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KOMATSU GALEO PC300LL-7E0 LOGGINGROAD BUILDER EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 and UP) KOMATSU PC300LL 7E0 – PDF DOWNLOAD
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- KOMATSU GALEO PC300LL-7E0 LOGGINGROAD BUILDER EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:A86001 and UP
- PUBLICATION NUMBER:CEBM017800
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KOMATSU GALEO PC300LL-7E0 LOGGINGROAD BUILDER EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 and UP) KOMATSU PC300LL 7E0
KOMATSU GALEO PC300LL-7E0 LOGGINGROAD BUILDER EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 AND UP) KOMATSU PC300LL 7E0 – PDF DOWNLOAD:
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KOMATSU GALEO PC300LL-7E0 LOGGINGROAD BUILDER EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 and UP) KOMATSU PC300LL 7E0
- 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 sections. These sections are further divided into 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, ADJUSTING AND TROUBLESHOOTING
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 PC300LL-7E0 LOGGINGROAD BUILDER EXCAVATOR SERVICE REPAIR MANUAL (SN:A86001 and UP) KOMATSU PC300LL 7E0
COVER.................................................................................................. 1 CONTENTS............................................................................................... 3 FOREWORD............................................................................................... 2 SAFETY............................................................................................. 4 SAFETY NOTICE.................................................................................. 4 IMPORTANT SAFETY NOTICE.................................................................... 4 GENERAL PRECAUTIONS........................................................................ 4 PREPARATIONS FOR WORK...................................................................... 4 PRECAUTIONS DURING WORK.................................................................... 5 01 GENERAL............................................................................................. 6 HOW TO READ THE SHOP MANUAL........................................................................ 9 VOLUMES........................................................................................ 9 DISTRIBUTION AND UPDATING...................................................................... 9 FILING METHOD.................................................................................. 9 REVISED EDITION MARK........................................................................... 9 REVISIONS...................................................................................... 9 SYMBOLS........................................................................................ 10 HOISTING INSTRUCTIONS.............................................................................. 11 HOISTING....................................................................................... 11 WIRE ROPES..................................................................................... 11 PUSH PULL COUPLER.................................................................................. 13 TYPE 1......................................................................................... 13 DISCONNECTION.............................................................................. 13 CONNECTION................................................................................. 13 TYPE 2......................................................................................... 14 DISCONNECTION.............................................................................. 14 CONNECTION................................................................................. 14 TYPE 3......................................................................................... 15 DISCONNECTION.............................................................................. 15 CONNECTION................................................................................. 15 EXPLANATION OF MAINTENANCE STANDARD TERMS.......................................................... 16 STANDARD TIGHTENING TORQUE......................................................................... 18 BOLTS AND NUTS................................................................................. 18 TIGHTENING TORQUE OF HOSE NUTS................................................................. 19 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS........................................................ 19 TIGHTENING TORQUE FOR FLARED NUTS.............................................................. 19 TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS............................................... 20 TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS.............................................. 20 TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE).................................... 20 ELECTRIC WIRE CODE................................................................................. 8 CLASSIFICATION BY THICKNESS.................................................................... 8 CLASSIFICATION BY COLOR AND CODE............................................................... 8 HOW TO READ ELECTRIC WIRE CODE................................................................. 21 CONVERSION TABLES.................................................................................. 24 METHOD OF USING THE CONVERSION TABLE........................................................... 24 COATING MATERIALS.................................................................................. 30 SPECIFICATIONS..................................................................................... 32 DIMENSIONS..................................................................................... 32 ROAD BUILDER............................................................................... 32 LOG LOADER - 42 FT KOMATSU FOREST FRONT.................................................... 32 WORKING RANGES................................................................................. 34 ROAD BUILDER............................................................................... 34 LOG LOADER - 42 FT KOMATSU FOREST FRONT.................................................... 36 WEIGHT TABLE....................................................................................... 41 FUEL, COOLANT, AND LUBRICANTS...................................................................... 43 10 STRUCTURE AND FUNCTION.............................................................................. 45 ENGINE RELATED PARTS............................................................................... 48 RADIATOR . OIL COOLER . AFTERCOOLER................................................................ 49 POWER TRAIN........................................................................................ 50 FINAL DRIVE........................................................................................ 51 SPROCKET........................................................................................... 55 SPROCKET TOOL.................................................................................. 56 SWING MACHINERY.................................................................................... 