This Complete Service Repair Workshop Manual PDF Download for the Komatsu PC100-6 (SN: 40001 and up), PC120-6 (SN: 45001 and up) Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu PC100-6 Hydraulic Excavator
Serial Numbers : 40001 and up
Komatsu PC120-6 Hydraulic Excavator
Serial Numbers : 45001 and up
TABLE OF CONTENTS :
01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM003307
Total Pages : 1036
This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!
This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
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COVER
CONTENTS
SAFETY
FOREWORD
-GENERAL
-HOW TO READ THE SHOP MANUAL
-HOISTING INSTRUCTIONS
-METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
-COATING MATERIALS
-STANDARD TIGHTENING TORQUE
-ELECTRIC WIRE CODE
-CONVERSION TABLE
-UNITS
01 GENERAL
-GENERAL ASSEMBLY DRAWING
-SPECIFICATIONS
-WEIGHT TABLE
-LIST OF LUBRICANT AND WATER
10 STRUCTURE AND FUNCTION
-RADIATOR AND OIL COOLER
-PTO (COUPLING)
-POWER TRAIN
-SWING CIRCLE
-SWING MACHINERY
-TRACK FRAME
-IDLER
-IDLER CUSHION
-CARRIER ROLLER
-TRACK ROLLER
-TRACK SHOE
-HYDRAULIC PIPING DRAWING
-HYDRAULIC CIRCUIT DIAGRAM
-HYDRAULIC TANK
-HYDRAULIC PUMP
-CONTROL VALVE
-CLSS
-SWING MOTOR
-CENTER SWIVEL JOINT
-TRAVEL MOTOR
-VALVE CONTROL
-WORK EQUIPMENT - SWING PPC VAVLE
-TRAVEL PPC VALVE
-SERVICE PPC VALVE
-SAFETY LOCK VALVE
-PPC ACCUMULATOR
-PPC SHUTTLE - TRAVEL JUNCTION VALVE
-EPC - SOLENOID VALVE
-BOOM HOLDING VALVE
-HYDRAULIC CYLINDER
-ACCUMULATOR FOR BREAKER
-ADDITIONAL FILTER FOR BREAKER
-WORK EQUIPMENT
-ELECTRICAL WIRING DIAGRAM
-ELECTRICAL CIRCUIT DIAGRAM
-ENGINE CONTROL SYSTEM
-ELECTRONIC CONTROL SYSTEM
-MACHINE MONITOR SYSTEM
20 TESTING AND ADJUSTING
-TABLE OF JUDGEMENT STANDARD VALUE
-STANDARD VALUE TABLE FOR ELECTRICAL PARTS
-TOOLS FOR TESTING ADJUSTING, AND TROUBLESHOOTING
-MEASURING ENGINE SPEED
-MEASURING EXHAUST GAS COLOR
-ADJUSTING VALVE CLEARENCE
-MEASURING COMPRESSION PRESSURE
-MEASURING BLOWBY PRESSURE
-TESTING AND ADJUSTING FUEL INJECTION TIMING
-MEASURING ENGINE OIL PRESSURE
-TESTING AND ADJUSTING FAN BELT TENSION
-TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
-ADJUSTING ENGINE SPEED SENSOR
-TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
-TESTING CLEARANCE OF SWING CIRCLE BEARING
-TESTING AND ADJUSTING TRACK SHOE TENSION
-TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
-TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTION INPUT PRESSURE)
-TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LD DIFFERENTIAL PRESSURE
-TESTING AND ADJUSTING VARIABLE THROTTLE VALVE
-TESTING AND ADJUSTIN CONTROL PUMP CIRCUIT OIL PRESSURE
-TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE
-MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE
-ADJUSTING WORK EQUIPMENT - SWING PPC VALVE
-ADJUSTING TRAVEL LEVER
-TESTING TRAVEL DEVIATION
-TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
-MEASURING OIL LEAKAGE
-RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
-BLEEDING AIR
-TROUBLESHOOTING
--POINTS TO REMEMBER WHEN TROUBLESHOOTING
--CONNECTOR TYPES AND MOUNTING LOCATIONS
--CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
--EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
--DISPLAY METHOD AND SPECIAL FUNCTION OF MONITOR PANEL
--METHOD OF USING JUDGEMENT TABLE
--METHOD OF USING TROUBLESHOOTING CHARTS
--DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
--TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)
---N-1 COMMUNICATION ABNORMALITY
---N-1 [E218] COMMUNICATION ABNORMALITY
--TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)
---POINTS TO REMEMBER WHEN CARRYIN GOUT TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM
---ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
---JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATED PARTS
---ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAM
---TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE
----E-1 ABNORMALITY IN ENGINE THROTTLE CONTROLLER POWER SOURCE SYSTEM
----E-2 [E3:08} ABNORMALITY IN FUEL CONTROL DIAL INPUT VLAVUE SYSTEM IS DISPLAYED
----E-3 [E3:17] ABNORMALITY (DISCONNECTION) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED
----E-4 [E3:18] ABNORMALITY (SHORT CIRCUIT) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED
----E-5 [E3:01] ABNORMALITY IN NETWORK RECEPTION SYSTEM IS DISPLAYED
