Komatsu Hydraulic Excavator PC1100, PC1100LC, PC1100SP Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,233 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEAM018304T-00 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 avance Operation & Maintenance Manual.pdf
SEAW001100 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 Field Assembly Manual.pdf
SEBM014207 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 Shop Manual.pdf
MAIN SECTIONS
SEAM018304T-00 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 avance Operation & Maintenance Manual....2
COVER....2
1. FOREWORD....3
2. SAFETY INFORMATION....6
3. INTRODUCTION....7
4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR....8
5. CONTENTS....9
SAFETY....13
6. GENERAL PRECAUTIONS....14
7. PRECAUTIONS DURING OPERATION....22
7.1 BEFORE STARTING ENGINE....22
7.2 AFTER STARTING ENGINE....23
7.3 TRANSPORTATION....29
7.4 BATTERY....30
7.5 TOWING....32
8. SAFETY MAINTENANCE INFORMATION....33
8.1 BEFORE CARRYING OUT MAINTENANCE....33
9. POSITION FOR ATTACHING SAFETY LABELS....39
9.1 POSITION FOR ATTACHING SAFETY LABELS....39
9.2 CONTENT AND USE OF WARNING PLATES....43
OPERATION....44
10. GENERAL VIEW....45
10.1 GENERAL VIEW OF MACHINE....45
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....46
11. EXPLANATION OF COMPONENTS....47
11.1 MACHINE MONITOR....47
11.2 SWITCHES....59
11.3 CONTROL LEVERS,PEDALS....65
11.4 DOOR LOCK....67
11.5 CAP,COVER WITH LOCK....68
11.6 EMERGENCY EXIT FROM OPERATOR'S CAB....69
11.7 HOT AND COOL BOX....69
11.8 LUGGAGE BOX....69
11.9 ASHTRAY....69
11.10 POWER SUPPLY SOCKET....69
11.11 FUSE....70
11.12 FUSIBLE LINK....71
11.13 CONTROLLERS....71
11.14 TOOL HOLDER (CLOTH BAG)....71
11.15 HANDLING GREASE PUMP....71
11.16 HANDLING ACCUMULATOR....74
12. OPERATION....76
12.1 CHECK BEFORE STARTING ENGINE....76
12.2 STARTING ENGINE....89
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....92
12.4 MOVING MACHINE OFF....99
12.5 STEERING MACHINE....102
12.6 STOPPING MACHINE....104
12.7 SWINGING....105
12.8 OPERATION OF WORK EQUIPMENT....106
12.9 HANDLING WORKING MODE....107
12.10 PROHIBITIONS FOR OPERATION....108
12.11 PRECAUTIONS FOR OPERATION....110
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS....111
12.13 HOW TO ESCAPE FROM MUD....113
12.14 WORK POSSIBLE USING HYDRAULIC....114
12.15 REPLACEMENT OF BUCKET....115
12.16 PARKING MACHINE....117
12.17 CHECK AFTER FINISHING WORK....118
12.18 STOPPING ENGINE....119
12.19 CHECK AFTER STOPPING ENGINE....120
12.20 LOCKING....120
13. TRANSPORTATION....121
13.1 PRECAUTIONS FOR TRANSPORTATION....121
13.2 METHOD OF LIFTING MACHINE....121
13.3 PRECAUTIONS FOR LOADING....123
13.4 TRANSPORTATION....124
14. COLD WEATHER OPERATION....130
14.1 PRECAUTIONS FOR LOW TEMPERATURE....130
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....132
14.3 AFTER COLD WEATHER....132
15. LONG-TERM STORAGE....133
15.1 BEFORE STORAGE....133
15.2 DURING STORAGE....134
15.3 AFTER STORAGE....134
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE....134
16. TROUBLESHOOTING....135
16.1 WHEN MACHINE RUNS OUT OF FUEL....135
16.2 PHENOMENA THAT ARE NOT FAILURES ....135
16.3 METHOD OF TOWING MACHINE....135
16.4 PRECAUTIONS ON PARTICULAR JOBSITES....135
16.5 IF BATTERY IS DISCHARGED....136
16.6 OTHER TROUBLE....141
MAINTENANCE....147
17. GUIDES TO MAINTENANCE....148
18. OUTLINES OF SERVICE....150
18.1 OUTLINE OF OIL,FUEL,COOLANT....150
18.2 OUTLINE OF ELECTRIC SYSTEM....154
18.3 OUTLINE OF HYDRAULIC SYSTEM....155
