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Komatsu PC340-6K, PC340LC-6K, PC340NLC-6K Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC340-6K, PC340LC-6K, PC340NLC-6K Hydraulic Excavator Shop Manual
MACHINE MODEL
PC340-6K
PC340LC-6K
PC340NLC-6K
SERIAL NUMBER
K32001 and up, K34001 and up
K32001 and up, K34001 and up
K32001 and up, K34001 and up
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Description
Komatsu PC340-6K, PC340LC-6K, PC340NLC-6K Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC340-6K, PC340LC-6K, PC340NLC-6K Hydraulic Excavator Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEBM000901
Total Pages : 748
DESCRIPTION:
Komatsu PC340-6K, PC340LC-6K, PC340NLC-6K Hydraulic Excavator Shop Manual
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters: these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs , as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling eachr 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 PC340-6K, PC340LC-6K, PC340NLC-6K Hydraulic Excavator Shop Manual
SAFETY ........................................................................................................................................................................................................................ 3 SAFETY NOTICE ............................................................................................................................................................................................................. 3 SAFETY SAFETY NOTICE GENERAL PRECAUTIONS .............................................................................................................................................................................. 3 PREPARATIONS FOR WORK. ................................................................................................................................................................................................ 3 SAFETY SAFETY NOTICE PRECAUTIONS DURING WORK .......................................................................................................................................................................... 4 FOREWORD ...................................................................................................................................................................................................................... 5 GENERAL ................................................................................................................................................................................................................... 5 STRUCTURE AND FUNCTION ................................................................................................................................................................................................ 5 TESTING AND ADJUSTING ................................................................................................................................................................................................. 5 DISASSEMBLY AND ASSEMBLY .............................................................................................................................................................................................. 5 MAINTENANCE STANDARD .................................................................................................................................................................................................. 5 FOREWORD FOREWORD GENERAL VOLUMES ..................................................................................................................................................................................... 6 Chassis volume: ....................................................................................................................................................................................................... 6 Engine model: ......................................................................................................................................................................................................... 6 Electrical volume: Attachments volume: ................................................................................................................................................................................ 6 DISTRIBUTION AND UPDATING ............................................................................................................................................................................................. 6 FILING METHOD ......................................................................................................................................................................................................... 6 10 - 3 ................................................................................................................................................................................................................ 6 1 2 - 5 ............................................................................................................................................................................................................... 6 REVISED EDITION MARK .................................................................................................................................................................................................. 6 REVISIONS ............................................................................................................................................................................................................. 6 SYMBOLS ............................................................................................................................................................................................................... 6 FOREWORD HOW TO READ THE SHOP MANUAL .................................................................................................................................................................................. 6 HOW TO READ THE SHOP MANUAL ................................................................................................................................................................................................... 6 HOISTING INSTRUCTIONS ......................................................................................................................................................................................................... 7 COATING MATERIALS ............................................................................................................................................................................................................. 8 STANDARD TIGHTENING TORQUE .................................................................................................................................................................................................... 9 ELECTRIC WIRE CODE ............................................................................................................................................................................................................ 11 CONVERSION TABLE .............................................................................................................................................................................................................. 12 GENERAL ....................................................................................................................................................................................................................... 19 SPECIFICATION DRAWINGS .................................................................................................................................................................................................... 20 FUEL, COOLANT AND LUBRICANTS .............................................................................................................................................................................................. 26 STRUCTURE AND FUNCTION ........................................................................................................................................................................................................ 29 PARTS RELATED TO ENGINE ................................................................................................................................................................................................... 30 RADIATOR, OIL COOLER ...................................................................................................................................................................................................... 32 POWER TRAIN ............................................................................................................................................................................................................... 33 FINAL DRIVE ............................................................................................................................................................................................................... 34 SWING CIRCLE .............................................................................................................................................................................................................. 35 SWING MACHINERY ........................................................................................................................................................................................................... 36 TRACK FRAME, RECOIL SPRING ................................................................................................................................................................................................ 37 TRACK SHOE ................................................................................................................................................................................................................ 38 HYDRAULIC PIPING DRAWING .................................................................................................................................................................................................. 