57 SWING CIRCLE................................................................................... 61 TRACK FRAME . RECOIL SPRING........................................................................ 62 IDLER.............................................................................................. 64 TRACK ROLLER/CARRIER ROLLER........................................................................ 66 TRACK SHOE......................................................................................... 68 TRIPLE GROUSER SHOE................................................................................ 71 DOUBLE GROUSER SHOE................................................................................ 72 HYDRAULIC EQUIPMENT................................................................................ 73 HYDRAULIC TANK AND FILTER.......................................................................... 75 HYDRAULIC PUMP..................................................................................... 76 HPV125 + 125................................................................................... 76 LS VALVE....................................................................................... 82 PC VALVE....................................................................................... 87 LS(PC)-EPC VALVE............................................................................... 94 VARIABLE VOLUME VALVE.......................................................................... 98 CONTROL VALVE......................................................................................100 CLSS...............................................................................................112 VALVE FUNCTIONS AND OPERATION......................................................................116 UNLOADER VALVE.....................................................................................118 INTRODUCTION OF LS PRESSURE........................................................................120 LS BYPASS VALVE....................................................................................121 PRESSURE COMPENSATION VALVE........................................................................122 PRESSURE COMPENSATION VALVE INNER SHUTTLE......................................................125 BOOM REGENERATION CIRCUIT......................................................................127 ARM REGENERATION CIRCUIT.......................................................................129 MERGE-DIVIDER VALVE................................................................................131 LS SELECT VALVE....................................................................................133 SELF PRESSURE REDUCING VALVE.......................................................................134 TRAVEL JUNCTION VALVE..............................................................................137 TRAVEL PPC SHUTTLE VALVE...........................................................................139 BOOM DRIFT PREVENTION VALVE........................................................................141 ARM DRIFT PREVENTION VALVE.........................................................................144 QUICK RETURN VALVE.................................................................................148 LIFT CHECK VALVE...................................................................................150 MAIN RELIEF VALVE..................................................................................151 2-STAGE SAFETY-SUCTION VALVE.......................................................................152 VARIABLE PRESSURE COMPENSATION VALVE...............................................................154 CONTROL VALVE......................................................................................156 PPC VALVE..........................................................................................157 WORK EQUIPMENT AND SWING PPC VALVE.............................................................157 TRAVEL PPC VALVE...............................................................................163 PRESSURE REDUCING VALVE............................................................................166 STRAIGHT TRAVEL PPC VALVE......................................................................172 PPC ACCUMULATOR................................................................................174 SOLENOID VALVE.....................................................................................175 ATTACHMENT SOLENOID VALVE..........................................................................176 CENTER SWIVEL JOINT................................................................................178 TRAVEL MOTOR.......................................................................................179 TYPE: KMV200ADT-2..............................................................................179 OPERATION OF MOTOR.............................................................................182 PARKING BRAKE......................................................................................184 BRAKE VALVE OPERATION..........................................................................186 SAFETY VALVE.......................................................................................188 SWING MOTOR........................................................................................191 TYPE: KMF230ABE-5..............................................................................191 SWING HOLDING BRAKE............................................................................194 RELIEF VALVE PORTION...........................................................................195 REVERSE PREVENTION VALVE...........................................................................196 EXPLANATORY DRAWING OF EFFECTS.................................................................197 HYDRAULIC CYLINDERS - EXCAVATOR WORK EQUIPMENT.....................................................200 BOOM CYLINDER..................................................................................200 ARM CYLINDER...................................................................................200 BUCKET CYLINDER................................................................................201 WORK EQUIPMENT PIVOT POINT MEASUREMENTS............................................................202 BOSS BUSHING/PINS - EXCAVATOR WORK EQUIPMENT...................................................202 DIMENSION OF ARM - EXCAVATOR WORK EQUIPMENT....................................................204 DIMENSION OF BUCKET............................................................................206 CAB AND ATTACHMENTS................................................................................208 AIR CONDITIONER PIPING.........................................................................208 ELECTRICAL SYSTEM..................................................................................209 ENGINE CONTROL.................................................................................209 ELECTRONIC COMPONENTS..............................................................................211 FUEL CONTROL DIAL..............................................................................211 ENGINE CONTROLLER..............................................................................212 COOLANT TEMPERATURE SENSOR.....................................................................216 