Komatsu PC160-6K, PC180LC-6K, PC180NLC-6K Hydraulic Excavator Shop Manual SN K32001, K34001 and up – PDF DOWNLOAD

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Komatsu PC160-6K, PC180LC-6K, PC180NLC-6K Hydraulic Excavator Shop Manual

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Komatsu PC160-6K, PC180LC-6K, PC180NLC-6K Hydraulic Excavator Shop Manual 

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DESCRIPTION:

Komatsu PC160-6K, PC180LC-6K, PC180NLC-6K Hydraulic Excavator 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 judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

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 thissection.
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 PC160-6K, PC180LC-6K, PC180NLC-6K Hydraulic Excavator Shop Manual 

MAIN MENU...........................................................................................................................................................................................  0
COVER...............................................................................................................................................................................................  1
CONTENTS............................................................................................................................................................................................  1
SAFETY..............................................................................................................................................................................................  1
	SAFETY NOTICE...................................................................................................................................................................................  6
FOREWARD............................................................................................................................................................................................  8
	GENERAL.........................................................................................................................................................................................  8
	HOW TO READ THE SHOP MANUAL.....................................................................................................................................................................  9
	HOISTING INSTRUCTIONS........................................................................................................................................................................... 10
	COATING MATERIALS............................................................................................................................................................................... 11
	STANDARD TIGHTENING TORQUE...................................................................................................................................................................... 12
	ELECTRIC WIRE CODE.............................................................................................................................................................................. 14
	CONVERSION TABLE................................................................................................................................................................................ 15
01 GENERAL.......................................................................................................................................................................................... 22
	SPECIFICATIONS.................................................................................................................................................................................. 23
	SPECIFICATION DRAWINGS.......................................................................................................................................................................... 25
	WEIGHT TABLE.................................................................................................................................................................................... 29
	FUEL, COOLANT AND LUBRICANTS.................................................................................................................................................................... 33
10 STRUCTURE AND FUNCTION........................................................................................................................................................................... 35
	ENGINE RELATED PARTS............................................................................................................................................................................ 36
	RADIATOR * OIL COOLER........................................................................................................................................................................... 37
	POWER TRAIN..................................................................................................................................................................................... 38
	FINAL DRIVE..................................................................................................................................................................................... 39
	SWING CIRCLE.................................................................................................................................................................................... 40
	SWING MACHINERY................................................................................................................................................................................. 41
	TRACK FRAME, RECOIL SPRING...................................................................................................................................................................... 43
	TRACK SHOE...................................................................................................................................................................................... 44
	HYDRAULIC CIRCUIT DIAGRAM....................................................................................................................................................................... 47
	FUEL & HYDRAULIC TANK........................................................................................................................................................................... 48
	HYDRAULIC PUMP.................................................................................................................................................................................. 51
	CONTROL VALVE................................................................................................................................................................................... 58
	CLSS............................................................................................................................................................................................ 64
	SWING MOTOR.....................................................................................................................................................................................101
	CENTER SWIVEL JOINT.............................................................................................................................................................................103
	TRAVEL MOTOR....................................................................................................................................................................................104
	VALVE CONTROL...................................................................................................................................................................................112
	WORK EQUIPMENT - SWING PPC VALVE................................................................................................................................................................113
	TRAVEL PPC PEDAL................................................................................................................................................................................117
	SAFETY LOCK VALVE...............................................................................................................................................................................124
	PPC ACCUMULATOR.................................................................................................................................................................................124
	PPC SHUTTLE * TRAVEL JUNCTION VALVE.............................................................................................................................................................125
	EPC * SOLENOID VALVE............................................................................................................................................................................132
	HYDRAULIC CYLINDER..............................................................................................................................................................................137
	ADDITIONAL FILTER FOR BREAKING..................................................................................................................................................................139
	OVERLOAD WARNING DEVICE.........................................................................................................................................................................140
	HOSE BURST PROTECTION VALVE (BOOM)..............................................................................................................................................................144
	WORK EQUIPMENT..................................................................................................................................................................................147
	ELECTRICAL CIRCUIT DIAGRAM FOR E MODE...........................................................................................................................................................150
	ENGINE CONTROL SYSTEM...........................................................................................................................................................................151
	ELECTRONIC CONTROL SYSTEM.......................................................................................................................................................................157
	MACHINE MONITOR SYSTEM..........................................................................................................................................................................181
20 TESTING AND ADJUSTING............................................................................................................................................................................193
	TABLE OF JUDGEMENT STANDARD VALUE...............................................................................................................................................................194
	STANDARD VALUE TABLE FOR ELECTRICAL PARTS.......................................................................................................................................................204
	CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR..............................................................................................................................212
	ADJUSTING ENGINE SPEED SENSOR...................................................................................................................................................................213