40 HYDRAULIC CIRCUIT DIAGRAM ................................................................................................................................................................................................. 42 HYDRAULIC PUMP ............................................................................................................................................................................................................ 45 CONTROL VALVE ............................................................................................................................................................................................................. 66 SELF- REDUCING PRESSURE VALVE SUCTION SAFETY VALVE ........................................................................................................................................................................ 81 CLSS .......................................................................................................................................................................................................................... 83 SWING MOTOR ...................................................................................................................................................................................................................148 CENTER SWIVEL JOINT ...........................................................................................................................................................................................................154 TRAVEL MOTOR ..................................................................................................................................................................................................................156 VALVE CONTROL .................................................................................................................................................................................................................165 WORK EQUIPMENT Ł SWING PPC VALVE ..............................................................................................................................................................................................166 TRAVEL PPC VALVE SERVICE PPC VALVE ............................................................................................................................................................................................174 PPC SAFETY LOCK VALVE .........................................................................................................................................................................................................177 PPC ACCUMULATOR ...............................................................................................................................................................................................................177 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE ......................................................................................................................................................................................179 LS- EPC VALVE .................................................................................................................................................................................................................186 SOLENOID VALVE ................................................................................................................................................................................................................190 WORK EQUIPMENT ................................................................................................................................................................................................................198 AIR CONDITIONER ...............................................................................................................................................................................................................199 ACTUAL ELECTRIC WIRING DIAGRAM ................................................................................................................................................................................................200 ELECTRIC CIRCUIT DIAGRAM ......................................................................................................................................................................................................204 ENGINE CONTROL ................................................................................................................................................................................................................208 ELECTRONIC CONTROL SYSTEM .....................................................................................................................................................................................................215 MACHINE MONITOR SYSTEM ........................................................................................................................................................................................................242 TESTING AND ADJUSTING .........................................................................................................................................................................................................253 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS .............................................................................................................................................................................256 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS ............................................................................................................................................................................257 STANDARD VALUE TABLE FOR ELECTRICAL PARTS .................................................................................................................................................................................265 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING .............................................................................................................................................................................274 MEASURING ENGINE SPEED ........................................................................................................................................................................................................275 MEASURING EXHAUST COLOR .......................................................................................................................................................................................................276 ADJUSTING VALVE CLEARANCE .....................................................................................................................................................................................................277 MEASURING COMPRESSION PRESSURE ................................................................................................................................................................................................278 MEASURING BLOW- BY PRESSURE ...................................................................................................................................................................................................278 TESTING AND ADJUSTING FUEL INJECTION TIMING ...................................................................................................................................................................................279 MEASURING ENGINE OIL PRESSURE .................................................................................................................................................................................................280 TESTING AND ADJUSTING ALTERNATOR BELT TENSION .................................................................................................................................................................................281 TESTING AND ADJUSTING WATER PUMP BELT TENSION .................................................................................................................................................................................281 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR .............................................................................................................................................................282 ADJUSTING ENGINE SPEED SENSOR .................................................................................................................................................................................................282 MEASURING AIR SUPPLY PRESSURE ( BOOST PRESSURE) ...............................................................................................................................................................................283 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE .............................................................................................................................................................................284 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT .............................................................................................................................................285 TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE ( SERVO PISTON INPUT PRESSURE) ................................................................................................................................................288 TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE ( SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE ....................................................................................................................290 TESTING CONTROL CIRCUIT OIL PRESSURE ( OIL PRESSURE WHEN SELF- PRESSURE IS REDUCED) ...........................................................................................................................................293 TESTING SOLENOID VALVE OUTPUT PRESSURE ........................................................................................................................................................................................294 