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KOMATSU PC600-8 PC600LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:30001 & UP) – PDF Download
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- KOMATSU PC600-8 PC600LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:30001 & UP
- PUBLICATION NUMBER:SEN00128-16
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Description
KOMATSU PC600-8 PC600LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:30001 & UP)
KOMATSU PC600-8 PC600LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:30001 & UP) – PDF DOWNLOAD:
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KOMATSU PC600-8 PC600LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:30001 & UP)
This shop manual contains the necessary technical information for services performed in a workshop.For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. 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.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing arts.
TABLE OF CONTENTS:
KOMATSU PC600-8 PC600LC-8 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:30001 & UP)
COVER ...................................................................................................................... 1 00 Index and foreword....................................................................................................... 0 Index................................................................................................................... 3 Composition of shop manual.......................................................................................... 4 Table of contents................................................................................................... 6 Foreword and general information........................................................................................ 15 Safety notice....................................................................................................... 16 How to read the shop manual......................................................................................... 21 Explanation of terms for maintenance standard....................................................................... 23 Handling of electric equipment and hydraulic component.............................................................. 25 Handling of connectors newly used for engines....................................................................... 34 How to read electric wire code...................................................................................... 37 Precautions when carrying out operation............................................................................. 40 Method of disassembling and connecting push-pull type coupler....................................................... 43 Standard tightening torque table.................................................................................... 46 Conversion table.................................................................................................... 50 01 Specification............................................................................................................ 0 Specification and technical data........................................................................................ 57 Specification and technical data.................................................................................... 58 Specification drawings.......................................................................................... 58 Working range drawings.......................................................................................... 60 Specifications.................................................................................................. 62 Weight table.................................................................................................... 70 Table of fuel, coolant and lubricants........................................................................... 74 10 Structure, function and maintenance standard............................................................................. 0 Engine and cooling system............................................................................................... 77 Engine and cooling system........................................................................................... 78 Parts related to engine......................................................................................... 78 PTO............................................................................................................. 80 Fan, control and PTO lubrication pump........................................................................... 82 Radiator, oil cooler............................................................................................ 83 Power train............................................................................................................. 85 Power train......................................................................................................... 86 Power train..................................................................................................... 86 Final drive..................................................................................................... 89 Sprocket........................................................................................................ 92 Swing circle.................................................................................................... 94 Swing machinery................................................................................................. 96 Undercarriage and frame................................................................................................. 99 Undercarriage and frame............................................................................................. 100 Track frame, recoil spring...................................................................................... 100 Idler........................................................................................................... 102 Carrier roller.................................................................................................. 104 Track roller.................................................................................................... 105 Track shoe...................................................................................................... 106 Hydraulic system, Part 1................................................................................................ 113 Hydraulic system, Part 1............................................................................................ 114 Hydraulic piping drawing........................................................................................ 114 Hydraulic tank, hydraulic filter................................................................................ 116 Hydraulic pump (piston pump).................................................................................... 118 Line oil filter................................................................................................. 146 Cooling fan pump................................................................................................ 148 Cooling fan motor............................................................................................... 156 Hydraulic system, Part 2................................................................................................ 163 Hydraulic system, Part 2............................................................................................ 164 Control valve................................................................................................... 164 Swing motor..................................................................................................... 183 Swing brake..................................................................................................... 186 Safety valve.................................................................................................... 187 Reverse prevention valve........................................................................................ 