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Komatsu PC100-6 PC120-6 Shop Manual SEBD003307 – PDF DOWNLOAD
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Komatsu PC100-6 PC120-6 Shop Manual
MACHINE MODEL SERIAL NUMBER
PC100-6 40001 and up
PC120-6 45001 and up
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Description
Komatsu PC100-6 PC120-6 Shop Manual
FILE DETAILS:
Komatsu PC100-6 PC120-6 Shop Manual
Size: 62.4 MB
Fomat: PDF
Language: English
Brand: Komatsu
Type of Document: Shop Manual
Model: D475A-2
Serial: 40001 and up
Number of Page: 1036 Pages
DESCRIPTION:
Komatsu PC100-6 PC120-6 Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding. the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs. as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating ‘Problems’ to “Causes” are also included In this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu PC100-6 PC120-6 Shop Manual
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 SAFETY....................................................................................................................................... 7 FOREWORD..................................................................................................................................... 9 GENERAL.................................................................................................................................. 9 HOW TO READ THE SHOP MANUAL.............................................................................................................. 10 HOISTING INSTRUCTIONS.................................................................................................................... 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER............................................................................... 12 COATING MATERIALS........................................................................................................................ 14 STANDARD TIGHTENING TORQUE............................................................................................................... 16 ELECTRIC WIRE CODE....................................................................................................................... 19 CONVERSION TABLE......................................................................................................................... 20 UNITS.................................................................................................................................... 26 01 GENERAL .................................................................................................................................. 27 GENERAL ASSEMBLY DRAWING................................................................................................................. 28 SPECIFICATIONS........................................................................................................................... 30 WEIGHT TABLE............................................................................................................................. 32 LIST OF LUBRICANT AND WATER.............................................................................................................. 36 10 STRUCTURE AND FUNCTION.................................................................................................................... 37 RADIATOR AND OIL COOLER.................................................................................................................. 38 PTO (COUPLING)........................................................................................................................... 42 POWER TRAIN.............................................................................................................................. 43 SWING CIRCLE............................................................................................................................. 44 SWING MACHINERY.......................................................................................................................... 47 TRACK FRAME.............................................................................................................................. 48 IDLER.................................................................................................................................... 50 IDLER CUSHION............................................................................................................................ 50 CARRIER ROLLER........................................................................................................................... 51 TRACK ROLLER............................................................................................................................. 51 TRACK SHOE............................................................................................................................... 52 HYDRAULIC PIPING DRAWING................................................................................................................. 52 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 52 HYDRAULIC TANK........................................................................................................................... 68 HYDRAULIC PUMP........................................................................................................................... 69 CONTROL VALVE............................................................................................................................ 100 CLSS..................................................................................................................................... 125 SWING MOTOR.............................................................................................................................. 166 CENTER SWIVEL JOINT...................................................................................................................... 173 TRAVEL MOTOR............................................................................................................................. 174 VALVE CONTROL............................................................................................................................ 187 WORK EQUIPMENT - SWING PPC VAVLE......................................................................................................... 188 TRAVEL PPC VALVE......................................................................................................................... 192 SERVICE PPC VALVE........................................................................................................................ 198 SAFETY LOCK VALVE........................................................................................................................ 203 PPC ACCUMULATOR.......................................................................................................................... 203 PPC SHUTTLE - TRAVEL JUNCTION VALVE...................................................................................................... 204 EPC - SOLENOID VALVE..................................................................................................................... 208 BOOM HOLDING VALVE....................................................................................................................... 214 HYDRAULIC CYLINDER....................................................................................................................... 217 ACCUMULATOR FOR BREAKER.................................................................................................................. 219 ADDITIONAL FILTER FOR BREAKER............................................................................................................ 220 WORK EQUIPMENT........................................................................................................................... 221 ELECTRICAL WIRING DIAGRAM................................................................................................................ 222 ELECTRICAL CIRCUIT DIAGRAM............................................................................................................... 224 ENGINE CONTROL SYSTEM.................................................................................................................... 237 ELECTRONIC CONTROL SYSTEM................................................................................................................ 244 MACHINE MONITOR SYSTEM................................................................................................................... 278 20 TESTING AND ADJUSTING..................................................................................................................... 291 TABLE OF JUDGEMENT STANDARD VALUE........................................................................................................ 292 STANDARD VALUE TABLE FOR ELECTRICAL PARTS................................................................................................ 