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KOMATSU PC300-6 CUSTOM PC300LC-6 CUSTOM SHOP MANUAL SEBM007201 – PDF
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Description
KOMATSU PC300-6 CUSTOM PC300LC-6 CUSTOM SHOP MANUAL SEBM007201 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC300-6 CUSTOM PC300LC-6 CUSTOM SHOP MANUAL SEBM007201 – PDF DOWNLOAD
Language : English
Pages : 582
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
KOMATSU PC300-6 CUSTOM PC300LC-6 CUSTOM SHOP MANUAL SEBM007201 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For case at understanding. the manual la divided into the following chapters: these chapters are iurther divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTiNG
This section explains checks to be made before ant: after performing repairs, as well as adiuetments to be made at completion of the checks and repairs. Troubleshooting charts correlating ‘Preblems’ to ‘Causes‘ are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing. disassembling or assembling each component. as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when Inspecting disassembled parts.
TABLE OF CONTENTS:
KOMATSU PC300-6 CUSTOM PC300LC-6 CUSTOM SHOP MANUAL SEBM007201 – PDF DOWNLOAD
COVER............................................................................................................................... 1
CONTENTS............................................................................................................................ 2
01 GENERAL.......................................................................................................................... 24
SPECIFICATION DRAWINGS.......................................................................................................... 25
SPECIFICATIONS.................................................................................................................. 26
WEIGHT TABLE.................................................................................................................... 28
FUEL, COOLANT AND LUBRICANTS.................................................................................................... 30
10 STRUCTURE AND FUNCTION........................................................................................................... 32
PARTS RELATED TO ENGINE......................................................................................................... 33
RADIATOR, OIL COOLER............................................................................................................ 35
POWER TRAIN..................................................................................................................... 36
FINAL DRIVE..................................................................................................................... 37
SWING CIRCLE.................................................................................................................... 38
SWING MACHINERY................................................................................................................. 39
TRACK FRAME, RECOIL SPRING...................................................................................................... 40
TRACK SHOE...................................................................................................................... 41
HYDRAULIC PIPING DRAWING........................................................................................................ 42
HYDRAULIC CIRCUIT DIAGRAM....................................................................................................... 43
HYDRAULIC TANK, HYDRAULIC FILTER................................................................................................ 44
HYDRAULIC PUMP.................................................................................................................. 45
CONTROL VALVE................................................................................................................... 64
SUCTION SAFETY VALVE............................................................................................................ 73
CLSS............................................................................................................................ 74
SWING MOTOR.....................................................................................................................115
CENTER SWIVEL JOINT.............................................................................................................119
TRAVEL MOTOR....................................................................................................................120
VALVE CONTROL...................................................................................................................129
WORK EQUIPMENT, SWING PPC VALVE.................................................................................................130
TRAVEL PPC VALVE................................................................................................................134
SERVICE PPC VALVE...............................................................................................................138
PPC SAFETY LOCK VALVE...........................................................................................................141
PPC ACCUMULATOR.................................................................................................................141
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE........................................................................................142
SOLENOID VALVE..................................................................................................................149
BOOM HOLDING VALVE..............................................................................................................153
HYDRAULIC CYLINDER..............................................................................................................156
WORK EQUIPMENT..................................................................................................................157
ACTUAL ELECTRIC WIRING DIAGRAM..................................................................................................158
ELECTRIC CIRCUIT DIAGRAM........................................................................................................160
ENGINE CONTROL SYSTEM...........................................................................................................163
ELECTRIC CONTROL SYSTEM.........................................................................................................164
MACHINE MONITOR SYSTEM..........................................................................................................168
SENSORS.........................................................................................................................171
20 TESTING AND ADJUSTING............................................................................................................173
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS...................................................................................174
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS..................................................................................175
STANDARD VALUE TABLE FOR ELECTRICAL PARTS.......................................................................................183
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...............................................................................185
MEASURING ENGINE SPEED..........................................................................................................186
MEASURING EXHAUST COLOR.........................................................................................................187
ADJUSTING VALVE CLEARANCE.......................................................................................................188
MEASURING COMPRESSION PRESSURE..................................................................................................189
MEASURING BLOW-BY PRESSURE......................................................................................................189
TESTING AND ADJUSTING FUEL INJECTION TIMING.....................................................................................190
MEASURING ENGINE OIL PRESSURE...................................................................................................191
TESTING AND ADJUSTING ALTERNATOR BELT TENSION...................................................................................192
TESTING AND ADJUSTING WATER PUMP BELT TENSION...................................................................................192
