Komatsu Hydraulic Excavator PC45MR-5 PC55MR-5 Shop Manual (SEN06574-14) PDF

Description

Komatsu COMPACT Hydraulic Excavator PC45MR-5 PC55MR-5 Shop Manual (SEN06574-14) – PDF DOWNLOAD

FILE DETAILS:

Komatsu COMPACT Hydraulic Excavator PC45MR-5 PC55MR-5 Shop Manual (SEN06574-14) – PDF DOWNLOAD

Language : English
Pages :1272
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu COMPACT Hydraulic Excavator PC45MR-5 PC55MR-5 Shop Manual (SEN06574-14) – PDF DOWNLOAD

SERIAL NUMBERS PC45MR-30001
PC55MR-20001 and up

TABLE OF CONTENTS:

Komatsu COMPACT Hydraulic Excavator PC45MR-5 PC55MR-5 Shop Manual (SEN06574-14) – PDF DOWNLOAD

SERIAL NUMBERS PC45MR-30001
PC55MR-20001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 13
Foreword, Safety, Basic Information 19
How to Read the Shop Manual 19
Safety Notice for Operation 21
Precautions to Prevent Fire 30
Procedures If Fire Occurs 32
Precautions When You Discard Waste Materials 33
Precautions When You Handle Hydraulic Equipment 34
Precautions When You Disconnect and Connect Pipings 37
Precautions When You Handle Electrical Equipment 44
Precautions When You Handle Fuel System Equipment 46
Precautions When You Handle Intake System Equipment 47
Practical Use of KOMTRAX 48
Disconnect and Connect Push-Pull Type Coupler 49
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 49
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 50
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 51
Precautions for Disconnection and Connection of Connectors 53
Disconnect and Connect Deutsch Connector 57
How to Disconnect and Connect Slide Lock Type Connector 58
Disconnect and Connect Connector with Lock to Pull 60
Disconnect and Connect Connector with Lock to Push 61
Disconnect and Connect Connector with Housing to Rotate 63
How to Read the Codes for Electric Cable 64
Explanation of Terms for Maintenance Standard 68
Standard Tightening Torque Table 71
Conversion Table 78
01 Specification 83
Table of Contents 84
Abbreviation List 85
Specifications 91
Specification Drawing 91
Specification Drawing: PC45MR-5 91
Specification Drawing: PC55MR-5 93
Working Range Drawings 95
Working Range: PC45MR-5 95
Working Range: PC55MR-5 96
Specifications 97
Specifications: PC45MR-5 97
Specifications: PC55MR-5 101
Weight Table 105
Weight Table: PC45MR-5 105
Weight Table: PC55MR-5 107
Table of Fuel, Coolant, and Lubricants 109
10 Structure and Function 111
Table of Contents 112
Abbreviation List 114
Boot-up System 120
Layout Drawing of Boot-up System 120
System Operating Lamp System 122
System Diagram of System Operating Lamp System 122
Function of Operation Lamp System 122
Battery Disconnect Switch 124
Function of Battery Disconnect Switch 124
Engine System 125
Layout Drawing of Engine System 125
Engine Control System 126
System Diagram of Engine Control 126
Function of Engine Control System 127
Auto-Deceleration System 130
System Diagram of Auto-Deceleration System 130
Function of Auto-Deceleration System 130
Operation of Auto-Deceleration System 131
Overheat Prevention System 132
Overheat Prevention System Diagram 132
Function of Overheat Prevention System 133
Automatic Idle Stop System 134
System Diagram of Automatic Idle Stop System 134
Function of Automatic Idle Stop System 134
Component Parts of Engine System 136
PTO 136
Cooling System 137
Layout Drawing of Cooling System 137
Specifications of Cooling System 138
Control System 139
Layout Drawing of Control System 139
Machine Monitor System 140
System Diagram of Machine Monitor System 140
KOMTRAX System 141
System Diagram of KOMTRAX System 141
Function of KOMTRAX System 141
Component Parts of Control System 142
Machine Monitor 142
KOMTRAX Terminal 150
Machine Controller 152
Fuel Control Dial 156
Hydraulic System 158
Layout Drawing of Hydraulic System 158
CLSS 160
Structure of CLSS 160