19. WEAR PARTS LIST....156
20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....157
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....161
21.1 INTRODUCTION OF NECESSARY TOOLS....161
21.2 TORQUE LIST....162
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....163
23. MAINTENANCE SCHEDULE CHART....165
23.1 MAINTENANCE SCHEDULE CHART....165
24. SERVICE PROCEDURE....169
24.1 INITIAL 100 HOURS SERVICE....169
24.2 INITIAL 250 HOURS SERVICE....169
24.3 WHEN REQUIRED....170
24.4 CHECK BEFORE STARTING....191
24.5 EVERY 10 HOURS SERVICE....192
24.6 EVERY 100 HOURS SERVICE....194
24.7 EVERY 250 HOURS SERVICE....195
24.8 EVERY 500 HOURS SERVICE....206
24.9 EVERY 1000 HOURS SERVICE....214
24.10 EVERY 2000 HOURS SERVICE....221
24.11 EVERY 4000 HOURS SERVICE....225
SPECIFICATIONS....226
25. SPECIFICATIONS....227
OPTION PARTS,ATTACHMENTS....233
26. GENERAL PRECAUTIONS....234
26.1 PRECAUTIONS REPLATED TO SAFETY....234
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....235
27. HANDLING BUCKET WITH HOOK....236
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK....236
27.2 PROHIBITED OPERATIONS....236
27.3 PRECAUTIONS DURING OPERATIONS....236
28. USING SEAT BELT....237
28.1 SEAT BELT....237
29. INTRODUCTION OF OPTIONAL PARTS,ATTACHMENTS....239
29.1 COMBINATIONS OF WORK EQUIPMENT....239
29.2 SELECTION OF TRACK SHOES....241
30. HANDLING AIR CONDITIONER....243
30.1 HANDLING AIR CONDITIONER....243
31. HANDLING CAR RADIO....246
31.1 HANDLING CAR RADIO....246
32. AUTO-GREASING SYSTEM....251
32.1 GENERAL LOCATIONS....251
32.2 EXPLANATION OF EQUIPMENT....252
32.3 GREASING POINTS FOR AUTO-GREASING SYSTEM....254
32.4 OPERATION....255
32.5 TROUBLESHOOTING....258
32.6 MAINTENANCE....259
LOADING SHOVEL....265
33. GENERAL LOCATIONS....266
34. INSTRUMENTS AND CONTROLS....267
34.1 SWITCH....267
35. OPERATIONS....269
35.1 OPERATION OF WORK EQUIPMENT....269
36. PRECAUTIONS FOR MACHINE OPERATION....271
36.1 PRECAUTIONS DURING OPERATION....271
37. PRECAUTIONS WHEN DISASSEMBLING MACHINE....274
38. MAINTENANCE....275
38.1 CHECK BEFORE STARTING....275
38.2 EVERY 10 HOURS SERVICE....276
38.3 EVERY 2000 HOURS SERVICE....279
39. EXCAVATOR WORK....281
40. TRANSPORTATION....282
40.1 TRANSPORTATION....282
41. CONSUMABLE PARTS LIST....284
42. SPECIFICATIONS....285
43. COMBINATIONS OF WORK EQUIPMENT....288
43.1 COMBINATIONS OF WORK EQUIPMENT....288
SEAW001100 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 Field Assembly Manual....290
COVER....290
CONTENTS ....291
Outline of work processes....292
Tool list....293
Transportation posture, dimensions and weights of main components ....294
Outline of size of work place ....299
Precautions during operation ....300
List of parts sent individually....304
Detailed procedure for parts assembly work....313
Procedure for flushing hydraulic circuit....350
Procedure for bleeding air from hydraulic circuit....354
Procedure for adjusting track link....358
Procedure for inspecting oil, water, fuel....361
APPENDIX....369
FIELD ASSEMBLY INSPECTION REPORT....369
SEBM014207 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 Shop Manual....395
COVER....395
CONTENTS....396
01 GENERAL....422
SPECIFICATION DRAWINGS....423
SPECIFICATIONS....426
WEIGHT TABLE....430
FUEL, COOLANT AND LUBRICANTS....434
10 STRUCTURE AND FUNCTION....436
PTO....437
PTO LUBRICATION SYSTEM....438
RADIATOR, OIL COOLER, AFTERCOOLER....439
POWER TRAIN....441
SWING MACHINERY....443
SWING CIRCLE....444
FINAL DRIVE....445
TRACK FRAME....446
