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Komatsu PC600-6, PC600LC-6 Hydraulic Excavator Shop Manual 10001 and up – PDF DOWNLOAD
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Komatsu PC600-6, PC600LC-6 Hydraulic Excavator Shop Manual 10001 and up
MACHINE MODEL SERIAL NUMBER
PC600-6 10001 and up
PC600LC-6 10001 and up
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Description
Komatsu PC600-6, PC600LC-6 Hydraulic Excavator Shop Manual 10001 and up
FILE DETAILS:
Komatsu PC600-6, PC600LC-6 Hydraulic Excavator Shop Manual 10001 and up
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC600-6, PC600LC-6
Serial Number: 10001 and up
Book Code: SEBM017111
Language: English
Pages: 1041
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC600-6, PC600LC-6 Hydraulic Excavator Shop Manual 10001 and up
1 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, FUNCTION AND MAINTENANCE STANDARD:
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. In addition, this section gives the judgement standards when inspecting disassembled parts.
STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in 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:
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.
OTHERS:
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC600-6, PC600LC-6 Hydraulic Excavator Shop Manual 10001 and up
COVER PAGE ..................................................................................................................................................................................... 1 CONTENTS ....................................................................................................................................................................................... 2 LIST OF REVISED PAGES ...................................................................................................................................................................... 3 01 GENERAL ..................................................................................................................................................................................... 29 SPECIFICATIONS.............................................................................................................................................................................. 30 WEIGHT TABLE................................................................................................................................................................................ 40 FUEL, COOLANT AND LUBRICANTS................................................................................................................................................................ 44 10 STRUCTURE AND FUNCTION....................................................................................................................................................................... 45 PARTS RELATED TO ENGINE..................................................................................................................................................................... 46 PTO......................................................................................................................................................................................... 48 RADIATOR, OIL COOLER........................................................................................................................................................................ 49 POWER TRAIN................................................................................................................................................................................. 50 FINAL DRIVE................................................................................................................................................................................. 52 SWING CIRCLE................................................................................................................................................................................ 53 SWING MACHINERY............................................................................................................................................................................. 54 TRACK FRAME, RECOIL SPRING.................................................................................................................................................................. 55 TRACK SHOE.................................................................................................................................................................................. 56 HYDRAULIC PIPING DRAWING.................................................................................................................................................................... 58 HYDRAULIC TANK, HYDRAULIC FILTER............................................................................................................................................................ 60 HYDRAULIC PUMP (PISTON PUMP)................................................................................................................................................................ 63 SERVO VALVE............................................................................................................................................................................. 66 TVC VALVE............................................................................................................................................................................... 73 CO+NC VALVE............................................................................................................................................................................. 79 SERVO VALVE (NO.2 FRONT)................................................................................................................................................................ 89 LINE OIL FILTER............................................................................................................................................................................. 91 CONTROL VALVE............................................................................................................................................................................... 92 TRAVEL SHUTTLE VALVE.................................................................................................................................................................... 98 STRAIGHT-TRAVEL VALVE................................................................................................................................................................... 101 SWING PRIORITY VALVE.................................................................................................................................................................... 103 ARM THROTTLE VALVE...................................................................................................................................................................... 105 SWING MOTOR................................................................................................................................................................................. 107 SWING BRAKE............................................................................................................................................................................. 111 SAFETY VALVE............................................................................................................................................................................ 112 REVERSE PREVENTION VALVE................................................................................................................................................................ 114 CENTRAL SWIVEL JOINT........................................................................................................................................................................ 117 TRAVEL MOTOR................................................................................................................................................................................ 118 PARKING BRAKE........................................................................................................................................................................... 122 VALVE CONTROL............................................................................................................................................................................... 128 WORK EQUIPMENT - SWING PPC VALVE............................................................................................................................................................ 130 TRAVEL PPC VALVE............................................................................................................................................................................ 134 SERVICE PPC VALVE........................................................................................................................................................................... 138 PPC SAFETY LOCK VALVE....................................................................................................................................................................... 141 PPC ACCUMULATOR............................................................................................................................................................................. 141 PPC SHUTTLE VALVE........................................................................................................................................................................... 142 SOLENOID VALVE.............................................................................................................................................................................. 143 BUCKET CURL HI CANCEL................................................................................................................................................................... 145 BOOM HOLDING VALVE.......................................................................................................................................................................... 146 BOOM LOWER REGENERATION VALVE............................................................................................................................................................... 150 AIR CONDITIONER............................................................................................................................................................................. 153 ACTUAL ELECTRIC WIRING DIAGRAM.............................................................................................................................................................. 154 ENGINE CONTROL.............................................................................................................................................................................. 162 MACHINE CONTROL SYSTEM...................................................................................................................................................................... 173 MACHINE CONTROL SYSTEM DIAGRAM.......................................................................................................................................................... 174 MONITOR SYSTEM.......................................................................................................................................................................... 208 20 TESTING AND ADJUSTING........................................................................................................................................................................ 225 STANDARD VALUE TABLE FOR ENGING............................................................................................................................................................. 