Komatsu HYDRAULIC EXCAVATOR PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 Shop Manual PDF
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Komatsu HYDRAULIC EXCAVATOR PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 Shop Manual SEN06931-C2 – PDF DOWNLOAD
SERIAL NUMBERS
PC300- C91744
PC350- C91744 and up
Description
Komatsu HYDRAULIC EXCAVATOR PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 Shop Manual SEN06931-C2 – PDF DOWNLOAD
FILE DETAILS:
Komatsu HYDRAULIC EXCAVATOR PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 Shop Manual SEN06931-C2 – PDF DOWNLOAD
Language : English
Pages :2072
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu HYDRAULIC EXCAVATOR PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 Shop Manual SEN06931-C2 – PDF DOWNLOAD
SERIAL NUMBERS
PC300- C91744
PC350- C91744 and up
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
REMARK
The illustrations in the shop manual reproduce the display of the machine monitor. They are not always the
same as the terminology in the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 Maintenance Standard
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 Others
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit Diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
Komatsu HYDRAULIC EXCAVATOR PC300-8M2 PC300LC-8M2 PC350-8M2 PC350LC-8M2 Shop Manual SEN06931-C2 – PDF DOWNLOAD
SERIAL NUMBERS
PC300- C91744
PC350- C91744 and up
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 16
FOREWORD, SAFETY, BASIC INFORMATION 19
HOW TO READ THE SHOP MANUAL 19
SAFETY NOTICE FOR OPERATION 21
PRECAUTIONS TO PREVENT FIRE 29
ACTIONS IF FIRE OCCURS 30
PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS 31
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 32
PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS 35
PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT 42
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 44
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 45
PRACTICAL USE OF KOMTRAX 46
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 47
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 47
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 48
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 49
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 51
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 55
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 56
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 58
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 59
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 61
HOW TO READ ELECTRICAL WIRE CODE 62
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 66
STANDARD TIGHTENING TORQUE TABLE 69
CONVERSION TABLE 76
01 SPECIFICATION 81
CONTENTS 82
SPECIFICATIONS 83
SPECIFICATION DRAWING 83
SPECIFICATION DRAWING: PC300-8M2 83
SPECIFICATION DRAWING: PC300LC-8M2 84
SPECIFICATION DRAWING: PC350-8M2 84
SPECIFICATION DRAWING: PC350LC-8M2 85
SPECIFICATION DRAWING: PC360-8M2 86
SPECIFICATION DRAWING: PC360LC-8M2 86
WORKING RANGE DRAWINGS 88
WORKING RANGE DRAWINGS: PC300-8M2 88
WORKING RANGE DRAWINGS: PC300LC-8M2 89
WORKING RANGE DRAWINGS: PC350-8M2 90
WORKING RANGE DRAWINGS: PC350LC-8M2 91
WORKING RANGE DRAWINGS: PC360-8M2 92
WORKING RANGE DRAWINGS: PC360LC-8M2 93
SPECIFICATIONS 94
SPECIFICATIONS: PC300-8M2 94
SPECIFICATIONS: PC300LC-8M2 96
SPECIFICATIONS: PC350-8M2 99
SPECIFICATIONS: PC350LC-8M2 102
SPECIFICATIONS: PC360-8M2 104
SPECIFICATIONS: PC360LC-8M2 107
WEIGHT TABLE 111
WEIGHT TABLE: PC300-8M2 111
WEIGHT TABLE: PC300LC-8M2 112
WEIGHT TABLE: PC350-8M2 113
WEIGHT TABLE: PC350LC-8M2 114
WEIGHT TABLE: PC360-8M2 116
WEIGHT TABLE: PC360LC-8M2 117
FUEL, COOLANT, LUBRICANT 119
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 119
10 STRUCTURE AND FUNCTION 121
CONTENTS 122
BOOT-UP SYSTEM 125
LAYOUT DRAWING OF BOOT-UP SYSTEM 125
SYSTEM OPERATING LAMP SYSTEM 126
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 126
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 126
OPERATION OF SYSTEM OPERATING LAMP 126
BATTERY DISCONNECT SWITCH 127
FUNCTION OF BATTERY DISCONNECT SWITCH 127
OPERATION OF BATTERY DISCONNECT SWITCH 127
ENGINE SYSTEM 128
LAYOUT DRAWING OF ENGINE SYSTEM 128
ENGINE CONTROL SYSTEM 130
ENGINE CONTROL SYSTEM DIAGRAM 130
OPERATION OF ENGINE CONTROL SYSTEM 130
AUTO-DECELERATION SYSTEM 132
AUTO-DECELERATION SYSTEM DIAGRAM 132
FUNCTION OF AUTO-DECELERATION SYSTEM 132
OPERATION OF AUTO-DECELERATION SYSTEM 133
ENGINE AUTOMATIC WARM-UP SYSTEM 134
SYSTEM DIAGRAM OF ENGINE AUTOMATIC WARM-UP SYSTEM 134
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 134
OPERATION OF ENGINE AUTOMATIC WARM-UP SYSTEM 134
OVERHEAT PREVENTION SYSTEM 135
SYSTEM DIAGRAM OF OVERHEAT PREVENTION SYSTEM 135
FUNCTION OF OVERHEAT PREVENTION SYSTEM 135
TURBOCHARGER PROTECTION SYSTEM 137
