Komatsu PC200-6 C10001 and up Hydraulic Excavator Shop Manual – PDF DOWNLOAD

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Komatsu PC200-6 C10001 and up Hydraulic Excavator Shop Manual

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Komatsu PC200-6 C10001 and up Hydraulic Excavator Shop Manual 

Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200-6
Serial Number: C10001 and up
Book Code: SEBM010201K
Language: English
Pages: 531
File Format: Portable Document Format (PDF)

KOMATSU PC200-6 C10001 AND UP HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD:

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DESCRIPTION:

Komatsu PC200-6 C10001 and up 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 PC200-6 C10001 and up Hydraulic Excavator Shop Manual 

MAIN MENU.....................................................................................................................................  0
COVER.........................................................................................................................................  1
CONTENTS......................................................................................................................................  2
SAFETY .......................................................................................................................................  3
	SAFETY NOTICE ............................................................................................................................  3
FOREWORD .....................................................................................................................................  5
	GENERAL...................................................................................................................................  5
	HOW TO READ THE SHOP MANUAL...............................................................................................................  6
	HOISTING INSTRUCTIONS.....................................................................................................................  7
	COATING MATERIALS.........................................................................................................................  8
	STANDARD TIGHTENING TORQUE................................................................................................................ 10
	ELECTRIC WIRE CODE........................................................................................................................ 13
	CONVERSION TABLE.......................................................................................................................... 14
01 GENERAL.................................................................................................................................... 20
	SPECIFICATION DIMENSION DRAWINGS.......................................................................................................... 21
	SPECIFICATIONS ........................................................................................................................... 22
	WEIGHT TABLE ............................................................................................................................. 24
	FUEL, COOLANT AND LUBRICANTS.............................................................................................................. 26
10 STRUCTURE AND FUNCTION..................................................................................................................... 28
	ENGINE RELATED PARTS ..................................................................................................................... 29
	RADIATOR, OIL COOLER, AFTERCOOLER ........................................................................................................ 30
	ENGINE CONTROL ........................................................................................................................... 31
	POWER TRAIN .............................................................................................................................. 32
	FINAL DRIVE .............................................................................................................................. 33
	SWING CIRCLE ............................................................................................................................. 34
	SWING MACHINERY .......................................................................................................................... 35
	TRACK FRAME, RECOIL SPRING ............................................................................................................... 36
	TRACK SHOE ............................................................................................................................... 37
	HYDRAULIC PIPING DRAWING.................................................................................................................. 38
	HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................ 39
	HYDRAULIC TANK ........................................................................................................................... 40
	HYDRAULIC PUMP ........................................................................................................................... 41
	CONTROL VALVE ............................................................................................................................ 60
	SELF-REDUCING PRESSURE VALVE ............................................................................................................. 68
	CLSS ..................................................................................................................................... 73
	SWING MOTOR...............................................................................................................................107
	CENTER SWIVEL JOINT.......................................................................................................................111
	TRAVEL MOTOR..............................................................................................................................113
	VALVE CONTROL.............................................................................................................................121
	WORK EQUIPMENT, SWING PPC VALVE...........................................................................................................122
	TRAVEL PPC VALVE..........................................................................................................................126
	SERVICE PPC VALVE.........................................................................................................................130
	ACCUMULATOR...............................................................................................................................133
	STRAIGHT-TRAVEL SYSTEM....................................................................................................................134
	EPC SOLENOID VALVE........................................................................................................................135
	BOOM HOLDING VALVE........................................................................................................................137
	ADDITIONAL FILTER FOR BREAKER.............................................................................................................140
	WORK EQUIPMENT............................................................................................................................141
	ACTUAL ELECTRICAL WIRING DIAGRAM..........................................................................................................142
	ELECTRICAL CIRCUIT DIAGRAM................................................................................................................144
	ELECTRIC CONTROL SYSTEM...................................................................................................................146
	MACHINE MONITOR SYSTEM....................................................................................................................153
	SENSORS...................................................................................................................................156
20 TESTING AND ADJUSTING......................................................................................................................158
	STANDARD VALUE TABLE FOR ENGINE RELATED PARTS ............................................................................................159
	STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS ...........................................................................................160
	STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM ...............................................................................................168
	TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ........................................................................................171
