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KOMATSU PC160LC-7 SERVICE REPAIR MANUAL (SN:10001 & UP) – PDF DOWNLOAD
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KOMATSU PC160LC-7 SERVICE REPAIR MANUAL
Publication NumberSEBM028606
SERIAL NUMBER:10001 & UP
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Description
KOMATSU PC160LC-7 SERVICE REPAIR MANUAL (SN:10001 & UP)
KOMATSU PC160LC-7 SERVICE REPAIR MANUAL (SN:10001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC160LC-7 SERVICE REPAIR MANUAL (SN:10001 & UP)
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following 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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards. - 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” with “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them. - MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION. - OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
KOMATSU PC160LC-7 SERVICE REPAIR MANUAL (SN:10001 & UP)
COVER............................................................................................................................. 1 CONTENTS.......................................................................................................................... 2 01 GENERAL........................................................................................................................ 27 SPECIFICATION DIMENSION DRAWINGS ............................................................................................. 28 SPECIFICATIONS................................................................................................................ 30 WEIGHT TABLE.................................................................................................................. 32 FUEL,COOLANT,AND LUBRICANTS................................................................................................... 34 10 STRUCTURE, FUNCTION, AND MAINTENANCE STANDARD.................................................................................. 35 ENGINE RELATED PARTS.......................................................................................................... 36 RADIATOR・OIL COOLER・AFTERCOOLER............................................................................................... 37 POWER TRAIN................................................................................................................... 38 SWING MACHINERY............................................................................................................... 39 SWING CIRCLE.................................................................................................................. 40 FINAL DRIVE................................................................................................................... 41 TRACK FRAME・RECOIL SPRING..................................................................................................... 43 IDLER......................................................................................................................... 45 CARRIER ROLLER................................................................................................................ 47 TRACK ROLLER.................................................................................................................. 48 TRACK SHOE.................................................................................................................... 49 HYDRAULIC EQUIPMENT LAYOUT DRAWING............................................................................................ 53 VALVE CONTROL................................................................................................................. 55 HYDRAULIC TANK................................................................................................................ 56 HYDRAULIC PUMP................................................................................................................ 57 PC-EPC VALVE.................................................................................................................. 75 CONTROL VALVE................................................................................................................. 80 CLSS.......................................................................................................................... 93 TRAVEL JUNCTION VALVE.........................................................................................................123 SELF-REDUCING PRESSURE VALVE..................................................................................................124 CENTER SWIVEL JOINT...........................................................................................................125 SWING MOTOR ..................................................................................................................126 TRAVEL MOTOR..................................................................................................................127 WORK EQUIPMENT・SWING PPC VALVE................................................................................................136 TRAVEL PPC VALVE..............................................................................................................140 SERVICE PPC VALVE.............................................................................................................149 SOLENOID VALVE................................................................................................................152 ACCUMULATOR...................................................................................................................154 RETURN OIL FILTER ............................................................................................................155 ATTACHMENT CIRCUIT SELECTOR VALVE.............................................................................................156 HYDRAULIC CYLINDER............................................................................................................158 WORK EQUIPMENT................................................................................................................160 AIR CONDITIONER...............................................................................................................166 ENGINE CONTROL................................................................................................................167 ELECTRONIC CONTROL SYSTEM ....................................................................................................173 MULTI MONITOR SYSTEM..........................................................................................................198 7-SEGMENT MONITOR SYSTEM......................................................................................................218 SENSOR........................................................................................................................225 20 TESTING AND ADJUSTING..........................................................................................................228 STANDARD VALVE TABLE FOR ENGINE RELATED PARTS.................................................................................229 STANDARD VALVE TABLE FOR CHASSIS RELATED PARTS................................................................................230 TESTING AND ADJUSTING.........................................................................................................239 TOOLS FOR TESTING,ADJUSTING AND TROUBLESHOOTING...........................................................................240 