226 STANDARD VALUE TABLE FOR CHASSIS........................................................................................................................................................ 229 STANDARD VALUE TABLE FOR ELECTRICAL PARTS............................................................................................................................................... 239 TESTING AND ADJUSTING....................................................................................................................................................................... 257 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING........................................................................................................................................ 258 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).......................................................................................................................................... 259 MEASURING EXHAUST TEMPERATURE........................................................................................................................................................... 260 MEASURING EXHAUST COLOR................................................................................................................................................................. 261 ADJUSTING VALVE CLEARANCE............................................................................................................................................................... 262 MEASURING COMPRESSION PRESSURE.......................................................................................................................................................... 263 MEASURING BLOW-BY PRESSURE.............................................................................................................................................................. 263 MEASURING ENGINE OIL PRESSURE........................................................................................................................................................... 264 HANDLING EQUIPMENT IN FUEL CIRCUIT...................................................................................................................................................... 265 RELEASING REMAINING PRESSURE IN FUEL SYSTEM............................................................................................................................................. 265 MEASURING FUEL PRESSURE................................................................................................................................................................. 266 REDUCED CYLINDER OPERATION FOR ENGINE................................................................................................................................................... 267 BLEEDING AIR FROM FUEL SYSTEM........................................................................................................................................................... 269 CHECK FOR LEAKAGE IN FUEL SYSTEM........................................................................................................................................................ 270 ADJUSTING ENGINE SPEED SENSORY.......................................................................................................................................................... 271 TESTING AND ADJUSTING ALTERNATOR BELT TENSION........................................................................................................................................... 272 TESTING AND ADJUSTING FAN BELT TENSION.................................................................................................................................................. 273 HANDLING ENGINE CONTROLLER HIGH VOLTAGE CIRCUIT......................................................................................................................................... 274 TESTING AND ADJUSTING AIR CONDITIONAL COMPRESSOR DRIVE BELT TENSION..................................................................................................................... 275 TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE....................................................................................................................................... 276 TESTING WEAR OF SPROCKET................................................................................................................................................................ 277 TESTING AND ADJUSTING TRACK SHOE TENSION................................................................................................................................................ 278 TESTING CLEARANCE OF SWING CIRCLE BEARING............................................................................................................................................... 279 TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....................................................................................................... 280 TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE................................................................................................................................. 283 TESTING AND ADJUSTING PISTON PUMP CONTROL OIL PRESSURE.................................................................................................................................. 285 MEASURING PPC VALVE OUTPUT PRESSUSRE.................................................................................................................................................... 291 TESTING SOLENOID VALVE OUTPUT PRESSURE.................................................................................................................................................. 292 ADJUSTING WORK EQUIPMENT, SWING PPC VALVE............................................................................................................................................... 293 TESTING TRAVEL DEVIATION................................................................................................................................................................ 294 TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT............................................................................................................................. 295 MEASURING OIL LEAKAGE................................................................................................................................................................... 296 BLEEDING AIR............................................................................................................................................................................ 299 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....................................................................................................................................... 301 PROCEDURE FOR CHECKING DIODE............................................................................................................................................................ 302 TROUBLESHOOTING............................................................................................................................................................................. 303 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................................................................. 304 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................................................................... 305 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE........................................................................................................................................ 306 CHECKS BEFORE TROUBLESHOOTING........................................................................................................................................................... 314 CONNECTOR TYPES AND MOUNTING LOCATIONS.................................................................................................................................................. 316 CONNECTOR ARRANGEMENT DIAGRAM........................................................................................................................................................... 318 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.............................................................................................................................................. 330 EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM.................................................................................................................................. 354 DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL................................................................................................................................... 357 TABLE OF MONITORING CODES........................................................................................................................................................... 362 TABLE OF SERVICE CODES.............................................................................................................................................................. 375 TABLE 1 OF MONITORING CODES (ALL CODES)............................................................................................................................................. 379 TABLE 2 OF MONITORING CODES (DETAILS OF BIT PATTERN CODE)........................................................................................................................... 380 METHOD OF USING JUDGEMENT TABLE......................................................................................................................................................... 387 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................................................. 391 DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE................................................................................................................................ 395 TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (n MODE)................................................................................................................................ 405 N-1(E218) COMMUNICATION ABNORMALITY..................................................................................................................................................... 406 TROUBLESHOOTING OF CUMMUNICATION ABNORMALITY SYSTEM (N MODE)................................................................................................................................ 409 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.............................................................................................................. 410 ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM............................................................................................................................................. 412 N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY............................................................................................................. 413 N-2 [E117, E218 OCCUR AT SAME TIME] ENGINEER CONTROLLER COMMUNICATION ABNORMALITY....................................................................................................... 415 N-3 [E118, E955 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY........................................................................................................... 417 TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM0, ENGING CONTROL SYSTEM (E MODE).............................................................................. 419 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER SYSTEM........................................................................................ 420 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.............................................................................................................. 