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 137
COOLING SYSTEM 138
LAYOUT DRAWING OF COOLING SYSTEM 138
SPECIFICATIONS OF COOLING SYSTEM 138
CONTROL SYSTEM 139
LAYOUT DRAWING OF CONTROL SYSTEM 139
MACHINE MONITOR SYSTEM 141
MACHINE MONITOR SYSTEM DIAGRAM 141
FUNCTION OF MACHINE MONITOR SYSTEM 141
KOMTRAX SYSTEM 143
KOMTRAX SYSTEM DIAGRAM 143
FUNCTION OF KOMTRAX SYSTEM 143
CONTROL SYSTEM 144
MACHINE MONITOR 144
GATEWAY FUNCTION CONTROLLER 154
COMMUNICATION TERMINAL 157
PUMP CONTROLLER 159
RESISTOR FOR PC-EPC VALVE 163
CAN TERMINATING RESISTOR 163
ENGINE CONTROLLER 164
FUEL CONTROL DIAL 168
HYDRAULIC SYSTEM 169
LAYOUT DRAWING OF HYDRAULIC SYSTEM 169
CLSS 172
STRUCTURE OF CLSS 172
OPERATION OF UNLOAD VALVE AND LS PRESSURE 174
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 175
PRESSURE COMPENSATION CONTROL 188
ENGINE AND PUMP COMBINED CONTROL SYSTEM 189
SYSTEM DIAGRAM OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 189
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 190
PUMP AND VALVE CONTROL SYSTEM 195
SYSTEM DIAGRAM OF PUMP AND VALVE CONTROL SYSTEM 195
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 195
HYDRAULIC SYSTEM 197
HYDRAULIC TANK 197
MAIN PUMP 200
CONTROL VALVE 220
WORK EQUIPMENT SYSTEM 279
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 279
ONE-TOUCH POWER MAXIMIZING SYSTEM 283
SYSTEM DIAGRAM OF ONE-TOUCH POWER MAXIMIZING SYSTEM 283
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 283
MACHINE PUSH-UP SYSTEM 285
SYSTEM DIAGRAM OF MACHINE PUSH-UP SYSTEM 285
FUNCTION OF MACHINE PUSH-UP SYSTEM 285
PPC LOCK SYSTEM 287
PPC LOCK SYSTEM DIAGRAM 287
FUNCTION OF PPC LOCK SYSTEM 288
ATTACHMENT OIL FLOW ADJUSTER SYSTEM 289
SYSTEM DIAGRAM OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM 289
FUNCTION OF ATTACHMENT OIL FLOW ADJUSTER SYSTEM 289
WORK EQUIPMENT SYSTEM 290
WORK EQUIPMENT AND SWING PPC VALVE 290
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 295
2ND-LINE ATTACHMENT PPC VALVE 298
SOLENOID VALVE 300
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 302
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 304
PILOT CIRCUIT ACCUMULATOR 306
ATTACHMENT CIRCUIT ACCUMULATOR 306
SWING SYSTEM 309
LAYOUT DRAWING OF SWING SYSTEM 309
SYSTEM DIAGRAM OF SWING CONTROL SYSTEM 311
FUNCTION OF SWING CONTROL SYSTEM 311
SWING SYSTEM 313
SWING MOTOR 313
SWING MACHINERY 321
SWING CIRCLE 323
TRAVEL SYSTEM 325
LAYOUT DRAWING OF TRAVEL SYSTEM 325
SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM 327
FUNCTION OF TRAVEL CONTROL SYSTEM 327
TRAVEL SYSTEM 329
TRAVEL MOTOR 329
FINAL DRIVE 341
TRAVEL PPC VALVE 342
CENTER SWIVEL JOINT 347
UNDERCARRIAGE AND FRAME 349
LAYOUT DRAWING OF UNDERCARRIAGE 349
SPECIFICATIONS OF UNDERCARRIAGE 349
WORK EQUIPMENT 351
STRUCTURE OF WORK EQUIPMENT 351
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 352
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 352
BUCKET CLEARANCE ADJUSTMENT SHIM 353
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 353
CAB RELATED PARTS 354
ROPS CAB 354
STRUCTURE OF ROPS CAB 354
FUNCTION OF ROPS CAB 354
CAB MOUNT 355
STRUCTURE OF CAB MOUNT 355
FUNCTION OF CAB MOUNT 356
CAB TIPPING STOPPER 357
STRUCTURE OF CAB TIPPING STOPPER 357
FUNCTION OF CAB TIPPING STOPPER 357
20 STANDARD VALUE TABLE 359
CONTENTS 360
STANDARD VALUE TABLE FOR ENGINE 361
STANDARD VALUE TABLE FOR ENGINE: PC300,300LC-8M2/PC350,350LC-8M2/PC360,360LC-8M2 361
STANDARD VALUE TABLE FOR MACHINE 364
STANDARD VALUE TABLE FOR MACHINE: PC300,300LC-8M2/PC350,350LC-8M2/PC360,360LC-8M2 364
MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE 376
30 TESTING AND ADJUSTING 379
CONTENTS 380
RELATED INFORMATION ON TESTING AND ADJUSTING 383
TOOLS FOR TESTING AND ADJUSTING 383
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 388
ENGINE AND COOLING SYSTEM 389
TEST ENGINE SPEED 389
TEST ENGINE HIGH IDLE SPEED 389
Test engine low idle speed 389
TEST ENGINE SPEED AT 2 PUMPS RELIEF 389
Test engine speed at 2 pumps relief and one-touch power maximizing 390
TEST ENGINE SPEED WITH AUTO-DECELERATION 390
Test boost pressure 392
TEST BOOST PRESSURE ON MACHINE MONITOR 392
TEST BOOST PRESSURE BY TESTING TOOL 393
TEST EXHAUST GAS COLOR 395
TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 395
TEST EXHAUST GAS COLOR BY SMOKE METER 396
TEST AND ADJUST VALVE CLEARANCE 398
TEST VALVE CLEARANCE 398
ADJUST VALVE CLEARANCE 400
TEST COMPRESSION PRESSURE 401
TEST COMPRESSION PRESSURE 401
TEST BLOWBY PRESSURE 406
TEST BLOWBY PRESSURE ON MACHINE MONITOR (MACHINE WITH BLOWBY PRESSURE SENSOR (OPT)) 406
TEST BLOWBY PRESSURE BY TESTING TOOL (MACHINE WITHOUT BLOWBY PRESSURE SENSOR) 407
TEST ENGINE OIL PRESSURE 409
TEST ENGINE OIL PRESSURE 409
TEST FUEL PRESSURE 411
TEST FUEL PRESSURE 412
TEST FUEL RETURN RATE AND LEAKAGE 417
TEST FUEL RETURN RATE AND LEAKAGE 418
BLEED AIR FROM FUEL SYSTEM 421
