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KOMATSU PC60-7 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:45001 THRU 52373) KOMATSU PC60-7 – PDF DOWNLOAD
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- KOMATSU PC60-7 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:45001 THRU 52373
- PUBLICATION NUMBER:SEBM004101
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Description
KOMATSU PC60-7 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:45001 THRU 52373) KOMATSU PC60-7
KOMATSU PC60-7 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:45001 THRU 52373) KOMATSU PC60-7 – PDF DOWNLOAD:
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KOMATSU PC60-7 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:45001 THRU 52373) KOMATSU PC60-7
- 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 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 PC60-7 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:45001 THRU 52373) KOMATSU PC60-7
MAIN MENU............................................................................................................................................ 0 COVER................................................................................................................................................ 1 CONTENTS............................................................................................................................................. 2 SAFETY............................................................................................................................................... 6 FOREWORD............................................................................................................................................. 8 HOW TO READ THE SHOP MANUAL...................................................................................................................... 9 HOISTING INSTRUCTIONS............................................................................................................................ 10 COATING MATERIALS................................................................................................................................ 11 STANDARD TIGHTENING TORQUE....................................................................................................................... 12 ELECTRIC WIRE CODE............................................................................................................................... 14 COVERSION TABLE.................................................................................................................................. 15 01 GENERAL........................................................................................................................................... 21 GENERAL ASSEMBLY DRAWING......................................................................................................................... 22 SPECIFICATIONS................................................................................................................................... 23 WEIGHT TABLE..................................................................................................................................... 25 LIST OF LUBRICANT AND WATER...................................................................................................................... 27 10 STRUCTURE AND FUNCTION............................................................................................................................ 29 RADIATOR AND OIL COOLER.......................................................................................................................... 30 PTO (COUPLING)................................................................................................................................... 31 ENGINE CONTROL................................................................................................................................... 32 POWER TRAIN...................................................................................................................................... 33 SWING CIRCLE..................................................................................................................................... 34 SWING MACHINERY.................................................................................................................................. 35 TRACK FRAME...................................................................................................................................... 36 IDLER............................................................................................................................................ 37 IDER CUSHION..................................................................................................................................... 37 CARRIER ROLLER................................................................................................................................... 38 TRACK ROLLER..................................................................................................................................... 38 TRACK SHOE....................................................................................................................................... 39 HYDRAULIC PIPING DRAWING......................................................................................................................... 41 HYDRAULIC CIRCUIT DIAGRAM........................................................................................................................ 42 HYDRAULIC TANK................................................................................................................................... 44 HYDRAULIC PUMP................................................................................................................................... 45 BLADE PUMP....................................................................................................................................... 71 CONTROL VALVE.................................................................................................................................... 72 CLSS............................................................................................................................................. 84 BLADE CONTROL VAVE...............................................................................................................................114 SWING MOTOR......................................................................................................................................115 CENTER SWIVEL JOINT..............................................................................................................................119 TRAVEL MOTOR.....................................................................................................................................121 VALVE CONTROL....................................................................................................................................127 WORK EQUIPMENT - SWING PPC VALVE.................................................................................................................128 TRAVEL PPC VALVE.................................................................................................................................132 SERVICE PPC VALVE................................................................................................................................136 PPC SHUTTLE VALVE................................................................................................................................142 SOLENOID VALVE...................................................................................................................................143 HYDRAULIC CYLINDER...............................................................................................................................145 WORK