This Complete Service Repair Workshop Manual PDF Download for the PC1250-7, PC1250SP-7, PC1250LC-7 Komatsu Hydraulic Excavator (S/N: 20001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu PC1250-7 – S/N: 20001 and up
Komatsu PC1250SP-7 – S/N: 20001 and up
Komatsu PC1250LC-7 – S/N: 20001 and up
TABLE OF CONTENTS :
– GENERAL
– STRUCTURE AND FUNCTION
– MAINTENANCE STANDARD
– TESTING AND ADJUSTING
– DISASSEMBLY AND ASSEMBLY
– OTHERS
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM027309
Total Pages : 940
This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
–
CONTENTS
01 GENERAL
SPECIFICATION DIMENSION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
PTO
PTO LUBRICATION SYSTEM
RADIATOR, OIL COOLER, AFTERCOOLER AND FUEL COOLER
POWER TRAIN
SWING MACHINERY
SWING CIRCLE
FINAL DRIVE
SPROCKET
TRACK FRAME
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
AIR PIPING DIAGRAM
AIR CIRCUIT DIAGRAM
AIR GOVERNOR
AIR TANK
SAFETY VALVE
HORN VALVE
GREASE PUMP
HYDRAULIC EQUIPMENT LAYOUT DRAWING
HYDRAULIC TANK
HYDRAULIC PUMP
NO.1 PUMP
NO.2 PUMP
NO.3 PUMP
LINE OIL FILTER
PILOT OIL FILTER
RETURN OIL FILTER
DRAIN OIL FILTER
L.H.5-SPOOL CONTROL VALVE
R.H.4-SPOOL CONTROL VALVE
SWING 4-SPOOL CONTROL VALVE
STRAIGHT-TRAVEL VALVE
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
PPC CONTROL RELIEF VALVE
ACCUMULATOR
VALVE CONTROL
WORK EQUIPMENT, SWING PPC VALVE
TRAVEL PPC VALVE
SOLENOID VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT
DIMENSIONS OF WORK EQUIPMENT
AIR CONDITIONER
ENGINE CONTROL
HPI ENGINE CONTROL SYSTEM
MACHINE CONTROL SYSTEM
MONITOR SYSTEM
SENSOR
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
TROUBLESHOOTING FOR INJECTOR
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
ADJUSTING INJECTOR SET LOAD
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
HANDLING EQUIPMENT IN FUEL SYSTEM
MEASURING FUEL CIRCUIT PRESSURE
VISUAL INSPECTION OF RETURN FUEL
ARRANGEMENT OF CONTROL DEVICES FOR HPI
BLEEDING AIR FROM FUEL CIRCUIT
ADJUSTING ENGINE SPEED SENSOR
REPLACING AND ADJUSTING FAN BELT
TESTING AND ADJUSTING ALTERNATOR AND AIR COMPRESSOR BELT TENSION
TESTING CLEARANCE OF SWING CIRCLE BEARING
MEASURING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE
TESTING SERVO PISTON STROKE
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING SWING PPC SHUTTLE VALVE
MEASURING SOLENOID VALVE OUTPUT PRESSURE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
TESTING TRAVEL DEVIATION
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURING OIL LEAKAGE
MEASURING FAN SPEED
MEASURING FAN CIRCUIT OIL PRESSURE
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
INSPECTION PROCEDURES FOR DIODE
SPECIAL FUNCTION OF MONITOR PANEL
INITIALIZATION PROCEDURES FOR VHMS CONTROLLER
SETTING PROCEDURES FOR REPLACING VHMS CONTROLLER
TESTING AND ADJUSTING DEVICES RELATED TO VHMS
PM-CLINIC SERVICE
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-BRANCH BOX AND T-BRANCH TABLE
TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (1/2)
INFORMATION IN TROUBLESHOOTING TABLE
ERROR CODE IN ELECTRICAL SYSTEM [C111] (ECM MICROPROCESSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C112] (TIMING ACTUATOR STUCK)
ERROR CODE IN ELECTRICAL SYSTEM [C113] (TIMING ACTUATOR CURRENT)
ERROR CODE IN ELECTRICAL SYSTEM [C115] (ENGINE SPEED SENSOR (2))
ERROR CODE IN ELECTRICAL SYSTEM [C116] (TIMING RAIL P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C117] (TIMING RAIL P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C118] (FUEL PUMP P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C119] (FUEL PUMP P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C121] (ENGINE SPEED SENSOR (1))