BLEED AIR FROM FUEL SYSTEM 421
Test fuel system for leakage 422
Test fuel circuit for leakage 422
CYLINDER CUT-OUT MODE OPERATION 424
NO-INJECTION CRANKING OPERATION 425
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 426
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 426
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 426
POWER TRAIN 427
Test swing circle bearing clearance 427
Test swing circle bearing clearance 427
UNDERCARRIAGE AND FRAME 428
Test and adjust track shoe tension 428
Test track shoe tension 428
Adjust track shoe tension 428
HYDRAULIC SYSTEM 430
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 430
RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK 430
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 430
Release remaining pressure from swing motor circuit 434
RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 434
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 435
Test oil pressure in work equipment, swing, and travel circuits 435
Adjust oil pressure in work equipment, swing, and travel circuits 443
TEST OIL PRESSURE OF CONTROL CIRCUIT 446
Test oil pressure of control circuit 446
Test and adjust oil pressure in pump PC control circuit 448
Test PC valve outlet pressure (servo piston inlet pressure) 448
TEST PC-EPC VALVE OUTLET PRESSURE 450
Adjust oil pressure in pump PC control circuit 451
Test and adjust oil pressure in pump LS control circuit 452
Test LS differential pressure by testing tool 452
Test LS valve outlet pressure (servo piston inlet pressure) 454
Test LS-EPC valve outlet pressure 456
Adjust LS valve 457
Test outlet pressure of solenoid valve 458
TEST OUTLET PRESSURE OF SOLENOID VALVE 458
OPERATING CONDITION OF SOLENOID VALVE 460
Test PPC valve outlet pressure 462
Test outlet pressure of PPC valve with machine monitor 462
TEST OUTLET PRESSURE OF PPC VALVE BY TESTING TOOL 463
Adjust play of work equipment and swing PPC valve 465
Adjust play of work equipment and swing PPC valve 465
Test parts causing hydraulic drift in work equipment 466
Test parts causing hydraulic drift of boom cylinder and bucket cylinder 466
Test parts causing hydraulic drift of arm cylinder 466
Test parts causing hydraulic drift of boom hydraulic drift prevention valve 467
Test parts causing hydraulic drift of PPC valve 467
TEST OIL LEAKAGE 468
Test oil leakage from travel motor 468
Test oil leakage from swing motor 469
TEST OIL LEAKAGE FROM BOOM CYLINDER 470
TEST OIL LEAKAGE FROM ARM CYLINDER 471
TEST OIL LEAKAGE FROM BUCKET CYLINDER 471
Bleed air from hydraulic system 473
Bleed air from main pump 474
BLEED AIR FROM CYLINDER 475
BLEED AIR FROM SWING MOTOR 476
BLEED AIR FROM TRAVEL MOTOR 476
CAB RELATED PARTS 478
Test cab tipping stopper 478
Test cab tipping stopper 478
METHOD FOR ADJUSTING MIRRORS 479
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 479
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 480
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 481
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 482
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 483
ELECTRICAL SYSTEM 485
SET AND OPERATE MACHINE MONITOR 485
OPERATOR MODE 489
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 489
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 489
CHECK FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 490
CHECK FUNCTION OF SERVICE METER 490
SET USAGE LIMITATION AND CHANGE MAINTENANCE PASSWORD 490
SERVICE MODE 493
OPERATE SERVICE MODE 493
Check pre-defined monitoring information 494
CHECK MONITORING INFORMATION 498
ABNORMALITY RECORD MENU 506
CHECK MAINTENANCE RECORD 509
MAINTENANCE MODE SETTING 511
Phone number entry setting 515
DEFAULT SETTING MENU 516
TESTING MENU 523
ADJUSTMENT MENU 525
NO-INJECTION CRANKING OPERATION 535
KOMTRAX SETTINGS MENU 538
Display service message 540
START UP KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 542
STOP USING OF KOMTRAX SYSTEM (MACHINE WITH GATEWAY FUNCTION CONTROLLER) 548
Adjust rearview camera angle 550
ADJUST REARVIEW CAMERA ANGLE 550
ENGINE CONTROLLER VOLTAGE CIRCUIT 552
HANDLE BATTERY DISCONNECT SWITCH 553
TEST DIODES 554
TEST DIODES BY DIGITAL TESTER 554
TEST DIODES BY ANALOG TESTER 554
Pm-CLINIC 555
Pm CLINIC SERVICE 555
Pm CLINIC CHECK SHEET: PC300,300LC-8M2/PC350,350LC-8M2/PC360,360LC-8M2 558
40 TROUBLESHOOTING 565
CONTENTS 566
RELATED INFORMATION FOR TROUBLESHOOTING 573
GENERAL TROUBLESHOOTING POINTS 573
SEQUENCE OF EVENTS IN TROUBLESHOOTING 574
CHECKS BEFORE TROUBLESHOOTING 576
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 578
WALK-AROUND CHECK 578
TEST ENGINE RELATED PARTS 579
TEST WORK EQUIPMENT AND UNDERCARRIAGE 581
CHECK ELECTRIC EQUIPMENT 582
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 587
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 587
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 587
