Complete service repair manual with Electrical Wiring Diagrams for Komatsu PC100, PC120, PC130 Hydraulic Excavators, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu PC100-2, PC100L-2, PC100-5, PC100-6, PC120-2, PC120-5, PC120-5 Mighty, PC120-6, PC120-6 Excel, PC120LC-6, PC130-6 Hydraulic Excavator 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.
SEBM0202B03 – Hydraulic Excavator PC100-2, PC100L-2, PC120-2 Shop Manual.pdf
SEBM003307 – Hydraulic Excavator PC100-6, PC120-6 Shop Manual.pdf
SEBM010404 – Hydraulic Excavator PC120-6 Excel Shop Manual.pdf
SEBM010611 – Hydraulic Excavator PC100-6, PC120-6, PC120LC-6, PC130-6 Shop Manual.pdf
SEBM02020508 – Hydraulic Excavator PC100-5, PC120-5, PC120-5 Mighty Shop Manual.pdf
WEAM000402 – Hydraulic Excavator PC110R-1 Operation & Maintenance Manual.pdf
MEAM2P1200 – Hydraulic Excavator PC100-6 Operation & Maintenance Manual.pdf
SEAM002201 – Hydraulic Excavator PC100-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM002203 – Hydraulic Excavator PC100-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM002205 – Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM002207 – Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM002213T – Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC120LG-6, PC130-6 Mighty Operation & Maintenance Manual.pdf
SEAM063601T – Hydraulic Excavator GALEO PC120-6, PC120LC-6 Operation & Maintenance Manual.pdf
Total Pages: 5,490 pages
File Format: PDF
Language: English
MEAM2P1200 – Hydraulic Excavator PC100-6 Operation & Maintenance Manual…2
COVER…2
1. FOREWORD…3
2. SAFETY INFORMATION…4
3. INTRODUCTION…5
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…6
5. CONTENTS…7
SAFETY…11
6. GENERAL INFORMATION…12
7. PRECAUTIONS DURING OPERATION…18
7.1 BEFORE STARTING ENGINE…18
7.2 OPERATING MACHINE…20
7.3 TRANSPORTATION…25
7.4 BATTERY…26
7.5 TOWING…27
7.6 BUCKET WITH HOOK…28
8. PRECAUTIONS FOR MAINTENANCE…31
8.1 BEFORE CARRYING OUT MAINTENANCE…31
8.2 DURING MAINTENANCE…34
9. POSITION FOR ATTACHING SAFETY LABELS…38
OPERATION…43
10. GENERAL VIEW…44
10.1 GENERAL VIEW OF MACHINE…44
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…45
11. EXPLANATION OF COMPONENTS…46
11.1 MACHINE MONITOR…46
11.2 METER…57
11.3 SWITCHES…58
11.4 CONTROL LEVERS, PEDALS…63
11.5 CEILING WINDOW…68
11.6 FRONT WINDOW…69
11.7 DOOR LOCK…71
11.8 CAP, COVER WITH LOCK…72
11.9 HOT/COOL BOX…73
11.10 LUGGAGE BOX…73
11.11 ASHTRAY…73
11.12 AIR CONDITIONER…74
11.13 CAR RADIO…77
11.14 FUSE…81
11.15 FUSIBLE LINK…82
11.16 CONTROLLERS…82
11.17 TOOL BOX…82
11.18 GREASE PUMP HOLDER…82
12. OPERATION…83
12.1 CHECK BEFORE STARTING ENGINE…83
12.2 STARTING ENGINE…93
12.3 OPERATIONS AND CHECKS AFTER STSRTING ENGINE…96
12.4 MOVING MACHINE…102
12.5 STEERING MACHINE…105
12.6 STOPPING MACHINE…107
12.7 SWINGING…108
12.8 OPERATIONS OF WORK EQUIPMENT…109
12.9 WORKING MODE SELECTION…110
12.10 PROHIBITIOINS FOR OPERATION…112
12.11 PRECAUTIONS FOR OPERATION…114
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…115
12.13 HOW TO ESCAPE FROM MUD…117
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…118
12.15 REPLACEMENT AND INVERSION OF BUCKET…119
12.16 PARKING MACHINE…121
12.17 CHECK AFTER FINISHING WORK…122
12.18 STOPPING ENGINE…123
12.19 CHECK AFTER STOPPING ENGINE…124
12.20 LOCKING…124
13. TRANSPORTATION…125
13.1 LOADING, UNLOADING WORK…125
13.2 PRECAUTIONS AFTER COMPLETION OF WORK…127
13.3 PRECAUTIONS FOR TRANSPORTATION…128
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 PHENOMENA THAT ARE NOT FAILURES…135
16.2 METHOD OF TOWING MACHINE…135
16.3 USING METHOD OF LIGHT-WEIGHT TOWING HOOK…135
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…136
16.5 IF BATTERY IS DISCHARGED…136
16.6 OTHER TROUBLE…140
MAINTENANCE…145
17. GUIDES TO MAINTENANCE…146
18. OUTLINES OF SERVICE…148
18.1 OUTLINE OF OIL, FUEL, COOLANT…148
18.2 OUTLINE OF ELECTRIC SYSTEM …151
18.3 OUTLINE OF HYDRAULIC SYSTEM…152
19. WEAR PARTS LIST…153
20. USE OF FUEL LIST…154
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…158
21.1 INTRODUCTION OF NECESSARY TOOLS…158
21.2 TORQUE LIST…159
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…160
23. MAINTENANCE SCHEDULE CHART…162
23.1 MAINTENANCE SCHEDULE CHART…162
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…164
24. SERVICE PROCEDURE…165
24.1 INITIAL 250 HOURS SERVICE…165
24.2 WHEN REQUIRED…166
24.3 CHECK BEFORE STARTING…184
24.4 EVERY 50 HOURS SERVICE…188
24.5 EVERY 100 HOURS SERVICE…189
24.6 EVERY 250 HOURS SERVICE…192
24.7 EVERY 500 HOURS SERVICE…199
24.8 EVERY 1000 HOURS SERVICE…204
24.9 EVERY 2000 HOURS SERVICE…207
24.10 EVERY 4000 HOURS SERVICE…213
SPECIFICATIONS…215
25. SPECIFICATIONS…216
OPTIONS, ATTACHMENTS…223
26. GENERAL PRECAUTIONS…224
26.1 PRECAUTIONS RELATED TO SAFETY…224
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…225
27. HANDLING BUCKET WITH HOOK…226
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…226
27.2 PROHIBITED OPERATIONS…226
27.3 PRECAUTIONS DURING OPERATIONS…226
28. USING SEAT BELT…227
28.1 EAT BELT…227
29. HANDLING CAR HEATER…229
29.1 EXPLANATION OF COMPONENTS…229
29.2 PREPARING CAR HEATER…230
30. MACHINES READY FOR ATTACHMENTS…231
30.1 GENERAL LOCATIONS…231
30.2 HYDRAULIC CIRCUIT…233
30.3 OPERATION…236
30.4 HANDLING ACCUMULATOR…238
30.5 LONG-TERM STORAGE…239
30.6 SPECIFICATIONS…239
31. INTRODUCTION OF OPITIONAL PARTS AND ATTACHMENTS…240
31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…240
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…241
31.3 SELECTION OF TRACK SHOES…242
31.4 HANDLING RUBBER PAD SHOE…243
31.5 HANDLING AUTOMATIC GREASING CONTROLLER…245
32. EXTENDING MACHINE SERVICE LIFE…250
32.1 HYDRAULIC BREAKER…250
32.2 POWER RIPPER…253
32.3 FORK FORK GRAB…254
32.4 GRAPPLE BUCKET…255
32.5 SCRAP GRAPPLE…256
32.6 CRUSHER & SMASHER…257
32.7 HYDRAULIC PILE DRIVER…258
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE…259
SEAM002201 – Hydraulic Excavator PC100-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual…261
COVER…261
1. FOREWORD…264
2. SAFETY INFORMATION…265
3. INTRODUCTION…266
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…267
5. CONTENTS…268
SAFETY…272
6. GENERAL PRECAUTIONS…273
7. PRECAUTIONS DURING OPERATION…279
7.1 BEFORE STARTING ENGINE…279
7.2 OPERATING MACHINE…281
7.3 TRANSPORTATION…286
7.4 BATTERY…287
7.5 TOWING…288
7.6 BUCKET WITH HOOK…289
8. PRECAUTIONS FOR MAINTENANCE…292
8.1 BEFORE CARRYING OUT MAINTENANCE…292
8.2 DURING MAINTENANCE…295
9. POSITION FOR ATTACHING SAFETY LABELS…299
OPERATION…304
10. GENERAL VIEW…305
10.1 GENERAL VIEW OF MACHINE…305
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…306
11. EXPLANATION OF COMPONENTS…307
11.1 MACHINE MONITOR…307
11.2 METER…318
11.3 SWITCHES…319
11.4 CONTROL LEVERS, PEDALS…324
11.5 CEILING WINDOW…329
11.6 FRONT WINDOW…330
11.7 DOOR LOCK…332
11.8 CAP, COVER WITH LOCK…333
11.9 HOT/COOL BOX…334
11.10 LUGGAGE BOX…334
11.11 ASHTRAY…334
11.12 AIR CONDITIONER…335
11.13 CAR RADIO…338
11.14 FUSE…342
11.15 FUSIBLE LINK…343
11.16 CONTROLLERS…343
11.17 TOOL BOX…343
11.18 GREASE PUMP HOLDER…343
12. OPERATION…344
12.1 CHECK BEFORE STARTING ENGINE…344
12.2 STARTING ENGINE…354
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…357
12.4 MOVING MACHINE OFF…363
12.5 STEERING MACHINE…366
12.6 STOPPING MACHINE…368
12.7 SWINGING…369
12.8 OPERATION OF WORK EQUIPMENT…370
12.9 WORKING MODE SELECTION…371
12.10 PROHIBITIONS FOR OPERATION…373
12.11 PRECAUTIONS FOR OPERATION…375
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…376
12.13 HOW TO ESCAPE FROM MUD…378
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…379
12.15 REPLACEMENT AND INVERSION OF BUCKET…380
12.16 PARKING MACHINE…382
12.17 CHECK AFTER FINISHING WORK…383
12.18 STOPPING ENGINE…384
12.19 CHECK AFTER STOPPING ENGINE…385
12.20 LOCKING…385
13. TRANSPORTATION…386
13.1 LOADING, UNLOADING WORK…386
13.2 PRECAUTIONS FOR LOADING…388
13.3 PRECAUTIONS FOR TRANSPORTATION…389
14. COLD WEATHER OPERATION…391
14.1 PRECAUTIONS FOR LOW TEMPERATURE…391
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…393
14.3 AFTER COLD WEATHER…393
15. LONG-TERM STORAGE…394
15.1 BEFORE STORAGE…394
15.2 DURING STORAGE…395
15.3 AFTER STORAGE…395
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…395
16. TROUBLESHOOTING…396
16.1 PHENOMENA THAT ARE NOT FAILURES…396
16.2 METHOD OF TOWING MACHINE…396
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK…396
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…397
16.5 IF BATTERY IS DISCHARGED…397
16.6 OTHER TROUBLE…401
MAINTENANCE…406
17. GUIDES TO MAINTENANCE…407
18. OUTLINES OF SERVICE…409
18.1 OUTLINE OF OIL, FUEL, COOLANT…409
18.2 OUTLINE OF ELECTRIC SYSTEM…412
18.3 OUTLINE OF HYDRAULIC SYSTEM…413
19. WEAR PARTS LIST…414
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…415
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…419
21.1 INTRODUCTION OF NECESSARY TOOLS…419
21.2 TORQUE LIST…420
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…421
23. MAINTENANCE SCHEDULE CHART…423
23.1 MAINTENANCE SCHEDULE CHART…423
23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER…425
24. SERVICE PROCEDURE…426
24.1 INITIAL 250 HOURS SERVICE…426
REPLACE FUEL FILTER CARTRIDGE…426
CHECK ENGINE VALVE CLEARANCE, ADJUST…426
24.2 WHEN REQUIRED…427
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…427
CLEAN INSIDE OF COOLING SYSTEM…429
CHECK AND TIGHTEN TRACK SHOE BOLTS…433
CHECK AND ADJUST TRACK TENSION…434
CHECK ELECTRICAL INTAKE AIR HEATER…436
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…437
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…440
ADJUST BUCKET CLEARANCE…441
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…442
CHECK AND ADJUST AIR CONDITIONER…443
REPLACE ADDITIONAL BREAKER FILTER ELEMENT…444
24.3 CHECK BEFORE STARTING…445
CHECK COOLANT LEVEL, ADD WATER…445
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…445
CHECK FUEL LEVEL, ADD FUEL…446
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…447
CHECK AIR CLEANER FOR CLOGGING…448
CHECK ELECTRIC WIRINGS…448
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER…448
24.4 EVERY 50 HOURS SERVICE…449
DRAIN WATER AND SEDIMENT FROM FUEL TANK…449
24.5 EVERY 100 HOURS SERVICE…450
LUBRICATING…450
BOOM CYLINDER FOOT PIN (2 POINTS)…450
BOOM FOOT PIN (2 POINTS)…450
BOOM CYLINDER ROD END (2 POINTS)…450
ARM CYLINDER FOOT PIN (1 POINT)…451
BOOM-ARM COUPLING PIN (1 POINT)…451
ARM CYLINDER ROD END (1 POINT)…451
BUCKET CYLINDER FOOT PIN (1 POINT)…451
ARM-LINK COUPLING PIN (1 POINT)…451
ARM-BUCKET COUPLING PIN (1 POINT)…451
LINK COUPLING PIN (1 POINT)…451
BUCKET CYLINDER ROD END (1 POINT)…451
BUCKET-LINK COUPLING PIN (2 POINTS)…451
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…452
24.6 EVERY 250 HOURS SERVICE…453
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…453
CHECK LEVEL OF BATTERY ELECTROLYTE…454
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…455
REPLACE HYDRAULIC FILTER ELEMENT…456
CHECK FAN BELT TENSION, ADJUST…458
CHECK, ADJUST TENSION AIR CONDITIONER COMPRESSOR BELT…459
24.7 EVERY 500 HOURS SERVICE…460
REPLACE FUEL FILTER CARTRIDGE…460
CHECK SWING PINION GREASE LEVEL, ADD GREASE…462
LUBRICATE SWING CIRCLE (2 POINTS)…462
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…463
CLEAN INTERNAL AND EXTERNAL AIR FILTER OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…464
24.8 EVERY 1000 HOURS SERVICE…465
CHANGE OIL IN SWING MACHINERY CASE…465
CHANGE OIL IN FINAL DRIVE CASE…466
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…466
CHECK PLAY OF TURBOCHARGER ROTOR…466
REPLACE CORROSION RESISTOR CARTRIDGE…467
24.9 EVERY 2000 HOURS SERVICE…468
CHECK OIL LEVEL IN PTO CASE, ADD OIL…468
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…469
CLEAN, CHECK TURBOCHARGER…473
CHECK ALTERNATOR, STARTING MOTOR…473
CHECK ENGINE VALVE CLEARANCE, ADJUST…473
24.10 EVERY 4000 HOURS SERVICE…474
CHECK WATER PUMP…474
SPECIFICATIONS…476
25. SPECIFICATIONS…477
OPTIONS, ATTACHMENTS…484
26. GENERAL PRECAUTIONS…485
26.1 PRECAUTIONS RELATED TO SAFETY…485
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…486
27. HANDLING BUCKET WITH HOOK…487
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…487
27.2 PROHIBITED OPERATIONS…487
27.3 PRECAUTIONS DURING OPERATIONS…487
28. USING SEAT BELT…488
28.1 SEAT BELT…488
29. HANDLING CAR HEATER…490
29.1 EXPLANATION OF COMPONENTS…490
29.2 PREPARING CAR HEATER…491
30. MACHINES READY FOR ATTACHMENTS…492
30.1 GENERAL LOCATIONS…492
30.2 HYDRAULIC CIRCUIT…494
30.3 OPERATION…497
30.4 HANDLING ACCUMULATOR…499
30.5 LONG-TERM STORAGE…500
30.6 SPECIFICATIONS…500
31. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…501
31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…501
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…502
31.3 SELECTION OF TRACK SHOES…503
31.4 HANDLING RUBBER PAD SHOE…504
32. EXTENDING MACHINE SERVICE LIFE…506
32.1 HYDRAULIC BREAKER…506
32.2 POWER RIPPER…509
32.3 FORK GRAB…510
32.4 GRAPPLE BUCKET…511
32.5 SCRAP GRAPPLE…512
32.6 CRUSHER & SMASHER…513
32.7 HYDRAULIC PILE DRIVER…514
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE…515
SEAM002203 – Hydraulic Excavator PC100-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual…518
COVER…518
1. FOREWORD…522
2. SAFETY INFORMATION…523
3. INTRODUCTION…524
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…525
5. CONTENTS…526
SAFETY…530
6. GENERAL PRECAUTIONS…531
7. PRECAUTIONS DURING OPERATION…537
7.1 BEFORE STARTING ENGINE …537
7.2 OPERATING MACHINE…539
7.3 TRANSPORATION…544
7.4 BATTERY…545
7.5 TOWING…546
7.6 BUCKET WITH HOOK…547
8. PRECAUTIONS FOR MAINTENANCE…550
8.1 BEFORE CARRYING OUT MAINTENANCE…550
8.2 DURING MAINTENANCE…553
9. POSITION FOR ATTACHING SAFETY LABELS…557
OPERATION…562
10. GENERAL VIEW…563
10.1 GENERAL VIEW OF MACHINE…563
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…564
11. EXPLANATION OF COMPONENTS…565
11.1 MACHINE MAONITOR…565
11.2 METER…576
11.3 SWITCHES…577
11.4 CONTROL LEVERS, PEDALS…582
11.5 CEILING WINDOW…587
11.6 FRONT WINDOW…588
11.7 DOOR LOCK…590
11.8 CAP, COVER WITH LOCK…591
11.9 HOT/COOL BOX…592
11.10 LUGGAGE BOX…592
11.11 ASHTRAY…592
11.12 AIR CONDITIONER…593
11.13 CAR RADIO…596
11.14 FUSE…600
11.15 FUSIBLE LINK…601
11.16 CONTROLLERS…601
11.17 TOOL BOX…601
11.18 GREASE PUMP HOLDER…601
12. OPERATION…602
12.1 CHECK BEFORE STARTING ENGINE…602
12.2 STARTING ENGINE…612
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…615
12.4 MOVING MACHINE OFF…621
12.5 STEERING MACHINE…624
12.6 STOPPING MACHINE…626
12.7 SWINGING…627
12.8 OPERATION OF WORK EQUIPMENT…628
12.9 WORKING MODE SELECTION…629
12.10 PROHIBITIONS FOR OPERATION…631
12.11 PRECAUTIONS FOR OPERATION…633
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…634
12.13 HOW TO ESCAPE FROM MUD…636
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…637
12.15 REPLACEMENT AND INVERSION OF BUCKET…638
12.16 PARKING MACHINE…640
12.17 CHECK AFTER FINISHING WORK…641
12.18 STOPPING ENGINE…642
12.19 CHECK AFTER STOPPING ENGINE…643
12.20 LOCKING…643
13. TRANSPORTATION…644
13.1 LOADING, UNLOADING WORK…644
13.2 PRECAUTIONS FOR LOADING…646
13.3 PRECAUTIONS FOR TRANSPORTATION…647
14. COLD WEATHER OPERATION…649
14.1 PRECAUTIONS FOR LOW TEMPERATURE…649
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…651
14.3 AFTER COLD WEATHER…651
15. LONG-TERM STORAGE…652
15.1 BEFORE STORAGE…652
15.2 DURING STORAGE…653
15.3 AFTER STORAGE…653
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…653
16. TROUBLESHOOTING…654
16.1 PHENOMENA THAT ARE NOT FAILURES…654
16.2 METHOD OF TOWING MACHINE…654
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK…654
16.4 PRECAUTIONS OF PARTICULAR JOBSITES…655
