Komatsu PC400LC-7L Hydraulic Excavator Shop Manual PDF

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Komatsu PC400LC-7L Hydraulic Excavator Shop Manual CEBM012503 – PDF DOWNLOAD

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Komatsu PC400LC-7L Hydraulic Excavator Shop Manual CEBM012503 – PDF DOWNLOAD 

Language : English
Pages : 826
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC400LC-7L Hydraulic Excavator Shop Manual CEBM012503 – PDF DOWNLOAD

SERIAL NUMBERS PC400LC-7L A86001 and up
ENGINE SAA6D125E-3

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 sections. These sections are further divided into each main group of components.

GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
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, ADJUSTING AND TROUBLESHOOTING
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 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 PC400LC-7L Hydraulic Excavator Shop Manual CEBM012503 – PDF DOWNLOAD 

SERIAL NUMBERS PC400LC-7L A86001 and up
ENGINE SAA6D125E-3

COVER 1
CONTENTS 2
FOREWORD 13
SAFETY 13
SAFETY NOTICE 13
IMPORTANT SAFETY NOTICE 13
GENERAL PRECAUTIONS 13
PREPARATIONS FOR WORK 13
PRECAUTIONS DURING WORK 14
GENERAL 15
HOW TO READ THE SHOP MANUAL 16
VOLUMES 16
DISTRIBUTION AND UPDATING 16
FILING METHOD 16
REVISED EDITION MARK 16
REVISIONS 16
SYMBOLS 16
HOISTING INSTRUCTIONS 17
HOISTING 17
WIRE ROPES 17
COATING MATERIALS 18
STANDARD TIGHTENING TORQUE 20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 20
TIGHTENING TORQUE OF HOSE NUTS 21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 21
TIGHTENING TORQUE FOR FLARED NUTS 21
ELECTRIC WIRE CODE 22
CLASSIFICATION BY THICKNESS 22
CLASSIFICATION BY COLOR AND CODE 22
CONVERSION TABLES 23
METHOD OF USING THE CONVERSION TABLE 23
01 GENERAL 29
SPECIFICATIONS 30
WEIGHT TABLE 35
FUEL COOLANT AND LUBRICANTS 37
10 STRUCTURE AND FUNCTION 39
RADIATOR OIL COOLER AFTERCOOLER 41
POWER TRAIN 42
FINAL DRIVE 43
SWING MACHINERY 45
SWING CIRCLE 47
TRACK FRAME AND RECOIL SPRING 48
IDLER 50
CARRIER ROLLER 51
TRACK ROLLER 52
TRACK SHOE 54
TRIPLE GROUSER SHOE 57
HYDRAULIC SYSTEM 58
HYDRAULIC PIPING DRAWING 58
HYDRAULIC TANK 60
HYDRAULIC PUMP 62
LS VALVE 67
PC VALVE 67
LS(PS)-EPC VALVE 79
VARIABLE VOLUME VALVE 82
CONTROL VALVE 84
MAIN RELIEF VALVE 98
CLSS (CLOSED CENTER LOAD SENSING SYSTEM) 100
SELF PRESSURE REDUCING VALVE 103
SWING MOTOR 106
RELIEF VALVE 110
REVERSAL PREVENTION VALVE 112
CENTER SWIVEL JOINT 114
TRAVEL MOTOR 115
PARKING BRAKE 120
TRAVEL JUNCTION VALVE 126
CONTROL VALVE 128
TRAVEL PPC SHUTTLE VALVE 130
WORK EQUIPMENT SWING PPC VALVE 133
TRAVEL PPC VALVE 138
SERVICE PPC VALVE 146
SOLENOID VALVE 147
PPC ACCUMULATOR 149
RETURN OIL FILTER 150
BOOM HYDRAULIC DRIFT PREVENTION VALVE 152
ARM HYDRAULIC DRIFT PREVENTION VALVE 157
QUICK RETURN VALVE 161
LIFT CHECK VALVE 163