TRACE SHOE....447
AIR PIPING DIAGRAM....448
AIR CIRCUIT DIAGRAM....449
AIR GOVERNOR....450
AIR TANK....450
SAFETY VALVE....451
HORN VALVE....451
GREASE PUMP....452
HYDRAULIC PIPING DRAWING....453
HYDRAULIC CIRCUIT DIAGRAM....458
HYDRAULIC TANK....459
HYDRAULIC PUMP....460
NO.1 PUMP....461
NO.2 PUMP....484
NO.3 PUMP....489
LINE OIL FILTER....498
PILOT OIL FILTER....499
RETURN OIL FILTER....500
DRAIN OIL FILTER ....501
L.H.5-SPOOL CONTROL VALVE....502
R.H.4-SPOOL CONTROL VALVE....504
SWING 4-SPOOL CONTROL VALVE....506
STRAIGHT-TRAVEL VALVE....508
BOOM LOWER REGENERATION VALVE....511
SWING MOTOR....514
CENTER SWIVEL JOINT....516
TRAVEL MOTOR....517
PPC CONTROL RELIEF VALVE....527
SAFETY LOCK VALVE....528
ACCUMULATOR....529
VALVE CONTROL....530
WORK EQUIMENT, SWING PPC VALVE....531
TRAVLE PPC VALVE....535
SOLENOID VALVES....539
WORK EQUIPMENT....541
AIR CONDITIONER....542
ACTUAL ELECTRIC WIRING DIAGRAM....543
ELECTRICAL CIRCUIT DIAGRAM....548
ENGINE CONTROL....549
MACHINE CONTROL SYSTEM....559
MACHINE MONITOR SYSTEM....588
20 TESTING AND ADJUSTING....595
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS....596
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....597
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....614
TESTING AND ADJUSTING....629
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....630
MEASURING ENGINE SPEED....631
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....632
MEASURING EXHAUST TEMPERATURE....633
MEASURING EXHAUST COLOR....634
ADJUSTING VALVE CLEARANCE....635
MEASURING COMPRESSION PRESSURE....636
MEASURING BLOW-BY PRESSURE....637
TESTING AND ADJUSTING FUEL INJECTION TIMING....638
MEASURING ENGINE OIL PRESSURE....639
TESTING AND ADJUSTING FAN BELT TENSION....640
TESTING AND ADJUSTING ALTERNATOR BELT TENSION....640
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR....641
ADJUSTING ENGINE SPEED SENSOR....641
TESTING CLEARANCE OF SWING CIRCLE BEARING....642
MEASURING WEAR OF SPROCKET....643
TESTING AND ADJUSTING TRACK SHOE TENSION ....644
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....645
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE....650
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE....651
MEASURING SERVO PISTON STROKE....659
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE....660
TESTING SOLENOID VALVE OUTPUT PRESSURE....664
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE....666
TESTING TRAVEL DEVIATION....667
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT....668
MEASURING OIL LEAKAGE....669
BLEEDING AIR....673
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....675
TROUBLESHOOTING....676
POINTS TO REMEMBER WHEN TROUBLESHOOTING....677
SEQUENCE OF EVENTS IN TROUBLESHOOTING....678
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....679
CHECKS BEFORE TROUBLESHOOTING....687
CONNECTOR TYPES AND MOUNTING LOCATIONS....688
COONECTION TABLE FOR CONNECTIOR PIN NUMBERS....694
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....705
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL....706
ORDER OF TROUBLESHOOTING WHEN CARRYING OUT TROUBLESHOOTING....721
METHOD OF USING JUDGEMENT TABLE....723
METHOD OF USING TROUBLESHOOTING CHARTS....725
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)....727
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....728
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM....730
N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY....731