422 JUDGEMENT TABLE FOR ENGINE THROTTLE & PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS................................................................................ 426 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM............................................................................................................................................ 428 E-1 ABNORMALITY IN ENGINE THROTTLE & PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)............................................................................................... 430 E-2 [E308] (ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE) IS DISPLAYED.................................................................................................................. 431 E-3 [E317] (ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM) IS DISPLAYED............................................................................................................. 432 E-4 [E318] (ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED.............................................................................................................. 433 E-5 [E306] (ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM) IS DISPLAYED.................................................................................................................. 434 E-6 [E315] (ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM) IS DISPLAYED.................................................................................................... 435 E-7 [E316] (ABNORMALITY (STEP-0UT) IN MOTOR) IS DISPLAYED............................................................................................................................... 436 E-8 ENGINE SPEED IS IRREGULAR........................................................................................................................................................... 438 E-9 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)................................................................................................................................ 442 E-10 ENGINE DOES NOT START.............................................................................................................................................................. 444 E-11 ENGINE DOES NOT STOP (DEFECT IN ENGINE STOP SOLENOID SYSTEM)....................................................................................................................... 447 E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (MONITOR PANEL, CONTROLLER DO NOT STOP)................................................................................................ 448 E-13 ENGINE DOES NOT STOP............................................................................................................................................................... 450 TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM (E MODE)........................................................................................................................................ 451 ACTION TAKEN BY CONTROLLER AND CONDITION OF MACHINE WHEN ERROR CODE IS DISPLAYED........................................................................................................ 452 JUDGEMENT TABLE FOR ENGINE CONTROLLER AND ENGINE RELATED PARTS.......................................................................................................................... 460 ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM........................................................................................................................................... 462 E-1 [E91b] (ABNORMALITY IN ENGINE SPEED NE SENSOR SYSTEM) IS DISPLAYED.................................................................................................................. 464 E-2 [E91C] (ABNORMALITY IN ENGINE G ROTATION SENSOR SYSTEM) IS DISPLAYED................................................................................................................ 465 E-3 [E920] (ABNORMALITY IN MODEL SELECTION SYSTEM) IS DISPLAYED......................................................................................................................... 466 E-4 [E922] (ENGINE OVERRUN) IS DISPLAYED................................................................................................................................................ 467 E-5 [E924] (DROP IN ENGINE OIL PRESSURE IS DISPLAYED.................................................................................................................................... 468 E-6 [E931] (ABNORMALITY IN FUEL CONTROL DIAL SENSOR SYSTEM) IS DISPLAYED................................................................................................................ 469 E-7 [E934] (ABNORMALITY IN ENGINE WATER TEMPERATURE 9HIGH) SENSOR SYSTEM) IS DISPLAYED.................................................................................................. 470 E-8 [E936] (ABNORMALITY IN ENGINE OIL PRESSURE SWITCH SYSTEM) IS DISPLAYED.............................................................................................................. 471 E-9 [E93C] (ABNORMALITY IN BOOST PRESSURE SENSOR SYSTEM) IS DISPLAYED................................................................................................................... 472 E-10 [E93d] 9ABNORMALITY IN FUEL TEMPERATURE SENSOR SYSTEM) IS DISPLAYED................................................................................................................ 473 E-11 [E954] (SHORT CIRCUIT IN STARTING SWITCH C SYSTEM) IS DISPLAYED.................................................................................................................... 474 E-12 [E955] (ABNORMALITY IN NETWORK SYSTEM) IS DISPLAYED................................................................................................................................ 474 E-13 [E956] (POWER SOURCE SYSTEM ABNORMALITY 1) IS DISPLAYED............................................................................................................................ 475 E-14 [E957] (POWER SOURCE SYSTEM ABNORMALITY 2) IS DISPLAYED............................................................................................................................ 476 E-15 [E95A] (ABNORMALITY IN FUEL INJECTION QUANTITY CONTROL SWITCH SIGNAL) IS DISPLAYED................................................................................................. 477 E-16 [E96A} (ABNORMALITY IN ENGINE WATER TEMPERATURE (LOW) SENSOR SYSTEM) IS DISPLAYED.................................................................................................. 478 E-17 [E970] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV1 SYSTEM) IS DISPLAYED............................................................................................................... 479 E-18 [E971] (EXCESS CURRENT IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED............................................................................................................... 480 E-19 [E974] (DISCONNECTION IN FUEL SUPPLY PUMP PCV 1 SYSTEM) IS DISPLAYED............................................................................................................... 481 E-20 [E975] (DISCONNECTION IN FUEL SUPPLY PUMP PCV2 SYSTEM) IS DISPLAYED................................................................................................................ 482 E-21 [E977] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE SENSOR SYSTEM) IS DISPLAYED....................................................................................................... 483 E-22 [E979] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 1) IS DISPLAYED................................................................................................................. 484 E-22 [E97A] (COMMON RAIL FUEL HIGH PRESSURE ABNORMALITY 2) IS DISPLAYED................................................................................................................. 484 E-23 [E97b] (FUEL SUPPLY PUMP NON-FORCE FEED 1) IS DISPLAYED............................................................................................................................ 485 E-23 [E97C] (FUEL SUPPLY PUMP NON-FORCE FEED 2) IS DISPLAYED............................................................................................................................ 485 E-24 [E97d] (ABNORMALITY IN COMMON RAIL FUEL PRESSURE) IS DISPLAYED..................................................................................................................... 487 E-25 [E980] (DEFECTIVE ENGINE CONTROLLER) IS DISPLAYED.................................................................................................................................. 487 E-26 [E981] (DISCONNECTION IN NO. 1 FUEL INJECTOR SYSTEM) IS DISPLAYED.................................................................................................................. 488 E-27 [E982] (DISCONNECTION IN NO. 2 FUEL INJECTOR SYSTEM) IS DISPLAYED.................................................................................................................. 489 E-28 [E983] (DISCONNECTION IN NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED.................................................................................................................. 490 E-29 [E984] (DISCONNECTION IN NO. 4 FUEL INJECTOR SYSTEM) IS DISPLAYED................................................................................................................. 491 E-30 [E985] (DISCONNECTION IN NO. 5 FUEL INJECTOR SYSTEM) IS DISPLAYED.................................................................................................................. 492 E-31 [E986] (DISCONNECTION IN NO. 6 FUEL INJECTOR SYSTEM) IS DISPLAYED.................................................................................................................. 493 E-32 [E98A] (SHORT CIRCUIT IN NO. 1, NO. 2, NO. 3 FUEL INJECTOR SYSTEM) IS DISPLAYED.................................................................................................... 494 E-33 [E98b] (SHORT CIRCUIT IN NO. 3, NO. 4, NO. 5 FUEL INJECTOR SYSTEM,) IS DISPLAYED................................................................................................... 497 TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROL SYSTEM) (C MODE).......................................................................................................................... 501 POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM.......................................................................................................................... 502 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.............................................................................................................. 504 JUDGEMENT TABLE FOR ENGINE THROTTLE & PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS................................................................................. 510 ELECTRICAL CIRCUIT DIAGRAM FOR C MODE................................................................................................................................................... 512 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)............................................................................................................... 514 C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED..................................................................................................................... 515 C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED..................................................................................................................... 517 C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED.......................................................................................................... 519 C-5 [E213] (DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM) IS DISPLAYED.................................................................................................................. 