ERROR CODE IN ELECTRICAL SYSTEM [C122] (BOOST P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C123] (BOOST P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C131] (THROTTLE SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C132] (THROTTLE SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C135] (OIL P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C141] (OIL P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C143] (OIL P. LOW)
ERROR CODE IN ELECTRICAL SYSTEM [C144] (COOLANT T. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C145] (COOLANT T. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C151] (COOLANT T. HIGH)
ERROR CODE IN ELECTRICAL SYSTEM [C153] (INTAKE MANIFOLD T. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C154] (INTAKE MANIFOLD T. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C221] (AMBIENT AIR P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C222] (AMBIENT AIR P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C234] (ENGINE OVERSPEED)
ERROR CODE IN ELECTRICAL SYSTEM [C254] (FSOV CIRCUIT)
ERROR CODE IN ELECTRICAL SYSTEM [C259] (FSOV CIRCUIT)
ERROR CODE IN ELECTRICAL SYSTEM [C261] (FUEL T. HIGH)
ERROR CODE IN ELECTRICAL SYSTEM [C263] (FUEL T. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C265] (FUEL T. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C316] (FUEL PUMP ACTUATOR CURRENT)
ERROR CODE IN ELECTRICAL SYSTEM [C318] (FUEL PUMP ACTUATOR STUCK)
ERROR CODE IN ELECTRICAL SYSTEM [C346] (ECM POWERDOWN)
ERROR CODE IN ELECTRICAL SYSTEM [C423] (TIMING RAIL P. IN RANGE ERROR)
ERROR CODE IN ELECTRICAL SYSTEM [C441] (BATTERY VOLTAGE)
ERROR CODE IN ELECTRICAL SYSTEM [C442] (BATTERY VOLTAGE)
ERROR CODE IN ELECTRICAL SYSTEM [C451] (FUEL RAIL P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C452] (FUEL RAIL P. SENSOR)
ERROR CODE IN ELECTRICAL SYSTEM [C455] (FUEL RAIL ACTUATOR CURRENT)
ERROR CODE IN ELECTRICAL SYSTEM [C467] (TIMING ACTUATOR CONTROL)
ERROR CODE IN ELECTRICAL SYSTEM [C468] (RAIL ACTUATOR CONTROL)
ERROR CODE IN ELECTRICAL SYSTEM [C514] (RAIL ACTUATOR STUCK)
ERROR CODE IN ELECTRICAL SYSTEM [C554] (FUEL RAIL P. IN RANGE ERROR)
TROUBLESHOOTING WHEN ERROR CODE (ELECTRICAL SYSTEM) AND FAILURE CODE (MECHANICAL SYSTEM) ARE DISPLAYED (2/2)
ERROR CODE IN ELECTRICAL SYSTEM [E101] (ABNORMALITY ERROR RECORD)
ERROR CODE IN ELECTRICAL SYSTEM [E112] (WIPER DRIVE (FOR) S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E113] (WIPER DRIVE (REV) S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E114] (WASHER DRIVE S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E115] (WIPER WORKING ABNORMALITY)
ERROR CODE IN ELECTRICAL SYSTEM [E116] (WIPER PARKING ABNORMALITY)
ERROR CODE IN ELECTRICAL SYSTEM [E201] (CO CANCEL SOL. S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E202] (TRAVEL JUNCTION SOL. S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E203] (SWING BRAKE SOL. S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E204] (2-STAGE RELIEF SOL. S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E205] (SWING PRIORITY SOL. S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E206] (TRAVEL SPEED SOL. S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E207] (FLASH LIGHT RELAY S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E211] (CO CANCEL SOL. DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E212] (TRAVEL JUNCTION SOL. DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E213] (SWING BRAKE SOL. DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E214] (2-STAGE RELIEF SOL. DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E215] (SWING PRIORITY SOL. DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E216] (TRAVEL SPEED SOL. DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E217] (MODEL SELECTION ABNORMALITY)