INSPECTION AND ADJUSTING OF ENGINE RPM....................................................................................242 MEASUREMENT OF EXHAUST GAS COLOR..........................................................................................244 ADJUSTMENT OF VALVE CLEARANCE.............................................................................................245 MEASUREMENT OF COMPRESSION PRESSURE.......................................................................................247 MEASUREMENT OF BLOW-BY PRESSURE...........................................................................................248 INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING........................................................................249 MEASUREMENT OF ENGINE OIL PRESSURE........................................................................................251 ADJUSTMENT OF ENGINE SPEED SENSOR.........................................................................................252 INSPECTION AND ADJUSTMENT OF AIR COMPRESSOR BELT TENSION..................................................................253 MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS.........................................................................254 INSPECTION AND ADJUSTMENT OF TRACK SHOE TENSION...........................................................................255 INSPECTION AND ADJUSTMENT OIL PRESSURE IN WORK EQUIPMENT,SWING, AND TRAVEL CIRCUITS.......................................256 INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE.................................................................259 INSPECTION AND ADJUSTMENT OF PUMP PC CONTROL CIRCUIT OIL PRESSURE.........................................................260 INSPECTION AND ADJUSTMENT PUMP LS CONTROL CIRCUIT OIL PRESSURE............................................................263 MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE.............................................................................266 MEASUREMENT OF PPC VALVE OUTPUT PRESSURE..................................................................................269 ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE..........................................................................270 INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT..............................................................271 TESTING AND ADJUSTING TRAVEL DEVIATION ...................................................................................273 RELEASE OF RESIDUAL PRESSURE FROM HYDRAULIC CIRCUIT.......................................................................275 MEASUREMENT OF OIL LEAKAGE ...............................................................................................276 BLEEDING AIR FROM EACH PART...............................................................................................278 INSPECTION PROCEDURES FOR DIODE...........................................................................................280 SPECIAL FUNCTION OF MONITOR PANEL.........................................................................................281 SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL.............................................................................306 PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM........................................................................322 PM-TUNE UP SERVICE .......................................................................................................324 TROUBLESHOOTING...............................................................................................................329 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................330 SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................................331 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..........................................................................332 CHECKS BEFORE TROUBLESHOOTING ............................................................................................340 CLASSIFICATION AND STEPS FOR TROUBLESHOOTING..............................................................................341 CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM.........................................................345 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................................378 T-ADAPTER-BOXES AND T-ADAPTER TABLE ......................................................................................401 TROUBLESHOOTING ERROR CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED.........................404 BEFORE TROUBLESHOOTING FOR DISPLAYED CODE.............................................................................406 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE........................................................................411 ERROR CODE IN ELECTRICAL SYSTEM[E101](ABNORMAL DATA IN ERROR HISTORY).................................................413 ERROR CODE IN ELECTRICAL SYSTEM[E112](SHORT-CIRCUITING IN NORMAL ROTATOIN SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE).....415 ERROR CODE IN ELECTRICAL SYSTEM[E113](SHORT-CIRCUITING IN REVERSE ROTATION SYSTEM OF WINDSHIELD WIPER MOTOR DRIVE)....417 ERROR CODE IN ELECTRICAL SYSTEM[E114](SHORT-CIRCUITING IN WINDOW WASHER DRIVE SYSTEM).................................419 ERROR CODE IN ELECTRICAL SYSTEM[E115](ABNORMAL OPERATION OF WINDSHIELD WIPER).........................................423 ERROR CODE IN ELECTRICAL SYSTEM[E116](ABNORMALITY OPERATION IN RETRACTING WINDSHIELD WIPER)...........................425 ERROR CODE IN ELECTRICAL SYSTEM[E201](SHORT-CIRCUITING IN TRAVEL JUNCTION SOLENOID)...................................427 ERROR CODE IN ELECTRICAL SYSTEM[E203](SHORT-CIRCUITING IN SWING HOLDING BRAKE SOLENOID)...............................431 ERROR CODE IN ELECTRICAL SYSTEM[E204](SHORT-CIRCUITING IN MERGE/DIVIDE SOLENOID)......................................435 ERROR CODE IN ELECTRICAL SYSTEM[E205](SHORT-CIRCUITING IN 2-STAGE RELIEF SOLENOID)....................................439 ERROR CODE IN ELECTRICAL SYSTEM[E206](SHORT-CIRCUITING IN TRAVEL SPEED SHIFTING SOLENOID).............................443 ERROR CODE IN ELECTRICAL SYSTEM[E211](DISCONNECTION IN TRAVEL JUNCTION SOLENOID)......................................447 ERROR CODE IN ELECTRICAL SYSTEM[E213](DISCONNECTION IN SWING HOLDING BRAKE SOLENOID)..................................451 ERROR CODE IN ELECTRICAL SYSTEM[E214](DISCONNECTION OF MERGE/DIVIDE SOLENOID).........................................455 ERROR CODE IN ELECTRICAL SYSTEM[E215](DISCONNECTION IN 2-STAGE RELIEF SOLENOID).......................................459 ERROR CODE IN ELECTRICAL SYSTEM[E216](DISCONNECTION IN TRAVEL SPEED SHIFTING SOLENOID)................................463 ERROR CODE IN ELECTRICAL SYSTEM[E217](ABNORMALITY IN INPUTTING MODEL CODE)............................................467 ERROR CODE IN ELECTRICAL SYSTEM[E218](DISCONNECTION OF S-NET SIGNAL)..................................................469 ERROR CODE IN ELECTRICAL SYSTEM[E224](ABNORMALITY IN F PUMP PRESSURE SENSOR)..........................................471 ERROR CODE IN ELECTRICAL SYSTEM[E225](ABNORMALITY IN R PUMP PRESSURE SENSOR)..........................................473 ERROR CODE IN ELECTRICAL SYSTEM[E226](ABNORMALITY IN PRESSURE SENSOR POWER SOURCE)....................................475 ERROR CODE IN ELECTRICAL SYSTEM[E227](ABNORMALITY IN ENGINE ROTATION SENSOR)..........................................477 ERROR CODE IN ELECTRICAL