304 TOOLS FOR TESTING ADJUSTING, AND TROUBLESHOOTING......................................................................................... 323 MEASURING ENGINE SPEED................................................................................................................... 324 MEASURING EXHAUST GAS COLOR.............................................................................................................. 325 ADJUSTING VALVE CLEARENCE................................................................................................................ 326 MEASURING COMPRESSION PRESSURE........................................................................................................... 327 MEASURING BLOWBY PRESSURE................................................................................................................ 327 TESTING AND ADJUSTING FUEL INJECTION TIMING.............................................................................................. 328 MEASURING ENGINE OIL PRESSURE............................................................................................................ 329 TESTING AND ADJUSTING FAN BELT TENSION................................................................................................... 330 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR........................................................................ 330 ADJUSTING ENGINE SPEED SENSOR............................................................................................................ 331 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE........................................................................................ 332 TESTING CLEARANCE OF SWING CIRCLE BEARING................................................................................................ 333 TESTING AND ADJUSTING TRACK SHOE TENSION................................................................................................. 334 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT........................................................ 335 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTION INPUT PRESSURE)........................................................... 341 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LD DIFFERENTIAL PRESSURE................................ 348 TESTING AND ADJUSTING VARIABLE THROTTLE VALVE............................................................................................ 351 TESTING AND ADJUSTIN CONTROL PUMP CIRCUIT OIL PRESSURE................................................................................... 353 TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE........................................................................................ 355 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE........................................................................ 359 ADJUSTING WORK EQUIPMENT - SWING PPC VALVE............................................................................................... 363 ADJUSTING TRAVEL LEVER................................................................................................................... 364 TESTING TRAVEL DEVIATION................................................................................................................. 365 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.............................................................................. 366 MEASURING OIL LEAKAGE.................................................................................................................... 368 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT........................................................................................ 370 BLEEDING AIR............................................................................................................................. 372 TROUBLESHOOTING.......................................................................................................................... 377 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................................................. 378 CONNECTOR TYPES AND MOUNTING LOCATIONS............................................................................................... 390 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................................... 399 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM............................................................................... 410 DISPLAY METHOD AND SPECIAL FUNCTION OF MONITOR PANEL................................................................................. 413 METHOD OF USING JUDGEMENT TABLE...................................................................................................... 432 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................... 434 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE............................................................................. 436 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)......................................................................... 445 N-1 COMMUNICATION ABNORMALITY.................................................................................................... 446 N-1 [E218] COMMUNICATION ABNORMALITY............................................................................................. 447 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE)........................................................................ 449 POINTS TO REMEMBER WHEN CARRYIN GOUT TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM........................................ 450 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................... 451 JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATED PARTS.......................................................... 453 ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAM............................................................................... 454 TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE................................................................................ 455 E-1 ABNORMALITY IN ENGINE THROTTLE CONTROLLER POWER SOURCE SYSTEM............................................................ 455 E-2 [E3:08} ABNORMALITY IN FUEL CONTROL DIAL INPUT VLAVUE SYSTEM IS DISPLAYED................................................ 456 E-3 [E3:17] ABNORMALITY (DISCONNECTION) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED ......................................... 457 E-4 [E3:18] ABNORMALITY (SHORT CIRCUIT) IN GOVERNOR MOTOR DRIVE SYSTEM IS DISPLAYED.......................................... 458 E-5 [E3:01] ABNORMALITY IN NETWORK RECEPTION SYSTEM IS DISPLAYED............................................................. 459 E-6 [E3:05] ABNORMALITY IN MODEL CODE IS DISPLAYED........................................................................... 461 E-7 [E3:06] ABNORMALTIY IN GOVERNOR POTENTIOMETER SYSTEM IS DISPLAYED........................................................ 462 E-8 [E3:07] ABNORMALITY IN PUMP CONTROLLER THROTTLE SYSTEM IS DISPLAYED...................................................... 463 E-9 [E3:15] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED.......................................... 463 E-10 [E3:16] ABNORMALITY (STEP-OUT) IN GOVERNOT MOTOR SYSTEM IS DISPLAYED.................................................... 464 E-11 ENGINE DOES NOT START................................................................................................... 466 E-12 ENGINE SPEED IS IRREGULAR............................................................................................... 468 A) KILLING SPEED IS IRREGULAR............................................................................................ 468 B) THERE IS HUNTING...................................................................................................... 470 E-13 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW).................................................................... 472 E-14 ENGINE DOES NOT STOP ................................................................................................... 474 E-15 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)...................................................... 476 TROUBLESHOOTING OF ENGINE THROTTLE PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)................................................ 477 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER SYSTEM.................................. 478 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................... 480 JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER POWERSOURCE (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS............. 484 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE............................................................................................ 486 E-1 ABNORMALITY IN ENGINE THRO0TTLE - PUMP CONTROLLER POWER SOURCE (CONTROLLER LED ID OFF)....................................... 488 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED............................................................ 489 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................ 