ATTACHMENT CIRCUIT SELECTOR VALVE 164
HOLDING VALVE 166
HYDRAULIC CYLINDER 170
BOOM CYLINDER 170
ARM CYLINDER 170
BUCKET CYLINDER 170
WORK EQUIPMENT 172
DIMENSION ARM 174
DIMENSION OF BUCKET 176
AIR CONDITIONER 178
AIR CONDITIONER PIPING 178
ENGINE CONTROL 179
OPERATION OF SYSTEM 179
STARTING ENGINE 179
ENGINE SPEED CONTROL 179
STOPPING ENGINE 179
COMPONENTS OF SYSTEM 180
FUEL CONTROL DIAL 180
ENGINE CONTROLLER 181
ELECTRONIC CONTROL SYSTEM 184
CONTROL FUNCTIONS 184
TOTAL SYSTEM DIAGRAM 186
ENGINE AND PUMP CONTROL FUNCTION 188
PUMP/VALVE CONTROL FUNCTION 193
ONE-TOUCH POWER MAXIMIZING/MACHINE PUSH-UP FUNCTION 196
AUTO-DECELERATION FUNCTION 198
AUTO-WARM-UP/OVERHEAT PREVENTION FUNCTION 200
SWING CONTROL FUNCTION 202
TRAVEL CONTROL FUNCTION 204
ATT FLOW CONTROL, CIRCUIT SELECTOR FUNCTION (IF EQUIPMENT) 206
SYSTEM COMPONENT PARTS 207
ENGINE REVOLUTION SENSOR 207
PPC OIL PRESSURE SWITCH 208
PUMP PRESSURE SENSOR 209
PUMP CONTROLLER 210
MONITOR SYSTEM 213
MONITOR CONTROL, DISPLAY PORTION 216
MONITOR PORTION 216
MONITOR ITEMS AND DISPLAY 217
SWITCHES 221
SELECT MODE FUNCTION 224
MAINTENANCE FUNCTION 227
SERVICE METER CHECK FUNCTION 230
DISPLAY LCD CHECK FUNCTION 230
SENSOR 232
ENGINE OIL LEVER SENSOR 232
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE) 232
COOLANT TEMPERATURE SENSOR 233
HYDRAULIC OIL TEMPERATURE SENSOR 233
FUEL LEVEL SENSOR 233
AIR CLEANER CLOGGING SENSOR 234
20 TESTING, ADJUSTING AND TROUBLESHOOTING 235
STANDARD VALUE TABLE FOR ENGINE 236
STANDARD VALUE TABLE FOR CHASSIS 237
TESTING AND ADJUSTING 247
SERVICE TOOLS 248
MEASURING ENGINE SPEED 250
ENGINE 251
FUEL 251
BLEEDING AIR FROM FUEL CIRCUIT 251
FUEL PRESSURE 251
HANDLING FUEL SYSTEM DEVICES 251
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE 251
RELEASING RESIDUAL FUEL SYSTEM PRESSURE 251
ADJUSTING ENGINE SPEED SENSOR 251
ADJUSTING VALVE CLEARANCE 251
BLOW-BY PRESSURE 251
COMPRESSION PRESSURE 251
ENGINE OIL PRESSURE 251
ENGINE SPEED SENSOR 251
EXHAUST GAS COLOR 251
EXHAUST TEMPERATURE 251
INTAKE AIR PRESSURE (BOOST PRESSURE) 251
FAN BELT AND ALTERNATOR BELT TENSION 252
AIR CONDITIONER COMPRESSOR BELT TENSION 253
SWING CIRCLE BEARING CLEARANCE 254
TRACK SHOE TENSION 255
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS 256
CONTROL CIRCUIT – BASIC PRESSURE 261
PUMP PC CONTROL CIRCUIT 262
PUMP LS CONTROL CIRCUIT 266
SOLENOID VALVE – OUTPUT PRESSURE 271
PPC VALVE – OUTPUT PRESSURE 274
WORK EQUIPMENT PPC VALVE – PLAY ADJUSTMENT 276
SWING PPC VALVE – PLAY ADJUSTMENT 276
WORK EQUIPMENT – HYDRAULIC DRIFT – CAUSE 277
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT 279
MEASURING OIL LEAKAGE 280
BLEEDING AIR FROM EACH PART 283
DIODE TESTING PROCEDURE 286
MONITOR PANEL – SPECIAL FUNCTIONS 287
HANDLING OF ENGINE CONTROLLER 313
PREPARATION WORK FOR TROUBLESHOOTING 314
PM CLINIC SERVICE 316
UNDERCARRIAGE INSPECTION 322
TROUBLESHOOTING GENERAL 323