Function of CLSS 161
Engine and Pump Combined Control System 163
Engine and Pump Combined Control System Diagram 163
Function of Engine and Pump Combined Control System 164
Component Parts of Hydraulic System 166
Hydraulic Tank 166
Main Pump 170
Control Valve 182
Work Equipment System 226
Layout Drawing of Work Equipment System 226
Structure of Valve Control 230
PPC Lock System 232
System Diagram of PPC Lock 232
Function of PPC Lock System 233
Work Equipment and Travel Automatic Lock System 234
Function of Work Equipment and Travel Automatic Lock System 234
Operation of Lock Lever Automatic Lock System 234
Attachment Oil Flow Adjuster System 235
Attachment Oil Flow Adjuster System Diagram 235
Function of Attachment Oil Flow Adjuster System 236
Component Parts of Work Equipment System 237
Work Equipment and Swing PPC Valve 237
Attachment PPC Valve 242
Blade PPC Valve 244
Boom Swing PPC Valve 246
Bipartite Solenoid Valve 248
Multi-Control Valve 251
Pilot Circuit Accumulator 252
Swing System 253
Layout Drawing of Swing System 253
Component Parts of Swing System 254
Swing Motor 254
Swing Machinery 261
Swing Circle 263
Travel System 264
Layout Drawing of Travel System 264
System Diagram of Travel Control System 266
Function of Travel Control System 266
Component Parts of Travel System 268
Travel Motor 268
Travel PPC Valve 276
Center Swivel Joint 278
Undercarriage and Frame 279
Layout Drawing of Undercarriage 279
Specifications of Undercarriage 279
Idler Cushion 280
Structure of Idler Cushion 280
Specifications of Idler Cushion 280
Work Equipment 281
Structure of Work Equipment 281
Function of Work Equipment 282
Work Equipment Clearance Adjustment Shim 283
Function of Work Equipment Clearance Adjustment Shim 283
CAB Related Parts 284
ROPS CAB 284
Structure of ROPS CAB 284
Function of ROPS CAB 284
Tilt Type Floor 285
Structure of Tilt Type Floor 285
Function of Tilt Type Floor 285
20 Standard Value Table 287
Table of Contents 288
Abbreviation List 289
Standard Value Table for Engine 295
Standard Value Table for Engine: PC45MR-5 295
Standard Value Table for Engine: PC55MR-5 297
Standard Value Table for Machine 299
Standard Value Table for Machine: PC45MR-5 299
Standard Value Table for Machine: PC55MR-5 311
Machine Posture and Procedures to Measure Performance 323
30 Testing and Adjusting 327
Table of Contents 328
Abbreviation List 331
Precautions Before Work 337
Related Information on Testing and Adjusting 338
Tools for Testing and Adjusting 338
Sketch of Tools for Testing and Adjusting 342
Engine and Cooling System 344
Examine Engine Speed 344
How to Examine Engine Speed 344
Examine Exhaust Gas Color 346
How to Examine Exhaust Gas Color with the Handy Smoke Checker 346
How to Examine Exhaust Gas Color with Smoke Meter 347
Examine and Adjust Valve Clearance 348
Check Valve Clearance 348
Adjust Valve Clearance 349
Examine Compression Pressure 350
How to Examine Compression Pressure 350
Examine Engine Oil Pressure 352
How to Examine Engine Oil Pressure 352
Bleed Air from Fuel System 354
How to Bleed Air from Fuel System 354
Examine Fuel Circuit for Leakage 356
How to Examine Fuel System for Leakage 356
Handle Cylinder Cut-out Mode Operation 357
Examine and Adjust Alternator Belt Tension 358
How to Examine Alternator Belt Tension 358
Adjust Alternator Belt Tension 358
Examine and Adjust Air Conditioner Compressor Belt Tension 359
How to Examine and Adjust Air Conditioner Compressor Belt Tension 359
Power Train 361
Examine Swing Circle Bearing Clearance 361
How to Examine Swing Circle Bearing Clearance 361
Undercarriage and Frame 362
Examine and Adjust Track Tension 362
How to Examine Track Tension 362
How to Adjust Track Tension 362
Hydraulic System 364
Release Remained Pressure in Hydraulic Circuit 364
How to Release Remained Pressure from Hydraulic Tank 364