490 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................ 491 E-5 [E306] ABNORMALITY IN FEED BACK POTENTIOMETER SYSTEM IS DISPLAYED............................................................ 492 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED............................................... 493 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED.......................................................................... 494 E-8 ENGINE DOES NOT START........................................................................................................ 496 E-9 ENGINE SPEED IS IRREGULAR.................................................................................................... 498 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)........................................................................ 502 E-11 ENGINE DOES NOT STOP........................................................................................................ 504 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP).......................................................... 506 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................ 509 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................... 510 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).................................................................... 514 S-2 ENGINE DOES NOT START........................................................................................................ 515 (1) ENGINE DOES NOT TURN..................................................................................................... 515 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................................................. 516 (3) EXHAUST SMOKE COMES OUT BUT ENGINES DOES NOT START (FUEL IS BEING INJECTED).............................................. 517 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)......................................................................... 518 S-4 ENGINE STOPS DURING OPERATIONS............................................................................................... 519 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................................... 520 S-6 ENGINE LACKS OUTPUT (NO POWER)............................................................................................... 521 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................................... 522 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...................................................................... 523 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................................................. 524 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................... 525 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN..................................................... 526 S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)................................................................... 527 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................ 528 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................ 529 S-15 ABNORMAL NOISE IS MADE...................................................................................................... 530 S-16 VIBRATION IS EXCESSIVE...................................................................................................... 531 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)................................................................................... 533 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM................................................................... 534 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS OCCUR ON MACHINE................................................. 535 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HDURAULIC RELATED PARTS.................................................................. 539 PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM........................................................................................... 540 TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE................................................................................ 541 C-1 ABNORMALITY IN PUMP CONTROLLER POWER SOURCE SYSTEM....................................................................... 541 C-2 [E2:32] SHORT CIRCUIT IN TVC SOLENOID SYSTEM IS DISPLAYED................................................................ 542 C-3 [E2:33] DISCONNECTION IN TVC SOLENOID SYSTEM IS DISPLAYED................................................................ 544 C-4 [E2:03] SHORT CIRCUIT IN SWING BRAKE SOLENOIL SYSTEM IS DISPLAYED........................................................ 546 C-5 [E2:13] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED........................................................ 548 C-6 [E2:01] SHORT CIRCUIT IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED.......................................................... 550 [E2:05] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED..................................................... 550 E2:06] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM ID IDSPLAYED........................................................ 550 C-7 [E2:11] DISCONNECTION IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED.......................................................... 552 [E2:15] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED..................................................... 552 [E2:16] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED....................................................... 552 C-8 [E2:17] MODEL SELECTIONINPUT ERROR IS DISPLAYED.......................................................................... 554 C-9 [E2:18] NETWORK RESPONSE OVERTIME ERROR IS DISPLAYED..................................................................... 555 C-10 [E2:22] SHORT CIRCUIT IN LS CONTROL EPC SOLENOID SYSTME IS DISPLAYED.................................................... 557 C-11 [E2:23] DISCONNECTION IN LS CONTROL EPC SOLENIOD SYSTEM IS DISPLAYED.................................................... 558 C-12 [E2:24] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED......................................................... 559 C-13 [E2-26] ABNORMALITY IN PUMP PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED............................................ 560 C-14 [E2:27] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED.......................................................... 561 C-15 [E2:28] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED..................................................... 562 TROUBLESHOOTING OF ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE).................................................. 563 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM................................................................... 564 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................... 566 JUDGEMENT TABLE FOR ENGINE THROTTLE - PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.......................... 574 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE............................................................................................ 576 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)........................................................ 578 C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED................................................................ 579 C-3 [E233] DISCONNECTION IN PUM TVC SOLENOID SYSTEM IS DISPLAYED................................................................. 581 C-4 [E201] SHORT CIRCUIT IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED............................................................... 583 C-5 [E211] DISCONNECTION IN LS BYPASS SOLENOID SYSTEM IS DISPLAYED............................................................... 584 C-6 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED............................................................. 585 C-7 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED............................................................. 587 C-8 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.......................................................... 589 C-9 [E215} DISCONNECTION IN 2 -STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED......................................................... 590 C-10 [C206] SHORT CIRCUIT IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED.................................................. 591 C-11 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED.................................................. 592 C-12 [E207] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED............................................................ 593 C-13 [E208] DISCONNECTION IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED............................................................ 594 C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED............................................................................. 595 C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOIND SYSTEM IS DISPLAYED................................................................ 