OIL PRESSURE SWITCH............................................................................216 ENGINE SPEED SENSOR............................................................................217 BOOST PRESSURE AND TEMPERATURE SENSOR..........................................................217 WIF (WATER-IN-FUEL DETECTION) SENSOR...........................................................218 ENGINE OIL LEVEL SENSOR........................................................................218 ELECTRONIC CONTROL SYSTEM..........................................................................219 CONTROL FUNCTION...............................................................................219 SYSTEM DIAGRAM.............................................................................220 ENGINE AND PUMP CONTROL FUNCTION...............................................................222 PUMP AND VALVE CONTROL.........................................................................226 LS CONTROL FUNCTION........................................................................227 CUT-OFF FUNCTION...........................................................................227 2-STAGE RELIEF FUNCTION....................................................................227 POWER MAXIMIZING AND MACHINE PUSH-UP...........................................................228 AUTO-DECELERATION..............................................................................230 AUTO-WARM-UP AND OVERHEAT PREVENTION...........................................................231 SWING CONTROL..................................................................................233 TRAVEL CONTROL.................................................................................235 ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR (IF EQUIPPED).....................................237 SYSTEM COMPONENTS..................................................................................238 PPC OIL PRESSURE SWITCH........................................................................238 OIL PRESSURE SENSOR............................................................................239 PUMP PRESSURE SENSOR (HIGH PRESSURE)...........................................................240 PUMP CONTROLLER................................................................................241 MONITOR SYSTEM.....................................................................................245 MACHINE MONITOR................................................................................246 MONITOR CONTROL AND DISPLAY........................................................................249 MONITOR........................................................................................249 DISPLAY........................................................................................250 SWITCHES...........................................................................................254 BRIGHTNESS, CONTRAST ADJUSTMENT................................................................262 SERVICE METER CHECK FUNCTION...................................................................263 DISPLAY LCD CHECK FUNCTION.....................................................................263 USER CODE DISPLAY FUNCTION.....................................................................264 SENSOR.............................................................................................266 HYDRAULIC OIL LEVEL SENSOR.....................................................................266 HYDRAULIC OIL AND COOLANT TEMPERATURE SENSOR...................................................266 FUEL LEVEL SENSOR..............................................................................267 AIR CLEANER CLOGGING SENSOR....................................................................268 KOMTRAX TERMINAL SYSTEM............................................................................269 KOMTRAX TERMINAL...............................................................................270 20 TESTING, ADJUSTING ANDTROUBLESHOOTING...............................................................273 TESTING AND ADJUSTING..............................................................................274 STANDARD VALUE TABLES..........................................................................277 ENGINE RELATED.............................................................................277 CHASSIS RELATED............................................................................278 SERVICE TOOLS..................................................................................286 ENGINE SERVICE TOOLS.......................................................................286 CHASSIS SERVICE TOOLS......................................................................287 ENGINE.........................................................................................288 AIR BOOST PRESSURE.........................................................................288 AIR COMPRESSOR BELT TENSION................................................................288 BLOW-BY PRESSURE...........................................................................288 COMPRESSION PRESSURE.......................................................................288 ENGINE OIL PRESSURE........................................................................288 ENGINE SPEED...............................................................................288 EXHAUST GAS COLOR..........................................................................288 FUEL CIRCUIT FOR LEAKAGE...................................................................288 FUEL CIRCUIT FOR BLEEDING AIR..............................................................288 FUEL PRESSURE..............................................................................288 FUEL RETURN RATE...........................................................................288 FUEL INJECTION TIMING......................................................................288 VALVE CLEARANCE............................................................................288 ENGINE FUNCTIONS...............................................................................289 MEASURE ENGINE SPEED WITH MACHINE MONITOR..................................................289 PREPARATION............................................................................289 MEASURING LOW IDLE SPEED...............................................................289 MEASURING HIGH IDLE SPEED..............................................................289 MEASURING THE ENGINE SPEED WHEN 2-PUMPS ARE RELIEVED...................................289 MEASURING THE ENGINE SPEED AT 2-PUMP RELIEF AND POWER MAXIMIZING (NEAR RATED SPEED)....289 MEASURING THE SPEED WHEN AUTO-DECELERATION SPEED IS IN OPERATION.......................289 CYLINDER CUT-OUT OPERATION.................................................................290 NO INJECTION CRANKING OPERATION............................................................290 REFRIGERANT COMPRESSOR BELT....................................................................291 INSPECTION.................................................................................291 ADJUSTMENT.................................................................................291 SWING CIRCLE BEARING CLEARANCE.................................................................292 TRACK SHOE