POINTS TO REMEMBER WHEN TROUBLESHOOTING 325
SEQUENCE OF EVENTS IN TROUBLESHOOTING 327
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 328
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT 328
HANDLING WIRING HARNESSES AND CONNECTORS 328
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES 330
HANDLING CONTROL BOX 333
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS 334
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 334
CHECKS BEFORE TROUBLESHOOTING 336
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING 337
CLASSIFICATION OF TROUBLESHOOTING 337
STEPS FOR TROUBLESHOOTING 337
PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NOS 338
CONNECTOR ARRANGEMENT DRAWING 341
CONNECTORS LIST 341
CONNECTOR LOCATION DIAGRAM 346
MONITOR PANEL SYSTEM CIRCUIT DIAGRAM (M CIRCUIT) 352
ENGINE CONTROL SYSTEM CIRCUIT DIAGRAM (E CIRCUIT) 353
PUMP CONTROLLER SYSTEM CIRCUIT DIAGRAM (P CIRCUIT) 354
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 355
T-BRANCH BOX AND T-BRANCH TABLE 376
CONNECTION TABLE OF FUSE BOX 380
TROUBLESHOOTING ERROR CODES IN MONITOR SYSTEM 381
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 386
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF 387
USER CODE MEMORY RETENTION FUNCTION 387
INFORMATION CONTAINED IN TESTING PROCEDURES 388
E101 390
ERROR IN DATA HISTORY 390
E112 392
SHORT OR OPEN IN WIPER MOTOR DRIVE SYSTEM 392
E113 394
SHORT OR OPEN IN REVERSE ROTATION OF WIPER MOTOR DRIVE 394
E114 396
SHORT OR OPEN IN WINDOW WASHER SYSTEM 396
E115 398
ABNORMAL WIPER MOTOR OPERATION 398
E116 400
ABNORMALITY IN PARKING WIPER ARM 400
E117 402
ENGINE CONTROLLER S-NET COMMUNICATION ERROR 402
E118 404
PUMP CONTROLLER S-NET COMMUNICTION ERROR 404
E128 406
MONITOR COMMUNICATION ABNORMALITY 406
E201 408
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID 408
E203 410
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM 410
E204 412
SHORT IN MERGE/DIVIDE SOLENOID 412
E205 414
SHORT IN 2-STAGE RELIEF SOLENOID 414
E206 416
SHORT IN TRAVEL SPEED SHIFT SOLENOID 416
E211 418
OPEN IN TRAVEL INTERLOCKING SOLENOID 418
E213 420
OPEN IN SWING HOLDING BRAKE SOLENOID 420
E214 422
OPEN IN MERGE/DIVIDE SOLENOID 422
E215 424
OPEN IN 2-STAGE RELIEF SOLENOID 424
E216 426
OPEN IN TRAVEL SPEED SOLENOID 426
E217 428
ABNORMAL INPUT MODEL CODE 428
E218 430
OPEN IN S-NET COMMUNICATION SIGNAL 430
E222 432
SHORT IN LS-EPC SOLENOID 432
E223 434
OPEN IN LS-EPC SOLENOID SYSTEM 434
E224 436
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL 436
E225 438
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL 438
E226 440
ABNORMAL PRESSURE SENSOR POWER SUPPLY 440
E227 442
ABNORMALITY IN ENGINE ROTATION (RPM) SENSOR 442
E228 444
SHORT IN ATTACHMENT RETURN SWITCHING RELAY 444
E232 446
SHORT IN PC-EPC SOLENOID 446
E233 448
OPEN IN PC-EPC SOLENOID 448
E238 450
OPEN IN ATTACHMENT RETURN SWITCHING RELAY 450