SYSTEM[E228](SHORT-CIRCUITING IN ATTACHMENT RETURN SWITCHING RELAY)..........................479 ERROR CODE IN ELECTRICAL SYSTEM[E232](SHORT-CIRCUITING IN PC-EPC SOLENOID)............................................481 ERROR CODE IN ELECTRICAL SYSTEM[E233](DISCONNECTION IN PC-EPC SOLENOID)...............................................483 ERROR CODE IN ELECTRICAL SYSTEM[E238](DISCONNECTION IN ATTACHMENT RETURN SWITCHING RELAY).............................485 ERROR CODE IN ELECTRICAL SYSTEM[E245](SHORT-CIRCUITING IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SOLENOID)............487 ERROR CODE IN ELECTRICAL SYSTEM[E246](DISCONNECTION IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SOLENOID)...............488 ERROR CODE IN ELECTRICAL SYSTEM[E306](ABNORMALITY IN GOVERNOR POTENTIOMETER)..........................................489 ERROR CODE IN ELECTRICAL SYSTEM[E308](ABNORMALITY IN FUEL DIAL).......................................................491 ERROR CODE IN ELECTRICAL SYSTEM[E311](SHORT-CIRCUITING IN COLD STARTING SOLENOID RELAY)...............................493 ERROR CODE IN ELECTRICAL SYSTEM[E312](DISCONNECTION IN COLD STARTING SOLENOID RELAY)..................................495 ERROR CODE IN ELECTRICAL SYSTEM[E315](SHORT-CIRCUITING IN BATTERY RELAY)..............................................497 ERROR CODE IN ELECTRICAL SYSTEM[E316](STEP-OUT IN GOVERNOR MOTOR).....................................................499 ERROR CODE IN ELECTRICAL SYSTEM[E317](DISCONNECTION IN GOVERNOR MOTOR PHASE A AND B)..................................500 ERROR CODE IN ELECTRICAL SYSTEM[E318](SHORT-CIRCUITING IN GOVERNOR MOTOR PHASE A AND PRASE B).........................502 FAILURE CODE IN MECHANICAL SYSTEM[A000N1](OUT-OF-RATE ENGINE ROTATION AT HIGH IDLING).................................504 FAILURE CODE IN MECHANICAL SYSTEM[A000N2](OUT-OF-RATE ENGINE ROTATION AT LOW IDLING)..................................504 FAILURE CODE IN MECHANICAL SYSTEM[AA10NX](AIR CLEANER CLOGGING).......................................................505 FAILURE CODE IN MECHANICAL SYSTEM[ABOOKE](ABNORMALLY LOWERED CHARGING VOLTAGE)........................................506 FAILURE CODE IN MECHANICAL SYSTEM[B@BAZG](ABNORMALLY LOWERED ENGINE OIL PRESSURE).....................................508 FAILURE CODE IN MECHANICAL SYSTEM[B@BAZK](ABNORMALLY LOWERED ENGINE OIL LEVEL)........................................509 FAILURE CODE IN MECHANICAL SYSTEM[B@BCNS](ENGINE COOLING WATER OVERHEATING)...........................................510 FAILURE CODE IN MECHANICAL SYSTEM[B@BAZK](ABNORMALLY LOWERED RADIATOR WATER LEVEL)....................................511 FAILURE CODE IN MECHANICAL SYSTEM[B@HANS](HYDRAULIC OIL OVERHEATING)..................................................512 TROUBLESHOOTING OF ELECTRICAL SYSTEM(E-MODE)..............................................................................513 BEFORE CONDUCTING E-MODE TROUBLESHOOTING .............................................................................514 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE........................................................................515 E-1 ENGINE DOES NOT START.............................................................................................516 E-2 ENGINE STOPS WHILE IN OPERATION...................................................................................521 E-3 ENGINE ROTATES UNSTABLY OR HUNTING ...............................................................................522 E-4 ENGINE DOES NOT STOP..............................................................................................524 E-5 AUTO-DECELERATOR DOES NOT WORK....................................................................................526 E-6 AUTO ENGINE WARM-UP DEVICE DOES NOT WORK..........................................................................527 E-7 PREHEATER DOES NOT OPERATE........................................................................................528 E-8 ALL WORK EQUIPMENT,SWING AND TRAVEL DO NOT MOVE...................................................................530 E-9 ONE-TOUCH POWER MAX SWITCH DOES NOT WORK..........................................................................532 E-10 ATTACHMENT CIRCUIT DOES NOT CHANGE ..............................................................................533 E-11 NO DISPLAY IN MONITOR PANEL AT ALL ..............................................................................534 E-12 MONITOR PANEL DOES NOT DISPLAY PARTIALLY ........................................................................536 E-13 CONTENTS OF MONITOR PANEL ARE DIFFERENT FROM MOUNTED MODEL.......................................................536 E-14 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .....................................................537 E-15 ENGINE COOLING WATER TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY...............................................538 E-16 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY.......................................................539 E-17 FUEL GAUGE DOES NOT DISPLAY CORRECTLY............................................................................540 E-18 SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY....................................................................541 E-19 WHEN MONITOR SWITCH IS OPERATED,NOTHING IS DISPLAYED.............................................................543 E-20 WINDSHIELD WIPER AND WINDOW WASHER DOES NOT WORK.................................................................545 E-21 ALARMING BUZZER CANNOT BE CANCELLED..............................................................................551 E-22 "BOOM RAISE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................................................552 E-23 "BOOM LOWER" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION......................................................553 E-24 "ARM IN" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION..........................................................554 E-25 "ARM OUT" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.........................................................555 E-26 "BUCKET CURL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....................................................556 E-27 "BUCKET DUMP" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.....................................................557 E-28 "SWING" IS NOT CORRECTLY DISPLAYED IS MONITOR FUNCTION...........................................................558 E-29 "TRAVEL" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION .........................................................560 E-30 "TRAVEL DIFFERENTIAL PRESSURE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION....................................562 E-31 "SERVICE" IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION.........................................................564 E-32 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM.......................................................................566 E-33 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING............................................................579 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...............................................................581 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE........................................................................582 SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS.....................................................................583 