16.5 IF BATTERY IS DISCHARGED…655
16.6 OTHER TROUBLE…659
MAINTENANCE…664
17. GUIDES TO MAINTENANCE…665
18. OUTLINES OF SERVICE…667
18.1 OUTLINE OF OIL, FUEL, COOLANT…667
18.2 OUTLINE OF ELECTRIC SYSTEM…670
18.3 OUTLINE OF HYDRAULIC SYSTEM…671
19. WEAR PARTS LIST…672
20. USE OF FUEL ,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…673
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…677
21.1 INTRODUCTION OF NECESSARY TOOLS…677
21.2 TORQUE LIST…678
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…679
23. MAINTENANCE SCHEDULE CHART…681
23.1 MAINTENANCE SCHEDULE CHART…681
23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER…683
24. SERVICE PROCEDURE…684
24.1 INITIAL 250 HOURS SERVICE…684
REPLACE FUEL CARTRIDGE…718
CHECK ENGINE VALVE CLEARANCE, ADJUST…731
24.2 WHEN REQUIRED…685
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…685
CLEAN INSIDE OF COOLING SYSTEM…687
CHECK AND TIGHTEN TRACK SHOE BOLTS…691
CHECK AND ADJUST TRACK TENSION…692
CHECK ELECTRICAL INTAKE AIR HEATER…694
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…695
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…698
ADJUST BUCKET CLEARANCE…699
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…700
CHECK AND ADJUST AIR CONDITIONER…701
REPLACE ADDITIONAL BREAKER FILTER ELEMENT…702
24.3 CHECK BEFORE STARTING …703
CHECK COOLANT LEVEL, ADD WATER…703
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…703
CHECK FUEL LEVEL, ADD FUEL…704
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…705
CHECK AIR CLEANER FOR CLOGGING …706
CHECK ELECTRIC WIRINGS…706
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER…706
24.4 EVERY 50 HOURS SERVICE…707
DRAIN WATER AND SEDIMENT FROM FUEL TANK…707
24.5 EVERY 100 HOURS SERVICE…708
LUBRICATING…708
BOOM CYLINDER FOOT PIN (2 POINTS)…708
BOOM FOOT PIN (2 POINTS)…708
BOOM CYLINDER ROD END (2 POINTS)…708
ARM CYLINDER PIN (1 POINT)…708
BOOM-ARM COUPLING PIN (1 POINT)…709
ARM CYLINDER ROD END (1 POINT)…709
BUCKET CYLINDER FOOT PIN (1 POINT)…709
ARM-LINK COUPLING PIN (1 POINT)…709
ARM-BUCKET COUPLING PIN (1 POINT)…709
LINK COUPLING PIN (1 POINT)…709
BUCKET CYLINDER ROD END (1 POINT)…709
BUCKET-LINK COUPLING PIN (2 POINTS)…709
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…710
24.6 EVERY 250 HOURS SERVICE…711
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…711
CHECK LEVEL OF BATTERY ELECTROLYTE…712
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…713
REPLACE HYDRAULIC FILTER ELEMENT…714
CHECK FAN BELT TENSION, ADJUST…716
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…717
24.7 EVERY 500 HOURS SERVICE…718
REPLACE FUEL FILTER CARTRIDGE …718
CHECK SWING PINION GREASE LEVEL, ADD GREASE…720
LUBRICATE SWING CIRCLE (2 POINTS)…720
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…721
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…722
24.8 EVERY 1000 HOURS SERVICE…723
CHANGE OIL IN SWING MACHINERY CASE…723
CHANGE OIL IN FINAL DRIVE CASE…724
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…724
CHECK PLAY OF TURBOCHARGER ROTOR…724
REPLACE CORROSION RESISTOR CARTRIDGE…725
24.9 EVERY 2000 HOURS SERVICE…726
CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL…726
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…727
CLEAN, CHECK TURBOCHARGER…731
CHECK ALTERNATOR, STARTING MOTOR…731
CHECK ENGINE VALVE CLEARANCE, ADJUST…731
24.10 EVERY 4000 HOURS SERVICE…732
CHECK WATER PUMP…732
SPECIFICATIONS…734
25. SPECIFICATIONS…735
OPTIONS, ATTACHMENTS…742
26. GENERAL PRECAUTIONS…743
26.1 PRECAUTIONS RELATED TO SAFETY…743
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…744
27. HANDLING BUCKET WITH HOOD…745
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOD…745
27.2 PROHIBITED OPERATIONS…745
27.3 PRECAUTIONS DURING OPERATIONS…745
28. USING SEAT BELT…746
28.1 SEAT BELT…746
29. HANDLING CAR HEATER…748
29.1 EXPLANATION OF COMPONENTS…748
29.2 PREPARING CAR HEATER…749
30. MACHINE READY FOR ATTACHMENTS…750
30.1 GENERAL LOCATIONS…750
30.2 HYDRAULIC CIRCUIT…752
30.3 OPERATION…755
30.4 HANDLING ACCUMULATOR…757
30.5 LONG-TERM STORAGE…758
30.6 SPECIFICATIONS…758
31. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…759
31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…759
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…760
31.3 SELECTION OF TRACK SHOES…761
31.4 HANDLING RUBBER PAD SHOE…762
31.5 HANDLING AUTOMATIC GREASING CONTROLLER…764
32. EXTENDING MACHINE SERVICE LIFE…769
32.1 HYDRAULIC BREAKER…769
32.2 POWER RIPPER…772
32.3 FORK GRAB…773
32.4 GRAPPLE BUCKET…774
32.5 SCRAP GRAPPLE…775
32.6 CRUSHER & SHASHER…776
32.7 HYDRAULIC PILE DRIVER…777
32.8 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE…778
SEAM002205 – Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual…781
COVER…781
1. FOREWARD…785
2. SAFETY INFORMATION…786
3. INTRODUCTION…787
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…788
5. CONTENTS…789
SAFETY…793
6. GENERAL PRECAUTIONS…794
7. PRECAUTIONS DURING OPERATION…800
7.1 BEFORE STARTING ENGINE…800
7.2 OPERATING MACHINE…802
7.3 TRANSPORTATION…807
7.4 BATTERY…808
7.5 TOWING…809
7.6 BUCKET WITH HOOK…810
8. PRECAUTIONS FOR MAINTENANCE…813
8.1 BEFORE CARRYING OUT MAINTENANCE…813
8.2 DURING MAINTENANCE…816
9. POSITION FOR ATTACHING SAFETY LABELS…820
OPERATION…825
10. GENERAL VIEW…826
10.1 GENERAL VIEW OF MACHINE…826
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…827
11. EXPLANATION OF COMPONENTS…828
11.1 MACHINE MONITOR…828
11.2 SWITCHES…839
11.3 CONTROL LEVERS, PEDALS…844
11.4 CEILING WINDOW…849
11.5 FRONT WINDOW…850
11.6 DOOR LOCK…852
11.7 CAP, COVER WITH LOCK…853
11.8 HOT/COOL BOX…854
11.9 LUGGAGE BOX…854
11.10 ASHTRAY…854
11.11 AIR CONDITIONER…855
11.12 CAR RADIO…858
11.13 FUSE…863
11.14 FUSIBLE LINK…864
11.15 CONTROLLERS…864
11.16 TOOL BOX…864
11.17 GREASE PUMP HOLDER…864
12. OPERATION…865
12.1 CHECK BEFORE STARTING ENGINE…865
12.2 STARTING ENGINE…878
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…881
12.4 MOVING MACHINE OFF…887
12.5 STEERING MACHINE…890
12.6 STOPPING MACHINE…892
12.7 SWINGING…893
12.8 OPERATION OF WORK EQUIPMENT…894
12.9 WORKING MODE SELECTION…895
12.10 HANDLING ACTIVE MODE…897
12.11 PROHIBITIONS FOR OPERATION…898
12.12 PRECAUTIONS FOR OPERATION…900
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…901
12.14 HOW TO ESCAPE FROM MUD…903
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…904
12.16 REPLACEMENT AND INVERSION OF BUCKET…905
12.17 PARKING MACHINE…907
12.18 CHECK AFTER FINISHING WORK…908
12.19 STOPPING ENGINE…909
12.20 CHECK AFTER STOPPING ENGINE…910
12.21 LOCKING…910
13. TRANSPORTATION…911
13.1 LOADING, UNLOADING WORK…911
13.2 PRECAUTIONS FOR LOADING…913
13.3 PRECAUTIONS FOR TRANSPORTATION…914
14. COLD WEATHER OPERATION…916
14.1 PRECAUTIONS FOR LOW TEMPERATURE…916
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…918
14.3 AFTER COLD WEATHER…918
15. LONG-TERM STORAGE…919
15.1 BEFORE STORAGE…919
15.2 DURING STORAGE…920
15.3 AFTER STORAGE…920
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…920
16. TROUBLESHOOTING…921
16.1 PHENOMENA THAT ARE NOT FAILURES…921
16.2 METHOD OF TOWING MACHINE…921
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK…921
16.4 PRECAUTIONS ON PARTICULAR JOBSITES…922
16.5 IF BATTERY IS DISCHARGED…922
16.6 OTHER TROUBLE…926
MAINTENANCE…931
17. GUIDES TO MAINTENANCE…932
18. OUTLINES OF SERVICE…934
18.1 OUTLINE OF OIL, FUEL, COOLANT…934
18.2 OUTLINE OF ELECTRIC SYSTEM…937
18.3 OUTLINE OF HYDRAULIC SYSTEM…938
19. WEAR PARTS LIST…939
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…940
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…944
21.1 INTRODUCTION OF NECESSARY TOOLS…944
21.2 TORQUE LIST…945
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…946
23. MAINTENANCE SCHEDULE CHART…948
23.1 MAINTENANCE SCHEDULE CHART…948
23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER…950
24. SERVICE PROCEDURE…951
24.1 INITIAL 250 HOURS SERVICE…951
REPLACE FUEL FILTER CARTRIDGE…948
CHECK ENGINE VALVE CLEARANCE, ADJUST…948
24.2 WHEN REQUIRED…952
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…948
CLEAN INSIDE OF COOLING SYSTEM…948
CHECK AND TIGHTEN TRACK SHOE BOLTS…948
CHECK AND ADJUST TRACK TENSION…948
CHECK ELECTRICAL INTAKE AIR HEATER…948
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…948
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…948
ADJUST BUCKET CLEARANCE…948
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…948
CHECK AND ADJUST AIR CONDITIONER…948
REPLACE ADDITIONAL BREAKER FILTER ELEMENT…948
24.3 CHECK BEFORE STARTING…970
CHECK COOLANT LEVEL, ADD WATER…948
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…948
CHECK FUEL LEVEL, ADD FUEL…948
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…948
CHECK AIR CLEANER FOR CLOGGING…948
CHECK ELECTRIC WIRINGS…948
CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER…948
24.4 EVERY 50 HOURS SERVICE…974
DRAIN WATER AND SEDIMENT FROM FUEL TANK…948
24.5 EVERY 100 HOURS SERVICE…975
LUBRICATING…948
BOOM CYLINDER FOOT PIN (2 POINTS)…948
BOOM FOOT PIN (2 POINTS)…948
BOOM CYLINDER ROD END (2 POINTS)…948
ARM CYLINDER FOOT PIN (1 POINT)…949
BOOM-ARM COUPLING PIN (1 POINT)…949
ARM CYLINDER ROD END (1 POINT)…949
BUCKET CYLINDER FOOT PIN (1 POINT)…949
ARM-LINK COUPLING PIN (1 POINT)…949
ARM-BUCKET COUPLING PIN (1 POINT)…949
LINK COUPLING PIN (1 POINT)…949
BUCKET CYLINDER ROD END (1 POINT)…949
BUCKET-LINK COUPLING PIN (2 POINTS)…949
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…949
24.6 EVERY 250 HOURS SERVICE…978
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…949
CHECK LEVEL OF BATTERY ELECTROLYTE…949
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…949
REPLACE HYDRAULIC FILTER ELEMENT…949
CHECK FAN BELT TENSION, ADJUST…949
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…949
24.7 EVERY 500 HOURS SERVICE…986
REPLACE FUEL FILTER CARTRIDGE…949
CHECK SWING PINION GREASE LEVEL, ADD GREASE…949
LUBRICATE SWING CIRCLE (2 POINTS)…949
CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…949
CLEAN INTERNAL AND EXTERNAL AIR FILTERS OF AIR CONDITIONER SYSTEM (ONLY FOR MACHINES EQUIPPED WITH AIR CONDITIONER)…949
24.8 EVERY 1000 HOURS SERVICE…991
CHANGE OIL IN SWING MACHINARY CASE…949
CHANGE OIL IN FINAL DRIVE CASE…949
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…949
CHECK PLAY OF TURBOCHARGER ROTOR…949
REPLACE CORROSION RESISTOR CARTRIDGE…949
24.9 EVERY 2000 HOURS SERVICE…995
CHECK OIL LEVEL IN PTO GEAR CASE, ADD OIL…950
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER…950
CLEAN, CHECK TURBOCHARGER…950
CHECK ALTERNATOR, STARTING MOTOR…950
CHECK ENGINE VALVE CLEARANCE, ADJUST…950
24.10 EVERY 4000 HOURS SERVICE…1001
CHECK WATER PUMP…950
SPECIFICATIONS…1003
25. SPECIFICATIONS…1004
OPTIONS, ATTACHMENTS…1013
26. GENERAL PRECAUTIONS…1014
26.1 PRECAUTIONS RELATED TO SAFETY…1014
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…1015
27. HANDLING BUCKET WITH HOOK…1016
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…1016
27.2 PROHIBITED OPERATIONS…1016
27.3 PRECAUTIONS DURING OPERATIONS…1016
28. USING SEAT BELT…1017
28.1 SEAT BELT…1017
29. HANDLING CAR HEATER…1019
29.1 EXPLANATION OF COMPONENTS…1019
29.2 PREPARING CAR HEATER…1020
30. MACHINES READY FOR ATTACHMENTS…1021
30.1 GENERAL LOCATIONS…1021
30.2 HYDRAULIC CIRCUIT…1023
30.3 OPERATION…1026
30.4 HANDLING ACCUMULATOR…1028
30.5 LONG-TERM STORAGE…1029
30.6 SPECIFICATIONS…1029
31. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…1030
31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…1030
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…1031
31.3 SELECTION OF TRACK SHOES…1032
31.4 HANDLING RUBBER PAD SHOE…1033
31.5 HANDLING AUTOMATIC GREASING CONTROLLER…1035
32. EXTENDING MACHINE SERVICE LIFE…1040
32.1 HYDRAULIC BREAKER…1040
32.2 POWER RIPPER…1043
32.3 FORK GRAB…1044
32.4 GRAPPLE BUCKET…1045
32.5 SCRAP GRAPPLE…1046
32.6 CRUSHER & SMASHER…1047
32.7 HYDRAULIC PILE DRIVER…1048
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE…1049
SEAM002207 – Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC130-6 Mighty Operation & Maintenance Manual…1052
COVER…1052
1. FOREWORD…1055
2. SAFETY INFORMATION…1056
3. INTRODUCTION…1057
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1058
5. CONTENTS…1059
SAFETY…1063
6. GENERAL PRECAUTIONS…1064
7. PRECAUTIONS DURING OPERATION…1071
7.1 BEFORE STARTING ENGINE…1071
7.2 AFTER STARTING ENGINE…1073
7.3 TRANSPORTATION…1080
7.4 BATTERY…1081
7.5 TOWING…1083
7.6 BUCKET WITH HOOK…1084
8. PRECAUTIONS FOR MAINTENANCE…1085
8.1 BEFORE CARRYING OUT MAINTENANCE…1085
8.2 DURING MAINTENANCE…1089
9. POSITION FOR ATTACHING SAFETY LABELS…1094
OPERATION…1099
10. GENERAL VIEW…1100
10.1 GENERAL VIEW OF MACHINE…1100
10.2 GENRAL VIEW OF CONTROLS AND GAUGES…1101
11. EXPLANATION OF COMPONENTS…1102
11.1 MACHINE MONITOR…1102
11.2 SWITCHES…1113
11.3 CONTROL LEVERS, PEDALS…1118
11.4 CEILING WINDOW…1123
11.5 FRONT WINDOW…1124
11.6 DOOR LOCK…1126
11.7 CAP, COVER WITH LOCK…1127
11.8 HOT / COOL BOX…1128
11.9 LUGGAGE BOX…1128
11.10 ASHTRAY…1128
11.11 AIR CONDITIONER…1129
11.12 CAR RADIO…1132
11.13 ELECTRIC POWER SOURCE…1136
11.14 FUSE…1137
11.15 FUSIBLE LINK…1138
11.16 CONTROLLERS…1138
11.17 TOOL BOX…1138
11.18 GREASE PUMP HOLDER…1138
12. OPERATION…1139
12.1 CHECK BEFORE STARTING ENGINE…1139
12.2 STARTING ENGINE…1151
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…1154
12.4 MOVING MACHINE OFF…1160
12.5 STEERING MACHINE…1163
12.6 STOPPING MACHINE…1165
12.7 SWINGING…1166
12.8 OPERATION OF WORK EQUIPMENT…1167
12.9 WORKING MODE SELECTION…1168
12.10 HANDLING ACTIVE MODE…1170
12.11 PROHIBITIONS FOR OPERATION…1172
12.12 PRECAUTIONS FOR OPERATION…1174
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…1175
12.14 HOW TO ESCAPE FROM MUD…1177
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…1178
12.16 REPLACEMENT AND INVERSION OF BUCKET…1179
12.17 PARKING MACHINE…1181
12.18 CHECK AFTER FINISHING WORK…1182
12.19 STOPPING ENGINE…1183
12.20 CHECK AFTER STOPPING ENGINE…1184
12.21 LOCKING…1184
12.22 HANDLING ROAD LINER (ROAD LINER ONLY)…1185
13. TRANSPORTATION…1189
13.1 LOADING, UNLOADING WORK…1189
13.2 PRECAUTIONS FOR LOADING…1191
13.3 PRECAUTIONS FOR TRANSPORTATION…1192
14. COLD WEATHER OPERATION…1195
14.1 PRECAUTIONS FOR LOW TEMPERATURE…1195
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…1197
14.3 AFTER COLD WEATHER…1197
15. LONG-TERM STORAGE…1198
15.1 BEFORE STORAGE…1198
15.2 DURING STORAGE…1199
15.3 AFTER STORAGE…1199
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…1199
16. TROUBLESHOOTING…1200
16.1 WHEN MACHINE RUNS OUT OF FUEL…1200
16.2 PHENOMENA…1200
16.3 METHOD OF TOWING MACHINE…1200
16.4 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK…1201
16.5 PRECAUTIONS ON PARTICULAR JOBSITES…1201
16.6 IF BATTERY IS DISCHARGED…1202
16.7 OTHER TROUBLE…1206
MAINTENANCE…1211
17. GUIDES TO MAINTENANCE…1212
18. OUTLINES OF SERVICE…1214
18.1 OUTLINE OF OIL, FUEL, COOLANT…1214
18.2 OUTLINE OF ELECTRIC SYSTEM…1217
18.3 OUTLINE OF HYDRAULIC SYSTEM…1218
19. WEAR PARTS LIST…1219
20. USE OF FUEL, COOLANT, AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1220
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1224
21.1 INTRODUCTION OF NECESSARY TOOLS…1224
21.2 TORQUE LIST…1225
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1226
23. MAINTENANCE SCHEDULE CHART…1230
23.1 MAINTENANCE SCHEDULE CHART…1230
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…1232
24. SERVICE PROCEDURE…1233
24.1 INITIAL 250 HOURS SERVICE…1233
24.2 WHEN REQUIRED…1234
24.3 CHECK BEFORE STARTING…1253
24.4 EVERY 50 HOURS SERVICE…1258
24.5 EVERY 100 HOURS SERVICE…1259
24.6 EVERY 250 HOURS SERVICE…1262