N-2 [E117, E218 OCCUR AT SAME TIME] ENGINE CONTROLLER COMMUNICATION ABNORMALITY....733
N-3 [E118, E507 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY....735
TROUBLESHOOTING OF ENGINE CONTROLLER & APS CONTROLLER SYSTEM (E MODE)....737
JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS....738
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM....741
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....742
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM....750
E-1 [E501] ABNORMALITY IN ENGINE CONTROLLER POWER SOURCE SYSTEM IS DISPLAYED....754
E-2 [E502] ABNORMALITY IN ENGINE CONTROLLER IS DISPLAYED....755
E-3 [E521] DISCONNECTION IN GOVERNOR CONTROL SOLENOID SYSTEM IS DISPLAYED....756
E-4 [E522] SHORT CIRCUIT IN GOVERNOR CONTROL SOLENOID SYSTEM IS DISPLAYED....757
E-5 [E531] ABNORMALITY IN GOVERNOR SERVO IS DISPLAYED....758
E-6 [E537] ABNORMALITY IN CONTORLLER SOLENOID POWER SUPPLE SYSTEM IS DISPLAYED....759
E-7 [E508] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM IS DISPLAYED....760
E-8 [E511] ABNORMALITY IN RACK SENSOR SIGNAL SYSTEM IS DISPLAYED....761
E-9 [E515] DISCONNECTION IN PRESTROKE CONTROL SOLENOID SYSTEM IS DISPLAYED....762
E-10 [E516] SHORT CIRCUIT IN PRESTROKE CONCTOR SOLENOID SYSTEM IS DISPLAYED....763
E-11 [E513] ABNORMALITY IN ENGINE SPEED (1) SYSTEM IS DISPLAYED....764
E-12 [E514] ABNORMALITY IN ENGINE SPEED SENSOR (2) SYSTEM IS DISPLAYED....765
E-13 [E525] DISCONNECTION IN GOVERNOR CUT RELAY SYSTEM IS DISPLAYED....766
E-14 [E526] SHORT CIRCUIT IN GOVERNOR CUT RELAY SYSTEM IS DISPLAYED....767
E-15 [E505] ABNORMALITY IN FUEL CONTROL DIAL VOLTAGE IS DISPLAYED....768
E-16 [E503] MISTAKEN CONNECTION OF CONNECTOR IS DISPLAYED....769
E-17 [E504] ENGINE OVERRUN IS DISPLAYED....770
E-18 [E535] ABNORMALITY IN ENGINE CONTORLLER BACKUP POWER SUPPLE SYSTEM IS DISPLAYED....771
E-19 [E536] ABNORMALITY IN CONTROLLER POWER SUPPLE SYSTEM IS DISPLAYED....772
E-20 ENGINE DOES NOT START....773
E-21 ENGINE DOES NOT STOP....776
E-22 DEFECTIVE ACTUATION OF APS....777
E-23 [E534] ABNORMALITY IN MACHINE SELECTION INPUT TO ENGINE CONTROLLER IS DISPLAYED....784
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....785
METHOD OF USING TROUBLESHOOTING CHARTS....786
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....790
S-2 ENGINE DOES NOT START....791
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)....793
S-4 ENGINE STOPS DURING OPERATIONS....794
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)....795
S-6 ENGINE LACKS OUTPUT(NO POWER)....796
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)....797
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)....798
S-9 OIL BECOMES CONTAMINATED QUICKLY....799
S-10 FUEL CONSUMPTION IS EXCESSIVE....800
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN ....801
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)....802
S-13 OIL LEVEL RISES....803
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)....804
S-15 ABNORMAL NOISE IS MADE....805
S-16 VIBRATION IS EXCESSIVE....806
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM(C MODE)....807
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC(MECHANICAL)RELATED PARTS....808
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM....811
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....812
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM....818
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM(CONTROLLER LED IS OFF)....820
C-2 [E232] SHORT CIRCUIT IN TVC SOLENOID SYSTEM IS DISPLAYED....821