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE .............................................................................................................................................................297 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE .....................................................................................................................................................................................299 TESTING TRAVEL DEVIATION ......................................................................................................................................................................................................300 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT ...................................................................................................................................................................301 MEASURING OIL LEAKAGE .........................................................................................................................................................................................................303 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT .............................................................................................................................................................................305 TESTING CLEARANCE OF SWING CIRCLE BEARING .....................................................................................................................................................................................306 TESTING WEAR OF SPROCKET ......................................................................................................................................................................................................307 TESTING AND ADJUSTING TRACK SHOE TENSION ......................................................................................................................................................................................308 BLEEDING AIR ..................................................................................................................................................................................................................309 POINTS TO REMEMBER WHEN TROUBLESHOOTING .......................................................................................................................................................................................312 CHECKS BEFORE TROUBLESHOOTING .................................................................................................................................................................................................322 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ....................................................................................................................................................................................329 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM ........................................................................................................................................................................339 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL .........................................................................................................................................................................340 METHOD OF USING JUDGEMENT TABLE ...............................................................................................................................................................................................349 METHOD OF USING TROUBLESHOOTING CHARTS ........................................................................................................................................................................................351 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE ......................................................................................................................................................................353 SERVICE CODE TABLE ............................................................................................................................................................................................................358 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER ( GOVERNOR CONTROL SYSTEM) ( E MODE) .............................................................................................................................................362 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM ..................................................................................................................................363 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE ................................................................................................................................................365 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER ( GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS .........................................................................................................................369 JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER ( GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS .............................................................................................................................369 E- 1 Abnormality in governor, pump controller power source ( controller LED is OFF) ...........................................................................................................................................373 E- 2 [ E308] Abnormality in fuel control dial input value is displayed ........................................................................................................................................................374 E- 3 [ E317] Abnormality ( disconnection) in motor drive system is displayed ..................................................................................................................................................375 E- 4 [ E318] Abnormality ( short circuit) in motor drive system is displayed ..................................................................................................................................................376 E- 5 [ E306] Abnormality in feedback potentiometer system is displayed ........................................................................................................................................................377 E- 6 [ E315] Abnormality ( short circuit) in battery relay output system is displayed .........................................................................................................................................378 E- 7 [ E316] Abnormality ( step- out) in motor is displayed ...................................................................................................................................................................379 E- 8 Engine does not start ....................................................................................................................................................................................................381 E- 9 Engine speed is irregular ................................................................................................................................................................................................383 E- 10 Lack of output ( engine high idling speed is too low) ...................................................................................................................................................................387 E- 11 Engine does not stop ....................................................................................................................................................................................................389 E- 12 Defective operation of battery relay system ( engine does not stop) .....................................................................................................................................................391 TROUBLESHOOTING OF ENGINE SYSTEM ( S MODE) ....................................................................................................................................................................................393 S- 1 Starting performance is poor ( starting always takes time) ...........................................................................................................................................................398 S- 2 Engine does not start ................................................................................................................................................................................................399 S- 3 Engine does not pick up smoothly ( follow- up is poor) ...............................................................................................................................................................402 S- 4 Engine stops during operations .......................................................................................................................................................................................403 S- 5 Engine does not rotate smoothly ( hunting) ...........................................................................................................................................................................404 S- 6 Engine lacks output ( no power) ......................................................................................................................................................................................405 S- 7 Exhaust smoke is black ( incomplete combustion) ......................................................................................................................................................................406 S- 8 Oil consumption is excessive ( or exhaust smoke is blue) .............................................................................................................................................................407 S- 9 Oil becomes contaminated quickly .....................................................................................................................................................................................408 S- 10 Fuel consumption is excessive .......................................................................................................................................................................................409 S- 11 Oil is in cooling water, or water spurts back, or water level goes down .............................................................................................................................................410 S- 12 Oil pressure caution lamp lights up ( drop in oil pressure) .........................................................................................................................................................411 S- 13 Oil level rises ( water, fuel in oil) ...............................................................................................................................................................................412 S- 14 Water temperature becomes too high ( overheating) ...................................................................................................................................................................413 S- 15 Abnormal noise is made ..............................................................................................................................................................................................414 S- 16 Vibration is excessive ..............................................................................................................................................................................................415 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER ( PUMP CONTROL SYSTEM) ( C MODE) .................................................................................................................................................416 C- 1 Abnormality in controller power source system ( controller LED is OFF) ...............................................................................................................................................431 C- 2 [ E232] Short circuit in front pump TVC solenoid system is displayed .................................................................................................................................................432 C- 3 [ E233] Disconnection in front pump TVC solenoid system is displayed .................................................................................................................................................434 C- 4 [ E236] Short circuit in rear pump TVC solenoid system is displayed ..................................................................................................................................................436 C- 5 [ E237] Disconnection in rear pump TVC solenoid system is displayed ..................................................................................................................................................438 C- 6 [ E207] Short circuit in active mode ( boom) solenoid system is displayed ............................................................................................................................................440 C- 7 [ E208] Disconnection in active mode ( boom) solenoid system is displayed ............................................................................................................................................441 C- 8 [ E203] Short circuit in swing brake solenoid system is displayed ....................................................................................................................................................442 C- 9 [ E213] Disconnection in swing brake solenoid system is displayed ....................................................................................................................................................444 C- 10 [ E204] Short circuit in pump merge/ divider solenoid system is displayed ...........................................................................................................................................446 C- 11 [ E214] Disconnection in pump merge/ divider solenoid system is displayed ...........................................................................................................................................447 C- 12 [ E206] Short circuit in travel speed solenoid system is displayed ..................................................................................................................................................448 C- 13 [ E216] Disconnection in travel speed selector solenoid system is displayed .........................................................................................................................................449 C- 14 [ E231] Short circuit in active mode ( swing) solenoid system is displayed ..........................................................................................................................................450 C- 15 [ E235] Disconnection in active mode ( swing) solenoid system is displayed ..........................................................................................................................................451 C- 16 [ E217] Model selection input error is displayed ....................................................................................................................................................................452 C- 17 [ E222] Short circuit in LS- EPC solenoid system is displayed .......................................................................................................................................................454 C- 18 [ E223] Disconnection in LS- EPC solenoid system is displayed .......................................................................................................................................................455 C- 19 [ E224] Abnormality in front pump pressure sensor system is displayed ...............................................................................................................................................456 C- 20 [ E225] Abnormality in rear pump pressure sensor system is displayed ................................................................................................................................................457 C- 21 [ E226] Abnormality in pressure sensor power source system is displayed .............................................................................................................................................458 C- 22 [ E227] Abnormality in engine speed sensor system is displayed ......................................................................................................................................................459 C- 23 Abnormality in machine push- up solenoid system ( no service code displayed) ........................................................................................................................................460 TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER ( INPUT SIGNAL SYSTEM) ( F MODE) .................................................................................................................................................464 F- 1 Bit pattern 20-( 1) Swing oil pressure switch does not light up ......................................................................................................................................................467 F- 2 Bit pattern 20-( 2) Travel oil pressure switch does not light up .....................................................................................................................................................468 F- 3 Bit pattern 20-( 3) Boom LOWER oil pressure switch does not light up .................................................................................................................................................469 F- 4 Bit pattern 20-( 4) Boom RAISE oil pressure switch does not light up .................................................................................................................................................470 F- 5 Bit pattern 20-( 5) Arm IN oil pressure switch does not light up .....................................................................................................................................................471 F- 6 Bit pattern 20-( 6) Arm OUT oil pressure switch does not light up ....................................................................................................................................................472 F- 7 Bit pattern 21-( 1) Bucket CURL oil pressure switch does not light up ................................................................................................................................................473 F- 8 Bit pattern 21-( 2) Bucket DUMP oil pressure switch does not light up ................................................................................................................................................474 F- 9 Bit pattern 21-( 3) Swing lock switch does not light up ..............................................................................................................................................................475 F- 10 Bit pattern 22-( 5) Kerosene mode connection does not light up ......................................................................................................................................................476 F- 11 Bit pattern 22-( 6) L. H. knob switch does not light up .............................................................................................................................................................477 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM ( H MODE) .....................................................................................................................................................................478 H- 1 Speeds of all work equipment, swing, travel are slow or lack power ...................................................................................................................................................485 H- 2 There is excessive drop in engine speed, or engine stalls ............................................................................................................................................................487 