189 Center swivel joint............................................................................................. 192 Travel motor.................................................................................................... 193 Parking brake................................................................................................... 198 Brake valve..................................................................................................... 200 Set pressures varying mechanism................................................................................. 203 Valve control................................................................................................... 204 Work equipment, swing PPC valve................................................................................. 206 Travel PPC valve................................................................................................ 210 Service PPC valve............................................................................................... 212 PPC accumulator................................................................................................. 213 PPC shuttle valve............................................................................................... 214 Solenoid valve.................................................................................................. 215 Boom holding valve.............................................................................................. 220 Boom LOWER regeneration valve................................................................................... 224 Quick return valve.............................................................................................. 227 Hydraulic cylinder.............................................................................................. 230 Work equipment.......................................................................................................... 235 Work equipment...................................................................................................... 236 Work equipment.................................................................................................. 236 Dimensions of work equipment.................................................................................... 240 Cab and its attachments................................................................................................. 245 Cab and its attachments............................................................................................. 246 Air conditioner piping.......................................................................................... 246 Electrical system....................................................................................................... 248 Engine control...................................................................................................... 249 Machine control system diagram...................................................................................... 254 Monitor system...................................................................................................... 278 Sensors............................................................................................................. 293 KOMTRAX system...................................................................................................... 297 20 Standard value table..................................................................................................... 0 Standard service value table............................................................................................ 300 Standard value table for engine..................................................................................... 301 Standard value table for chassis.................................................................................... 302 30 Testing and adjusting.................................................................................................... 0 Testing and adjusting, Part 1........................................................................................... 324 Tools for testing, adjusting and troubleshooting.................................................................... 327 Measuring engine speed.............................................................................................. 332 Measuring intake air pressure (boost pressure)...................................................................... 333 Measuring exhaust gas temperature................................................................................... 334 Measuring exhaust gas color......................................................................................... 335 Adjusting valve clearance........................................................................................... 336 Measuring compression pressure...................................................................................... 337 Measuring blow-by pressure.......................................................................................... 339 Measuring engine oil pressure....................................................................................... 339 Testing EGR valve and bypass valve drive oil pressure............................................................... 340 Handling equipment in fuel circuit.................................................................................. 341 Releasing remaining pressure in fuel system......................................................................... 341 Measuring fuel pressure............................................................................................. 342 Reduced cylinder mode operation..................................................................................... 343 No-injection cranking............................................................................................... 343 Testing leakage from pressure limiter and return rate from injector................................................. 344 Bleeding air from fuel circuit...................................................................................... 346 Testing fuel system for leakage..................................................................................... 348 Testing and adjusting alternator belt tension....................................................................... 349 Testing and adjusting air conditioner compressor belt tension....................................................... 350 Testing clearance of swing circle bearing........................................................................... 351 Testing and adjusting track shoe tension............................................................................ 352 Testing and adjusting work equipment, swing, and travel circuit oil pressures....................................... 353 Testing and adjusting control circuit oil pressure.................................................................. 358 Testing and adjusting piston pump control oil pressure.............................................................. 360 Testing servo piston stroke......................................................................................... 366 Measuring PPC valve output pressure................................................................................. 367 Measuring outlet pressures of solenoid valve and PPC shuttle valve.................................................. 371 Adjusting work equipment, swing PPC valve........................................................................... 377 Testing and adjusting travel deviation.............................................................................. 378 Measuring fan speed................................................................................................. 380 Measuring fan circuit oil pressure.................................................................................. 380 Inspection of locations of hydraulic drift of work equipment........................................................ 381 Measuring oil leakage............................................................................................... 