521 C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED..................................................................................................................... 523 C-7 [E211] (DISCONNECTION IN C0 CANCEL SOLENOID SYSTEM) IS DISPLATED.................................................................................................................... 524 C-8 [E205] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED............................................................................................................... 525 C-9 [E-215] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED.............................................................................................................. 526 C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED................................................................................................................ 527 C-11 [E216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED................................................................................................................ 528 C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED....................................................................................................... 529 C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED....................................................................................................... 530 C-14 [E217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED.................................................................................................................................. 531 C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED............................................................................................................. 533 C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED.............................................................................................................. 534 C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DISPLAYED........................................................................................................... 535 C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................................................... 536 C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)......................................................................................................... 537 TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE).......................................................................................................................................... 539 POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM.......................................................................................................... 540 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.............................................................................................................. 542 JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS......................................................................................................................... 550 ELECTRICAL CIRCUIT DIAGRAM OF C MODE SYSTEM............................................................................................................................................. 552 C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)............................................................................................................... 554 C-2 [E232] (SHORT CIRCUIT IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED..................................................................................................................... 555 C-3 [E233] (DISCONNECTION IN PUMP TVC SOLENOID SYSTEM) IS DISPLAYED..................................................................................................................... 557 C-4 [E203] (SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED.......................................................................................................... 559 C-5 [E213] (DISCONNECTION IN SWING HOLDING BRAKE SOLENOID SYSTEM) IS DISPLAYED.......................................................................................................... 561 C-6 [E201] (SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED.................................................................................................................... 563 C-7 [E211] (DISCONNECTION IN CO CANCEL SOLENOID SYSTEM) IS DISPLAYED.................................................................................................................... 564 C-8 [E204] (SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED............................................................................................................... 565 C-9 [E214] (DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM) IS DISPLAYED............................................................................................................... 566 C-10 [E206] (SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED................................................................................................................ 567 C-11 [E-216] (DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM) IS DISPLAYED............................................................................................................... 568 C-12 [E311] (SHORT CIRCUIT IN BUCKET CURL HI CANCELSOLENOID SYTEM) IS DISPLAYED......................................................................................................... 569 C-13 [E312] (DISCONNECTION IN BUCKET CURL HI CANCEL SOLENOID SYSTEM) IS DISPLAYED....................................................................................................... 570 C-14 [E-217] (MODEL SELECTION INPUT ERROR) IS DISPLAYED................................................................................................................................. 571 C-15 [E224] (ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED............................................................................................................. 573 C-16 [E225] (ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM) IS DISPLAYED.............................................................................................................. 574 C-17 [E226] (ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM) IS DISPLAYED........................................................................................................... 575 C-18 [E227] (ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM) IS DISPLAYED.................................................................................................................... 576 C-19 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)......................................................................................................... 577 C-20 [E207] SHORT CIRCUIT IN FLASHING LIGHT RELAY DRIVE SYSTEM IS DISPLAYED............................................................................................................. 579 C-21 FLASHING LIGHT RELAY DOES NOT WORK................................................................................................................................................. 580 C-22 [E231] ABNORMALITY (SHORT CIRCUIT) IN STEP LIGHT POWER SOURCE RETENTION RELAY OUTPUT SYSTEM IS DISPLAYED........................................................................... 581 C-23 STEP LIGHT SWITCH DOES NOT WORK.................................................................................................................................................... 582 C-24 [E302] SHORT CIRCUIT IN STEP LIGHT RELAY DRIVE SYSTEM IS DISPLAYED................................................................................................................. 583 C-25 STEP LIGHT DOES NOT LIGHT UP....................................................................................................................................................... 584 C-26 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED................................................................................................................. 585 TROUBLESHOOTING OF ENGINE THROTTLE & PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)......................................................................................................... 587 ELECTRICAL CIRCUIT DIAGRAM FOR F MODE................................................................................................................................................... 588 F-1 BIT PATTERN 20-(1) (SWING OILS PRESSURE SWITCH) DOES NOT LIGHT UP................................................................................................................... 590 F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP................................................................................................................... 591 F-3 BIT PATTERN 20-3 (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP................................................................................................................. 592 F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH ) DOES NOT LIGHT UP.............................................................................................................. 593 F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP................................................................................................................... 594 F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP.................................................................................................................. 595 F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP............................................................................................................... 596 F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP.............................................................................................................. 597 F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP............................................................................................................ 598 F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP........................................................................................................................... 599 F-11 BIT PATTERN 22-(5) (KEROSENE MODE CONNECTION) DOES NOT LIGHT UP.................................................................................................................... 600 F-12 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP............................................................................................................................ 601 TROUBLESHOOTING OF PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)........................................................................................................................... 603 ELECTRICAL CIRCUIT DIAGRAM FOR F MOD.................................................................................................................................................... 604 F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP..................................................................................................................... 606 F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP................................................................................................................... 607 F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP............................................................................................................... 608 F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP............................................................................................................... 609 F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DIES NOT LIGHT UP................................................................................................................... 610 F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP.................................................................................................................. 611 F-7 BIT PATTERN 21-(1) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP'............................................................................................................. 