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Komatsu PC200LC-6Z Hydraulic Excavator Shop Manual C10827 and up – PDF DOWNLOAD
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Komatsu PC200LC-6Z Hydraulic Excavator Shop Manual
SERIAL NUMBERS : PC200LC-6Z – C10827
Book Code: SEBM010202
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Description
Komatsu PC200LC-6Z Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC200LC-6Z Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC200LC-6Z
Serial Number: C10827 and up
Book Code: SEBM010202
Language: English
Pages: 540
File Format: Portable Document Format (PDF)
KOMATSU PC200LC-6Z HYDRAULIC EXCAVATOR SHOP MANUAL C10827 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu PC200LC-6Z Hydraulic Excavator Shop Manual
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 CONTENTS..................................................................................................................................... 2 01 GENERAL................................................................................................................................... 3 SPECIFICATION DIMENSION DRAWINGS......................................................................................................... 4 SPECIFICATIONS........................................................................................................................... 5 WEIGHT TABLE............................................................................................................................. 7 FUEL, COOLANT AND LUBRICANTS............................................................................................................. 9 10 STRUCTURE AND FUNCTION.................................................................................................................... 10 ENGINE RELATED PARTS..................................................................................................................... 11 RADIATOR OIL COOLER AFTERCOOLER.......................................................................................................... 12 ENGINE CONTROL........................................................................................................................... 13 POWER TRAIN.............................................................................................................................. 14 FINAL DRIVE.............................................................................................................................. 15 SWING CIRCLE............................................................................................................................. 16 SWING MACHINERY.......................................................................................................................... 17 TRACK FRAME RECOIL SPRING............................................................................................................... 18 TRACK SHOE............................................................................................................................... 19 HYDRAULIC PIPING DRAWING................................................................................................................. 20 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 21 HYDRAULIC TANK........................................................................................................................... 22 HYDRAULIC PUMP........................................................................................................................... 23 IN-LINE FILTER........................................................................................................................... 42 CONTROL VALVE............................................................................................................................ 43 SELF-REDUCING PRESSURE VALVE............................................................................................................. 51 CLSS..................................................................................................................................... 56 SWING MOTOR.............................................................................................................................. 90 CENTER SWIVEL JOINT...................................................................................................................... 94 TRAVEL MOTOR............................................................................................................................. 96 VALVE CONTROL............................................................................................................................104 WORK EQUIPMENT SWING PPC VALVE...........................................................................................................105 TRAVEL PPC VALVE.........................................................................................................................109 SERVICE PPC VALVE........................................................................................................................113 ACCUMULATOR..............................................................................................................................116 STRAIGHT-TRAVEL SYSTEM...................................................................................................................117 EPC SOLENOID VALVE.......................................................................................................................118 BOOM HOLDING VALVE.......................................................................................................................120 ADDITIONAL FILTER FOR BREAKER............................................................................................................123 WORK EQUIPMENT...........................................................................................................................124 ACTUAL ELECTRICAL WIRING DIAGRAM.........................................................................................................125 ELECTRIC CIRCUIT SYSTEM..................................................................................................................127 ELECTRIC CONTROL SYSTEM..................................................................................................................129 MACHINE MONITOR SYSTEM...................................................................................................................135 SENSORS..................................................................................................................................138 20 TESTING AND ADJUSTING.....................................................................................................................140 STANDARD VALVE TABLE FOR ENGINE RELATED PARTS............................................................................................141 STANDARD VALVE TABLE FOR ENGINE CHASSIS RELATED PARTS....................................................................................142 STANDARD VALVE TABLE FOR ENGINE ELECTRICAL SYSTEM........................................................................................150 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING........................................................................................153 MEASURING ENGINE SPEED...................................................................................................................154 MEASURING EXHAUST COLOR..................................................................................................................155 ADJUSTING VALVE CLEARANCE................................................................................................................156 MEASURING COMPRESSION PRESSURE...........................................................................................................157 MEASURING BLOW BY PRESSURE...............................................................................................................157 TESTING AND ADJUSTING FUEL INJECTION TIMING..............................................................................................158 MEASURING ENGINE OIL PRESSURE............................................................................................................159 TESTING AND ADJUSTING FAN BELT TENSION...................................................................................................160 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR........................................................................160 ADJUSTING ENGINE SPEED SENSOR............................................................................................................161 ADJUSTING FUEL CONTROL LEVER.............................................................................................................162 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT........................................................164 TESTING AND ADJUSTING PC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)............................................................167 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE ..............................168 TESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURE.......................................................................................171 TESTING SOLENOID VALVE OUTPUT PRESSURE...................................................................................................172 MEASURING PPC VALVE PUTPUT PRESSURE......................................................................................................173 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE................................................................................................175 TESTING TRAVEL DEVIATION.................................................................................................................176 