	MEASURING ENGINE SPEED....................................................................................................................172
	MEASURING EXHAUST GAS COLOR ..............................................................................................................173
	ADJUSTING VALVE CLEARANCE ................................................................................................................174
	MEASURING COMPRESSION PRESSURE ...........................................................................................................175
	MEASURING BLOW-BY PRESSURE ...............................................................................................................175
	TESTING AND ADJUSTING FUEL INJECTION TIMING ..............................................................................................176
	MEASURING ENGINE OIL PRESSURE ............................................................................................................177
	TESTING AND ADJUSTING FAN BELT TENSION ...................................................................................................178
	TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR ........................................................................178
	MEASURING SPEED SENSOR ...................................................................................................................179
	ADJUSTING FUEL CONTROL LEVER .............................................................................................................180
	TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT ........................................................182
	TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) .............................................................185
	TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE ................................187
	TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE .......................................................................................190
	TESTING SOLENOID VALVE OUTPUT PRESSURE ...................................................................................................191
	MEASURING PPC VALVE OUTPUT PRESSURE ......................................................................................................192
	ADJUSTING WORK EQUIPMENT, SWING PPC VALVE ................................................................................................194
	TESTING TRAVEL DEVIATION .................................................................................................................195
	TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ..............................................................................196
	MEASURING OIL LEAKAGE ....................................................................................................................198
	RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT ........................................................................................200
	TESTING CLEARANCE OF SWING CIRCLE BEARING.................................................................................................201
	TESTING AND ADJUSTING TRACK SHOE TENSION..................................................................................................202
	BLEEDING AIR..............................................................................................................................203
	TROUBLESHOOTING...........................................................................................................................205
		POINTS TO REMEMBER WHEN TROUBLESHOOTING...............................................................................................206
		SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................................................207
		POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE......................................................................................208
		CHECKS BEFORE TROUBLESHOOTING.........................................................................................................216
		CONNECTOR TYPES AND MOUNTING LOCATIONS................................................................................................217
		CONNECTION TABLE FOR CONNECTOR PIN NUMBERS............................................................................................222
		METHOD OF USING TROUBLESHOOTING CHARTS................................................................................................232
		TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).............................................................................................234
			METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................235
			S-1 Starting performance is poor (starting always takes time).....................................................................239
			S-2 Engine does not start.........................................................................................................240
				(1) Engine does not turn......................................................................................................240
				(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)..................................................241
				(3) Exhaust smoke comes out but engine does not start (fuel is being injected)................................................242
			S-3 Engine does not pick up smoothly (follow-up is poor)..........................................................................243
			S-4 Engine stops during operations................................................................................................244
			S-5 Engine does not rotate smoothly (hunting).....................................................................................245
			S-6 Engine lacks output (no power)................................................................................................246
			S-7 Exhaust smoke is black (incomplete combustion)................................................................................247
			S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................................................248
			S-9 Oil becomes contaminated quickly..............................................................................................249
			S-10 Fuel consumption is excessive................................................................................................250
			S-11 Oil is in cooling water, or water spurts back, or water level goes down......................................................251
			S-12 Oil pressure caution lamp lights up (drop in oil pressure)...................................................................252
			S-13 Oil level rises (water, fuel in oil).........................................................................................253
			S-14 Water temperature becomes too high (overheating).............................................................................254
			S-15 Abnormal noise is made.......................................................................................................255
			S-16 Vibration is excessive.......................................................................................................256
		TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).........................................................................................257
			JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS.................................................................258
			ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM......................................................................................260
			FAILURE CODES.....................................................................................................................261
				E-1 Abnormality in PC-EPC control system......................................................................................261
					a) Engine stops even when throttle lever is not returned to STOP position. When sudden load is applied, engine stalls.....261
					b) Lacks power when throttle lever is at FULL, work equipment speed is slow...............................................262
				E-2 Abnormality in travel speed selector system (travel speed does not switch)................................................264
				E-3 Abnormality in swing holding brake solenoid system........................................................................265
					a) Swing holding brake solenoid is not actuated (cannot swing)............................................................265
					b) Remains actuated (swing cannot be locked)..............................................................................266
				E-4 Abnormality in PPC oil pressure lock solenoid system......................................................................267
					a) Solenoid is not actuated (safety lock is not canceled).................................................................267
					b) Remains actuated (safety lock is not actuated).........................................................................268