How to Release Remained Pressure in PPC Accumulator Circuit 364
How to Release Remained Pressure in Hydraulic Cylinder Circuit 364
How to Release Remained Pressure from Swing Motor Circuit 369
How to Release Remained Pressure from Travel Motor Circuit 369
Examine and Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 370
How to Examine Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 370
Adjust Oil Pressure in Work Equipment, Travel, and Boom Swing Circuits 380
Examine and Adjust Swing and Blade Circuit Oil Pressure 381
How to Examine Oil Pressure in Swing and Blade Circuits 381
Adjust Oil Pressure in Swing and Blade Circuits 386
Examine and Adjust Oil Pressure in Control Circuit 388
Examine Oil Pressure in Control Circuit 388
Adjust Oil Pressure in Control Circuit 390
Adjust Oil Pressure in Pump PC Control Circuit 392
How to Adjust Oil Pressure in Pump PC Control Circuit 392
Examine and Adjust Oil Pressure in Pump LS Control Circuit 394
Examine LS Differential Pressure with Machine Monitor 394
Examine LS Differential Pressure by Testing Tool 395
Adjust LS Valve 397
Examine Outlet Pressure of Solenoid Valve 398
How to Examine Outlet Pressure of Solenoid Valve by Machine Monitor 398
How to Examine Outlet Pressure of Solenoid Valve by Testing Tool 399
Operating Condition of Solenoid Valve 400
Examine PPC Valve Outlet Pressure 401
How to Examine Outlet Pressure of PPC Valve with Machine Monitor 401
How to Examine Outlet Pressure of PPC Valve by Testing Tool 404
Adjust Play of Work Equipment and Swing PPC Valves 406
How to Adjust Play of Work Equipment and Swing PPC Valves 406
Examine Swing Parking Brake Release Pressure 407
How to Examine Swing Parking Brake Release Pressure with Machine Monitor 407
How to Examine Swing Parking Brake Release Pressure by Testing Tool 407
Examine and Adjust Travel Deviation 409
How to Examine Travel Deviation 409
How to Adjust Travel Deviation 409
Examine Parts Which Cause Hydraulic Drift of Work Equipment 412
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 412
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder 412
How to Examine Parts that Cause Hydraulic Drift of PPC Valve 413
Examine Oil Leakage 414
How to Examine Oil Leakage from Boom Cylinder 414
How to Examine Oil Leakage from Arm Cylinder 414
How to Examine Oil Leakage from Bucket Cylinder 415
How to Examine Oil Leakage from Blade Cylinder 415
Bleed Air from Hydraulic System 417
How to Bleed Air from Hydraulic System 418
Pressurize Hydraulic Tank 420
How to Pressurize Hydraulic Tank 420
CAB Related Parts 421
How to Open and Close Floor Unit 421
Procedure to Open Floor Unit 422
Procedure to Close Floor Unit 427
Electrical System 431
Set and Operate Machine Monitor 431
Operator Mode 434
Examine Function by LCD (Liquid Crystal Display) 434
Examine Function of Service Meter 434
Usage Limitation and Maintenance Password Change Function 434
Service Mode 437
How to Operate Service Mode 437
How to See Pre-defined Monitoring Information 438
How to Examine Self-Define Monitor Information 442
Abnormality Record Menu 449
How to See Maintenance Record 452
Maintenance Mode Setting 453
Set Phone Number Entry 457
Default Menu 459
Diagnostic Tests Menu 464
Adjustment Menu 472
How to Operate Battery Disconnect Switch Setting 476
KOMTRAX Settings Menu 478
Show Service Message 480
How to Start Up KOMTRAX Terminal 482
Handle Voltage Circuit of Engine Controller 486
Examine Diodes 487
Examine Diodes by Digital Tester 487
How to Examine Diodes by Analog Tester 487
Pm Clinic 488
Pm Clinic Service 488
Pm Clinic Check Sheet: PC45MR-5 489
Pm Clinic Check Sheet: PC55MR-5 496
40 Troubleshooting 503
Table of Contents 504
Abbreviation List 508
Precautions Before Work 514
Related Information to Troubleshooting 515
General Troubleshooting Points 515
Sequence of Events in Troubleshooting 516