C-3 [E233] DISCONNECTION IN TVC SOLENOID SYSTEM IS DISPLAYED....823
C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID RELAY SYSTEM IS DISPLAYED....825
C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID RELAY SYSTEM IS DISPLAYED....827
C-6 [E201] SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED....829
C-7 [E211] DISCONNECTION IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED....830
C-8 [E202] SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED....831
C-9 [E212] DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED....832
C-10 [E204] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED....833
C-11 [E214] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED....834
C-12 [E205] SHORT CIRCUIT IN SWING PRIORITY SOLENOID SYSTEM IS DISPLAYED....835
C-13 [E215] DISCONNECTION IN SWING PRIORITY SOLENOID SYSTEM IS DISPLAYED....836
C-14 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED....837
C-15 [E216] DISCONNECTION IN TRAVELE SPEED SOLENOID SYSTEM IS DISPLAYED....838
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED....839
C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR(2)SYSTEM IS DISPLAYED....841
C-18 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED....842
C-19 ABNORMALITY IN SWING HOLDING BRAKE SYSTEM(NO SERVICE CODE IS DISPLAYED)....843
C-20 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM(NO SERVICE CODE IS DISPLAYED)....845
C-21 ABNORMALITY IN BOOM SHOCKLESS SOLENOID SYSTEM(NO SERVICE CODE IS DISPLAYED)....847
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTE(F MODE)....850
ELECTRICAL CIRCUIT DIAGRAM OF F MODE....851
F-1 [BIT PATTERN 20-(1)] (SWING TO RIGHT OIL PRESSURE SWITCH)DOES NOT LIGHT UP....853
F-2 [BIT PATTERN 20-(2)] (R.H.TRAVEL OIL PRESSURE SWITCH)DOES NOT LIGHT UP....854
F-3 [BIT PATTERN 20-(3)] (BOOM LOWER OIL PRESSURE SWITCH)DOES NOT LIGHT UP....855
F-4 [BIT PATTERN 20-(4)] (BOOM RAISE OIL PRESSURE SWITCH)DOES NOT LIGHT UP....856
F-5 [BIT PATTERN 20-(5)] (ARM IN OIL PRESSURE SWITCH)DOES NOT LIGHT UP....857
F-6 [BIT PATTERN 20-(6)] (ARM OUT OIL PRESSURE SWITCH)DOES NOT LIGHT UP....858
F-7 [BIT PATTERN 21-(1)] (BUCKET CURL OIL PRESSURE SWITCH)DOES NOT LIGHT UP....859
F-8 [BIT PATTERN 21-(2)] (BUCKET DUMP OIL PRESSURE SWITCH)DOES NOT LIGHT UP....860
F-9 [BIT PATTERN 21-(5)] (L.H.TRAVEL OIL PRESSURE SWITCH)DOES NOT LIGHT UP....861
F-10 [BIT PATTERN 26-(5)] (SWING TO LEFT OIL PRESSURE SWITCH)DOES NOT LIGHT UP....862
F-11 [BIT PATTERN 21-(3)] (SWING LOCK SWITCH)DOES NOT LIGHT UP....863
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE)....864
TABLE OF FALIURE MODES AND CAUSES....865
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM(H MODE)....867
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER....872
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS....874
H-3 NO WORK EQUIPMENT,TRAVEL,SEWING MOVE....876
H-4 ABNORMAL NOISE GENERATED(FORM AROUND PUMP)....877
H-5 BOOM IS SLOW OR LACKS POWER....878
H-6 ARM IS SLOW OR LACKS POWER....880
H-7 BUCKET IS SLOW OR LACKS POWER....880
H-8 BOOM DOES NOT MOVE....881
H-9 ARM DOES NOT MOVE ....881
H-10 BUCKET DOES NOT MOVE....881
H-11 EXCESSIVE HYDRAULIC DRIFT....882
H-12 EXCESSIVE TIME LAG....882
H-13 BOOM SHOCKLESS FUNCTION IS NOT ACTUATED OR CANNOT BE CANCELED....883
H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS....884
H-15 DEVIATION IS EXCESSIVE WHEN STRARTING....886
H-16 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS....887
H-17 TRAVEL SPEED IS SLOW OR LACKS POWER....887