H- 3 No work equipment, travel, swing move H- 4 Abnormal noise generated ( around pump) H- 5 Auto- deceleration does not work ( when PPC shuttle valve is cause) ..........................................................489 H- 6 Fine control ability is poor or response is poor H- 7 Boom is slow or lacks power ....................................................................................................................................491 H- 8 Arm is slow or lacks power ...........................................................................................................................................................................................493 H- 9 Bucket is slow or lacks power ........................................................................................................................................................................................495 H- 10 Work equipment ( boom, arm, bucket) does not move ( but travel and swing are normal) ................................................................................................................................496 H- 11 Excessive hydraulic drift ( boom, arm, bucket) ......................................................................................................................................................................496 H- 12 Excessive time lag ( engine at low idling) ..........................................................................................................................................................................497 H- 13 Other equipment moves when single circuit is relieved H- 14 In L/ O, F/ O modes, work equipment speed is faster than specified speed ................................................................................498 H- 15 Defective actuation of machine push- up function ....................................................................................................................................................................498 H- 16 In compound operations, work equipment with larger load is slow .....................................................................................................................................................498 H- 17 In swing + boom RAISE, boom RAISE is slow ...........................................................................................................................................................................499 H- 18 In swing + arm, arm is slow .........................................................................................................................................................................................499 H- 19 In swing + travel, travel speed drops excessively ...................................................................................................................................................................499 H- 20 Travel deviation ....................................................................................................................................................................................................500 H- 21 Travel speed is slow ................................................................................................................................................................................................501 H- 22 Steering does not turn easily or lacks power ........................................................................................................................................................................503 H- 23 Travel speed does not switch or is faster than specified speed ......................................................................................................................................................505 H- 24 Travel does not move ( one side only) ...............................................................................................................................................................................505 H- 25 Does not swing ......................................................................................................................................................................................................506 H- 26 Swing acceleration is poor or swing speed is slow ...................................................................................................................................................................507 H- 27 Excessive overrun when stopping swing ...............................................................................................................................................................................509 H- 28 Excessive shock when stopping swing ( one direction only) H- 29 Excessive abnormal noise when stopping swing ........................................................................................................510 H- 30 Excessive hydraulic drift of swing ..................................................................................................................................................................................511 H- 31 Swing speed is faster than specified swing speed ....................................................................................................................................................................512 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM ( M MODE) ...........................................................................................................................................................................513 M- 1 [ E101] Abnormality in error data is displayed [ E102] Error in clock data is displayed ..............................................................................................................................520 M- 2 [ E103] Short circuit in buzzer output or contact of 24V wiring harness with buzzer drive harness is displayed .......................................................................................................521 M- 3 [ E104] Air cleaner clogging detected is displayed ...................................................................................................................................................................522 M- 4 [ E106] Drop in engine oil Hi pressure detected is displayed .........................................................................................................................................................522 M- 5 [ E108] Engine water temperature 105 ° C detected is displayed .......................................................................................................................................................523 M- 6 When starting switch is turned ON, none of lamps on monitor panel light up for 3 seconds .............................................................................................................................524 M- 7 When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out M- 8 When starting switch is turned ON, items lighted up on monitor panel are different from actual machine ( model) ....526 M- 9 When starting switch is turned ON ( engine stopped), basic check items flash .........................................................................................................................................527 M- 10 Preheating is not being used but ( preheating monitor) lights up ....................................................................................................................................................530 M- 11 When starting switch is turned ON and engine is started, basic check items flash ....................................................................................................................................531 M- 12 When starting switch is turned ON ( engine stopped), caution items, emergency items flash ( battery, engine oil pressure lamps do not light up) .....................................................................533 M- 13 When starting switch is turned ON and engine is started, caution items, emergency items flash ( when there is no abnormality in engine or items to check before troubleshooting) ....................................535 M- 14 When starting switch is turned ON ( engine stopped), buzzer does not sound for 1 second Caution item flashes but buzzer does not sound ..............................................................................538 M- 15 No abnormality is displayed on monitor but buzzer sounds ............................................................................................................................................................538 M- 16 Night lighting on monitor panel does not light up ( liquid crystal display is normal) ...............................................................................................................................539 M- 17 Coolant temperature gauge does not rise .............................................................................................................................................................................540 M- 18 Coolant temperature gauge does not give any display ( none of gauge lamps light up during operation) ................................................................................................................540 M- 19 Fuel level gauge always displays FULL ...............................................................................................................................................................................541 M- 20 Fuel level gauge does not give display ..............................................................................................................................................................................541 M- 21 Swing lock switch is turned ON ( LOCK) but ( swing lock monitor) does not light up ..................................................................................................................................542 M- 22 Swing prolix switch is turned ON ( prolix), but ( swing lock monitor) does not flash ................................................................................................................................542 M- 23 Service meter does not advance while engine is running M- 24 