Checks Before Troubleshooting 518
Inspection Procedure Before Troubleshooting 520
Walk-Around Check 520
Test in Accordance with Testing Procedure 522
Examine Fuel Level and Type 522
Examine Fuel Prefilter 523
Examine Water Separator, Drain Water and Sediment 525
Examine Fuel Main Filter 526
Examine Engine Oil Level (Oil Quantity in Oil Pan) 529
Examine Coolant Level (Reservoir Tank) 530
Examine Air Cleaner Clogging 531
Clean Outer Element (Single Element) 532
Clean Outer Element (Double Element) 535
Replace Single Element 537
Replace Double Element 539
Examine Hydraulic Oil Level 541
Examine Hydraulic Oil Strainer 545
Examine Hydraulic Oil Filter 546
Examine Oil Level in Final Drive Case 548
Bleed Air from Fuel System 548
Bleed Air from Hydraulic System 548
How to Examine Electric Equipment 548
Preparation for Troubleshooting of Electrical System 556
Procedure for Troubleshooting 560
Symptom and Troubleshooting Numbers 563
Information Shown in Troubleshooting Table 567
Connector List and Layout 569
Connector Contact Identification (For 4D88E-7 Engine) 585
T-Branch Box and T-Branch Adapter Table 589
Fuse Location Table 595
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 599
Failure Code Table 601
Troubleshooting by Failure Code (Display of Code) 611
Failure Code [989L00] 611
Failure Code [989M00] 612
Failure Code [989N00] 613
Failure Code [AQ20R1] 614
Failure Code [B@BCNS] 615
Failure Code [D19JKZ] 616
Failure Code [D811MC] 619
Failure Code [D862KA] 620
Failure Code [D8ALKA] 621
Failure Code [D8ALKB] 623
Failure Code [D8AQKR] 625
Failure Code [DAF0KT] 627
Failure Code [DAF0MB] 628
Failure Code [DAF0MC] 629
Failure Code [DAF3KK] 630
Failure Code [DAF9KQ] 632
Failure Code [DAFGMC] 633
Failure Code [DAFLKA] 634
Failure Code [DAFLKB] 636
Failure Code [DAFQKR] 638
Failure Code [DB2QKR] 639
Failure Code [DBH0MC] 643
Failure Code [DBH2KK] 644
Failure Code [DBH5KP] 647
Failure Code [DBH5KP] 649
Failure Code [DBH9KQ] 651
Failure Code [DBHLKA] 653
Failure Code [DBHLKB] 655
Failure Code [DBHQKR] 657
Failure Code [DDNRKA] 662
Failure Code [DDNRKY] 664
Failure Code [DDNS00] 666
Failure Code [DDWLKA] 668
Failure Code [DDWLKB] 670
Failure Code [DFB1KZ] 672
Failure Code [DFB3L8] 674
Failure Code [DFB5KZ] 676
Failure Code [DHS1MA] 678
Failure Code [DHS5MA] 680
Failure Code [DKULKA] 682
Failure Code [DKULKB] 684
Failure Code [DKULKY] 686
Failure Code [DV00KB] 688
Failure Code [DV20KB] 689
Failure Code [DW43KA] 691
Failure Code [DW43KB] 693
Failure Code [DW43KY] 695
Failure Code [DW4CKY] 696
Failure Code [DXA8KA] 698
Failure Code [DXA8KB] 700
Failure Code [DXE7KA] 702
Failure Code [DXE7KB] 704
Failure Code [DXE7KY] 706
Failure Code [DXEAKA] 708
Failure Code [DXEAKB] 710
Failure Code [DXEAKY] 712
Troubleshooting of Electrical System (E-Mode) 714
E-1 Engine Does Not Start (Engine Does Not Crank) 714
E-2 Engine Does Not Start (Fuel Feed Pump System) 720
E-3 Automatic Preheating System Does Not Operate 722
E-4 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing 724
E-5 Engine Coolant Temperature Monitor Comes On in White While Engine Runs 727
E-6 Charge Level Monitor Comes On in Red While Engine is in Operation 728
E-7 Fuel Level Monitor Comes On in Red While Engine Runs 729
E-8 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 730
E-9 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 731
E-10 Fuel Gauge Display Does Not Move from Minimum or Maximum 732
E-11 Display of Fuel Gauge is Different from Actual Fuel Level 734
E-12 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 735
E-13 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 736
E-14 Some Areas of Machine Monitor Screen are Not Shown 737
E-15 Function Switch Does Not Operate 738
E-16 Auto-Decelerator is Not Operated or Canceled with Lever 739
E-17 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 740