	TESTING AND ADJUSTING GOVERNOR MOTOR LEVEL STROKE...............................................................................................................................................214
	TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................................................................................................216
	TESTING AND ADJUSTING TRACK SHOE TENSION........................................................................................................................................................217
	TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................................................................................................218
	TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...................................................................................................................226
	TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE.......................................................................................228
	TESTING AND ADJUSTING PILOT CIRCUIT OIL PRESSURE................................................................................................................................................231
	TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE................................................................................................................................................233
	MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...............................................................................................................................235
	ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.......................................................................................................................................................237
	TESTING TRAVEL DEVIATION........................................................................................................................................................................238
	TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................................................................................................239
	MEASURING OIL LEAKAGE...........................................................................................................................................................................241
	RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................................................243
	BLEEDING AIR....................................................................................................................................................................................244
	TROUBLESHOOTING.................................................................................................................................................................................247
		POINTS TO REMEMBER WHEN TROUBLSHOOTING......................................................................................................................................................248
		SEQUENCE OF EVENTS IN TROUBLSHOOTING........................................................................................................................................................249
		PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...................................................................................................................................................250
		CHECKS BEFORE TROUBLESHOOTING...............................................................................................................................................................257
		CONNECTOR TYPES AND MOUNTING LOCATIONS......................................................................................................................................................258
		CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................................................................................263
		EXPLANATION OF CONTROL MACHANISM FOR ELECTRICAL SYSTEM......................................................................................................................................276
		DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL.......................................................................................................................................277
		METHOD OF USING JUDGEMENT TABLE.............................................................................................................................................................285
		METHOD OF USING TROUBLESHOOTING CHARTS......................................................................................................................................................287
		DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE....................................................................................................................................289
		SERVICE CODE TABLE..........................................................................................................................................................................294
		TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)................................................................................................................................295
			N-1 [E218] COMMUNICATION ABNORMALITY....................................................................................................................................................296
		TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE).............................................................................................................298
			POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM................................................................................................299
			ACTION BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................................................................300
			JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS..........................................................................................304
			ELECTRICAL CIRCUIT DIAGRAM FOR E MODE...................................................................................................................................................306
			E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF).......................................................................................................308
			E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED....................................................................................................................309
			E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED...............................................................................................................310
			E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED...............................................................................................................311
			E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED....................................................................................................................312
			E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED......................................................................................................313
			E-7 [E316] ABNORMALITY (STEP OUT) IN MOTOR IS DISPLAYED.................................................................................................................................314
			E-8 ENGINE DOES NOT START...............................................................................................................................................................316
			E-9 ENGINE SPEED IS IRREGULAR...........................................................................................................................................................318
				a) IDLING SPEED IS IRREGULAR........................................................................................................................................................318
				b) THERE IS HUNTING.................................................................................................................................................................320
			E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)...............................................................................................................................322
			E-11 ENGINE DOES NOT STOP...............................................................................................................................................................324
			E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP).................................................................................................................326
		TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...................................................................................................................................................329
			METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................................................................................330
			S-1 STARTING PERFORMARMANCE IS POOR (STARTING ALWAYS TAKES TIME)........................................................................................................................334
			S-2 ENGINE DOES NOT START...............................................................................................................................................................335
				1) ENGINE DOES NOT TURN.............................................................................................................................................................335
				2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEEN INJECTED)..........................................................................................................336
				3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FEUL IS BEING INJECTED).......................................................................................................337
			S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)................................................................................................................................338
			S-4 ENGINE STOPS DURING OPERATIONS......................................................................................................................................................339
			S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................................................................................................340
			S-6 ENGINE LACKS OUTPUT (NO POWER)......................................................................................................................................................341
			S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)......................................................................................................................................342
			S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................................................................................................343
			S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................................................................................................344
			S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................................................................................................345
			S-11 OIL LEVEL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN......................................................................................................346
			S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).........................................................................................................................347