EQUIPMENT...................................................................................................................................147 WORK EQUIPMENT PIN AUTO-GREASING SYSTEM..........................................................................................................148 ELECTRICAL WIRING DIAGRAM........................................................................................................................161 ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................................163 ELECTRICAL CONTROL SYSTEM........................................................................................................................165 MACHINE MONITOR SYSTEM...........................................................................................................................173 20 TESTING AND ADJUSTING.............................................................................................................................178 TABLE OF JUDGEMENT STANDARD VALVE................................................................................................................179 FOR ENGINE...................................................................................................................................179 FOR CHASSIS..................................................................................................................................181 FOR ELECTRICAL PARTS.........................................................................................................................189 TESTING AND ADJUSTING............................................................................................................................190 LIST OF EQUlPMENTS FOR INSPECTION ADJUSTMENT AND TROUBLE-SHOOTING ........................................................................191 MEASURING ENGINE SPEED.......................................................................................................................192 MEASURING EXHAUST GAS COLOR..................................................................................................................193 ADJUSTING VALVE CLEARANCE....................................................................................................................194 MEASURING COMPRESSION PRESSURE...............................................................................................................195 MEASURING BLOWBY PRESSURE....................................................................................................................196 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................................................................197 MEASURING ENGINE OIL PRESSURE................................................................................................................201 TESTING AND ADJUSTING ALTERNATOR FAN BELT TENSION............................................................................................202 ADJUSTING ENGINE OIL SOLENOID................................................................................................................203 ADJUSTING FUEL CONTROL LEVER.................................................................................................................204 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITS .......................................................205 ADJUSTING PC VALVE...........................................................................................................................206 MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE....................................................................................207 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN THE BLADE CIRCUIT................................................................................209 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN THE CONTROL PUMP CIRCUIT.........................................................................210 TESTING OUTLET PRESSURE OF SOLENOID VALVE....................................................................................................212 MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE ...........................................................................213 ADJUSTING WORK EQUIPMENT AND SWING PPC VALVE.................................................................................................214 TESTING TRAVEL DEVIATION.....................................................................................................................215 MEASURING OIL LEAKAGE........................................................................................................................216 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT............................................................................................218 CHECKING OF CLEARANCE OF SWING CIRCLE BEARING................................................................................................219 CHECKING AND ADJUSTING TRACK SHOE TENSION....................................................................................................220 BLEEDING AIR.................................................................................................................................221 AUTOMATIC GREASING CONTROLLER................................................................................................................223 TROUBLESHOOTING..................................................................................................................................234 POINTS TO REMEMBER WHEN TROUBLESHOOTING......................................................................................................235 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................................236 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.............................................................................................237 CHECKS BEFORE TROUBLESHOOTING................................................................................................................245 CONNECTOR TYPES AND MOUNTING LOCATIONS.......................................................................................................246 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...................................................................................................249 METHOD OF USING JUDGEMENT TABLE..............................................................................................................259 METHOD OF USING TROUBLESHOOTING CHARTS.......................................................................................................260 FAILURE MODES AND JUDGEMENT TABLE............................................................................................................262 TROUBLESHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM (E MODE) AND TROUBLESHOOTING OF ENGINE (S MODE).........................................263 E-1 WORK EQUIPMENT DOES NOT MOVE EVEN WHEN THE PPC HYDRAULIC PRESSURE LOCK LEVER IS SET TO THE DRIVE SIDE................................264 E-2 WORK EQUIPMENT DOES NOT MOVE EVEN IF THE PPC HYDRAULIC PRESSURE LOCK LEVER IS AT THE LOCK POSITION...................................265 E-3 DOES NOT SWING.......................................................................................................................266 E-4 SWING BRAKE DOES NOT WORK............................................................................................................269 E-5 TRAVEL SPEED CANNOT BE SWITCHED......................................................................................................271 A) CANNOT BE SWITCHED TO HI..........................................................................................................271 B) CANNOT BE SWITHED TO LO...........................................................................................................271 E-6 POWER MODE CANNOT BE CHANGED.........................................................................................................272 A) WORK EQUIPMENT SPEED IS