Hitachi Zaxis 330-3 Class 330LC-3, 350H-3, 350LC-3, 350LCH-3, 350LCK-3, 350LCN-3 Hydraulic Excavator Shop Manual + Operational + Troubleshooting – DOWNLOAD

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Hitachi Zaxis 330-3 Class 330LC-3, 350H-3, 350LC-3, 350LCH-3, 350LCK-3, 350LCN-3 Hydraulic Excavator Shop Manual + Operational + Troubleshooting

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HITACHI ZAXIS 330-3 CLASS 330LC-3, 350H-3, 350LC-3, 350LCH-3, 350LCK-3, 350LCN-3 HYDRAULIC EXCAVATOR SHOP MANUAL + OPERATIONAL + TROUBLESHOOTING – DOWNLOAD:

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DESCRIPTION:

Hitachi Zaxis 330-3 Class 330LC-3, 350H-3, 350LC-3, 350LCH-3, 350LCK-3, 350LCN-3 Hydraulic Excavator Shop Manual + Operational + Troubleshooting

TO THE READER
• This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine.
• Be sure to thoroughly read this manual for correct product information and service procedures.
• If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual.

ADDITIONAL REFERENCES
• Please refer to the materials listed below in addition to this manual.
• The Operator’s Manual
• The Parts Catalog
• The Engine Manual
• Parts Catalog of the Engine
• Hitachi Training Material

MANUAL COMPOSITION
• This manual consists of three portions: the Technical Manual (Operational Principle), the Technical Manual (Troubleshooting) and the Workshop Manual.
• Information included in the Technical Manual (Operational Principle): technical information needed for redelivery and delivery, operation and activation of all devices and systems.
• Information included in the Technical Manual (Troubleshooting): technical information needed for operational performance tests, and troubleshooting procedures.
• Information included in the Workshop Manual: technical information needed for maintenance and repair of the machine, tools and devices needed for maintenance and repair, maintenance standards, and removal/installation and assemble/ disassemble procedures.

FOLLOW SAFETY INSTRUCTIONS
• Carefully read and follow all safety signs on the machine and all safety messages in this manual.
• Safety signs should be installed, maintained and replaced when necessary.
• If a safety sign or this manual is damaged or missing, order a replacement from your authorized dealer in the same way you order other replacement parts (be sure to state machine model
and serial number when ordering).
• Learn how to operate the machine and its controls correctly and safely.
• Allow only trained, qualified, authorized personnel to operate the machine.
• Keep your machine in proper working condition

TABLE OF CONTENTS:

Hitachi Zaxis 330-3 Class 330LC-3, 350H-3, 350LC-3, 350LCH-3, 350LCK-3, 350LCN-3 Hydraulic Excavator Shop Manual + Operational + Troubleshooting