TENSION.............................................................................293 INSPECTION.................................................................................293 ADJUSTMENT.................................................................................293 OIL PRESSURE IN WORK EQUIPMENT.................................................................294 OIL PRESSURE IN SWING..........................................................................294 OIL PRESSURE IN TRAVEL CIRCUIT.................................................................294 MEASURING..................................................................................294 ADJUSTING..................................................................................296 CONTROL CIRCUIT OIL PRESSURE...................................................................299 MEASURING..................................................................................299 PUMP PC CONTROL CIRCUIT OIL PRESSURE...........................................................300 MEASURING..................................................................................300 ADJUSTING..................................................................................302 PUMP LS CONTROL CIRCUIT OIL PRESSURE...........................................................303 MEASURING..................................................................................303 ADJUSTING..................................................................................307 SOLENOID VALVE OUTPUT PRESSURE.................................................................308 ATTACHMENT SOLENOID VALVE OUTPUT...............................................................311 PPC VALVE OUTPUT...............................................................................313 ATTACHMENT PPC VALVE OUTPUT....................................................................314 WORK EQUIPMENT AND SWING PPC VALVES............................................................315 HYDRAULIC DRIFT IN WORK EQUIPMENT..............................................................316 BOOM AND BUCKET CYLINDERS INSPECTION.......................................................316 ARM CYLINDER INSPECTION....................................................................316 BOOM LOCK VALVE INSPECTION.................................................................317 PPC VALVE INSPECTION.......................................................................317 RELEASE REMAINING PRESSURE IN HYDRAULIC CIRCUIT................................................318 OIL LEAKAGE AMOUNT.........................................................................318 BLEEDING AIR FROM VARIOUS SYSTEMS..............................................................321 DIODE INSPECTION PROCEDURES....................................................................323 MACHINE MONITOR - SPECIAL FUNCTIONS............................................................324 ORDINARY AND SPECIAL FUNCTIONS.............................................................325 OPERATORS MENU AND DISPLAY (OUTLINE).......................................................326 SERVICE MENU OPERATION AND DISPLAY.............................................................334 SWITCHING TO SERVICE MENU..................................................................334 MONITORING [01] FUNCTION...................................................................335 FUNCTION OF ABNORMALITY RECORD [02]........................................................340 FUNCTION OF MAINTENANCE RECORD [03]........................................................342 FUNCTION OF MAINTENANCE MODE CHANGE [04]...................................................343 FUNCTION OF PHONE NUMBER ENTRY [05]........................................................345 FUNCTION OF DEFAULT [06]...................................................................346 FUNCTION OF ADJUSTMENT [07]................................................................348 FUNCTION OF CYLINDER CUT OUT OPERATION [08]................................................349 FUNCTION OF NO INJECTION CRANKING [09].....................................................351 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................353 PROCEDURE FOR TURNING ON KOMTRAX TERMINAL......................................................354 KOMTRAX TERMINAL LAMP INDICATIONS..............................................................357 TROUBLESHOOTING ELECTRICAL SYSTEM..............................................................360 PM-CLINIC INSPECTION TABLE.....................................................................363 TROUBLESHOOTING (GENERAL)..........................................................................369 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................370 SEQUENCE OF EVENTS IN TROUBLESHOOTING..........................................................372 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE......................................................373 PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT.............................................373 HANDLING ELECTRONIC CONTROL UNIT...........................................................378 POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS................................379 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.......................................381 CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS......................................384 TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS.............................................385 TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS..............................................387 POSSIBLE PROBLEMS WHEN TROUBLESHOOTING A MODE..................................................389 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....................................................392 T-ADAPTER TABLE................................................................................414 TROUBLESHOOTING OF ELECTRICALSYSTEM (E-MODE).......................................................417 CONNECTOR TYPES AND LOCATIONS..................................................................420 CONNECTOR LAYOUT DRAWINGS......................................................................426 TROUBLESHOOTING BY FAILURE CODE................................................................432 BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED.........................435 LOCATION OF FUSE BOX AND FUSE NUMBERS......................................................436 INFORMATION CONTAINED IN TESTING PROCEDURES....................................................438 A000N1 - ENGINE OVER SPEED.....................................................................441 AA10NX - AIR CLEANER CLOG SENSOR SYSTEM........................................................442 AB00KE - CHARGE VOLTAGE IS LOW.................................................................444 B@BAZG - ENGINE OIL PRESSURE DROP..............................................................446 B@BAZK - ENGINE OIL LEVEL DROP.................................................................448 B@BCNS - COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS).................................450 B@BCZK - ENGINE COOLANT LEVEL DROP.............................................................452 B@HANS - HYDRAULIC OIL OVERHEAT CONDITION......................................................453 CA111 - CRITICAL INTERNAL