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR...............................................................193
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)..................................................................................194
ADJUSTING FUEL CONTROL LEVER....................................................................................................195
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT...............................................197
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)...................................................200
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE.......................202
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE.........................................................................205
TESTING SOLENOID VALVE OUTPUT PRESSURE..........................................................................................207
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE...............................................................208
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE.......................................................................................210
TESTING TRAVEL DEVIATION........................................................................................................211
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....................................................................212
MEASURING OIL LEAKAGE...........................................................................................................214
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................216
TESTING CLEARANCE OF SWING CIRCLE BEARING.......................................................................................217
TESTING AND ADJUSTING TRACK SHOE TENSION........................................................................................218
BLEEDING AIR....................................................................................................................219
TROUBLESHOOTING.................................................................................................................221
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....................................................................................222
SEQUENCE OF EVENTS IN TROUBLESHOOTING.......................................................................................223
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................224
CHECKS BEFORE TROUBLESHOOTING...............................................................................................232
CONNECTOR TYPES AND MOUNTING LOCATIONS......................................................................................233
CONNECTOR ARRANGEMENT DIAGRAM...............................................................................................234
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..................................................................................236
METHOD OF USING TROUBLESHOOTING CHARTS......................................................................................246
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...................................................................................248
METHOD OF USING TROUBLESHOOTING CHARTS..................................................................................249
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)...........................................................253
S-2 ENGINE DOES NOT START...............................................................................................254
(1) ENGINE DOES NOT TURN............................................................................................254
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)........................................255
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).....................................256
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)................................................................257
S-4 ENGINE STOPS DURING OPERATIONS......................................................................................258
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................................259
S-6 ENGINE LACKS OUTPUT (NO POWER)......................................................................................260
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)......................................................................261
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).............................................................262
S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................................263
S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................................264
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN............................................265
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).........................................................266
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL )..............................................................................267
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...................................................................268
S-15 ABNORMAL NOISE IS MADE.............................................................................................269
S-16 VIBRATION IS EXCESSIVE.............................................................................................270
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...............................................................................271
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM, HYDRAULIC AND MECHANICAL SYSTEM..................................................272
E MODE ELECTRICAL SYSTEM DIAGRAM........................................................................................274
E-1 ABNORMALITY IN PUMP TVC CONTROL SYSTEM..............................................................................275
a) ENGINE STALLS WHEN FUEL CONTROL LEVER IS AT FULL (FUEL CONTROL LEVER SWITCH OFF).................................275
b) ENGINE STALLS BELOW MIDRANGE SPEED {ENGINE SPEED: BELOW 1600 rpm (FUEL CONTROL LEVER LIMIT SWITCH ON)}...........276
c) FUEL CONTROL LEVER IS AT FULL, WORK EQUIPMENT SPEED IS SLOW OR LACKS POWER.......................................277
E-2 ABNORMALITY IN PPC OIL PRESSURE LOCK SOLENOID SYSTEM................................................................278
a) IS NOT ACTUATED (SAFETY LOCK IS NOT RELEASED)....................................................................278
b) REMAINS ACTUATED (SAFETY LOCK IS NOT APPLIED)....................................................................279
E-3 ABNORMALITY IN SWING LOCK SOLENOID SYSTEM...........................................................................280
a) IS NOT ACTUATED (CANNOT SWING)...................................................................................280
b) REMAINS ACTUATED (SWING CANNOT BE LOCKED)........................................................................281
E-4 STEERING DOES NOT TURN EASILY (ABNORMALITY IN PUMP MERGE/DIVIDER SOLENOID SYSTEM)...................................282
E-5 ABNORMALITY IN TRAVEL SPEED SOLENOID SYSTEM.........................................................................284
a) TRAVEL SPEED DOES NOT CHANGE TO HI (TRAVEL SPEED STAYS IN LO)....................................................284
b) TRAVEL SPEED DOES NOT CHANGE TO LO (TRAVEL SPEED STAYS IN HI)....................................................285
E-6 ABNORAMLITY IN ENGINE STARTING SYSTEM (ENGINE DOES NOT START).......................................................286
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)....................................................................288
TABLE OF FAILURE MODES AND CAUSES.......................................................................................289
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER..............................................293
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.......................................................295
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE...........................................................................296
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)..........................................................................296
H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR................................................................297
H-6 BOOM IS SLOW OR LACKS POWER.....................................................................................298