			S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...............................................................................................................................................348
			S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................................................................................349
			S-15 ABNORMAL NOISE IS MADE.............................................................................................................................................................350
			S-16 VIBRATION IS EXCESSIVE.............................................................................................................................................................351
		TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE).................................................................................................................352
			POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM..........................................................................................................................353
			ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..............................................................................................................354
			JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.........................................................................................360
			ELECTRICAL CIRCUIT DIAGRAM FOR C MODE ..................................................................................................................................................362
			C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)...............................................................................................................364
			C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................365
			C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED.......................................................................................................................367
			C-6 [E201] SHORT CIRCUIT IN ACTIVE MODE SOLENOID SYSTEM IS DISPLAYED....................................................................................................................369
			C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED....................................................................................................................371
			C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED....................................................................................................................373
			C-10 [E205] SHORT CIRCUIT IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED................................................................................................................375
			C-11 [E215] DISCONNECTION IN 2 STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED................................................................................................................376
			C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED..................................................................................................................377
			C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED.........................................................................................................378
			C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED....................................................................................................................................379
			C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED........................................................................................................................381
			C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM DISPLAYS............................................................................................................................382
			C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.....................................................................................................................383
			C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED.............................................................................................................384
			C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED......................................................................................................................385
		TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE).................................................................................................................387
			ELECTRICAL CIRCUIT DIAGRAM FOR F MODE...................................................................................................................................................388
			F-1 BIT PATTERN 20- (1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP.....................................................................................................................390
			F-2 BIT PATTERN 20- (2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP....................................................................................................................391
			F-3 BIT PATTERN 20- (3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................................................................................392
			F-4 BIT PATTERN 20- (4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP................................................................................................................393
			F-5 BIT PATTERN 20- (5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP....................................................................................................................394
			F-6 BIT PATTERN 20- (6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP...................................................................................................................395
			F-7 BIT PATTERN 21- (1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................396
			F-8 BIT PATTERN 21- (2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................................................................397
			F-9 BIT PATTERN 21- (3) SWING LOCK SWITCH DOES NOT LIGHT UP.............................................................................................................................398
			F-10 BIT PATTERN 22- (5) KEROSENE MODE CONNECTION DOES NOT LIGHT UP.....................................................................................................................399
			F-11 BIT PATTERN 22- (6) L.H. KNOB SWITCH DOES NOT LIGHT UP.............................................................................................................................400
		TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)....................................................................................................................................401
			TABLE OF FAILURE MODES AND CAUSES.......................................................................................................................................................402
			H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER..................................................................................................................406
			H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS...........................................................................................................................408
			H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...............................................................................................................................................409
			H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)..............................................................................................................................................409
			H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)...................................................................................................................410
			H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR....................................................................................................................................410
			H-7 BOOM IS SLOW OR LACKS POWER.........................................................................................................................................................412
			H-8 ARM IS SLOW OR LACKS POWER..........................................................................................................................................................414
			H-9 BUCKET IS SLOW OR LACKS POWER.......................................................................................................................................................416
			H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).................................................................................................417
			H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)......................................................................................................................................417
			H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)..........................................................................................................................................418
			H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED..............................................................................................................................418
			H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED..................................................................................................................419
			H-15 LACK OF POWER WHEN PRESSURE RISES..................................................................................................................................................419
			H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW....................................................................................................................419
			H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW..........................................................................................................................................420
			H-20 TRAVEL DEVIATION...................................................................................................................................................................421
			H-21 TRAVEL SPEED IS SLOW...............................................................................................................................................................422
			H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER.......................................................................................................................................424
			H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED.....................................................................................................................426
			H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...............................................................................................................................................426
			H-25 DOES NOT SWING.....................................................................................................................................................................427
			H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW..................................................................................................................................428
			H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING..............................................................................................................................................430
