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Komatsu PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K Excavator Shop Manual
Book Code: UEBM001701
MACHINE MODEL SERIAL NUMBER
PC210-7K K40001 AND UP
PC210LC-7K K40001 AND UP
PC210-NLC-7K K40001 AND UP
PC240LC-7K K40001 AND UP
PC240NLC-7K K40001 AND UP
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Description
Komatsu PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K Excavator Shop Manual
FILE DETAILS:
Komatsu PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K
Serial Number: K40001 and up
Book Code: UEBM001701
Language: English
Pages: 668
File Format: Portable Document Format (PDF)
TABLE OF CONTENTS:
Komatsu PC210-7K, PC210LC-7K, PC210NLC-7K, PC240LC-7K, PC240NLC-7K Excavator Shop Manual
MAIN MENU.................................................................................................................................... 0 COVER........................................................................................................................................ 1 10 STRUCTURE AND FUNCTION.................................................................................................................... 2 ENGINE RELATED PARTS..................................................................................................................... 3 RADIATOR - OIL COOLER, AFTERCOOLER....................................................................................................... 4 POWER TRAIN.............................................................................................................................. 5 SWING CIRCLE............................................................................................................................. 6 SWING MACHINERY.......................................................................................................................... 7 UNDERCARRIAGE............................................................................................................................ 9 TRANSMISSION............................................................................................................................. 10 AXLE..................................................................................................................................... 13 SUSPENSION LOCK CYLINDER................................................................................................................. 17 BRAKING TRAIN............................................................................................................................ 19 BRAKE PEDAL.............................................................................................................................. 20 BRAKE VALVE.............................................................................................................................. 21 ACCUMULATOR FOR BRAKE SYSTEM............................................................................................................. 22 STEERING TRAIN........................................................................................................................... 23 STEERING COLUMN.......................................................................................................................... 25 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 26 HYDRAULIC TANK........................................................................................................................... 28 HYDARULIC PUMP........................................................................................................................... 29 CONTROL VALVE............................................................................................................................ 48 CLSS..................................................................................................................................... 58 SWING MOTOR.............................................................................................................................. 93 CENTER SWIVEL JOINT...................................................................................................................... 96 TRAVEL MOTOR (FRONT, REAR)............................................................................................................... 97 WORK EQUIPMENT, SWING PPC VALVE.......................................................................................................... 99 TRAVEL PPC PEDAL.........................................................................................................................103 SERVICE PPC VALVE........................................................................................................................104 SAFETY LOCK VALVE........................................................................................................................107 PPC ACCUMULATOR..........................................................................................................................107 PPC SHUTTLE VALVE........................................................................................................................108 EPC, SOLENOID VALVE......................................................................................................................111 HYDRAULIC CYLINDER.......................................................................................................................123 WORK EQUIPMENT...........................................................................................................................127 ELECTRICAL WIRING DIAGRAM................................................................................................................128 ELECTRICAL WIRING DIAGRAM................................................................................................................129 ELECTRICAL WIRING DIAGRAM................................................................................................................130 ENGINE CONTROL SYSTEM....................................................................................................................131 ELECTRONIC CONTROL SYSTEM................................................................................................................137 MACHINE MONITOR SYSTEM...................................................................................................................160 20 TESTING AND ADJUSTING.....................................................................................................................171 TABLE OF JUDGEMENT STANDARD VALUE........................................................................................................172 STANDARD VALUE TABLE FOR ELETRICAL PARTS.................................................................................................182 CHECKING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.......................................................................190 ADJUSTING ENGINE SPEED SENSOR............................................................................................................191 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE........................................................................................192 TESTING CLEARANCE OF SWING CIRCLE BEARING................................................................................................194 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT........................................................195 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)............................................................198 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE................................200 TESTING AND ADJUSTING PPC PRESSURE.......................................................................................................203 TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE.........................................................................................204 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE........................................................................206 ADJUSTING WORK EQUIPMENT - SWING PPC VALVE...............................................................................................208 TESTING LOCATION CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT...............................................................................209 MEASURING OIL LEAKAGE....................................................................................................................211 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT........................................................................................212 BLEEDING AIR.............................................................................................................................213 ACCUMULATORS.............................................................................................................................215 TROUBLESHOOTING..........................................................................................................................219 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................220 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................221 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................222 CHECKS BEFORE TROUBLESHOOTING........................................................................................................229 CONNECTOR TYPES......................................................................................................................230 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................233 EXPLANATION OF CONTROL MECHANISM OF ELECTRICAL SYSTEM................................................................................246 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL................................................................................247 METHOD OF USING JUDGEMENT TABLE......................................................................................................255 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................257 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE.............................................................................259 SERVICE CODE TABLE...................................................................................................................264 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE).........................................................................265 N-1 [E218] COMMUNICATION ABNORMALITY.............................................................................................266 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E-MODE.......................................................268 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSEM..........................................269 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS......................................................270 JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS...................................274 ELECTRICAL CIRCUIT DIAGRAM OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM)................................................276 E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)...............................................278 E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED.............................................................279 E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................280 E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED........................................................281 E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED.............................................................282 E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY OUTPUT SYSTEM IS DISPLAYED....................................................283 E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED..........................................................................284 E-8 ENGINE DOES NOT START........................................................................................................285 E-9 ENGINE SPEED IS IRREGULAR....................................................................................................287 A) IDLING SPEED IS IRREGULAR.................................................................................................287 B) THERE IS HUNTING..........................................................................................................289 E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)........................................................................291 E-11 ENGINE DOES NOT STOP........................................................................................................293 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)..........................................................295 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)............................................................................................296 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................297 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................................................................301 S-2 ENGINE DOES NOT START........................................................................................................302 (1) ENGINE DOES NOT RUN......................................................................................................302 (2) ENGINE TURNS BUT NOT EXHAUST COMES OUT (FUEL IS NOT BEING INJECTED)......................................................303 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...............................................304 S-3 ENGINE DOES NOT PICK UP SMOOTHLY ............................................................................................305 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................306 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................307 S-6 ENGINE LACKS OUTPUT (NO POWER)...............................................................................................308 S-7 EXHAUST SMOKE IS BLACK ......................................................................................................309 S-8 OIL CONSUMPTION IS EXCESSIVE, OR EXHAUST SMOKE IS BLUE.......................................................................310 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................311 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................312 S-11 OIL IS IN COOLING WATER.....................................................................................................313 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)..................................................................314 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................315 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................316 S-15 ABNORMAL NOISE IS MADE......................................................................................................317 S-16 VIBRATION IS EXCESSIVE......................................................................................................318 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)..........................................................319 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM...................................................................320 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS...............................................................................321 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER AND HYDRAULIC RELATED PARTS........................................................327 ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEMS.....................................................................................329 C-1 ABNORMALITY IN CONTROLER POWER SOURCE (CONTROLLER LED IS OFF)................................................................331 C-2 [E232] SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED...............................................................332 C-3 [E233] DISCONNECTION IN PUMP TVC SOLENOID SYSTEM IS DISPLAYED................................................................334 C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................336 C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.............................................................338 C-10 [E205] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED.........................................................340 C-11 [E215] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED ........................................................341 C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED...........................................................342 C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED..................................................343 C-16[E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED..................................................................344 C-17 [E224] ABNORMALITY IN PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED..............................................................345 C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED ............................................................346 C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED...............................................................347 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)..........................................................348 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE............................................................................................349 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP...............................................................351 F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWTICH DOES NOT LIGHT UP..............................................................352 F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................353 F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP..........................................................354 F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP..............................................................355 F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP.............................................................356 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP.........................................................357 F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP.........................................................358 F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP.......................................................................359 F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP.......................................................................360 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H-MODE).............................................................................361 TABLE OF FAILURE MODES AND CAUSES................................................................................................362 ALL WORK EQUIPMENT, TRAVEL, SWING................................................................................................366 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER.......................................................366 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS................................................................368 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE....................................................................................369 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)...................................................................................369 H-5 AUTO-DECELERATION DOES NOT WORK .........................................................................................370 H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR.........................................................................370 WORK EQUIPMENT...................................................................................................................371 H-7 BOOM IS SLOW OR LACKS POWER..............................................................................................371 H-8 ARM IS SLOW OR LACKS POWER...............................................................................................373 H-9 BUCKET IS SLOW OR LACKS POWER............................................................................................375 H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE .......................................................................376 H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM BUCKET)............................................................................376 H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)...............................................................................377 H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED...................................................................377 H-14 IN F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED.......................................................378 H-15 LACK OF POWER WHEN PRESSURE RISES.......................................................................................378 COMPOUND OPERATIONS..............................................................................................................378 H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW.........................................................378 H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW...............................................................................379 TRAVEL SYSTEM....................................................................................................................380 H-21 TRAVEL SPEED IS SLOW....................................................................................................380 H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED..........................................................382 SWING SYSTEM.....................................................................................................................383 H-25 DOES NOT SWING (BOTH LEFT AND RIGHT, ON DIRECTION