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT..............................................................................177 MEASURING OIL LEAKAGE....................................................................................................................179 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT........................................................................................181 TESTING CLEARANCE OF SWING CIRCLE BEARING................................................................................................182 TESTING AND ADJUSTING TRACK SHOE TENSION.................................................................................................183 BLEEDING AIR.............................................................................................................................184 TROUBLESHOOTING..........................................................................................................................186 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................187 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................188 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................189 CHECKS BEFORE TROUBLESHOOTING........................................................................................................197 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................198 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................203 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................213 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................215 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................216 S-1 STARTING PERFORMANCE IS POOR (ALWAYS TAKES TIME).............................................................................220 S-2 ENGINE DOES NOT START........................................................................................................221 (1) ENGINE DOES NOT RUN......................................................................................................221 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).................................................222 (3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES START (FUEL IS BEING INJECTED)..................................................223 S-3 ENGINE DOES NOT PICK SMOOTHY (FOLLOW-UP IS POOR).............................................................................224 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................225 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................226 S-6 ENGINE LACKS OUTPUT (NO POWER)...............................................................................................227 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION................................................................................228 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)........................................................................229 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................230 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................231 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.....................................................232 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................233 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................234 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................235 S-15 ABNORMAL NOISE IS MADE......................................................................................................236 S-16 VIBRATION IS EXCESSIVE......................................................................................................237 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................238 JUDGEMENT TABLE FOR ELECTRICAL, HYDRAULIC, AND MECHANICAL SYSTEMS................................................................239 ELECTRICAL CIRCUIT DIAGRAM FOR SYSTEM............................................................................................241 FAILURE CODES....................................................................................................................242 E-1 ABNORMALITY IN PC-EPC CONTROL SYSTEM.....................................................................................242 A) ENGINE STOPS EVEN WHEN THROTTLE LEVER IS NOT RETURNED TO STOP POSITION. WHEN SUDDEN LOAD IS APPLIED, ENGINE STALLS....242 B) LACKS POWER WHEN THROTTLT LEVER IS AT FULL, WORK EQUIPMENT SPEED IS SLOW .............................................243 E-2 ABNORMALITY IN TRAVEL SPEED SELECTOR SYSTEM (TRAVEL SPEED DOES NOT SWITCH)...............................................245 E-3 ABNORMALITY IN SWING HOLDING BRAKE SOLENOID SYSTEM.......................................................................246 A) SWING HOLDING BRAKE SOLENOID IS NOT ACTUATED (CANNOT SWING)...........................................................246 B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED)........................................................................247 E-4 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM.....................................................................248 A) SOLENOID IS NOT ACTUATED (SAFETY LOCK IS NOT CANCELED)................................................................248 B) REMAINS ACTUATED (SAFETY LOCK IS NOT ACTUATED)........................................................................249 E-5 ABNORMALITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START)............................................................250 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..........................................................................253 TABLE OF FAILURE MODES AND CAUSES................................................................................................254 H-1 SPEEDS OF ALL WORK EQUIPMENT, TRAVEL, SWING ARE SLOW OR LACKS POWER..........................................................258 H-2 THERE IS NOT EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS................................................................260 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE........................................................................................261 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).......................................................................................261 H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR.............................................................................262 H-6 BOOM IS SLOW OR LACKS POWER..................................................................................................263 H-7 ARM IS SLOW OR LACKS POWER...................................................................................................265 H-8 BUCKET IS SLOW OR LACKS POWER................................................................................................267 H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL............................................267 H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...............................................................................268 H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...................................................................................269 H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED.......................................................................269 H-13 IN COMPUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS LOW...............................................................269 H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...................................................................................270 H-15 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY...........................................................................270 H-16 TRAVEL DEVIATION............................................................................................................271 A) DEVIATION IS EXCESSIVE IN NORMAL TRAVEL...................................................................................271 B) DEVIATION IS EXCESSIVE WHEN STARTING......................................................................................271 H-17 TRAVEL SPEED IS SLOW........................................................................................................272 H-18 STEERING DOES NOT TURN EASILY OR LACKS POWER................................................................................273 H-19 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)........................................................................................274 H-20 TRAVEL SPEED DOES NOT SWITCH................................................................................................274 H-21 DOES NOT SWING..............................................................................................................275 A) DOES NOT SWING TO EITHER LEFT OR RIGHT....................................................................................275 B) DOES NOT SWING IN ONE DIRECTION...........................................................................................275 H-22 SWING ACCELERATION IS POOR OR SWING SPEED IS LOW............................................................................276 H-23 EXCESSIVE OVERRUN WHEN STOPPING SWING.......................................................................................278 A) ONE DIRECTION ONLY........................................................................................................278 B) BOTH DIRECTIONS...........................................................................................................278 H-24 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)....................................................................279 H-25 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING................................................................................279 