24.7 EVERY 500 HOURS SERVICE…1268
24.8 EVERY 1000 HOURS SERVICE…1274
24.9 EVERY 2000 HOURS SERVICE …1279
24.10 EVERY 4000 HOURS SERVICE…1281
24.11 EVERY 5000 HOURS SERVICE…1282
SPECIFICATIONS…1287
25. SPECIFICATIONS…1288
OPTIONS, ATTACHMENTS…1297
26. GENERAL PRECAUTIONS…1298
26.1 PRECAUTIONS RELATED TO SAFETY…1298
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…1299
27. HANDLING BUCKET WITH HOOK…1300
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…1300
27.2 PROHIBITED OPERATIONS…1300
27.3 PRECAUTIONS DURING OPERATIONS…1300
28. USING SEAT BELT…1301
28.1 SEAT BELT…1301
29. HANDLING CAR HEATER…1303
29.1 EXPLANATION OF COMPONENTS…1303
29.2 PREPARING CAR HEATER…1304
30. MACHINES…1305
30.1 GENERAL LOCATIONS…1305
30.2 HYDRAULIC CIRCUIT…1308
30.3 OPERATION…1311
30.4 HANDLING ACCUMULATOR…1313
30.5 LONG-TERM STORAGE…1314
30.6 SPECIFICATIONS…1314
31. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…1315
31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…1315
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…1316
31.3 SELECTION OF TRACK SHOES…1317
31.4 HANDLING ROAD LINER…1318
31.5 HANDLING AUTOMATIC GREASING CONTROLLER…1320
32. EXTENDING MACHINE SERVICE LIFE…1325
32.1 HYDRAULIC BREAKER…1325
32.2 POWER RIPPER…1329
32.3 FORK GRAB…1330
32.4 GRAPPLE BUCKET…1331
32.5 SCRAP GRAPPLE…1332
32.6 CRUSHER AND SMASHER…1333
32.7 HYDRAULIC PILE DRIVER…1334
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE…1335
SEAM002213T – Hydraulic Excavator PC100-6, PC100L-6, PC120-6, PC120LG-6, PC130-6 Mighty Operation & Maintenance Manual…1338
COVER…1338
1. FOREWORD…1339
2. SAFETY INFORMATION…1342
3. INTRODUCTION…1343
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1344
5. CONTENTS…1345
SAFETY…1349
6. GENERAL PRECAUTIONS…1350
7. PRECAUTIONS DURING OPERATION…1357
7.1 BEFORE STARTING ENGINE…1357
7.2 AFTER STARTING ENGINE…1359
7.3 TRANSPORTATION…1366
7.4 BATTERY…1367
7.5 TOWING…1369
7.6 BUCKET WITH HOOK…1370
8. PRECAUTIONS FOR MAINTENANCE…1371
8.1 BEFORE CARRYING OUT MAINTENANCE…1371
8.2 DURING MAINTENANCE…1375
9. POSITION FOR ATTACHING SAFETY LABELS…1381
OPERATION…1385
10. GENERAL VIEW…1386
10.1 GENERAL VIEW OF MACHINE…1386
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…1387
11. EXPLANATION OF COMPONENTS…1388
11.1 MACHINE MONITOR…1388
11.2 SWITCHES…1399
11.3 CONTROL LEVERS, PEDALS…1404
11.4 CEILING WINDOW…1409
11.5 FRONT WINDOW…1410
11.6 DOOR LOCK…1412
11.7 CAP, COVER WITH LOCK…1413
11.8 HOT/COOL BOX…1414
11.9 LUGGAGE BOX…1414
11.10 ASHTRAY…1414
11.11 AIR CONDITIONER…1415
11.12 CAR RADIO…1418
11.13 ELECTRIC POWER SOURCE…1422
11.14 FUSE…1423
11.15 FUSIBLE LINK…1424
11.16 CONTROLLERS…1424
11.17 TOOL BOX…1424
11.18 GREASE PUMP HOLDER…1424
12. OPERATION…1425
12.1 CHECK BEFORE STARTING ENGINE…1425
12.2 STARTING ENGINE…1437
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE…1440
12.4 MOVING MACHINE OFF…1446
12.5 STEERING MACHINE…1449
12.6 STOPPING MACHINE…1451
12.7 SWINGING…1452
12.8 OPERATION OF WORK EQUIPMENT…1453
12.9 WORKING MODE SELECTION…1454
12.10 HANDLING ACTIVE MODE…1456
12.11 PROHIBITIONS FOR OPERATION…1458
12.12 PRECAUTIONS FOR OPERATION…1460
12.13 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…1461
12.14 HOW TO ESCAPE FROM MUD…1463
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…1464
12.16 REPLACEMENT AND INVERSION OF BUCKET…1465
12.17 PARKING MACHINE…1467
12.18 CHECK AFTER FINISHING WORK…1468
12.19 STOPPING ENGINE…1469
12.20 CHECK AFTER STOPPING ENGINE…1470
12.21 LOCKING…1470
12.22 HANDLING ROAD LINER (ROAD LINER ONLY)…1471
13. TRANSPORTATION…1475
13.1 LOADING, UNLOADING WORK…1475
13.2 PRECAUTIONS FOR LOADING…1477
13.3 PRECAUTIONS FOR TRANSPORTATION…1478
14. COLD WEATHER OPERATION…1481
14.1 PRECAUTIONS FOR LOW TEMPERATURE…1481
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…1483
14.3 AFTER COLD WEATHER…1483
15. LONG-TERM STORAGE…1484
15.1 BEFORE STORAGE…1484
15.2 DURING STORAGE…1485
15.3 AFTER STORAGE…1485
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE…1485
16. TROUBLESHOOTING…1486
16.1 WHEN MACHINE RUNS OUT OF FUEL …1486
16.2 PHENOMENA THAT ARE NOT FAILURES…1486
16.3 METHOD OF TOWING MACHINE…1486
16.4 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK…1487
16.5 PRECAUTIONS ON PARTICULAR JOBSITES…1487
16.6 IF BATTERY IS DISCHARGED…1488
16.7 OTHER TROUBLE…1492
MAINTENANCE…1497
17. GUIDES TO MAINTENANCE…1498
18. OUTLINES OF SERVICE…1500
18.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…1500
18.2 OUTLINE OF ELECTRIC SYSTEM…1504
18.3 OUTLINE OF HYDRAULIC SYSTEM…1505
19. WEAR PARTS LIST…1506
20. RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1507
20.1 USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1508
20.2 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1509
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1510
21.1 INTRODUCTION OF NECESSARY TOOLS…1510
21.2 TORQUE LIST…1511
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1512
23. MAINTENANCE SCHEDULE CHART…1516
23.1 MAINTENANCE SCHEDULE CHART…1516
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…1518
24. SERVICE PROCEDURE…1519
24.1 INITIAL 250 HOURS SERVICE…1519
24.2 WHEN REQUIRED…1520
24.3 CHECK BEFORE STARTING…1539
24.4 EVERY 50 HOURS SERVICE…1544
24.5 EVERY 100 HOURS SERVICE…1545
24.6 EVERY 250 HOURS SERVICE…1548
24.7 EVERY 500 HOURS SERVICE…1555
24.8 EVERY 1000 HOURS SERVICE…1561
24.9 EVERY 2000 HOURS SERVICE…1566
24.10 EVERY 4000 HOURS SERVICE…1568
24.11 EVERY 5000 HOURS SERVICE…1569
SPECIFICATIONS…1574
25. SPECIFICATIONS…1575
OPTIONS, ATTACHMENTS…1587
26. GENERAL PRECAUTIONS…1588
26.1 PRECAUTIONS RELATED TO SAFETY…1588
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS…1589
27. HANDLING BUCKET WITH HOOK…1590
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK…1590
27.2 PROHIBITED OPERATIONS…1590
27.3 PRECAUTIONS DURING OPERATIONS…1590
28. USING SEAT BELT …1591
28.1 SEAT BELT…1591
29. HANDLING CAR HEATER…1593
29.1 EXPLANATION OF COMPONENTS…1593
29.2 PREPARING CAR HEATER…1594
30. MACHINES READY FOR ATTACHMENTS…1595
30.1 GENERAL LOCATIONS…1595
30.2 HYDRAULIC CIRCUIT…1598
30.3 OPERATION…1601
30.4 HANDLING ACCUMULATOR…1603
30.5 LONG-TERM STORAGE…1604
30.6 SPECIFICATIONS…1604
31. INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…1605
31.1 INTRODUCTION OF OPTIONAL PARTS AND ATTACHMENTS…1605
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE…1606
31.3 SELECTION OF TRACK SHOES…1607
31.4 HANDLING ROAD LINER…1608
31.5 HANDLING AUTOMATIC GREASING CONTROLLER…1610
32. EXTENDING MACHINE SERVICE LIFE…1615
32.1 HYDRAULIC BREAKER…1615
32.2 POWER RIPPER…1619
32.3 FORK GRAB…1620
32.4 GRAPPLE BUCKET…1621
32.5 SCRAP GRAPPLE…1622
32.6 CRUSHER AND SMASHER…1623
32.7 HYDRAULIC PILE DRIVER…1624
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE…1625
SEAM063601T – Hydraulic Excavator GALEO PC120-6, PC120LC-6 Operation & Maintenance Manual…1627
COVER…1627
1. FOREWORD…1628
2. SAFETY INFORMATION…1631
3. INTRODUCTION…1633
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…1634
5. CONTENTS…1636
SAFETY…1640
6. GENERAL PRECAUTIONS…1641
7. PRECAUTIONS DURING OPERATION…1648
7.1 BEFORE STARTING ENGINE…1648
7.2 AFTER STARTING ENGINE…1650
7.3 TRANSPORTATION…1657
7.4 BATTERY…1658
7.5 TOWING…1660
7.6 BUCKET WITH HOOK…1661
8. PRECAUTIONS FOR MAINTENANCE…1662
8.1 BEFORE CARRYING OUT MAINTENANCE…1662
8.2 DURING MAINTENANCE…1666
9. POSITION FOR ATTACHING SAFETY LABELS…1672
OPERATION…1678
10. GENERAL VIEW…1679
10.1 GENERAL VIEW OF MACHINE…1679
10.2 GENERAL VIEW OF CONTROLS AND GAUGES…1680
11. EXPLANATION OF COMPONENTS…1681
11.1 MACHINE MONITOR…1681
11.2 SWITCHES…1692
11.3 CONTROL LEVERS, PEDALS…1697
11.4 CEILING WINDOW…1702
11.5 FRONT WINDOW …1703
11.6 DOOR LOCK…1705
11.7 CAP, COVER WITH LOCK…1706
11.8 HOT/COOL BOX …1707
11.9 LUGGAGE BOX…1707
11.10 ASHTRAY…1707
11.11 AIR CONDITIONER…1708
11.12 CAR RADIO…1711
11.13 ELECTRIC POWER SOURCE …1715
11.14 FUSE …1716
11.15 FUSIBLE LINK…1717
11.16 CONTROLLERS…1717
11.17 TOOL BOX …1717
11.18 GREASE PUMP HOLDER…1717
12. OPERATION…1718
12.1 CHECK BEFORE STARTING ENGINE…1718
12.2 STARTING ENGINE…1730
12.3 OPERATION AND CHECKS AFTER STARTING ENGINE…1734
12.4 STOPPING THE ENGINE …1740
12.5 MOVING MACHINE OFF…1741
12.6 STREETING MACHINE …1744
12.7 STOPPING MACHINE …1746
12.8 SWINGING …1747
12.9 OPERATION OF WORK EQUIPMENT…1748
12.10 WORKING MODE SELECTION…1749
12.11 HANDLING ACTIVE MODE …1751
12.12 PROHIBITIONS FOR OPERATION …1753
12.13 PRECAUTIONS FOR OPERATION …1755
12.14 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS …1756
12.15 HOW TO ESCAPE FROM MUD…1758
12.16 WORK POSSIBLE USING HYDRAULIC EXCAVATOR…1759
12.17 REPLACEMENT AND INVERSION OF BUCKET …1760
12.18 PARKING MACHINE …1762
12.19 CHECK AFTER STOPPING ENGINE …1764
12.20 CHECK AFTER DAILY WORK …1764
12.21 LOCKING …1764
12.22 HANDLING ROAD LINER (ROAD LINER ONLY)…1765
13. TRANSPORTATION…1769
13.1 LOADING, UNLOADING WORK…1769
13.2 PRECAUTIONS FOR LOADING…1771
13.3 PRECAUTIONS FOR TRANSPORTATION…1772
14. COLD WEATHER OPERATION…1774
14.1 PRECAUTIONS FOR LOW TEMPERATURE…1774
14.2 PRECAUTIONS AFTER COMPLETION OF WORK…1776
14.3 AFTER COLD WEATHER…1776
15. LONG-TERM STORAGE…1777
15.1 BEFORE STORAGE…1777
15.2 DURING STORAGE…1778
15.3 AFTER STORAGE…1778
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE …1778
16. TROUBLESHOOTING…1779
16.1 WHEN MACHINE RUNS OUT OF FUEL …1779
16.2 PHENOMENA THAT ARE NOT FAILURES…1779
16.3 METHOD OF TOWING MACHINE…1779
16.4 USING METHOD FOR LIGHT-WEIGHT TOWING HOOK…1780
16.5 PRECAUTIONS ON PARTICULAR JOBSITES …1780
16.6 IF BATTERY IS DISCHARGED…1781
16.7 OTHER TROUBLE…1785
MAINTENANCE…1790
17. GUIDES TO MAINTENANCE…1791
18. OUTLINES OF SERVICE…1793
18.1 HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC …1793
18.2 OUTLINE OF ELECTRIC SYSTEM…1797
18.3 OUTLINE OF HYDRAULIC SYSTEM…1798
19. WEAR PARTS LIST…1799
20. RECOMMENDED FUEL, COOLANT, AND LUBRICANT…1800
20.1 USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…1801
20.2 RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…1802
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…1803
21.1 INTRODUCTION OF NECESSARY TOOLS…1803
21.2 TORQUE LIST…1804
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…1805
23. MAINTENANCE SCHEDULE CHART…1807
23.1 MAINTENANCE SCHEDULE CHART…1807
23.2 MAINTENANCE INTERVAL WHEN USING HYDRAULIC BREAKER…1809
24. SERVICE PROCEDURE…1810
24.1 INITIAL 250 HOURS SERVICE…1810
24.2 WHEN REQUIRED…1811
24.3 CHECK BEFORE STARTING…1832
24.4 EVERY 50 HOURS SERVICE…1837
24.5 EVERY 100 HOURS SERVICE…1838
24.6 EVERY 250 HOURS SERVICE…1841
24.7 EVERY 500 HOURS SERVICE…1845
24.8 EVERY 1000 HOURS SERVICE…1851
24.9 EVERY 2000 HOURS SERVICE…1855
24.10 EVERY 4000 HOURS SERVICE…1857
24.11 EVERY 5000 HOURS SERVICE…1858
SPECIFICATIONS…1863
25. SPECIFICATIONS…1864
OPTIONS, ATTACHMENTS …1869
26. GENERAL PRECAUTIONS…1870
26.1 PRECAUTIONS RELATED FOR SAFETY …1870
27. HANDLING BUCKET WITH HOOK …1871
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK …1871
27.2 PROHIBITED OPERATIONS …1871
27.3 PRECAUTIONS DURING OPERATIONS…1871
28. USING SEAT BELT …1872
28.1 SEAT BELT …1872
29. HANDLING CAR HEATER …1874
29.1 EXPANATION OF COMPONENTS…1874
29.2 PREPARING CAR HEATER …1875
30. MACHINES READY FOR ATTACHMENTS …1876
30.1 GENERAL LOCATIONS …1876
30.2 HYDRAULIC CIRCUIT …1879
30.3 OPERATION…1882
30.4 HANDLING ACCUMULATOR…1884
30.5 LONG-TERM STORAGE …1885
30.6SPECIFICATIONS…1885
31. INTRODUCTION OF OPTIONAL PARTS AND ATTCHMENTS …1886
31.1 INTRODUCTION OF OPTIOAL PARTS AND ATTACHMENTS …1886
31.2 ATTACHMENT INSTALLATION COMBINATION TABLE …1887
31.3 SELECTION OF TRACK SHOES …1888
31.4 HANDLING ROAD LINER …1889
31.5 HANDLING AUTOMATIC GREASING CONTROLLER …1891
32. EXTENDING MACHINE SERVICE LIFE …1896
32.1 HYDRAULIC BREAKER …1896
32.2 POWER RIPPER …1900
32.3 FORK GRAB…1901
32.4 GRAPPLE BUCKET …1902
32.5 SCRAP GRAPPLE …1903
32.6 CRUSHER AND SMASHER …1904
32.7 HYDRAULIC PILE DRIVER …1905
32.8 HYDRAULIC EXCAVATOR WITH MULTI-PURPOSE CRANE …1906
SEBM003307 – Hydraulic Excavator PC100-6, PC120-6 Shop Manual…1908
COVER…1908
CONTENTS…1909
SAFETY…1914
FOREWORD…1916
GENERAL…1916
HOW TO READ THE SHOP MANUAL…1917
HOISTING INSTRUCTIONS…1918
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER…1919
COATING MATERIALS…1921
STANDARD TIGHTENING TORQUE…1923
ELECTRIC WIRE CODE…1926
CONVERSION TABLE…1927
UNITS…1933
01 GENERAL …1934
GENERAL ASSEMBLY DRAWING…1935
SPECIFICATIONS…1937
WEIGHT TABLE…1939
LIST OF LUBRICANT AND WATER…1943
10 STRUCTURE AND FUNCTION…1944
RADIATOR AND OIL COOLER…1945
PTO (COUPLING)…1949
POWER TRAIN…1950
SWING CIRCLE…1951
SWING MACHINERY…1954
TRACK FRAME…1955
IDLER…1957
IDLER CUSHION…1957
CARRIER ROLLER…1958
TRACK ROLLER…1958
TRACK SHOE…1959
HYDRAULIC PIPING DRAWING…1959
HYDRAULIC CIRCUIT DIAGRAM…1959
HYDRAULIC TANK…1975
HYDRAULIC PUMP…1976
CONTROL VALVE…2007
CLSS…2032
SWING MOTOR…2073
CENTER SWIVEL JOINT…2080
TRAVEL MOTOR…2081
VALVE CONTROL…2094
WORK EQUIPMENT – SWING PPC VAVLE…2095
TRAVEL PPC VALVE…2099
SERVICE PPC VALVE…2105
SAFETY LOCK VALVE…2110
PPC ACCUMULATOR…2110
PPC SHUTTLE – TRAVEL JUNCTION VALVE…2111
EPC – SOLENOID VALVE…2115
BOOM HOLDING VALVE…2121
HYDRAULIC CYLINDER…2124
ACCUMULATOR FOR BREAKER…2126
ADDITIONAL FILTER FOR BREAKER…2127
WORK EQUIPMENT…2128
ELECTRICAL WIRING DIAGRAM…2129
ELECTRICAL CIRCUIT DIAGRAM…2131
ENGINE CONTROL SYSTEM…2144
ELECTRONIC CONTROL SYSTEM…2151
MACHINE MONITOR SYSTEM…2185
20 TESTING AND ADJUSTING…2198
TABLE OF JUDGEMENT STANDARD VALUE…2199
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…2211
TOOLS FOR TESTING ADJUSTING, AND TROUBLESHOOTING…2230
MEASURING ENGINE SPEED…2231
MEASURING EXHAUST GAS COLOR…2232
ADJUSTING VALVE CLEARENCE…2233
MEASURING COMPRESSION PRESSURE…2234
MEASURING BLOWBY PRESSURE…2234
TESTING AND ADJUSTING FUEL INJECTION TIMING…2235
MEASURING ENGINE OIL PRESSURE…2236
TESTING AND ADJUSTING FAN BELT TENSION…2237
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…2237
ADJUSTING ENGINE SPEED SENSOR…2238
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE…2239
TESTING CLEARANCE OF SWING CIRCLE BEARING…2240
TESTING AND ADJUSTING TRACK SHOE TENSION…2241
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…2242
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTION INPUT PRESSURE)…2248
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LD DIFFERENTIAL PRESSURE…2255
TESTING AND ADJUSTING VARIABLE THROTTLE VALVE…2258
TESTING AND ADJUSTIN CONTROL PUMP CIRCUIT OIL PRESSURE…2260
TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE…2262
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE…2266
ADJUSTING WORK EQUIPMENT – SWING PPC VALVE…2270
ADJUSTING TRAVEL LEVER…2271
TESTING TRAVEL DEVIATION…2272
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…2273
MEASURING OIL LEAKAGE…2275
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…2277
BLEEDING AIR…2279
TROUBLESHOOTING…2284
POINTS TO REMEMBER WHEN TROUBLESHOOTING…2285
CONNECTOR TYPES AND MOUNTING LOCATIONS…2297
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…2306
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM…2317
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITOR PANEL…2320
METHOD OF USING JUDGEMENT TABLE…2339
METHOD OF USING TROUBLESHOOTING CHARTS…2341
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…2343
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)…2352
N-1 COMMUNICATION ABNORMALITY…2353
N-1 [E218] COMMUNICATION ABNORMALITY…2354
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)…2356
POINTS TO REMEMBER WHEN CARRYIN GOUT TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM…2357
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2358
JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATED PARTS…2360
ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAM…2361
TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE…2362
E-1 ABNORMALITY IN ENGINE THROTTLE CONTROLLER POWER SOURCE SYSTEM…2362
E-2 [E3:08} ABNORMALITY IN FUEL CONTROL DIAL INPUT VLAVUE SYSTEM IS DISPLAYED…2363
E-3 [E3:17] ABNORMALITY (DISCONNECTION) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED …2364
E-4 [E3:18] ABNORMALITY (SHORT CIRCUIT) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED…2365
E-5 [E3:01] ABNORMALITY IN NETWORK RECEPTION SYSTEM IS DISPLAYED…2366
E-6 [E3:05] ABNORMALITY IN MODEL CODE IS DISPLAYED…2368
E-7 [E3:06] ABNORMALTIY IN GOVERNOR POTENTIOMETER SYSTEM IS DISPLAYED…2369
E-8 [E3:07] ABNORMALITY IN PUMP CONTROLLER THROTTLE SYSTEM IS DISPLAYED…2370
E-9 [E3:15] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…2370
E-10 [E3:16] ABNORMALITY (STEP-OUT) IN GOVERNOT MOTOR SYSTEM IS DISPLAYED…2371
E-11 ENGINE DOES NOT START…2373
E-12 ENGINE SPEED IS IRREGULAR…2375
A) KILLING SPEED IS IRREGULAR…2375
B) THERE IS HUNTING…2377
E-13 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)…2379
E-14 ENGINE DOES NOT STOP …2381
E-15 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)…2383
TROUBLESHOOTING OF ENGINE THROTTLE PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)…2384
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER SYSTEM…2385
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2387
JUDGEMENT TABLE FOR ENGINE THROTTLE – PUMP CONTROLLER POWERSOURCE (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS…2391
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE…2393
E-1 ABNORMALITY IN ENGINE THRO0TTLE – PUMP CONTROLLER POWER SOURCE (CONTROLLER LED ID OFF)…2395
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…2396
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED…2397
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED…2398
E-5 [E306] ABNORMALITY IN FEED BACK POTENTIOMETER SYSTEM IS DISPLAYED…2399
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…2400
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED…2401
E-8 ENGINE DOES NOT START…2403
E-9 ENGINE SPEED IS IRREGULAR…2405
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)…2409
E-11 ENGINE DOES NOT STOP…2411
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)…2413
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)…2416
METHOD OF USING TROUBLESHOOTING CHARTS…2417
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…2421
S-2 ENGINE DOES NOT START…2422
(1) ENGINE DOES NOT TURN…2422
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…2423
(3) EXHAUST SMOKE COMES OUT BUT ENGINES DOES NOT START (FUEL IS BEING INJECTED)…2424
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…2425
S-4 ENGINE STOPS DURING OPERATIONS…2426
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…2427
S-6 ENGINE LACKS OUTPUT (NO POWER)…2428
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…2429
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…2430
S-9 OIL BECOMES CONTAMINATED QUICKLY…2431
S-10 FUEL CONSUMPTION IS EXCESSIVE…2432
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…2433
S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)…2434
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…2435
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…2436
S-15 ABNORMAL NOISE IS MADE…2437
S-16 VIBRATION IS EXCESSIVE…2438
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)…2440
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…2441
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS OCCUR ON MACHINE…2442
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HDURAULIC RELATED PARTS…2446
PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM…2447
TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE…2448
C-1 ABNORMALITY IN PUMP CONTROLLER POWER SOURCE SYSTEM…2448
C-2 [E2:32] SHORT CIRCUIT IN TVC SOLENOID SYSTEM IS DISPLAYED…2449
C-3 [E2:33] DISCONNECTION IN TVC SOLENOID SYSTEM IS DISPLAYED…2451
C-4 [E2:03] SHORT CIRCUIT IN SWING BRAKE SOLENOIL SYSTEM IS DISPLAYED…2453
C-5 [E2:13] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…2455
C-6 [E2:01] SHORT CIRCUIT IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED…2457
[E2:05] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…2457
E2:06] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM ID IDSPLAYED…2457
C-7 [E2:11] DISCONNECTION IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED…2459
[E2:15] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…2459
[E2:16] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED…2459
C-8 [E2:17] MODEL SELECTIONINPUT ERROR IS DISPLAYED…2461
C-9 [E2:18] NETWORK RESPONSE OVERTIME ERROR IS DISPLAYED…2462
C-10 [E2:22] SHORT CIRCUIT IN LS CONTROL EPC SOLENOID SYSTME IS DISPLAYED…2464
C-11 [E2:23] DISCONNECTION IN LS CONTROL EPC SOLENIOD SYSTEM IS DISPLAYED…2465
C-12 [E2:24] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…2466
C-13 [E2-26] ABNORMALITY IN PUMP PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED…2467
C-14 [E2:27] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…2468
C-15 [E2:28] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED…2469
TROUBLESHOOTING OF ENGINE THROTTLE – PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)…2470
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…2471
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2473
JUDGEMENT TABLE FOR ENGINE THROTTLE – PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS…2481
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE…2483
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)…2485
C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED…2486
C-3 [E233] DISCONNECTION IN PUM TVC SOLENOID SYSTEM IS DISPLAYED…2488
C-4 [E201] SHORT CIRCUIT IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED…2490
C-5 [E211] DISCONNECTION IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED…2491
C-6 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…2492
C-7 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED…2494
C-8 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…2496
C-9 [E215} DISCONNECTION IN 2 -STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…2497
C-10 [C206] SHORT CIRCUIT IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED…2498
C-11 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED…2499
C-12 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED…2500
C-13 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED…2501
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED…2502
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOIND SYSTEM IS DISPLAYED…2504
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…2505
C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…2506
C-18 [E226] ABNORMALITY IN PRESSURE SENSOR SYSTEM POWER SOURCE IS DISPLAYED…2507
C-19 [E227] ABNORMALTIY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…2508
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)…2510
TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE…2511
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP…2511
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…2512
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP…2513
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP…2514
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP…2515
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP…2516
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP…2517
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP…2518
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCYH DOES NOT LIGHT UP…2519
F-10 ENGINE SPEED IS NOT DISPLAYED IN MONITORING CODE 10 (ABNORMALITY IN SPEED SENSOR SYSTEM)…2520
F-11 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP…2521
F-12 BIT PATTERN 22-(6) L.H. KNOB SWITCYH DOES NOT LIGHT UP…2522
TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (INPUT SIGNAL SYSTEM)(F MODE)…2524
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE…2525
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP…2527
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP…2528
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP…2529
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP…2530
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP…2531
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP…2532
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP…2533
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP…2534
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP…2535
F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP…2536
F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP…2537
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…2538
TABLE OF FAILURE MODES AND CAUSED FOR HYDRAULIC AND MECHANICAL SYSTEM…2540
TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE…2540
ALL WORK EQUIPMETN, TRAVEL, SWING…2540
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…2542
H-3 NO WORK EQUIPMENT, TRAVEL SWING MOVE…2543
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)…2543
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)…2544
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR…2544
WORK EQUIPMENT…2546
H-7 BOOM IS SLOW OR LACKS POWER…2546
H-8 ARM IS SLOW OR LACKS POWER…2548
H-9 BUCKET IS SLOW OR LACKS POWER…2550
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET( DOES NOT MOVE…2551
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)…2551
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)…2552
H-13 LACK OF POWER WHEN PRESSURE RISES…2552
H-14 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…2552
H-15 WORK EQUIPMENT IS SLOW WHEN ACTIVE MODE ID ON OR IS FAST WHE ACTIVE MODE IS OFF…2553
H-16 IN F/O MODE, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED…2554
COMPOUND OPERATIONS…2554
H-17 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD IS SLOW…2554
H-18 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW…2555
H-19 IN SWING + TRAVEL,TRAVEL SPEED DROPS EXCESSIVELY…2555
H-20 IN WORK EQUIPMENT + TRAVE, TRAVEL SPEED DROPS EXCESSIVELY…2555
TRAVEL SYSTEM…2556
H-21 TRAVEL DEVIATION…2556
H-22 TRAVEL SPEED IS SLOW…2558
H-23 STEERING DOES NOT TURNEALISLY OR LACKS POWER…2560
H-24 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…2562
H-25 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…2562
SWING SYSTEM…2563
H-26 DOES NOT SWING…2563
H-27 SWING ACCELERATION IS POOR…2564
H-28 EXCESSIVE OVERRUN WHEN STOPPING SWING…2566
H-29 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…2567
H-30 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…2567
H-31 EXCESSIVE HYDRAULIC DRIFT OF SWING…2568
H-32 SWING SPEED IS FASTER THAN SPECIFIED SPEED…2569
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…2571
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS…2573
MACHINE MONITOR SYSTEM CIRCUIT DIAGRAM…2574
TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE…2575
M-1 [E1:01] ABNORMALITY IN ERRO DATA IS DISPLAYED…2575
M-2 [E1:02] ERROR IN CLOCK DATA IS DISPLAYED…2575
M-3 [E1:03] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED…2575
M-4 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS…2576
A) NONE OF LAMPS ON MONITO PANEL LIGHT UP…2576
B) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP…2576
M-5 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT…2577
M-6 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM MACHINE MODEL…2577
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH…2578
A) COOLANT LEVEL FLASHES…2578
B) ENGINE OIL LEVEL FLASHES…2579
M-8 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY LIGHTS UP…2580
M-9 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEM FLASH…2581
A) ALTERNATOR SYSTEM…2581
B) ENGINE OIL PRESSURE SYSTEM…2582
M-10 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH…2583
A) ALTERNATOR SYSTEM…2583
B) ENGINE OIL PRESSURE SENSOR SYSTEM…2583
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH…2585
A) ENGINE OIL PRESSURE FLASHES…2585
B) COOLANT LEVEL FLASHES…2586
C) COOLANT TEMPERATURE FLASHES…2586
D) BATTERY CHARGE FLASHES…2587
E) FUEL LEVEL FLASHES…2587
M-12 A) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND…2588
CAUTION TIEMS ARE FLASHING BUT BUZZER DOES NOT SOUND…2588
B) NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS…2588
M-13 LIQUID CRYSTAL NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP…2589
M-14 COOLANT TEMPERATURE GAUGE DOES NOT RISE…2590
M-15 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY …2591
M-16 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…2592
M-17 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…2592
M-18 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT MONITOR PANEL PARKING DISPLAY DOES NOT LIGHT UP…2593
M-19 SWING PROLIX SWITCH IS ON (PROLIX), BUT MONITOR PANEL PARKING DISPLAY DOES NOT FLASH…2593
M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM…2594
M-21 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM…2595
M-22 DEFECTIVE ENGINE OIL LEVEL SENSOR…2596
M-23 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…2597
M-24 WORKING LAMP, PANEL LIGHTING DOES NOT LIGHT UP, OR SWITCH IS NOT BEING USED BUT LAMPS LIGHT UP…2598
A) WORKING LAMP DOES NOT LIGHT UP…2598
B) PANEL LIGHTING DOES NOT LIGHT UP…2598
C) LIGHT SWITCH IS NOT BEING USED BUT WORKING LAMP LIGHTS UP…2599
M-25 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…2600
A) WIPER DOES NOT WORK…2600
B) WIPER SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…2602
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…2605
ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…2608
ELECTRICAL CIRCUIT DIAGRAM…2612
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED…2614
[E102] ERROR IN CLOCK DATA IS DISPLAYED…2614
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED…2615
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED…2616
M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED…2616
M-5 [E108] ENGINE WATER TEMPERATURE 105°C DETECTED IS DISPLAYED…2617
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS…2618
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT…2620
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)…2620
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES…2621
M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP…2623
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH…2624
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH…2626
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH…2628
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND. CAUTION ITEM FLASHES BUT BUZZER …2631
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUND…2631
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAYE IS NORMAL)…2632
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE…2633
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY …2633
M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…2634
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…2634
M-21 SWING LOCK SWITCH IS TURNED ON 9LOCK) BUT (SWING LOCK MONITOR) DOES NOT FLASH…2635
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH…2635
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING…2636
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED…2636
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM…2637
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM…2638
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM…2639
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…2640
M-29 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…2642
M-30 WASHER MOTOR DOES NOT WORK, SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED…2648