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 588
PREPARATION FOR TROUBLESHOOTING OF GATEWAY FUNCTION CONTROLLER 588
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 588
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PUSH 593
DISCONNECT AND CONNECT DEUTSCH CONNECTOR 593
DISCONNECT AND CONNECT BOSCH CONNECTOR 593
DISCONNECT AND CONNECT AMP CONNECTOR 594
DISCONNECT AND CONNECT SUMITOMO CONNECTOR 595
DISCONNECT AND CONNECT CONNECTOR WITH LOCK TO PULL 596
DISCONNECT AND CONNECT DELPHI CONNECTOR AND PACKARD CONNECTOR 596
DISCONNECT AND CONNECT SLIDE TYPE CONNECTOR 597
DISCONNECT AND CONNECT FRAMATOME CONNECTOR 597
DISCONNECT AND CONNECT TYCO CONNECTOR 598
DISCONNECT AND CONNECT CONNECTOR WITH HOUSING TO ROTATE 599
PROCEDURE FOR TROUBLESHOOTING 600
INFORMATION DESCRIBED IN TROUBLESHOOTING 601
DIAGNOSE OPEN CIRCUIT OF HYDRAULIC PRESSURE SENSOR SYSTEM WIRING HARNESS 604
CONNECTORS LIST 607
CONNECTOR LAYOUT 613
CONNECTOR CONTACT IDENTIFICATION 619
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 661
FUSE LOCATION AND CONNECTION TABLE 667
FAILURE CODES TABLE 669
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 677
FAILURE CODE [602KNX] 677
FAILURE CODE [879AKA] 680
FAILURE CODE [879AKB] 682
FAILURE CODE [879BKA] 684
FAILURE CODE [879BKB] 687
FAILURE CODE [879CKA] 690
FAILURE CODE [879CKB] 692
FAILURE CODE [879DKZ] 694
FAILURE CODE [879EMC] 697
FAILURE CODE [879FMC] 699
FAILURE CODE [879GKX] 701
FAILURE CODE [989L00] 704
FAILURE CODE [989M00] 705
FAILURE CODE [989N00] 706
FAILURE CODE [AA10NX] 707
FAILURE CODE [AB00KE] 710
FAILURE CODE [B@BAZG] 712
FAILURE CODE [B@BAZK] 713
FAILURE CODE [B@BCNS] 715
FAILURE CODE [B@BCQA] 716
FAILURE CODE [B@BCZK] 718
FAILURE CODE [B@HANS] 720
FAILURE CODE [CA111] 721
FAILURE CODE [CA115] 722
FAILURE CODE [CA122] 723
FAILURE CODE [CA123] 725
FAILURE CODE [CA131] 727
FAILURE CODE [CA132] 729
FAILURE CODE [CA144] 731
FAILURE CODE [CA145] 733
FAILURE CODE [CA153] 735
FAILURE CODE [CA154] 737
FAILURE CODE [CA155] 739
FAILURE CODE [CA187] 740
FAILURE CODE [CA221] 742
FAILURE CODE [CA222] 744
FAILURE CODE [CA227] 746
FAILURE CODE [CA234] 747
FAILURE CODE [CA238] 748
FAILURE CODE [CA271] 750
FAILURE CODE [CA272] 752
FAILURE CODE [CA281] 754
FAILURE CODE [CA322] 755
FAILURE CODE [CA323] 757
FAILURE CODE [CA324] 759
FAILURE CODE [CA325] 761
FAILURE CODE [CA331] 763
FAILURE CODE [CA332] 765
FAILURE CODE [CA342] 767
FAILURE CODE [CA351] 768
FAILURE CODE [CA352] 769
FAILURE CODE [CA386] 771
FAILURE CODE [CA428] 772
FAILURE CODE [CA429] 774
FAILURE CODE [CA435] 776
FAILURE CODE [CA441] 777
FAILURE CODE [CA442] 779
FAILURE CODE [CA449] 780
FAILURE CODE [CA451] 781
FAILURE CODE [CA452] 783
FAILURE CODE [CA488] 785
FAILURE CODE [CA553] 786
FAILURE CODE [CA559] 787
FAILURE CODE [CA689] 791
FAILURE CODE [CA731] 796
FAILURE CODE [CA757] 798
FAILURE CODE [CA778] 799
FAILURE CODE [CA2185] 804
FAILURE CODE [CA2186] 806
FAILURE CODE [CA2249] 808
FAILURE CODE [CA2265] 809
FAILURE CODE [CA2266] 811
FAILURE CODE [CA2311] 813
FAILURE CODE [CA2555] 814
FAILURE CODE [CA2556] 817
FAILURE CODE [D110KB] 819
FAILURE CODE [D19JKZ] 822
FAILURE CODE [D811MC] 827
FAILURE CODE [D862KA] 828
FAILURE CODE [D8ALKA] 831
FAILURE CODE [D8ALKB] 835
FAILURE CODE [D8AQKR] 838
FAILURE CODE [D8ARKR] 847
FAILURE CODE [D8G1KT] 853
FAILURE CODE [D8G6KT] 854
FAILURE CODE [DA20MC] 855
FAILURE CODE [DA22KK] 856
FAILURE CODE [DA25KP] 861
FAILURE CODE [DA26KP] 866
FAILURE CODE [DA29KQ] 870
FAILURE CODE [DA2LKA] 875
FAILURE CODE [DA2LKB] 879
FAILURE CODE [DA2QKR] 882
FAILURE CODE [DA2RKR] 893
FAILURE CODE [DAF0MB] 902
FAILURE CODE [DAF0MC] 903
FAILURE CODE [DAF8KB] 904
FAILURE CODE [DAF9KQ] 906
FAILURE CODE [DAFGMC] 908
FAILURE CODE [DAFLKA] 910
FAILURE CODE [DAFLKB] 914
FAILURE CODE [DAFQKR] 917
FAILURE CODE [DAZ9KQ] 927
FAILURE CODE [DAZQKR] 929
FAILURE CODE [DB2QKR] 938
FAILURE CODE [DDPAKA] 948
FAILURE CODE [DGH2KA] 951
FAILURE CODE [DGH2KB] 954
FAILURE CODE [DHA4KA] 957
FAILURE CODE [DHE5MA] 960
FAILURE CODE [DHPAMA] 964
FAILURE CODE [DHPBMA] 968
FAILURE CODE [DHS3MA] 972
FAILURE CODE [DHS4MA] 976
FAILURE CODE [DHS8MA] 980
FAILURE CODE [DHS9MA] 984
FAILURE CODE [DHSAMA] 988
FAILURE CODE [DHSBMA] 992
FAILURE CODE [DHSCMA] 996
FAILURE CODE [DHSDMA]1000
FAILURE CODE [DHSFMA]1004
FAILURE CODE [DHSGMA]1008
FAILURE CODE [DHSHMA]1012
FAILURE CODE [DHSJMA]1016
FAILURE CODE [DKR2MA]1020
FAILURE CODE [DKR2NX]1024
FAILURE CODE [DR21KX]1026
FAILURE CODE [DR31KX]1028
FAILURE CODE [DV20KB]1029
FAILURE CODE [DW43KA]1032
FAILURE CODE [DW43KB]1035
FAILURE CODE [DW43KY]1038
FAILURE CODE [DW45KA]1040
FAILURE CODE [DW45KB]1044
FAILURE CODE [DW45KY]1048
FAILURE CODE [DW91KA]1051
FAILURE CODE [DW91KB]1053
FAILURE CODE [DW91KY]1056
FAILURE CODE [DWA2KA]1058
FAILURE CODE [DWA2KB]1060
FAILURE CODE [DWA2KY]1063
FAILURE CODE [DWJ0KA]1065
FAILURE CODE [DWJ0KB]1067
FAILURE CODE [DWJ0KY]1069