SLOW WHEN ENGINE SPPED IS MIDDLE AND HIGHER...............................................................272 B) EXCESSIVE ENGINE SPEED DROP AT ENGINE SPEED MIDDLE AND LOWER......................................................................272 E-7 ENGINE DOES NOT START................................................................................................................273 A) STARTER DOES NOT WORK.............................................................................................................273 B) ENGINE STOP SOLENOID DOES NOT WORK................................................................................................275 E-8 ENGINE DOES NOT STOP.................................................................................................................276 E-9 WIPER DOES NOT WORK..................................................................................................................277 TROUBLESHOOTING OF ENGINE (S MODE)...........................................................................................................278 METHOD OF USING TROUBLESHOOTING CHART....................................................................................................279 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)........................................................................283 S-2 ENGINE DOES NOT START............................................................................................................284 1) ENGINE DOES NOT START.........................................................................................................284 2) ENGINE RUNS BUT EXHUAST GAS DOES NOT COME OUT (FUEL IS NOT BEING INJECTED)....................................................285 3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)......................................................286 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).............................................................................287 S-4 ENGINE STOPS DURING OPERATION....................................................................................................288 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)........................................................................................289 S-6 ENGINE LACKS OUTPUT (NO POWER)...................................................................................................290 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION).....................................................................................291 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)............................................................................292 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................................................293 S-10 FUEL CONSUMPTION IS EXCESSIVE...................................................................................................294 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.........................................................295 S-12 OIL PRESSURE WARNING LAMP LIGHTS UP (DROP IN OIL PRESSURE)......................................................................296 S-13 OIL LEVEL RISES ................................................................................................................297 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................................................298 S-15 ABNORMAL NOISE IS MADE..........................................................................................................299 S-16 VIBRATION IS EXCESSIVE..........................................................................................................300 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)..................................................................................301 TROUBLESHOOTING FLOW CHARTS FOR EACH FAILURE MODE........................................................................................301 ALL WORK EQUIPMENT, TRAVEL, SWING........................................................................................................302 H-1 SPEEDS OF ALL WORK EQUIPMENTS, SWING AND TRAVEL ARE SLOW OR LACK POWER...........................................................302 H-2 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.................................................................................304 H-3 ALL WORK EQUIPMENT, TRAVEL AND SWING DO NOT MOVE.................................................................................305 H-4 ABNORMAL SOUND IS GENERATED (AROUD THE PUMP).....................................................................................305 H-5 FINE CONTROL ABILITY IS POOR, OR RESPONSE........................................................................................306 WORK EQUIPMENT...........................................................................................................................306 H-6 BOOM MOVEMENT IS SLOW OR LACKS OF POWER..........................................................................................306 H-7 ARM MOVEMENT IS SLOW OR LACKS OF POWER...........................................................................................308 H-8 BUCKET MOVEMENT IS SLOW OR LACKS OF POWER........................................................................................310 H-9 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)...............................................311 H-10 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)...................................................................................311 H-11 EXCESSIVE TIME LAG (ENGINE AT LOW SPEED)........................................................................................312 COMPOUND OPERATIONS......................................................................................................................312 H-12 IN COMPOUND OPERATIONS, WORK EQUIPMENTS, MOVEMENT OF ONE WITH LARGER LOAD IS SLOW ..............................................312 H-13 iN SWING + BOOM RAISE OPERATION, BOOM RAISE MOVEMENT IS SLOW....................................................................313 H-14 IN TRAVEL + SWING OPERATION, TRAVEL SPEED DROP IS EXCESSIVE.....................................................................313 H-15 IN TRAVEL + WORK EQUIPMENT (BOOM RAISE) OPERATION, TRAVEL SPEED DROP IS EXCESSIVE...............................................313 TRAVEL SYSTEM............................................................................................................................314 H-16 VEHICLE CURVES UNINTENTIONALLY DURING TRAVEL....................................................................................314 H-17 TRAVEL DEVIATION IS LARGER AT STARTING..........................................................................................316 H-18 TRAVEL SPEED IS LOW, OR LACKS OF POWER..........................................................................................316 H-19 STEERING OPERATION IS DIFFICULT.................................................................................................317 H-20 TRAVEL SPEED CANNOT BE SWITCHED.................................................................................................318 H-21 TRAVEL DOES NOT WORK (ONE SIDE ONLY)............................................................................................318 SWING SYSTEM.............................................................................................................................319 H-22 DOES NOT SWING (BOTH SIDES, ONE SIDE ONLY)......................................................................................319 H-23 SWING ACCELERATION IS POOR......................................................................................................320 H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING (BOTH SIDES, ONE SIDE ONLY)...............................................................322 H-25 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY) .......................................................................323 