597 C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED................................................................. 598 C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.............................................................. 599 C-18 [E226] ABNORMALITY IN PRESSURE SENSOR SYSTEM POWER SOURCE IS DISPLAYED...................................................... 600 C-19 [E227] ABNORMALTIY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED............................................................... 601 TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)...................................................................... 603 TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE................................................................................ 604 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP............................................................... 604 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................. 605 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP.......................................................... 606 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP.......................................................... 607 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................. 608 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP............................................................. 609 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................... 610 F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................... 611 F-9 BIT PATTERN 21-(3) SWING LOCK SWITCYH DOES NOT LIGHT UP...................................................................... 612 F-10 ENGINE SPEED IS NOT DISPLAYED IN MONITORING CODE 10 (ABNORMALITY IN SPEED SENSOR SYSTEM).................................... 613 F-11 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP............................................................... 614 F-12 BIT PATTERN 22-(6) L.H. KNOB SWITCYH DOES NOT LIGHT UP...................................................................... 615 TROUBLESHOOTING OF ENGINE THROTTLE, PUMP CONTROLLER (INPUT SIGNAL SYSTEM)(F MODE).................................................... 617 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE............................................................................................ 618 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP............................................................... 620 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................. 621 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP.......................................................... 622 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP.......................................................... 623 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................. 624 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP............................................................. 625 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................... 626 F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP......................................................... 627 F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP....................................................................... 628 F-10 BIT PATTERN 22-(5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP............................................................... 629 F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP....................................................................... 630 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE).......................................................................... 631 TABLE OF FAILURE MODES AND CAUSED FOR HYDRAULIC AND MECHANICAL SYSTEM............................................................ 633 TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE................................................................................ 633 ALL WORK EQUIPMETN, TRAVEL, SWING................................................................................................ 633 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS................................................................ 635 H-3 NO WORK EQUIPMENT, TRAVEL SWING MOVE..................................................................................... 636 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)................................................................................... 636 H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)........................................................ 637 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR......................................................................... 637 WORK EQUIPMENT................................................................................................................... 639 H-7 BOOM IS SLOW OR LACKS POWER.............................................................................................. 639 H-8 ARM IS SLOW OR LACKS POWER............................................................................................... 641 H-9 BUCKET IS SLOW OR LACKS POWER............................................................................................ 643 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET( DOES NOT MOVE........................................................................ 644 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)........................................................................... 644 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)............................................................................... 645 H-13 LACK OF POWER WHEN PRESSURE RISES....................................................................................... 645 H-14 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED................................................................... 645 H-15 WORK EQUIPMENT IS SLOW WHEN ACTIVE MODE ID ON OR IS FAST WHE ACTIVE MODE IS OFF......................................... 646 H-16 IN F/O MODE, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED........................................................ 647 COMPOUND OPERATIONS.............................................................................................................. 647 H-17 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD IS SLOW.......................................................... 647 H-18 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW............................................................................... 648 H-19 IN SWING + TRAVEL,TRAVEL SPEED DROPS EXCESSIVELY........................................................................ 648 H-20 IN WORK EQUIPMENT + TRAVE, TRAVEL SPEED DROPS EXCESSIVELY............................................................... 648 TRAVEL SYSTEM.................................................................................................................... 649 H-21 TRAVEL DEVIATION........................................................................................................ 649 H-22 TRAVEL SPEED IS SLOW.................................................................................................... 651 H-23 STEERING DOES NOT TURNEALISLY OR LACKS POWER............................................................................ 653 H-24 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED.......................................................... 655 H-25 TRAVEL DOES NOT MOVE (ONE SIDE ONLY).................................................................................... 655 SWING SYSTEM..................................................................................................................... 656 H-26 DOES NOT SWING.......................................................................................................... 656 H-27 SWING ACCELERATION IS POOR.............................................................................................. 657 H-28 EXCESSIVE OVERRUN WHEN STOPPING SWING................................................................................... 659 H-29 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)................................................................ 660 H-30 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING............................................................................ 660 H-31 EXCESSIVE HYDRAULIC DRIFT OF SWING...................................................................................... 661 H-32 SWING SPEED IS FASTER THAN SPECIFIED SPEED.............................................................................. 662 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)................................................................................... 