Operational Manual

COVER......................................................................................................................................................................  1
INTRODUCTION...............................................................................................................................................................  3
CONTENTS...................................................................................................................................................................  5
SECTION 1 GENERAL..........................................................................................................................................................  7
	Specifications.........................................................................................................................................................  9
		SPECIFICATIONS.....................................................................................................................................................  9
		WORKING RANGES..................................................................................................................................................... 10
	Component Layout....................................................................................................................................................... 13
		MAIN COMPONENTS.................................................................................................................................................... 13
		ELECTRICAL SYSTEM (OVERVIEW)....................................................................................................................................... 15
		ENGINE............................................................................................................................................................. 20
		PUMP DEVICE........................................................................................................................................................ 21
		SWING DEVICE....................................................................................................................................................... 21
		CONTROL VALVE...................................................................................................................................................... 22
		SIGNAL CONTROL VALVE............................................................................................................................................... 22
		SOLENOID VALVE UNIT................................................................................................................................................ 23
		TRAVEL DEVICE...................................................................................................................................................... 23
	Component Specifications............................................................................................................................................... 25
		ENGINE............................................................................................................................................................. 25
		ENGINE ACCESSORIES................................................................................................................................................. 28
		HYDRAULIC COMPONENT................................................................................................................................................ 29
		ELECTRICAL COMPONENT............................................................................................................................................... 34
SECTION 2 SYSTEM........................................................................................................................................................... 37
	Controller............................................................................................................................................................. 39
		OUTLINE............................................................................................................................................................ 39
		CAN (NETWORK PROVIDED FOR MACHINE)................................................................................................................................. 40
		MC: MAIN CONTROLLER................................................................................................................................................ 42
		ECM: ENGINE CONTROL MODULE......................................................................................................................................... 58
		ICF: INFORMATION CONTROLLER........................................................................................................................................ 60
		OUTLINE............................................................................................................................................................ 63
	Control System......................................................................................................................................................... 73
		OUTLINE............................................................................................................................................................ 73
		ENGINE CONTROL..................................................................................................................................................... 76
		PUMP CONTROL....................................................................................................................................................... 98
		VALVE CONTROL......................................................................................................................................................112
		OTHER CONTROLS.....................................................................................................................................................132
	ECM System.............................................................................................................................................................137
		OUTLINE............................................................................................................................................................137
		FUEL INJECTION CONTROL.............................................................................................................................................138
		ENGINE START CONTROL...............................................................................................................................................146
		EGR (EXHAUST GAS RECIRCULATION) CONTROL............................................................................................................................148
		FUEL INJECTION AMOUNT CORRECTION...................................................................................................................................150
		ENGINE STOP CONTROL................................................................................................................................................152
	Hydraulic System.......................................................................................................................................................155
		OUTLINE............................................................................................................................................................155
		PILOT CIRCUIT......................................................................................................................................................156
		MAIN CIRCUIT.......................................................................................................................................................166
		BOOM LOWER METER-IN CUT CONTROL....................................................................................................................................178
	Electrical System......................................................................................................................................................183
		OUTLINE............................................................................................................................................................183
		MAIN CIRCUIT.......................................................................................................................................................184
		ELECTRIC POWER CIRCUIT (KEY SWITCH: OFF)...........................................................................................................................186
		ACCESSORY CIRCUIT..................................................................................................................................................188
		STARTING CIRCUIT (KEY SWITCH: START)...............................................................................................................................190
		CHARGING CIRCUIT (KEY SWITCH: ON)..................................................................................................................................194
		SERGE VOLTAGE PREVENTION CIRCUIT...................................................................................................................................198
		PILOT SHUT-OFF CIRCUIT (KEY SWITCH: ON)............................................................................................................................200
		SEUCURITY LOCK CIRCUIT.............................................................................................................................................202