			H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)...........................................................................................................................431
			H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING.......................................................................................................................................431
			H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING.................................................................................................................................................432
			H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED...................................................................................................................................433
		TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)..........................................................................................................................................435
			ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................................................................436
			ELECTRICAL CIRCUIT DIAGRAM FOR M MODE...................................................................................................................................................438
			M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED; [E102] ERROR IN CLOCK DATA IS DISPLAYED..............................................................................................440
			M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED.......................................................................441
			M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED...........................................................................................................................................442
			M-4 [E106] DROP IN ENGINE OIL PRESSURE DETECTED IS DISPLAYED............................................................................................................................442
			M-5 [E108] ENGINE WATER TEMPERATURE 105 c  DETECTED IS DISPLAYED........................................................................................................................443
			M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL LIGHT UP FOR 3 SECONDS....................................................................................444
			M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT........................................................................................446
			M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)......................................................................446
			M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES.......................................................................................................447
			M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP....................................................................................................................449
			M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH...................................................................................................450
			M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)......................................452
			M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN ENGINE OR ITEMS TO CHECK BEFORE TROUBLESHOOTING)....454
			M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND..............................................457
			M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS...........................................................................................................................457
			M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)...............................................................................................458
			M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE............................................................................................................................................459
			M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)................................................................................459
			M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL..............................................................................................................................................460
			M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY.............................................................................................................................................460
			M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP...................................................................................................461
			M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH.................................................................................................461
			M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING.............................................................................................................................462
			M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED................................................................................462
			M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM.................................................................................................................................................463
			M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM........................................................................................................................................464
			M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM...........................................................................................................................................465
			M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM..............................................................................................................................................466
			M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED..............................................................................................................467
30 DISASSEMBLY AND ASSEMBLY.........................................................................................................................................................................473
	METHOD OF USING MANUAL..........................................................................................................................................................................475
	PRECAUTIONS WHEN CARRYING OUT OPERATION.........................................................................................................................................................477
	SPECIAL TOOL LIST...............................................................................................................................................................................479
	GOVERNOR MOTOR ASSEMBLY.........................................................................................................................................................................482
		REMOVAL AND INSTALLATION....................................................................................................................................................................482
	HYDRAULIC OIL COOLER ASSEMBLY...................................................................................................................................................................483
		REMOVAL AND INSTALLATION....................................................................................................................................................................483
	RADIATOR * HYDRAULIC OIL COOLER ASSEMBLY........................................................................................................................................................484
		REMOVAL.....................................................................................................................................................................................484
		INSTALLATION................................................................................................................................................................................485
	ENGINE * HYDRAULIC PUMP ASSEMBLY................................................................................................................................................................486
		REMOVAL.....................................................................................................................................................................................486
		INSTALLATION................................................................................................................................................................................489
	DAMPER ASSEMBLY.................................................................................................................................................................................490
		REMOVAL AND INSTALLATION....................................................................................................................................................................490
	FUEL/HYDRAULIC TANK ASSEMBLY....................................................................................................................................................................491
		REMOVAL.....................................................................................................................................................................................491
		INSTALLATION................................................................................................................................................................................492
	CENTER SWIVEL JOINT ASSEMBLY....................................................................................................................................................................493
		DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................493
	TRAVEL MOTOR ASSEMBLY...........................................................................................................................................................................494
		REMOVAL AND INSTALLATION....................................................................................................................................................................494
	FINAL DRIVE ASSEMBLY............................................................................................................................................................................495
		REMOVAL AND INSTALLATION....................................................................................................................................................................495
	SPROCKET........................................................................................................................................................................................497
		REMOVAL AND INSTALLATION....................................................................................................................................................................497
	SWING MOTOR ASSEMBLY............................................................................................................................................................................498
		REMOVAL AND INSTALLATION....................................................................................................................................................................498