				E-5 Abnormality in engine starting system (engine does not start).............................................................269
		TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)...........................................................................272
			TABLE OF FAILURE MODES AND CAUSES (1/2)...........................................................................................273
			TABLE OF FAILURE MODES AND CAUSES (2/2)...........................................................................................275
				H-1 Speeds of all work equipments, travel, swing are slow or lacks power......................................................277
				H-2 There is excessive drop in engine speed, or engine stalls.................................................................279
				H-3 No work equipment, travel, swing move.....................................................................................280
				H-4 Abnormal noise generated (around pump)....................................................................................280
				H-5 Fine control ability is poor or response is poor..........................................................................281
				H-6 Boom is slow or lacks power...............................................................................................282
				H-7 Arm is slow or lacks power................................................................................................284
				H-8 Bucket is slow or lacks power.............................................................................................286
				H-9 Work equipment (boom, arm, bucket) does not move (but travel and swing are normal)........................................286
				H-10 Excessive hydraulic drift (boom, arm, bucket)............................................................................287
				H-11 Excessive time lag (engine at low idling)................................................................................288
				H-12 Other equipment moves when single circuit is relieved....................................................................288
				H-13 In compound operations, work equipment with larger load is slow..........................................................288
				H-14 In swing + boom RAISE, boom RAISE is slow................................................................................289
				H-15 In swing + travel, travel speed drops excessively........................................................................289
				H-16 Travel deviation (deviation is excessive in normal travel and when starting).............................................290
					a) Deviation is excessive in normal travel................................................................................290
					b) Deviation is excessive when starting...................................................................................290
				H-17 Travel speed is slow.....................................................................................................291
				H-18 Steering does not turn easily or lacks power.............................................................................292
				H-19 Travel does not move (one side only).....................................................................................293
				H-20 Travel speed does not switch.............................................................................................293
				H-21 Does not swing...........................................................................................................294
					a) Does not swing to either left or right.................................................................................294
					b) Does not swing in one direction........................................................................................294
				H-22 Swing acceleration is poor or swing speed is slow........................................................................295
				H-23 Excessive overrun when stopping swing....................................................................................297
					a) One direction only.....................................................................................................297
					b) Both directions........................................................................................................297
				H-24 Excessive shock when stopping swing (one direction only).................................................................298
				H-25 Excessive abnormal noise when stopping swing.............................................................................298
				H-26 Excessive hydraulic drift of swing.......................................................................................299
					a) When swing lock is ON..................................................................................................299
					b) When swing lock is OFF.................................................................................................299
		TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)....................................................................................300
			MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM.........................................................................................301
				M-1 When the starting switch is turned ON, no display is given (lamps does not light up for 3 seconds)........................302
				M-2 When starting switch is turned ON, lamps light up for 3 seconds, but then do not go out...................................302
				M-3 When starting switch is turned ON, some lamps do not light up for 3 seconds...............................................303
					a) No gauge lamps light up (caution lamps light up).......................................................................303
					b) Swing lock, preheating lamps do not light up...........................................................................303
					c) Charge caution lamp does not light up..................................................................................303
					d) Engine oil pressure caution lamp does not light up.....................................................................303
				M-4 When power is turned on (before engine is started), charge caution lamp does not light up.................................304
				M-5 When Dower is turned on (before engine is started), engine oil pressure caution lamp does not light up....................304
				M-6 During preheating, preheating pilot lamp does not light up................................................................305
				M-7 When switch is operated, swing lock lamp does not light up................................................................305
				M-8 Engine oil pressure caution lamp lights up when engine is running (engine oil pressure is normal).........................306
				M-9 Charge caution lamp lights up when engine is running......................................................................306
				M-10 Abnormality in coolant temperature gauge.................................................................................307
					a) After engine is started, level stays at bottom (white range) and does not move.........................................307
					b) After engine is started, level immediately rises. Engine is not overheating but indicator enters red range.............307
					c) Coolant temperature gauge goes out.....................................................................................307
				M-11 Abnormality in fuel gauge................................................................................................308
					a) All fuel gauge segments go out.........................................................................................308
					b) Even when fuel level goes down, fuel gauge continues to show FULL......................................................308
					c) Even when tank is filled, fuel gauge does not show FULL................................................................308
				M-12 Defective operation of alarm buzzer......................................................................................310
					a) Buzzer does not sound..................................................................................................310
					b) Buzzer continues to sound and does not stop............................................................................310
				M-13 Engine is running, but service meter does not move.......................................................................311
					a) Charge caution lamp lights up..........................................................................................311
					b) Charge caution lamp does not light up..................................................................................311
				M-14 Night lighting does not light up.........................................................................................312