ERROR CODE IN ELECTRICAL SYSTEM [E218] (S-NET COMM. DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E221] (J1939 COMM. ERROR)
ERROR CODE IN ELECTRICAL SYSTEM [E222] (WORKING MODE OUTPUT S/C (1))
ERROR CODE IN ELECTRICAL SYSTEM [E223] (WORKING MODE OUTPUT DISC.(1))
ERROR CODE IN ELECTRICAL SYSTEM [E224] (WORKING MODE OUTPUT S/C (2))
ERROR CODE IN ELECTRICAL SYSTEM [E225] (WORKING MODE OUTPUT DISC.(2))
ERROR CODE IN ELECTRICAL SYSTEM [E226] (AUTO-DECELERATION OUTPUT DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E227] (ENGINE SPEED SENSOR ABNORMALITY)
ERROR CODE IN ELECTRICAL SYSTEM [E228] (AUTO-DECELERATION OUTPUT S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E232] (TVC SOL. S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E233] (TVC SOL. DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E234] (LEVER NEUTRAL OUTPUT S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E235] (LEVER NEUTRAL OUTPUT DISC.)
ERROR CODE IN ELECTRICAL SYSTEM [E241] (PRE. SENS VOLTAGE FAILURE)
ERROR CODE IN ELECTRICAL SYSTEM [E242] (F PUMP PRE. SENS FAILURE)
ERROR CODE IN ELECTRICAL SYSTEM [E243] (R PUMP PRE. SENS FAILURE)
ERROR CODE IN ELECTRICAL SYSTEM [E244] (SWING PRE. SENS FAILURE)
ERROR CODE IN ELECTRICAL SYSTEM [E245] (HIGH RELIEF PRESS F PUMP)
ERROR CODE IN ELECTRICAL SYSTEM [E246] (HIGH RELIEF PRESS R PUMP)
ERROR CODE IN ELECTRICAL SYSTEM [E247] (HIGH RELIEF PRESS PUMP SWING)
ERROR CODE IN ELECTRICAL SYSTEM [E302] (STEP LIGHT RELAY S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E304] (STEP LIGHT POWER DRIVE RELAY S/C)
ERROR CODE IN ELECTRICAL SYSTEM [E315] (BATTERY RELAY DRIVE S/C)
FAILURE CODE IN VHMS SYSTEM [A000N1] (ENGINE OVER SPEED)
FAILURE CODE IN MECHANICAL SYSTEM [AA10NX] (AIRCLEANER CLOGGING)
FAILURE CODE IN MECHANICAL SYSTEM [AB00KE] (CHARGE VOLTAGE LOW)
FAILURE CODE IN MECHANICAL SYSTEM [[email protected]] (ENG. OIL PRESS. LOW)
FAILURE CODE IN MECHANICAL SYSTEM [[email protected]] (ENG. OIL LEVEL LOW)
FAILURE CODE IN MECHANICAL SYSTEM [[email protected]] (ENG. WATER OVERHEAT)
FAILURE CODE IN MECHANICAL SYSTEM [[email protected]] (ENG. WATER LVL LOW)
FAILURE CODE IN VHMS SYSTEM [[email protected]] (HIGH PTO TEMPERATURE)
FAILURE CODE IN MECHANICAL SYSTEM [[email protected]] (HYDR. OIL OVERHEAT)
FAILURE CODE IN VHMS SYSTEM [DBB0KK] (VHMS SOURCE VOLTAGE ERROR)
FAILURE CODE IN VHMS SYSTEM [DBB5KP] (VHMS 5V SOURCE SYS ERROR)
FAILURE CODE IN VHMS SYSTEM [DBB6KP] (VHMS 24V SOURCE SYS ERROR)
FAILURE CODE IN VHMS SYSTEM [DBBQKR] (KOM-NET/C ERROR)
FAILURE CODE IN VHMS SYSTEM [DBBRKR] (CAN-NET SYS (J1939) ERROR)
FAILURE CODE IN VHMS SYSTEM [DGE1KB] (ENG OIL TEMP. SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DGE1KY] (ENG OIL TEMP. SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DGE5KX] (AMBIENT AIR TEMP SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DGT3KZ] (PTO TEMP SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DGT4KA] (F EXHAUST TEMP. SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DGT4KB] (F EXHAUST TEMP. SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DGT5KA] (R EXHAUST TEMP. SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DGT5KB] (R EXHAUST TEMP. SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DHE5KB] (BLOWBY PRES. SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [DHE5KY] (BLOWBY PRES. SENSOR FAILURE)