FAILURE CODE [DWK0KA]1070
FAILURE CODE [DWK0KB]1072
FAILURE CODE [DWK0KY]1075
FAILURE CODE [DWK2KA]1077
FAILURE CODE [DWK2KB]1079
FAILURE CODE [DWK2KY]1082
FAILURE CODE [DXA8KA]1084
FAILURE CODE [DXA8KB]1087
FAILURE CODE [DXE0KA]1091
FAILURE CODE [DXE0KB]1094
FAILURE CODE [DXE4KA]1097
FAILURE CODE [DXE4KB]1100
FAILURE CODE [DXE4KY]1103
FAILURE CODE [DY20KA]1105
FAILURE CODE [DY20MA]1110
FAILURE CODE [DY2CKB]1114
FAILURE CODE [DY2DKB]1119
FAILURE CODE [DY2EKB]1122
FAILURE CODE [F313KA]1125
FAILURE CODE [F313KB]1127
FAILURE CODE [F318KB]1130
FAILURE CODE [F318KY]1133
FAILURE CODE [F@BBZL]1135
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1138
ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1138
MANUAL PREHEATING SYSTEM DOES NOT WORK1148
AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1152
WHILE PREHEATING IS IN OPERATION, PREHEATING MONITOR DOES NOT LIGHT UP1156
WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR SHOWS NOTHING1161
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL CAUTION LAMP LIGHTS UP IN YELLOW1164
WHEN STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL CAUTION LAMP LIGHTS UP IN YELLOW1166
ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION1168
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP WHILE ENGINE IS IN OPERATION1170
AIR CLEANER CLOGGING MONITOR LIGHT UP IN YELLOW WHILE ENGINE IS IN OPERATION1172
CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1174
FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1178
WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1179
ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1180
HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS IN OPERATION1181
FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1183
FUEL GAUGE INDICATES INCORRECT LEVEL1186
COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1188
COOLANT TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE1189
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM1191
HYDRAULIC OIL TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE1194
MACHINE MONITOR SHOWS INCORRECT MODEL1196
SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1197
FUNCTION SWITCH DOES NOT OPERATE1198
AUTOMATIC WARM-UP SYSTEM DOES NOT OPERATE (IN COLD WEATHER)1199
AUTO-DECELERATION MONITOR DOES NOT LIGHT UP OR GO OUT WHILE AUTO-DECELERATION SWITCH IS OPERATED1201
AUTO-DECELERATION DOES NOT OPERATE OR IS NOT CANCELLED TO MEET LEVER OPERATION1202
WORK MODE SELECTOR SCREEN DOES NOT APPEAR WHILE WORK MODE SWITCH IS OPERATED1205
ENGINE AND HYDRAULIC PUMP SETTINGS DO NOT CHANGE WHILE WORK MODE IS CHANGED1206
TRAVEL SPEED MONITOR DOES NOT CHANGE WHILE TRAVEL SPEED SWITCH IS OPERATED1207
TRAVEL SPEED DOES NOT CHANGE WHILE TRAVEL SPEED IS CHANGED1208
ALARM BUZZER DOES NOT STOP1210
SERVICE METER IS NOT DISPLAYED WHILE STARTING SWITCH IS IN OFF POSITION1211
MACHINE DOES NOT CHANGE TO SERVICE MODE1212
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT OPERATE1213
ALL WORK EQUIPMENT, SWING OR TRAVEL DOES NOT LOCK1217
MACHINE DOES NOT SWING WHILE SWING PARKING BRAKE RELEASE SWITCH IS RELEASED1219
MACHINE SWINGS WHILE SWING PARKING BRAKE RELEASE SWITCH IS ON1223
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE NORMALLY OR MONITOR DOES NOT DISPLAY1226
ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT RELEASED1230
TRAVEL ALARM DOES NOT SOUND1232
TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS1235
HORN DOES NOT SOUND1237
HORN DOES NOT STOP1241
WIPER MONITOR DOES NOT LIGHT UP OR GO OUT WHILE WIPER SWITCH IS OPERATED1243
WIPER DOES NOT OPERATE WHEN WIPER SWITCH IS OPERATED1244
WINDOW WASHER DOES NOT OPERATE WHEN WINDOW WASHER SWITCH IS OPERATED1247
MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED1250
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE1252
BOOM RAISE IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1254
BOOM LOWER IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1255
ARM OUT IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION1256
ARM IN IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1257
BUCKET DUMP IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION1258
BUCKET CURL IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION1259
SWING IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1260
TRAVEL IS NOT SHOWN NORMALLY WITH MONITORING FUNCTION1261
SERVICE IN IS NOT DISPLAYED CORRECTLY WITH MONITORING FUNCTION1262
ATTACHMENT CIRCUIT CANNOT BE CHANGED1265
KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1267
QUICK COUPLER DOES NOT WORK1269
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1274
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (H MODE)1274
ALL WORK EQUIPMENTS, SWING AND TRAVEL DO NOT WORK1275
All WORK EQUIPMENTS, SWING, AND TRAVEL LACK SPEED OR POWER1277
FINE CONTROL PERFORMANCE OR RESPONSE IS POOR1290
UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP1295
ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1297
BOOM SPEED OR POWER IS LOW1306
Arm speed or power is low1318
BUCKET SPEED OR POWER IS LOW1329
WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1339
HYDRAULIC DRIFT OF BOOM IS LARGE1343
HYDRAULIC DRIFT OF ARM IS LARGE1345
HYDRAULIC DRIFT OF BUCKET IS LARGE1349
WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES1352
TIME LAG OF WORK EQUIPMENT IS LARGE1354
ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE1361
ATTACHMENT CIRCUIT CANNOT BE CHANGED1364
OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED1366
IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER1368
IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY1370
IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISE SPEED IS LOW1371
MACHINE DOES NOT TRAVEL STRAIGHT1372
MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW1383
TRAVEL SPEED IS SLOW1399
ONE OF TRACKS DOES NOT RUN1410
TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST1420
MACHINE DOES NOT SWING TO RIGHT OR LEFT1423
SWINGS ONLY IN ONE DIRECTION1428
SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)1431
SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION1438
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)1442
UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)1444
SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS1448
LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS1450
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1453
SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1455
FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR DOES NOT MOVE)1459
UNUSUAL NOISE IS HEARD FROM AROUND FAN1460
TROUBLESHOOTING OF ENGINE (S-MODE)1461
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1461
ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO1462
ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1463
FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1464
ENGINE STARTABILITY IS POOR1466
ENGINE DOES NOT PICK UP SMOOTHLY1468
ENGINE STOPS DURING OPERATION1470
ENGINE RUNS ROUGH OR IS UNSTABLE1472
ENGINE LACKS POWER1473
EXHAUST SMOKE IS BLACK1475
ENGINE OIL CONSUMPTION IS EXCESSIVE1477
OIL BECOMES CONTAMINATED QUICKLY1478
FUEL CONSUMPTION IS EXCESSIVE1479
OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)1480
OIL PRESSURE DROPS1481
FUEL MIXES INTO ENGINE OIL1482
WATER MIXES INTO ENGINE OIL (MILKY)1483
COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)1484
UNUSUAL NOISE IS HEARD1485
VIBRATION IS EXCESSIVE1486
AIR CANNOT BE BLED FROM FUEL CIRCUIT1487
50 DISASSEMBLY AND ASSEMBLY1489
CONTENTS1490
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY1493
HOW TO READ THIS MANUAL1494
COATING MATERIALS LIST1495
SPECIAL TOOLS LIST1500
SKETCHES OF SPECIAL TOOLS1506
PREPARATION1510
DRAIN AND ADD COOLANT1510
DRAIN COOLANT1510
ADD COOLANT1511
DRAIN AND ADD HYDRAULIC OIL1512
DRAIN HYDRAULIC OIL1512
ADD HYDRAULIC OIL1512
DRAIN AND ADD FUEL1514
DRAIN FUEL1514
ADD FUEL1514
COLLECT AND REFILL REFRIGERANT1515
COLLECT REFRIGERANT1515
REFILL REFRIGERANT1515
ENGINE AND COOLING SYSTEM1517
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY1517
REMOVE SUPPLY PUMP ASSEMBLY1517
INSTALL SUPPLY PUMP ASSEMBLY1521
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY1527
REMOVE CYLINDER HEAD ASSEMBLY1527
INSTALL CYLINDER HEAD ASSEMBLY1534
REMOVE AND INSTALL RADIATOR ASSEMBLY1549
REMOVE RADIATOR ASSEMBLY1549
INSTALL RADIATOR ASSEMBLY1551
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY1554
REMOVE HYDRAULIC OIL COOLER ASSEMBLY1554
INSTALL HYDRAULIC OIL COOLER ASSEMBLY1556
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY1559
REMOVE AFTERCOOLER ASSEMBLY1559
INSTALL AFTERCOOLER ASSEMBLY1559
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY1561
REMOVE ENGINE AND MAIN PUMP ASSEMBLY1561
INSTALL ENGINE AND MAIN PUMP ASSEMBLY1568
REMOVE AND INSTALL ENGINE FRONT OIL SEAL1576
REMOVE ENGINE FRONT OIL SEAL1576
INSTALL ENGINE FRONT OIL SEAL1577
REMOVE AND INSTALL ENGINE REAR OIL SEAL1580
REMOVE ENGINE REAR OIL SEAL1580
INSTALL ENGINE REAR OIL SEAL1582
POWER TRAIN1586
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY1586
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY1586
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY1587
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY1589
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY1590
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY1594
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY1602
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY1602
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY1603
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY1605
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY1605
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY1608