664 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS............................................................................ 666 MACHINE MONITOR SYSTEM CIRCUIT DIAGRAM........................................................................................... 667 TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE................................................................................ 668 M-1 [E1:01] ABNORMALITY IN ERRO DATA IS DISPLAYED................................................................................ 668 M-2 [E1:02] ERROR IN CLOCK DATA IS DISPLAYED..................................................................................... 668 M-3 [E1:03] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED............... 668 M-4 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS................................. 669 A) NONE OF LAMPS ON MONITO PANEL LIGHT UP.................................................................................... 669 B) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP............................................................................ 669 M-5 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT..................................... 670 M-6 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM MACHINE MODEL............................ 670 M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH........................................................ 671 A) COOLANT LEVEL FLASHES..................................................................................................... 671 B) ENGINE OIL LEVEL FLASHES.................................................................................................. 672 M-8 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY LIGHTS UP................................................................ 673 M-9 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEM FLASH.................................................... 674 A) ALTERNATOR SYSTEM......................................................................................................... 674 B) ENGINE OIL PRESSURE SYSTEM................................................................................................ 675 M-10 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH..................................................... 676 A) ALTERNATOR SYSTEM......................................................................................................... 676 B) ENGINE OIL PRESSURE SENSOR SYSTEM......................................................................................... 676 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH................................................ 678 A) ENGINE OIL PRESSURE FLASHES............................................................................................... 678 B) COOLANT LEVEL FLASHES..................................................................................................... 679 C) COOLANT TEMPERATURE FLASHES............................................................................................... 679 D) BATTERY CHARGE FLASHES.................................................................................................... 680 E) FUEL LEVEL FLASHES........................................................................................................ 680 M-12 A) WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND................................... 681 CAUTION TIEMS ARE FLASHING BUT BUZZER DOES NOT SOUND......................................................................... 681 B) NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS.................................................................. 681 M-13 LIQUID CRYSTAL NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP............................................................ 682 M-14 COOLANT TEMPERATURE GAUGE DOES NOT RISE..................................................................................... 683 M-15 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY ........................................................................ 684 M-16 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL....................................................................................... 685 M-17 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...................................................................................... 685 M-18 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT MONITOR PANEL PARKING DISPLAY DOES NOT LIGHT UP................................... 686 M-19 SWING PROLIX SWITCH IS ON (PROLIX), BUT MONITOR PANEL PARKING DISPLAY DOES NOT FLASH........................................ 686 M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM.......................................................................................... 687 M-21 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM................................................................................. 688 M-22 DEFECTIVE ENGINE OIL LEVEL SENSOR........................................................................................... 689 M-23 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM....................................................................................... 690 M-24 WORKING LAMP, PANEL LIGHTING DOES NOT LIGHT UP, OR SWITCH IS NOT BEING USED BUT LAMPS LIGHT UP.............................. 691 A) WORKING LAMP DOES NOT LIGHT UP............................................................................................ 691 B) PANEL LIGHTING DOES NOT LIGHT UP.......................................................................................... 691 C) LIGHT SWITCH IS NOT BEING USED BUT WORKING LAMP LIGHTS UP................................................................. 692 M-25 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED....................................................... 693 A) WIPER DOES NOT WORK....................................................................................................... 693 B) WIPER SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED...................................................................... 695 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)................................................................................... 698 ACTIONS TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE................................................... 701 ELECTRICAL CIRCUIT DIAGRAM....................................................................................................... 705 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED................................................................................ 707 [E102] ERROR IN CLOCK DATA IS DISPLAYED...................................................................................... 707 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED............... 708 M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED............................................................................ 709 M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED.................................................................. 709 M-5 [E108] ENGINE WATER TEMPERATURE 105°C DETECTED IS DISPLAYED.................................................................. 710 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS................................. 711 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT..................................... 713 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)................... 713 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES................................................ 714 M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP............................................................. 716 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH............................................ 717 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH.................................... 719 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH............................... 721 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND. CAUTION ITEM FLASHES BUT BUZZER .... 724 M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUND..................................................................... 724 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAYE IS NORMAL)....................................... 725 M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE..................................................................................... 726 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY ........................................................................ 726 M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...................................................................................... 727 M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY...................................................................................... 727 M-21 SWING LOCK SWITCH IS TURNED ON 9LOCK) BUT (SWING LOCK MONITOR) DOES NOT FLASH............................................... 