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Komatsu GALEO PC300LC-7E0, PC300HD-7E0 Excavator Shop Manual CEBM016802 – PDF DOWNLOAD
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Komatsu GALEO PC300LC-7E0, PC300HD-7E0 Excavator Shop Manual
SERIAL NUMBERS:
PC300LC-7E0 A88001 and UP
PC300HD-7E0 A86001 and UP
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Description
Komatsu GALEO PC300LC-7E0, PC300HD-7E0 Excavator Shop Manual
FILE DETAILS:
Komatsu GALEO PC300LC-7E0, PC300HD-7E0 Excavator Shop Manual
Language : English
Pages : 947
Downloadable : Yes
File Type : PDF
Size: 46.4 MB
Book Code: CEBM016802
KOMATSU GALEO PC300LC-7E0, PC300HD-7E0 EXCAVATOR SHOP MANUAL CEBM016802 – PDF DOWNLOAD:
DESCRIPTION:
Komatsu GALEO PC300LC-7E0, PC300HD-7E0 Excavator Shop Manual
FOREWORD:
GENERAL:
- This shop 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 shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu GALEO PC300LC-7E0, PC300HD-7E0 Excavator Shop Manual
COVER.................................................................................................. 1 FOREWARD............................................................................................... 2 CONTENTS........................................................................................... 2 SAFETY............................................................................................. 11 SAFETY NOTICE.................................................................................. 11 IMPORTANT SAFETY NOTICE.................................................................... 11 GENERAL PRECAUTIONS........................................................................ 11 PREPARATIONS FOR WORK...................................................................... 11 PRECAUTIONS DURING WORK.................................................................... 11 GENERAL............................................................................................ 13 HOW TO READ THE SHOP MANUAL........................................................................ 14 VOLUMES........................................................................................ 14 DISTRIBUTION AND UPDATING...................................................................... 14 FILING METHOD.................................................................................. 14 REVISED EDITION MARK........................................................................... 14 REVISIONS...................................................................................... 14 SYMBOLS........................................................................................ 14 HOISTING INSTRUCTIONS.............................................................................. 15 HOISTING....................................................................................... 15 WIRE ROPES..................................................................................... 15 PUSH PULL COUPLER.................................................................................. 16 TYPE 1......................................................................................... 16 DISCONNECTION.............................................................................. 16 CONNECTION................................................................................. 16 TYPE 2......................................................................................... 17 DISCONNECTION.............................................................................. 17 CONNECTION................................................................................. 17 TYPE 3......................................................................................... 18 DISCONNECTION.............................................................................. 18 CONNECTION................................................................................. 18 EXPLANATION OF MAINTENANCE STANDARD TERMS.......................................................... 19 STANDARD TIGHTENING TORQUE......................................................................... 21 BOLTS AND NUTS................................................................................. 21 TIGHTENING TORQUE OF HOSE NUTS................................................................. 22 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS........................................................ 22 TIGHTENING TORQUE FOR FLARED NUTS.............................................................. 22 TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS............................................... 23 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS.............................................. 23 TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE).................................... 23 ELECTRIC WIRE CODE................................................................................. 24 CLASSIFICATION BY THICKNESS.................................................................... 24 CLASSIFICATION BY COLOR AND CODE............................................................... 24 HOW TO READ ELECTRIC WIRE CODE................................................................. 25 CONVERSION TABLES.................................................................................. 28 METHOD OF USING THE CONVERSION TABLE........................................................... 28 COATING MATERIALS.................................................................................. 34 01 GENERAL............................................................................................. 36 SPECIFICATIONS..................................................................................... 37 DIMENSIONS..................................................................................... 37 WORKING RANGES................................................................................. 38 SPECIFICATIONS..................................................................................... 39 WEIGHT TABLE....................................................................................... 41 FUEL, COOLANT, AND LUBRICANTS...................................................................... 43 10 STRUCTURE AND FUNCTION.............................................................................. 45 ENGINE RELATED PARTS............................................................................... 50 RADIATOR . OIL COOLER . AFTERCOOLER................................................................ 51 FINAL DRIVE........................................................................................ 53 PC300LC-7E0 MODEL.............................................................................. 53 PC300HD-7E0 MODEL.............................................................................. 55 SPROCKET........................................................................................... 57 PC300LC-7E0 MODEL.............................................................................. 57 SPROCKET TOOL.................................................................................. 58 PC300HD-7E0 MODEL.............................................................................. 59 SPROCKET TOOL.................................................................................. 60 SWING MACHINERY.................................................................................... 61 SWING CIRCLE................................................................................... 63 TRACK FRAME . RECOIL SPRING........................................................................ 64 PC300LC-7E0.................................................................................... 64 PC300HD-7E0.................................................................................... 66 IDLER.............................................................................................. 68 PC300LC-7E0 MODEL.............................................................................. 68 PC300HD-7E0 MODEL.............................................................................. 70 CARRIER ROLLER..................................................................................... 72 PC300LC-7E0 MODEL.............................................................................. 72 PC300HD-7E0 MODEL.............................................................................. 74 TRACK ROLLER....................................................................................... 76 PC300LC-7E0 MODEL.............................................................................. 76 PC300HD-7E0 MODEL.............................................................................. 78 TRACK SHOE......................................................................................... 80 PC300LC-7E0 MODEL.............................................................................. 80 PC300HD-7E0 MODEL.............................................................................. 83 TRIPLE GROUSER SHOE................................................................................ 86 PC300LC-7E0 MODEL.............................................................................. 86 PC300HD-7E0 MODEL.............................................................................. 87 HYDRAULIC EQUIPMENT................................................................................ 88 HYDRAULIC TANK AND FILTER.......................................................................... 90 HYDRAULIC PUMP..................................................................................... 91 HPV125 + 125................................................................................... 91 FUNCTION................................................................................... 94 STRUCTURE.................................................................................. 94 OPERATION.................................................................................. 95 LS VALVE....................................................................................... 97 FUNCTION................................................................................... 97 OPERATION.................................................................................. 