----E-6 [E3:05] ABNORMALITY IN MODEL CODE IS DISPLAYED
----E-7 [E3:06] ABNORMALTIY IN GOVERNOR POTENTIOMETER SYSTEM IS DISPLAYED
----E-8 [E3:07] ABNORMALITY IN PUMP CONTROLLER THROTTLE SYSTEM IS DISPLAYED
----E-9 [E3:15] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED
----E-10 [E3:16] ABNORMALITY (STEP-OUT) IN GOVERNOT MOTOR SYSTEM IS DISPLAYED
----E-11 ENGINE DOES NOT START
----E-12 ENGINE SPEED IS IRREGULAR
-----A) KILLING SPEED IS IRREGULAR
-----B) THERE IS HUNTING
----E-13 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)
----E-14 ENGINE DOES NOT STOP
----E-15 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)
--TROUBLESHOOTING OF ENGINE THROTTLE PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)
---POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER SYSTEM
---ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
---JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER POWERSOURCE (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
---ELECTRICAL CIRCUIT DIAGRAM FOR E MODE
---E-1 ABNORMALITY IN ENGINE THRO0TTLE - PUMP CONTROLLER POWER SOURCE (CONTROLLER LED ID OFF)
---E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED
---E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED
---E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED
---E-5 [E306] ABNORMALITY IN FEED BACK POTENTIOMETER SYSTEM IS DISPLAYED
---E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED
---E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED
---E-8 ENGINE DOES NOT START
---E-9 ENGINE SPEED IS IRREGULAR
---E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)
---E-11 ENGINE DOES NOT STOP
---E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)
--TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
---METHOD OF USING TROUBLESHOOTING CHARTS
---S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
---S-2 ENGINE DOES NOT START
----(1) ENGINE DOES NOT TURN
----(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
----(3) EXHAUST SMOKE COMES OUT BUT ENGINES DOES NOT START (FUEL IS BEING INJECTED)
---S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
---S-4 ENGINE STOPS DURING OPERATIONS
---S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
---S-6 ENGINE LACKS OUTPUT (NO POWER)
---S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
---S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
---S-9 OIL BECOMES CONTAMINATED QUICKLY
---S-10 FUEL CONSUMPTION IS EXCESSIVE
---S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
---S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)
---S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
---S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
---S-15 ABNORMAL NOISE IS MADE
---S-16 VIBRATION IS EXCESSIVE
--TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)
---POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM
---ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS OCCUR ON MACHINE
---JUDGEMENT TABLE FOR PUMP CONTROLLER AND HDURAULIC RELATED PARTS
---PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM
---TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE
----C-1 ABNORMALITY IN PUMP CONTROLLER POWER SOURCE SYSTEM
----C-2 [E2:32] SHORT CIRCUIT IN TVC SOLENOID SYSTEM IS DISPLAYED
----C-3 [E2:33] DISCONNECTION IN TVC SOLENOID SYSTEM IS DISPLAYED
----C-4 [E2:03] SHORT CIRCUIT IN SWING BRAKE SOLENOIL SYSTEM IS DISPLAYED
----C-5 [E2:13] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED
----C-6 [E2:01] SHORT CIRCUIT IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED
-----[E2:05] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED
-----E2:06] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM ID IDSPLAYED
----C-7 [E2:11] DISCONNECTION IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED
-----[E2:15] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED
-----[E2:16] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED
----C-8 [E2:17] MODEL SELECTIONINPUT ERROR IS DISPLAYED
----C-9 [E2:18] NETWORK RESPONSE OVERTIME ERROR IS DISPLAYED
----C-10 [E2:22] SHORT CIRCUIT IN LS CONTROL EPC SOLENOID SYSTME IS DISPLAYED
----C-11 [E2:23] DISCONNECTION IN LS CONTROL EPC SOLENIOD SYSTEM IS DISPLAYED
----C-12 [E2:24] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED
----C-13 [E2-26] ABNORMALITY IN PUMP PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED
----C-14 [E2:27] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED
----C-15 [E2:28] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED
--TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)
---POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM
---ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
---JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
---ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
---C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)
---C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED
---C-3 [E233] DISCONNECTION IN PUM TVC SOLENOID SYSTEM IS DISPLAYED
---C-4 [E201] SHORT CIRCUIT IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED
---C-5 [E211] DISCONNECTION IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED
---C-6 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED
---C-7 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED
---C-8 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED
---C-9 [E215} DISCONNECTION IN 2 -STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED
---C-10 [C206] SHORT CIRCUIT IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED
---C-11 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED
---C-12 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED
---C-13 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED
---C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED
---C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOIND SYSTEM IS DISPLAYED
---C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED
---C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED
---C-18 [E226] ABNORMALITY IN PRESSURE SENSOR SYSTEM POWER SOURCE IS DISPLAYED
---C-19 [E227] ABNORMALTIY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED
--TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)
---TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE
---F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-9 BIT PATTERN 21-(3) SWING LOCK SWITCYH DOES NOT LIGHT UP
---F-10 ENGINE SPEED IS NOT DISPLAYED IN MONITORING CODE 10 (ABNORMALITY IN SPEED SENSOR SYSTEM)
---F-11 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP
---F-12 BIT PATTERN 22-(6) L.H. KNOB SWITCYH DOES NOT LIGHT UP
--TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (INPUT SIGNAL SYSTEM)(F MODE)
---ELECTRICAL CIRCUIT DIAGRAM FOR F MODE
---F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP
---F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP
---F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP
---F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP
--TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
---TABLE OF FAILURE MODES AND CAUSED FOR HYDRAULIC AND MECHANICAL SYSTEM
---TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE
---ALL WORK EQUIPMETN, TRAVEL, SWING
----H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS
----H-3 NO WORK EQUIPMENT, TRAVEL SWING MOVE
----H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)
----H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)
----H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR
---WORK EQUIPMENT
----H-7 BOOM IS SLOW OR LACKS POWER
----H-8 ARM IS SLOW OR LACKS POWER
----H-9 BUCKET IS SLOW OR LACKS POWER
----H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET( DOES NOT MOVE
----H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)
----H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)
----H-13 LACK OF POWER WHEN PRESSURE RISES
----H-14 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED
----H-15 WORK EQUIPMENT IS SLOW WHEN ACTIVE MODE ID ON OR IS FAST WHE ACTIVE MODE IS OFF
----H-16 IN F/O MODE, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED
---COMPOUND OPERATIONS
----H-17 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD IS SLOW
----H-18 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW
----H-19 IN SWING + TRAVEL,TRAVEL SPEED DROPS EXCESSIVELY
----H-20 IN WORK EQUIPMENT + TRAVE, TRAVEL SPEED DROPS EXCESSIVELY
---TRAVEL SYSTEM
----H-21 TRAVEL DEVIATION
----H-22 TRAVEL SPEED IS SLOW
----H-23 STEERING DOES NOT TURNEALISLY OR LACKS POWER
----H-24 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED
----H-25 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)