H-18 TRAVEL DOES NOT MOVE(ONE SIDE ONLY)....888
H-19 TRAVEL SPEED DOES NOT SWITCH....889
H-20 DOES NOT SWING ....890
H-21 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR....891
H-22 IN COMPOUND OPERATIONS WITH BUCKET,SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR....892
H-23 IN COMPOUND OPERATIONS WITH BOON WHEN SWING PRIORITY IS ON,SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR....892
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING....893
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING....894
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....895
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING....895
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)....896
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....897
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM....901
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED OR [E102]ABNORMALITY IN CLOCK DATA IS DISPLAYEED....903
M-2 [E103] SHOT CIRCUIT IN BUZZER OUTPUT SYSTEM IS DISPLAYED....904
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED....905
M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED....905
M-5 [E108] ENGINE WATER TEMPERATURE 105C DETECTED IS DISPLAYED....906
M-6 WHEN STARTING SWITCH IS TURNED ON,NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS....907
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHT UP AND DO NOT GO OUT....909
M-8 WHEN STARTING SWITCH IS TURNED ON,ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM MACHINE....909
M-9 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),BASIC CHECK ITEMS FLASH....910
M-10 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),(PREHEATING MONITOR)DISPLAY IS NOT NORMAL....913
M-11 WHEN ENGINE IS STARTED,BASIC CHECK ITEMS FLASH....914
M-12 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH....916
M-13 WHEN ENGINE IS STARTED,CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH(BUT THERE IS NO ABNORMALITY IN ANY ITEM)....918
M-14 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND....923
M-15 NO ABNORMALITY IS DISPLAYED NO MONITOR BUT BUZZER SOUNDS....923
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP....924
M-17 ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE....925
M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY(GAUGE DOES NOT EVEN DISPLAY 1ST LEAVE)....925
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL....926
M-20 FUEL LEVEL GAUGE DOES NOT GIVE ANY DISPLAY(GAUGE DOSENOT EVEN DISPLAY 1ST LEVEN....926
M-21 SWING LOCK SWITCH IS TURNED ON,BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP ....927
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX),BUT (SWING LOCK MONITOR) DOES NOT FLASH....928
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING....929
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED,SERVICE METER DOES NOT GIVE DISPLAY....929
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM....930
M-26 DEFECTIVE ENGINE WATER TEMPERATURE SENSOR SYSTEM AND DEFECTIVE HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM....931
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM AND DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM....932
M-28 DEFECTIVE RADIATOR WATER LEVEL SENSOR SYSTEM....933
M-29 DEFECTIVE OPERATION OF WIPER(INCLUDING CASES WHERE[E113]IS DISPLAYED]....934
M-30 DEFECTIVE OPERATION OF WINDOW WASHER(INCLUDING CASES WHERE SERVICE CODE[E114]IS DISPLAYED)....937
30 DISASSEMBLY AND ASSEMBLY....940
METHOD OF USING MANUAL....942