98 PC VALVE.......................................................................................102 FUNCTION...................................................................................102 OPERATION..................................................................................103 OUTLINE....................................................................................105 OPERATION..................................................................................105 LS(PC)-EPC Valve...............................................................................109 FUNCTION...................................................................................110 OPERATION..................................................................................110 VARIABLE VOLUME VALVE..........................................................................112 FUNCTION...................................................................................112 OPERATION..................................................................................112 CONTROL VALVE......................................................................................113 OUTLINE........................................................................................113 CLSS...............................................................................................125 OUTLINE OF CLSS................................................................................125 FEATURES.......................................................................................125 STRUCTURE......................................................................................125 BASIC PRINCIPLE................................................................................126 VALVE FUNCTIONS AND OPERATION..................................................................129 UNLOADER VALVE.....................................................................................131 FUNCTION.......................................................................................131 OPERATION......................................................................................131 INTRODUCTION OF LS PRESSURE....................................................................133 FUNCTION...................................................................................133 OPERATION..................................................................................133 LS BYPASS VALVE....................................................................................134 FUNCTION.......................................................................................134 PRESSURE COMPENSATION VALVE........................................................................135 FUNCTION.......................................................................................135 FUNCTION.......................................................................................136 OPERATION......................................................................................136 FUNCTION.......................................................................................137 PRESSURE COMPENSATION VALVE INNER SHUTTLE......................................................138 FUNCTION...................................................................................138 OUTLINE....................................................................................139 BOOM REGENERATION CIRCUIT......................................................................140 FUNCTION...................................................................................140 OPERATION..................................................................................140 FUNCTION...................................................................................141 ARM REGENERATION CIRCUIT.......................................................................142 FUNCTION...................................................................................142 OPERATION..................................................................................142 FUNCTION...................................................................................143 MERGE-DIVIDER VALVE................................................................................144 FUNCTION.......................................................................................144 OPERATION......................................................................................144 OPERATION......................................................................................145 LS SELECT VALVE....................................................................................146 FUNCTION.......................................................................................146 OPERATION......................................................................................146 SELF PRESSURE REDUCING VALVE.......................................................................147 FUNCTION.......................................................................................147 OPERATION......................................................................................147 TRAVEL JUNCTION VALVE..............................................................................150 FUNCTION.......................................................................................150 OPERATION......................................................................................150 OPERATION......................................................................................151 TRAVEL PPC SHUTTLE VALVE...........................................................................152 FUNCTION.......................................................................................152 OPERATION......................................................................................152 OPERATION......................................................................................153 BOOM DRIFT PREVENTION VALVE........................................................................154 FUNCTION.......................................................................................154 OPERATION......................................................................................154 OPERATION......................................................................................155 OPERATION......................................................................................156 ARM DRIFT PREVENTION VALVE.........................................................................157 FUNCTION.......................................................................................157 OPERATION......................................................................................157 OPERATION......................................................................................158 OPERATION......................................................................................159 QUICK RETURN VALVE.................................................................................161 FUNCTION.......................................................................................161 OPERATION......................................................................................161 OPERATION......................................................................................162 LIFT CHECK VALVE...................................................................................163 FUNCTION.......................................................................................163 OPERATION......................................................................................163 MAIN RELIEF VALVE..................................................................................164 FUNCTION.......................................................................................164 OPERATION......................................................................................164 2-STAGE SAFETY-SUCTION VALVE.......................................................................165 FUNCTION.......................................................................................165 OPERATION......................................................................................165 VARIABLE PRESSURE COMPENSATION VALVE...............................................................167 FUNCTION.......................................................................................167 ATTACHMENT CIRCUIT SELECTOR VALVE..................................................................169 FUNCTION.......................................................................................170 OPERATION......................................................................................170 VALVE CONTROL......................................................................................171 PPC VALVE..........................................................................................172 WORK EQUIPMENT AND SWING PPC VALVE.............................................................172 OPERATION..................................................................................174 TRAVEL PPC VALVE...............................................................................176 PRESSURE REDUCING VALVE............................................................................179 OPERATION......................................................................................179 OPERATION......................................................................................181 SERVICE PPC VALVE..............................................................................185 PPC ACCUMULATOR................................................................................187 SOLENOID VALVE.....................................................................................188 OPERATION......................................................................................189 RETURN OIL FILTER..................................................................................190 FOR BREAKER....................................................................................190 CENTER SWIVEL JOINT................................................................................191 TRAVEL MOTOR.......................................................................................192 TYPE: HMV160ADT-3..............................................................................192 OPERATION OF MOTOR.............................................................................195 PARKING BRAKE (PC300LC-7E0)........................................................................197 BRAKE VALVE OPERATION..........................................................................199 FUNCTION...................................................................................199 TRAVEL MOTOR.......................................................................................201 TYPE: KMV200ADT-2..............................................................................201 OPERATION OF MOTOR.............................................................................205 PARKING BRAKE (PC300HD-7E0)........................................................................207 BRAKE VALVE OPERATION..........................................................................209 