H-7 ARM IS SLOW OR LACKS POWER......................................................................................300
H-8 BUCKET IS SLOW OR LACKS POWER...................................................................................302
H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)..............................302
H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)..................................................................303
H-11 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)......................................................................304
H-12 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED..........................................................304
H-13 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW................................................304
H-14 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW......................................................................305
H-15 IN SWING + ARM OUT, ARM OUT IS SLOW............................................................................305
H-16 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY..............................................................305
H-17 TRAVEL DEVIATION...............................................................................................306
H-18 TRAVEL SPEED IS SLOW...........................................................................................307
H-19 STEERING DOES NOT TURN EASILY OR LACKS POWER...................................................................309
H-20 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED.................................................311
H-21 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)...........................................................................311
H-22 DOES NOT SWING.................................................................................................312
H-23 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW..............................................................313
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING..........................................................................315
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY).......................................................316
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING...................................................................316
H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING.............................................................................317
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)..........................................................................318
MONITOR SYSTEM ELECTRICAL CIRCUIT DIAGRAM...............................................................................319
M-1 WHEN THE STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS)................320
M-2 WHEN STARTING SWITCH IS TURNED ON, LAMPS LIGHT UP FOR 3 SECONDS, BUT THEN DO NOT GO OUT.........................320
M-3 WHEN STARTING SWITCH IS TURNED ON, SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS.....................................321
a) NO GAUGE LAMPS LIGHT UP (CAUTION LAMPS LIGHT UP).............................................................321
b) SWING LOCK PREHEATING LAMPS DO NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP).......................................321
c) CHARGE CAUTION LAMP DOES NOT LIGHT UP........................................................................321
d) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...........................................................321
M-4 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), CHARGE CAUTION LAMP DOES NOT LIGHT UP.......................322
M-5 WHEN POWER IS TURNED ON (BEFORE ENGINE IS STARTED), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP..........322
M-6 DURING PREHEATING, PREHEATING PILOT LAMP DOES NOT LIGHT UP......................................................323
M-7 WHEN SWITCH IS OPERATED, SWING LOCK LAMP DOES NOT LIGHT UP......................................................323
M-8 ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING (ENGINE OIL PRESSURE IS NORMAL)...............324
M-9 CHARGE CAUTION LAMP LIGHTS UP WHEN ENGINE IS RUNNING............................................................324
M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE.......................................................................325
a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM (WHITE RANGE) AND GOES NOT MOVE...............................325
b) AFTER ENGINE IS STARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE....325
c) COOLANT TEMPERATURE GAUGE GOES OUT...........................................................................325
M-11 ABNORMALITY IN FUEL GAUGE......................................................................................326
a) ALL FUEL GAUGE SEGMENTS GO OUT...............................................................................326
b) EVEN WHEN FUEL LEVEL GOES DOWN, FUEL GAUGE CONTINUES TO SHOW FULL............................................326
c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOES NOT SHOW FULL......................................................326
M-12 DEFECTIVE OPERATION OF ALARM BUZZER............................................................................328
a) BUZZER DOES NOT SOUND........................................................................................328
b) BUZZER CONTINUES TO SOUND AND DOES NOT STOP..................................................................328
M-13 ENGINE IS RUNNING, BUT SERVICE METER DOES NOT MOVE.............................................................329
a) CHARGE CAUTION LAMP LIGHTS UP................................................................................329
b) CHARGE CAUTION LAMP DOES NOT LIGHT UP........................................................................329
M-14 NIGHT LIGHTING DOES NOT LIGHT UP...............................................................................330
a) GAUGE LIGHTING DOES NOT LIGHT UP.............................................................................330
b) SERVICE METER LIGHTING DOES NOT LIGHT UP (SERVICE METER IS WORKING NORMALLY).................................330
M-15 WIPER DOES NOT MOVE, OR DOES NOT STOP MOVING...................................................................331
a) WIPER DOES NOT MOVE WHEN WIPER SWITCH IS TURNED TO ON........................................................331
b) WIPER MOVES EVEN WHEN WIPER SWITCH IS NOT TURNED TO ON.......................................................331
M-16 HEATER DOES NOT WORK...........................................................................................332
a) DOES NOT WORK AT EITHER HI OR LO.............................................................................332
b) DOES NOT WORK AT LO ONLY.....................................................................................332
c) DOES NOT WORK AT HI ONLY.....................................................................................332
30 DISASSEMBLY AND ASSEMBLY.........................................................................................................333
METHOD OF USING MANUAL..........................................................................................................335
PRECAUTIONS WHEN CARRYING OUT OPERATION.........................................................................................337
SPECIAL TOOL LIST...............................................................................................................339
SKETCHES OF SPECIAL TOOLS.......................................................................................................344
STARTING MOTOR ASSEMBLY.........................................................................................................349
REMOVAL AND INSTALLATION....................................................................................................349
ALTERNATOR ASSEMBLY.............................................................................................................350
REMOVAL AND INSTALLATION....................................................................................................350
ENGINE OIL COOLER ASSEMBLY......................................................................................................351
REMOVAL AND INSTALLATION....................................................................................................351
FUEL INJECTION PUMP ASSEMBLY....................................................................................................352
REMOVAL.....................................................................................................................352