H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING (ONE DIRECTION ONLY)...............................................................323 H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING (WHEN THE SWING BRAKE IS RELEASED OR ACTIVATED)..............................................324 H-28 SWING SPEED IS FASTER THAN THE SPECIFIED SPEED..................................................................................325 H-29 BLADE SPEED IS SLOW, OR LACK OF POWER...........................................................................................325 H-30 BLADE DOES NOT MOVE.............................................................................................................326 H-31 EXCESSIVE HYDRAULIC DRIFT OF THE BLADE..........................................................................................326 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)...........................................................................................327 ELECTRIC CIRCUIT DIAGRAM OF MACHINE MONITOR SYSTEM.......................................................................................328 M-1 NO INDICATOR LAMP LIGHTS UP WHEN THE STARTING SWITCH IS TURNED ON (3-SECOND SELF-CHECK IS NOT CARRIED OUT EITHER)................329 M-2 ALL THE LAMPS REMAIN LIGHTING-UP AFTER 3-SECOND SELF-CHECK COMPLETED AFTER THE STARTING SWITCH IS TURNED ON......................329 M-3 SOME LAMPS DO NOT LIGHT UP DURING SELF-CHECK (ALL LAMPS LIGHTS UP FOR 3 SECONDS) UPON STARTING SWITCH ON.........................330 A) ALL GAUGE LAMPS DO NOT LIGHT UP (CAUTION LAMP DOES LIGHT UP)..................................................................330 B) SWING LOCK, AUTO-GREASING FAILURE OR PREHEAT DOES NOT LIGHT UP (ALL GAUGE LAMPS LIGHT UP).....................................330 C) CHARGE CAUTION LAMP DOES NOT LIGHT UP.........................................................................................330 D) ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP............................................................................330 M-4 WHEN TURNING ON THE POWER (BEFORE ENGINE STARTING), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...........................331 M-5 WHEN TURNING ON THE POWER (BEFORE ENGINE STARTING), ENGINE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT UP...........................331 M-6 AT PREHEATING, PREHEATING INDICATOR LAMP DOES NOT LIGHT UP.......................................................................332 M-7 THOUGH THE SWITCH IS OPERATED, SWING LOCK DOES NOT LIGHT UP......................................................................332 M-8 WHILE ENGINE RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL).................................333 M-9 CHARGE CAUTION LAMP LIGHTS UP WHILE ENGINE RUNNING..............................................................................333 M-10 ABNORMALITY IN COOLANT TEMPERATURE GAUGE........................................................................................334 A) INDICATOR REMAINS IN THE LOWEST LEVEL (WHITE RANGE) AND DOES NOT RISE AFTER ENGINE STARTED....................................334 B) LEVEL RISES IMMEDIATELY AFETR STARTING THE ENGINE. INDICATOR GOES IN THE RED RANGE LAMP GOES OFF..............................334 C) COOLANT TEMPERATUR GAUGE LAMP GOES OFF........................................................................................334 M-11 ABNORMALITY IN FUEL GAUGE.......................................................................................................335 A) ALL SEGMENTS OF THE FUEL GAUGE GO OFF.........................................................................................335 B) FUEL GAUGE INDICATES FULL THOUGH THE LEVEL IS LOW.............................................................................335 C) FUEL GAUGE DOES NOT INDICATE FULL THOUGH THE TANK IS FULL.....................................................................335 M-12 MALFUNCTION OF BUZZER...........................................................................................................337 A) BUZZER DOES NOT SOUND.........................................................................................................337 B) BUZZER DOES NOT STOP SOUNDING.................................................................................................337 M-13 SERVICE METER DOES NOT WORK WHILE THE ENGINE IS RUNNING.........................................................................338 A) WHEN THE CHARGE CAUTION LAMP DOES NOT LIGHT UP................................................................................338 B) WHEN THE CHARGE CAUTION LAMP LIGHTS UP, REFER TO THE ITEM M-9.................................................................338 M-14 AUTO-GREASING ABNORMALITY ALARM LIGHTS UP (AUTO-GREASING CONTROLLER IS NORMAL)..................................................338 M-15 ILLUINATION DOES NOT LIGHT UP...................................................................................................339 A) ILLUMINATION AT GAUGE SECTION DOES NOT LIGHT UP...............................................................................339 B) ILLUMINATION AT THE SERVICE METER SECTION DOES NOT LIGHT UP (SERVE METER ITSELF DO WORK NORMALLY) (SERVICE METER ITSELF DO....339 M-16 HEATER DOES NOT WORK............................................................................................................340 A) BOTH HI AND LO DO NOT WORK....................................................................................................340 B) LO ONLY DOES NOT WORK.........................................................................................................340 C) HI ONLY DOES NOT WORK.........................................................................................................340 TROUBLESHOOTING OF AUTO-GREASING SYSTEM (D MODE).............................................................................................341 D-1 [ALTERNATE BLINKING OF [E] AND [A]] ABNORMALITY IN PUMP PRESSURIZATION IS DISPLAYED..................................................342 D-2 [ALTERNATE BLINKING OF [E] AND [B]] ABNORMALITY IN PUMP DEPRESSURIZATION IS DISPLAYED................................................344 [ALTERNATE BLINKING OF [E] AND [A]] ABNORMALITY IN PUMP PRESSURE DETECTION IS DISPLAYED..............................................344 D-3 [ALTERNATE BLINKING OF [E] AND [D]] ABNORMALITY IN CONTROLLER SETTING IS DISPLAYED...................................................344 D-4 ABNORMAL SOUND IS GENERATED FROM THE WORK EQUIPMENT PIN, THOUGH NO ABNORMALITY IS DISPLAYED ON THE MONITOR PANEL AND GREA............345 D-5 ALL LEDS ON THE GREASING CONTROLLER GOES OFF.........................................................................................347 D-6 PUMP DOES NOT RUN EVEN THOUGH THE START-UP SWITCH IS PRESSED.........................................................................347 30 DISASSEMBLY AND ASSEMBLY..........................................................................................................................349 METHOD OF USING MANUAL...........................................................................................................................351 PRECAUTIONS WHEN CARRYING OUT OPERATION..........................................................................................................353 SPECIAL TOOL LIST................................................................................................................................355 SPECIAL TOOL ....................................................................................................................................357 STARTING MOTOR...................................................................................................................................360 REMOVAL AND INSTALLATION.....................................................................................................................360 