FUNCTION...................................................................................209 SAFETY VALVE.......................................................................................211 FUNCTION.......................................................................................211 SWING MOTOR........................................................................................214 TYPE: KMF230ABE-5..............................................................................214 SPECIFICATIONS.............................................................................214 SWING HOLDING BRAKE............................................................................217 OPERATION..................................................................................217 OPERATION..................................................................................217 RELIEF VALVE PORTION...........................................................................218 OUTLINE....................................................................................218 FUNCTION...................................................................................218 OPERATION..................................................................................218 REVERSE PREVENTION VALVE...........................................................................219 EXPLANATORY DRAWING OF EFFECTS.................................................................220 FUNCTION...................................................................................221 OPERATION..................................................................................221 HYDRAULIC CYLINDERS................................................................................222 BOOM CYLINDER..................................................................................222 ARM CYLINDER...................................................................................222 BUCKET CYLINDER................................................................................223 WORK EQUIPMENT PIVOT POINT MEASUREMENTS............................................................224 BOSS BUSHING/PINS..............................................................................224 DIMENSION OF ARM...............................................................................226 DIMENSION OF BUCKET............................................................................228 CAB AND ATTACHMENTS................................................................................230 AIR CONDITIONER PIPING.........................................................................230 ELECTRICAL SYSTEM..................................................................................231 ENGINE CONTROL.................................................................................231 OUTLINE....................................................................................231 OPERATION OF SYSTEM........................................................................232 ELECTRONIC COMPONENTS..............................................................................233 FUEL CONTROL DIAL..............................................................................233 FUNCTION...................................................................................233 ENGINE CONTROLLER..............................................................................234 COOLANT TEMPERATURE SENSOR.....................................................................238 OIL PRESSURE SWITCH............................................................................238 ENGINE SPEED SENSOR............................................................................239 BOOST PRESSURE AND TEMPERATURE SENSOR..........................................................239 WIF (WATER-IN-FUEL DETECTION) SENSOR...........................................................240 ENGINE OIL LEVEL SENSOR........................................................................240 ELECTRONIC CONTROL SYSTEM..........................................................................241 CONTROL FUNCTION...............................................................................241 SYSTEM DIAGRAM.............................................................................242 ENGINE AND PUMP CONTROL FUNCTION...............................................................244 PUMP AND VALVE CONTROL.........................................................................248 LS CONTROL FUNCTION........................................................................249 CUT-OFF FUNCTION...........................................................................249 2-STAGE RELIEF FUNCTION....................................................................249 POWER MAXIMIZING AND MACHINE PUSH-UP...........................................................250 AUTO-DECELERATION..............................................................................252 OPERATION..................................................................................252 AUTO-WARM-UP AND OVERHEAT PREVENTION...........................................................253 SWING CONTROL..................................................................................255 TRAVEL CONTROL.................................................................................257 ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR (IF EQUIPPED).....................................259 SYSTEM COMPONENTS..................................................................................260 PPC OIL PRESSURE SWITCH........................................................................260 FUNCTION...................................................................................260 OIL PRESSURE SENSOR............................................................................261 OPERATION..................................................................................261 PUMP PRESSURE SENSOR (HIGH PRESSURE)...........................................................262 OPERATION..................................................................................262 PUMP CONTROLLER................................................................................263 MONITOR SYSTEM.....................................................................................267 MACHINE MONITOR................................................................................268 OUTLINE....................................................................................268 MONITOR CONTROL AND DISPLAY........................................................................271 MONITOR........................................................................................271 DISPLAY........................................................................................272 SWITCHES...........................................................................................276 BRIGHTNESS, CONTRAST ADJUSTMENT................................................................284 SERVICE METER CHECK FUNCTION...................................................................285 DISPLAY LCD CHECK FUNCTION.....................................................................285 USER CODE DISPLAY FUNCTION.....................................................................286 SENSOR.............................................................................................288 HYDRAULIC OIL LEVEL SENSOR.....................................................................288 HYDRAULIC OIL AND COOLANT TEMPERATURE SENSOR...................................................288 FUEL LEVEL SENSOR..............................................................................289 AIR CLEANER CLOGGING SENSOR....................................................................290 KOMTRAX TERMINAL SYSTEM............................................................................291 KOMTRAX TERMINAL...............................................................................292 20 TESTING, ADJUSTING AND TROUBLESHOOTING..............................................................295 TESTING AND ADJUSTING..............................................................................297 STANDARD VALUE TABLES..........................................................................297 ENGINE RELATED.............................................................................297 CHASSIS RELATED............................................................................298 SERVICE TOOLS..................................................................................306 ENGINE SERVICE TOOLS.......................................................................306 CHASSIS SERVICE TOOLS......................................................................307 ENGINE.........................................................................................308 AIR BOOST PRESSURE.........................................................................308 AIR COMPRESSOR BELT TENSION................................................................308 BLOW-BY PRESSURE...........................................................................308 COMPRESSION PRESSURE.......................................................................308 ENGINE OIL PRESSURE........................................................................308 ENGINE RPM.................................................................................308 ENGINE SPEED...............................................................................308 EXHAUST GAS COLOR..........................................................................308 FUEL INJECTION TIMING......................................................................308 VALVE CLEARANCE............................................................................308 MEASURING ENGINE FUNCTIONS.....................................................................309 MEASURE ENGINE SPEED WITH MACHINE MONITOR..................................................309 PREPARATION............................................................................309 MEASURING LOW IDLE SPEED...............................................................309 MEASURING HIGH IDLE SPEED..............................................................309 MEASURING THE ENGINE SPEED WHEN 2-PUMPS ARE RELIEVED...................................309 MEASURING THE ENGINE SPEED AT 2-PUMP RELIEF AND POWER MAXIMIZING (NEAR RATED SPEED)....309 MEASURING THE SPEED WHEN AUTO-DECELERATION SPEED IS IN OPERATION.......................309 CYLINDER CUT-OUT OPERATION.................................................................310 NO INJECTION CRANKING OPERATION............................................................310 CHECK