FAILURE..............................................................454 CA115 - ENGINE NE AND BACKUP SPEED SENSOR ERROR................................................455 CA122 - CHARGE AIR PRESSURE SENSOR HIGH ERROR..................................................456 CA123 - CHARGE AIR PRESSURE SENSOR LOW ERROR...................................................458 CA131 - THROTTLE SENSOR HIGH ERROR.............................................................460 CA132 - THROTTLE SENSOR LOW ERROR..............................................................461 CA144 - COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)....................................462 CA145 - COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (KX).....................................464 CA153 - CHARGE AIR PRESSURE SENSOR HIGH ERROR..................................................466 CA154 - CHARGE AIR PRESSURE SENSOR LOW ERROR...................................................468 CA187 - SENSOR SUPPLY 2 VOLT LOW ERROR.........................................................470 CA221 - AMBIENT PRESSURE SENSOR HIGH ERROR.....................................................472 CA222 - AMBIENT PRESSURE SENSOR LOW ERROR......................................................474 CA227 - SENSOR SUPPLY 2 VOLT HIGH ERROR........................................................476 CA234 - ENGINE OVER SPEED......................................................................478 CA238 - SPEED SENSOR SUPPLY VOLT ERROR.........................................................479 CA271 - UMV/PCV1 SHORT ERROR...................................................................480 CA272 - UMV/PCV1 OPEN ERROR....................................................................481 CA322 - OPEN IN NO. 1 INJECTOR SOLENOID VALVE..................................................482 CA323 - OPEN IN NO. 5 INJECTOR SOLENOID VALVE..................................................484 CA324 - OPEN IN NO. 3 INJECTOR SOLENOID VALVE..................................................486 CA325 - OPEN IN NO. 6 INJECTOR SOLENOID VALVE..................................................488 CA331 - OPEN IN NO. 2 INJECTOR SOLENOID VALVE..................................................490 CA332 - OPEN IN NO. 4 INJECTOR SOLENOID VALVE..................................................492 CA342 - CALIBRATION CODE INCOMPATIBILITY.......................................................494 CA351 - INJECTOR DRIVE CIRCUIT ERROR...........................................................496 CA352 - AMBIENT PRESSURE SENSOR 1 VOLT LOW ERROR...............................................498 CA386 - AMBIENT PRESSURE SENSOR 1 VOLT HIGH ERROR..............................................500 CA428 - WATER IN FUEL SENSOR HIGH ERROR........................................................502 CA429 - WATER IN FUEL SENSOR LOW ERROR.........................................................504 CA441 - BATTERY VOLTAGE LOW ERROR..............................................................506 CA442 - BATTERY VOLTAGE HIGH ERROR.............................................................508 CA449 - RAIL PRESSURE VERY HIGH................................................................510 CA451 - RAIL PRESSURE SENSOR HIGH ERROR........................................................514 CA452 - RAIL PRESSURE SENSOR LOW ERROR.........................................................516 CA553 - RAIL PRESSURE ERROR....................................................................518 CA559 - RAIL PRESSURE VERY LOW.................................................................520 CA689 - ENGINE NE SPEED SENSOR ERROR...........................................................522 CA731 - ENGINE BACK-UP SPEED SENSOR PHASE ERROR................................................524 CA757 - PERSISTENT DATA LOSS ERROR.............................................................526 CA778 - ENGINE BKUP SPEED SENSOR ERROR.........................................................528 CA1633 - (KOMNET) DATALINK HAS TIME-OUT ERROR..................................................530 CA2185 - THROTTLE SENSOR HIGH ERROR............................................................532 CA2186 - THROTTLE SENSOR LOW ERROR.............................................................533 CA2249 - RAIL PRESSURE VERY LOW................................................................534 CA2265 - ELECTRIC LIFT PUMP HIGH ERROR.........................................................536 CA2266 - ELECTRIC LIFT PUMP LOW ERROR..........................................................537 CA2556 - GRID HEATER RELAY VOLT LOW ERROR......................................................538 CA2555 - GRID HEATER RELAY VOLT HIGH ERROR.....................................................540 D110KB - BATTERY RELAY DRIVE S/C...............................................................542 D196KA - SERVICE RETURN RELAY ERROR............................................................544 D196KB - SERVICE RETURN RELAY ERROR............................................................546 DA25KP - SENSOR POWER ERROR....................................................................548 DA2RMC - PUMP COMMUNICATION ERROR..............................................................550 DA2SKQ - MODEL SELECTION ERROR.................................................................552 DAFRMC - MONITOR COMMUNICATION ERROR...........................................................554 DHPAMA - F PUMP PRESSURE SENSOR ERROR..........................................................556 DHPBMA - R PUMP PRESSURE SENSOR ERROR..........................................................558 DHS3MA - ARM CURL PRESSURE SENSOR ERROR........................................................560 DHS4MA - CURL PPC PRESSURE SENSOR ERROR........................................................562 DW43KA - TRAVEL SPEED SOLENOID ERROR...........................................................564 DW43KB - TRAVEL SPEED SOLENOID ERROR...........................................................566 DW45KA - SWING BRAKE SOLENOID ERROR............................................................568 DW45KB - SWING BRAKE SOLENOID ERROR............................................................571 DW91KA - TRAVEL JUNCTION SOLENOID ERROR........................................................574 DW91KB - TRAVEL JUNCTION SOLENOID ERROR........................................................576 DWJ0KA - MERGE-DIVIDER SOLENOID ERROR..........................................................578 DWJ0KB - MERGE-DIVIDER SOLENOID ERROR..........................................................580 DWK0KA - 2-STAGE RELIEF SOLENOID ERROR.........................................................582 DWK0KB - 2-STAGE RELIEF SOLENOID ERROR.........................................................584 DXA0KA - PC-EPC SOLENOID ERROR.................................................................586 DXA0KB - PC-EPC SOLENOID ERROR.................................................................588 DXE0KA - LS-EPC SOLENOID ERROR.................................................................590 DXE0KB - LS-EPC SOLENOID ERROR.................................................................592 DXE4KA - SERVICE CURRENT EPC ERROR.............................................................594 DXE4KB - SERVICE CURRENT EPC ERROR.............................................................596 DY20KA - WINDSHIELD WIPER MOTOR DRIVE