		ENGINE STOP CIRCUIT (KEY SWITCH: OFF)..............................................................................................................................204
		SECURITY HORN CIRCUIT..............................................................................................................................................206
		WORKING LIGHT CIRCUIT..............................................................................................................................................208
		WIPER CIRCUIT......................................................................................................................................................210
SECTION 3 COMPONENT OPERATION..............................................................................................................................................215
	Pump Device............................................................................................................................................................217
		OUTLINE............................................................................................................................................................217
		MAIN PUMPS 1, 2....................................................................................................................................................218
		REGULATOR..........................................................................................................................................................222
		PILOT PUMP.........................................................................................................................................................238
		PUMP DELIVERY PRESSURE SENSOR......................................................................................................................................238
	Swing Device...........................................................................................................................................................239
		OUTLINE............................................................................................................................................................239
		SWING REDUCTION GEAR...............................................................................................................................................240
		SWING MOTOR........................................................................................................................................................241
		SWING PARKING BRAKE................................................................................................................................................242
		VALVE UNIT.........................................................................................................................................................244
		SWING DAMPENER VALVE...............................................................................................................................................247
	Control Valve..........................................................................................................................................................257
		OUTLINE............................................................................................................................................................257
		HYDRAULIC CIRCUIT..................................................................................................................................................274
		FLOW COMBINER VALVE................................................................................................................................................284
		MAIN RELIEF VALVE..................................................................................................................................................286
		OVERLOAD RELIEF VALVE..............................................................................................................................................288
		REGENERATIVE VALVE.................................................................................................................................................290
		ANTI-DRIFT VALVE...................................................................................................................................................294
		FLOW RATE CONTROL VALVE............................................................................................................................................296
		DIGGING REGENERATIVE VALVE.........................................................................................................................................298
		BOOM LOWER METER-IN CUT VALVE......................................................................................................................................300
		BYPASS SHUT-OUT VALVE..............................................................................................................................................302
	Pilot Valve............................................................................................................................................................303
		OUTLINE............................................................................................................................................................303
		OPERATION..........................................................................................................................................................306
		SHOCKLESS FUNCTION (ONLY FOR TRAVEL PILOT VALVE)...................................................................................................................314
	Travel Device..........................................................................................................................................................315
		OUTLINE............................................................................................................................................................315
		TRAVEL REDUCTION GEAR..............................................................................................................................................316
		TRAVEL MOTOR.......................................................................................................................................................318
		TRAVEL BRAKE VALVE.................................................................................................................................................320
		TRAVEL MODE CHANGE.................................................................................................................................................324
		PARKING BRAKE......................................................................................................................................................328
	Signal Control Valve...................................................................................................................................................331
		OUTLINE............................................................................................................................................................331
		PILOT PORT.........................................................................................................................................................332
		SHUTTLE VALVE......................................................................................................................................................336
		SHOCKLESS VALVE....................................................................................................................................................340
		PUMP 1 AND PUMP 2 FLOW RATE CONTROL VALVES.........................................................................................................................344
		BUCKET FLOW RATE CONTROL VALVE CONTROL SPOOL, FLOW COMBINER VALVE CONTROL SPOOL, SWING PARKING BRAKE RELEASE SPOOL, ARM 1 FLOW RATE CONTROL VALVE CONTROL SPOOL....346
	Others (Upperstructure)................................................................................................................................................347
		PILOT SHUT-OFF SOLENOID VALVE......................................................................................................................................347
		SOLENOID VALVE.....................................................................................................................................................349
		HOSE RUPTURE VALVE.................................................................................................................................................352
		PILOT RELIEF VALVE.................................................................................................................................................358
	Others (Undercarriage).................................................................................................................................................359
		SWING BEARING......................................................................................................................................................359
		CENTER JOINT.......................................................................................................................................................360
		TRACK ADJUSTER.....................................................................................................................................................361
SERVICE MANUAL REVISION REQUEST FORM.......................................................................................................................................