612 F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP.............................................................................................................. 613 F-9 BIT PATTERN 21-(2) (SERVICE VALVE OIL PRESSURE SWITCH) DOES NOT LIGHT UP............................................................................................................ 614 F-10 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP........................................................................................................................... 615 F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP............................................................................................................................ 616 F-12 WHEN STEP LIGHT SWITCH IS ON, BIT PATTERN 24-(1) DOES NOT GO OUT................................................................................................................... 617 F-13 WHEN HORN SWITCH IS ON, BIT PATTERN 24-(2) DOES NOT GO OUT......................................................................................................................... 618 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)..................................................................................................................................... 619 TABLE OF FAILURE MODES AND CAUSES....................................................................................................................................................... 620 BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)........................................................................................................................ 622 WORK EQUIPMENT IS SLOW OR LACKS POWER............................................................................................................................................... 623 HYDRAULIC CIRCUIT DIAGRAM AFTER INTERCHANGING HOSES................................................................................................................................. 624 H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER.................................................................................................................. 625 H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS........................................................................................................................... 626 H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE............................................................................................................................................... 628 H-4 ABNORMAL NOISE GENERATED (AROUND PUMP).............................................................................................................................................. 629 H-6 WORK EQUIPMENT (BOOM, ARM, BUCKET) IS SLOW OR LACKS PWOER........................................................................................................................... 630 H-7 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL).................................................................................................. 631 H-8 EXCESSIVE HYDRULIC DRIFT............................................................................................................................................................ 631 H-9 EXCESSIVE TIME LAG.................................................................................................................................................................. 632 H-10 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION.................................................................................................................................... 632 H-11 IN COMPOUND OPERATIONS WITH SWING, WORK EQUIPMENT SPEED IS SLOW.................................................................................................................... 633 H-12 IN COMPOUND OPERATIONS WITH BUCKET CURL, SWING AND OTHER WORK EQUIPMENT SPEEDS ARE SLOW............................................................................................ 633 H-13 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS........................................................................................................................... 633 H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRVELOPERATIONS...................................................................................................................... 634 H-15 DEVIATION IS EXCESSIVE WHEN STARTING............................................................................................................................................... 638 H-16 TRAVEL SPEED IS SLOW............................................................................................................................................................... 640 H-17 TRAVEL SPEED DOES NOT SWITCH....................................................................................................................................................... 641 H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)............................................................................................................................................... 641 H-19 DOES NOT SWING..................................................................................................................................................................... 642 H-20 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR.................................................................................................................................. 643 H-21 EXCESSIVE OVERRUN WHEN STOPPING SWING.............................................................................................................................................. 644 H-22 EXCESSIVE SHOCK WHEN STOPPING SWING................................................................................................................................................ 645 H-23 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....................................................................................................................................... 645 H-24 EXCESSIVE HYDRAULIC DRIFT OF SWING................................................................................................................................................. 646 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).......................................................................................................................................... 647 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................................... 650 ELECTRICAL CIRCUIT DIGRAM FOR M MODE SYSTEM............................................................................................................................................. 652 M-1 [E101] ABNORMALITY IN ERROR DATA) IS DISPLAYED...................................................................................................................................... 654 M-1 [E-102] (ERROR IN CLOCK DATA) IS DISPLAYED.......................................................................................................................................... 654 M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED...................................................................... 655 M-3 [E-104] (AIR CLEANER CLOGGING DETECTED) IS DISPLAYED................................................................................................................................ 656 M-4 [E-106] (DROP IN ENGINE OIL PRESSURE DETECTED) IS DISPLAYED ........................................................................................................................ 656 M-5 [E-108] (ENGINE WATER TEMPERATURE 105 DEG. C DETECTED) IS DISPLAYED................................................................................................................. 657 M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS............................................................................................ 658 M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT........................................................................................ 660 M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)...................................................................... 660 M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH......................................................................................................... 661 M-10 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH................................................................................................... 664 M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE LAMPS DO NOT LIGHT UP)...................................... 666 M-12 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).... 668 M-13 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND. CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND........................................... 672 M-14 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS........................................................................................................................... 672 M-15 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)............................................................................................... 673 M-16 COOLANT TEMPERATURE GAUGE DOES NOT RISE............................................................................................................................................ 674 M-17 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)................................................................................ 674 M-18 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL.............................................................................................................................................. 675 M-19 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY............................................................................................................................................. 675 M-20 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT graphic (SWING LOCK MONITOR) DOES NOT LIGHT UP........................................................................................... 676 M-21 SWING HOLDING BRAKE RELEASE SWITCH IS TURNED ON, BUT graphic (SWING LOCK MONITOR) DOES NOT FLASH................................................................................... 676 M-22 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING............................................................................................................................. 677 M-23 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED................................................................................ 677 M-24 DEFECTIVE FUEL LEVEL SENSOR SYSTEM................................................................................................................................................. 678 M-25 DEFECTIVE COOLAND TEMPERATURE SENSOR SYSTEM........................................................................................................................................ 679 M-26 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM........................................................................................................................................... 680 M-27 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.............................................................................................................................................. 681 M-28 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM........................................................................................................................................ 682 M-29 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113)........................................................................................ 