					a) Gauge lighting does not light up.......................................................................................312
					b) Service meter lighting does not light up (service meter is working normally)...........................................312
				M-15 Wiper does not move, or does not stop moving.............................................................................313
					a) Wiper does not move when wiper switch is turned to ON..................................................................313
					b) Wiper moves even when wiper switch is not turned to ON.................................................................313
				M-16 Heater does not work.....................................................................................................315
					a) Does not work at either Hi or Lo.......................................................................................315
					b) Does not work at Lo only...............................................................................................315
					c) Does not work at Hi only...............................................................................................315
30 DISASSEMBLY AND ASSEMBLY...................................................................................................................316
	METHOD OF USING MANUAL....................................................................................................................318
	PRECAUTIONS WHEN CARRYING OUT OPERATION...................................................................................................319
	SPECIAL TOOL LIST.........................................................................................................................321
	SKETCHES OF SPECIAL TOOLS.................................................................................................................325
	STARTING MOTOR ASSEMBLY...................................................................................................................326
		REMOVAL AND INSTALLATION..............................................................................................................326
	ALTERNATOR ASSEMBLY.......................................................................................................................327
		REMOVAL AND INSTALLATION..............................................................................................................327
	AIR CONDITIONER COMPRESSOR ASSEMBLY.......................................................................................................328
		REMOVAL AND INSTALLATION..............................................................................................................328
	CONDENSER ASSEMBLY........................................................................................................................329
		REMOVAL AND INSTALLATION..............................................................................................................329
	ENGINE OIL COOLER CORE ASSEMBLY...........................................................................................................330
		REMOVAL AND INSTALLATION..............................................................................................................330
	FUEL INJECTION PUMP ASSEMBLY..............................................................................................................331
		REMOVAL...............................................................................................................................331
		INSTALLATION..........................................................................................................................334
	WATER PUMP ASSEMBLY.......................................................................................................................336
		REMOVAL...............................................................................................................................336
		INSTALLATION..........................................................................................................................337
	NOZZLE HOLDER ASSEMBLY....................................................................................................................338
		REMOVAL AND INSTALLATION..............................................................................................................338
	TURBOCHARGER ASSEMBLY.....................................................................................................................339
		REMOVAL AND INSTALLATION..............................................................................................................339
	THERMOSTAT ASSEMBLY.......................................................................................................................340
		REMOVAL...............................................................................................................................340
		INSTALLATION..........................................................................................................................341
	CYLINDER HEAD ASSEMBLY....................................................................................................................342
		REMOVAL...............................................................................................................................342
		INSTALLATION..........................................................................................................................346
	RADIATOR, HYDRAULIC OIL COOLER ASSEMBLY...................................................................................................349
		REMOVAL...............................................................................................................................349
		INSTALLATION..........................................................................................................................351
	ENGINE, MAIN PUMP ASSEMBLY................................................................................................................352
		REMOVAL...............................................................................................................................352
		INSTALLATION..........................................................................................................................356
	DAMPER ASSEMBLY...........................................................................................................................357
		REMOVAL AND INSTALLATION..............................................................................................................357
	FUEL TANK ASSEMBLY........................................................................................................................358
		REMOVAL AND INSTALLATION..............................................................................................................358
	CENTER SWIVEL JOINT ASSEMBLY..............................................................................................................359
		REMOVAL...............................................................................................................................359
		INSTALLATION..........................................................................................................................360
		DISASSEMBLY AND ASSEMBLY..............................................................................................................361
	FINAL DRIVE ASSEMBLY......................................................................................................................362
		REMOVAL AND INSTALLATION..............................................................................................................362
		DISASSEMBLY...........................................................................................................................363
		ASSEMBLY..............................................................................................................................366
	SPROCKET..................................................................................................................................371
		REMOVAL AND INSTALLATION..............................................................................................................371
	SWING MOTOR, SWING MACHINERY ASSEMBLY.....................................................................................................372
		REMOVAL...............................................................................................................................372
		INSTALLATION..........................................................................................................................373
		DISASSEMBLY...........................................................................................................................374
		ASSEMBLY..............................................................................................................................378