E-18 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 741
E-19 Alarm Buzzer Does Not Sound 743
E-20 Alarm Buzzer Cannot be Canceled 744
E-21 Service Meter is Not Shown, While Starting Switch is in OFF Position 745
E-22 Service Mode Cannot be Selected 746
E-23 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 747
E-24 All of Work Equipment, Swing, and Travel Mechanism Do Not Lock 749
E-25 Alarm Does Not Sound During Travel 751
E-26 Travel Alarm Does Not Stop When Machine Stops 753
E-27 Horn Does Not Sound 754
E-28 Horn Does Not Sound (For Proportional Lever Spec) 756
E-29 Horn Does Not Stop 758
E-30 Horn Does Not Stop (For Proportional Lever Spec) 760
E-31 Working Lamp or Travel Lamp Does Not Come On (Canopy Spec) 762
E-32 Working Lamp, Travel Lamp, and Additional Lamp Do Not Come On (CAB Spec) 766
E-33 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 770
E-34 When Window Washer Switch is Operated, Window Washer Does Not Operate 772
E-35 Travel Indicator is Not Shown Correctly with Monitoring Function 774
E-36 Swing or Arm IN is Not Shown Normally in Monitoring Function 775
E-37 Work Equipment is Not Shown Normally in Monitoring Function 776
E-38 KOMTRAX System Does Not Operate Normally 778
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 779
Information Shown in Troubleshooting Table (H-Mode) 779
H-1 All Work Equipment, Travel, Swing or Blade Do Not Operate 780
H-2 All Work Equipment or Travel Does Not Operate 781
H-3 Travel or Blade Does Not Operate 782
H-4 Swing or Blade Does Not Operate 783
H-5 All Work Equipment, Travel, Swing and Blade Speed or Power is Low 784
H-6 All Work Equipment and Travel Speed or Power is Low 785
H-7 Travel and Blade Speed or Power is Low 786
H-8 Swing and Blade Speed or Power is Low 787
H-9 Fine Control Performance or Response is Unsatisfactory 788
H-10 Unusual Noise is Heard from Around Hydraulic Pump 789
H-11 Engine Speed Drops Largely or Engine Stops 790
H-12 All Work Equipment Speed or Power is Low 792
H-13 All Work Equipment and Blade Speed or Power is Low 793
H-14 Blade Does Not Operate 794
H-15 All Work Equipment Do Not Operate 795
H-16 All Work Equipment or Blade Do Not Operate 796
H-17 Speed or Power of Boom is Low 797
H-18 Arm Speed or Power is Low 799
H-19 Bucket Speed or Power is Low 800
H-20 Blade Speed or Power is Low 801
H-21 Boom Swing Speed or Power is Low 803
H-22 Work Equipment Does Not Move in Single Operation 804
H-23 Hydraulic Drift of Boom is Large 805
H-24 Hydraulic Drift of Arm is Large 806
H-25 Hydraulic Drift of Bucket is Large 807
H-26 Hydraulic Drift of Blade is Large 808
H-27 Time Lag of Work Equipment is Large 810
H-28 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 811
H-29 Machine Does Not Travel Straight 812
H-30 Machine Does Not Move Off Straight 814
H-31 Machine is Not Steered Correctly or Steering Power is Low 815
H-32 Travel Speed is Low 817
H-33 Two Sides of Crawlers Do Not Move 819
H-34 One of Tracks Does Not Run 820
H-35 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 822
H-36 Upper Structure Does Not Swing to Right and Left 823
H-37 Upper Structure Swings Only to Right or Left 825
H-38 Swing Acceleration or Swing Speed is Low in Right and Left Directions 827
H-39 Swing Acceleration or Swing Speed is Low in Only One Direction 829
H-40 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 830
H-41 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 831
H-42 Shock is Large When Upper Structure Stops Swing Operation 832
H-43 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation 833
H-44 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 834
H-45 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 835
Troubleshooting of Engine (S-Mode) 836
Information Shown in Troubleshooting Table (S-Mode) 836
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 837