AND ADJUST REFRIGERANT COMPRESSOR BELT...................................................311 INSPECTION.................................................................................311 ADJUSTMENT.................................................................................311 MEASURING SWING CIRCLE BEARING CLEARANCE.......................................................312 CHECK AND ADJUST TRACK SHOE TENSION............................................................313 INSPECTION.................................................................................313 ADJUSTMENt.................................................................................313 CHECK AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUIT......................314 MEASURING..................................................................................314 ADJUSTING..................................................................................316 CHECKING CONTROL CIRCUIT OIL PRESSURE..........................................................319 MEASURING..................................................................................319 CHECK AND ADJUST PUMP PC CONTROL CIRCUIT OIL PRESSURE..........................................320 MEASURING..................................................................................320 ADJUSTING..................................................................................322 CHECK AND ADJUST PUMP LS CONTROL CIRCUIT OIL PRESSURE..........................................323 MEASURING..................................................................................323 ADJUSTING..................................................................................327 MEASURING SOLENOID VALVE OUTPUT PRESSURE.......................................................328 MEASURING PPC VALVE OUTPUT PRESSURE............................................................332 ADJUSTING PLAY IN WORK EQUIPMENT AND SWING PPC VALVES..........................................333 TROUBLESHOOTING HYDRAULIC DRIFT IN WORK EQUIPMENT..............................................334 INSPECTION OF BOOM AND BUCKET CYLINDERS....................................................334 INSPECTION OF ARM CYLINDER.................................................................334 INSPECTION OF BOOM LOCK VALVE..............................................................335 INSPECTION OF PPC VALVE....................................................................335 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..............................................336 MEASURING OIL LEAKAGE AMOUNT...............................................................336 BLEEDING AIR FROM VARIOUS SYSTEMS..............................................................339 DIODE INSPECTION PROCEDURES....................................................................341 SPECIAL FUNCTIONS OF MACHINE MONITOR...........................................................342 ORDINARY AND SPECIAL FUNCTIONS OF MACHINE MONITOR..........................................343 OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE)..........................................344 SERVICE MENU OPERATION AND DISPLAY.............................................................352 SWITCHING TO SERVICE MENU..................................................................352 MONITORING [01] FUNCTION...................................................................353 FUNCTION OF ABNORMALITY RECORD [02]........................................................358 FUNCTION OF MAINTENANCE RECORD [03]........................................................360 FUNCTION OF MAINTENANCE MODE CHANGE [04]...................................................361 FUNCTION OF PHONE NUMBER ENTRY [05]........................................................362 FUNCTION OF DEFAULT [06]...................................................................363 FUNCTION OF ADJUSTMENT [07]................................................................365 FUNCTION OF CYLINDER CUT OUT OPERATION [08]................................................366 FUNCTION OF NO INJECTION CRANKING [09].....................................................369 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................371 PROCEDURE FOR TURNING ON KOMTRAX TERMINAL......................................................372 KOMTRAX TERMINAL LAMP INDICATIONS..............................................................375 TROUBLESHOOTING ELECTRICAL SYSTEM..............................................................378 PM-CLINIC INSPECTION TABLE.....................................................................381 TROUBLESHOOTING (GENERAL)..........................................................................387 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................388 SEQUENCE OF EVENTS IN TROUBLESHOOTING..........................................................390 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE......................................................391 PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT.............................................391 HANDLING ELECTRONIC CONTROL UNIT...........................................................396 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS................................397 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.......................................398 CHECKS BEFORE TROUBLESHOOTING..................................................................400 CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS......................................401 TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS.............................................402 TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS..............................................404 POSSIBLE PROBLEMS WHEN TROUBLESHOOTING A MODE..................................................406 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....................................................409 T-ADAPTER TABLE................................................................................431 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)......................................................435 CONNECTOR TYPES AND LOCATIONS..................................................................440 CONNECTOR LAYOUT DRAWINGS......................................................................446 TROUBLESHOOTING BY FAILURE CODE................................................................452 BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED.........................455 LOCATION OF FUSE BOX AND FUSE NUMBERS......................................................456 INFORMATION CONTAINED IN TESTING PROCEDURES....................................................458 FAILURE CODE [A000N1]..........................................................................460 ENGINE OVER SPEED..........................................................................460 FAILURE CODE [AA10NX]..........................................................................461 AIR CLEANER CLOG SENSOR SYSTEM.............................................................461 FAILURE CODE [AB00KE]..........................................................................463 CHARGE VOLTAGE IS LOW......................................................................463 FAILURE CODE [B@BAZG]..........................................................................465 ENGINE OIL PRESSURE DROP...................................................................465 FAILURE CODE [B@BAZK]..........................................................................467 ENGINE OIL LEVEL DROP......................................................................467 FAILURE CODE [B@BCNS]..........................................................................469 COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)......................................469 FAILURE CODE [B@BCZK]..........................................................................471 ENGINE COOLANT LEVEL DROP..................................................................471 FAILURE CODE [B@HANS]..........................................................................473 HYDRAULIC OIL OVERHEAT CONDITION...........................................................473 FAILURE CODE [CA111]...........................................................................475 CRITICAL INTERNAL FAILURE..................................................................475 FAILURE CODE [CA115]...........................................................................476 ENGINE NE AND BACKUP SPEED SENSOR ERROR....................................................476 FAILURE CODE [CA122]...........................................................................477 CHARGE AIR PRESSURE SENSOR HIGH ERROR......................................................477 FAILURE CODE [CA123]...........................................................................479 CHARGE AIR PRESSURE SENSOR LOW ERROR.......................................................479 FAILURE CODE [CA131]...........................................................................481 THROTTLE SENSOR HIGH ERROR.................................................................481 FAILURE CODE [CA132]...........................................................................483 THROTTLE SENSOR LOW ERROR..................................................................483 FAILURE CODE [CA144]...........................................................................485 COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)........................................485 FAILURE CODE [CA145]...........................................................................487 COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (KX).........................................487 FAILURE CODE [CA153]...........................................................................489 CHARGE AIR PRESSURE SENSOR HIGH ERROR......................................................489 FAILURE CODE [CA154]...........................................................................491 CHARGE AIR PRESSURE SENSOR LOW ERROR.......................................................491 FAILURE CODE [CA187]...........................................................................493 SENSOR SUPPLY 2 VOLT LOW ERROR.............................................................493 FAILURE CODE [CA221]...........................................................................495 AMBIENT PRESSURE SENSOR HIGH ERROR.........................................................495 FAILURE CODE [CA222]...........................................................................497 AMBIENT PRESSURE SENSOR