H-1 SPEED OR POWER OF ALL WORK EQUIPMENT, SWING, AND TRAVEL ARE LOW...................................................585 H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS.......................................................................586 H-3 NO WORK EQUIPMENT,TRAVEL OR SWING MOVE ...........................................................................587 H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP................................................................587 H-5 AUTO-DECELERATOR DOES NOT WORK....................................................................................588 H-6 FINE CONTROL MODE DOES NOT FUNCTION...............................................................................588 H-7 SPEED OR POWER OF BOOM IS LOW.....................................................................................589 H-8 SPEED OR POWER OF ARM IS LOW......................................................................................590 H-9 SPEED OR POWER OF BUCKET IS LOW ..................................................................................591 H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION.............................................................592 H-11 HYDRAULIC DRIFT OF WORK EQUIPMENT IS LARGE ......................................................................593 H-12 TIME LAG OF WORK EQUIPMENT IS LARGE..............................................................................594 H-13 ONE-TOUCH POWER MAX SYSTEM DOES NOT OPERATE......................................................................594 H-14 WORK EQUIPMENT LOADED MORE IS LOWER DURING COMPOUND OPERATION ...................................................595 H-15 BOOM RAISE SPEED IS LOW IN COMPOUND OPERATION OF SWING+BOOM RAISE................................................595 H-16 TRAVEL SPEED LOWERS LARGELY DURING COMPOUND OPERATION OF WORK EQUIPMENT/SWING+TRAVEL ............................596 H-17 MACHINE DEVIATES DURING TRAVEL ..................................................................................597 H-18 TRAVEL SPEED IS LOW .............................................................................................598 H-19 MACHINE CANNOT BE STEERED EASILY OR STEERING POWER IS LOW........................................................599 H-20 TRAVEL SPEED DOES NOT CHANGE, OR IT IS KEPT LOW OR HIGH..........................................................600 H-21 TRACK DOES NOT MOVE (ONLY EITHER SIDE)...........................................................................600 H-22 MACHINE DOES NOT SWING ..........................................................................................601 H-23 SWING ACCELERATION OR SWING SPEED IS LOW.........................................................................602 H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING ...........................................................................603 H-25 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SHOCK .......................................................604 H-26 WHEN UPPER STRUCTURE STOPS SWINGING, IT MAKES LARGE SOUND........................................................604 H-27 HYDRAULIC DRIFT OF SWING IS LARGE ...............................................................................605 H-28 ATTACHMENT CIRCUIT DOES NOT CHANGE ..............................................................................606 H-29 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED...............................................................606 TROUBLESHOOTING OF ENGINE (S-MODE)........................................................................................607 METHOD OF USING TROUBLESHOOTING CHARTS................................................................................608 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).........................................................612 S-2 ENGINE DOES NOT START.............................................................................................614 (1) ENGINE DOES NOT TURN..........................................................................................614 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)......................................615 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....................................616 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)..............................................................617 S-4 ENGINE STOPS DURING OPERATIONS....................................................................................618 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).........................................................................619 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)..............................................................................620 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....................................................................621 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...........................................................622 S-9 OIL BECOMES CONTAMINATED QUICKLY..................................................................................623 S-10 FUEL CONSUMPTION IS EXCESSIVE....................................................................................624 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN............................................625 S-12 OIL PRESSURE MONITOR LIGHTS UP (DROP IN OIL PRESSURE)............................................................626 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)..............................................................................627 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).................................................................628 S-15 ABNORMAL NOISE IS MADE...........................................................................................629 S-16 VIBRATION IS EXCESSIVE...........................................................................................630 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................631 HOW TO READ THIS MANUAL ......................................................................................................633 PRECAUTIONS WHEN PERFORMING OPERATION ........................................................................................635 SPECIAL TOOL LIST ............................................................................................................637 SKETCHES OF SPECIAL TOOLS ....................................................................................................641 STARTING MOTOR ...............................................................................................................642 REMOVAL AND INSTALLATION .................................................................................................642 FUEL INJECTION PUMP ..........................................................................................................643 SPECIAL TOOLS ............................................................................................................643 REMOVAL...................................................................................................................643 INSTALLATION .............................................................................................................645 ENGINE FRONT SEAL.............................................................................................................647 REMOVAL ..................................................................................................................647 