H-26 EXCESSIVE HYDRAULIC DRIFT OF SWING..........................................................................................280 A) WHEN SWING LOCK IS ON.....................................................................................................280 B) WHEN SWING LOCK IS OFF....................................................................................................280 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...................................................................................281 MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM........................................................................................282 M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS).........................283 M-2 WHEN THE STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT..............................283 M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS..............................................284 A) NO GAUGE LAMP LIGHTS UP (CAUTION LAMPS LIGHT UP.......................................................................284 B) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP)................................................284 C) CHARGE CAUTION LAMP DOES NOT LIGHT UP ................................................................................284 D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP....................................................................284 M-4 WHEN POWER IS ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP ......................................285 M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...................285 M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP...............................................................286 M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP...............................................................286 M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)........................287 M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING.....................................................................287 M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE................................................................................288 A) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND DOES NOT MOVE........................................288 B) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE.............288 C) COOLANT TEMPERATURE GAUGE GOES OUT....................................................................................288 M-11 ABNORMALITY IN FUEL GAUGE...............................................................................................289 A) ALL FUEL GAUGE SEGMENTS GO OUT........................................................................................289 B) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL.....................................................289 C) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL...............................................................289 M-12 DEFECTIVE OPERATION OF ALARM BUZZER.....................................................................................291 A) BUZZER DOES NOT SOUND.................................................................................................291 B) BUZZER CONTINUES TO SOUND AND DOES NOT STOP...........................................................................291 M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE......................................................................292 A) CHARGE CAUTION LAMP LIGHTS UP........................................................................................292 B) CHARGE CAUTION LAMP DOES NOT LIGHT UP.................................................................................292 M-14 NIGHT LIGHTING DOES NOT LIGHT UP........................................................................................293 A) GAUGE LIGHTING DOES NOT LIGHT UP......................................................................................293 B) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY)..........................................293 M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVING............................................................................294 A) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED ON....................................................................294 B) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED ON...................................................................294 M-16 HEATER DOES NOT WORK AT EITHER HI OR LO.................................................................................296 A) DOES NOT WORK AT EITHER HI OR LO......................................................................................296 B) DOES NOT WORK AT LO ONLY .............................................................................................296 C) DOES NOT WORK AT HI ONLY .............................................................................................296 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................297 METHOD OF USING MANUAL...................................................................................................................299 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................300 SPECIAL TOOL LIST........................................................................................................................302 SKETCHES OF SPECIAL TOOLS................................................................................................................306 STARTING MOTOR ASSEMBLY..................................................................................................................307 REMOVAL AND INSTALLATION.............................................................................................................307 ALTERNATIVE ASSEMBLY.....................................................................................................................308 REMOVAL AND INSTALLATION.............................................................................................................308 AIR CONDITIONER COMPRESSOR ASSEMBLY......................................................................................................309 REMOVAL AND INSTALLATION.............................................................................................................309 CONDENSER ASSEMBLY.......................................................................................................................310 REMOVAL AND INSTALLATION.............................................................................................................310 ENGINE OIL COOLER CORE ASSEMBLY..........................................................................................................311 REMOVAL AND INSTALLATION.............................................................................................................311 FUEL INJECTION PUMP ASSEMBLY.............................................................................................................312 REMOVAL..............................................................................................................................312 INSTALLATION.........................................................................................................................315 WATER PUMP ASSEMBLY......................................................................................................................317 REMOVAL AND INSTALLATION.............................................................................................................318 NOZZLE HOLDER ASSEMBLY...................................................................................................................319 REMOVAL AND INSTALLATION.............................................................................................................319 TURBOCHARGER ASSEMBLY....................................................................................................................320 REMOVAL AND INSTALLATION.............................................................................................................320 THERMOSTAT ASSEMBLY......................................................................................................................321 REMOVAL AND INSTALLATION.............................................................................................................322 CYLINDER HEAD ASSEMBLY...................................................................................................................323 REMOVAL..............................................................................................................................323 INSTALLATION.........................................................................................................................327 RADIATOR - HYDRAULIC COOLER ASSEMBLY.....................................................................................................330 REMOVAL..............................................................................................................................330 INSTALLATION.........................................................................................................................332 ENGINE - MAIN PUMP ASSEMBLY..............................................................................................................333 REMOVAL..............................................................................................................................333 INSTALLATION.........................................................................................................................337 DAMPER ASSEMBLY..........................................................................................................................338 REMOVAL AND