684 M-30 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114)................................................................................ 689 M-31 ELECTRIC GREASE GUN DOES NOT WORK.................................................................................................................................................. 691 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).......................................................................................................................................... 693 ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE........................................................................................................... 696 ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM............................................................................................................................................ 698 M-1 [E101] ABNORMALITY IN ERROR DATA ) OR [E102] (ABNORMALITY IN CLOCK DATA) IS DISPLAYED............................................................................................... 700 M-2 [E103] (SHORT CIRCUIT IN BUZZER OUTPUT SYSTEM) IS DISPLAYED......................................................................................................................... 701 M-3 [E-104] (AIR CLEANER CLOGGING DETECTION) IS DISPLAYED............................................................................................................................... 702 M-4 [E108] (ENGINE WATER TEMPERATURE 105 DEG. C) IS DISPLAYED........................................................................................................................... 702 M-5 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS............................................................................................ 703 M-6 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT........................................................................................ 705 M-7 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE.............................................................................. 705 M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH......................................................................................................... 706 M-9 PREHEATING IS NOT BEING USED BUT PREHEATING DISPLAY MONITOR LAMP LIGHTS UP.......................................................................................................... 709 M-10 WHEN ENGINE IS STARTED, BASIC CHECK ITEMS FLASH.................................................................................................................................... 710 M-11 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH................................................................................... 711 M-12 WHEN ENGINE IS STARTED, CAUTION ITEMS AND EMERGENCY STOP ITEMS FLASH............................................................................................................... 712 M-13 OPERATION OF ALARM BUZZER IS NOT NORMAL............................................................................................................................................ 716 M-14 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP.................................................................................................................................. 718 M-15 ENGINE WATER TEMPERATURE DISPLAY IS NOT NORMAL..................................................................................................................................... 719 M-16 FUEL LEVEL GAUGE DISPLAY IS NOT NORMAL............................................................................................................................................. 720 M-17 SWING LOCK SWITCH IS TURNED ON BUT SWING LOCK MONITOR LAMP DOES NOT LIGHT UP....................................................................................................... 722 M-18 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL (EMERGENCY), SWING LOCK MONITOR LAMP DOES NOT FLASH................................................................................ 723 M-19 SERVICE METER DOES NOT GIVE NORMAL DISPLAY......................................................................................................................................... 724 M-20 DEFECTIVE FUEL LEVEL SENSOR SYSTEM................................................................................................................................................. 725 M-21 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM........................................................................................................................................... 726 M-22 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM.............................................................................................................................................. 727 M-23 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM........................................................................................................................................ 728 M-24 WIPER IS NOT ACTUATED WHEN WIPER SWITCH IS OPERATED OR WIPER IS ACTUATED WHEN WIPER SWITCH IS NOT OPERATED......................................................................... 729 M-25 WINDOW WASHER IS NOT ACTUATED WHEN SWITCH IS OPERATED OR WINDOW WASHER IS ACTUATED WHEN SWITCH IS NOT OPERATED..................................................................... 734 M-26 ELECTRIC GREASE GUN DOES NOT WORK (MACHINES EQUIPPED WITH ELECTRIC GREASE GUN)..................................................................................................... 737 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................... 739 METHOD OF USING MANUAL...................................................................................................................................................................... 742 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................................................................... 745 SPECIAL TOOL LIST........................................................................................................................................................................... 747 SKETCHES OF SPECIAL TOOLS................................................................................................................................................................... 757 REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY.............................................................................................................................................. 766 REMOVAL OF FUEL SUPPLY PUMP ASSEMBLY........................................................................................................................................................ 767 INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY................................................................................................................................................... 769 REMOVAL OF FUEL INJECTOR ASSEMBLY........................................................................................................................................................... 770 INSTALLATION OF FUEL INJECTOR ASSEMBLY...................................................................................................................................................... 772 REMOVAL OF NOZZLE TIP....................................................................................................................................................................... 774 INSTALLATION OF NOZZLE TIP.................................................................................................................................................................. 775 REMOVAL OF ENGINE FRONT SEAL................................................................................................................................................................ 775 INSTALLATION OF ENGINE FRONT SEAL........................................................................................................................................................... 777 REMOVAL OF ENGINE REAR SEAL................................................................................................................................................................. 779 INSTALLATION OF ENGINE REAR SEAL............................................................................................................................................................ 780 REMOVAL OF CYLINDER HEAD ASSEMBLY........................................................................................................................................................... 784 INSTALLATION OF CYLINDER HEAD ASSEMBLY...................................................................................................................................................... 787 REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY.............................................................................................................................................. 791 INSTALLATION OF RADIATOR, HYDRUALIC COOLER ASSEMBLY......................................................................................................................................... 792 REMOVAL OF RADIATOR, HYDRAULIC COOLER ASSEMBLY.............................................................................................................................................. 793 INSTALLATION OF RADIATOR, HYDRAULIC COOLER ASSEMBLY......................................................................................................................................... 794 REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY............................................................................................................................................. 796 INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY........................................................................................................................................ 799 REMOVAL OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY............................................................................................................................................. 800 INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY........................................................................................................................................ 803 REMOVAL OF PTO ASSEMBLY..................................................................................................................................................................... 804 INSTALLATION OF ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY........................................................................................................................................ 804 DISASSEMBLY OF PTO ASSEMBLY................................................................................................................................................................. 805 ASSEMBLY OF PTO ASSEMBLY.................................................................................................................................................................... 807 REMOVAL OF FUEL TANK ASSEMBLY............................................................................................................................................................... 809 INSTALLATION OF FUEL TANK................................................................................................................................................................... 809 REMOVAL OF FUEL TANK ASSEMBLY............................................................................................................................................................... 