S-2 Engine Cranks but No Exhaust Smoke Comes Out 838
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 839
S-4 Engine Startability is Unsatisfactory 840
S-5 Engine Does Not Pick Up Smoothly 842
S-6 Engine Stops During Operation 844
S-7 Engine Runs Rough or is Not Stable 845
S-8 Engine Lacks Power 846
S-9 KDPF Becomes Clogged in a Short Time 848
S-10 Engine Oil Consumption is Excessive 849
S-11 Oil Becomes Dirty Quickly 850
S-12 Fuel Consumption is Excessive 851
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 852
S-14 Oil Pressure Drops 853
S-15 Fuel Mixes Into Engine Oil 855
S-16 Water Mixes Into Engine Oil (Milky) 856
S-17 Coolant Temperature Increases Too High (Overheating) 857
S-18 Unusual Noise is Heard 858
S-19 Vibration is Excessive 859
S-20 Air Cannot be Bled from Fuel Circuit 860
50 Disassembly and Assembly 861
Table of Contents 862
Abbreviation List 865
Precautions Before Work 871
Related Information on Disassembly and Assembly 872
How to Read This Manual 872
Coating Materials List 873
Special Tool List 878
Sketches of Special Tools 883
Engine and Cooling System 884
Remove and Install Supply Pump Assembly 884
Remove Supply Pump Assembly 884
Install Supply Pump Assembly 887
Remove and Install Starter Assembly 891
Remove Starting Motor Assembly 891
Install Starting Motor Assembly 892
Remove and Install Radiator Assembly 893
How to Remove Radiator Assembly 893
How to Install Radiator Assembly 896
Remove and Install Hydraulic Oil Cooler Assembly 900
How to Remove Hydraulic Oil Cooler Assembly 900
How to Install Hydraulic Oil Cooler Assembly 903
Remove and Install Engine and Main Pump Assembly 907
Remove Engine and Main Pump Assembly 907
Install Engine and Main Pump Assembly 913
Remove and Install Fuel Tank Assembly 920
Remove Fuel Tank Assembly 920
Install Fuel Tank Assembly 922
Remove and Install KDPF Assembly 925
How to Remove KDPF Assembly 925
How to Install KDPF Assembly 927
Disassemble and Assemble KDPF Assembly 929
Power Train 930
Remove and Install Travel Motor and Final Drive Assembly 930
Remove Travel Motor and Final Drive Assembly 930
Install Travel Motor and Final Drive Assembly 932
Disassemble and Assemble Final Drive Assembly 934
How to Disassemble Final Drive Assembly 934
How to Assemble Final Drive Assembly 938
Remove and Install Swing Motor and Swing Machinery Assembly 943
Remove Swing Motor and Swing Machinery Assembly 943
Install Swing Motor and Swing Machinery Assembly 944
Disassemble and Assemble Swing Machinery Assembly 945
Disassemble Swing Machinery Assembly 945
Assemble Swing Machinery Assembly 948
Remove and Install Swing Circle Assembly 952
Remove Swing Circle Assembly 952
Install Swing Circle Assembly 952
Undercarriage and Frame 953
Disassemble and Assemble Recoil Spring Assembly 953
Disassemble Recoil Spring Assembly 953
Assemble Recoil Spring Assembly 954
Separate and Connect Track Assembly 956
Separate Track Assembly 956
Install Track Assembly 956
Disassemble and Assemble Idler Assembly 958
Disassemble Idler Assembly 958
Assemble Idler Assembly 959
Disassemble and Assemble Track Roller Assembly 961
Disassemble Track Roller Assembly 961
Assemble Track Roller Assembly 962
Disassemble and Assemble Carrier Roller Assembly 964
Disassemble Carrier Roller Assembly 964
Assemble Carrier Roller Assembly 965
Remove and Install Revolving Frame Assembly 967
Remove Revolving Frame Assembly 967
Install Revolving Frame Assembly 968
Remove and Install Counterweight Assembly 970
Remove Counterweight Assembly 970
Install Counterweight Assembly 973
Hydraulic System 978
Remove and Install Center Swivel Joint Assembly 978
Remove Center Swivel Joint Assembly 978
Install Center Swivel Joint Assembly 979
Disassemble and Assemble Center Swivel Joint Assembly 982
Disassemble Center Swivel Joint Assembly 983
Assemble Center Swivel Joint Assembly 984