INSTALLATION.............................................................................................................338 FUEL TANK ASSEMBLY.......................................................................................................................339 REMOVAL AND INSTALLATION.............................................................................................................339 CENTER SWIVEL JOINT ASSEMBLY.............................................................................................................340 REMOVAL AND INSTALLATION.............................................................................................................341 DISASSEMBLY AND ASSEMBLY.............................................................................................................342 FINAL DRIVE ASSEMBLY.....................................................................................................................343 REMOVAL AND INSTALLATION.............................................................................................................343 DISASSEMBLY..........................................................................................................................344 ASSEMBLY.............................................................................................................................347 SPROCKET ................................................................................................................................352 REMOVAL AND INSTALLATION.............................................................................................................352 SWIMG MOTOR, SWING MACHINERY.............................................................................................................353 REMOVAL AND INSTALLATION.............................................................................................................354 DISASSEMBLY..........................................................................................................................355 ASSEMBLY.............................................................................................................................359 REVOLVING FRAME ASSEMBLY ................................................................................................................364 REMOVAL..............................................................................................................................364 INSTALLATION.........................................................................................................................365 SWING CIRCLE ASSEMBLY....................................................................................................................366 REMOVAL..............................................................................................................................366 INSTALLATION.........................................................................................................................367 IDLER - RECOIL SPRING ASSEMBLY...........................................................................................................368 REMOVAL AND INSTALLATION.............................................................................................................368 RECOIL SPRING ASSEMBLY...................................................................................................................369 DISASSEMBLY..........................................................................................................................369 ASSEMBLY.............................................................................................................................370 IDLER ASSEMBLY...........................................................................................................................371 DISASSEMBLY..........................................................................................................................371 ASSEMBLY.............................................................................................................................372 TRACK ROLLER ASSEMBLY....................................................................................................................374 REMOVAL AND INSTALLATION.............................................................................................................374 DISASSEMBLY..........................................................................................................................375 ASSEMBLY.............................................................................................................................377 CARRIER ROLLER ASSEMBLY..................................................................................................................379 REMOVAL AND INSTALLATION.............................................................................................................379 DISASSEMBLY..........................................................................................................................380 ASSEMBLY.............................................................................................................................382 TRACK SHOE ASSEMBLY......................................................................................................................384 REMOVAL AND INSTALLATION.............................................................................................................384 HYDRAULAIC TANK ASSEMBLY.................................................................................................................385 REMOVAL..............................................................................................................................385 INSTALLATION.........................................................................................................................386 MAIN PUMP ASSEMBLY.......................................................................................................................387 REMOVAL..............................................................................................................................387 INSTALLATION.........................................................................................................................389 MAIN PUMP INPUT SHAFT OIL SEAL...........................................................................................................390 REMOVAL AND INSTALLATION.............................................................................................................390 CONTROL VALVE ASSEMBLY...................................................................................................................391 REMOVAL..............................................................................................................................391 INSTALLATION.........................................................................................................................393 DISASSEMBLY..........................................................................................................................394 ASSEMBLY.............................................................................................................................399 MAIN RELIEF VALVE ASSEMBLY...............................................................................................................405 DISASSEMBLY AND ASSEMBLY.............................................................................................................405 PC VALVE ASSEMBLY........................................................................................................................406 REMOVAL AND INSTALLATION.............................................................................................................407 LS VALVE ASSEMBLY........................................................................................................................408 REMOVAL AND INSTALLATION.............................................................................................................408 PC-EPC VALVE ASSEMBLY....................................................................................................................409 REMOVAL AND INSTALLATION.............................................................................................................409 SOLENOID VALVE ASSEMBLY..................................................................................................................410 REMOVAL AND INSTALLATION.............................................................................................................410 WORK EQUIPMENT - SWING PPC VALVE ASSEMBLY................................................................................................411 REMOVAL AND INSTALLATION.............................................................................................................411 DISASSEMBLY..........................................................................................................................412 ASSEMBLY.............................................................................................................................413 TRAVEL PPC VALVE ASSEMBLY................................................................................................................414 REMOVAL AND INSTALLATION.............................................................................................................414 DISASSEMBLY AND ASSEMBLY.............................................................................................................415 ASSEMBLY.............................................................................................................................416 BOOM LOCK VALVE ASSEMBLY.................................................................................................................417 REMOVAL AND INSTALLATION.............................................................................................................417 