INSTALLATION................................................................................................................353
WATER PUMP ASSEMBLY.............................................................................................................354
REMOVAL AND INSTALLATION....................................................................................................354
NOZZLE HOLDER ASSEMBLY..........................................................................................................355
REMOVAL AND INSTALLATION....................................................................................................355
TURBOCHARGER ASSEMBLY...........................................................................................................356
REMOVAL AND INSTALLATION....................................................................................................356
THERMOSTAT ASSEMBLY.............................................................................................................357
REMOVAL AND INSTALLATION....................................................................................................357
ENGINE FRONT SEAL...............................................................................................................358
REMOVAL.....................................................................................................................358
INSTALLATION................................................................................................................359
CYLINDER HEAD ASSEMBLY..........................................................................................................360
REMOVAL.....................................................................................................................360
INSTALLATION................................................................................................................362
AFTERCOOLER ASSEMBLY............................................................................................................365
REMOVAL AND INSTALLATION....................................................................................................365
HYDRAULIC COOLER ASSEMBLY.......................................................................................................366
REMOVAL AND INSTALLATION....................................................................................................366
RADIATOR, HYDRAULIC COOLER ASSEMBLY.............................................................................................367
REMOVAL.....................................................................................................................367
INSTALLATION................................................................................................................368
ENGINE, MAIN PUMP ASSEMBLY......................................................................................................369
REMOVAL.....................................................................................................................369
INSTALLATION................................................................................................................371
DAMPER ASSEMBLY.................................................................................................................372
REMOVAL AND INSTALLATION....................................................................................................372
FUEL TANK ASSEMBLY..............................................................................................................373
REMOVAL AND INSTALLATION....................................................................................................373
CENTER SWIVEL JOINT ASSEMBLY....................................................................................................374
REMOVAL AND INSTALLATION....................................................................................................374
DISASSEMBLY AND ASSEMBLY....................................................................................................375
FINAL DRIVE ASSEMBLY............................................................................................................376
REMOVAL AND INSTALLATION....................................................................................................376
DISASSEMBLY.................................................................................................................377
ASSEMBLY....................................................................................................................381
TRAVEL MOTOR ASSEMBLY...........................................................................................................387
DISASSEMBLY.................................................................................................................387
ASSEMBLY....................................................................................................................392
SPROCKET........................................................................................................................401
REMOVAL AND INSTALLATION....................................................................................................401
SWING MOTOR ASSEMBLY............................................................................................................402
REMOVAL AND INSTALLATION....................................................................................................402
DISASSEMBLY.................................................................................................................403
ASSEMBLY....................................................................................................................406
SWING MACHINERY ASSEMBLY........................................................................................................413
REMOVAL AND INSTALLATION....................................................................................................413
DISASSEMBLY.................................................................................................................414
ASSEMBLY....................................................................................................................418
REVOLVING FRAME ASSEMBLY........................................................................................................423
REMOVAL.....................................................................................................................423
INSTALLATION................................................................................................................424
SWING CIRCLE ASSEMBLY...........................................................................................................425
REMOVAL AND INSTALLATION....................................................................................................425
IDLER, RECOIL SPRING ASSEMBLY...................................................................................................426
REMOVAL AND INSTALLATION....................................................................................................426
IDLER ASSEMBLY..................................................................................................................427
DISASSEMBLY.................................................................................................................427
ASSEMBLY....................................................................................................................428
RECOIL SPRING ASSEMBLY..........................................................................................................430
DISASSEMBLY.................................................................................................................430
ASSEMBLY....................................................................................................................431
TRACK ROLLER ASSEMBLY...........................................................................................................432
REMOVAL AND INSTALLATION....................................................................................................432
DISASSEMBLY.................................................................................................................433
ASSEMBLY....................................................................................................................434
CARRIER ROLLER ASSEMBLY.........................................................................................................436
REMOVAL AND INSTALLATION....................................................................................................436