Troubleshooting Manual

COVER............................................................................................................  1
INTRODUCTION.....................................................................................................  3
SAFETY...........................................................................................................  5
CONTENTS......................................................................................................... 41
SECTION 4 OPERATIONAL
PERFORMANCE TEST........................................................................... 43
	Introduction................................................................................................. 45
		OPERATIONAL PERFORMANCE TESTS............................................................................ 45
		PREPARATION FOR PERFORMANCE TESTS........................................................................ 46
	Standard..................................................................................................... 47
		ZX330-3 CLASS OPERATIONAL PERFORMANCE STANDARD TABLE..................................................... 47
		MAIN PUMP P-Q DIAGRAM.................................................................................... 52
		SENSOR ACTIVATING RANGE.................................................................................. 54
	Engine Test.................................................................................................. 55
		ENGINE SPEED............................................................................................. 55
		ENGINE COMPRESSION PRESSURE.............................................................................. 57
		VALVE CLEARANCE.......................................................................................... 58
		LUBRICANT CONSUMPTION.................................................................................... 61
	Excavator Test............................................................................................... 63
		TRAVEL SPEED............................................................................................. 63
		TRACK REVOLUTION SPEED................................................................................... 64
		MISTRACK CHECK........................................................................................... 65
		TRAVEL PARKING LEAKAGE................................................................................... 66
		SWING SPEED.............................................................................................. 67
		SWING FUNCTION DRIFT CHECK............................................................................... 68
		SWING MOTOR LEAKAGE...................................................................................... 70
		MAXIMUM SWINGABLE SLANT ANGLE............................................................................ 72
		SWING BEARING PLAY....................................................................................... 74
		HYDRAULIC CYLINDER CYCLE TIME............................................................................ 76
		DIG FUNCTION DRIFT CHECK................................................................................. 78
		CONTROL LEVER OPERATING FORCE............................................................................ 80
		CONTROL LEVER STROKE..................................................................................... 82
		COMBINED OPERATION OF BOOM RAISE / SWING FUNCTION CHECK.................................................. 84
		COMBINED OPERATION OF BOOM RAISE / ARM ROLL-IN FUNCTION CHECK............................................ 86
	Component Test............................................................................................... 87
		PRIMARY PILOT PRESSURE................................................................................... 87
		SECONDARY PILOT PRESSURE................................................................................. 89
		SOLENOID VALVE SET PRESSURE.............................................................................. 91
		MAIN PUMP DELIVERY PRESSURE.............................................................................. 94
		MAIN RELIEF SET PRESSURE................................................................................. 95
		RELIEF PRESSURE (WHEN RELIEVING SWING)................................................................... 99
		OVERLOAD RELIEF VALVE SET PRESSURE.......................................................................100
		MAIN PUMP FLOW RATE MEASUREMENT..........................................................................103
		SWING MOTOR DRAINAGE.....................................................................................110
		TRAVEL MOTOR DRAINAGE....................................................................................113
SECTION 5 TROUBLESHOOTING........................................................................................117
	Diagnosing Procedure.........................................................................................121
		INTRODUCTION.............................................................................................121
		DIAGNOSING PROCEDURE.....................................................................................122
	Monitor Unit.................................................................................................127
		OUTLINE..................................................................................................127
		HOW TO USE SCREENS.......................................................................................137
		PRIMARY SCREEN...........................................................................................147
		SCREEN DISPLAY WHEN AN ALARM IS ISSUED...................................................................148
		CONTENTS OF ALARMS.......................................................................................150
		TROUBLESHOOTING..........................................................................................152
		CONTROLLER VERSION.......................................................................................154
		MONITORING...............................................................................................156
		DISPLAYING OPERATING CONDITIONS..........................................................................159
		PUMP 2 FLOW RATE ADJUSTMENT (Only Machines Equipped with Optional Parts).................................160
		ATTACHMENT SELECTION (Only Machines Equipped with Optional Parts)........................................162
		TIME SET.................................................................................................166
		FUEL RATE DISPLAY/NO DISPLAY.............................................................................168
		BACK MONITOR SETTINGS....................................................................................172
		MAINTENANCE SETTINGS.....................................................................................180
		LANGUAGE SETTINGS........................................................................................186
		MAIL (Optional)..........................................................................................188
	Dr. ZX.......................................................................................................191
		OUTLINE..................................................................................................191
		SELECT CONTROLLER........................................................................................196