30 DISASSEMBLY AND ASSEMBLY…2651
METHOD OF USING MANUAL…2653
PRECAUTIONS WHEN CARRYING OUT OPERATION…2654
SPECIAL TOOL LIST…2656
STARTING MOTOR ASSEMBLY…2660
REMOVAL AND INSTALLATION…2660
ALTERNATOR…2661
REMOVAL AND INSTALLATION…2661
AIR CONDITIONER COMPRESSOR…2662
REMOVAL AND INSTALLATION…2662
CONDENSER…2663
REMOVAL AND INSTALLATION…2663
ENGINE OIL COOLER CORE…2664
REMOVAL AND INSTALLATION…2664
FUEL INJECTION PUMP…2665
REMOVAL…2665
INSTALLATION…2666
WATER PUMP…2667
REMOVAL AND INSTALLATION…2667
NOZZLE HOLDER…2668
REMOVAL AND INSTALLATION…2668
TURBOCHARGER…2669
REMOVAL AND INSTALLATION…2669
THERMOSTAT…2670
REMOVAL AND INSTALLATION…2670
ENGINE FRONT OIL …2671
REMOVAL AND INSTALLATION…2671
ENGINE REAR OIL SEAL…2672
REMOVAL AND INSTALLATION…2672
GOVERNOR MOTOR…2673
REMOVAL AND INSTALLATION…2673
CYLINDER HEAD…2674
REMOVAL …2674
INSTALLATION…2676
ENGINE – HYDRAULIC PUMP…2678
REMOVAL…2678
INSTALLATION…2681
HYDRAULIC OIL COOLER …2682
REMOVAL AND INSTALLATION…2682
RADIATOR – HYDRAULIC C…2684
REMOVAL…2684
INSTALLATION…2685
FUEL TANK…2686
REMOVAL AND INSTALLATION…2686
CENTER SWIVEL JOINT…2688
REMOVAL AND INSTALLATION…2688
DISASSEMBLY AND ASSEMBLY…2689
SPROCKET…2690
REMOVAL AND INSTALLATION…2690
TRAVEL MOTOR…2691
REMOVAL AND INSTALLATION…2691
DISASSEMBLY AND ASSEMBLY (GM18VL-MSRV)…2693
SWING MACHINERY – SWING MOTOR…2744
REMOVAL AND INSTALLATION…2744
SWING MACHINERY…2746
DISASSEMBLY…2746
ASSEMBLY…2749
SWING MOTOR…2753
REMOVAL AND INSTALLATION (KMF40AB-2)…2753
DISASSEMBLY (KMF40AB-2)…2754
ASSEMBLY (KMF40AB-2)…2757
REMOVAL AND INSTALLATION (KMF40AB-3)…2761
REVOLVING FRAME…2762
REMOVAL…2762
INSTALLATION…2764
SWING CIRCLE…2765
REMOVAL AND INSTALLATION…2765
IDLER – RECOIL SPRING …2766
REMOVAL AND INSTALLATION…2766
RECOIL SPRING…2767
DISASSEMBLY…2767
ASSEMBLY…2768
IDLER …2769
DISASSEMBLY…2769
ASSEMBLY…2770
TRACK ROLLER …2772
REMOVAL AND INSTALLATION…2772
DISASSEMBLY…2773
ASSEMBLY…2774
CARRIER ROLLER…2776
REMOVAL AND INSTALLATION…2776
TRACK SHOE…2777
REMOVAL…2777
INSTALLATION…2777
HYDRAULIC TANK…2779
REMOVAL …2779
INSTALLATION…2780
CONTROL PUMP…2781
REMOVAL AND INSTALLATION…2781
MAIN PUMP…2784
REMOVAL …2784
INSTALLATION…2785
DISASSEMBLY…2788
ASSEMBLY…2793
MAIN PUMP INPUT SHAFT OIL SEAL…2806
REMOVAL AND INSTALLATION…2806
CONTROL VALVE…2807
REMOVAL…2807
INSTALLATION…2808
DISASSEMBLY…2813
ASSEMBLY…2815
LS SELECT VALVE…2827
DISASSEMBLY AND ASSEMBLY…2827
LS SHUTTLE VALVE …2829
DISASSEMBLY AND ASSEMBLY…2829
PRESSURE COMPENSATION VALVE…2831
DISASSEMBLY…2831
ASSEMBLY…2832
MAIN RELIEF VALVE…2835
DISASSEMBLY…2835
ASSEMBLY…2836
TVC – LS VALVE…2837
REMOVAL AND INSTALLATION…2837
LS CONTROL EPC VALVE…2838
REMOVAL AND INSTALLATION…2838
SOLENOID VALVE…2840
REMOVAL AND INSTALLATION…2840
WORK EQUIPMENT – SWING PPC VALVE…2842
REMOVAL AND INSTALLATION…2842
DISASSEMBLY…2843
ASSEMBLY…2844
TRAVEL PPC VALVE…2845
REMOVAL AND INSTALLATION…2845
DISASSEMBLY…2847
ASSEMBLY…2848
BOOM HOLDING VALVE…2852
REMOVAL AND INSTALLATION…2852
BOOM CYLINDER…2853
REMOVAL…2853
INSTALLATION…2854
ARM CYLINDER…2855
REMOVAL…2855
INSTALLATION…2856
BUCKET CYLINDER…2857
REMOVAL…2857
INSTALLATION…2858
HYDRAULIC CYLINDER …2859
DISASSEMBLY…2859
ASSEMBLY…2861
WORK EQUIPMENT …2865
REMOVAL…2865
INSTALLATION…2866
BUCKET …2867
REMOVAL…2867
INSTALLATION…2868
ARM …2869
REMOVAL…2869
INSTALLATION…2870
BUCKET – ARM…2871
REMOVAL…2871
INSTALLATION…2872
BOOM …2873
REMOVAL…2873
INSTALLATION…2874
OPERATOR'S CAB…2875
REMOVAL…2875
INSTALLATION…2877
COUNTERWEIGHT…2878
REMOVAL AND INSTALLATION…2878
ENGINE THROTTLE CONTROLLER…2879
REMOVAL AND INSTALLATION…2879
PUMP CONTROLLER…2880
REMOVAL AND INSTALLATION…2880
ENGINE THROTTLE, PUMP CONTROLLER …2881
REMOVAL AND INSTALLATION…2881
MONITOR …2882
REMOVAL AND INSTALLATION…2882
40 MAINTENANCE STANDARD…2884
SWING MACHINERY…2885
SWING CIRCLE…2887
TRACK FRAME…2890
IDLER…2891
CARRIER ROLLER…2892
TRACK ROLLER…2893
SPROCKET…2894
TRACK SHOE…2895
HYDRAULIC PUMP…2899
CONTROL VALVE…2902
SWING MOTOR…2920
CENTER SWIVEL JOINT…2922
WORK EQUIPMENT – SWING PPC VALVE…2923
TRAVEL PPC VALVE…2924
SERVICE PPC VALVE…2926
PPC SHUTTLE – TRAVEL JUNCTION VALVE …2929
EPC – SOLENOID VALVE …2931
BOOM HOLDING VALVE…2932
HYDRAULIC CYLINDER…2933
WORK EQUIPMENT…2935
SEBM010404 – Hydraulic Excavator PC120-6 Excel Shop Manual…2944
COVER…2944
CONTENTS…2945
01 GENERAL…2966
GENERAL ASSEMBLY DRAWING …2967
SPECIFICATIONS…2968
WEIGHT TABLE…2970
LIST OF LUBRICANT AND WATER…2972
10 STRUCTURE AND FUNCTION…2974
RADIATOR AND OIL COOLER…2975
ENGINE CONTROL…2976
PTO (COUPLING)…2977
POWER TRAIN…2978
SWING CIRCLE…2979
SWING MACHINERY…2980
TRACK FRAME …2981
TRACK SHOE…2982
HYDRAULIC CIRCUIT DIAGRAM…2983
HYDRAULIC TANK…2988
HYDRAULIC PUMP…2989
CONTROL VALVE…3009
CLSS…3020
SWING MOTOR…3066
CENTER SWIVEL JOINT…3069
TRAVEL MOTOR…3070
VALVE CONTROL…3078
WORK EQUIPMENT・SWING PPC VALVE…3080
TRAVEL PPC VALVE…3084
SERVICE PPC VALVE…3088
SAFETY LOCK VALVE…3091
PPC ACCUMULATOR…3091
STRAIGHT-TRAVEL SYSTEM…3092
SOLENOID VALVE …3093
ACCUMULATOR FOR BREAKER…3097
ADDITIONAL FILTER FOR BREAKER…3098
WORK EQUIPMENT…3099
AIR CONDITIONER…3100
ACTUAL ELERICAL WIRING DIAGRAM…3101
ELECTRICAL CIRCUIT DIAGRAM…3105
ELECTRIC CONTROL SYSTEM…3110
MACHINE MONITOR SYSTEM…3115
SENSORS…3118
20 TESTING AND ADJUSTING…3120
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…3121
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…3122
STANDARD VALUE TABLE FOR ELECTRICAL PARTS…3130
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…3132
MEASURING ENGINE SPEED…3133
MEASURING EXHAUST COLOR…3134
ADJUSTING VALVE CLEARANCE…3135
MEASURING BLOW-BY PRESSURE…3136
TESTING AND ADJUSTING FUEL INJECTION TIMING…3137
MEASURING ENGINE OIL PRESSURE…3138
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…3139
ADJUSTING FUEL CONTROL LEVER…3140
ADJUSTING ENGINE SPEED SENSOR…3142
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…3143
TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)…3145
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…3147
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE…3150
TESTING SOLENOID VALVE OUTPUT PRESSURE…3152
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…3154
TESTING TRAVEL DEVIATION…3155
MEASURING OIL LEAKAGE…3156
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…3158
TESTING CLEARANCE OF SWING CIRCLE BEARING…3159
TESTING AND ADJUSTING TRACK SHOE TENSION…3160
MEASURING WEAR OF SPROCKET…3161
BLEEDING AIR…3162
TROUBLESHOOTING…3164
POINTS TO REMEMBER WHEN TROUBLESHOOTING…3165
SEQUENCE OF EVENTS IN TROUBLESHOOTING…3166
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…3167
CHECKS BEFORE TROUBLESHOOTING…3175
CONNECTOR TYPES AND MOUNTING LOCATIONS…3176
CONNECTOR ARRANGEMENT DIAGRAM…3178
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…3180
METHOD OF USING JUDGEMENT TABLE…3190
METHOD OF USING TROUBLESHOOTING CHARTS…3192
TROUBLESHOOTING OF ENGINE (S MODE)…3194
METHOD OF USING TROUBLESHOOTING CHART…3195
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…3199
S-2 ENGINE DOES NOT START…3201
1) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…3201
2) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…3202
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…3203
S-4 ENDINE STOPS DURING OPERATIONS…3204
S-5 ENGINE DOES NOT ROTATES SMOOTHLY (HUNTING)…3205
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…3206
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…3207
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…3208
S-9 OIL BECOMES CONTAMINATED QUICKLY…3209
S-10 FUEL CONSUMPTION IS EXCESSIVE…3210
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN…3211
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…3212
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)…3213
S-14 WATER TEMPERTURE BECOMES TOO HIGH (OVERHEATING)…3214
S-15 ABNORMAL NOISE IS MADE …3215
S-16 VIBRATION IS EXCESSIVE…3216
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)…3217
JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS…3218
E MODE RELATED ELECTRIC CIRCUIT DIAGRAM…3220
E-1 ABNORMALITY IN PC-EPC SYSTEM…3223
a) SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER…3223
b) THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…3224
E-2 ABNORMALITY IN PPC LOCK SOLENOID SYSTEM…3226
a) WORK EQUIPMENT, SWING, TRAVEL DO NOT MOVE EVEN WHEN SAFETY LOCK IS PLACED AT FREE…3226
b) WORK EQUIPMENT, SWING, TRAVEL MOVE EVEN WHEN SAFETY LOCK IS PLACED AT LOCK…3226
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM…3229
a) SWING DOES NOT MOVE EVEN WHEN SWING LOCK SWITCH IS PLACED AT FREE…3229
b) SWING MOVES EVEN WHEN SWING LOCK SWITCH IS PLACED AT LOCK…3229
E-4 ABNORMALITY IN TRAVEL SPEED SOLENOID SYSTEM…3231
a) MACHINE DOES NOT TRAVEL AT HIGH SPEED EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS AT HI…3231
b) MACHINE DOES NOT TRAVEL AT LOW SPEED EVEN WHEN TRAVEL SPEED SELECTOR SWITCH IS AT LO…3231
E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START)…3233
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)…3236
TABLE OF FAILURE MODES AND CAUSES…3237
H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACK POWER…3239
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…3239
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE…3240
H-4 ABNORMALITY NOISE GENERATED (AROUND PUMP)…3240
H-5 FINE CONTROL ABLITY IS POOR OR RESPONSE IS POOR…3241
H-6 BOOM IS SLOW OR LACKS POWER…3242
H-7 ARM IS SLOW OR LACKS POWER…3242
H-8 BUCKET IS SLOW OR LACKS POWER…3244
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…3244
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, OR BUCKET)…3245
H-11 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW …3245
H-12 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW …3246
H-13 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY…3246
H-14 IN WORK EQUIPMENT + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY…3246
H-15 TRAVEL DEVIATION…3247
a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL…3247
b) DEVIATION IS EXCESSIVE WHEN STARTING…3247
H-16 TRAVEL SPEED IS SLOW…3248
H-17 STEERING IS DIFFERENT TO TURN OR LACKS POWER…3249
H-18 TRAVEL SPEED DOES NOT SWITCH…3251
H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…3251
H-20 DOES NOT SWING …3252
a) DOES NOT SWING TO EITHER LEFT OR RIGHT…3252
b) DOES NOT SWING IN ONE DIRECTION…3252
H-21 SWING ACCELERATION IS POOR…3253
H-22 EXCESSIVE OVERRUN WHEN STOPPING SWING…3255
a) ONE DIRECTION ONLY …3255
b) BOTH DIRECTIONS…3255
H-23 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…3256
H-24 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…3256
H-25 EXCESSIVE HYDRULIC DRIFT OF SWING …3257
a) WHEN SWING LOCK SWITCH IS OFF…3257
b) WHEN SWING LOCK SWITCH IS AT LOCK…3257
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…3258
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM…3259
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (3 SECOND SELF CHECK IS ALSO NOT CARRIED OUT)…3260
M-2 WHEN STARTING SWITCH IS TURNED ON, EVEN WHEN SELF CHECK IS COMPLETED (ALL LAMPS LIGHT UP FOR 3 SECOND), LAMPS DO NOT GO OUT…3260
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME SELF CHECK LAMPS DO NOT LIGHT UP FOR 3 SECONDS…3261
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP)…3261
b) SWING LOCK OR PREHEATING LAMPS DO NOT LIGHT UP (GAUGE LAMPS ALL LIGHT UP)…3261
c) BATTERY CHARGE LAMP DOES NOT LIGHT UP…3261
d) ENGINE OIL PRESSURE LAMP DOES NOT LIGHT UP…3261
M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP…3262
M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP…3262
M-6 WHEN STARTING SWITCH IS TURNED TO HEAT, PREHEATING PILOT LAMP DOES NOT LIGHT UP…3263
M-7 WHEN SWING LOCK IS TURNED ON, SWING LOCK PILOT LAMP DOES NOT LIGHT UP…3263
M-8 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL)…3264
M-9 WHEN ENGINE IS RUNNING, BATTERY CHARGE CAUTION LAMP LIGHTS UP…3264
M-10 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE…3265
a) AFTER ENGINE IS STARTED, ONLY LOWEST LEVEL LAMP (WHITE RANGE) LIGHTS UP AND LEVEL DOES NOT RISE…3265
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES AND ENTERS RED RANGE (THERE IS NO OVERHEATING)…3265
c) GAUGE GOES OUT…3265
M-11 ABNORMALITY IN FUEL GAUGE …3267
a) ALL SEGMENTS OF GAUGE GO OUT …3267
b) FUEL LEVEL HAS GONE DOWN, BUT GAUGE ALWAYS DISPLAYS FULL…3267
c) EVEN WHEN FUEL TANK IS FILED, GAUGE DOES NOT DISPLAY FULL…3267
M-12 DEFETIVE OPERATION OF ALARM BUZZER…3269
a) BUZZER DOES NOT SOUND…3269
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP…3269
M-13 WHEN ENGINE IS RUNNING, SERVICE METER DOES NOT ADVANCE…3270
a) WHEN BATTERY CHARGE CAUTION LAMP DOES NOT LIGHT UP…3270
b) WHEN BATTERY CHARGE CAUTION LAMP LIGHTS UP…3270
M-14 NIGHT LIGHTING DOES NOT LIGHT UP…3271
a) GAUGE LIGHTING DOES NOT LIGHT UP…3271
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER WORKS NORMALLY)…3271
M-15 HEATER DOES NOT WORK (MACHINES WITH HEATER)…3272
a) BOTH LO AND HI DO NOT WORK …3272
b) ONLY LO DOES NOT WORK…3272
c) ONLY HI DOES NOT WORK…3272
30 DISASSEMBLY AND ASSEMBLY…3274
METHOD OF USING MANUAL…3276
PRECAUTIONS WHEN CARRYING OUT OPERATION…3277
SPECIAL TOOL LIST…3279
SKETCHES OF SPECIAL TOOLS…3283
STARTING MOTOR…3285
REMOVAL AND INSTALLATION…3285
ALTERNATOR…3286
REMOVAL AND INSTALLATION…3286
AIR CONDITIONER COMPRESSOR…3288
REMOVAL AND INSTALLATION…3288
CONDENSER…3289
REMOVAL AND INSTALLATION…3289
ENGINE OIL COOLER…3290
REMOVAL AND INSTALLATION…3290
FUEL INJECTION PUMP…3291
REMOVAL…3291
INSTALLATION…3293
WATER PUMP…3295
REMOVAL AND INSTALLATION…3295
NOZZLE HOLDER…3296
REMOVAL AND INSTALLATION…3296
TURBOCHARGER…3297
REMOVAL AND INSTALLATION…3297
THERMOSTAT…3298
REMOVAL AND INSTALLATION…3298
CYLINDER HEAD…3299
REMOVAL…3299
INSTALLATION…3304
ENGINE, MAIN PUMP…3307
REMOVAL…3307
INSTALLATION…3311
HYDRAULIC COOLER…3312
REMOVAL AND INSTALLATION…3312
RADIATOR, HYDRAULIC COOLER…3313
REMOVAL…3313
INSTALLATION…3314
FUEL TANK …3315
REMOVAL AND INSTALLATION…3315
CENTER SWIVEL JOINT…3316
REMOVAL AND INSTALLATION…3316
DISASSEMBLY AND ASSEMBLY…3317
SPROCKET…3318
REMOVAL AND INSTALLATION…3318
TRAVEL MOTOR…3319
REMOVAL AND INSTALLATION…3319
SWING MACHINERY, SWING MOTOR…3320
REMOVAL AND INSTALLATION…3320
SWING MOTOR…3321
REMOVAL AND INSTALLATION…3321
DISASSEMBLY…3322
ASSEMBLY…3326
SWING MACHINERY…3334
DISASSEMBLY…3334
ASSEMBLY…3337
REVOLVING FRAME…3341
REMOVAL…3341
INSTALLATION…3342
SWING CIRCLE…3343
REMOVAL AND INSTALLATION…3343
IDLER, RECOIL SPRING…3344
REMOVAL AND INSTALLATION…3344
IDLER…3345
DISASSEMBLY…3345
ASSEMBLY…3346
RECOIL SPRING…3348
DISASSEMBLY…3348
ASSEMBLY…3349
TRACK ROLLER…3350
REMOVAL AND INSTALLATION…3350
DISASSEMBLY…3351
ASSEMBLY…3352
CARRIER ROLLER…3354
REMOVAL AND INSTALLATION…3354
TRACK SHOE…3355
REMOVAL AND INSTALLATION…3355
HYDRAULIC TANK…3356
REMOVAL…3356
INSTALLATION…3357
CONTROL PUMP…3358
REMOVAL AND INSTALLATION…3358
MAIN PUMP…3359
REMOVAL…3359
INSTALLATION…3360
DISASSEMBLY…3361
ASSEMBLY…3371
MAIN PUMP INPUT SHAFT OIL SEAL…3383
REMOVAL AND INSTALLATION…3383
CONTROL VALVE…3384
REMOVAL…3384
INSTALLATION…3385
DISASSEMBLY…3386
ASSEMBLY…3391
LS SELECT VALVE…3397
DISASSEMBLY AND ASSEMBLY…3397
PC-EPC VALVE…3398
REMOVAL AND INSTALLATION…3398
PC VALVE…3399
REMOVAL AND INSTALLATION…3399
LS VALVE…3400
REMOVAL AND INSTALLATION…3400
SOLENOID VALVE…3401
REMOVAL AND INSTALLATION…3401
PPC VALVE…3403
REMOVAL AND INSTALLATION…3403
WORK EQUIPMENT RIGHT SIDE PPC VALVE…3404
REMOVAL AND INSTALLATION…3404
WORK EQUIPMENT, SWING PPC VALVE…3405
DISASSEMBLY…3405
ASSEMBLY…3406
TRAVEL PPC VALVE…3407
REMOVAL AND INSTALLATION…3407
DISASSEMBLY…3408
ASSEMBLY…3409
BOOM CYLINDER…3410
REMOVAL…3410
INSTALLATION…3411
ARM CYLINDER…3412
REMOVAL…3412
INSTALLATION…3413