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY1616
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY1616
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY1616
UNDERCARRIAGE AND FRAME1618
SEPARATION AND CONNECTION OF TRACK ASSEMBLY1618
METHOD FOR SEPARATING TRACK ASSEMBLY1618
METHOD FOR INSTALLING TRACK ASSEMBLY1620
REMOVE AND INSTALL SPROCKET1623
METHOD FOR REMOVING SPROCKET1623
METHOD FOR INSTALLING SPROCKET1623
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY1625
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY1625
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY1626
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY1627
METHOD FOR DISASSEMBLING IDLER ASSEMBLY1627
METHOD FOR ASSEMBLING IDLER ASSEMBLY1628
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY1632
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY1633
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY1633
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY1635
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY1636
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY1637
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY1639
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY1639
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY1640
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY1643
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY1643
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY1645
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY1648
REMOVE COUNTERWEIGHT ASSEMBLY1648
INSTALL COUNTERWEIGHT ASSEMBLY1649
HYDRAULIC SYSTEM1651
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY1651
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY1651
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY1652
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY1655
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY1656
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY1657
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY1658
REMOVE HYDRAULIC TANK ASSEMBLY1658
INSTALL HYDRAULIC TANK ASSEMBLY1661
REMOVE AND INSTALL MAIN PUMP ASSEMBLY1665
REMOVE MAIN PUMP ASSEMBLY1665
INSTALL MAIN PUMP ASSEMBLY1669
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY1673
REMOVE CONTROL VALVE ASSEMBLY1673
INSTALL CONTROL VALVE ASSEMBLY1677
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY1681
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING1682
ASSEMBLE CONTROL VALVE ASSEMBLY1683
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY1688
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY1688
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY1689
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY1691
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY1691
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY1692
WORK EQUIPMENT1694
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY1694
REMOVE WORK EQUIPMENT ASSEMBLY1694
INSTALL WORK EQUIPMENT ASSEMBLY1696
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY1698
DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY1698
ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY1703
CAB RELATED PARTS1712
REMOVE AND INSTALL OPERATOR CAB ASSEMBLY1712
REMOVE OPERATOR CAB ASSEMBLY1712
INSTALL OPERATOR CAB ASSEMBLY1722
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)1733
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)1735
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)1735
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY1745
REMOVE FRONT WINDOW ASSEMBLY1745
INSTALL FRONT WINDOW ASSEMBLY1748
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY1754
REMOVE FLOOR FRAME ASSEMBLY1754
INSTALL FLOOR FRAME ASSEMBLY1760
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY1768
REMOVE AIR CONDITIONER UNIT ASSEMBLY1768
INSTALL AIR CONDITIONER UNIT ASSEMBLY1776
REMOVE AND INSTALL OPERATOR SEAT1784
REMOVE OPERATOR’S SEAT1784
INSTALL OPERATOR’S SEAT1785
REMOVE AND INSTALL SEATBELT1786
REMOVE SEATBELT1786
INSTALL SEATBELT1787
REMOVE AND INSTALL FRONT WIPER ASSEMBLY1788
REMOVE FRONT WIPER ASSEMBLY1788
INSTALL FRONT WIPER ASSEMBLY1793
ELECTRICAL SYSTEM1801
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY1801
REMOVE ENGINE CONTROLLER ASSEMBLY1801
INSTALL ENGINE CONTROLLER ASSEMBLY1802
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY1804
REMOVE PUMP CONTROLLER ASSEMBLY1804
INSTALL PUMP CONTROLLER ASSEMBLY1806
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY1810
REMOVE MACHINE MONITOR ASSEMBLY1810
INSTALL MACHINE MONITOR ASSEMBLY1813
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY1817
REMOVE GATEWAY FUNCTION CONTROLLER ASSEMBLY1817
INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY1821
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS1825
REMOVE COMMUNICATION TERMINAL WIRING HARNESS1825