		MAIN CONTROLLER..........................................................................................197
		MAIN MENU MONITOR DISPLAY................................................................................198
		SPECIAL FUNCTION.........................................................................................204
		SETTING..................................................................................................206
		ADJUSTMENT DATA..........................................................................................210
		ATTACHMENT ADJUSTMENT DATA LIST..........................................................................214
		ATTACHMENT SETTING.......................................................................................234
		ENGINE CONTROLLER........................................................................................240
		MAIN MENU
MONITOR DISPLAY...............................................................................241
		RECORED DATA DISPLAY.....................................................................................244
		PASSWORD CHANGE..........................................................................................245
		ICF CONTROLLER...........................................................................................246
		MAIN MENU INFORMATION C/U VARIOUS SETUP..................................................................247
		INFORMATION C/U: INITIALIZE..............................................................................248
		ENTER MODEL AND SERIAL No................................................................................249
		ENTER DATE AND TIME......................................................................................250
		CONTROL DATA: INITIALIZE.................................................................................251
		SATELLITE TERMINAL: INITIALIZE...........................................................................252
		SATELLITE TERMINAL No. CONFIRMATION......................................................................253
		COMMUNICATING STATE CHECK................................................................................254
		ENTER SATELLITE COMM. START / STOP.......................................................................255
		DATE DOWNLOAD............................................................................................257
		SAVE DATA CHECK..........................................................................................258
		PASSWORD CHANGE..........................................................................................259
		MONITOR CONTROLLER.......................................................................................260
		MONITORING...............................................................................................261
		VARIOUS SETTINGS.........................................................................................264
		OPTIONAL FUNCTION ALLOCATION.............................................................................266
		OVERLOAD ALARM ENABLE / DISABLE SELECTION................................................................274
		BACK MONITOR SETTING.....................................................................................276
		OPERATING CONDITION ENABLE / DISABLE SELECTION...........................................................280
		TIME SETTING FUNCTION ENABLE / DISABLE SELECTION.........................................................282
		MAINTENANCE SETTING MAINTENANCE OPERATION ALLOW / NOT ALLOW SELECTION....................................284
		NOTIFICATION FUNCTION ENABLE / DISABLE SELECTION.........................................................286
		MAINTENANCE DISPLAY ITEM ON/OFF SELECTION................................................................288
		INTERNAL HOUR METER SYNCHRONIZATION......................................................................292
		FUEL CONSUMPTION GAUGE DISPLAY ENABLE / DIABLE SELECTION.................................................293
		PASSWORD CHANGE..........................................................................................295
	e-Shovel.....................................................................................................297
		OUTLINE..................................................................................................297
		LIST OF DAILY REPORT DATA................................................................................298
		LIST OF FREQUENCY DISTRIBUTION DATA......................................................................301
		LIST OF TOTAL OPERATING HOURS............................................................................302
		HOW TO DOWNLOAD AND UPLOAD DATA OF ICF...................................................................304
		VARIOUS SETUP OF ICF AND SATELLITE COMMUNICATION TERMINAL BY USING Dr. ZX................................307
		LIST OF FAULT CODE.......................................................................................319
		SATELLITE COMMUNICATION SYSTEM...........................................................................320
	Component Layout.............................................................................................323
		MAIN COMPONENTS..........................................................................................323
		ELECTRICAL SYSTEM (OVERVIEW).............................................................................325
		ENGINE...................................................................................................330
		PUMP DEVICE..............................................................................................331
		SWING DEVICE.............................................................................................331
		CONTROL VALVE............................................................................................332
		SIGNAL CONTROL VALVE.....................................................................................332
		SOLENOID VALVE UNIT......................................................................................333
		TRAVEL DEVICE............................................................................................333
		PILOT PORT (Signal Control Valve)........................................................................350
	Troubleshooting A............................................................................................355
		TROUBLESHOOTING A PROCEDURE..............................................................................355
		FAULT CODE LIST..........................................................................................356
		ECM......................................................................................................374
		ICF......................................................................................................398
		CONTROLLER HARDWARE FAILURE MC FAULT CODE 11000 to 11002.................................................404
		MC FAULT CODE 11003......................................................................................405
		MC FAULT CODE 11004......................................................................................406
		CAN HARNESS CHECK........................................................................................408
		ENGINE FAILURE MC FAULT CODE 11100.......................................................................428
		MC FAULT CODE 11101......................................................................................429