DISASSEMBLY.................................................................................................................437
ASSEMBLY....................................................................................................................439
TRACK SHOE ASSEMBLY.............................................................................................................441
REMOVAL AND INSTALLATION....................................................................................................441
HYDRAULIC TANK ASSEMBLY.........................................................................................................442
REMOVAL.....................................................................................................................442
INSTALLATION................................................................................................................443
CONTROL PUMP ASSEMBLY...........................................................................................................444
REMOVAL AND INSTALLATION....................................................................................................444
MAIN PUMP ASSEMBLY..............................................................................................................445
REMOVAL.....................................................................................................................445
INSTALLATION................................................................................................................446
DISASSEMBLY.................................................................................................................447
ASSEMBLY....................................................................................................................453
MAIN PUMP INPUT SHAFT OIL SEAL..................................................................................................467
REMOVAL AND INSTALLATION....................................................................................................467
CONTROL VALVE ASSEMBLY..........................................................................................................468
REMOVAL.....................................................................................................................468
INSTALLATION................................................................................................................470
DISASSEMBLY.................................................................................................................471
ASSEMBLY....................................................................................................................475
PUMP MERGE/DIVIDER VALVE ASSEMBLY...............................................................................................480
DISASSEMBLY AND ASSEMBLY....................................................................................................480
PRESSURE COMPENSATION VALVE ASSEMBLY............................................................................................481
DISASSEMBLY AND ASSEMBLY....................................................................................................481
SERVO VALVE ASSEMBLY FOR FRONT PUMP.............................................................................................482
REMOVAL AND INSTALLATION....................................................................................................482
SERVO VALVE ASSEMBLY FOR REAR PUMP..............................................................................................483
REMOVAL AND INSTALLATION....................................................................................................483
PPC LOCK AND SWING BRAKE SOLENOID VALVE ASSEMBLY................................................................................484
REMOVAL AND INSTALLATION....................................................................................................484
MERGE/FLOW DIVIDER AND TRAVEL HI/LO SOLENOID VALVE ASSEMBLY.....................................................................485
REMOVAL AND INSTALLATION....................................................................................................485
WORK EQUIPMENT PPC VALVE ASSEMBLY...............................................................................................486
REMOVAL AND INSTALLATION....................................................................................................486
DISASSEMBLY.................................................................................................................487
ASSEMBLY....................................................................................................................488
TRAVEL PPC VALVE ASSEMBLY.......................................................................................................489
REMOVAL AND INSTALLATION....................................................................................................489
DISASSEMBLY.................................................................................................................490
ASSEMBLY....................................................................................................................491
PPC SHUTTLE VALVE ASSEMBLY......................................................................................................492
REMOVAL.....................................................................................................................492
INSTALLATION................................................................................................................493
DISASSEMBLY.................................................................................................................494
ASSEMBLY....................................................................................................................495
BOOM LOCK VALVE ASSEMBLY........................................................................................................496
REMOVAL AND INSTALLATION....................................................................................................496
DISASSEMBLY AND ASSEMBLY....................................................................................................497
BOOM CYLINDER ASSEMBLY..........................................................................................................498
REMOVAL.....................................................................................................................498
INSTALLATION................................................................................................................499
ARM CYLINDER ASSEMBLY...........................................................................................................500
REMOVAL.....................................................................................................................500
INSTALLATION................................................................................................................501
BUCKET CYLINDER ASSEMBLY........................................................................................................502
REMOVAL.....................................................................................................................502
INSTALLATION................................................................................................................503
HYDRAULIC CYLINDER ASSEMBLY.....................................................................................................504
DISASSEMBLY.................................................................................................................504
ASSEMBLY....................................................................................................................506
WORK EQUIPMENT ASSEMBLY.........................................................................................................508
REMOVAL.....................................................................................................................508
INSTALLATION................................................................................................................509
BUCKET ASSEMBLY.................................................................................................................510
REMOVAL.....................................................................................................................510
INSTALLATION................................................................................................................511
ARM ASSEMBLY....................................................................................................................512