PRECAUTIONS WHEN CARRYING OUT OPERATION....944
SPECIAL TOOL LIST....946
SKETCHES OF SPECIAL TOOLS....953
STARTING MOTOR ASSEMBLY....960
REMOVAL AND INSTALLATION....960
ALTERNATOR ASSEMBLY....961
REMOVAL AND INSTALLATION....961
NOZZLE HOLDER ASSEMBLY....962
REMOVAL AND INSTALLATION....962
ENGINE OIL COOLER ASSEMBLY....963
REMOVAL AND INSTALLATION....963
FUEL INJECTION PUMP ASSEMBLY....964
REMOVAL....964
INSTALLATION....965
WATER PUMP ASSEMBLY....966
REMOVAL AND INSTALLATION....966
TURBOCHARGER ASSEMBLY....967
REMOVAL AND INSTALLATION....967
THERMOSTAT ASSEMBLY....968
REMOVAL AND INSTALLATION....968
AIR COMPRESSOR ASSEMBLY....969
REMOVAL AND INSTALLATION....969
ENGINE FRONT SEAL ....970
REMOVAL AND INSTALLATION....970
ENGINE REAR SEAL ....972
REMOVAL AND INSTALLATION....972
CYLINDER HEAD ASSEMBLY....974
REMOVAL....974
INSTALLATION....978
AFTERCOOLER ASSEMBLY....980
REMOVAL AND INSTALLATION....980
RADIATOR,HYDRAULLIC COOLER ASSEMBLY....981
REMOVAL....981
INSTALLATION....982
HYDRAULIC COOLER ASSEMBLY....983
REMOVAL AND INSTALLATION....983
ENGINE,PTO,HYDRAULIC PUMP ASSEMBLY....984
REMOVAL....984
INSTALLATION....987
PTO ASSEMBLY....988
REMOVAL....988
INSTALLATION ....989
DISASSEMBLY....990
ASSEMBLY....992
FUEL TANK ASSEMBLY....994
REMOVAL AND INSTALLATION....994
FINAL DRIVE ASSEMBLY....995
REMOVAL AND INSTALLATION....995
DISASSEMBLY....996
ASSEMBLY....1000
REVOLVING FRAME ASSEMBLY....1008
REMOVAL AND INSTALLATION....1008
SWING MACHINERY ASSEMBLY....1009
REMOVAL AND INSTALLATION....1009
DISASSEMBLY....1010
ASSEMBLY....1014
SWING CIRCLE ASSEMBLY....1019
REMOVAL AND INSTALLATION....1019
TRACK SHOE ASSEMBLY....1020
REMOVAL....1020
INSTALLATION....1021
SPROCKET....1022
REMOVAL AND INSTALLATION....1022
IDLER ASSEMBLY....1023
REMOVAL AND INSTALLATION....1023
DISASSEMBLY....1024
ASSEMBLY....1026
IDLER ADJUSTMENT CYLINDER ASSEMBLY....1028
DISASSEMBLY AND ASSEMBLY....1028
RECOIL SPRING ASSEMBLY....1029
REMOVAL AND INSTALLATION....1029
DISASSEMBLY....1031
ASSEMBLY....1032
CARRIER ROLLER ASSEMBLY....1033
REMOVAL AND INSTALLATION....1033
DIAASSEMBLY....1034
ASSEMBLY....1035
TRACK ROLLER ASSEMBLY....1036
REMOVAL AND INSTALLATION....1036
DISASSEMBLY....1037
ASSEMBLY....1038
HYDRAULIC TANK ASSEMBLY....1040
REMOVAL....1040
INSTALLATION....1041
TVC VALVE ASSEMBLY....1042
REMOVAL AND INSTALLATION....1042
SERVO VALVE ASSEMBLY....1043
REMOVAL AND INSTALLATION....1043
HYDEAULIC PUMP ASSEMBLY....1044
REMOVAL AND INSTALLATION....1044
NO.1, 2 PUMP (HPV95+95)....1045
DISASSEMBLY ....1045
ASSEMBLY....1055
NO.3 PUMP (HPV160+160)....1071
DISASSEMBLY....1071
ASSEMBLY....1081
MAIN PUMP INPUT SHAFT OIL SEAL....1096
REMOVAL AND INSTALLATION....1096
MAIN RELIEF VALVE ASSEMBLY....1097
REMOVAL AND INSTALLATION....1097
DISASSEMBLY AND ASSEMBLY....1098
PILOT RELIEF VALVE ASSEMBLY....1099
REMOVAL AND INSTALLATION....1099
5-SPOOL CONTROL VALVE ASSEMBLY(NO.1)....1100
REMOVAL....1100
INSTALLATION....1101
4-SPOOL CONTROL VALVE ASSEMBLY(NO.2)....1102
REMOVAL....1102
INSTALLATION....1103
4-SPOOL CONTROL VALVE ASSEMBLY(NO.3)....1104
REMOVAL....1104
INSTALLATION ....1105
CONTROL VALVE ASSEMBLY(NO.1)....1106
DISASSEMBLY....1106
ASSEMBLY....1107
CONTROL VALVE ASSEMBLY(NO.2)....1109
DISASSEMBLY....1109
ASSEMBLY....1110
CONTROL VAVLE ASSEMBLY(NO.3)....1113
DISASSEMBLY....1113
ASSEMBLY....1114
SWING MOTOP ASSEMBLT....1117
REMOVAL AND INSTALLATION....1117
CENTER SWIVEL JOINT ASSEMBLY....1118
REMOVAL AND INSTALLATION....1118
DISASSEMBLY AND ASSEMBLY....1119
TRAVEL MOTOR ASSEMBLY....1120