810 INSTALLATION OF FUEL TANK................................................................................................................................................................... 810 DISASSEMBLY OF FINAL DRIVE ASSEMBLY......................................................................................................................................................... 812 ASSEMBLY OF FINAL DRIVE ASSEMBLY............................................................................................................................................................ 818 REMOVAL OF REVOLVING FRAME ASSEMBLY......................................................................................................................................................... 826 INSTALLATION OF REVOLVING FRAME ASSEMBLY.................................................................................................................................................... 827 REMOVAL OF SWING MOTOR ASSEMBLY............................................................................................................................................................. 828 INSTALLATION OF SWING MOTOR ASSEMBLY........................................................................................................................................................ 828 DISASSEMBLY OF SWING MOTOR ASSEMBLY......................................................................................................................................................... 829 ASSEMBLY OF SWING MOTOR ASSEMBLY............................................................................................................................................................ 833 REMOVAL OF SWING MACHINERY ASSEMBLY......................................................................................................................................................... 841 INSTALLATION OF SWING MACHINERY ASSEMBLY.................................................................................................................................................... 841 DISASSEMBLY OF SWING MACHINERY ASSEMBLY..................................................................................................................................................... 842 ASSEMBLY OF SWING MACHINERY ASSEMBLY........................................................................................................................................................ 846 REMOVAL OF SWING CIRCLE ASSEMBLY............................................................................................................................................................ 851 INSTALLATION OF SWING CIRCLE ASSEMBLY....................................................................................................................................................... 851 REMOVAL OF TRACK SHOE ASSEMBLY.............................................................................................................................................................. 852 INSTALLATION OF TRACK SHOE ASSEMBLY......................................................................................................................................................... 853 DISASSEMBLY OF ONE LINK IN FIELD............................................................................................................................................................ 854 ASSEMBLY OF ONE LINK IN FIELD............................................................................................................................................................... 856 REMOVAL OF IDLER, RECOIL SPRING ASSEMBLY.................................................................................................................................................... 858 INSTALLATION OF IDLER, RECOIL SPRING ASSEMBLY............................................................................................................................................... 858 DISASSEMBLY OF IDLER ASSEMBLY............................................................................................................................................................... 859 ASSEMBLY OF IDLER ASSEMBLY.................................................................................................................................................................. 861 DISASSEMBLY OF RECOIL SPRING ASSEMBLY....................................................................................................................................................... 863 ASSEMBLY OF RECOIL SPRING ASSEMBLY.......................................................................................................................................................... 864 REMOVAL OF TRACK ROLLER ASSEMBLY............................................................................................................................................................ 865 INSTALLATION OF TRACK ROLLER ASSEMBLY....................................................................................................................................................... 865 DISASSEMBLY OF TRACK ROLLER ASSEMBLY........................................................................................................................................................ 866 ASSEMBLY OF TRACK ROLLER ASSEMBLY........................................................................................................................................................... 867 REMOVAL OF CARRIER ROLLER ASSEMBLY.......................................................................................................................................................... 869 INSTALLATION OF CARRIER ROLLER ASSEMBLY..................................................................................................................................................... 869 DISASSEMBLY OF CARRIER ROLLER ASSEMBLY...................................................................................................................................................... 870 ASSEMBLY OF CARRIER ROLLER ASSEMBLY......................................................................................................................................................... 871 REMOVAL OF HYDRAULIC TANK ASSEMBLY.......................................................................................................................................................... 873 INSTALLATION OF HYDRAULIC TANK ASSEMBLY..................................................................................................................................................... 874 DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY................................................................................................................................................... 876 ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY...................................................................................................................................................... 877 REMOVAL OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY...................................................................................................................................... 878 INSTALLATION OF MAIN CONTROL VALVE, SOLENOID VALVE ASSEMBLY................................................................................................................................. 879 DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY.................................................................................................................................................. 880 ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY..................................................................................................................................................... 882 REMOVAL OF NO. 1 AND NO. 2 PUMP ASSEMBLY.................................................................................................................................................... 884 INSTALLATION OF NO. 1 AND NO. 2 PUMP ASSEMBLY............................................................................................................................................... 885 DISASSEMBLY OF HYDRAULIC PUMP ASSEMBLY...................................................................................................................................................... 886 ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY......................................................................................................................................................... 896 REMOVAL OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY........................................................................................................................................... 912 INSTALLATION OF CONTROL, PTO LUBRICATION PUMP ASSEMBLY...................................................................................................................................... 912 REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY..................................................................................................................................................... 913 INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLY................................................................................................................................................ 913 DISASSEMBLY OF CENTER SWIVEL JOING ASSEMBLY................................................................................................................................................. 914 ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY.................................................................................................................................................... 914 DISASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY............................................................................................................................................ 915 ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLY............................................................................................................................................... 916 DISASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY.................................................................................................................................................... 917 ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLY....................................................................................................................................................... 918 REMOVAL OF BUCKET CYLINDER ASSEMBLY......................................................................................................................................................... 919 INSTALLATION OF BUCKET CYLINDER ASSEMBLY.................................................................................................................................................... 920 REMOVAL OF ARM CYLINDER ASSEMBLY............................................................................................................................................................ 921 INSTALLATION OF ARM CYLINDER ASSEMBLY....................................................................................................................................................... 922 REMOVAL OF BOOM CYLINDER ASSEMBLY........................................................................................................................................................... 923 INSTALLATION OF BOOM CYLINDER ASSEMBLY...................................................................................................................................................... 924 DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................................................................. 925 ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..................................................................................................................................................... 