION CAP...3686
SPECIFICATIONS...3687
SPECIFICATIONS...3688
ATTACHMENTS AND OPTIONS...3691
GENERAL PRECAUTIONS...3692
PRECAUTIONS RELATED TO SAFETY...3692
PRECAUTIONS WHEN INSTALLING ATTACHMENTS...3694
ATTACHMENT GUIDE...3695
COMBINATIONS OF WORK EQUIPMENT...3695
PROTECTIVE GUARD...3696
AUTO GREASING SYSTEM...3697
LOADING SHOVEL...3701
GENERAL VIEW...3702
GENERAL VIEW OF MACHINE...3702
GENERAL VIEW OF CONTROLS AND GAUGES...3703
EXPLANATION OF COMPONENTS...3704
SWITCHES...3704
CONTROL BOX...3705
OPERATIONS...3706
OPERATION OF WORK EQUIPMENT...3706
PRECAUTIONS DURING OPERATION...3708
EXCAVATOR WORK...3712
PRECAUTIONS WHEN DISASSEMBLING MACHINE...3713
RELEASING PRESSURE...3713
TROUBLESHOOTING...3714
WORK EQUIPMENT AUTOMATIC CONTROL CONTROLLER...3714
TRANSPORTATION...3715
MACHINE CONFIGURATION FOR TRANSPORT...3715
MAINTENANCE SCHEDULE...3716
EVERY 10 HOURS MAINTENANCE...3716
SPECIFICATION...3725
COMBINATION OF WORK EQUIPMENT...3727
COMBINATION OF WORK EQUIPMENT...3727
INDEX...3729