FAILURE CODE IN VHMS SYSTEM [[email protected]] (HIGH BLOWBY PRESSURE)
FAILURE CODE IN VHMS SYSTEM [[email protected]] (HIGH F CYL. EXHAUST TEMP. 2)
FAILURE CODE IN VHMS SYSTEM [[email protected]] (HIGH F CYL. EXHAUST TEMP. 1)
FAILURE CODE IN VHMS SYSTEM [[email protected]] (HIGH R CYL. EXHAUST TEMP. 2)
FAILURE CODE IN VHMS SYSTEM [[email protected]] (HIGH R CYL. EXHAUST TEMP. 1)
FAILURE CODE IN VHMS SYSTEM [J100KA] (CNT. PUMP PRE. SENS FAILURE)
FAILURE CODE IN VHMS SYSTEM [J100KA] (FAN PUMP PRE. SENS FAILURE)
FAILURE CODE IN VHMS SYSTEM [J100KB] (CNT. PUMP PRE. SENS FAILURE)
FAILURE CODE IN VHMS SYSTEM [J100KB] (FAN PUMP PRE. SENS FAILURE)
FAILURE CODE IN VHMS SYSTEM [J100L6](ABNOMAL CNT. GEAR PUMP PRESS)
FAILURE CODE IN VHMS SYSTEM [J10016] (ABNOMAL FAN GEAR PUMP PRESS)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
E-1 ENGINE DOES NOT START (ENGINE DOES NOT ROTATE)
E-2 AUTO-DECELERATOR DOES NOT WORK
E-3 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK
E-4 PREHEATER DOES NOT WORK
E-5 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT MOVE
E-6 MACHINE PUSH-UP CIRCUIT DOES NOT WORK
E-7 BOOM SHOCKLESS CIRCUIT CANNOT BE RESET
E-8 NO DISPLAY IN MONITOR PANEL AT ALL
E-9 PART OF DISPLAY ON MONITOR PANEL IS MISSING
E-10 MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL
E-11 FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY
E-13 FUEL GAUGE DOES NOT DISPLAY CORRECTLY
E-14 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY
E-15 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS
E-16 WINDSHIELD WIPER DOES NOT WORK
E-17 ALARMING BUZZER CANNOT BE CANCELLED
E-18 “BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
E-19 “BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
E-20 “ARM DIGGING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
E-21 “ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
E-22 “BUCKET DIGGING ” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
E-23 “BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
E-24 “SWING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
E-25 “TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION
E-26 AIR CONDITIONER DOES NOT WORK
E-27 TRAVEL ALARM DOES NOT SOUND
E-28 ANY OF PANEL LAMP, HEAD LAMP, WORKING LAMP (INCLUDING ADDITIONAL LAMP) DOES NOT LIGHT UP
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
BEFORE TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS
INFORMATION IN TROUBLESHOOTING TABLE
H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, TRAVEL, AND SWING IS LOW
H-2 ENGINE SPEED LOWERS REMARKABLY OR ENGINE STALLS
H-3 ALL WORK EQUIPMENT, TRAVEL, AND SWING SYSTEMS DO NOT WORK
H-4 ABNORMAL SOUND IS HEARD FROM AROUND PUMP
H-5 SPEED OR POWER OF BOOM IS LOW
H-6 SPEED OR POWER OF ARM IS LOW
H-7 SPEED OR POWER OF BUCKET IS LOW
H-8 BOOM DOES NOT MOVE
H-9 ARM DOES NOT MOVE
H-10 BUCKET DOES NOT MOVE
H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE
H-12 TIME LAG OF WORK EQUIPMENT IS LARGE
H-13 BOOM SHOCKLESS FUNCTION CANNOT BE TURNED ON OR OFF
H-14 MACHINE DEVIATES IN ONE DIRECTION
H-15 MACHINE DEVIATES LARGELY AT START
H-16 MACHINE DEVIATES LARGELY DURING COMPOUND OPERATION
H-17 TRAVEL SPEED OR POWER IS LOW
H-18 MACHINE DOES NOT TRAVEL (ONLY ONE TRACK)
H-19 TRAVEL SPEED DOES NOT CHANGE
H-20 MACHINE DOES NOT SWING
H-21 SWING SPEED OR ACCELERATION IS LOW
H-22 SWING SPEED OR POWER IS LOW IN COMPOUND OPERATION OF TRAVEL AND BUCKET
H-23 SWING SPEED OR POWER IS LOW IN COMPOUND OPERATION OF TRAVEL AND BOOM IN SWING PRIORITY MODE