---SWING SYSTEM
----H-26 DOES NOT SWING
----H-27 SWING ACCELERATION IS POOR
----H-28 EXCESSIVE OVERRUN WHEN STOPPING SWING
----H-29 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)
----H-30 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING
----H-31 EXCESSIVE HYDRAULIC DRIFT OF SWING
----H-32 SWING SPEED IS FASTER THAN SPECIFIED SPEED
--TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
---ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS
---MACHINE MONITOR SYSTEM CIRCUIT DIAGRAM
---TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE
---M-1 [E1:01] ABNORMALITY IN ERRO DATA IS DISPLAYED
---M-2 [E1:02] ERROR IN CLOCK DATA IS DISPLAYED
---M-3 [E1:03] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED
---M-4 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS
----A) NONE OF LAMPS ON MONITO PANEL LIGHT UP
----B) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP
---M-5 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT
---M-6 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM MACHINE MODEL
---M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH
----A) COOLANT LEVEL FLASHES
----B) ENGINE OIL LEVEL FLASHES
---M-8 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY LIGHTS UP
---M-9 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEM FLASH
----A) ALTERNATOR SYSTEM
----B) ENGINE OIL PRESSURE SYSTEM
---M-10 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH
----A) ALTERNATOR SYSTEM
----B) ENGINE OIL PRESSURE SENSOR SYSTEM
---M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH
----A) ENGINE OIL PRESSURE FLASHES
----B) COOLANT LEVEL FLASHES
----C) COOLANT TEMPERATURE FLASHES
----D) BATTERY CHARGE FLASHES
----E) FUEL LEVEL FLASHES
---M-12 A) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND
----CAUTION TIEMS ARE FLASHING BUT BUZZER DOES NOT SOUND
----B) NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS
---M-13 LIQUID CRYSTAL NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP
---M-14 COOLANT TEMPERATURE GAUGE DOES NOT RISE
---M-15 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY
---M-16 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL
---M-17 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY
---M-18 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT MONITOR PANEL PARKING DISPLAY DOES NOT LIGHT UP
---M-19 SWING PROLIX SWITCH IS ON (PROLIX), BUT MONITOR PANEL PARKING DISPLAY DOES NOT FLASH
---M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM
---M-21 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM
---M-22 DEFECTIVE ENGINE OIL LEVEL SENSOR
---M-23 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM
---M-24 WORKING LAMP, PANEL LIGHTING DOES NOT LIGHT UP, OR SWITCH IS NOT BEING USED BUT LAMPS LIGHT UP
----A) WORKING LAMP DOES NOT LIGHT UP
----B) PANEL LIGHTING DOES NOT LIGHT UP
----C) LIGHT SWITCH IS NOT BEING USED BUT WORKING LAMP LIGHTS UP
---M-25 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED
----A) WIPER DOES NOT WORK
----B) WIPER SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED
--TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
---ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
---ELECTRICAL CIRCUIT DIAGRAM
---M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED
----[E102] ERROR IN CLOCK DATA IS DISPLAYED
---M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED
---M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED
---M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED
---M-5 [E108] ENGINE WATER TEMPERATURE 105°C DETECTED IS DISPLAYED
---M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS
---M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT
---M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)
---M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES
---M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP
---M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH
---M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH
---M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH
---M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND. CAUTION ITEM FLASHES BUT BUZZER
---M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUND
---M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAYE IS NORMAL)
---M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE
---M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY
---M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY
---M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY
---M-21 SWING LOCK SWITCH IS TURNED ON 9LOCK) BUT (SWING LOCK MONITOR) DOES NOT FLASH
---M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH
---M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING
---M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED
---M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM
---M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM
---M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM
---M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM
---M-29 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED
---M-30 WASHER MOTOR DOES NOT WORK, SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED
30 DISASSEMBLY AND ASSEMBLY
-METHOD OF USING MANUAL
-PRECAUTIONS WHEN CARRYING OUT OPERATION
-SPECIAL TOOL LIST
-STARTING MOTOR ASSEMBLY
--REMOVAL AND INSTALLATION
-ALTERNATOR
--REMOVAL AND INSTALLATION
-AIR CONDITIONER COMPRESSOR
--REMOVAL AND INSTALLATION
-CONDENSER
--REMOVAL AND INSTALLATION
-ENGINE OIL COOLER CORE
--REMOVAL AND INSTALLATION
-FUEL INJECTION PUMP
--REMOVAL
--INSTALLATION
-WATER PUMP
--REMOVAL AND INSTALLATION
-NOZZLE HOLDER
--REMOVAL AND INSTALLATION
-TURBOCHARGER
--REMOVAL AND INSTALLATION
-THERMOSTAT
--REMOVAL AND INSTALLATION
-ENGINE FRONT OIL
--REMOVAL AND INSTALLATION
-ENGINE REAR OIL SEAL
--REMOVAL AND INSTALLATION
-GOVERNOR MOTOR
--REMOVAL AND INSTALLATION
-CYLINDER HEAD
--REMOVAL
--INSTALLATION
-ENGINE - HYDRAULIC PUMP
--REMOVAL
--INSTALLATION
-HYDRAULIC OIL COOLER
--REMOVAL AND INSTALLATION
-RADIATOR - HYDRAULIC C
--REMOVAL
--INSTALLATION
-FUEL TANK
--REMOVAL AND INSTALLATION
-CENTER SWIVEL JOINT
--REMOVAL AND INSTALLATION
--DISASSEMBLY AND ASSEMBLY
-SPROCKET
--REMOVAL AND INSTALLATION
-TRAVEL MOTOR
--REMOVAL AND INSTALLATION
--DISASSEMBLY AND ASSEMBLY (GM18VL-MSRV)
-SWING MACHINERY - SWING MOTOR
--REMOVAL AND INSTALLATION
-SWING MACHINERY
--DISASSEMBLY
--ASSEMBLY
-SWING MOTOR
--REMOVAL AND INSTALLATION (KMF40AB-2)
--DISASSEMBLY (KMF40AB-2)
--ASSEMBLY (KMF40AB-2)
--REMOVAL AND INSTALLATION (KMF40AB-3)
-REVOLVING FRAME
--REMOVAL
--INSTALLATION
-SWING CIRCLE
--REMOVAL AND INSTALLATION
-IDLER - RECOIL SPRING
--REMOVAL AND INSTALLATION
-RECOIL SPRING
--DISASSEMBLY
--ASSEMBLY
-IDLER
--DISASSEMBLY
--ASSEMBLY
-TRACK ROLLER
--REMOVAL AND INSTALLATION
--DISASSEMBLY
--ASSEMBLY
-CARRIER ROLLER
--REMOVAL AND INSTALLATION
-TRACK SHOE
--REMOVAL
--INSTALLATION
-HYDRAULIC TANK
--REMOVAL
--INSTALLATION
-CONTROL PUMP
--REMOVAL AND INSTALLATION
-MAIN PUMP
--REMOVAL
--INSTALLATION
--DISASSEMBLY
--ASSEMBLY
-MAIN PUMP INPUT SHAFT OIL SEAL
--REMOVAL AND INSTALLATION
-CONTROL VALVE
--REMOVAL
--INSTALLATION
--DISASSEMBLY
--ASSEMBLY
-LS SELECT VALVE
--DISASSEMBLY AND ASSEMBLY
-LS SHUTTLE VALVE
--DISASSEMBLY AND ASSEMBLY
-PRESSURE COMPENSATION VALVE
--DISASSEMBLY
--ASSEMBLY
-MAIN RELIEF VALVE
--DISASSEMBLY
--ASSEMBLY
-TVC - LS VALVE
--REMOVAL AND INSTALLATION
-LS CONTROL EPC VALVE
--REMOVAL AND INSTALLATION
-SOLENOID VALVE
--REMOVAL AND INSTALLATION
-WORK EQUIPMENT - SWING PPC VALVE
--REMOVAL AND INSTALLATION
--DISASSEMBLY
--ASSEMBLY
-TRAVEL PPC VALVE
--REMOVAL AND INSTALLATION
--DISASSEMBLY
--ASSEMBLY
-BOOM HOLDING VALVE
--REMOVAL AND INSTALLATION
-BOOM CYLINDER
--REMOVAL
--INSTALLATION
-ARM CYLINDER
--REMOVAL
--INSTALLATION
-BUCKET CYLINDER
--REMOVAL
--INSTALLATION
-HYDRAULIC CYLINDER
--DISASSEMBLY
--ASSEMBLY
-WORK EQUIPMENT
--REMOVAL
--INSTALLATION
-BUCKET
--REMOVAL
--INSTALLATION
-ARM
--REMOVAL
--INSTALLATION
-BUCKET - ARM
--REMOVAL
--INSTALLATION
-BOOM
--REMOVAL
--INSTALLATION
-OPERATOR'S CAB
--REMOVAL
--INSTALLATION
-COUNTERWEIGHT
--REMOVAL AND INSTALLATION
-ENGINE THROTTLE CONTROLLER
--REMOVAL AND INSTALLATION
-PUMP CONTROLLER
--REMOVAL AND INSTALLATION
-ENGINE THROTTLE, PUMP CONTROLLER
--REMOVAL AND INSTALLATION
-MONITOR
--REMOVAL AND INSTALLATION
40 MAINTENANCE STANDARD
-SWING MACHINERY
-SWING CIRCLE
-TRACK FRAME
-IDLER
-CARRIER ROLLER
-TRACK ROLLER
-SPROCKET
-TRACK SHOE
-HYDRAULIC PUMP
-CONTROL VALVE
-SWING MOTOR
-CENTER SWIVEL JOINT
-WORK EQUIPMENT - SWING PPC VALVE
-TRAVEL PPC VALVE
-SERVICE PPC VALVE
-PPC SHUTTLE - TRAVEL JUNCTION VALVE
-EPC - SOLENOID VALVE
-BOOM HOLDING VALVE
-HYDRAULIC CYLINDER
-WORK EQUIPMENT
-