Remove and Install Hydraulic Tank Assembly 985
Remove Hydraulic Tank Assembly 985
How to Install Hydraulic Tank Assembly 988
Remove and Install Main Pump Assembly 991
Remove Main Pump Assembly 991
Install Main Pump Assembly 993
Remove and Install Accumulator Assembly 997
How to Remove Accumulator Assembly (EU Specification) 997
How to Remove Accumulator Assembly (North America Specification, for Machine with Quick Coupler) 998
How to Install Accumulator Assembly (EU Specification)1000
How to Install Accumulator Assembly (North America Specification, for Machine with Quick Coupler)1001
Disassemble and Assemble Work Equipment PPC Valve Assembly1003
Disassemble Work Equipment PPC Valve Assembly1003
How to Assemble Work Equipment PPC Valve Assembly1004
Disassemble and Assemble Travel PPC Valve Assembly1006
Disassemble Travel PPC Valve Assembly1006
How to Assemble Travel PPC Valve Assembly1007
Work Equipment1009
Remove and Install Blade Assembly1009
Remove Blade Assembly1009
Install Blade Assembly1010
Remove and Install Work Equipment Assembly1011
Remove Work Equipment Assembly1011
Install Work Equipment Assembly1012
Disassemble and Assemble Work Equipment Cylinder Assembly1015
How to Disassemble Work Equipment Cylinder Assembly1016
How to Assemble Work Equipment Cylinder Assembly1019
CAB Related Parts1024
Remove and Install Operator CAB Assembly (CAB Specification)1024
Remove Operator CAB Assembly (CAB Specification)1024
Install Operator CAB Assembly (CAB Specification)1027
Remove and Install Floor Frame Assembly (Canopy Specification)1031
Remove Floor Frame Assembly (Canopy Specification)1031
Install Floor Frame Assembly (Canopy Specification)1034
Remove and Install Operator Cab Glass (Adhered Glass)1037
Remove Operator CAB Glass (Adhered Glass)1038
Install Operator CAB Glass (Adhered Glass)1039
Remove and Install Front Window Assembly1047
Remove Front Window Assembly1047
Install Front Window Assembly1048
Remove and Install Air Conditioner Unit Assembly1050
Remove Air Conditioner Unit Assembly1050
Install Air Conditioner Unit Assembly1054
Remove and Install Operator Seat1059
Remove Operator’s Seat1059
Install Operator’s Seat1059
How to Remove and Install Seat Belt1061
How to Remove Seat Belt1061
How to Install Seatbelt1061
Electrical System1062
Remove and Install Engine Controller Assembly1062
Remove Engine Controller Assembly1062
Install Engine Controller Assembly1063
Remove and Install Machine Controller Assembly1064
Remove Machine Controller Assembly1064
Install Machine Controller Assembly1065
Remove and Install Machine Monitor Assembly1067
Remove Machine Monitor Assembly1067
Install Machine Monitor Assembly1068
Remove and Install KOMTRAX Terminal Assembly1070
Remove KOMTRAX Terminal Assembly1070
Install KOMTRAX Terminal Assembly1071
60 Maintenance Standard1073
Table of Contents1074
Abbreviation List1075
Engine and Cooling System1081
Maintenance Standard for PTO1081
Maintenance Standard for Cooling System1082
Power Train1083
Maintenance Standard for Swing Circle1083
Maintenance Standard for Swing Machinery1084
Maintenance Standard for Sprocket1086
Undercarriage and Frame1087
Maintenance Standard for Track Frame and Idler Cushion1087
Maintenance Standard for Idler1088
Maintenance Standard for Track Roller1090
Maintenance Standard for Carrier Roller1091
Maintenance Standard for Track Shoes1092
Maintenance Standard for Triple Shoes1094
Maintenance Standard for Road Liner1095
Maintenance Standard for Rubber Shoes1096
Hydraulic System1097
Maintenance Standard for Hydraulic Tank1097
Maintenance Standard for Main Pump1098
Maintenance Standard for Main Pump Servo Valve1099
Maintenance Standard for PC-EPC Valve1100
Maintenance Standard for Swing Motor1101
Maintenance Standard for Travel Motor1103
Maintenance Standard for Control Valve1104