928 REMOVAL OF BUCKET ASSEMBLY.................................................................................................................................................................. 932 INSTALLATION OF BUCKET ASSEMBLY............................................................................................................................................................. 933 REMOVAL OF ARM ASSEMBLY..................................................................................................................................................................... 934 INSTALLATION OF ARM ASSEMBLY................................................................................................................................................................ 935 REMOVAL OF BOOM ASSEMBLY.................................................................................................................................................................... 936 INSTALLATION OF BOOM ASSEMBLY............................................................................................................................................................... 937 REMOVAL OF OPERATOR'S CAB ASSEMBLY.......................................................................................................................................................... 938 INSTALLATION OF OPERATOR'S CAB ASSEMBLY..................................................................................................................................................... 939 REMOVAL OF COUNTERWEIGHT ASSEMBLY........................................................................................................................................................... 940 INSTALLATION OF COUNTERWEIGHT ASSEMBLY...................................................................................................................................................... 940 40 MAINTENANCE STANDARD......................................................................................................................................................................... 941 ENGINE MOUNT................................................................................................................................................................................ 942 PTO......................................................................................................................................................................................... 943 SWING MACHINERY............................................................................................................................................................................. 944 SWING CIRCLE................................................................................................................................................................................ 946 FINAL DRIVE................................................................................................................................................................................. 948 TRACK FRAME AND RECOIL SPRING............................................................................................................................................................... 950 IDLER....................................................................................................................................................................................... 952 CARRIER ROLLER.............................................................................................................................................................................. 954 TRACK ROLLER................................................................................................................................................................................ 955 TRACK SHOE.................................................................................................................................................................................. 956 DOUBLE SHOE............................................................................................................................................................................. 959 TRIPLE GROUSER SHOE..................................................................................................................................................................... 960 HYDRAULIC PUMP.............................................................................................................................................................................. 961 CONTROL AND PTO LUBRICATION PUMP............................................................................................................................................................ 963 CONTROL VALVE............................................................................................................................................................................... 964 SWING MOTOR................................................................................................................................................................................. 971 TRAVEL MOTOR................................................................................................................................................................................ 972 WORK EQUIPMENT - SWING PPC VALVE............................................................................................................................................................ 973 TRAVEL PPC VALVE............................................................................................................................................................................ 974 SERVICE PPC VALVE........................................................................................................................................................................... 975 SOLENOID VALVE.............................................................................................................................................................................. 976 CENTER SWIVEL JOINT......................................................................................................................................................................... 977 BOOM HOLDING VALVE.......................................................................................................................................................................... 978 BOOM LOWER REGENERATION VALVE............................................................................................................................................................... 979 HYDRAULIC CYLINDER.......................................................................................................................................................................... 980 BACKHOE SPECIFICATION................................................................................................................................................................... 980 BOOM CYLINDER....................................................................................................................................................................... 980 ARM CYLINDER........................................................................................................................................................................ 980 BUCKET CYLINDER..................................................................................................................................................................... 980 LOADING SHOVEL SPECIFICATION............................................................................................................................................................ 982 BOOM CYLINDER....................................................................................................................................................................... 982 ARM CYLINDER........................................................................................................................................................................ 982 BUCKET CYLINDER..................................................................................................................................................................... 982 BOTTOM DUMP CYLINDER................................................................................................................................................................ 983 WORK EQUIPMENT.............................................................................................................................................................................. 984 BACKHOE SPECIFICATION................................................................................................................................................................... 984 LOADING SHOVEL SPECIFICATION............................................................................................................................................................ 986 DIMENSIONS OF WORK EQUIPMENT................................................................................................................................................................ 988 BACKHOE SPECIFICATION................................................................................................................................................................... 988 ARM................................................................................................................................................................................. 988 BUCKET.............................................................................................................................................................................. 990 90 OTHERS....................................................................................................................................................................................... 993 HYDRAULIC CIRCUIT DIAGRAM (2/2)............................................................................................................................................................. 995 HYDRAULIC CIRCUIT DIAGRAM (1/2).............................................................................................................................................................1000 HYDRAULIC CIRCUIT DIAGRAM (2/2).............................................................................................................................................................1005 ELECTRIC CIRCUIT DIAGRAM (1/3)..............................................................................................................................................................1006 ELECTRIC CIRCUIT DIAGRAM (2/3)..............................................................................................................................................................1011 ELECTRIC CIRCUIT DIAGRAM (3/3)..............................................................................................................................................................1016 ELECTRIC CIRCUIT DIAGRAM (1/4)..............................................................................................................................................................1021 ELECTRIC CIRCUIT DIAGRAM (2/4)..............................................................................................................................................................1026 ELECTRIC CIRCUIT DIAGRAM (3/4)..............................................................................................................................................................1031 ELECTRIC CIRCUIT DIAGRAM (4/4)..............................................................................................................................................................1036
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