		PUMP FAILURE MC FAULT CODE 11200.........................................................................430
		MC FAULT CODE 11202......................................................................................431
		MC FAULT CODE 11206......................................................................................432
		MC FAULT CODE 11208......................................................................................433
		PILOT FAILURE MC FAULT CODE 11301........................................................................434
		MC FAULT CODE 11302......................................................................................435
		MC FAULT CODE 11303......................................................................................436
		MC FAULT CODE 11304......................................................................................437
		MC FAULT CODE 11307......................................................................................438
		PROPORTIONAL SOLENOID VALVE FAILURE
MC FAULT CODE 11400.................................................439
		MC FAULT CODE 11401......................................................................................440
		MC FAULT CODE 11402......................................................................................441
		MC FAULT CODE 11403......................................................................................442
		MC FAULT CODE 11404......................................................................................443
		MC FAULT CODE 11405......................................................................................444
		MC FAULT CODE 11410......................................................................................445
		CAN DATA RECEPTION FAILURE MC FAULT CODE 11910...........................................................446
		CAN HARNESS CHECK MC FAULT CODE 11910....................................................................448
		MC FAULT CODE 11918......................................................................................451
		CAN HARNESS CHECK MC FAULT CODE 11918....................................................................452
		MC FAULT CODE 11911......................................................................................455
		CAN HARNESS CHECK MC FAULT CODE 11911....................................................................456
		MC FAULT CODE 11920......................................................................................459
		CAN HARNESS CHECK MC FAULT CODE 11920....................................................................460
		MC FAULT CODE 11914......................................................................................463
		CAN HARNESS CHECK MC FAULT CODE 11914....................................................................464
		OTHER FAILURES MC FAULT CODE 11901.......................................................................467
		ECM, SENSOR SYSTEM ECM FAULT CODES 100, 102, 105, 108, 110, 157, 172.....................................468
		ECM FAULT CODES 174, 636, 723, 10001.....................................................................469
		ECM, EXTERNAL DEVICE SYSTEM ECM FAULT CODES 651, 652, 653, 654, 655, 656, 1347, 10002....................470
		ECM, FUEL SYSTEM ECM FAULT CODES 157, 633, 1239, 1240....................................................471
		ECM, ENGINE PROTECTION ECM FAULT CODES 110, 190..........................................................472
		ECM, ENGINE PROTECTION ECM FAULT CODES 987, 1485.........................................................473
		ECM, INTERNAL CIRCUIT SYSTEM ECM FAULT CODES 628, 1077, 1079, 1080, 10003, 10004, 10005..................474
		ECM FAULT CODES 10006, 10007, 10008, 10009, 10010, 10011, 10013..........................................475
		ECM, COMMUNICATION SYSETEM ECM FAULT CODE 639............................................................476
		ICF, SATELLITE TERMINAL FAULT CODES 14000 to 14003.......................................................477
		ICF, SATELLITE TERMINAL FAULT CODES 14006, 14008, 14100 to 14106.........................................481
		MONITOR UNIT FAULT CODE 13303............................................................................483
		MONITOR UNIT FAULT CODE 13304............................................................................484
		MONITOR UNIT FAULT CODES 13306, 13308....................................................................485
		MONITOR UNIT FAULT CODE 13310............................................................................486
		MONITOR UNIT FAULT CODE 13311............................................................................487
		PILOT SHUT-OFF LEVER ALARM...............................................................................488
	Troubleshooting B............................................................................................489
		TROUBLESHOOTING B PROCEDURE..............................................................................489
		RELATIONSHIP BETWEEN MACHINE TROUBLE SYMPTOMS AND RELATED 
PARTS.........................................490
		CORRELATION BETWEEN TROUBLE SYMPTOMS AND PART FAILURES...................................................506
		ENGINE SYSTEM TROUBLESHOOTING............................................................................520
		ALL ACTUATOR SYSTEM TROUBLESHOOTING......................................................................546
		FRONT ATTACHMENT SYSTEM TROUBLESHOOTING..................................................................558
		SWING SYSTEM TROUBLESHOOTING.............................................................................572
		TRAVEL SYSTEM TROUBLESHOOTING............................................................................576
		OTHER SYSTEM TROUBLESHOOTING.............................................................................584
		EXCHANGE INSPECTION......................................................................................604
		EMERGENCY BOOM LOWERING PROCEDURE........................................................................607
		ONE PART OF DATA, “DAILY REPORT DATA”, “DISTRIBUTION DATA” AND TOTAL OPERATING HOURS” IN NOT RECORDED....608
	Electrical System Inspection.................................................................................613
		PRECAUTIONS FOR INSPECTION AND MAINTENANCE...............................................................613
		INSTRUCTIONS FOR DISCONNECTING CONNECTORS................................................................615
		FUSE INSPECTION..........................................................................................616
		FUSIBLE LINK INSPECTION..................................................................................617
		BATTERY VOLTAGE CHECK....................................................................................618
		ALTERNATOR CHECK.........................................................................................619
		CONTINUITY CHECK.........................................................................................620
		VOLTAGE AND CURRENT MEASUREMENT..........................................................................622
		CHECK BY FALSE SIGNAL....................................................................................629
		TEST HARNESS.............................................................................................630
SERVICE MANUAL REVISION REQUEST FORM.............................................................................633
THE ATTACHED DIAGRAM LIST........................................................................................634