ALTERNATOR.......................................................................................................................................361 REMOVAL AND INSTALLATION.....................................................................................................................361 FUEL INJECTION PUMP..............................................................................................................................362 REMOVAL......................................................................................................................................362 INSTALLATION.................................................................................................................................363 WATER PUMP.......................................................................................................................................364 REMOVAL AND INSTALLATION.....................................................................................................................364 NOZZLER HOLDER...................................................................................................................................365 REMOVAL AND INSTALLATION.....................................................................................................................365 THERMOSTAT.......................................................................................................................................366 REMOVAL AND INSTALLATION.....................................................................................................................366 ENGINE FRONT SEAL................................................................................................................................367 REMOVAL AND INSTALLATION.....................................................................................................................367 ENGINE REAR SEAL.................................................................................................................................368 REMOVAL AND INSTALLATION.....................................................................................................................368 CYLINDER HEAD....................................................................................................................................369 REMOVAL......................................................................................................................................369 INSTALLATION.................................................................................................................................371 ENGINE - MAIN PUMP...............................................................................................................................373 REMOVAL......................................................................................................................................373 INSTALLATION.................................................................................................................................376 PTO ASSEMBLY.....................................................................................................................................377 REMOVAL AND INSTALLATION.....................................................................................................................377 DISASSEMBLY AND ASSEMBLY.....................................................................................................................378 HYDRAULIC OIL COOLER.............................................................................................................................379 REMOVAL AND INSTALLATION.....................................................................................................................379 RADIATOR - HYDRAULIC OIL COOLER..................................................................................................................380 REMOVAL......................................................................................................................................380 INSTALLATION.................................................................................................................................381 FUEL TANK........................................................................................................................................382 REMOVAL AND INSTALLATION.....................................................................................................................382 CENTER SWIVEL JOINT..............................................................................................................................383 REMOVAL......................................................................................................................................383 INSTALLATION.................................................................................................................................384 DISASSEMBLY AND ASSEMBLY.....................................................................................................................385 SPROCKET.........................................................................................................................................386 REMOVAL AND INSTALLATION.....................................................................................................................386 TRAVEL MOTOR.....................................................................................................................................387 REMOVAL AND INSTALLATION.....................................................................................................................387 SWING MACHINERY - SWING MOTOR....................................................................................................................388 REMOVAL AND INSTALLATION.....................................................................................................................388 SWING MACHINERY..................................................................................................................................389 DISASSEMBLY..................................................................................................................................389 ASSEMBLY.....................................................................................................................................392 REVOLVING FRAME..................................................................................................................................395 REMOVAL......................................................................................................................................395 INSTALLATION.................................................................................................................................396 SWING CIRCLE.....................................................................................................................................397 REMOVAL AND INSTALLATION.....................................................................................................................397 IDER - RECOIL SPRING.............................................................................................................................398 REMOVAL AND INSTALLATION.....................................................................................................................398 RECOIL SPRING....................................................................................................................................399 DISASSEMBLY..................................................................................................................................399 ASSEMBLY.....................................................................................................................................400 IDER.............................................................................................................................................401 