LOW ERROR..........................................................497 FAILURE CODE [CA227]...........................................................................499 SENSOR SUPPLY 2 VOLT HIGH ERROR............................................................499 FAILURE CODE [CA234]...........................................................................501 ENGINE OVER SPEED..........................................................................501 FAILURE CODE [CA238]...........................................................................502 SPEED SENSOR SUPPLY VOLT ERROR.............................................................502 FAILURE CODE [CA271]...........................................................................503 UMV/PCV1 SHORT ERROR.......................................................................503 FAILURE CODE [CA272]...........................................................................505 UMV/PCV1 OPEN ERROR........................................................................505 FAILURE CODE [CA322]...........................................................................506 OPEN IN NO. 1 INJECTOR SOLENOID VALVE......................................................506 FAILURE CODE [CA323]...........................................................................508 OPEN IN NO. 5 INJECTOR SOLENOID VALVE......................................................508 FAILURE CODE [CA324]...........................................................................510 OPEN IN NO. 3 INJECTOR SOLENOID VALVE......................................................510 FAILURE CODE [CA325]...........................................................................512 OPEN IN NO. 6 INJECTOR SOLENOID VALVE......................................................512 FAILURE CODE [CA331]...........................................................................514 OPEN IN NO. 2 INJECTOR SOLENOID VALVE......................................................514 FAILURE CODE [CA332]...........................................................................516 OPEN IN NO. 4 INJECTOR SOLENOID VALVE......................................................516 FAILURE CODE [CA342]...........................................................................518 CALIBRATION CODE INCOMPATIBILITY...........................................................518 FAILURE CODE [CA351]...........................................................................519 INJECTOR DRIVE CIRCUIT ERROR...............................................................519 FAILURE CODE [CA352]...........................................................................521 AMBIENT PRESSURE SENSOR 1 VOLT LOW ERROR...................................................521 FAILURE CODE [CA386]...........................................................................523 AMBIENT PRESSURE SENSOR 1 VOLT HIGH ERROR..................................................523 FAILURE CODE [CA428]...........................................................................525 WATER IN FUEL SENSOR HIGH ERROR............................................................525 FAILURE CODE [CA429]...........................................................................527 WATER IN FUEL SENSOR LOW ERROR.............................................................527 FAILURE CODE [CA441]...........................................................................529 BATTERY VOLTAGE LOW ERROR..................................................................529 FAILURE CODE [CA442]...........................................................................531 BATTERY VOLTAGE HIGH ERROR.................................................................531 FAILURE CODE [CA449]...........................................................................533 RAIL PRESSURE VERY HIGH....................................................................533 FAILURE CODE [CA451]...........................................................................536 RAIL PRESSURE SENSOR HIGH ERROR............................................................536 FAILURE CODE [CA452]...........................................................................538 RAIL PRESSURE SENSOR LOW ERROR.............................................................538 FAILURE CODE [CA553]...........................................................................540 RAIL PRESSURE ERROR........................................................................540 FAILURE CODE [CA559]...........................................................................541 RAIL PRESSURE VERY LOW.....................................................................541 FAILURE CODE [CA689]...........................................................................543 ENGINE NE SPEED SENSOR ERROR...............................................................543 FAILURE CODE [CA731]...........................................................................545 ENGINE BACK-UP SPEED SENSOR PHASE ERROR....................................................545 FAILURE CODE [CA757]...........................................................................546 PERSISTENT DATA LOSS ERROR.................................................................546 FAILURE CODE [CA778]...........................................................................548 ENGINE BKUP SPEED SENSOR ERROR.............................................................548 FAILURE CODE [CA1633]..........................................................................550 (KOMNET) DATALINK HAS TIME-OUT ERROR.......................................................550 FAILURE CODE [CA2185]..........................................................................552 THROTTLE SENSOR HIGH ERROR.................................................................552 FAILURE CODE [CA2186]..........................................................................554 THROTTLE SENSOR LOW ERROR..................................................................554 FAILURE CODE [CA2249]..........................................................................556 RAIL PRESSURE VERY LOW.....................................................................556 FAILURE CODE [CA2265]..........................................................................558 ELECTRIC LIFT PUMP HIGH ERROR..............................................................558 FAILURE CODE [CA2266]..........................................................................559 ELECTRIC LIFT PUMP LOW ERROR...............................................................559 FAILURE CODE [CA2556]..........................................................................560 GRID HEATER RELAY VOLT LOW ERROR...........................................................560 FAILURE CODE [CA2555]..........................................................................562 GRID HEATER RELAY VOLT HIGH ERROR..........................................................562 FAILURE CODE [D110KB]..........................................................................564 BATTERY RELAY DRIVE S/C....................................................................564 FAILURE CODE [D196KA]..........................................................................566 SERVICE RETURN RELAY ERROR.................................................................566 FAILURE CODE [D196KB]..........................................................................568 SERVICE RETURN RELAY ERROR.................................................................568 FAILURE CODE [DA25KP]..........................................................................570 SENSOR POWER ERROR.........................................................................570 FAILURE CODE [DA2RMC]..........................................................................572 PUMP COMMUNICATION ERROR...................................................................572 FAILURE CODE [DA2SKQ]..........................................................................574 MODEL SELECTION ERROR......................................................................574 FAILURE CODE [DAFRMC]..........................................................................576 MONITOR COMMUNICATION ERROR................................................................576 FAILURE CODE [DHPAMA]..........................................................................578 F PUMP PRESSURE SENSOR ERROR...............................................................578 FAILURE CODE [DHPBMA]..........................................................................580 R PUMP PRESSURE SENSOR ERROR...............................................................580 FAILURE CODE [DHS3MA]..........................................................................582 ARM CURL PRESSURE SENSOR ERROR.............................................................582 FAILURE CODE [DHS4MA]..........................................................................584 CURL PPC PRESSURE SENSOR ERROR.............................................................584 FAILURE CODE [DW43KA]..........................................................................586 TRAVEL SPEED SOLENOID ERROR................................................................586 FAILURE CODE [DW43KB]..........................................................................588 TRAVEL SPEED SOLENOID ERROR................................................................588 FAILURE CODE [DW45KA]..........................................................................590 SWING BRAKE SOLENOID ERROR.................................................................590 FAILURE CODE [DW45KB]..........................................................................593 SWING BRAKE SOLENOID ERROR.................................................................593 FAILURE CODE [DW91KA]..........................................................................596 TRAVEL JUNCTION SOLENOID ERROR.............................................................596 FAILURE CODE [DW91KB]..........................................................................598 TRAVEL JUNCTION SOLENOID ERROR.............................................................598 FAILURE CODE [DWJ0KA]..........................................................................600 MERGE-DIVIDER SOLENOID ERROR...............................................................600 FAILURE CODE [DWJ0KB]..........................................................................602 MERGE-DIVIDER SOLENOID ERROR...............................................................602 FAILURE CODE [DWK0KA]..........................................................................604 2-STAGE RELIEF SOLENOID