	SWING MACHINERY ASSEMBLY........................................................................................................................................................................499
		REMOVAL AND INSTALLATION....................................................................................................................................................................499
	SWING MOTOR.....................................................................................................................................................................................501
		DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................501
	REVOLVIING FRAME ASSEMBLY.......................................................................................................................................................................508
		REMOVAL.....................................................................................................................................................................................508
		INSTALLATION................................................................................................................................................................................509
	SWING CIRCLE ASSEMBLY...........................................................................................................................................................................510
		REMOVAL.....................................................................................................................................................................................510
		INSTALLATION................................................................................................................................................................................511
	IDLER * RECOIL SPRING ASSEMBLY..................................................................................................................................................................512
		REMOVAL AND INSTALLATION....................................................................................................................................................................512
	RECOIL SPRING ASSEMBLY..........................................................................................................................................................................513
		DISASSEMBLY.................................................................................................................................................................................513
		ASSEMBLY....................................................................................................................................................................................514
	IDLER ASSEMBLY..................................................................................................................................................................................515
		DISASSEMBLY.................................................................................................................................................................................515
		ASSEMBLY....................................................................................................................................................................................516
	TRACK ROLLER....................................................................................................................................................................................518
		REMOVAL AND INSTALLATION....................................................................................................................................................................518
		DISASSEMBLY.................................................................................................................................................................................519
		ASSEMBLY....................................................................................................................................................................................520
	CARRIER ROLLER ASSEMBLY.........................................................................................................................................................................522
		REMOVAL AND INSTALLATION....................................................................................................................................................................522
		DISASSEMBLY.................................................................................................................................................................................523
		ASSEMBLY....................................................................................................................................................................................524
	TRACK SHOE ASSEMBLY.............................................................................................................................................................................526
		REMOVAL AND INSTALLATION....................................................................................................................................................................526
	MAIN PUMP ASSEMBLY..............................................................................................................................................................................529
		REMOVAL.....................................................................................................................................................................................529
		INSTALLATION................................................................................................................................................................................530
	CONTROL VALVE ASSEMBLY..........................................................................................................................................................................531
		REMOVAL.....................................................................................................................................................................................531
		INSTALLATION ...............................................................................................................................................................................532
		DISASSEMBLY.................................................................................................................................................................................533
		ASSEMBLY....................................................................................................................................................................................535
	LS SELECT VALVE ASSEMBLY........................................................................................................................................................................537
		DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................537
	LS SHUTTLE VALVE................................................................................................................................................................................538
		DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................538
	PRESSURE COMPENSATION VALVE ASSEMBLY............................................................................................................................................................539
		DISASSEMBLY.................................................................................................................................................................................539
		ASSEMBLY....................................................................................................................................................................................540
	MAIN RELIEF VALVE ASSEMBLY......................................................................................................................................................................541
		DISASSEMBLY.................................................................................................................................................................................541
		ASSEMBLY....................................................................................................................................................................................542
	LS CONTROL EPC VALVE ASSEMBLY...................................................................................................................................................................543
		REMOVAL AND INSTALLATION....................................................................................................................................................................543
	SOLENOID VALVE ASSEMBLY.........................................................................................................................................................................544
		REMOVAL AND INSTALLATION....................................................................................................................................................................544
	PPC SHUTTLE VALVE ASSEMBLY......................................................................................................................................................................545
		REMOVAL.....................................................................................................................................................................................545
		INSTALLATION................................................................................................................................................................................546
		DISASSEMBLY.................................................................................................................................................................................547
		ASSEMBLY....................................................................................................................................................................................548
	WORK EQUIPMENT SWING PPC VALVE ASSEMBLY.........................................................................................................................................................549
		REMOVAL AND INSTALLATION....................................................................................................................................................................549
	TRAVEL PPC VALVE ASSEMBLY.......................................................................................................................................................................550
		REMOVAL AND INSTALLATION....................................................................................................................................................................550
		DISASSEMBLY AND ASSEMBLY....................................................................................................................................................................551
	BOOM CYLINDER ASSEMBLY..........................................................................................................................................................................553
		REMOVAL.....................................................................................................................................................................................553
		INSTALLATION................................................................................................................................................................................554