When starting switch is at OFF and time switch is pressed, time and service meter are not displayed M- 25 Defective fuel level sensor system ...........544 M- 26 Defective coolant temperature sensor system .........................................................................................................................................................................545 M- 27 Defective engine oil level sensor system ............................................................................................................................................................................546 M- 28 Defective coolant level sensor system ...............................................................................................................................................................................547 M- 29 Defective hydraulic oil level sensor system .........................................................................................................................................................................548 M- 30 Wiper does not work, or switch is not being used but wiper is actuated ( include E112, E113) ........................................................................................................................550 M- 31 Washer motor does not work, or switch is not being used but washer motor is actuated ( include E114) ................................................................................................................555 30 ............................................................................................................................................................................................................................558 METHOD OF USING MANUAL ....................................................................................................................................................................................................560 PRECAUTIONS WHEN CARRYING OUT OPERATION ...................................................................................................................................................................................562 SPECIAL TOOL LIST .........................................................................................................................................................................................................564 SKETCHES OF SPECIAL TOOLS .................................................................................................................................................................................................567 REMOVAL OF STARTING MOTOR ASSEMBLY ........................................................................................................................................................................................569 INSTALLATION OF STARTING MOTOR ASSEMBLY ...................................................................................................................................................................................569 REMOVAL OF ALTERNATOR ASSEMBLY ............................................................................................................................................................................................570 INSTALLATION OF ALTERNATOR ASSEMBLY .......................................................................................................................................................................................570 REMOVAL OF ENGINE OIL COOLER ASSEMBLY .....................................................................................................................................................................................571 INSTALLATION OF ENGINE OIL COOLER ASSEMBLY ................................................................................................................................................................................571 REMOVAL OF FUEL INJECTION PUMP ASSEMBLY ...................................................................................................................................................................................572 INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY ..............................................................................................................................................................................573 REMOVAL OF WATER PUMP ASSEMBLY ............................................................................................................................................................................................574 INSTALLATION OF WATER PUMP ASSEMBLY .......................................................................................................................................................................................574 REMOVAL OF NOZZLE HOLDER ASSEMBLY .........................................................................................................................................................................................575 INSTALLATION OF NOZZLE HOLDER ASSEMBLY ....................................................................................................................................................................................575 REMOVAL OF TURBOCHARGER ASSEMBLY ..........................................................................................................................................................................................576 INSTALLATION OF TURBOCHARGER ASSEMBLY .....................................................................................................................................................................................576 REMOVAL OF THERMOSTAT ASSEMBLY ............................................................................................................................................................................................577 INSTALLATION OF THERMOSTAT ASSEMBLY .......................................................................................................................................................................................577 REMOVAL OF ENGINE FRONT SEAL ..............................................................................................................................................................................................578 INSTALLATION OF ENGINE FRONT SEAL .........................................................................................................................................................................................579 REMOVAL OF ENGINE REAR SEAL ...............................................................................................................................................................................................580 INSTALLATION OF ENGINE REAR SEAL ..........................................................................................................................................................................................580 REMOVAL OF GOVERNOR MOTOR ASSEMBLY ........................................................................................................................................................................................582 INSTALLATION OF GOVERNOR MOTOR ASSEMBLY ...................................................................................................................................................................................582 REMOVAL OF CYLINDER HEAD ASSEMBLY .........................................................................................................................................................................................583 INSTALLATION OF CYLINDER HEAD ASSEMBLY ....................................................................................................................................................................................585 REMOVAL OF AFTERCOOLER ASSEMBLY ...........................................................................................................................................................................................588 INSTALLATION OF AFTERCOOLER ASSEMBLY ......................................................................................................................................................................................588 REMOVAL OF HYDRAULIC COOLER ASSEMBLY ......................................................................................................................................................................................589 INSTALLATION OF HYDRAULIC COOLER ASSEMBLY .................................................................................................................................................................................589 REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY ............................................................................................................................................................................590 INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY .......................................................................................................................................................................591 REMOVAL OF ENGINE, MAIN PUMP ASSEMBLY .....................................................................................................................................................................................592 INSTALLATION OF ENGINE, MAIN PUMP ASSEMBLY ................................................................................................................................................................................595 REMOVAL OF DAMPER ASSEMBLY ................................................................................................................................................................................................596 INSTALLATION OF DAMPER ASSEMBLY ...........................................................................................................................................................................................596 REMOVAL OF FUEL TANK ASSEMBLY .............................................................................................................................................................................................597 