H-24 UPPER STRUCTURE OVERRUNS LARGELY
H-25 LARGE SHOCKS ARE MADE WHEN UPPER STRUCTURE STOPS SWINGING
H-26 LARGE ABNORMAL SOUNDS ARE MADE WHEN UPPER STRUCTURE STOPS SWINGING
H-27 HYDRAULIC DRIFT OF SWING IS LARGE
TROUBLESHOOTING OF ENGINE BODY (S MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES
S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
PRECAUTIONS WHEN PERFORMING OPERATION
SPECIAL TOOL LIST
REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FUEL COOLER AND AIR CONDITIONER ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF PTO ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
DISASSEMBLY
ASSEMBLY
REMOVAL AND ASSEMBLY OF FUEL TANK ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
SKETCHES OF SPECIAL TOOLS
REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF SWING MACHINERY ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF SWING MACHINERY ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
SKETCHES OF SPECIAL TOOLS
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF TRACK SHOE ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF IDLER ADJUSTMENT CYLINDER ASSEMBLY
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
INSTALLATION
SKETCHES OF SPECIAL TOOLS
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
SKETCHES OF SPECIAL TOOLS
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF 5-SPOOL CONTROL VALVE ASSEMBLY (NO. 1)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF 4-SPOOL CONTROL VALVE ASSEMBLY (NO. 2)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF 4-SPOOL CONTROL VALVE ASSEMBLY (NO. 3)
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 1)
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 2)
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY (NO. 3)
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF SWING MOTOR ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF TRAVEL MOTOR ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (BACKHOE SPECIFICATION)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (BACKHOE SPECIFICATION )
SPECIAL TOOLS
REMOVAL
INSTALLATION
SKETCHES OF SPECIAL TOOLS
REMOVAL AND INSTALLATION OF ARM CYLINDER ASSEMBLY (LOADING SHOVEL)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (BACKHOE SPECIFICATION )
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF BOOM CYLINDER ASSEMBLY (LOADING SHOVEL )
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY (BACKHOE SPECIFICATION )
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (BACKHOE SPECIFICATION)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF BUCKET ASSEMBLY (LOADING SHOVEL)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ARM ASSEMBLY (BACKHOE SPECIFICATION)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ARM ASSEMBLY (LOADING SHOVEL)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (BACKHOE SPECIFICATION)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF BOOM ASSEMBLY (LOADING SHOVEL)
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS (STUCK GLASS)
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF RECEIVER TANK ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF VHMS CONTROLLER
REMOVAL
INSTALLATION
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM (1/3)
HYDRAULIC CIRCUIT DIAGRAM (2/3)
HYDRAULIC CIRCUIT DIAGRAM (3/3)
ELECTRICAL CIRCUIT DIAGRAM (1/7)
ELECTRICAL CIRCUIT DIAGRAM (2/7)
ELECTRICAL CIRCUIT DIAGRAM (3/7)
ELECTRICAL CIRCUIT DIAGRAM (4/7)
ELECTRICAL CIRCUIT DIAGRAM (5/7)
ELECTRICAL CIRCUIT DIAGRAM (6/7)
ELECTRICAL CIRCUIT DIAGRAM (7/7)
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