INSTALLATION .............................................................................................................649 ENGINE REAR SEAL..............................................................................................................651 REMOVAL...................................................................................................................651 INSTALLATION..............................................................................................................652 CYLINDER HEAD ................................................................................................................653 SPECIAL TOOLS.............................................................................................................653 REMOVAL...................................................................................................................653 INSTALLATION..............................................................................................................656 RADIATOR......................................................................................................................659 REMOVAL AND INSTALLATION .................................................................................................659 AFTERCOOLER ..................................................................................................................660 REMOVAL AND INSTALLATION .................................................................................................660 HYDRAULIC OIL COOLER .........................................................................................................661 REMOVAL AND INSTALLATION .................................................................................................661 ENGINE AND HYDRAULIC PUMP ....................................................................................................662 SPECIAL TOOLS.............................................................................................................662 REMOVAL ..................................................................................................................662 INSTALLATION .............................................................................................................665 TRACK SHOE ...................................................................................................................667 SPECIAL TOOLS ............................................................................................................667 EXPANSION ................................................................................................................667 INSTALLATION .............................................................................................................668 SPROCKET .....................................................................................................................669 REMOVAL AND INSTALLATION .................................................................................................669 FINAL DRIVE ..................................................................................................................670 REMOVAL AND INSTALLATION .................................................................................................670 SPECIAL TOOLS ............................................................................................................671 DISASSEMBLY ..............................................................................................................671 ASSEMBLY..................................................................................................................673 IDLER.........................................................................................................................678 SPECIAL TOOLS ............................................................................................................678 DISASSEMBLY ..............................................................................................................678 ASSEMBLY..................................................................................................................679 RECOIL SPRING ................................................................................................................681 SPECIAL TOOLS ............................................................................................................681 DISASSEMBLY...............................................................................................................681 ASSEMBLY .................................................................................................................682 TRACK ROLLER..................................................................................................................683 SPECIAL TOOLS ............................................................................................................683 DISASSEMBLY AND ASSEMBLY .................................................................................................683 CARRIER ROLLER................................................................................................................684 SPECIAL TOOLS ............................................................................................................684 DISASSEMBLY AND ASSEMBLY .................................................................................................684 SWING MOTOR AND SWING MACHINERY ..............................................................................................685 REMOVAL AND INSTALLATION .................................................................................................685 SPECIAL TOOLS ............................................................................................................686 DISASSEMBLY...............................................................................................................686 ASSEMBLY .................................................................................................................689 SWING MOTOR ..................................................................................................................694 SPECIAL TOOLS ............................................................................................................694 DISASSEMBLY ..............................................................................................................694 ASSEMBLY..................................................................................................................697 CENTER SWIVEL JOINT ..........................................................................................................702 REMOVAL...................................................................................................................702 INSTALLATION .............................................................................................................703 SPECIAL TOOLS ............................................................................................................704 DISASSEMBLY AND ASSEMBLY..................................................................................................704 WORK EQUIPMENT................................................................................................................705 SPECIAL TOOLS.............................................................................................................705 REMOVAL ..................................................................................................................705 