ERROR..............................................................604 FAILURE CODE [DWK0KB]..........................................................................606 2-STAGE RELIEF SOLENOID ERROR..............................................................606 FAILURE CODE [DXA0KA]..........................................................................608 PC-EPC SOLENOID ERROR......................................................................608 FAILURE CODE [DXA0KB]..........................................................................610 PC-EPC SOLENOID ERROR......................................................................610 FAILURE CODE [DXE0KA]..........................................................................612 LS-EPC SOLENOID ERROR......................................................................612 FAILURE CODE [DXE0KB]..........................................................................614 LS-EPC SOLENOID ERROR......................................................................614 FAILURE CODE [DXE4KA]..........................................................................616 SERVICE CURRENT EPC ERROR..................................................................616 FAILURE CODE [DXE4KB]..........................................................................618 SERVICE CURRENT EPC ERROR..................................................................618 FAILURE CODE [DY20KA]..........................................................................620 WINDSHIELD WIPER MOTOR DRIVE ERROR.........................................................620 FAILURE CODE [DY20MA]..........................................................................622 WINDSHIELD WIPER MOTOR DRIVE ERROR.........................................................622 FAILURE CODE [DY2CKB]..........................................................................624 WINDSHIELD WASHER DRIVE ERROR..............................................................624 FAILURE CODE [DY2DKB]..........................................................................626 WINDSHIELD WIPER DRIVE ERROR...............................................................626 FAILURE CODE [DY2EKB]..........................................................................628 WINDSHIELD WIPER DRIVE ERROR...............................................................628 [E-1]..........................................................................................630 ENGINE WILL NOT CRANK......................................................................630 [E-2]..........................................................................................632 AUTO DECELERATOR DOES NOT WORK.............................................................632 [E-3]..........................................................................................633 AUTO ENGINE WARM UP DEVICE DOES NOT WORK...................................................633 [E-4]..........................................................................................634 COLD START PRE-HEATER DOES NOT WORK........................................................634 [E-5]..........................................................................................636 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE........................................636 [E-6]..........................................................................................638 POWER MAXIMIZING FUNCTION DOES NOT OPERATE.................................................638 [E-7]..........................................................................................640 MACHINE MONITOR DOES NOT OPERATE...........................................................640 [E-8]..........................................................................................642 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS................................................642 [E-9]..........................................................................................643 MACHINE MONITOR DOES NOT DISPLAY ITEMS CORRECTLY...........................................643 [E-10].........................................................................................644 MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING..............................644 [E-11].........................................................................................645 COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT...........................................645 [E-12].........................................................................................647 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.................................647 [E-13].........................................................................................649 MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING..............................649 [E-17].........................................................................................650 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY..............................................650 [E-15].........................................................................................652 WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS....................................652 [E-16].........................................................................................654 WINDSHIELD WIPER AND WASHER DO NOT OPERATE.................................................654 WINDSHIELD WASHER DRIVE ERROR..............................................................656 [E-17].........................................................................................658 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................658 [E-18].........................................................................................660 BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR..............................................660 [E-19].........................................................................................662 BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR..............................................662 [E-20].........................................................................................664 ARM IN NOT CORRECTLY DISPLAYED ON MONITOR..................................................664 [E-21].........................................................................................666 ARM OUT NOT CORRECTLY DISPLAYED ON MONITOR.................................................666 [E-22].........................................................................................668 BUCKET CURL CORRECTLY DISPLAYED ON MONITOR.................................................668 [E-23].........................................................................................670 BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR.............................................670 [E-24].........................................................................................672 SWING NOT CORRECTLY DISPLAYED ON MONITOR...................................................672 [E-25].........................................................................................674 TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR..................................................674 [E-26].........................................................................................676 TRAVEL DIFFERENTIAL NOT CORRECTLY DISPLAYED ON MONITOR.....................................676 [E-27].........................................................................................678 SERVICE NOT CORRECTLY DISPLAYED ON MONITOR.................................................678 [E-28].........................................................................................680 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................680 [E-29].........................................................................................682 AIR CONDITIONER SYSTEM DOES NOT WORK.......................................................682 [E-30].........................................................................................684 TRAVEL ALARM DOES NOT SOUND................................................................684 [E-31].........................................................................................686 HORN DOES NOT SOUND........................................................................686 TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...........................................691 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SY...................................................693 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.................................................695 [H-1]..........................................................................................696 WORK EQUIPMENT, TRAVEL AND SWING SPEEDS ARE SLOW...........................................696 [H-2]..........................................................................................697 ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS................................................697 [H-3]..........................................................................................698 NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT................................................698 [H-4]..........................................................................................698 ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP................................................698 [H-5]..........................................................................................699 AUTO-DECELERATOR DOES NOT WORK.............................................................699 [H-6]..........................................................................................699 FINE CONTROL MODE DOES NOT FUNCTION........................................................699 [H-7]..........................................................................................700 BOOM MOVES SLOWLY OR LACKS POWER...........................................................700 [H-8]..........................................................................................701 WORK EQUIPMENT MOVES SLOWLY OR LACKS POWER.................................................701 [H-9]..........................................................................................702 BUCKET MOVES SLOWLY OR LACKS POWER.........................................................702 [H-10].........................................................................................702 WORK EQUIPMENT DOES NOT MOVE IN A INDEPENDENT OPERATION....................................702 [H-11].........................................................................................703 WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT...............................................703 [H-12].........................................................................................704 WORK EQUIPMENT HAS EXCESSIVE LAG TIM.......................................................704 [H-13].........................................................................................704 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT.................................704 [H-14].........................................................................................705 ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE...............................................705 [H-15].........................................................................................705 IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY.....................705 [H-16].........................................................................................705 IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY.......................................705 [H-17].........................................................................................706 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY..............................................706 [H-18].........................................................................................707 MACHINE SWERVES WHEN TRAVELING.............................................................707 [H-19].........................................................................................708 MACHINE TRAVELS SLOWLY.....................................................................708 [H-20].........................................................................................709 MACHINE CANNOT BE STEERED EASILY OR LACKS POWER............................................709 [H-21].........................................................................................710 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING.....................710 [H-22].........................................................................................710 TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY).................................................710 [H-23].........................................................................................711 MACHINE DOES NOT SWING.....................................................................711 [H-24].........................................................................................712 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW.........................................712 [H-25].........................................................................................713 EXCESSIVE OVERRUN WHEN STOPPING SWING......................................................713 [H-26].........................................................................................714 THERE IS A SUDDEN SHOCK WHEN STOPPING SWING................................................714 [H-27].........................................................................................714 ABNORMAL NOISE CAUSED WHEN STOPPING SWING..................................................714 30 DISASSEMBLY AND ASSEMBLY............................................................................716 METHOD OF USING MANUAL.............................................................................720 COATING MATERIALS LIST.............................................................................721 SPECIAL TOOLS LIST.................................................................................725 SKETCHES OF SPECIAL TOOLS..........................................................................729 PRECAUTIONS DURING OPERATION.......................................................................731 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK.....................................................731 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK................................................732 PRECAUTIONS WHEN COMPLETING THE OPERATIONS.....................................................733 OTHER PRECAUTIONS..............................................................................733 ENGINE.............................................................................................734 CONNECTOR REPAIR PROCEDURES........................................................................735 CONTACT TERMINAL REMOVAL (HD30 TYPE)...........................................................735 STRIPPING INSULATION...........................................................................736 CRIMPING CONTACT TERMINAL (HD30 TYPE)..........................................................737 INSERTION OF CONTACT TERMINAL (HD30 TYPE)......................................................738 CONTACT TERMINAL REMOVAL (DT TYPE).............................................................739 STRIPPING INSULATION...........................................................................740 CRIMPING CONTACT TERMINAL (DT TYPE)............................................................741 INSERTION OF CONTACT TERMINAL (DT TYPE)........................................................742 ENGINE AND COOLING SYSTEM..........................................................................743 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY..........................................743 SPECIAL TOOLS..............................................................................743 REMOVAL....................................................................................743 INSTALLATION...............................................................................745 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL..................................................748 SPECIAL TOOLS..............................................................................748 REMOVAL....................................................................................748 INSTALLATION...............................................................................750 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...................................................752 SPECIAL TOOLS..............................................................................752 REMOVAL....................................................................................752 INSTALLATION...............................................................................754 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.............................................759 SPECIAL TOOLS..............................................................................759 REMOVAL....................................................................................759 INSTALLATION...............................................................................766 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY..................................................774 REMOVAL....................................................................................774 INSTALLATION...............................................................................775 REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY......................................776 REMOVAL....................................................................................776 INSTALLATION...............................................................................778 REMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLY...............................................779 REMOVAL....................................................................................779 INSTALLATION...............................................................................779 REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY.................................780 SPECIAL TOOLS..............................................................................780 REMOVAL....................................................................................780 INSTALLATION...............................................................................785 POWER TRAIN........................................................................................786 REMOVAL AND INSTALLATION OF FINALDRIVE ASSEMBLY................................................786 REMOVAL....................................................................................786 INSTALLATION...............................................................................787 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE........................................................788 SPECIAL TOOLS..............................................................................788 DISASSEMBLY................................................................................788 ASSEMBLY...................................................................................793 REMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...........................799 REMOVAL....................................................................................799 INSTALLATION...............................................................................800 DISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY...........................801 SPECIAL TOOLS..............................................................................801 DISASSEMBLY................................................................................801 ASSEMBLY...................................................................................804 REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY..............................................811 REMOVAL....................................................................................811 INSTALLATION...............................................................................811 UNDERCARRIAGE AND FRAME............................................................................812 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY............................................812 SPECIAL TOOLS..............................................................................812 ASSEMBLY...................................................................................812 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY..............................................814 SPECIAL TOOLS..............................................................................814 ASSEMBLY...................................................................................814 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY.....................................................816 SPECIAL TOOLS..............................................................................816 DISASSEMBLY................................................................................816 