REMOVAL.....................................................................................................................512
INSTALLATION................................................................................................................513
BUCKET, ARM ASSEMBLY............................................................................................................514
REMOVAL.....................................................................................................................514
INSTALLATION................................................................................................................515
BOOM ASSEMBLY...................................................................................................................516
REMOVAL.....................................................................................................................516
INSTALLATION................................................................................................................517
OPERATOR'S CAB ASSEMBLY.........................................................................................................518
REMOVAL AND INSTALLATION....................................................................................................518
MONITOR ASSEMBLY................................................................................................................519
REMOVAL AND INSTALLATION....................................................................................................519
COUNTERWEIGHT ASSEMBLY..........................................................................................................520
REMOVAL AND INSTALLATION....................................................................................................520
CONTROL STAND CASE..............................................................................................................521
REMOVAL.....................................................................................................................521
INSTALLATION................................................................................................................522
AIR CONDITIONER COMPRESSOR ASSEMBLY.............................................................................................523
REMOVAL AND INSTALLATION....................................................................................................523
CONDENSER ASSEMBLY..............................................................................................................524
REMOVAL AND INSTALLATION....................................................................................................524
AIR CONDITIONER UNIT ASSEMBLY...................................................................................................525
REMOVAL.....................................................................................................................525
INSTALLATION................................................................................................................526
40 MAINTENANCE STANDARD.............................................................................................................527
ENGINE MOUNT....................................................................................................................528
SWING MACHINERY.................................................................................................................529
SWING CIRCLE....................................................................................................................531
FINAL DRIVE.....................................................................................................................532
TRACK FRAME AND RECOIL SPRING...................................................................................................534
IDLER...........................................................................................................................535
CARRIER ROLLER..................................................................................................................537
TRACK ROLLER....................................................................................................................538
TRACK...........................................................................................................................539
HYDRAULIC PUMP..................................................................................................................541
CONTROL PUMP AND RELIEF VALVE...................................................................................................542
CONTROL VALVE...................................................................................................................543
SUCTION-SAFETY VALVE............................................................................................................549
SWING MOTOR.....................................................................................................................550
TRAVEL MOTOR....................................................................................................................551
WORK EQUIPMENT, SWING PPC VALVE.................................................................................................552
TRAVEL PPC VALVE................................................................................................................553
SERVICE PPC VALVE...............................................................................................................554
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE........................................................................................555
CENTER SWIVEL JOINT.............................................................................................................556
BOOM HOLDING VALVE..............................................................................................................557
HYDRAULIC CYLINDER..............................................................................................................558
WORK EQUIPMENT..................................................................................................................559
90 OTHERS...........................................................................................................................564
HYDRAULIC PIPING DIAGRAM (10-12)................................................................................................565
HYDRAULIC CIRCUIT DIAGRAM (10-13)...............................................................................................566
OPERATION FOR EACH FUNCTION OF CLSS (10-50).....................................................................................567
OPERATION OF WHOLE CLSS SYSTEM..................................................................................................568
1. WHEN ALL WORK EQUIPMENT IS AT NEUTRAL (10-68)............................................................................568
2. PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY (10-70).............................................................569
3. PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY (10-72)..............................................................570
4. PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY (10-74)..................................................................571
5. PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY (10-76).................................................................572
6. PUMP FLOW DIVIDED, TRAVEL OPERATED INDEPENDENTLY (10-78).................................................................573
7. PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY (10-80)....................................................574
8. PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY (10-82).....................................................575
9. PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY (10-84)...................................................576
10. PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY (10-86)......................................................577
ACTUAL ELECTRIC WIRING DIAGRAM (10-134).....................................................................................578
ACTUAL ELECTRIC WIRING DIAGRAM (10-135).....................................................................................579
ELECTRIC CIRCUIT DIAGRAM (10-136)...........................................................................................580
ELECTRIC CIRCUIT DIAGRAM (10-137)...........................................................................................581
CONNECTOR ARRANGEMENT DIAGRAM (20-114)......................................................................................582S.S 13/12/24