Shop Manual

COVER..............................................................  1
INTRODUCTION.......................................................  3
SAFETY.............................................................  5
CONTENTS........................................................... 41
SECTION 1 GENERAL.................................................. 43
	Precautions for Disassembling and Assembling................... 45
		PRECAUTIONS FOR DISASSEMBLING AND ASSEMBLING............... 45
		MAINTENANCE STANDARD TERMINOLOGY........................... 51
	Tightening Torque.............................................. 53
		TIGHTENING TORQUE SPECIFICATION............................ 53
		TORQUE CHART............................................... 54
		PIPING JOINT............................................... 57
		PERIODIC REPLACEMENT OF PARTS.............................. 61
	Painting....................................................... 63
		PAINTING................................................... 63
	Bleeding Air from Hydraulic Oil Tank........................... 67
		BLEEDING AIR FROM HYDRAULIC OIL TANK....................... 67
SECTION 2 UPPERSTRUCTURE........................................... 71
	Cab............................................................ 73
		REMOVE AND INSTALL CAB..................................... 73
		DIMENSIONS OF THE CAB GLASS................................ 81
	Counterweight.................................................. 95
		REMOVE AND INSTALL COUNTERWEIGHT........................... 95
	Main Frame..................................................... 97
		REMOVE AND INSTALL MAIN FRAME.............................. 97
	Pump Device....................................................105
		REMOVE AND INSTALL PUMP DEVICE.............................105
		DISASSEMBLE PUMP DEVICE....................................112
		ASSEMBLE PUMP DEVICE.......................................118
		DISASSEMBLE MAIN PUMP......................................126
		ASSEMBLE MAIN PUMP.........................................134
		DISASSEMBLE REGULATOR......................................148
		ASSEMBLE REGULATOR.........................................150
		DISASSEMBLE PILOT PUMP.....................................152
		ASSEMBLE PILOT PUMP........................................154
	Control Valve..................................................157
		REMOVE AND INSTALL CONTROL VALVE...........................157
		DISASSEMBLE CONTROL VALVE 4-SPOOL SIDE.....................160
		ASSEMBLE CONTROL VALVE 4-SPOOL SIDE........................172
		DISASSEMBLE CONTROL VALVE 5-SPOOL SIDE.....................190
		ASSEMBLE CONTROL VALVE 5-SPOOL SIDE........................202
		DISASSEMBLE HOUSING........................................214
		ASSEMBLE HOUSING...........................................216
	Swing Device...................................................219
		REMOVE AND INSTALL SWING DEVICE............................219
		DISASSEMBLE SWING DEVICE...................................222
		ASSEMBLE SWING DEVICE......................................230
		DISASSEMBLE SWING MOTOR....................................238
		ASSEMBLE SWING MOTOR.......................................242
		STRUCTURE OF SWING PARKING BRAKE SWITCH VALVE..............246
		MAINTENANCE STANDARD.......................................247
	Pilot Valve....................................................249
		REMOVE AND INSTALL PILOT VALVE.............................249
		DISASSEMBLE RIGHT AND LEFT PILOT VALVES....................266
		ASSEMBLE RIGHT AND LEFT PILOT VALVES.......................270
		DISASSEMBLE TRAVEL PILOT VALVE.............................274
		ASSEMBLE TRAVEL PILOT VALVE................................278
		DISASSEMBLE POSITIONING PILOT VALVE (2-PIECE BOOM ONLY)....284
		ASSEMBLE POSITIONING PILOT VALVE (2-PIECE BOOM ONLY).......286
	Pilot Shut-Off Solenoid Valve..................................289
		REMOVE AND INSTALL PILOT SHUT-OFF SOLENOID VALVE...........289
		DISASSEMBLE PILOT SHUT-OFF SOLENOID VALVE..................290
		ASSEMBLE PILOT SHUT-OFF SOLENOID VALVE.....................292