ASSEMBLY...................................................................................817 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY.............................................820 SPECIAL TOOLS..............................................................................820 DISASSEMBLY................................................................................820 ASSEMBLY...................................................................................822 REMOVAL AND INSTALLATION OF SPROCKET...........................................................824 REMOVAL....................................................................................824 INSTALLATION...............................................................................824 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY..............................................825 SPECIAL TOOLS..............................................................................825 EXPANSION OF TRACK SHOE....................................................................825 INSTALLATION OF TRACK SHOE.................................................................826 REMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLY...........................................828 REMOVAL....................................................................................828 INSTALLATION...............................................................................830 REMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY.............................................831 REMOVAL....................................................................................831 INSTALLATION...............................................................................831 HYDRAULIC SYSTEM...................................................................................832 REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY.......................................832 REMOVAL....................................................................................832 INSTALLATION...............................................................................833 DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY.......................................834 SPECIAL TOOLS..............................................................................834 DISASSEMBLY................................................................................834 ASSEMBLY...................................................................................835 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY............................................836 REMOVAL....................................................................................836 INSTALLATION...............................................................................838 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY.............................................839 REMOVAL....................................................................................839 INSTALLATION...............................................................................842 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY.............................................843 SPECIAL TOOLS..............................................................................843 REMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLY............................................846 SPECIAL TOOLS..............................................................................846 REMOVAL....................................................................................846 INSTALLATION...............................................................................849 REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT.............................850 REMOVAL....................................................................................850 INSTALLATION...............................................................................850 DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY..................................851 DISASSEMBLY................................................................................851 ASSEMBLY...................................................................................851 DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY..........................................853 DISASSEMBLY................................................................................853 ASSEMBLY...................................................................................853 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY........................................854 SPECIAL TOOLS..............................................................................854 DISASSEMBLY................................................................................854 ASSEMBLY...................................................................................857 WORK EQUIPMENT.....................................................................................861 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY............................................861 SPECIAL TOOLS..............................................................................861 REMOVAL....................................................................................861 INSTALLATION...............................................................................863 CAB AND ITS ATTACHMENTS............................................................................865 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY............................................865 REMOVAL....................................................................................865 INSTALLATION...............................................................................867 REMOVAL AND INSTALLATION OF OPERATOR’S CAB FIXED WINDOW........................................868 SPECIAL TOOLS..............................................................................869 REMOVAL....................................................................................869 INSTALLATION...............................................................................870 REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY..............................................881 REMOVAL....................................................................................881 INSTALLATION...............................................................................884 ELECTRICAL SYSTEM..................................................................................889 REMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY............................................889 SPECIAL TOOLS..............................................................................889 REMOVAL....................................................................................889 INSTALLATION...............................................................................892 REMOVAL AND INSTALLATION OFMACHINE MONITOR.....................................................893 REMOVAL....................................................................................893 INSTALLATION...............................................................................893 REMOVAL AND INSTALLATION OF PUMP CONTROLLER....................................................894 REMOVAL....................................................................................894 INSTALLATION...............................................................................894 REMOVAL AND INSTALLATION OF KOMTRAX TERMINAL...................................................895 REMOVAL....................................................................................895 INSTALLATION...............................................................................895 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER..................................................896 REMOVAL....................................................................................896 INSTALLATION...............................................................................896 90 OTHERS..............................................................................................898 HYDRAULIC CIRCUIT DIAGRAMS.........................................................................900 (VIEW “A”) 1 OF 5..............................................................................900 (VIEW “A”) 2 OF 5..............................................................................902 (VIEW “A”) 3 OF 5..............................................................................904 (VIEW “A”) 4 OF 5..............................................................................906 (VIEW “A”) 5 OF 5..............................................................................908 (VIEW “B”) 1 OF 6..............................................................................910 (VIEW “B”) 2 OF 6..............................................................................912 (VIEW “B”) 3 OF 6..............................................................................914 (VIEW “B”) 4 OF 6..............................................................................916 (VIEW “B”) 5 OF 6..............................................................................918 (VIEW “B”) 6 OF 6..............................................................................920 ELECTRICAL CIRCUIT DIAGRAMS........................................................................922 TO CABIN HARNESS...............................................................................922 CABIN HARNESS VIEW 1...........................................................................924 CABIN HARNESS VIEW 2...........................................................................926 CONTROLLER (CR700) VIEW........................................................................928 FLOOR HARNESS VIEW.............................................................................930 MONITOR AND RADIO HARNESS VIEW.................................................................932 LEFT CONSOLE, FUSE PANEL AND KOMTRAX CONTROLLER................................................934 WARNING AND INDICATOR LAMPS....................................................................936 ENGINE AND DRIVE SYSTEM SENSORS AND CONTROLLERS................................................938 ENGINE SENSORS AND CONTROLLERS (PC300LC-7E0)...................................................940 FUEL INJECTOR SYSTEM VIEW (PC300LC-7E0)........................................................942 ENGINE SENSORS AND CONTROLLERS (PC300HD-7E0)...................................................944 FUEL INJECTOR SYSTEM VIEW (PC300HD-7E0)........................................................946
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