E245 452
SHORT IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM 452
E246 454
OPEN IN ATTACHMENT OIL FLOW RATE ADJUSTING EPC SYSTEM 454
E247 456
ABNORMALITY IN ARM IN PPC PRESSURE SENSOR 456
E248 458
ABNORMALITY IN BUCKET CURL PPC PRESSURE SENSOR 458
E257 460
ABNORMALITY IN PUMP 460
E315 462
SHORT IN BATTERY RELAY SYSTEM 462
E91B 464
ENGNE NE SENSOR PROBLEM 464
E91C 466
ENGINE G SENSOR PROBLEM 466
E920 468
ENGINE TYPE SELECTION ERROR 468
E921 470
ENGINE TYPE MISMATCH 470
E931 472
FUEL DIAL SYSTEM ERROR 472
E934 474
ENGINE COOLANT SENSOR HI ERROR 474
E96A 476
ENGINE COOLANT SENSOR LO ERROR 476
E936 478
ENGINE OIL PRESSURE SWITCH ERROR 478
E93C 480
ENGINE BOOST SENSOR ERROR 480
E93D 482
ENGINE FUEL TEMPERATURE SENSOR ERROR 482
E953 484
ENGINE COMMUNICATION ABNORMALITY 484
E954 486
SHORT IN ENGINE IGNITION SWITCH 486
E955 488
ENGINE S-NET ERROR 488
E956 490
ENGINE POWER FAILURE (1) 490
E957 492
ENGINE POWER FAILURE (2) 492
E95A 494
ENGINE Q-ADJUSTMENT SWITCH SIGNAL ERROR 494
E970 496
PCV1 OVER CURRENT 496
E971 498
PCV2 OVER CURRENT 498
E974 500
PCV1 LINE CUT 500
E975 502
PCV2 LINE CUT 502
E977 504
RAIL PRESSURE SENSOR ERROR 504
E979 506
RAIL PRESSURE HIGH 506
E97A 507
RAIL PRESSURE ABNORMAL HIGH 507
E97B 508
RAIL PRESSURE LOW 508
E97C 510
RAIL PRESSURE TOO LOW 510
E97D 511
RAIL PRESSURE OUT OF CONTROL 511
E980 512
ENGINE CONTROLLER ABNORMALITY 512
E981 514
FUEL INJECTOR 1 DISCONNECTION 514
E982 515
FUEL INJECTOR 2 DISCONNECTION 515
E983 516
FUEL INJECTOR 3 DISCONNECTION 516
E984 517
FUEL INJECTOR 4 DISCONNECTION 517
E985 518
FUEL INJECTOR 5 DISCONNECTION 518
E986 519
FUEL INJECTOR 6 DISCONNECTION 519
E98A 520
FUEL INJECTOR 1 – 3 S/C 520
E98B 522
FUEL INJECTOR 4 – 6 S/C 522
A000N1 524
ENGINE HIGH IDLELING SPEED OUT OF STANDARD 524
A000N2 525
ENGINE LOW IDLING SPEED OUT OF STANDARD 525
AA10NX 526
AIR CLEANER CLOGGED 526
AB00KE 528
CHARGE VOLTAGE LOW 528
B@BAZG 530
ENGINE OIL PRESSURE LOW 530
B@BAZK 532
ENGINE OIL LEVEL LOW 532
B@BCNS 534
ENGINE WATER OVERHEAT 534
B@BCZK 536
ENGINE WATER LEVEL LOW 536
B@HANS 538
HYDRAULIC OIL OVERHEAT 538
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 541
BEFORE CARRYING OUT TROUBLESHOOTING 543
CONNECTION TABLE OF FUSE BOX 543
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM 544
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF 545
USER CODE MEMORY RETENTION FUNCTION 545
INFORMATION CONTAINED IN TESTING PROCEDURES 546
E-1 548
THE ENGINE DOES NOT CRANK 548
E-2 551
PREHEATER DOES NOT OPERATE 551
PREHEATING MONITOR DOES NOT LIGHT 551
HEATER UNIT DOES NOT WARM 552
E-3 554
AUTO ENGINE WARM-UP DEVICE DOES NOT WORK 554
E-4 555
AUTO-DECELERATOR DOES NOT OPERATE 555
E-5 556
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE 556
E-6 558
ONE-TOUCH POWER MAX FUNCTION DOES NOT OPERATE 558
E-7 560
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY 560
MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 560
MACHINE PUSH-UP FUNCTION IS NOT TURNED OFF 561
E-8 564
ATTACHMENT CIRCUIT DOES NOT CHANGE 564
E-9 566
NO DISPLAY IN MONITOR PANEL AT ALL 566
E-10 568
PART OF DISPLAY ON MONITOR PANEL IS MISSING 568
E-11 568
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL 568
E-12 569
FUEL LEVEL MONITOR RED LAMP LIGHTS UP WHILE ENGINE IS RUNNING 569
E-13 570
ENGINE WATER TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 570
E-14 572
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY 572
E-15 574
FUEL GAUGE DOES NOT DISPLAY CORRECTLY 574
E-16 576
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY 576
E-17 578
WHEN MONITOR SWITCH IS OPERATED, NOTHING IS DISPLAYED 578
E-18 580
WINDSHIELD WIPER AND WINDOW WASHER DO NOT WORK 580
WINDSHIELD WIPER DOES NOT WORK 580
WINDSHIELD WASHER DOES NOT OPERATE 582
E-19 584
ALARM BUZZER CANNOT BE CANCELLED 584
E-20 586
“BOOM RAISE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 586
E-21 588
“BOOM LOWER” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 588
E-22 590
“ARM IN” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 590
E-23 591
“ARM DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 591
E-24 593
“BUCKET CURL” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 593
E-25 594
“BUCKET DUMPING” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 594
E-26 596
“SWING” IS NOT DISPLAYED NORMALLY IN MONITORING FUNCTION 596
E-27 598
“TRAVEL” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 598
E-28 600
“TRAVEL DIFFERENTIAL PRESSURE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 600
E-29 602
“SERVICE” IS NOT CORRECTLY DISPLAYED IN MONITOR FUNCTION 602
E-30 604
TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING 604
E-32 606
TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM 606
TROUBLESHOOTING PROCEDURE FOR AIR CONDITIONER SYSTEM 606
TROUBLESHOOTING BY SELF-DIAGNOSIS NOTICE 606
E-32-E11 DISCONNECTION IN RECIRCULATED AIR SENSOR 607
E-32-E12 SHORT CIRCUIT IN RECIRCULATED AIR SPACE 607
E-32-E15 DISCONNECTION IN WATER TEMPERATURE SENSOR 608
E-32-E16 SHORT CIRCUIT IN WATER TEMPERATURE SENSOR 608
E-32-E18 SHORT IN DAYLIGHT SENSOR 609
E-32-E43 ABNORMALITY IN AIR OUTLET DAMPER 609
E-32-E44 ABNORMALITY IN AIR MIX DAMPER 610
E-32-E45 ABNORMALITY IN RECIRCULATED AND FRESH AIR DAMPER 610
E-32 – TROUBLESHOOTING BY FAILURE PHENOMENON 612
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) 617
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS 619
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE 621
H-1 622
ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW 622
H-2 623
ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS 623
H-3 624
NO WORK EQUIPMENT, TRAVEL OR SWING MOVE 624
H-4 624
ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 624
H-5 625
AUTO-DECELERATOR DOES NOT WORK 625