	REVOLVING FRAME ASSEMBLY..................................................................................................................383
		REMOVAL...............................................................................................................................383
		INSTALLATION..........................................................................................................................384
	SWING CIRCLE ASSEMBLY.....................................................................................................................385
		REMOVAL...............................................................................................................................385
		INSTALLATION..........................................................................................................................386
	IDLER, RECOIL SPRING ASSEMBLY.............................................................................................................387
		REMOVAL AND INSTALLATION..............................................................................................................387
	RECOIL SPRING ASSEMBLY....................................................................................................................388
		DISASSEMBLY...........................................................................................................................388
		ASSEMBLY..............................................................................................................................389
	IDLER ASSEMBLY............................................................................................................................390
		DISASSEMBLY...........................................................................................................................390
		ASSEMBLY..............................................................................................................................391
	TRACK ROLLER ASSEMBLY.....................................................................................................................393
		REMOVAL AND INSTALLATION..............................................................................................................393
		DISASSEMBLY...........................................................................................................................394
		ASSEMBLY..............................................................................................................................396
	CARRIER ROLLER ASSEMBLY...................................................................................................................398
		REMOVAL AND INSTALLATION..............................................................................................................398
		DISASSEMBLY...........................................................................................................................399
		ASSEMBLY..............................................................................................................................401
	TRACK SHOE ASSEMBLY.......................................................................................................................403
		REMOVAL AND INSTALLATION..............................................................................................................403
	HYDRAULIC TANK ASSEMBLY...................................................................................................................404
		REMOVAL...............................................................................................................................404
		INSTALLATION..........................................................................................................................405
	MAIN PUMP ASSEMBLY........................................................................................................................406
		REMOVAL...............................................................................................................................406
		INSTALLATION..........................................................................................................................408
	MAIN PUMP INPUT SHAFT OIL SEAL............................................................................................................409
		REMOVAL AND INSTALLATION..............................................................................................................409
	CONTROL VALVE ASSEMBLY....................................................................................................................410
		REMOVAL...............................................................................................................................410
		INSTALLATION..........................................................................................................................412
		DISASSEMBLY...........................................................................................................................413
		ASSEMBLY..............................................................................................................................418
	MAIN RELIEF VALVE ASSEMBLY................................................................................................................424
		DISASSEMBLY AND ASSEMBLY..............................................................................................................424
	PC VALVE ASSEMBLY.........................................................................................................................425
		REMOVAL...............................................................................................................................425
		INSTALLATION..........................................................................................................................426
	LS VALVE ASSEMBLY.........................................................................................................................427
		REMOVAL AND INSTALLATION..............................................................................................................427
	PC-EPC VALVE ASSEMBLY.....................................................................................................................428
		REMOVAL AND INSTALLATION..............................................................................................................428
	SOLENOID VALVE ASSEMBLY...................................................................................................................429
		REMOVAL AND INSTALLATION..............................................................................................................429
	WORK EQUIPMENT, SWING PPC VALVE ASSEMBLY..................................................................................................430
		REMOVAL AND INSTALLATION..............................................................................................................430
		DISASSEMBLY...........................................................................................................................431
		ASSEMBLY..............................................................................................................................432
	TRAVEL PPC VALVE ASSEMBLY.................................................................................................................433
		REMOVAL AND INSTALLATION..............................................................................................................433
		DISASSEMBLY...........................................................................................................................434
		ASSEMBLY..............................................................................................................................435
	BOOM LOCK VALVE ASSEMBLY..................................................................................................................436
		REMOVAL AND INSTALLATION..............................................................................................................436
	BOOM CYLINDER ASSEMBLY....................................................................................................................437
		REMOVAL...............................................................................................................................437
		INSTALLATION..........................................................................................................................438
	ARM CYLINDER ASSEMBLY.....................................................................................................................439
		REMOVAL...............................................................................................................................439
		INSTALLATION..........................................................................................................................440
	BUCKET CYLINDER ASSEMBLY..................................................................................................................441