DISASSEMBLY..................................................................................................................................401 ASSEMBLY.....................................................................................................................................402 TRACK ROLLER.....................................................................................................................................404 REMOVAL AND INSTALLATION.....................................................................................................................404 DISASSEMBLY..................................................................................................................................405 ASSEMBLY.....................................................................................................................................406 CARRIER ROLLER...................................................................................................................................407 REMOVAL AND INSTALLATION.....................................................................................................................407 TRACK SHOE.......................................................................................................................................408 REMOVAL AND INSTALLATION.....................................................................................................................408 HYDRAULIC TANK...................................................................................................................................409 REMOVAL......................................................................................................................................409 INSTALLATION.................................................................................................................................410 CONTROL PUMP.....................................................................................................................................411 REMOVAL AND INSTALLATION.....................................................................................................................411 MAIN PUMP........................................................................................................................................412 REMOVAL......................................................................................................................................412 INSTALLATION.................................................................................................................................413 BLADE PUMP.......................................................................................................................................414 REMOVAL AND INSTALLATION.....................................................................................................................414 MAIN PUMP INPUT SHAFT OIL SEAL...................................................................................................................415 REMOVAL AND INSTALLATION.....................................................................................................................415 CONTROL VALVE....................................................................................................................................416 REMOVAL......................................................................................................................................416 INSTALLATION.................................................................................................................................417 DISASSEMBLY..................................................................................................................................418 ASSEMBLY.....................................................................................................................................422 MAIN RELIEF VALVE................................................................................................................................426 DISASSEMBLY AND ASSEMBLY.....................................................................................................................426 BLADE CONTROL VALVE..............................................................................................................................427 REMOVAL AND INSTALLATION.....................................................................................................................427 DISASSEMBLY AND ASSEMBLY.....................................................................................................................428 BLADE CONTROL VALVE MAIN RELIEF VALVE............................................................................................................430 DISASSEMBLY AND ASSEMBLY.....................................................................................................................430 SOLENOID VALVE...................................................................................................................................431 REMOVAL AND INSTALLATION.....................................................................................................................431 WORK EQUIPMENT LEFT SIDE PPC VALVE (FOR ARM, SWING CONTROL)......................................................................................432 REMOVAL AND INSTALLATION.....................................................................................................................432 WORK EQUIPMENT RIGHT SIDE PPC VALVE (FOR BOOM,BUCKET CONTROL)....................................................................................433 REMOVAL AND INSTALLATION.....................................................................................................................433 WORK EQUIPMENT PPC VALVE (FOR BOOM, ARM, BUCKET, SWING CONTROL PPC VALVE)........................................................................434 DISASSEMBLY..................................................................................................................................434 ASSEMBLY.....................................................................................................................................435 TRAVEL PPC VALVE.................................................................................................................................436 REMOVAL INSTALLATION.........................................................................................................................436 DISASSEMBLY AND ASSEMBLY.....................................................................................................................437 BOOM CYLINDER....................................................................................................................................439 REMOVAL......................................................................................................................................439 INSTALLATION.................................................................................................................................440 ARM CYLINDER.....................................................................................................................................441 REMOVAL......................................................................................................................................441 INSTALLATION.................................................................................................................................442 BUCKET CYLINDER..................................................................................................................................443 REMOVAL......................................................................................................................................443 INSTALLATION.................................................................................................................................444 BLADE CYLINDER...................................................................................................................................445 