BUCKET CYLINDER…3414
REMOVAL…3414
INSTALLATION…3415
HYDRAULIC CYLINDER…3416
DISASSEMBLY…3416
ASSEMBLY…3419
WORK EQUIPMENT…3423
REMOVAL…3423
INSTALLATION…3424
BUCKET…3425
REMOVAL…3425
INSTALLATION…3426
ARM …3427
REMOVAL…3427
INSTALLATION…3428
BUCKET, ARM…3429
REMOVAL…3429
INSTALLATION…3430
BOOM…3431
REMOVAL…3431
INSTALLATION…3432
OPERATOR'S CAB…3433
REMOVAL AND INSTALLATION…3433
COUNTERWEIGHT…3434
REMOVAL AND INSTALLATION…3434
MONITOR…3435
REMOVAL AND INSTALLATION…3435
40 MAINTENANCE STANDARD…3436
SWING MACHINERY…3437
SWING CIRCLE…3439
TRACK FRAME …3440
IDLER…3441
CARRIER ROLLER…3442
TRACK ROLLER…3443
SPROCKET…3444
TRACK SHOE…3445
HYDRAULIC PUMP…3452
CONTROL VALVE…3454
SWING MOTOR…3464
TRAVEL MOTOR…3465
CENTER SWIVEL JOINT…3466
WORK EQUIPMENT・SWING PPC VALVE…3467
TRAVEL PPC VALVE…3468
SERVICE PPC VALVE…3469
HYDRAULIC CYLINDER…3470
WORK EQUIPMENT…3472
DIMENSION OF WORK EQUIPMENT …3474
90 OTHER…3478
HYDRAULIC CIRCUIT DIAGRAM PC120-6 EXCEL SERIAL NO.57449-60967…3479
HYDRAULIC CIRCUIT DIAGRAM PC120-6 EXCEL SERIAL NO.60968 AND UP …3480
ELECTRICAL CIRCUIT GIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2) PC120-6 EXCEL SERIAL NO.57499-60967…3481
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/2) PC120-6 EXCEL SERIAL NO.57499-60967…3482
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2) PC120-6 EXCEL SERIAL NO.60968 AND UP…3483
ELECTRICAL CIRCUIT DIAGRAM CHASSIS ELECTRICAL CIRCUIT DIAGRAM (2/2) PC120-6 EXCEL SERIAL NO.60968 AND UP …3484
SEBM010611 – Hydraulic Excavator PC100-6, PC120-6, PC120LC-6, PC130-6 Shop Manual…3485
COVER…3485
CONTENTS…3486
01 GENERAL…3511
GENERAL ASSEMBLY DRAWING…3512
SPECIFICATIONS…3517
WEIGHT TABLE…3525
LIST OF LUBRICANT AND WATER…3533
10 STRUCTURE AND FUNCTION…3536
RADIATIR AND OIL COOLER…3537
PTO(COUPLING)…3540
POWER TRAIN …3541
FINAL DRIVE…3543
SWING CIRCLE…3544
SWING MACHINERY…3545
TRACK FARME…3546
TRACK SHOE…3550
HYDRAULIC PIPING DRAWING …3551
HYDRAULIC CIRCUIT DIAGRAM…3553
HYDRAULIC TANK…3558
HYDRAULIC PUMP…3559
CONTROL VALUE…3579
CLSS…3592
SWING MOTOR…3644
CENTER SWIVEL JOINT…3649
TRAVEL MOTOR …3650
VALVE CONTROL…3666
WORK EQUIPMENT・SWING PPC VALVED…3667
TRAVEL PPC VALVE…3671
SERVICE PPC VALVE…3675
SAFETY LOCK VALVE …3678
PPC ACCUMULATOR…3678
STRAIGHT-TRAVEL SYSTEM…3679
SOLENOID VALVE…3680
ACCUMULATOR FOR BREAKER…3682
ADDITIONAL FILTER FOR BREAKER…3683
WORK EQUIPMENT…3684
AIR CONDITIONER…3685
ACTUAL ELECTRIC WIRING DIAGRAM…3686
ELECTRIC CIRCUIT DIAGRAM…3690
ENGINE CONTROL SYSTEM…3695
ELECTRONIC CONTROL SYSTEM…3703
MACHINE MONITOR SYSTEM…3740
FRONT WINDOW AUTO PULL-UP SYSTEM…3751
20 TESTING AND ADJUSTING…3753
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…3754
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS …3756
STANDARD VALUE TABLE FOR ELECTRICAL PARTS …3767
TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING…3776
MEASURING ENGINE SPEED…3777
MEASURING EXHAUST COLOR…3778
ADJUSTING VALUE CLEARANCE…3779
MEASURING BLOW-BY PRESSURE…3780
TESTING AND ADJUSTING FUEL INJECTION TIMING …3781
MEASURING ENGINE OIL PRESSURE…3782
TESTNG AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR…3783
ADJUSTING ENGINE SPEED SENSOR…3784
ADJUSTING GOVERNOR MOTOR LEVER STROKE…3785
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT,SWING,TRAVEL CIRCUIT…3786
TESTING AND ADJUSTING PC VALUE OUTPUT PRESSURE(SERVO PISTION INPUT PRESURE…3789
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE…3791
TSETING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE…3794
TESTING SOLENOID VALVE OUTPUT PRESSURE…3796
MEASURING PPC VALVE OUTPUT PRESSURE…3797
ADJUSTING WORK EQUIPMENT,SWING PPC VALVE…3798
TESTING TRAVEL DEVIATION…3799
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…3800
MEASURING OIL LEAKAGE…3801
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT …3803
TESTING GLEARANCE OF SWING CIRCLE BEARING…3804
TESTING AND ADJUSTING TRACK SHOE TENSION…3805
BLEEDING AIR…3806
TROUBLESHOOTING…3808
POINTS TO REMEMBER WHEN TROUBLESHOOTING…3809
SEQUENCE OF EVENTS IN TROUBLESHOOTING …3810
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…3811
CHECKS BEFORE TROUBLESHOOTING …3819
CONNECTOR TYPES AND MOUNTING LOCATIONS…3820
CONNECTOR ARRANGEMENT DIAGRAM…3822
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…3825
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL…3836
METHOD OF USING JUDGEMENT TABLE…3846
METHOD OF USING TROUBLESHOOTING CHARTS…3848
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE…3850
SERVICE CODE TABLE…3855
TROUBLESHOOTING OF COMMUNICATIONS SYSTEM(N MODE)…3856
N-1 COMMUNICATIONS ABNORMALITY…3857
TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER[GOVERNOR CONTROL SYSTEM](E MODE)…3859
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER(GOVERNOR CONTROL SYSTEM)…3860
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…3861
JUDGEMENT TABLE FOR ENGINE THROTTLE,PUMP CONTROLLER(GOVERNOR CONTROL SYSTEM),AND ENGINE RELATED PARTS…3865
ELECTRICAL CIRCUIT DIAGRAM OF ENGINE THROTTLE,PUMP CONTROLLER SYSTEM…3867
E-1 ABNORMALITY IN ENGINE THROTTLE,PUMP CONTROLLER POWER SOURCE(CONTROLLER LED IS OFF)…3869
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED…3870
E-3 [E317] ABNORMALITY (DISCONNECTION) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED…3871
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED…3872
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED…3873
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED…3874
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED…3875
E-8 ENGINE DOES NOT START …3876
E-9 ENGINE SPEED IS IRREGULAR …3878
a) LDING SPEED IS IRREGULAR…3878
b) THERE IS HUNTING…3880
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)…3882
E-11 ENGINE DOES NOT STOP …3884
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)…3886
TROUBLESHOOTING OF ENGINE (S MODE)…3888
MOTHOD OF USING TROUBLESHOOTING CHART…3889
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)…3893
S-2 ENGINE DOES NOT START …3895
(1) ENGINE DOES NOT TURN …3895
(2) ENGINE TURNS BUT NO EXHAIST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)…3896
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)…3897
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)…3898
S-4 ENGINE STOPS DURING OPERATIONS…3899
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)…3900
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)…3901
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)…3902
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)…3903
S-9 OIL BECOMES CONTAMINATED QUICKY …3904
S-10 FUEL CONSUMPTION IS EXCESSIVE…3905
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN …3906
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)…3907
S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)…3908
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)…3909
S-15 ABNORMAL NOISE IS MADE…3910
S-16 VIBRATION IS EXCESSIVE…3911
TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER[PUMP CONTROL SYSTEM](C MODE)…3912
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM…3913
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE…3914
JUDGMENT TABLE FOR PUMP CONTROLLER AND HTDRAULIC RELATED PARTS…3922
ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM …3924
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)…3928
C-2 [E232] SHORT CIRCUIT IN PUMP PC-EPC SOLENOID SYSTEM IS DISPLAYED …3929
C-3 [E233] DISCONNECTION IN PC-EPC SOLENOID SYSTEM IS DISPLAYED…3931
C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED…3933
C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM IS DISPLAYED…3935
C-6 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…3937
C-7 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED…3938
C-8 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED…3939
C-9 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED…3940
C-10 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED…3941
C-11 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED …3942
C-12 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED …3943
C-13 [E222] SHORT CIRCUIT IN IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…3945
C-14 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED…3946
C-15 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED…3947
C-16 [E226] ABNORMALITY IN PRESSSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED…3948
C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED…3949
C-18 [E302] SHORT CIRCUIT IN SWING STRIKE LIMIT SOLENOID SYSTEM IS DISPLAYED …3950
C-19 [E215] DISCONNECTION IN SWING STROKE LIMIT SYSTEM IS DISPLAYED …3951
TROUBLESHOOTING OF ENGINE THROTTLE,PUMP CONTROLLER [INPUT SIGNAL SYSTEM](F MODE)…3952
ELECTRICAL CIRCUIT DIAGRAM OF F MODE SYSTEM …3953
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP …3957
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP …3958
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP …3959
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP …3960
F-5 BIT PARRTEN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP …3961
F-6 BIT PARRTEN 20(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP …3962
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP …3963
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP …3964
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP …3965
F-10 BIT PATTERN 22-(5) KEROSENNE MODE CONNECTION DOES NOT LIGHT UP …3966
F-11 BIT PATTERN 22-(6) L.H. KNOB DOES NOT LIGHT UP …3967
TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM(H MODE)…3968
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM …3969
H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER …3971
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS…3973
H-3 NO WORK EQUIPMENT,TRAVEL,SWING MOVE …3974
H-4 ABNORMAL NOISE GENERATED(AROUND PUMP)…3974
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)…3975
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR …3975
H-7 BOOM IS SLOW OR LACKS POWER …3976
H-8 ARM IS SLOW OR LACKS POWER …3978
H-9 BUCKET IS SLOW OR LACKS POWER …3980
H-10 WORK EQUIPMENT(BOOM,ARM ,BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)…3981
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM,ARM,BUCKET)…3981
H-12 EXCESSIVE TIME LAG(ENGINE AT LOW IDLING)…3982
H-13 LACK OF POWER WHEN PRESSURE RISES …3982
H-14 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED…3982
H-15 WORK EQUIPMENT SPEED IS SLOW WHEN ACTIVE MODE IS ON,OR IS FAST WHEN ACTIVE MODE IS OFF…3983
a)BOOM LOWER,ARM IN SPEEDS ARE TOO SLOW OR TOO FAST…3983
b)BOOM RAISE,ARM OUT,BUCKET CURL,DUMP SPEEDS ARE TOO SLOW OR TOO FAST …3983
H-16 IN F/O MODE, ARM IN SPEED IS FASTER THAN SPECIFIED SPEED …3984
H-17 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS LOW…3984
H-18 IN SWING+BOOM RAISE,BOOM RAISE IS SLOW …3985
H-19 IN SWING+TRAVEL,TRAVEL SPEED DROPS EXCESSIVELY…3985
H-20 IN WORK EQUIPMENT+TRAVEL,TRAVEL SPEEED DROPS EXCESSIVELY…3985
H-21 TRAVEL DEVIATION…3986
a)WHEN THERE IS DEVIATION NORMAL TRAVEL…3986
b)EXCESSIVE TRAVEL DEVIATION WHEN STARTING…3986
H-22 TRAVEL SPEED IS SLOW …3987
H-23 STEERING IS DIFFICULT TO TURN OR LACKS POWER …3989
H-24 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED…3991
H-25 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)…3991
H-26 DOES NOT SWING …3992
a)DOES NOT SWING TO EITHER LEFT OR RIGHT…3992
b)DOES NOT SWING IN ONE DIRECTION …3992
H-27 SWING ACCELERATION IS POOR …3993
H-28 EXCESSIVE OVERRUN WHEN STOPPING SWING …3995
a)ONE DIRECTION ONLY…3995
b)BOTH DIRECTIONS…3995
H-29 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)…3996
H-30 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…3996
H-31 EXCESSIVE HYDRAULIC DRIFT OF SWING…3997
a)WHEN HOLDING BRAKE IS RELEASED …3997
b)WHEN HOLDING BRAKE IS APPLIED …3997
H-32 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED …3998
TROUBLESHOOTING OF MACHINE MONITOR PANEL SYSTEM(M MODE)…3999
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE …4001
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM …4005
M-1 [E101] ABNORMALITY IN TROUBLE DATA MEMORY IS DISPLAYED [E102] ERROR IN TIME DATA IS DISPLAYED …4007
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED…4008
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED…4009
M-4 [E106] DROP IN ENGINE OIL PRESSURE DETECTED IS DISPLAYED …4009
M-5 [E108] ENGINE WATER TEMPERATURE 105゜C DETECTED IS DISPLAYED …4010
M-6 WHEN STARTING SWITCH IS TURNED ON,NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS…4011
a)NONE OF LAMPS ON MONITOR PANEL LIGHT UP …4011
b)SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP …4011
M-7 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT …4013
M-8 WHEN STARTING SWITCH IS TURNED ON,ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)…4013
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),BASIC CHECK ITEMS FLASH…4014
a)(COOLANT LEVEL) FLASHES…4014
b)(ENGINE OIL LEVEL)FLASHES…4015
M-10 PREHEATING IS NOT BEING USED BUT(PREHEATING MONITOR) LIGHTS UP …4016
M-11 WHEN STARRTING SWITCH IS TURNED ON AND ENGINE IS STARTED,BASIC CHECK ITEMS FLASH…4017
a)ALTERNATOR SYSTEM …4017
b)ENGINE OIL PRESSURE SYSTEM …4018
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH (BUT WHEN BATTERY,ENGINE OIL PRESSURE DO NOT LIGHT UP )…4019
a)ALTERNATOR SYSTEM…4019
b)ENGINE OIL PRESSURE SENSOR SYSTEM …4020
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH (BUT WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMSTO CHECK BEFORE TROUBLESHOOTING)…4021
a)(ENGINE OIL PRESSURE) FLASHES…4021
b)(COOLANT LEVEL) FLASHES…4021
c)CHARGE LEVEL) FLASHES…4021
d)(COOLANT TEMPERATURE) FLASHES…4022
e)(FUEL LEVEL) FLASHES…4022
f)(AIR CLEANER CLOGGING) FLASHES…4023
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEMS ARE FLASHING BUT BUZZER DOES NOT SOUND…4024
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS…4024
M-16 LIQUID CRYSTAL NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…4025
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE …4026
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)…4026
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL…4027
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY…4027
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP …4028
M-22 SWING PROLIX SWITCH IS ON (PROLIX),BUT (SWING LOCK MONITOR) DOES NOT NOT FLASH …4028
M-23 SERVICE METER DOES NOT ADVANCE WHEN ENGINE IS RUNNING …4029
M-24 WHEN STARTING SWITCH IS OFF AND TIME SWITCH IS PRESSED,TIME,SERVICE METER ARE NOT DISPLAYED…4029
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM …4030
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM …4031
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM …4032
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM…4033
M-29 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…4034
a)WIPER DOES NOT WORK…4034
b)WIPER SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED…4037
M-30 WASHER MOTOR DOE SNOT WORK,OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED …4040
a)WASHER MOTOR DOE SNOT WORK…4040
b)SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED…4041
30 DISASSEMBLY AND ASSEMBLY…4042
METHOD OF USING MANUAL…4044
SPECIAL TOOL LIST…4047
PRECAUTIONS WHEN CARRYING OUT OPERATION…4045
SKETCHES OF SPECIAL TOOLS…4052
STARTING MOTOR …4054
REMOVAL AND INSTALLATION…4054
ALTERNATOR …4055
REMOVAL AND INSTALLATION…4055
AIR CONDITIONER COMPRESSOR…4056
REMOVAL AND INSTALLATION…4056
CONDENSER…4058
REMOVAL AND INSTALLATION…4058
AFTERCOOLER …4059
REMOVAL AND INSTALLATION…4059
ENGINE OIL COOLER CORE…4060
REMOVAL AND INSTALLATION…4060
FUEL INJECTION PUMP…4061
REMOVAL …4061
INSTALLATION…4063
WATER PUMP…4065
REMOVAL AND INSTALLATION…4065
NOZZLE HOLDER …4066