	Signal Control Valve...........................................295
		REMOVE AND INSTALL SIGNAL CONTROL VALVE....................295
		STRUCTURE OF SIGNAL CONTROL VALVE..........................298
	4-Spool Solenoid Valve Unit....................................301
		REMOVE AND INSTALL 4-SPOOL SOLENOID VALVE..................301
		STRUCTURE OF 4-SPOOL SOLENOID VALVE UNIT...................302
	Engine.........................................................305
		REMOVE AND INSTALL ENGINE..................................305
SECTION 3 UNDERCARRIAGE............................................331
	Swing Bearing..................................................333
		REMOVE AND INSTALL SWING BEARING...........................333
		DISASSEMBLE SWING BEARING..................................336
		ASSEMBLE SWING BEARING.....................................338
	Travel Device..................................................341
		REMOVE AND INSTALL TRAVEL DEVICE...........................341
		DISASSEMBLE TRAVEL DEIVCE..................................344
		ASSEMBLE TRAVEL DEVICE.....................................350
		DISASSEMBLE TRAVEL MOTOR...................................358
		ASSEMBLE TRAVEL MOTOR......................................362
		DISASSEMBLE BRAKE VALVE....................................368
		ASSEMBLE BRAKE VALVE.......................................370
		MAINTENANCE STANDARD.......................................372
	Center Joint...................................................375
		REMOVE AND INSTALL CENTER JOINT............................375
		DISASSEMBLE CENTER JOINT...................................378
		ASSEMBLE CENTER JOINT......................................380
	Track Adjuster.................................................383
		REMOVE AND INSTALL TRACK ADJUSTER..........................383
		DISASSEMBLE TRACK ADJUSTER.................................384
		ASSEMBLE TRACK ADJUSTER....................................388
	Front Idler....................................................393
		REMOVE AND INSTALL FRONT IDLER.............................393
		DISASSEMBLE FRONT IDLER....................................394
		ASSEMBLE FRONT IDLER.......................................398
		MAINTENANCE STANDARD.......................................402
	Upper And Lower Roller.........................................403
		REMOVE AND INSTALL UPPER ROLLER............................403
		REMOVE AND INSTALL LOWER ROLLER............................406
		DISASSEMBLE LOWER ROLLER...................................410
		ASSEMBLE LOWER ROLLER......................................412
		MAINTENANCE STANDARD.......................................414
	Track..........................................................417
		REMOVE AND INSTALL TRACK...................................417
		MAINTENANCE STANDARD.......................................423
SECTION 4 FRONT ATTACHMENT.........................................429
	Front Attachment...............................................431
		HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE...............431
		REMOVE AND INSTALL FRONT ATTACHMENT (MONO BOOM)............432
		REMOVE AND INSTALL FRONT ATTACHMENT (2-PIECE BOOM).........440
		MAINTENANCE STANDARD.......................................448
		STANDARD DIMENSIONS FOR ARM AND BUCKET CONNECTION..........452
		STANDARD DIMENSIONS FOR ARM AND BOOM CONNECTION............453
	Cylinder.......................................................455
		HYDRAULIC CIRCUIT PRESSURE RELEASE PROCEDURE...............455
		REMOVE AND INSTALL CYLINDER................................456
		DISASSEMBLE BOOM, ARM, BUCKET CYLINDERS....................472
		DISASSEMBLE POSITIONING CYLINDER...........................478
		ASSEMBLE BOOM, ARM, BUCKET CYLINDERS.......................480
		ASSEMBLE POSITIONING CYLINDER..............................484
		MAINTENANCE STANDARD.......................................486
SERVICE MANUAL REVISION REQUEST FORM...............................489

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
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