728 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH.......................................... 728 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING...................................................................... 729 M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED......................... 729 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM.......................................................................................... 730 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM................................................................................. 731 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM.................................................................................... 732 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM....................................................................................... 733 M-29 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED....................................................... 735 M-30 WASHER MOTOR DOES NOT WORK, SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED........................................... 741 30 DISASSEMBLY AND ASSEMBLY.................................................................................................................. 744 METHOD OF USING MANUAL................................................................................................................... 746 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................. 747 SPECIAL TOOL LIST........................................................................................................................ 749 STARTING MOTOR ASSEMBLY.................................................................................................................. 753 REMOVAL AND INSTALLATION............................................................................................................. 753 ALTERNATOR............................................................................................................................... 754 REMOVAL AND INSTALLATION............................................................................................................. 754 AIR CONDITIONER COMPRESSOR............................................................................................................... 755 REMOVAL AND INSTALLATION............................................................................................................. 755 CONDENSER................................................................................................................................ 756 REMOVAL AND INSTALLATION............................................................................................................. 756 ENGINE OIL COOLER CORE................................................................................................................... 757 REMOVAL AND INSTALLATION............................................................................................................. 757 FUEL INJECTION PUMP...................................................................................................................... 758 REMOVAL.............................................................................................................................. 758 INSTALLATION......................................................................................................................... 759 WATER PUMP............................................................................................................................... 760 REMOVAL AND INSTALLATION............................................................................................................ 760 NOZZLE HOLDER............................................................................................................................ 761 REMOVAL AND INSTALLATION............................................................................................................. 761 TURBOCHARGER............................................................................................................................. 762 REMOVAL AND INSTALLATION............................................................................................................. 762 THERMOSTAT............................................................................................................................... 763 REMOVAL AND INSTALLATION............................................................................................................. 763 ENGINE FRONT OIL ........................................................................................................................ 764 REMOVAL AND INSTALLATION............................................................................................................. 764 ENGINE REAR OIL SEAL..................................................................................................................... 765 REMOVAL AND INSTALLATION............................................................................................................. 765 GOVERNOR MOTOR........................................................................................................................... 766 REMOVAL AND INSTALLATION............................................................................................................. 766 CYLINDER HEAD............................................................................................................................ 767 REMOVAL ............................................................................................................................. 767 INSTALLATION......................................................................................................................... 769 ENGINE - HYDRAULIC PUMP.................................................................................................................. 771 REMOVAL.............................................................................................................................. 771 INSTALLATION......................................................................................................................... 774 HYDRAULIC OIL COOLER .................................................................................................................... 775 REMOVAL AND INSTALLATION............................................................................................................. 775 RADIATOR - HYDRAULIC C................................................................................................................... 777 REMOVAL.............................................................................................................................. 777 INSTALLATION......................................................................................................................... 778 FUEL TANK................................................................................................................................ 779 REMOVAL AND INSTALLATION............................................................................................................. 779 CENTER SWIVEL JOINT...................................................................................................................... 781 REMOVAL AND INSTALLATION............................................................................................................. 781 DISASSEMBLY AND ASSEMBLY............................................................................................................. 782 SPROCKET................................................................................................................................. 783 REMOVAL AND INSTALLATION............................................................................................................. 783 TRAVEL MOTOR............................................................................................................................. 784 REMOVAL AND INSTALLATION............................................................................................................. 784 DISASSEMBLY AND ASSEMBLY (GM18VL-MSRV)............................................................................................... 786 SWING MACHINERY - SWING MOTOR............................................................................................................ 837 REMOVAL AND INSTALLATION............................................................................................................. 837 SWING MACHINERY.......................................................................................................................... 839 DISASSEMBLY.......................................................................................................................... 839 ASSEMBLY............................................................................................................................. 