REMOVAL......................................................................................................................................445 INSTALLATION.................................................................................................................................446 HYDRAULIC CYLINDER...............................................................................................................................447 DISASSEMBLY..................................................................................................................................447 ASSEMBLY.....................................................................................................................................449 WORK EQUIPMENT...................................................................................................................................452 REMOVAL......................................................................................................................................452 INSTALLATION.................................................................................................................................453 BUCKET ..........................................................................................................................................454 REMOVAL......................................................................................................................................454 INSTALLATION.................................................................................................................................455 ARM..............................................................................................................................................456 REMOVAL......................................................................................................................................456 INSTALLATION.................................................................................................................................457 BUCKET - ARM.....................................................................................................................................458 REMOVAL......................................................................................................................................458 INSTALLATION.................................................................................................................................459 BOOM.............................................................................................................................................460 REMOVAL......................................................................................................................................460 INSTALLATION.................................................................................................................................461 BLADE............................................................................................................................................462 REMOVAL AND INSTALLATION.....................................................................................................................462 OPERATOR'S CAB...................................................................................................................................463 REMOVAL AND INSTALLATION.....................................................................................................................463 COUNTERWEIGHT....................................................................................................................................464 REMOVAL AND INSTALLATION.....................................................................................................................464 MONITOR..........................................................................................................................................465 REMOVAL AND INSTALLATION.....................................................................................................................465 SWING CONTROLLER.................................................................................................................................465 REMOVAL AND INSTALLATION.....................................................................................................................465 AUTO-GREASING CONTROLLER.........................................................................................................................466 REMOVAL AND INSTALLATION.....................................................................................................................466 AUTO-GREASING PUMP...............................................................................................................................466 REMOVAL AND INSTALLATION.....................................................................................................................466 40 MAINTENANCE STANDARD..............................................................................................................................467 SWING MACHINERY..................................................................................................................................468 SWING CIRCLE.....................................................................................................................................470 TRACK FRAME......................................................................................................................................471 IDER.............................................................................................................................................472 TRACK ROLLER.....................................................................................................................................473 CARRIER ROLLER...................................................................................................................................474 SPROCKET.........................................................................................................................................475 TRACK SHOE.......................................................................................................................................476 HYDRAULIC PUMP...................................................................................................................................479 BLADE PUMP.......................................................................................................................................481 CONTROL VALVE....................................................................................................................................482 BLADE CONTROL VALVE..............................................................................................................................489 SWING MOTOR......................................................................................................................................490 CENTER SWIVEL JOINT..............................................................................................................................491 WORK EQUIPMENT - SWING PPC VALVE.................................................................................................................493 TRAVEL PPC VALVE.................................................................................................................................494 SERVICE PPC VALVE................................................................................................................................495 WORK EQUIPMENT...................................................................................................................................497 HYDRAULIC CYLINDER...............................................................................................................................501
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