ERROR....................................................598 DY20MA - WINDSHIELD WIPER MOTOR DRIVE ERROR....................................................600 DY2CKB - WINDSHIELD WASHER DRIVE ERROR.........................................................602 DY2DKB - WINDSHIELD WIPER DRIVE ERROR..........................................................604 DY2EKB - WINDSHIELD WIPER DRIVE ERROR..........................................................606 E-1 - ENGINE WILL NOT CRANK....................................................................608 E-2 - AUTO DECELERATOR DOES NOT WORK...........................................................610 E-3 - AUTO ENGINE WARM UP DEVICE DOES NOT WORK.................................................611 E-4 - COLD START PRE-HEATER DOES NOT WORK......................................................612 E-5 - ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE......................................614 E-6 - POWER MAXIMIZING FUNCTION DOES NOT OPERATE...............................................616 E-7 - MACHINE MONITOR DOES NOT OPERATE.........................................................618 E-8 - MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS..............................................620 E-9 - MACHINE MONITOR DOES NOT DISPLAY ITEMS CORRECTLY.........................................621 E-10 - MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING...........................622 E-11 - COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT........................................624 E-12 - HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY..............................626 E-13 - MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING...........................628 E-14 - SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY...........................................630 E-15 - WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS.................................632 E-16 - WINDSHIELD WIPER AND WASHER DO NOT OPERATE..............................................634 WINDSHIELD WASHER DRIVE ERROR..............................................................636 E-17 - MACHINE PUSH-UP FUNCTION DOES NOT OPERATE...............................................638 E-18 - BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR...........................................640 E-19 - BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR...........................................642 E-20 - ARM IN NOT CORRECTLY DISPLAYED ON MONITOR...............................................644 E-21 - ARM OUT NOT CORRECTLY DISPLAYED ON MONITOR..............................................646 E-22 - BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR..........................................648 E-23 - BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR..........................................650 E-24 - SWING NOT CORRECTLY DISPLAYED ON MONITOR................................................652 E-25 - TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR...............................................654 E-26 - TRAVEL DIFFERENTIAL NOT CORRECTLY DISPLAYED ON MONITOR..................................656 E-27 - SERVICE NOT CORRECTLY DISPLAYED ON MONITOR..............................................658 E-28 - KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY................................................660 E-29 - AIR CONDITIONER SYSTEM DOES NOT WORK....................................................662 E-30 - TRAVEL ALARM DOES NOT SOUND.............................................................664 E-31 - HORN DOES NOT SOUND.....................................................................666 TROUBLESHOOTING HYDRAULIC ANDMECHANICAL SYSTEM (H-MODE)............................................669 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS..............................................670 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE.................................................672 H-1 - WORK EQUIPMENT, TRAVEL AND SWING SPEEDS ARE SLOW.........................................673 H-2 - ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS..............................................674 H-3 - NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT..............................................675 H-4 - ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP..............................................675 H-5 - AUTO-DECELERATOR DOES NOT WORK...........................................................676 H-6 - FINE CONTROL MODE DOES NOT FUNCTION......................................................676 H-7 - BOOM MOVES SLOWLY OR LACKS POWER.........................................................677 H-8 - WORK EQUIPMENT MOVES SLOWLY OR LACKS POWER...............................................678 H-9 - BUCKET MOVES SLOWLY OR LACKS POWER.......................................................679 H-10 - WORK EQUIPMENT DOES NOT MOVE IN A INDEPENDENT OPERATION.................................679 H-11 - WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT............................................680 H-12 - WORK EQUIPMENT HAS EXCESSIVE LAG TIME...................................................681 H-13 - OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT..............................681 H-14 - ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE............................................682 H-15 - IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY..................682 H-16 - IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY....................................682 H-17 - IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY...........................................683 H-18 - MACHINE SWERVES WHEN TRAVELING..........................................................684 H-19 - MACHINE TRAVELS SLOWLY..................................................................685 H-20 - MACHINE CANNOT BE STEERED EASILY OR LACKS POWER.........................................686 H-21 - TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING..................687 H-22 - TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)..............................................687 H-23 - MACHINE DOES NOT SWING..................................................................688 H-25 - EXCESSIVE OVERRUN WHEN STOPPING SWING...................................................690 H-24 - SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW......................................689 H-26 - THERE IS A SUDDEN SHOCK WHEN STOPPING SWING.............................................691 H-27 - ABNORMAL NOISE CAUSED WHEN STOPPING SWING...............................................691 H-28 - SWING NATURAL DRIFT IS EXCESSIVE........................................................692 30 DISASSEMBLY AND ASSEMBLY............................................................................693 ENGINE COMPONENTS..................................................................................696 CYLINDER HEAD..................................................................................696 ENGINE FRONT SEAL..............................................................................696 ENGINE REAR SEAL...............................................................................696 FUEL SUPPLY PUMP...............................................................................696 VALVES.........................................................................................696 SPECIAL TOOLS