H-6 625
FINE CONTROL MODE DOES NOT FUNCTION 625
H-7 626
BOOM MOVES SLOWLY OR LACKS POWER 626
H-8 627
ARM MOVES SLOWLY OR LACKS POWER 627
H-9 628
BUCKET MOVES SLOWLY OR LACKS POWER 628
H-10 628
WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION 628
H-11 629
WORK EQUIPMENT HYDRAULIC DRIFT TOO FAST 629
H-12 630
WORK EQUIPMENT HAS BIG TIME LAG 630
H-13 630
OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT 630
H-14 630
ONE-TOUCH POWER MAX FUNCTION DOES NOT WORK 630
H-15 631
MACHINE PUSH-UP FUNCTION DOES NOT WORK 631
H-16 631
IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY 631
H-17 632
IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY 632
H-18 632
IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY 632
H-19 633
MACHINE SWERVES IN TRAVEL 633
H-20 634
MACHINE TRAVELS SLOWLY 634
H-21 635
MACHINE CANNOT BE EASILY STEERED OR LACKS POWER 635
H-22 636
TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED 636
H-23 636
TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY) 636
H-24 637
MACHINE DOES NOT SWING 637
H-25 638
SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW 638
H-26 639
EXCESSIVE OVERRUN WHEN STOPPING SWING 639
H-27 640
THERE IS BIG SHOCK WHEN STOPPING SWING 640
H-28 640
THERE IS BIG ABNORMAL NOISE CAUSED WHEN STOPPING SWING 640
H-29 641
SWING NATURAL DRIFT IS TOO BIG 641
H-30 642
ATTACHMENT CIRCUIT DOES NOT CHANGE 642
H-31 642
FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED 642
30 DISASSEMBLY AND ASSEMBLY 643
HOW TO READ THIS MANUAL 647
REMOVAL AND INSTALLATION OF ASSEMBLIES 647
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES 647
PRECAUTIONS DURING OPERATION 649
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 649
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 650
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 651
OTHER PRECAUTIONS 651
SPECIAL TOOL LIST 652
SKETCHES OF SPECIAL TOOLS 657
CONNECTOR REPAIR PROCEDURES 659
CONTACT TERMINAL REMOVAL (HD30 TYPE) 659
STRIPING INSULATION 660
CRIMPING CONTACT TERMINAL (HD30 TYPE) 661
INSERTION OF CONTACT TERMINAL (HD30 TYPE) 662
CONTACT TERMINAL REMOVAL (DT TYPE) 663
STRIPING INSULATION 664
CRIMPING CONTACT TERMINAL (DT TYPE) 665
INSERTION OF CONTACT TERMINAL (DT TYPE) 666
ENGINE 667
AFTERCOOLER 667
ALTERNATOR 667
CYLINDER HEAD 667
ENGINE FRONT SEAL 667
ENGINE OIL COOLER 667
ENGINE REAR SEAL 667
FUEL INJECTION PUMP 667
NOZZLE HOLDER 667
NOZZLE TIP 667
STARTING MOTOR 667
THERMOSTAT 667
TURBOCHARGER 667
WATER PUMP 667
RADIATOR 668
REMOVAL 668
INSTALLATION 670
HYDRAULIC OIL COOLER 671
REMOVAL 671
INSTALLATION 672
ENGINE AND HYDRAULIC PUMP 673
REMOVAL 673
INSTALLATION 678
SWING CIRCLE 679
REMOVAL 679
INSTALLATION 679
SWING MOTOR AND SWING MACHINERY 680
REMOVAL 680
INSTALLATION 681
DISASSEMBLY 682
ASSEMBLY 686
SPROCKET 692
REMOVAL 692
INSTALLATION 692
TRAVEL MOTOR AND FINAL DRIVE 693