	ARM CYLINDER ASSEMBLY...........................................................................................................................................................................555
		REMOVAL.....................................................................................................................................................................................555
		INSTALLATION................................................................................................................................................................................556
	BUCKET CYLINDER ASSEMBLY........................................................................................................................................................................557
		REMOVAL.....................................................................................................................................................................................557
		INSTALLATION................................................................................................................................................................................558
	HYDRAULIC CYLINDER ASSEMBLY.....................................................................................................................................................................559
		DISASSEMBLY.................................................................................................................................................................................559
		ASSEMBLY....................................................................................................................................................................................561
	WORK EQUIPMENT ASSEMBLY.........................................................................................................................................................................564
		REMOVAL.....................................................................................................................................................................................564
		INSTALLATION................................................................................................................................................................................565
	BUCKET ASSEMBLY.................................................................................................................................................................................566
		REMOVAL AND INSTALLATION....................................................................................................................................................................566
	ARM ASSEMBLY....................................................................................................................................................................................566
		REMOVAL AND INSTALLATION....................................................................................................................................................................566
	ARM, BUCKET ASSEMBLY............................................................................................................................................................................568
		REMOVAL AND INSTALLATION....................................................................................................................................................................568
	BOOM ASSEMBLY...................................................................................................................................................................................570
		REMOVAL.....................................................................................................................................................................................570
		INSTALLATION ...............................................................................................................................................................................571
	OPERATOR'S CAB ASSEMBLY.........................................................................................................................................................................572
		REMOVAL.....................................................................................................................................................................................572
		INSTALLATION................................................................................................................................................................................574
	COUNTERWEIGHT ASSEMBLY..........................................................................................................................................................................575
		REMOVAL AND INSTALLATION....................................................................................................................................................................575
	GOVERNOR, PUMP CONTROLLER ASSEMBLY..............................................................................................................................................................576
		REMOVAL AND INSTALLATION....................................................................................................................................................................576
	MONITOR PANEL ASSEMBLY..........................................................................................................................................................................577
		REMOVAL AND INSTALLATION....................................................................................................................................................................577
	FINAL DRIVE ASSEMBLY............................................................................................................................................................................583
		DISASSEMBLY.................................................................................................................................................................................583
		ASSEMBLY....................................................................................................................................................................................594
		(SPECIAL TOOLS).............................................................................................................................................................................606
	SWING MACHINERY ASSEMBLY........................................................................................................................................................................613
		DISASSEMBLY.................................................................................................................................................................................613
		ASSEMBLY....................................................................................................................................................................................629
		(SPECIAL TOOLS).............................................................................................................................................................................649
40 MAINTENANCE STANDARD.............................................................................................................................................................................653
	ENGINE MOUNT....................................................................................................................................................................................654
	SWING MACHINERY.................................................................................................................................................................................655
	SWING CIRCLE....................................................................................................................................................................................657
	FINAL DRIVE.....................................................................................................................................................................................658
	TRACK FRAME, RECOIL SPRING......................................................................................................................................................................660
	IDLER...........................................................................................................................................................................................661
	CARRIER ROLLER..................................................................................................................................................................................663
	TRACK ROLLER....................................................................................................................................................................................664
	TRACK SHOE......................................................................................................................................................................................665
	CONTROL VALVE...................................................................................................................................................................................667
	SUCTION-SAFETY VALVE............................................................................................................................................................................675
	SWING MOTOR.....................................................................................................................................................................................676
	WORK EQUIPMENT, SWING PPC VALVE.................................................................................................................................................................677
	TRAVEL PPC VALVE................................................................................................................................................................................678
	SERVICE PPC VALVE...............................................................................................................................................................................679
	PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE........................................................................................................................................................680
	EPC SOLENOID VALVE..............................................................................................................................................................................681
	CENTER SWIVEL JOINT.............................................................................................................................................................................682
	ARM, BOOM SAFETY VALVE..........................................................................................................................................................................683
	HYDRAULIC CYLINDER..............................................................................................................................................................................684
	WORK EQUIPMENT..................................................................................................................................................................................685

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]