INSTALLATION OF FUEL TANK ASSEMBLY ........................................................................................................................................................................................597 REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY ...................................................................................................................................................................................598 INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY ..............................................................................................................................................................................598 DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY ...............................................................................................................................................................................599 ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY ..................................................................................................................................................................................599 REMOVAL OF FINAL DRIVE ASSEMBLY ...........................................................................................................................................................................................600 INSTALLATION OF FINAL DRIVE ASSEMBLY ......................................................................................................................................................................................600 DISASSEMBLY OF FINAL DRIVE ASSEMBLY .......................................................................................................................................................................................601 ASSEMBLY OF FINAL DRIVE ASSEMBLY ..........................................................................................................................................................................................605 DISASSEMBLY OF TRAVEL MOTOR ASSEMBLY ..........................................................................................................................................................................................613 ASSEMBLY OF TRAVEL MOTOR ASSEMBLY .............................................................................................................................................................................................618 DISASSEMBLY OF MAIN PUMP ASSEMBLY .............................................................................................................................................................................................627 ASSEMBLY OF MAIN PUMP ASSEMBLY ................................................................................................................................................................................................633 DISASSEMBLY OF PUMP MERGE/ DIVIDER VALVE ASSEMBLY .............................................................................................................................................................................647 ASSEMBLY OF PUMP MERGE/ DIVIDER VALVE ASSEMBLY ................................................................................................................................................................................647 DISASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY ...........................................................................................................................................................................648 ASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY ..............................................................................................................................................................................648 REMOVAL OF SERVO VALVE ASSEMBLY FOR FRONT PUMP ................................................................................................................................................................................649 INSTALLATION OF SERVO VALVE ASSEMBLY FOR FRONT PUMP ...........................................................................................................................................................................649 REMOVAL OF SERVO VALVE ASSEMBLY FOR REAR PUMP .................................................................................................................................................................................650 INSTALLATION OF SERVO VALVE ASSEMBLY FOR REAR PUMP ............................................................................................................................................................................650 REMOVAL OF LS- EPC SOLENOID VALVE ASSEMBLY ....................................................................................................................................................................................651 INSTALLATION OF LS- EPC SOLENOID VALVE ASSEMBLY ...............................................................................................................................................................................651 REMOVAL OF SOLENOID VALVE ASSEMBLY ............................................................................................................................................................................................652 INSTALLATION OF SOLENOID VALVE ASSEMBLY .......................................................................................................................................................................................652 REMOVAL OF WORK EQUIPMENT PPC VALVE ASSEMBLY ..................................................................................................................................................................................653 INSTALLATION OF WORK EQUIPMENT, PPC VALVE ASSEMBLY ............................................................................................................................................................................653 DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY ..............................................................................................................................................................................654 ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY .................................................................................................................................................................................655 REMOVAL OF TRAVEL PPC VALVE ASSEMBLY ..........................................................................................................................................................................................656 INSTALLATION OF TRAVEL PPC VALVE ASSEMBLY .....................................................................................................................................................................................656 DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY ......................................................................................................................................................................................657 ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY .........................................................................................................................................................................................658 REMOVAL OF PPC SHUTTLE VALVE ASSEMBLY .........................................................................................................................................................................................659 INSTALLATION OF PPC SHUTTLE VALVE ASSEMBLY ....................................................................................................................................................................................660 DISASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY .....................................................................................................................................................................................661 ASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY ........................................................................................................................................................................................662 REMOVAL OF BOOM CYLINDER ASSEMBLY .............................................................................................................................................................................................663 INSTALLATION OF BOOM CYLINDER ASSEMBLY ........................................................................................................................................................................................664 REMOVAL OF ARM CYLINDER ASSEMBLY ..............................................................................................................................................................................................665 INSTALLATION OF ARM CYLINDER ASSEMBLY .........................................................................................................................................................................................666 REMOVAL OF BUCKET CYLINDER ASSEMBLY ...........................................................................................................................................................................................667 INSTALLATION OF BUCKET CYLINDER ASSEMBLY ......................................................................................................................................................................................668 DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY ....................................................................................................................................................................................669 ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY .......................................................................................................................................................................................672 