842 SWING MOTOR.............................................................................................................................. 846 REMOVAL AND INSTALLATION (KMF40AB-2)................................................................................................. 846 DISASSEMBLY (KMF40AB-2).............................................................................................................. 847 ASSEMBLY (KMF40AB-2)................................................................................................................. 850 REMOVAL AND INSTALLATION (KMF40AB-3)................................................................................................. 854 REVOLVING FRAME.......................................................................................................................... 855 REMOVAL.............................................................................................................................. 855 INSTALLATION......................................................................................................................... 857 SWING CIRCLE............................................................................................................................. 858 REMOVAL AND INSTALLATION............................................................................................................. 858 IDLER - RECOIL SPRING ................................................................................................................... 859 REMOVAL AND INSTALLATION............................................................................................................. 859 RECOIL SPRING............................................................................................................................ 860 DISASSEMBLY.......................................................................................................................... 860 ASSEMBLY............................................................................................................................. 861 IDLER ................................................................................................................................... 862 DISASSEMBLY.......................................................................................................................... 862 ASSEMBLY............................................................................................................................. 863 TRACK ROLLER ............................................................................................................................ 865 REMOVAL AND INSTALLATION............................................................................................................. 865 DISASSEMBLY.......................................................................................................................... 866 ASSEMBLY............................................................................................................................. 867 CARRIER ROLLER........................................................................................................................... 869 REMOVAL AND INSTALLATION............................................................................................................. 869 TRACK SHOE............................................................................................................................... 870 REMOVAL.............................................................................................................................. 870 INSTALLATION......................................................................................................................... 870 HYDRAULIC TANK........................................................................................................................... 872 REMOVAL ............................................................................................................................. 872 INSTALLATION......................................................................................................................... 873 CONTROL PUMP............................................................................................................................. 874 REMOVAL AND INSTALLATION............................................................................................................. 874 MAIN PUMP................................................................................................................................ 877 REMOVAL ............................................................................................................................. 877 INSTALLATION......................................................................................................................... 878 DISASSEMBLY.......................................................................................................................... 881 ASSEMBLY............................................................................................................................. 886 MAIN PUMP INPUT SHAFT OIL SEAL........................................................................................................... 899 REMOVAL AND INSTALLATION............................................................................................................. 899 CONTROL VALVE............................................................................................................................ 900 REMOVAL.............................................................................................................................. 900 INSTALLATION......................................................................................................................... 901 DISASSEMBLY.......................................................................................................................... 906 ASSEMBLY............................................................................................................................. 908 LS SELECT VALVE.......................................................................................................................... 920 DISASSEMBLY AND ASSEMBLY............................................................................................................. 920 LS SHUTTLE VALVE ........................................................................................................................ 922 DISASSEMBLY AND ASSEMBLY............................................................................................................. 922 PRESSURE COMPENSATION VALVE.............................................................................................................. 924 DISASSEMBLY.......................................................................................................................... 924 ASSEMBLY............................................................................................................................. 925 MAIN RELIEF VALVE........................................................................................................................ 928 DISASSEMBLY.......................................................................................................................... 928 ASSEMBLY............................................................................................................................. 929 TVC - LS VALVE........................................................................................................................... 930 REMOVAL AND INSTALLATION............................................................................................................. 930 LS CONTROL EPC VALVE..................................................................................................................... 931 REMOVAL AND INSTALLATION............................................................................................................. 931 SOLENOID VALVE........................................................................................................................... 933 REMOVAL AND INSTALLATION............................................................................................................. 933 WORK EQUIPMENT - SWING PPC VALVE......................................................................................................... 935 REMOVAL AND INSTALLATION............................................................................................................. 935 DISASSEMBLY.......................................................................................................................... 936 ASSEMBLY............................................................................................................................. 937 TRAVEL PPC VALVE......................................................................................................................... 938 REMOVAL AND INSTALLATION............................................................................................................. 