BOOM CYLINDER ASSEMBLY...................................................................................................................418 REMOVAL..............................................................................................................................418 INSTALLATION.........................................................................................................................419 ARM CYLINDER ASSEMBLY ...................................................................................................................420 REMOVAL..............................................................................................................................420 INSTALLATION.........................................................................................................................421 BUCKET CYLINDER ASSEMBLY.................................................................................................................422 REMOVAL..............................................................................................................................422 INSTALLATION.........................................................................................................................423 HYDRAULIC CYLINDER ASSEMBLY..............................................................................................................424 DISASSEMBLY..........................................................................................................................424 ASSEMBLY.............................................................................................................................427 WORK EQUIPMENT ASSEMBLY..................................................................................................................431 REMOVAL..............................................................................................................................431 INSTALLATION.........................................................................................................................432 BUCKET ASSEMBLY..........................................................................................................................433 REMOVAL..............................................................................................................................433 INSTALLATION.........................................................................................................................434 ARM ASSEMBLY.............................................................................................................................435 REMOVAL..............................................................................................................................435 INSTALLATION.........................................................................................................................436 BUCKET - ARM ASSEMBLY....................................................................................................................437 REMOVAL..............................................................................................................................437 INSTALLATION.........................................................................................................................438 BOOM ASSEMBLY............................................................................................................................298 REMOVAL..............................................................................................................................298 INSTALLATION.........................................................................................................................298 OPERATOR'S CAB ASSEMBLY..................................................................................................................439 REMOVAL AND INSTALLATION.............................................................................................................439 COUNTERWEIGHT ASSEMBLY...................................................................................................................440 REMOVAL AND INSTALLATION.............................................................................................................440 MONITOR ASSEMBLY.........................................................................................................................441 REMOVAL AND INSTALLATION.............................................................................................................441 40 MAINTENANCE STANDARD......................................................................................................................442 SWING MACHINERY..........................................................................................................................443 SWING CIRCLE.............................................................................................................................445 FINAL DRIVE..............................................................................................................................446 TRACK FRAME - RECOIL SPRING..............................................................................................................448 IDLER....................................................................................................................................449 CARRIER ROLLER...........................................................................................................................451 TRACK ROLLER.............................................................................................................................452 TRACK SHOE...............................................................................................................................453 HYDRAULIC PUMP...........................................................................................................................458 CONTROL VALVE............................................................................................................................459 SELF-REDUCING PRESSURE VALVE.............................................................................................................466 SWING MOTOR..............................................................................................................................467 TRAVEL MOTOR.............................................................................................................................468 WORK EQUIPMENT - SWING PPC VALVE.........................................................................................................469 TRAVEL PPC VALVE.........................................................................................................................470 SERVICE PPC VALVE........................................................................................................................471 CENTER SWIVEL JOINT......................................................................................................................472 BOOM HOLDING VALVE.......................................................................................................................474 HYDRAULIC CYLINDER.......................................................................................................................475 WORK EQUIPMENT...........................................................................................................................477 DIMENSION OF WORK EQUIPMENT..............................................................................................................479 90 OTHERS....................................................................................................................................483 HYDRAULIC PIPING DRAWING.................................................................................................................484 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................490 ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)...................................................................................................492 ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)...................................................................................................496 ELECTRICAL CIRCUIT DIAGRAM (1/2).........................................................................................................500 ELECTRICAL CIRCUIT DIAGRAM (2/2).........................................................................................................504 OPERATION OF CLSS SYSTEM AS A WHOLE......................................................................................................508 1. WHEN ALL WORK EQUIPMENT IS NEUTRAL................................................................................................508 2. ONE SIDE ACTUATED, OTHER SIDE NEUTRAL.............................................................................................512 3. ARM OUT, STANDARD MODE RELIEF (CUT-OFF CONTROL)..................................................................................516 4. BUCKET DUMP, POWER MAX RELIEF.....................................................................................................520 5. BOOM RAISE........................................................................................................................524 6. SWING OPERATED INDEPENDENTLY......................................................................................................528 7. TRAVEL OPERATED INDEPENDENTLY.....................................................................................................532 8. COMPOUND OPERATION................................................................................................................536
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
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