ONLY).................................................................383 H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY).............................384 H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY)........................................386 H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)................................................................387 H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING............................................................................387 H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN BRAKE IS ON, WHEN BRAKE IS OFF)................................................388 H-31 SWING SPEED IS FASTER THAN SPECIFIED SPEED..............................................................................389 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...................................................................................390 ACTION TAKEN BY PANEL AND CONDITION OF MACHINE WHEN ABNORMALITY OCCURS...........................................................391 ELECTRICAL CIRCUIT DIAGRAM OF MONITOR SYSTEM.....................................................................................393 M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED [E102] ERROR IN CLOCK DATA IS DISPLAYED........................................395 M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24 V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED...............396 M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED....................................................................................397 M-4 [E106] DROP IN ENGINE OIL PRESSURE HI DETECTED IS DISPLAYED..................................................................397 M-5 [E108] ENGINE WATER TEMPERATURE 105C DETECTED IS DISPLAYED...................................................................398 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL LIGHT UP FOR 3 SECONDS.............................399 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT.....................................401 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)...................401 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH..................................................402 M-10 PREHEATING IS NOT BEING USED BUT PREHEATING MONITOR LIGHTS UP...............................................................404 M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH............................................405 M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH...............................407 M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH..........................409 M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND. CAUTION ITEM FLASHES BUT BUZZER....412 M-15 NO ABNROMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS....................................................................412 M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)........................................413 M-17 COOLANT TEMPERATURE GAUGE DOE NOT RISE......................................................................................414 M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY.........................................................................414 M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.......................................................................................415 M-20 FUEL LEVEL GAUGE DOES NOT GIVE ANY DISPLAY..................................................................................415 M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT SWING LOCK MONITOR DOES NOT LIGHT UP..............................................416 M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH............................................416 M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING......................................................................417 M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED.........................417 M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM..........................................................................................418 M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM.................................................................................419 M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM....................................................................................420 M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.......................................................................................421 M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED.......................................................422 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................426 METHOD OF USING MANUAL...................................................................................................................428 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................430 SPECIAL TOOL LIST........................................................................................................................432 GOVERNOR MOTOR ASSEMBLY..................................................................................................................435 REMOVAL AND INSTALLATION.............................................................................................................435 HYDRAULIC COOLER ASSEMBLY................................................................................................................436 REMOVAL..............................................................................................................................436 RADIATOR, HYDRAULIC COOLER ASSEMBLY......................................................................................................437 REMOVAL..............................................................................................................................437 INSTALLATION.........................................................................................................................438 ENGINE, MAIN PUMP ASSEMBLY...............................................................................................................439 REMOVAL..............................................................................................................................439 INSTALLATION.........................................................................................................................442 DAMPER ASSEMBLY..........................................................................................................................443 REMOVAL AND INSTALLATION.............................................................................................................443 FUEL TANK ASSEMBLY.......................................................................................................................444 REMOVAL AND INSTALLATION.............................................................................................................444 CENTER SWIVEL JOINT ASSEMBLY.............................................................................................................445 REMOVAL AND INSTALLATION.............................................................................................................445 SWING MOTOR ASSEMBLY.....................................................................................................................446 REMOVAL AND INSTALLATION.............................................................................................................446 SWING MACHINERY ASSEMBLY.................................................................................................................447 REMOVAL AND INSTALLATION.............................................................................................................447 SWING MOTOR..............................................................................................................................449 DISASSEMBLY AND ASSEMBLY.............................................................................................................449 REVOLVING FRAME ASSEMBLY.................................................................................................................456 REMOVAL..............................................................................................................................456 INSTALLATION.........................................................................................................................458 SWING CIRCLE ASSEMBLY....................................................................................................................459 REMOVAL AND INSTALLATION.............................................................................................................459 HYDRAULIC TANK ASSEMBLY..................................................................................................................461 REMOVAL..............................................................................................................................461 INSTALLATION.........................................................................................................................462 MAIN PUMP ASSEMBLY.......................................................................................................................463 REMOVAL..............................................................................................................................463 INSTALLATION.........................................................................................................................464 CONTROL VALVE ASSEMBLY...................................................................................................................465 REMOVAL..............................................................................................................................465 INSTALLATION.........................................................................................................................466 DISASSEMBLY AND ASSEMBLY.............................................................................................................467 LS SELECT VALVE ASSEMBLY.................................................................................................................471 DISASSEMBLY AND ASSEMBLY.............................................................................................................471 LS SHUTTLE VALVE.........................................................................................................................472 DISASSEMBLY AND ASSEMBLY.............................................................................................................472 PRESSURE COMPENSATION VALVE..............................................................................................................473 DISASSEMBLY AND ASSEMBLY.............................................................................................................473 MAIN RELIEF VALVE ASSEMBLY...............................................................................................................475 