938 DISASSEMBLY.......................................................................................................................... 940 ASSEMBLY............................................................................................................................. 941 BOOM HOLDING VALVE....................................................................................................................... 945 REMOVAL AND INSTALLATION............................................................................................................. 945 BOOM CYLINDER............................................................................................................................ 946 REMOVAL.............................................................................................................................. 946 INSTALLATION......................................................................................................................... 947 ARM CYLINDER............................................................................................................................. 948 REMOVAL.............................................................................................................................. 948 INSTALLATION......................................................................................................................... 949 BUCKET CYLINDER.......................................................................................................................... 950 REMOVAL.............................................................................................................................. 950 INSTALLATION......................................................................................................................... 951 HYDRAULIC CYLINDER ...................................................................................................................... 952 DISASSEMBLY.......................................................................................................................... 952 ASSEMBLY............................................................................................................................. 954 WORK EQUIPMENT .......................................................................................................................... 958 REMOVAL.............................................................................................................................. 958 INSTALLATION......................................................................................................................... 959 BUCKET .................................................................................................................................. 960 REMOVAL.............................................................................................................................. 960 INSTALLATION......................................................................................................................... 961 ARM ..................................................................................................................................... 962 REMOVAL.............................................................................................................................. 962 INSTALLATION......................................................................................................................... 963 BUCKET - ARM............................................................................................................................. 964 REMOVAL.............................................................................................................................. 964 INSTALLATION......................................................................................................................... 965 BOOM .................................................................................................................................... 966 REMOVAL.............................................................................................................................. 966 INSTALLATION......................................................................................................................... 967 OPERATOR'S CAB........................................................................................................................... 968 REMOVAL.............................................................................................................................. 968 INSTALLATION......................................................................................................................... 970 COUNTERWEIGHT............................................................................................................................ 971 REMOVAL AND INSTALLATION............................................................................................................. 971 ENGINE THROTTLE CONTROLLER............................................................................................................... 972 REMOVAL AND INSTALLATION............................................................................................................. 972 PUMP CONTROLLER.......................................................................................................................... 973 REMOVAL AND INSTALLATION............................................................................................................. 973 ENGINE THROTTLE, PUMP CONTROLLER ........................................................................................................ 974 REMOVAL AND INSTALLATION............................................................................................................. 974 MONITOR ................................................................................................................................. 975 REMOVAL AND INSTALLATION............................................................................................................. 975 40 MAINTENANCE STANDARD...................................................................................................................... 977 SWING MACHINERY.......................................................................................................................... 978 SWING CIRCLE............................................................................................................................. 980 TRACK FRAME.............................................................................................................................. 983 IDLER.................................................................................................................................... 984 CARRIER ROLLER........................................................................................................................... 985 TRACK ROLLER............................................................................................................................. 986 SPROCKET................................................................................................................................. 987 TRACK SHOE............................................................................................................................... 988 HYDRAULIC PUMP........................................................................................................................... 992 CONTROL VALVE............................................................................................................................ 995 SWING MOTOR..............................................................................................................................1013 CENTER SWIVEL JOINT......................................................................................................................1015 WORK EQUIPMENT - SWING PPC VALVE.........................................................................................................1016 TRAVEL PPC VALVE.........................................................................................................................1017 SERVICE PPC VALVE........................................................................................................................1019 PPC SHUTTLE - TRAVEL JUNCTION VALVE .....................................................................................................1022 EPC - SOLENOID VALVE ....................................................................................................................1024 BOOM HOLDING VALVE.......................................................................................................................1025 HYDRAULIC CYLINDER.......................................................................................................................1026 WORK EQUIPMENT...........................................................................................................................1028
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