REMOVAL AND INSTALLATION…4066
TURBOCHARGER…4067
REMOVAL AND INSTALLATION…4067
THERMOSTAT…4069
REMOVAL AND INSTALLATION…4069
GOVERNOR MOTOR…4070
REMOVAL AND INSTALLATION…4070
CYLINDER HEAD…4071
REMOVAL …4071
INSTALLATION…4076
ENGINE,MAIN PUMP …4079
REMOVAL…4079
INSTALLATION…4083
HYDRAULIC COOLER…4084
REMOVAL AND INSTALLATION…4084
RADIATOR,HYDRAULIC COOLER…4085
REMOVAL…4085
INSTALLATION…4086
RADIATOR AND HYDRAULIC OIL COOLER…4087
REMOVAL …4087
INSTALLATION…4088
FUEL TANK …4089
REMOVAL AND INSTALLATION…4089
CENTER SWIVEL JOIN …4090
REMOVAL AND INSTALLATION…4090
DISASSEMBLY AND ASSEMBLY …4091
SPROCKET …4092
REMOVAL AND INSTALLATION…4092
TRAVEL MOTOR …4093
REMOVAL AND INSTALLATION…4093
DISASSEMBLY AND ASSEMBLY…4094
FINAL DRIVE …4130
DISASSEMBLY…4130
ASSEMBLY …4133
SWING MACHINERY,SWING MOTOR…4138
REMOVAL AND INSTALLATION…4138
SWING MOTOR…4139
REMOVAL AND INSTALLATION…4139
DISASSEMBLY …4140
ASSEMBLY …4144
SWING MACHINERY…4152
DISASSEMBLY…4152
ASSEMBLY…4155
REVOLVING FARME…4159
REMOVAL …4159
INSTALLATION…4161
SWING CIRCLE…4162
REMOVAL AND INSTALLATION…4162
IDLER,RECOIL SPRING…4163
REMOVAL AND INSTALLATION…4163
RECOIL SPRING …4164
DISASSEMBLY…4164
ASSEMBLY…4165
IDLER…4166
DISASSEMBLY…4166
ASSEMBLY…4167
TRACK ROLLER …4169
REMOVAL AND INSTALLATION…4169
DISASSEMBLY…4170
ASSEMBLY…4171
CARRIER ROLLER…4173
REMOVAL AND INSTALLATION…4173
DISASSEMBLY…4174
ASSEMBLY …4176
TRACK SHOE…4178
REMOVAL AND INSTALLATION…4178
HYDRAULIC TANK …4179
REMOVAL…4179
INSTALLATION…4180
CONTROL PUMP …4181
REMOVAL AND INSTALLATION…4181
MAIN PUMP…4182
REMOVAL…4182
INSTALLATION…4183
DISASSEMBLY …4184
ASSEMBLY …4194
MAIN PUMP INPUT SHAFT OIL SEAL …4206
REMOVAL AND INSTALLATION…4206
CONTROL VALUE…4207
REMOVAL …4207
INSTALLATION…4208
DISASSEMBLY…4209
ASSEMBLY…4214
LS SELECT …4220
DISASSEMBLY AND ASSEMBLY…4220
MAIN RELIEF VALVE …4221
DISASSEMBLY…4221
ASSEMBLY…4222
PC,LS-EPC VALVE…4223
REMOVAL AND INSTALLATION…4223
PC VALVE…4224
REMOVAL AND INSTALLATION…4224
LS VALVE …4225
REMOVAL AND INSTALLATION…4225
SOLENOID VALVE …4226
REMOVAL AND INSTALLATION…4226
WORK EQUIPMENT PPC VALVE…4227
REMOVAL AND INSTALLATION…4227
DISASSEMBLY …4228
ASSEMBLY…4229
TRAVEL PPC VALVE…4230
REMOVAL AND INSTALLATION…4230
DISASSEMBLY …4231
ASSEMBLY …4232
BOOM CYLINDER …4233
REMOVAL…4233
INSTALLATION…4234
ARM CYLINDER …4235
REMOVAL …4235
INSTALLATION…4236
BUCKET CYLINDER …4237
REMOVAL …4237
INSTALLATION…4238
HYDRAULIC CYLINDER…4239
DISASSEMBLY…4239
ASSEMBLY…4242
WORK EQUIPMENT…4246
REMOVAL…4246
INSTALLATION…4247
BUCKET…4248
REMOVAL…4248
INSTALLATION…4249
ARM…4250
REMOVAL…4250
INSTALLATION…4251
BUCKET,ARM…4252
REMOVAL…4252
INSTALLATION…4253
BOOM …4254
REMOVAL …4254
INSTALLATION…4255
OPERATOR'S CAB …4256
REMOVAL…4256
INSTALLATION…4258
COUNTERWEIGHT…4259
REMOVAL AND INSTALLATION…4259
ENGINE THROTTLE,PUMP CONTROLLER …4260
REMOVAL AND INSTALLATION…4260
MONITOR…4261
REMOVAL AND INSTALLATION…4261
CONTROL STAND …4262
REMOVAL …4262
INSTALLATION…4263
40 MAINTENANCE STANDARD…4264
SWING MACHINERY …4265
SWING CIRCLE …4267
FINAL DRIVE …4268
TRACK FARME…4270
IDLER…4273
CARRIER ROLLER…4276
TRACK ROLLER…4278
SPROCKET…4280
TRACK SHOE …4282
HYDRAULIC PUMP …4294
CONTROL VALVE …4296
CENTER SWIVEL JOINT…4308
WORK EQUIPMENT・SWING PPC VALVE …4309
TRAVEL PPC VALVE…4310
SPERVICE PPC VALVE …4311
EPC SOLENOID VALVE …4312
HYDRAULIC CYLINDER…4313
WORK EQUIPMENT…4315
DIMENSION OF WORK EQUIPMENT…4317
90 OTHER…4321
HYDRAULIC CIRCUIT DIAGRAM PC100-6 SERIAL NO.:45221-46058 PC100L-6 SERIAL NO.:15200-46058 PC120-6 SERIAL NO.:57499-60967 PC130-6 SERIAL NO.:51020-51479…4322
HYDRAULIC CIRCUIT DIAGRAM PC100-6 SERIAL NO.:46059 AND UP PC100L-6 SERIAL NO.:46059 AND UP PC120-6 SERIAL NO.:60968-70000 PC120LC-6 SERIAL NO.:65504-70000 PC130-6 SERIAL NO.:51480 AND UP …4323
HYDRAULIC CIRCUIT DIAGRAM PC 120-6 SERIAL NO.:70001 AND UP…4324
ELECTRICAL CIRCUIT DIAGRAM(1/2) PC100-6 SERIAL NO.:45221-46058 PC100L-6 SERIAL NO.:15200-46058 PC120-6 SERIAL NO.:57499-60967 PC130-6 SERIAL NO.:51020-51479…4325
ELECTRICAL CIRCUIT DIAGRAM(2/2) PC100-6 SERIAL NO.:45221-46058 PC100L-6 SERIAL NO.:15200-46058 PC120-6 SERIAL NO.:57499-60967 PC130-6 SERIAL NO.:51020-51479…4326
ELECTRICAL CIRCUIT DIAGRAM(1/2) PC100-6 SERIAL NO.:46059 AND UP PC100L-6 SERIAL NO.:46059 AND UP PC120-6 SERIAL NO.:60968-70000 PC120LC-6 SERIAL NO.:65504-70000 PC130-6 SERIAL NO.:51480 AND UP …4327
ELECTRICAL CIRCUIT DIAGRAM(2/2) PC100-6 SERIAL NO.:46059 AND UP PC100L-6 SERIAL NO.:46059 AND UP PC120-6 SERIAL NO.:60968-70000 PC120LC-6 SERIAL NO.:65504-70000 PC130-6 SERIAL NO.:51480 AND UP …4328
ELECTRICAL CIRCUIT DIAGRAM(1/2) PC120-6 SERIAL NO.:70001 AND UP …4329
ELECTRICAL CIRCUIT DIAGRAM(2/2) PC120-6 SERIAL NO.:70001 AND UP …4329
SEBM02020508 – Hydraulic Excavator PC100-5, PC120-5, PC120-5 Mighty Shop Manual…4331
COVER…4331
CONTENTS…4332
10 STRUCTURE AND FUNCTION…4355
ENGINE RELATED PARTS AND ENGINE MOUNT…4356
RADIATOR AND OIL COOLER…4357
P.T.O…4359
FUEL SYSTEM…4360
POWER TRAIN…4361
FINAL DRIVE…4363
SWING CIRCLE…4364
SWING MACHINERY…4365
TRACK FRAME…4366
IDLER…4368
IDLER CUSHION…4368
CARRIER ROLLER…4369
TRACK ROLLER…4369
TRACK SHOE…4370
HYDRAULIC PIPING…4373
HYDRAULIC CIRCUIT DIAGRAM…4375
HYDRAULIC TANK AND FUEL TANK…4382
OLSS (OPEN CENTER LOAD SENSING SYSTEM)…4384
HYDRAULIC PUMP…4386
L.H. 6-SPOOL CONTROL VALVE…4405
R.H. 5-SPOOL CONTROL VALVE…4410
SWING MOTOR…4415
CENTER SWIVEL JOINT…4418
TRAVEL MOTOR…4419
VALVE CONTROL…4433
PPC VALVE…4435
ACCUMULATOR…4443
SAFETY LOCK VALVE…4444
SOLENOID VALVE…4445
SHUTTLE VALVE…4450
BOOM HOLDING VALVE…4455
HYDRAULIC CYLINDER…4459
ELECTRICAL WIRING DIAGRAM…4461
ELECTRICAL CIRCUIT DIAGRAM…4465
ENGINE CONTROL SYSTEM…4471
PEMC SYSTEM…4482
EMACC (ELECTRONIC MONITOR AND CONTROL CONSOLE)…4513
20 TESTING AND ADJUSTING…4521
TABLE OF JUDGEMENT STANDARD VALUE…4522
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM…4537
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING…4559
ADJUSTING VALVE CLEARANCE…4560
MEASURING COMPRESSION PRESSURE…4561
TESTING AND ADJUSTING FUEL INJECTION TIMING…4562
TESTING AND ADJUSTING TRAVEL OF GOVERNOR MOTOR LEVER…4563
INSPECTION OF SWING CIRCLE BEARING CLEARANCE…4564
ADJUSTING ENGINE SPEED SENSOR…4565
ADJUSTING TRAVEL LIMIT SWITCH…4565
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT…4566
TESTING AND ADJUSTING CHARGING PUMP PRESSURE…4568
TESTING AND ADJUSTING MAIN PUMP CONTROL PRESSURE…4570
MEASURING STROKE OF SERVO PISTON…4577
TESTING AND ADJUSTING TRAVEL DEVIATION…4578
MEASURING OUTPUT PRESSURE OF PPC VALVE…4580
ADJUSTING PPC VALVE…4582
TESTING PPC SHUTTLE VALVE…4584
MEASURING SOLENOID VALVE OUTLET PORT PRESSURE…4585
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT…4587
BLEEDING AIR…4589
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT…4591
TROUBLESHOOTING…4592
POINTS TO REMEMBER WHEN TROUBLESHOOTING…4593
SEQUENCE OF EVENTS IN TROUBLESHOOTING…4594
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE…4595
CHECKS BEFORE TROUBLESHOOTING…4602
ELECTRICAL CIRCUIT DIAGRAM…4603
POSITION OF CONNECTORS FOR TROUBLESHOOTING…4610
CONNECTION TABLE FOR CONNECTOR…4621
HANDLING CONNECTORS…4629
EXPLANATION OF FUNCTIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM…4630
DISPLAY METHOD FOR MONITOR PANEL, PUMP CONTROLLER AND ENGINE THROTTLE CONTROLLER…4633
ACTION OF SELF-DIAGNOSTIC FUNCTION AND SYMPTOMS ON MACHINE…4637
METHOD OF USING JUDGEMENT TABLE…4642
METHOD OF USING TROUBLESHOOTING CHARTS…4644
TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)…4646
ENGINE THROTTLE CONTROLLER OR IN ENGINE RELATED PARTS…4647
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING ON ENGINE THROTTLE CONTROLLER SYSTEM…4648
E-1 [ABNORMALITY IN POWER SOURCE SYSTEM OR CONTROLLER] IS DISPLAYED (ALL LAMPS OFF)…4649
E-2 [SHORT CIRCUIT GOVERNOR MOTOR] IS DISPLAYED…4653
E-3 [ABNORMALITY IN BATTERY RELAY] IS DISPLAYED…4654
E-4 [DISCONNECTION IN WIRING HARNESS OF GOVERNOR MOTOR] IS DISPLAYED…4656
E-5 [ABNORMALITY IN GOVERNOR POTENTIOMETER] IS DISPLAYED…4657
E-6 [ABNORMALITY IN FUEL CONTROL DIAL] IS DISPLAYED…4659
E-7 [ABNORMALITY IN NO.2 THROTTLE SIGNAL] IS DISPLAYED…4660
E-8 ENGINE DOES NOT START…4662
E-9 ENGINE ROTATION IS IRREGULAR…4666
a) IDLING ROTATION IS IRREGULAR…4666
b) THERE IS HUNTING…4668
E-10 LACK OF OUTPUT POWER (MAX,ENGINE SPEED IS TOO LOW)…4670
E-11 ENGINE DOES NOT STOP…4672
E-12 AUTOMATIC WARMING-UP OPERATION IS DEFECTIVE…4676
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)…4677
CHART FOR DISTINGUISHING IF FAILURE IS IN PUMP CONTROLLER OR IN HYDRAULIC RELATED PARTS…4678
C-1 [OFF] SELF-DIAGNOSTIC DISPLAY OF CONTROLLER DOES NOT LIGHT UP…4680
C-2 [01] [SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED…4682
C-3 [02] [SHORT CIRCUIT IN BOOM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED…4683
C-4 [03] [SHORT CIRCUIT IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED…4684
C-5 [04] [SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED…4685
C-6 [05] [SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED…4686
C-7 [07] [SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED…4687
C-8 [08] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (1)] IS DISPLAYED…4688
C-9 [09] [SHORT CIRCUIT IN TVC SOLENOID SYSTEM (2)] IS DISPLAYED…4689
C-10 [11] [DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM] IS DISPLAYED…4690
C-11 [12] [DISCONNECTION IN BOOM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED…4691
C-12 [13] [DISCONNECTION IN ARM HALF FLOW SOLENOID SYSTEM] IS DISPLAYED…4692
C-13 [14] [DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM] IS DISPLAYED…4693
C-14 [15] [DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM] IS DISPLAYED…4694
C-15 [17] [DISCONNECTION IN CO CANCEL SOLENOID SYSTEM] IS DISPLAYED…4695
C-16 [18] [DISCONNECTION IN TVC SOLENOID SYSTEM] IS DISPLAYED…4696
C-17 [21] [ABNORMALITY IN NO.2 THROTTLE SIGNAL SYSTEM] IS DISPLAYED…4697
C-18 [22] [ABNORMALITY IN THROTTLE SIGNAL SYSTEM] IS DISPLAYED…4698
C-19 [23] [ABNORMALITY IN PUMP PRESSURE SENSOR SIGNAL SYSTEM] IS DISPLAYED…4699
C-20 [25] [ABNORMALITY IN PUMP PRESSURE SENSOR POWER SOURCE SYSTEM] IS DISPLAYED…4701
C-21 [26] [ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM] IS DISPLAYED…4702
C-22 [28] [ABNORMALITY IN AUTO-DECELERATION SIGNAL OUTPUT SYSTEM] IS DISPLAYED…4703
C-23 [29] [ABNORMALITY IN OVERHEAT SIGNAL SYSTEM] IS DISPLAYED…4704
C-24 [88] [CONTROLLER ABNORMALITY SYSTEM] IS DISPLAYED…4705
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)…4706
F-1 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P1] [WORK EQUIPMENT OIL PRESSURE SWITCH]…4707
F-2 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P2] [SWING OIL PRESSURE SWITCH]…4708
F-3 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [P6] [TRAVEL LIMIT SWITCH]…4709
F-4 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [b5] [SWING LOCK SWITCH]…4710
F-5 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [HI OR LO] [TRAVEL SPEED SWITCH]…4711
F-6 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [Ad] [AUTO-DECELERATION SWITCH]…4712
F-7 PUMP CONTROLLER MONITOR DOES NOT DISPLAY [88] [DECIMAL POINT OF ENGINE SPEED SENSOR]…4713
F-8 PUMP CONTROLLER WORKING MODE DISPLAY DOES NOT SWITCH [1234]…4714
F-9 PUMP CONTROLLER POWER SET DISPLAY DOES NOT SWITCH [H5L]…4715
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…4716
H-1 SPEEDS OF WORK EQUIPMENT, TRAVEL SWING ARE ALL SLOW…4717
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS…4719
H-3 WORK EQUIPMENT, TRAVEL, SWING DO NOT MOVE, OR SPEED IS EXTREMELY SLOW…4721
H-4 ALL WORK EQUIPMENT, TRAVEL, SWING LACK POWER…4723
H-5 POWER SET SELECTION SYSTEM DOES NOT SWITCH…4723
H-6 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)…4724
H-7 AUTO-DECELERATION DOES NOT ACTUATED…4724
H-8 BOOM, ARM SPEED IS EXTREMELY SLOW…4725
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) SPEED IS SLOW…4726
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) LACKS POWER…4730
H-11 EXCESSIVE HYDRAULIC DRIFT…4730
H-12 EXCESSIVE TIME LAG…4732
H-13 DOES NOT ENTER FINISHING OPERATION (F.O) MODE…4732
H-14 WHEN MACHINE IS TRAVELING, IT DEVIATES NATURALLY TO ONE SIDE…4733
a) DEVIATES IN SAME DIRECTION BOTH IN FORWARD AND REVERSE…4733
b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE…4735
H-15 EXCESSIVE DEVIATION DURING COMPOUND OPERATIONS…4736
H-16 EXCESSIVE DEVIATION WHEN STARTING…4737
H-17 TRAVEL LACKS POWER (OR SPEED IS SLOW)…4739
H-18 TRAVEL SPEED DOES NOT SWITCH…4739
H-19 MACHINE DOES NOT MOVE (ONE SIDE ONLY)…4740
H-20 TRAVEL LEVER IS HEAVY…4740
H-21 DOES NOT SWING…4741
H-22 SWING SPEED IS SLOW OR ACCELERATION IS POOR…4743
H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING…4744
H-24 EXCESSIVE SHOCK WHEN STOPPING SWING…4744
H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING…4745
H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING…4745
H-27 WHEN OPERATED SIMULTANEOUSLY WITH ARM, SWING SPEED IS SLOW…4745
TABLE OF FAILURE MODES AND CAUSES…4746
TROUBLESHOOTING OF MONITOR SYSTEM (P MODE)…4748
P-1 MONITOR PANEL LAMPS DO NOT LIGHT UP FOR 3 SECONDS WHEN STARTING SWITCH IS TURNED ON…4749
a) NO MONITOR PANEL LAMPS LIGHT UP…4749
b) SOME MONITOR PANEL LAMPS DO NOT LIGHT UP…4749
P-2 MONITOR PANEL LAMPS ALL LIGHT UP WHEN STARTING SWITCH IS TURNED ON, BUT DO NOT GO OUT…4750
P-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH (LEVELS FOR CHECK ITEMS ARE AS SPECIFIED)…4751
a) COOLANT LEVEL FLASHES…4751
b) ENGINE OIL LEVEL FLASHES…4752
P-4 PREHEATING IS NOT BEING USED, BUT PREHEATING DISPLAY LIGHTS UP…4753
P-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH…4754
a) ALTERNATOR SYSTEM…4754
b) ENGINE OIL PRESSURE SYSTEM…4754
P-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH…4755
P-7 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH…4756
a) ENGINE OIL PRESSURE FLASHES…4756
b) COOLANT LEVEL FLASHES…4756
c) COOLANT TEMPERATURE FLASHES…4757
d) CHARGE FLASHES…4757
e) FUEL LEVEL FLASHES…4758
P-8…4759
a) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND.CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND…4759
b) THERE IS NO ABNORMALITY DISPLAY ON THE MONITOR, BUT THE BUZZER SOUNDS…4759
P-9 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…4760
P-10 COOLANT TEMPERATURE SHOWS ABNORMALLY LOW TEMPERATURE…4761
P-11 COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY (DURING OPERATION,NO LEVEL OF GAUGE IS DISPLAYED)…4761
P-12 FUEL GAUGE ALWAYS DISPLAYS FULL…4762
P-13 FUEL GAUGE GIVES NO DISPLAY…4762
P-14…4763
a) LAMPS DO NOT LIGHT UP …4763
b) LAMPS LIGHT UP EVEN WHEN LAMP SWITCH IS NOT OPERATED…4763
P-15…4765
a) WIPERS DO NOT WORK…4765
b) WIPERS WORK EVEN WHEN WIPER SWITCH IS NOT OPERATED…4765
P-16…4767
a) FAN DOES NOT WORK…4767
b) FAN WORKS EVEN WHEN FAN SWITCH IS NOT OPERATED…4767
P-17 WORKING MODE DOES NOT SWITCH…4769
P-18 POWER SET DOES NOT SWITCH…4770
P-19 AUTO-DECELERATION DOES NOT SWITCH (DOES NOT ENTER AUTO-DECELERATION; AUTO-DECELERATION IS NOT CANCELED)…4771
P-20 TRAVEL SPEED DOES NOT SWITCH BETWEEN HI AND LO…4772
P-21 WARMING-UP OPERATION IS NOT CARRIED OUT BELOW 30℃, OR WARMING-UP OPERATION IS NOT CANCELED EVEN WHEN TEMPERATURE GOES ABOVE 30℃…4773
P-22 EVEN WHEN SWING LOCK SWITCH IS TURNED ON (LOCK), SWING LOCK LAMP ON MONITOR PANEL DOES NOT LIGHT UP…4774
P-23 FUEL LEVEL SENSOR SYSTEM DEFECTIVE…4775
P-24 COOLANT TEMPERATURE SENSOR SYSTEM DEFECTIVE…4776
P-25 ENGINE OIL LEVEL SENSOR SYSTEM DEFECTIVE…4777
P-26 COOLANT LEVEL SENSOR SYSTEM DEFECTIVE…4778
30 DISASSEMBLY AND ASSEMBLY…4779
METHOD OF USING MANUAL…4781
PRECAUTIONS WHEN CARRYING OUT OPERATION…4782
SPECIAL TOOL LIST…4784
WEIGHT TABLE…4786
TIGHTENING TORQUES AND STANDARD VALUES TABLE…4787
LUBRICANT AND COOLANT TABLE…4789