REMOVAL OF WORK EQUIPMENT ASSEMBLY ............................................................................................................................................................................................676 INSTALLATION OF WORK EQUIPMENT ASSEMBLY .......................................................................................................................................................................................677 REMOVAL OF BUCKET ASSEMBLY ....................................................................................................................................................................................................678 INSTALLATION OF BUCKET ASSEMBLY ...............................................................................................................................................................................................679 REMOVAL OF ARM ASSEMBLY .......................................................................................................................................................................................................680 INSTALLATION OF ARM ASSEMBLY ..................................................................................................................................................................................................681 REMOVAL OF BUCKET, ARM ASSEMBLY ...............................................................................................................................................................................................682 INSTALLATION OF BUCKET, ARM ASSEMBLY ..........................................................................................................................................................................................683 REMOVAL OF BOOM ASSEMBLY ......................................................................................................................................................................................................684 INSTALLATION OF BOOM ASSEMBLY .................................................................................................................................................................................................685 REMOVAL OF COUNTERWEIGHT ASSEMBLY .............................................................................................................................................................................................688 INSTALLATION OF COUNTERWEIGHT ASSEMBLY ........................................................................................................................................................................................688 REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY ................................................................................................................................................................................689 INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY ...........................................................................................................................................................................689 REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY .................................................................................................................................................................................690 INSTALLATION OF CONDENSER ASSEMBLY ............................................................................................................................................................................................690 REMOVAL OF RECEIVER TANK ASSEMBLY .............................................................................................................................................................................................691 INSTALLATION OF RECEIVER TANK ASSEMBLY ........................................................................................................................................................................................691 REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY ......................................................................................................................................................................................692 INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY .................................................................................................................................................................................693 REMOVAL OF GOVERNOR, PUMP CONTROLLER ASSEMBLY .................................................................................................................................................................................694 INSTALLATION OF GOVERNOR, PUMP CONTROLLER ASSEMBLY ............................................................................................................................................................................694 REMOVAL OF MONITOR PANEL ASSEMBLY .............................................................................................................................................................................................695 INSTALLATION OF MONITOR PANEL ASSEMBLY ........................................................................................................................................................................................695 REMOVAL OF CONTROL STAND CASE .................................................................................................................................................................................................696 INSTALLATION OF CONTROL STAND CASE ............................................................................................................................................................................................697 MAINTENANCE STANDARD ..........................................................................................................................................................................................................698 ENGINE MOUNT ..............................................................................................................................................................................................................699 SWING MACHINERY SWING CIRCLE ..............................................................................................................................................................................................703 FINAL DRIVE TRACK FRAME AND RECOIL SPRING .................................................................................................................................................................................707 IDLER .....................................................................................................................................................................................................................709 CARRIER ROLLER ............................................................................................................................................................................................................711 TRACK ROLLER ..............................................................................................................................................................................................................712 TRACK SHOE ................................................................................................................................................................................................................713 HYDRAULIC PUMP ............................................................................................................................................................................................................717 CONTROL VALVE .............................................................................................................................................................................................................719 SELF- REDUCING PRESSURE VALVE .............................................................................................................................................................................................726 SUCTION- SAFETY VALVE .....................................................................................................................................................................................................727 SWING MOTOR ...............................................................................................................................................................................................................728 TRAVEL MOTOR ..............................................................................................................................................................................................................729 TRAVEL PPC VALVE ..........................................................................................................................................................................................................731 PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE ..................................................................................................................................................................................733 LS- EPC VALVE .............................................................................................................................................................................................................734 SOLENOID VALVE HYDRAULIC CYLINDER .........................................................................................................................................................................................738 WORK EQUIPMENT ............................................................................................................................................................................................................740
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