INSTALL COMMUNICATION TERMINAL WIRING HARNESS1832
REMOVE AND INSTALL COMMUNICATION TERMINAL1841
REMOVE COMMUNICATION TERMINAL1841
INSTALL COMMUNICATION TERMINAL1843
60 MAINTENANCE STANDARD1845
CONTENTS1846
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD1847
ENGINE AND COOLING SYSTEM1849
MAINTENANCE STANDARD OF ENGINE MOUNT1849
MAINTENANCE STANDARD OF COOLING SYSTEM1851
POWER TRAIN1853
MAINTENANCE STANDARD OF SWING CIRCLE1853
MAINTENANCE STANDARD OF SWING MACHINERY1854
MAINTENANCE STANDARD OF FINAL DRIVE1856
MAINTENANCE STANDARD OF SPROCKET1858
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING1859
UNDERCARRIAGE AND FRAME1861
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION1861
MAINTENANCE STANDARD OF IDLER1863
MAINTENANCE STANDARD OF TRACK ROLLER1865
MAINTENANCE STANDARD OF CARRIER ROLLER1867
MAINTENANCE STANDARD OF TRACK SHOE1868
MAINTENANCE STANDARD OF TRIPLE SHOE1871
HYDRAULIC SYSTEM1872
MAINTENANCE STANDARD OF HYDRAULIC TANK1872
MAINTENANCE STANDARD OF MAIN PUMP1873
MAINTENANCE STANDARD OF SWING MOTOR1875
MAINTENANCE STANDARD OF TRAVEL MOTOR1878
MAINTENANCE STANDARD OF CONTROL VALVE1881
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE1892
MAINTENANCE STANDARD OF TRAVEL PPC VALVE1895
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)1898
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE1900
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE1901
MAINTENANCE STANDARD OF SOLENOID VALVE1903
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)1904
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)1905
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT1906
WORK EQUIPMENT1907
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE1907
DIMENSIONS OF ARM1910
DIMENSIONS OF BUCKET1913
MAINTENANCE STANDARD OF BOOM CYLINDER1916
MAINTENANCE STANDARD OF ARM CYLINDER1917
MAINTENANCE STANDARD OF BUCKET CYLINDER1918
80 OTHERS1919
CONTENTS1920
ABBREVIATION1922
AIR CONDITIONER SYSTEM1927
PRECAUTIONS FOR REFRIGERANT1927
LAYOUT DRAWING OF AIR CONDITIONER SYSTEM1928
SPECIFICATION OF AIR CONDITIONER1930
CONFIGURATION OF REFRIGERATION CYCLE1931
FUNCTION OF REFRIGERATION CYCLE1932
SYSTEM DIAGRAM OF AIR CONDITIONER1933
COMPONENT PARTS OF AIR CONDITIONER SYSTEM1934
AIR CONDITIONER UNIT1934
STRUCTURE OF AIR CONDITIONER UNIT1935
FUNCTION OF AIR CONDITIONER UNIT1936
COMPONENT PARTS OF AIR CONDITIONER UNIT1937
AIR CONDITIONER CONTROLLER1941
STRUCTURE OF AIR CONDITIONER CONTROLLER1941
FUNCTION OF AIR CONDITIONER CONTROLLER1941
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER1941
COMPRESSOR1943
STRUCTURE OF COMPRESSOR1943
SPECIFICATIONS OF COMPRESSOR1943
FUNCTION OF COMPRESSOR1943
OPERATION OF COMPRESSOR1943
CONDENSER1944
STRUCTURE OF CONDENSER1944
SPECIFICATIONS OF CONDENSOR1944
FUNCTION OF COMPRESSOR1944
AIR CONDITIONER RELATED SENSORS1946
STRUCTURE OF SUNLIGHT SENSOR1946
FUNCTION OF SUNLIGHT SENSOR1946
STRUCTURE OF OUTSIDE TEMPERATURE SENSOR1946
FUNCTION OF OUTSIDE AIR TEMPERATURE SENSOR1946
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS OF AIR CONDITIONER1947
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS1949
TEST AIR LEAKAGE (DUCT CONNECTION)1953
TEST AIR LEAKAGE (DUCT CONNECTION)1953
TEST AIR CONDITIONER BY SELF-DIAGNOSIS FUNCTION1956
TEST VENT (MODE) CHANGEOVER1957
TEST VENT (MODE) CHANGEOVER1957
TEST FRESH/RECIRC AIR CHANGEOVER1959
TEST FRESH/RECIRC AIR CHANGEOVER1959
TEST SUNLIGHT SENSOR1960
TEST SUNLIGHT SENSOR1960
TEST DUAL PRESSURE SWITCH1961
TEST DUAL PRESSURE SWITCH1961
TEST RELAY1962
TEST RELAY1962
SIMPLE CHECK OF REFRIGERANT VOLUME THROUGH SIGHT GLASS1964
PROCEDURE FOR TROUBLE SHOOTING OF AIR CONDITIONER1965
INFORMATION DESCRIBED IN TROUBLESHOOTING1966
FAILURE CODE [879AKA]1969
FAILURE CODE [879AKB]1971
FAILURE CODE [879BKA]1973
FAILURE CODE [879BKB]1976
FAILURE CODE [879CKA]1979
FAILURE CODE [879CKB]1981
FAILURE CODE [879DKZ]1983
FAILURE CODE [879EMC]1986
FAILURE CODE [879FMC]1988
FAILURE CODE [879GKX]1990
AIR CONDITIONER DOES NOT OPERATE1993
DEFECTIVE COOLING1996
HEATER DOES NOT OPERATE2005
COOL AIR DOES NOT COME OUT2009
NO AIR COMES OUT OR AIR FLOW IS ABNORMAL2015
FRESH/RECIRC AIR CHANGEOVER NOT POSSIBLE2019
CONNECT SERVICE TOOL2023
CONNECT SERVICE TOOL2024
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF AIR CONDITIONER PIPING2025
HANDLE COMPRESSOR OIL2027
REPLACE DESICCANT2029
90 CIRCUIT DIAGRAMS2031
CONTENTS2032
HOW TO READ THE CODES FOR ELECTRIC CABLE2033
HYDRAULIC CIRCUIT DIAGRAM2037
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2037
HYDRAULIC CIRCUIT DIAGRAM2041
ELECTRICAL CIRCUIT DIAGRAM2043
SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM2043
ELECTRICAL CIRCUIT DIAGRAM(1/6)2047
ELECTRICAL CIRCUIT DIAGRAM(2/6)2049
ELECTRICAL CIRCUIT DIAGRAM(3/6)2051
ELECTRICAL CIRCUIT DIAGRAM(4/6)2053
ELECTRICAL CIRCUIT DIAGRAM(5/6)2055
ELECTRICAL CIRCUIT DIAGRAM(6/6)2057
INDEX2059
S.M 30/12/24