		REMOVAL...............................................................................................................................441
		INSTALLATION..........................................................................................................................442
	HYDRAULIC CYLINDER ASSEMBLY...............................................................................................................443
		DISASSEMBLY...........................................................................................................................443
		ASSEMBLY..............................................................................................................................446
	WORK EQUIPMENT ASSEMBLY...................................................................................................................450
		REMOVAL...............................................................................................................................450
		INSTALLATION..........................................................................................................................451
	BUCKET ASSEMBLY...........................................................................................................................452
		REMOVAL...............................................................................................................................452
		INSTALLATION..........................................................................................................................453
	ARM ASSEMBLY..............................................................................................................................454
		REMOVAL...............................................................................................................................454
		INSTALLATION..........................................................................................................................455
	BUCKET, ARM ASSEMBLY......................................................................................................................456
		REMOVAL...............................................................................................................................456
		INSTALLATION..........................................................................................................................457
	BOOM ASSEMBLY.............................................................................................................................458
		REMOVAL...............................................................................................................................458
		INSTALLATION..........................................................................................................................459
	OPERATOR’S CAB ASSEMBLY...................................................................................................................460
		REMOVAL AND INSTALLATION..............................................................................................................460
	COUNTERWEIGHT ASSEMBLY....................................................................................................................461
		REMOVAL AND INSTALLATION..............................................................................................................461
	MONITOR ASSEMBLY..........................................................................................................................462
		REMOVAL AND INSTALLATION..............................................................................................................462
40 MAINTENANCE STANDARD.......................................................................................................................463
	SWING MACHINERY ..........................................................................................................................464
	SWING CIRCLE .............................................................................................................................466
	FINAL DRIVE ..............................................................................................................................467
	TRACK FRAME, RECOIL SPRING ...............................................................................................................469
	IDLER ....................................................................................................................................470
	CARRIER ROLLER............................................................................................................................472
	TRACK ROLLER .............................................................................................................................473
	TRACK SHOE ...............................................................................................................................474
	HYDRAULIC PUMP ...........................................................................................................................479
	CONTROL VALVE ............................................................................................................................480
	SELF-REDUCING PRESSURE VALVE .............................................................................................................487
	SWING MOTOR...............................................................................................................................488
	TRAVEL MOTOR .............................................................................................................................489
	WORK EQUIPMENT, SWING PPC VALVE ..........................................................................................................490
	TRAVEL PPC VALVE .........................................................................................................................491
	SERVICE PPC VALVE ........................................................................................................................492
	CENTER SWIVEL JOINT ......................................................................................................................493
	BOOM HOLDING VALVE .......................................................................................................................495
	HYDRAULIC CYLINDER .......................................................................................................................496
	WORK EQUIPMENT ...........................................................................................................................498
	DIMENSION OF WORK EQUIPMENT ..............................................................................................................500
90 OTHERS.....................................................................................................................................504
	HYDRAULIC PIPING DRAWING..................................................................................................................505
	HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................506
	ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)....................................................................................................511
	ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)....................................................................................................512
	ELECTRICAL CIRCUIT DIAGRAM (1/2)..........................................................................................................513
	ELECTRICAL CIRCUIT DIAGRAM (2/2)..........................................................................................................518
	OPERATION OF CLSS SYSTEM AS A WHOLE.......................................................................................................523
		1. When all work equipment is at neutral..............................................................................................523
		2. One side actuated, other side neutral..............................................................................................524
		3. Arm OUT, standard mode relief (cut-off control)....................................................................................525
		4. Bucket DUMP, power max. relief.....................................................................................................526
		5. Boom RAISE.........................................................................................................................527
		6. Swing operated independently.......................................................................................................528
		7. Travel operated independently......................................................................................................529
		8. Compound operation.................................................................................................................530

PLEASE NOTE

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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