INSTALLATION .............................................................................................................707 REVOLVING FRAME ..............................................................................................................708 REMOVAL ..................................................................................................................708 INSTALLATION .............................................................................................................709 SWING CIRCLE .................................................................................................................710 REMOVAL AND INSTALLATION .................................................................................................710 HYDRAULIC TANK ...............................................................................................................711 REMOVAL...................................................................................................................711 INSTALLATION .............................................................................................................713 CONTROL VALVE.................................................................................................................714 REMOVAL ..................................................................................................................714 INSTALLATION .............................................................................................................717 DISASSEMBLY AND ASSEMBLY..................................................................................................718 HYDRAULIC PUMP ...............................................................................................................720 SPECIAL TOOLS ............................................................................................................720 REMOVAL ..................................................................................................................720 INSTALLATION .............................................................................................................721 HYDRAULIC PUMP INPUT SHAFT OIL SEAL...........................................................................................722 SPECIAL TOOLS ............................................................................................................722 REMOVAL AND INSTALLATION..................................................................................................722 WORK EQUIPMENT PPC VALVE .....................................................................................................723 DISASSEMBLY AND ASSEMBLY .................................................................................................723 TRAVEL PPC VALVE .............................................................................................................724 DISASSEMBLY AND ASSEMBLY .................................................................................................724 HYDRAULIC CYLINDER ...........................................................................................................725 SPECIAL TOOLS ............................................................................................................725 DISASSEMBLY ..............................................................................................................725 ASSEMBLY .................................................................................................................727 COUNTERWEIGHT.................................................................................................................731 REMOVAL AND INSTALLATION .................................................................................................731 AIR CONDITIONER UNIT .........................................................................................................732 SPECIAL TOOLS ............................................................................................................732 REMOVAL ..................................................................................................................732 INSTALLATION .............................................................................................................734 OPERATOR'S CAB ...............................................................................................................737 REMOVAL...................................................................................................................737 INSTALLATION .............................................................................................................739 OPERATOR'S CAB GLASS (STUCK GLASS)............................................................................................743 SPECIAL TOOLS.............................................................................................................744 REMOVAL ..................................................................................................................744 INSTALLATION .............................................................................................................745 FRONT WINDOW .................................................................................................................754 REMOVAL ..................................................................................................................754 INSTALLATION .............................................................................................................756 MONITOR.......................................................................................................................759 REMOVAL AND INSTALLATION .................................................................................................759 GOVERNOR,PUMP CONTROLLER .....................................................................................................760 REMOVAL AND INSTALLATION .................................................................................................760 90 OTHERS.........................................................................................................................761 HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................762 SERIAL NO.:10001-11000........................................................................................................763 ELECTRICAL CIRCUIT DIAGRAM (1/4)..........................................................................................763 ELECTRICAL CIRCUIT DIAGRAM (2/4)..........................................................................................764 ELECTRICAL CIRCUIT DIAGRAM (3/4)..........................................................................................765 ELECTRICAL CIRCUIT DIAGRAM (4/4)..........................................................................................766 SERIAL NO.:11001 AND UP.......................................................................................................767 ELECTRICAL CIRCUIT DIAGRAM (1/4)..........................................................................................767 ELECTRICAL CIRCUIT DIAGRAM (2/4)..........................................................................................768 ELECTRICAL CIRCUIT DIAGRAM (3/4)..........................................................................................769 ELECTRICAL CIRCUIT DIAGRAM (4/4)..........................................................................................770
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