DISASSEMBLY..........................................................................................................................475 ASSEMBLY.............................................................................................................................476 LS CONTROL EPC VALVE ASSEMBLY............................................................................................................477 REMOVAL AND INSTALLATION.............................................................................................................477 EPC SOLENOID VALVE ASSEMBLY..............................................................................................................478 REMOVAL AND INSTALLATION.............................................................................................................478 PPC SHUTTLE VALVE ASSEMBLY...............................................................................................................479 REMOVAL..............................................................................................................................479 INSTALLATION.........................................................................................................................480 DISASSEMBLY..........................................................................................................................481 ASSEMBLY.............................................................................................................................482 WORK EQUIPMENT PPC VALVE ASSEMBLY........................................................................................................483 REMOVAL AND INSTALLATION.............................................................................................................483 TRAVEL PPC PEDAL ASSEMBLY................................................................................................................484 REMOVAL AND INSTALLATION.............................................................................................................484 BOOM CYLINDER ASSEMBLY...................................................................................................................485 REMOVAL..............................................................................................................................485 INSTALLATION.........................................................................................................................486 ARM CYLINDER ASSEMBLY....................................................................................................................487 REMOVAL..............................................................................................................................487 INSTALLATION.........................................................................................................................488 BUCKET CYLINDER ASSEMBLY.................................................................................................................489 REMOVAL..............................................................................................................................489 INSTALLATION.........................................................................................................................490 HYDRAULIC CYLINDER ASSEMBLY..............................................................................................................491 DISASSEMBLY .........................................................................................................................491 ASSEMBLY.............................................................................................................................493 WORK EQUIPMENT ASSEMBLY..................................................................................................................496 REMOVAL..............................................................................................................................496 INSTALLATION.........................................................................................................................497 BUCKET ASSEMBLY..........................................................................................................................498 REMOVAL..............................................................................................................................498 INSTALLATION.........................................................................................................................498 ARM ASSEMBLY.............................................................................................................................498 REMOVAL .............................................................................................................................498 INSTALLATION.........................................................................................................................498 BUCKET, ARM ASSEMBLY.....................................................................................................................500 REMOVAL .............................................................................................................................500 INSTALLATION.........................................................................................................................500 BOOM ASSEMBLY............................................................................................................................502 REMOVAL..............................................................................................................................502 INSTALLATION.........................................................................................................................503 OPERATOR'S CAB ASSEMBLY..................................................................................................................504 REMOVAL..............................................................................................................................504 INSTALLATION.........................................................................................................................506 COUNTERWEIGHT ASSEMBLY...................................................................................................................507 REMOVAL AND INSTALLATION.............................................................................................................507 GOVERNOR, PUMP CONTROLLER ASSEMBLY.......................................................................................................508 REMOVAL AND INSTALLATION.............................................................................................................508 MONITOR PANEL ASSEMBLY...................................................................................................................509 REMOVAL AND INSTALLATION.............................................................................................................509 SWING MACHINERY ASSEMBLY.................................................................................................................510 DISASSEMBLY..........................................................................................................................510 ASSEMBLY.............................................................................................................................525 (SPECIAL TOOLS)......................................................................................................................545 TRANSMISSION.............................................................................................................................547 FRONT AXLE...............................................................................................................................554 REAR AXLE................................................................................................................................571 BUCKET ADAPTER...........................................................................................................................585 WELDING INSTRUCTION..................................................................................................................585 OUTRIGGER + BLADE CYLINDER...............................................................................................................588 40 MAINTENANCE STANDARD......................................................................................................................590 ENGINE MOUNT.............................................................................................................................591 SWING MACHINERY..........................................................................................................................592 SWING CIRCLE.............................................................................................................................594 CONTROL VALVE............................................................................................................................595 SUCTION SAFETY VALVE.....................................................................................................................603 SWING MOTOR..............................................................................................................................604 WORK EQUIPMENT, SWING PPC VALVE..........................................................................................................605 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE.................................................................................................606 EPC SOLENOID VALVE.......................................................................................................................607 CENTER SWIVEL JOINT......................................................................................................................608 BOOM SAFETY VALVE (ARM SAFETY VALVE).....................................................................................................609 HYDRAULIC CYLINDER.......................................................................................................................610 WORK EQUIPMENT...........................................................................................................................611 DOZER BLADE, OUTRIGGER CLYINDERS.........................................................................................................619 OUTRIGGER BUSH PINS......................................................................................................................620 TRANSMISSION.............................................................................................................................621 FRONT AXLE...............................................................................................................................622 REAR AXLE................................................................................................................................623 ARM ROTATION CIRCLE......................................................................................................................624
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