Maintenance Standard for Work Equipment and Swing PPC Valve1116
Maintenance Standard for Blade PPC Valve1119
Maintenance Standard for Boom Swing PPC Valve1121
Maintenance Standard for Travel PPC Valve1123
Maintenance Standard for Attachment PPC Valve1126
Maintenance Standard for Center Swivel Joint1128
Work Equipment1129
Maintenance Standard for Work Equipment Linkage1129
Dimensions of Arm1135
Dimensions of Bucket1139
Maintenance Standard for Boom Cylinder1140
Maintenance Standard for Arm Cylinder1142
Maintenance Standard for Bucket Cylinder1144
Maintenance Standard for Blade Cylinder1146
Maintenance Standard for Boom Swing Cylinder1147
80 Appendix1149
Table of Contents1150
Abbreviation List1151
Precautions Before Work1157
Air Conditioner System1158
Precautions for Refrigerant1158
Air Conditioner Component1159
Specifications of Air Conditioner1160
Structure and Function of Refrigeration Cycle1161
Outline of Refrigeration Cycle1162
Component Parts of Air Conditioner System1164
Air Conditioner Unit1164
Configuration Diagram of Air Conditioner Unit1164
Compressor1166
Structure of Compressor1166
Specifications of Compressor1166
Function of Compressor1166
Condenser1168
Structure of Condenser1168
Specifications of Condenser1168
Function of Condenser1168
Receiver Drier1170
Structure of Receiver Dryer1170
Specifications of Receiver Dryer1170
Function of Receiver Dryer1170
Information Shown in Troubleshooting Table1171
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)1172
A-2 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)1175
A-3 Troubleshooting for Temperature Control Function1179
A-4 Troubleshooting for Air Conditioner Compressor and Cooling System (Electrical System)1182
A-5 Troubleshooting for Air Conditioner Compressor and Cooling System (Mechanical Systems)1186
A-6 Troubleshooting for Hot Water Circuit System1187
A-7 Unusual Noise is Heard from Air Conditioner Related Parts1188
A-8 Water Leaks from Air Conditioner Related Parts1189
A-9 Troubleshooting for Fresh/Recirc Air Changeover1190
Precautions for Disconnection and Connection of Air Conditioner Piping1191
Handle Compressor Oil1193
90 Circuit Diagrams1195
Table of Contents1196
Abbreviation List1197
Hydraulic Circuit Diagram1203
Symbols Used in Hydraulic Circuit Diagram1203
Hydraulic Circuit Diagram1207
Hydraulic Circuit Diagram (Quick Coupler Specifications) (1/2)1209
Hydraulic Circuit Diagram (Quick Coupler Specifications) (2/2)1211
Electrical Circuit Diagram1213
Symbols Used in Electric Circuit Diagram1213
Electrical Circuit Diagram (Canopy Spec) (1/5)1217
Electrical Circuit Diagram (Canopy Spec) (2/5)1219
Electrical Circuit Diagram (Canopy Spec) (3/5)1221
Electrical Circuit Diagram (Canopy Spec) (4/5)1223
Electrical Circuit Diagram (Canopy Spec) (5/5)1225
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (1/5)1227
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (2/5)1229
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (3/5)1231
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (4/5)1233
Electrical Circuit Diagram (Canopy Specifications, Quick Coupler Specifications) (5/5)1235
Electrical Circuit Diagram (Cab Spec) (1/6)1237
Electrical Circuit Diagram (Cab Spec) (2/6)1239
Electrical Circuit Diagram (Cab Spec) (3/6)1241
Electrical Circuit Diagram (Cab Spec) (4/6)1243
Electrical Circuit Diagram (Cab Spec) (5/6)1245
Electrical Circuit Diagram (Cab Spec) (6/6)1247
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (1/6)1249
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (2/6)1251
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (3/6)1253
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (4/6)1255
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (5/6)1257
Electrical Circuit Diagram (Cab Specifications, Quick Coupler Specifications) (6/6)1259
Index1261

IMAGES PREVIEW OF THE MANUAL:

S.M 26/12/24