STARTING MOTOR…4790
REMOVAL…4790
INSTALLATION…4790
ALTERNATOR…4790
REMOVAL…4790
INSTALLATION…4790
ENGINE OIL COOLER…4792
REMOVAL…4792
INSTALLATION…4792
FUEL INJECTION PUMP…4792
REMOVAL…4792
INSTALLATION…4792
WATER PUMP…4794
REMOVAL…4794
INSTALLATION…4794
NOZZLE HOLDER…4794
REMOVAL…4794
INSTALLATION…4794
TURBOCHARGER…4796
REMOVAL…4796
INSTALLATION…4796
THERMOSTAT…4796
REMOVAL…4796
INSTALLATION…4796
ENGINE FRONT SEAL…4798
REMOVAL…4798
INSTALLATION…4798
ENGINE REAR SEAL…4798
REMOVAL…4798
INSTALLATION…4798
GOVERNOR MOTOR…4800
REMOVAL…4800
INSTALLATION…4800
CYLINDER HEAD…4802
REMOVAL…4802
INSTALLATION…4802
HYDRAULIC COOLER …4804
REMOVAL…4804
INSTALLATION…4804
RADIATOR, HYDRAULIC COOLER…4804
REMOVAL…4804
INSTALLATION…4804
ENGINE HYDRAULIC PUMP…4806
REMOVAL…4806
INSTALLATION…4806
PTO…4808
REMOVAL…4808
INSTALLATION…4808
DISASSEMBLY…4808
ASSEMBLY…4808
CENTER SWIVEL JOINT…4810
REMOVAL…4810
INSTALLATION…4810
DISASSEMBLY…4810
ASSEMBLY…4810
FINAL DRIVE (PC120-5)…4812
REMOVAL…4812
INSTALLATION…4812
DISASSEMBLY…4814
ASSEMBLY…4816
TRAVEL MOTOR…4822
DISASSEMBLY…4822
ASSEMBLY…4830
SPROCKET…4852
REMOVAL…4852
INSTALLATION…4852
SWING MACHINERY…4854
DISASSEMBLY…4854
ASSEMBLY…4856
SWING MOTOR…4860
DISASSEMBLY…4860
ASSEMBLY…4864
REVOLVING FRAME…4870
REMOVAL…4870
INSTALLATION…4870
SWING CIRCLE…4870
REMOVAL…4870
INSTALLATION…4870
IDLER, RECOIL SPRING…4872
REMOVAL…4872
INSTALLATION…4872
RECOIL SPRING…4874
DISASSEMBLY…4874
ASSEMBLY…4874
TRACK ROLLER…4876
REMOVAL…4876
INSTALLATION…4876
CARRIER ROLLER…4876
REMOVAL…4876
INSTALLATION…4876
TRACK SHOE…4878
REMOVAL…4878
INSTALLATION…4878
CHARGING PUMP…4878
REMOVAL…4878
INSTALLATION…4878
HYDRAULIC PUMP…4880
REMOVAL…4880
INSTALLATION…4880
MAIN PUMP INPUT SHAFT…4880
REMOVAL…4880
INSTALLATION…4880
PISTON PUMP…4882
DISASSEMBLY…4882
ASSEMBLY…4886
CONTROL VALVE…4896
REMOVAL…4896
INSTALLATION…4896
DISASSEMBLY…4898
ASSEMBLY…4898
MAIN RELIEF VALVE…4900
REMOVAL…4900
INSTALLATION…4900
DISASSEMBLY…4900
ASSEMBLY…4900
TVC VALVE…4902
REMOVAL…4902
INSTALLATION…4902
CO.NC VALVE…4902
REMOVAL…4902
INSTALLATION…4902
SERVO VALVE…4904
REMOVAL…4904
INSTALLATION…4904
WORK EQUIPMENT PPC VALVE…4904
REMOVAL…4904
INSTALLATION…4904
PPC VALVE…4906
DISASSEMBLY…4906
ASSEMBLY…4906
PPC SHUTTLE VALVE…4910
REMOVAL…4910
INSTALLATION…4910
BOOM HOLDING VALVE…4912
REMOVAL…4912
INSTALLATION…4912
DISASSEMBLY…4912
ASSEMBLY…4912
BOOM CYLINDER…4914
REMOVAL…4914
INSTALLATION…4914
ARM CYLINDER…4916
REMOVAL…4916
INSTALLTAION…4916
BUCKET CYLINDER…4916
REMOVAL…4916
INSTALLATION…4916
HYDRAULIC CYLINDER…4920
DISASSEMBLY…4920
ASSEMBLY…4922
WORK EQUIPMENT…4924
REMOVAL…4924
INSTALLATION…4924
BUCKET…4926
REMOVAL…4926
INSTALLATION…4926
ARM…4926
REMOVAL…4926
INSTALLATION…4926
ARM, BUCKET…4928
REMOVAL…4928
INSTALLATION…4928
BOOM…4930
REMOVAL…4930
INSTALLATION…4930
OPERATOR'S CAB…4932
REMOVAL…4932
INSTALLATION…4932
COUNTERWEIGHT…4932
REMOVAL…4932
INSTALLATION…4932
ENGINE THROTTLE CONTROLLER…4934
REMOVAL…4934
INSTALLATION…4934
PUMP CONTROLLER…4934
REMOVAL…4934
INSTALLATION…4934
MONITOR PANEL…4936
REMOVAL…4936
INSTALLATION…4936
40 MAINTENANCE STANDARD…4938
FINAL DRIVE…4939
SWING CIRCLE…4941
SWING MACHINERY…4942
TRACK FRAME…4943
IDLER…4944
TRACK ROLLER…4945
CARRIER ROLLER…4946
TRACK SHOE…4947
HYDRAULIC PUMP…4950
CHARGING PUMP AND RELIEF VALVE…4951
L.H. 6-SPOOL CONTROL VALVE…4952
R.H. 5-SPOOL CONTROL VALVE…4958
SWING MOTOR…4964
CENTER SWIVEL JOINT…4965
TRAVEL MOTOR…4966
PPC VALVE…4967
BOOM HOLDING VALVE…4969
HYDRAULIC CYLINDER…4971
WORK EQUIPMENT…4973
SEBM0202B03 – Hydraulic Excavator PC100-2, PC100L-2, PC120-2 Shop Manual…4975
WEAM000402 – Hydraulic Excavator PC110R-1 Operation & Maintenance Manual…5279
1.1 FOREWORD…5281
1.2 INFORMATION ON SAFETY…5282
1.3 INTRODUCTION…5284
1.3.1 INTENDED USES…5284
1.3.2 IMPROPER OR UNAUTHORIZED USE…5284
1.3.3 MAIN CHARACTERISTICS…5285
1.3.4 RUNNING-IN…5285
1.4 PRODUCT IDENTIFICATION…5286
1.4.1 MACHINE SERIAL NUMBER…5286
1.4.2 MACHINE IDENTIFICATION PLATE…5286
1.4.3 NGINE SERIAL NUMBER AND EXHAUST GAS EMISSION PLATE…5287
1.4.4 TRAVEL REDUCTION GEAR SERIAL NUMBER…5288
1.4.5 SWING REDUCTION GEAR SERIAL NUMBER…5288
1.4.6 CAB SERIAL NUMBER…5288
1.4.7 SERIAL NUMBERS AND DEALER’S ADDRESS…5289
CONTENTS…5290
2.1 SAFETY, NOISE AND VIBRATION PLATES…5298
2.1.1 POSITION OF THE SAFETY PLATES…5298
2.1.2 PICTOGRAMS AND RELEVANT MEANINGS…5299
2.1.3 POSITION OF THE NOISE PLATES…5303
2.1.4 VIBRATIONS TO WHICH THE OPERATOR IS SUBJECTED…5304
2.2 GENERAL PRECAUTIONS…5305
2.2.1 GENERAL SAFETY RULES…5305
2.2.2 SAFETY DEVICES AND GUARDS…5305
2.2.3 CLOTHING AND PERSONAL PROTECTION ITEMS…5305
2.2.4 UNAUTHORIZED MODIFICATIONS…5306
2.2.5 LEAVING THE OPERATOR’S SEAT…5306
2.2.6 GETTING ON AND OFF THE MACHINE…5307
2.2.7 PREVENTING FIRES DUE TO FUEL AND OIL…5307
2.2.8 PREVENTING BURNS…5308
2.2.9 PREVENTING DAMAGE DUE TO ASBESTOS POWDER…5308
2.2.10 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…5309
2.2.11 FIRE EXTINGUISHERS AND FIRST AID KIT…5309
2.2.12 PRECAUTIONS CONCERNING THE CAB STRUCTURE…5309
2.2.13 PRECAUTIONS CONCERNING THE EQUIPMENT…5309
2.3 PRECAUTIONS TO BE TAKEN BEFORE STARTING THE ENGINE…5310
2.3.1 SAFETY ON THE WORK SITE…5310
2.3.2 FIRE PREVENTION…5310
2.3.3 PRECAUTIONS TO BE TAKEN FOR THE OPERATOR'S CAB…5310
2.3.4 ROOM VENTILATION…5311
2.3.5 PRECAUTIONS TO BE TAKEN FOR THE LIGHTS…5311
2.3.6 CLEANING THE WINDOWS AND THE REAR-VIEW MIRRORS – CHECKING THE WINDSHIELD WIPER BLADES…5311
2.4 PRECAUTIONS TO BE TAKEN WHEN WORKING…5312
2.4.1 STARTING THE ENGINE…5312
2.4.2 CHECK THE DIRECTION BEFORE STARTING THE MACHINE…5312
2.4.3 CHECKS FOR TRAVELLING IN REVERSE…5312
2.4.4 MOVING THE MACHINE…5313
2.4.5 MOVING ON SLOPES…5314
2.4.6 WORKING ON SLOPES…5315
2.4.7 UNAUTHORIZED OPERATIONS…5315
2.4.8 PREVENTING ELECTROCUTION…5316
2.4.9 VISIBILITY…5317
2.4.10 WORKING ON ICY OR SNOW-COVERED SURFACES…5317
2.4.11 PREVENTING DAMAGE CAUSED BY THE WORK EQUIPMENT…5317
2.4.12 WORKING ON LOOSE GROUND…5317
2.4.13 PARKING THE MACHINE…5318
2.5 TRANSPORTING THE MACHINE ON OTHER VEHICLES…5319
2.5.1 LOADING AND UNLOADING THE MACHINE…5319
2.5.2 SHIPPING…5319
2.6 BATTERY…5320
2.6.1 SAFETY PRECAUTIONS FOR WORK ON BATTERIES…5320
2.6.2 STARTING WITH BOOSTER CABLES…5320
2.7 PRECAUTIONS FOR EMERGENCY RECOVERY…5321
2.8 PRECAUTIONS TO BE TAKEN DURING MAINTENANCE…5322
2.8.1 WARNING PLATES…5322
2.8.2 TOOLS…5322
2.8.3 PERSONNEL…5322
2.8.4 EQUIPMENT…5323
2.8.5 WORKING UNDER THE MACHINE…5323
2.8.6 KEEPING THE MACHINE CLEAN…5323
2.8.7 USE OF THE ENGINE DURING MAINTENANCE…5324
2.8.8 PERIODICAL CHANGE OF THE PARTS THAT ARE CRITICAL FOR SAFETY…5324
2.8.9 STOP THE ENGINE BEFORE CARRYING OUT ANY MAINTENANCE OPERATION OR INSPECTION…5324
2.8.10 RULES FOR REFUELLING AND ADDING OIL…5325
2.8.11 CHECKING THE COOLANT LEVEL IN THE RADIATOR…5325
2.8.12 USING LAMPS…5325
2.8.13 PRECAUTIONS CONCERNING THE BATTERY AND THE ALTERNATOR…5326
2.8.14 PRECAUTIONS CONCERNING THE STARTER…5326
2.8.15 PRECAUTIONS CONCERNING HIGH-PRESSURE HOSES…5327
2.8.16 PRECAUTIONS TO BE TAKEN WHEN WORKING ON HIGH-PRESSURE SYSTEMSE…5327
2.8.17 PRECAUTIONS FOR MAINTENANCE WORK INVOLVING HIGH TEMPERATURES AND PRESSURES…5327
2.8.18 COOLING FAN AND FAN BELT…5328
2.8.19 WASTE MATERIALS…5328
2.8.20 PRECAUTIONS FOR THE USE OF THE synthetic biodegradable oil type HEES…5328
3.1 SAFETY LOCKS…5330
3.1.1 MACHINE LOCKS…5330
3.2 GENERAL VIEWS…5331
3.2.1 FRONT GENERAL VIEW (MONOBOOM)…5331
3.2.2 FRONT GENERAL VIEW (TWO-PIECE BOOM)…5332
3.2.3 CAB INSIDE GENERAL VIEW…5333
3.3 INSTRUMENTS AND CONTROLS…5335
3.3.1 INSTRUMENTS…5335
3.3.2 WARNING LIGHTS…5337
3.3.3 SWITCHES AND PUSH BUTTONS…5339
3.3.4 ELECTRICAL ACCESSORIES…5347
3.3.5 MACHINE CONTROLS…5349
3.4 FUSES AND RELAYS…5357
3.4.1 CENTRAL UNIT FUSES AND RELAYS…5357
3.4.1.1 CENTRAL UNIT FUSES…5358
3.4.1.2 CENTRAL UNIT RELAYS…5359
3.4.2 ENGINE LINE FUSES AND RELAYS…5360
3.4.2.1 ENGINE LINE FUSES…5360
3.4.2.2 ENGINE LINE RELAYS…5361
3.4.3 FUSES AND RELAYS OF THE AIR CONDITIONING SYSTEM (if provided)…5362
FUSES…5362
RELAYS…5362
FUSES…5363
RELAYS…5363
3.5 GUARDS AND DRIVER’S SEAT…5364
3.5.1 ENGINE HOOD…5364
3.5.2 SIDE COVER…5364
3.5.3 CAB…5365
3.5.4 VENTILATION AND HEATING…5369
3.5.5 AIR CONDITIONER (if provided)…5370
3.5.6 SEAT…5372
3.5.7 SAFETY BELT…5373
3.5.8 EMERGENCY EXIT…5373
3.5.9 TECHNICAL DOCUMENTATION CASE…5374
3.5.10 FIRE EXTINGUISHER…5374
3.5.11 FIRST AID KIT…5374
3.6 USE OF THE MACHINE…5375
3.6.1 CHECKS BEFORE STARTING THE ENGINE…5375
3.6.1.1 VISUAL CHECKS…5375
3.6.1.2 DAILY CHECKS…5375
3.6.1.3 OPERATIONAL CHECKS…5376
3.6.2 STARTING THE ENGINE…5377
3.6.2.1 STARTING WITH WARM ENGINE OR IN TEMPERATE CLIMATES…5377
3.6.2.2 STARTING WITH COLD ENGINE OR IN COLD CLIMATES…5378
3.6.3 WARMING THE ENGINE…5379
3.6.4 HEATING THE HYDRAULIC OIL…5379
3.6.5 HOW TO MOVE THE MACHINE…5379
3.6.5.1 STEERING (CHANGING DIRECTION)…5381
3.6.5.2 MOVING ON SLOPES…5382
3.6.5.3 MAXIMUM IMMERSION DEPTH…5383
3.7 PARKING THE MACHINE…5384
3.7.1 PARKING ON LEVEL GROUND…5384
3.7.2 PARKING ON SLOPES…5385
3.8 STOPPING THE ENGINE…5386
3.9 TRANSPORTING THE MACHINE ON OTHER VEHICLES…5387
3.9.1 LOADING AND UNLOADING THE MACHINE…5387
3.9.2 TRANSPORT…5388
3.10 PRECAUTIONS TO BE TAKEN IN THE COLD SEASON…5389
3.10.1 FUEL AND LUBRICANTS…5389
3.10.2 COOLANT…5389
3.10.3 BATTERY…5390
3.10.4 OTHER PRECAUTIONS…5390
3.10.5 PRECAUTIONS TO BE TAKEN AT THE END OF WORK…5390
3.11 PRECAUTIONS TO BE TAKEN IN THE WARM SEASON…5391
3.12 USING THE WORK EQUIPMENT…5392
3.12.1 ORGANIZING THE WORK AREA…5392
3.12.2 POSITIONING THE BUCKET ACCORDING TO THE WORK TO BE CARRIED OUT…5392
3.12.3 POSITIONING THE MACHINE FOR DIGGING OPERATIONS…5393
3.12.4 DIGGING METHOD…5394
3.12.5 CHANGING THE BUCKET…5395
3.13 LONG PERIODS OF INACTIVITY…5396
3.13.1 BEFORE THE PERIOD OF INACTIVITY…5396
3.13.2 DURING THE PERIOD OF INACTIVITY…5397
3.13.3 AFTER THE PERIOD OF INACTIVITY…5397
3.14 TROUBLESHOOTING…5398
3.14.1 HOW TO REMOVE THE MACHINE…5398
3.14.2 IF THE FUEL HAS BEEN COMPLETELY DEPLETED…5398
3.14.3 IF THE BATTERY IS DEPLETED…5399
3.14.3.1 STARTING WITH BOOSTER CABLES…5400
3.14.4 OTHER TROUBLES…5401
3.14.4.1 ELECTRICAL CIRCUIT…5401
3.14.4.2 HYDRAULIC SYSTEM…5402
3.14.4.3 ENGINE…5403
4.1 GUIDE TO MAINTENANCE…5406
4.2 MAINTENANCE NOTES…5408
4.2.1 NOTES REGARDING THE ENGINE…5408
4.2.1.1 ENGINE OIL…5408
4.2.1.2 COOLANT…5408
4.2.1.3 FUEL…5409
4.2.2 NOTES REGARDING THE HYDRAULIC SYSTEM…5409
4.2.3 NOTES REGARDING THE ELECTRICAL SYSTEM…5410
4.2.4 NOTES REGARDING LUBRICATION…5410
4.2.5 PARTS SUBJECT TO WEAR THAT PERIODICALLY NEED CHANGING…5411
4.3 FUEL, COOLANT AND LUBRICANTS…5412
LUBRICATION WITH GREASE…5412
4.3.1 HOMOLOGATED HEES SYNTHETIC BIODEGRADABLE LUBRICANTS…5414
4.4 DRIVING TORQUES FOR SCREWS AND NUTS…5415
4.4.1 STANDARD DRIVING TORQUES…5415
4.4.2 SPECIFIC DRIVING TORQUES…5415
4.5 LUBRICATION…5416
4.5.1 LUBRICATION DIAGRAM…5416
4.6 PERIODICAL CHANGE OF THE COMPONENTS CONNECTED WITH SAFETY…5417
4.6.1 CRITICAL PARTS FOR SAFETY…5418
4.7 MAINTENANCE PLAN…5421
4.7.1 WHEN REQUIRED…5425
4.7.1.a CHECKING, CLEANING OR CHANGING THE AIR CLEANER CARTRIDGE…5425
4.7.1.b CHECKING AND CLEANING THE CAB AIR FILTER…5427
4.7.1.c CHECKING AND CLEANING THE AIR RECIRCULATION FILTER (only for machines equipped with air c…5428
4.7.1.d CLEANING THE WATER SEPARATOR…5429
4.7.1.e CHECKING THE STEEL TRACK TENSION…5430
CHECK…5430
ADJUSTMENT…5431
4.7.1.f CHECKING THE SHOE FASTENING…5432
4.7.2 MAINTENANCE INTERVALS IN CASE OF USE OF THE DEMOLITION HAMMER…5433
4.7.2.a CHANGING THE HYDRAULIC OIL FILTER…5433
4.7.2.b CHANGING THE HYDRAULIC OIL…5433
4.7.3 CHECKS BEFORE STARTING…5434
4.7.3.a VARIOUS CHECKS…5434
4.7.3.b CHECKING THE COOLANT LEVEL…5434
4.7.3.c CHECKING THE FUEL LEVEL…5435
4.7.3.d CHECKING THE ENGINE OIL LEVEL…5435
4.7.3.e CHECKING THE OIL LEVEL IN THE HYDRAULIC CIRCUIT…5436
4.7.3.f DRAINING THE WATER SEPARATOR…5437
4.7.4 MAINTENANCE EVERY 10 HOURS OF OPERATION…5438
4.7.4.a LUBRICATING THE JOINTS…5438
BLADE LUBRICATION POINTS…5438
EQUIPMENT LUBRICATION POINTS (MONOBOOM)…5439
EQUIPMENT LUBRICATION POINTS (TWO-PIECE BOOM)…5440
4.7.5 MAINTENANCE AFTER THE FIRST 50 HOURS OF OPERATION (Only for machines in which the synthetic…5441
4.7.6 MAINTENANCE EVERY 50 HOURS OF OPERATION…5441
4.7.6.a CHECKING THE RADIATOR FLUID LEVEL…5441
4.7.6.b LUBRICATING THE SWING JOINT…5442
4.7.6.c CHECKING THE ELECTRICAL SYSTEM…5442
4.7.7 MAINTENANCE EVERY 100 HOURS OF OPERATION…5443
4.7.7.a LUBRICATING THE BALL-BEARING RING…5443
4.7.8 MAINTENANCE AFTER THE FIRST 250 HOURS OF OPERATION…5444
4.7.9 MAINTENANCE EVERY 250 HOURS OF OPERATION…5444
4.7.9.a ADJUSTING THE FAN BELT TENSION…5444
4.7.9.b ADJUSTING THE TENSION OF THE A/C COMPRESSOR BELT (only for machines equipped with air con…5445
4.7.9.c CHECKING THE BATTERY ELECTROLYTE LEVEL…5446
4.7.9.d CHECKING THE OIL LEVEL IN THE TRAVEL REDUCTION GEARS…5446
4.7.9.e CHECKING THE OIL LEVEL IN THE SWING REDUCTION GEAR…5447
4.7.10 MAINTENANCE AFTER THE FIRST 500 HOURS OF OPERATION (Only for machines in which the synthet…5448
4.7.11 MAINTENANCE EVERY 500 HOURS OF OPERATION…5448
4.7.11.a CHANGING THE HYDRAULIC SYSTEM OIL FILTER…5448
4.7.11.b CHANGING THE SERVO CONTROL FILTER…5450
4.7.11.c CHANGING THE ENGINE OIL…5451
4.7.11.d CHANGING THE ENGINE OIL FILTER…5452
4.7.11.e CHANGING THE FUEL FILTER…5453
4.7.11.f DRAINING THE FUEL TANK…5454
4.7.11.g CLEANING THE OUTSIDE OF THE RADIATORS…5454
4.7.11.h CLEANING THE OUTSIDE OF THE A/C CONDENSER (only for machines equipped with air conditioner)…5455
4.7.11.j CHECKING THE BALL-BEARING RING PINION LUBRICANT LEVEL…5456
4.7.11.k DRAINING THE HYDRAULIC OIL TANK (Only for machines in which the synthetic biodegradable …5456
4.7.12 MAINTENANCE EVERY 1000 HOURS OF OPERATION…5458
4.7.12.a CHECKING AND ADJUSTING THE ENGINE VALVE CLEARANCE…5458
4.7.13 MAINTENANCE EVERY 2000 HOURS OF OPERATION…5459
4.7.13.a CHANGING THE OIL IN THE TRAVEL REDUCTION GEARS…5459
4.7.13.b CHANGING THE OIL IN THE SWING REDUCTION GEAR…5460
4.7.13.c CHANGING THE HYDRAULIC SYSTEM OIL AND CLEANING THE SUCTION FILTER…5461
4.7.13.d CHANGING THE COOLANT…5464
4.7.13.e CHANGING THE BALL-BEARING RING PINION LUBRICANT…5465
4.7.13.f CHECKING THE ALTERNATOR AND THE STARTER…5465
4.7.13.g CHECKING THE A/C COOLING GAS QUANTITY (only for machines equipped with air conditioner)…5466
4.7.14 MAINTENANCE EVERY 4000 HOURS OF OPERATION…5467
4.7.14.a CHANGING THE A/C DEHYDRATOR FILTER (only for machines equipped with air conditioner)…5467
4.7.14.b CHECKING THE CORRECT OPERATION OF THE A/C COMPRESSOR (only for machines equipped with ai…5467
5.1 TECHNICAL DATA…5470
5.1.1 STANDARD OVERALL DIMENSIONS…5470
OVERALL DIMENSIONS WITH MONOBOOM…5470
OVERALL DIMENSIONS WITH TWO-PIECE BOOM…5470
5.1.2 TECHNICAL CHARACTERISTICS…5471
5.1.3 LIFTING CAPACITIES (Only for machines with overload alarm device)…5472
5.1.3.1 LIFTING CAPACITY TABLE…5472
5.1.3.2 LIFTING CAPACITY WITH MONOBOOM…5474
5.1.3.3 LIFTING CAPACITY WITH TWO-PIECE BOOM…5475
6.1 AUTHORIZED OPTIONAL EQUIPMENT…5478
6.1.1 PRECAUTIONS REGARDING SAFETY…5478
6.1.2 PRECAUTIONS REGARDING THE INSTALLATION OF EQUIPMENT…5479
6.1.3 CHARACTERISTICS OF THE OPTIONAL EQUIPMENT…5480
6.2 ARRANGEMENT FOR THE INSTALLATION OF THE DEMOLITION HAMMER…5481
6.2.1 DESCRIPTION AND OPERATION…5481
6.2.2 USE OF THE DEMOLITION HAMMER AND RULES TO BE OBSERVED…5481
FOR A CORRECT USE, IT IS NECESSARY TO:…5481
ALWAYS AVOID THE FOLLOWING INCORRECT USES:…5483
6.2.3 INSTALLING AND REMOVING THE DEMOLITION HAMMER…5485
6.2.3.1 INSTALLING THE HAMMER…5485
6.2.3.2 REMOVING THE HAMMER…5486
6.2.4 MAINTENANCE…5486
6.3 CLAMSHELL BUCKET…5487
6.3.1 DESCRIPTION AND OPERATION…5487
6.3.2 INSTALLING THE CLAMSHELL BUCKET…5488
6.3.3 MAINTENANCE…5490
Komatsu PC100, PC120, PC130 Hydraulic Excavator Repair Service Manuals