LIST.............................................................................697 CONNECTOR REPAIR PROCEDURES........................................................................700 CONTACT TERMINAL REMOVAL (HD30 TYPE)...........................................................700 STRIPPING INSULATION...........................................................................701 CRIMPING CONTACT TERMINAL (HD30 TYPE)..........................................................702 INSERTION OF CONTACT TERMINAL (HD30 TYPE)......................................................703 CONTACT TERMINAL REMOVAL (DT TYPE).............................................................704 STRIPPING INSULATION...........................................................................705 CRIMPING CONTACT TERMINAL (DT TYPE)............................................................706 INSERTION OF CONTACT TERMINAL (DT TYPE)........................................................707 ENGINE AND COOLING SYSTEM..........................................................................708 RADIATOR ASSEMBLY..............................................................................708 REMOVAL....................................................................................708 INSTALLATION...............................................................................709 HYDRAULIC OIL COOLER ASSEMBLY..................................................................710 REMOVAL....................................................................................710 INSTALLATION...............................................................................711 AFTERCOOLER ASSEMBLY...........................................................................712 REMOVAL....................................................................................712 INSTALLATION...............................................................................712 ENGINE AND HYDRAULIC PUMP ASSEMBLY.............................................................713 REMOVAL....................................................................................713 INSTALLATION...............................................................................717 POWER TRAIN........................................................................................719 FINAL DRIVE ASSEMBLY...........................................................................719 REMOVAL....................................................................................719 INSTALLATION...............................................................................720 DISASSEMBLY................................................................................720 ASSEMBLY...................................................................................725 SWING MOTOR AND SWING MACHINERY ASSEMBLY.......................................................731 REMOVAL....................................................................................731 INSTALLATION...............................................................................732 DISASSEMBLY................................................................................733 ASSEMBLY...................................................................................736 SWING CIRCLE ASSEMBLY..........................................................................742 REMOVAL....................................................................................742 INSTALLATION...............................................................................742 UNDERCARRIAGE AND FRAME............................................................................743 TRACK ROLLER ASSEMBLY AND CARRIER ROLLER ASSEMBLY..............................................743 DISASSEMBLY................................................................................743 ASSEMBLY...................................................................................743 IDLER ASSEMBLY.................................................................................745 DISASSEMBLY................................................................................745 ASSEMBLY...................................................................................746 RECOIL SPRING..................................................................................749 DISASSEMBLY................................................................................749 ASSEMBLY...................................................................................750 SPROCKET.......................................................................................752 REMOVAL....................................................................................752 INSTALLATION...............................................................................752 TRACK SHOE ASSEMBLY............................................................................753 EXPANSION OF TRACK SHOE....................................................................753 INSTALLATION OF TRACK SHOE.................................................................754 REVOLVING FRAME ASSEMBLY.......................................................................755 REMOVAL....................................................................................755 INSTALLATION...............................................................................757 COUNTERWEIGHT ASSEMBLY.........................................................................758 REMOVAL....................................................................................758 INSTALLATION...............................................................................758 HYDRAULIC SYSTEM...................................................................................759 CENTER SWIVEL JOINT ASSEMBLY...................................................................759 REMOVAL....................................................................................759 INSTALLATION...............................................................................760 DISASSEMBLY................................................................................761 ASSEMBLY...................................................................................761 HYDRAULIC TANK ASSEMBLY........................................................................762 REMOVAL....................................................................................762 INSTALLATION...............................................................................764 CONTROL VALVE ASSEMBLY.........................................................................765 REMOVAL....................................................................................765 INSTALLATION...............................................................................768 ASSEMBLY...................................................................................770 MAIN RELIEF VALVE ASSEMBLY.................................................................771 HYDRAULIC PUMP ASSEMBLY........................................................................772 REMOVAL....................................................................................772 INSTALLATION...............................................................................774 OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT.........................................................775 REMOVAL....................................................................................775 