REMOVAL AND INSTALLATION....1120
WORK EQUIPMENT PPC VALVE ASSEMBLY....1121
REMOVAL AND INSTALLATION....1121
DISASSEMBLY....1122
ASSEMBLY....1123
TRAVEL PPC VALVE ASSEMBLY....1124
REMOVAL AND INSTALLATION....1124
DISASSEMBLY....1125
ASSEMBLY ....1126
BUCKET CYLINDER ASSEMBLY....1127
BACKHOE....1127
REMOVAL....1127
INSTALLATION....1128
LOADING SHOVEL....1129
REMOVAL....1129
INSTALLATION....1130
ARM CYLINDER ASSEMBLY....1131
BACKHOE....1131
REMOVAL....1131
INSTALLATION....1132
LOADING....1133
REMOVAL....1133
INSTALLATION....1134
BOOM CYLINDER ASSEMBLY....1135
BACKHOE....1135
REMOVAL....1135
INSTALLATION....1136
LOADING....1137
REMOVAL....1137
INSTALLATION....1138
BOTTOM DUMP CYLINDER ASSEMBLY....1139
LOADING SHOVEL....1139
REMOVAL....1139
INSTALLATION....1140
BUCKET ASSEMBLY....1141
BACKHOE....1141
REMOVAL....1141
INSTALLATION....1142
LOADING SHOVEL....1143
REMOVAL....1143
INSTALLATION....1144
ARM ASSEMBLY....1145
BACKHOE....1145
REMOVAL....1145
INSTALLATION....1146
LOADING SHOVEL....1147
REMOVAL ....1147
INSTALLATION....1148
BOOM ASSEMBLY....1149
BACKHOE....1149
REMOVAL....1149
INSTALLATION....1150
LOADING SHOVEL....1151
REMOVAL....1151
INSTALLATION....1153
BUKET,ARM ASSEMBLY....1155
REMOVAL....1155
INSTALLATION ....1156
WORK EQUIPMENT ASSEMBLY....1157
BACKOE....1157
REMOVAL....1157
INSTALLATION....1158
LOADING SHOVEL....1159
REMOVAL ....1159
INSTALLATION....1160
CAB ASSEMBLY....1161
REMOVAL....1161
INSTALLATION....1162
COUNTERWEIGHT ASSEMBLY....1163
REMOVAL AND INSTALLATION....1163
RECEIVER TANK ASSEMBLY....1164
REMOVAL AND INSTALLATION....1164
AIR CONDITIONER CONDENSER ASSEMBLY....1165
REMOVAL AND INSTALLATION....1165
AIR CONDITIONER COMPRESSOR ASSEMBLY....1166
REMOVAL AND INSTALLATION....1166
AIR CONDITIONER UNIT ASSEMBLY....1167
REMOVAL ....1167
INSTALLATION ....1168
SOLENOID VAVLE ASSEMBLY....1169
REMOVAL AND INSTALLATION....1169
GOVERNOR CONTROLLER ASSEMBLY....1170
REMOVAL AND INSTALLATION....1170
MONITOR PANEL ASSEMBLY....1171
REMOVAL AND INSTALLATION....1171
PUMP CONTROLLER ASSEMBLY....1172
REMOVAL AND INSTALLATION....1172
BOOM ROCK PREVENTION VALVE ASSEMBLY....1173
REMOVAL AND INSTALLATION....1173
ACCUMULATOR ASSEMBLY....1174
REMOVAL AND INSTALLATION....1174
BOOM LOWER REGENERATION VALVE ASSEMBLY....1175
REMOVAL AND INSTALLATION....1175
40 MAINTENANCE STANDARD....1176
ENGINE MOUNT....1177
PTO....1178
SWING CIRCLE....1179
SWING MACHINERY....1180
FINAL DRIVE....1182
TRACK FRAME....1184
IDLER....1185
CARRIER ROLLER....1187
TRACK ROLLER....1188
TRACK SHOE....1189
HYDRAULIC PUMP....1193
CONTROL,PTO LUBRICATING,AFTERCOOLER FAN DRIVE PUMP....1195
L.H.5-SPOOL CONTROL VALVE....1196
R.H.4-SPOOL CONTROL VALVE....1198
SWING 4-SPOOL CONTROL VALVE....1200
STRAIGHT-TRAVEL VALVE....1203
BOOM LOWER REGENERATION VALVE....1204
SWING NOTOR....1205
TRAVEL MOTOR....1206
CENTER SWIVEL JOINT....1208
PPC CONTROL RELIEF VALVE....1209
WORK EQUIPMENTSWING PPC VALVE....1210
TRAVEL PPC VALVE....1211
HYDRAULIC CYLINDER ....1212
FOR BACKHOE....1212
FOR LOADING SHOVEL....1214
WORK EQUIPMENT....1215
FOR BACKHOE....1215
FOR LOADING SHOVEL....1217
DIMENSIONS OF WORK EQUIPMENT....1219
90 OTHERS....1223
HYDRAULIC CIRCUIT DIAGRAM....1224
FOR BACKHOE....1224
FOR LOADING SHOVEL....1225
ELECTRICAL CIRCUIT DIAGRAM....1226
FOR BACKHOE(1/4)....1226
FOR BACKHOE(2/4)....1227
FOR BACKHOE(3/4)....1228
FOR BACKHOE(4/4)....1229
FOR LOADING SHOVEL(1/4)....1230
FOR LOADING SHOVEL(2/4)....1231
FOR LOADING SHOVEL(3/4)....1232
FOR LOADING SHOVEL(4/4)....1233