REMOVAL 693
INSTALLATION 693
FINAL DRIVE 694
DISASSEMBLY 694
ASSEMBLY 699
CARRIER ROLLER 704
ASSEMBLY 704
TRACK ROLLER 706
ASSEMBLY 706
IDLER 707
DISASSEMBLY 707
ASSEMBLY 708
RECOIL SPRING 711
DISASSEMBLY 711
ASSEMBLY 712
TRACK SHOE 713
EXPANSION 713
INSTALLATION 714
AIR CONDITIONER UNIT 715
REMOVAL 715
INSTALLATION 717
OPERATOR’S CAB 718
REMOVAL 718
INSTALLATION 720
MONITOR 721
REMOVAL 721
INSTALLATION 721
PUMP CONTROLLER 722
REMOVAL 722
INSTALLATION 722
ENGINE CONTROLLER 723
REMOVAL 723
INSTALLATION 723
REVOLVING FRAME 724
REMOVAL 724
INSTALLATION 726
COUNTERWEIGHT 727
REMOVAL 727
INSTALLATION 727
HYDRAULIC TANK 728
REMOVAL 728
INSTALLATION 729
HYDRAULIC PUMP 730
REMOVAL 730
INSTALLATION 732
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT 733
REMOVAL 733
INSTALLATION 733
CONTROL VALVE 734
REMOVAL 734
INSTALLATION 737
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL 738
ASSEMBLY 740
CENTER SWIVEL JOINT 743
REMOVAL 743
INSTALLATION 744
DISASSEMBLY 745
ASSEMBLY 745
WORK EQUIPMENT PPC VALVE 746
ASSEMBLY 746
TRAVEL PPC VALVE 747
DISASSEMBLY 747
ASSEMBLY 747
HYDRAULIC CYLINDER 748
DISASSEMBLY 748
ASSEMBLY 751
WORK EQUIPMENT 755
REMOVAL 755
INSTALLATION 757
OPERATOR’S CAB GLASS 758
REMOVAL 759
INSTALLATION 760
FRONT WINDOW 769
REMOVAL 769
INSTALLATION 772
90 OTHERS 777
HYDRAULIC 779
HYDRAULIC DIAGRAM SHEET 1/2 (PART 1 OF 4) FOLDOUT 1 779
HYDRAULIC DIAGRAM SHEET 1/2 (PART 2 OF 4) FOLDOUT 2 781
HYDRAULIC DIAGRAM SHEET 1/2 (PART 3 OF 4) FOLDOUT 3 783
HYDRAULIC DIAGRAM SHEET 1/2 (PART 4 OF 4) FOLDOUT 4 785
HYDRAULIC DIAGRAM SHEET 2/2 (PART 1 OF 4) FOLDOUT 5 787
HYDRAULIC DIAGRAM SHEET 2/2 (PART 2 OF 4) FOLDOUT 6 789
HYDRAULIC DIAGRAM SHEET 2/2 (PART 3 OF 4) FOLDOUT 7 791
HYDRAULIC DIAGRAM SHEET 2/2 (PART 4 OF 4) FOLDOUT 8 793
ELECTRICAL 795
ELECTRICAL DIAGRAM SHEET 1/5 (PART 1 OF 2) FOLDOUT 9 795
ELECTRICAL DIAGRAM SHEET 1/5 (PART 2 OF 2) FOLDOUT 10 797
ELECTRICAL DIAGRAM SHEET 2/5 (PART 1 OF 1) FOLDOUT 11 799
ELECTRICAL DIAGRAM SHEET 3/5 (PART 1 OF 1) FOLDOUT 12 801
ELECTRICAL DIAGRAM SHEET 4/5 (PART 1 OF 2) FOLDOUT 13 803
ELECTRICAL DIAGRAM SHEET 4/5 (PART 2 OF 2) FOLDOUT 14 805
ELECTRICAL DIAGRAM SHEET 5/5 (PART 1 OF 2) FOLDOUT 15 807
ELECTRICAL DIAGRAM SHEET 5/5 (PART 2 OF 2) FOLDOUT 16 809
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 17 811
M CIRCUIT (MONITOR PANEL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 18 813
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 1 OF 2) FOLDOUT 19 815
E CIRCUIT (ENGINE CONTROL SYSTEM DIAGRAM) (PART 2 OF 2) FOLDOUT 20 817
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 1 OF 4) FOLDOUT 21 819
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 2 OF 4) FOLDOUT 22 821
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 3 OF 4) FOLDOUT 23 823
P CIRCUIT (PUMP CONTROLLER SYSTEM DIAGRAM) (PART 4 OF 4) FOLDOUT 24 825

S.V 15/12/24