INSTALLATION...............................................................................775 WORK EQUIPMENT PPC VALVE ASSEMBLY..............................................................776 DISASSEMBLY................................................................................776 ASSEMBLY...................................................................................776 TRAVEL PPC VALVE ASSEMBLY......................................................................777 DISASSEMBLY................................................................................777 ASSEMBLY...................................................................................777 HYDRAULIC CYLINDER ASSEMBLY....................................................................778 DISASSEMBLY................................................................................778 ASSEMBLY...................................................................................780 WORK EQUIPMENT.....................................................................................784 WORK EQUIPMENT ASSEMBLY........................................................................784 REMOVAL....................................................................................784 INSTALLATION...............................................................................785 CAB AND ITS ATTACHMENTS............................................................................787 OPERATOR'S CAB ASSEMBLY........................................................................787 REMOVAL....................................................................................787 INSTALLATION...............................................................................789 OPERATOR’S CAB GLASS (STUCK GLASS).............................................................790 REMOVAL....................................................................................791 INSTALLATION...............................................................................792 FRONT WINDOW ASSEMBLY..........................................................................801 REMOVAL....................................................................................801 INSTALLATION...............................................................................804 ELECTRICAL SYSTEM..................................................................................809 WORK EQUIPMENT ASSEMBLY........................................................................809 REMOVAL....................................................................................809 INSTALLATION...............................................................................810 MACHINE MONITOR................................................................................811 REMOVAL....................................................................................811 INSTALLATION...............................................................................811 PUMP CONTROLLER................................................................................812 REMOVAL....................................................................................812 INSTALLATION...............................................................................812 KOMTRAX TERMINAL...............................................................................813 REMOVAL....................................................................................813 INSTALLATION...............................................................................813 ENGINE CONTROLLER..............................................................................814 REMOVAL....................................................................................814 INSTALLATION...............................................................................814 90 OTHERS..............................................................................................815 ELECTRICAL CIRCUIT DIAGRAMS........................................................................817 TO CABIN HARNESS...............................................................................817 CABIN HARNESS VIEW 1...........................................................................819 CABIN HARNESS VIEW 2...........................................................................821 CONTROLLER (CR700) VIEW........................................................................823 FLOOR HARNESS VIEW.............................................................................825 MONITOR AND RADIO HARNESS VIEW.................................................................827 LEFT CONSOLE, FUSE PANEL AND KOMTRAX CONTROLLER................................................829 WARNING AND INDICATOR LAMPS....................................................................831 ENGINE AND DRIVE SYSTEM SENSORS AND CONTROLLERS................................................833 ENGINE SENSORS AND CONTROLLERS.................................................................835 FUEL INJECTOR SYSTEM VIEW......................................................................837 ELECTRICAL DIAGRAM – 1 OF 9....................................................................839 ELECTRICAL DIAGRAM – 2 OF 9....................................................................841 ELECTRICAL DIAGRAM – 3 OF 9....................................................................843 ELECTRICAL DIAGRAM – 4 OF 9....................................................................845 ELECTRICAL DIAGRAM – 5 OF 9....................................................................847 ELECTRICAL DIAGRAM – 6 OF 9....................................................................849 ELECTRICAL DIAGRAM – 7 OF 9....................................................................851 ELECTRICAL DIAGRAM – 8 OF 9....................................................................853 ELECTRICAL DIAGRAM – 9 OF 9....................................................................855 HYDRAULIC CIRCUIT DIAGRAMS.........................................................................857 VIEW "A" – 1 OF 11.............................................................................857 VIEW "A" – 2 OF 11.............................................................................859 VIEW "A" – 3 OF 11.............................................................................861 VIEW "A" – 4 OF 11.............................................................................863 VIEW "A" – 5 OF 11.............................................................................865 VIEW "A" – 6 OF 11.............................................................................867 VIEW "A" – 7 OF 11.............................................................................869 VIEW "A" – 8 OF 11.............................................................................871 VIEW "A" – 9 OF 11.............................................................................873 VIEW "A" – 10 OF 11............................................................................875 VIEW "A" – 11 OF 11............................................................................877 VIEW "B" – 1 OF 1..............................................................................879
PLEASE NOTE:
⦁ This is the SAME exact manual used by your dealers to fix your vehicle.
⦁ The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
⦁ Any queries / doubts regarding your purchase, please feel free to contact [email protected]