382 Releasing remaining pressure in hydraulic circuit................................................................... 386 Bleeding air from each part......................................................................................... 387 Inspection procedures for diode..................................................................................... 390 Testing and adjusting, Part 2........................................................................................... 392 Special function of machine monitor................................................................................. 393 Handling controller voltage circuit................................................................................. 427 Procedure for turning on KOMTRAX terminal........................................................................... 428 KOMTRAX terminal lamp indications................................................................................... 431 Preparation work for troubleshooting electrical system.............................................................. 434 Adjusting mirrors................................................................................................... 436 Pm-clinic service................................................................................................... 437 Undercarriage inspection............................................................................................ 443 40 Troubleshooting.......................................................................................................... 0 Failure code table and fuse locations................................................................................... 446 Failure codes table................................................................................................. 447 Fuse locations...................................................................................................... 451 General information on troubleshooting.................................................................................. 454 Points to remember when troubleshooting............................................................................. 455 Sequence of events in troubleshooting............................................................................... 456 Checks before troubleshooting....................................................................................... 457 Classification and procedures of troubleshooting.................................................................... 458 Information contained in troubleshooting table...................................................................... 459 Failure-looking phenomenon and troubleshooting No................................................................... 461 Connection table for connector pin numbers.......................................................................... 465 T- branch box and T- branch adapter table........................................................................... 501 Troubleshooting by failure code (Display of code), Part 1............................................................... 506 Failure code [A000N1] Eng. Hi Out of Std............................................................................ 508 Failure code [AA10NX] Aircleaner clogging........................................................................... 509 Failure code [AB00KE] Charge Voltage Low............................................................................ 511 Failure code [B@BAZG] Eng. Oil Press. Low........................................................................... 513 Failure code [B@BAZK] Eng. Oil Level Low............................................................................ 515 Failure code [B@BCNS] Eng. Water Overheat........................................................................... 516 Failure code [B@BCZK] Eng. Water Lvl Low............................................................................ 517 Failure code [B@HANS] Hydr. Oil Overheat............................................................................ 519 Failure code [CA111] ECM Critical Internal Failure.................................................................. 520 Failure code [CA115] Eng Ne and Bkup Speed Sens Error............................................................... 521 Failure code [CA122] Chg Air Press Sensor High Error................................................................ 523 Failure code [CA123] Chg Air Press Sensor Low Error................................................................. 525 Failure code [CA131] Throttle Sensor High Error..................................................................... 527 Failure code [CA132] Throttle Sensor Low Error...................................................................... 529 Failure code [CA135] Eng Oil Press Sensor High Error................................................................ 531 Failure code [CA141] Eng Oil Press Sensor Low Error................................................................. 533 Failure code [CA144] Coolant Temp Sens High Error................................................................... 535 Failure code [CA145] Coolant Temp Sens Low Error.................................................................... 537 Failure code [CA153] Chg Air Temp Sensor High Error................................................................. 539 Failure code [CA154] Chg Air Temp Sensor Low Error.................................................................. 541 Failure code [CA187] Sens Supply 2 Volt Low Error................................................................... 541 Failure code [CA221] Ambient Press Sens High Error.................................................................. 543 Failure code [CA222] Ambient Press Sens Low Error................................................................... 545 Failure code [CA227] Sens Supply 2 Volt High Error.................................................................. 547 Failure code [CA234] Eng Overspeed.................................................................................. 549 Failure code [CA238] Ne Speed Sens Supply Volt Error................................................................ 550 Failure code [CA263] Fuel Temp Sensor High Error.................................................................... 551 Failure code [CA265] Fuel Temp Sensor Low Error..................................................................... 553 Failure code [CA271] IMV/PCV1 Short Error........................................................................... 554 Failure code [CA272] IMV/PCV1 Open Error............................................................................ 555 Failure code [CA273] PCV2 Short Error............................................................................... 556 Failure code [CA274] PCV2 Open Error................................................................................ 557 Troubleshooting by failure code (Display of code), Part 2............................................................... 560 Failure code [CA322] Inj #1 (L#1) Open/Short Error.................................................................. 563 Failure code [CA323] Inj #5 (L#5) Open/Short Error.................................................................. 565 Failure code [CA324] Inj #3 (L#3) Open/Short Error.................................................................. 567 Failure code [CA325] Inj #6 (L#6) Open/Short Error.................................................................. 569 Failure code [CA331] Inj #2 (L#2) Open/Short Error.................................................................. 571 Failure code [CA332] Inj #4 (L#4) Open/Short Error.................................................................. 573 Failure code [CA342] Calibration Code Incompatibility............................................................... 575 Failure code [CA351] Injectors Drive Circuit Error.................................................................. 576 Failure code [CA352] Sens Supply 1 Volt Low Error................................................................... 578 Failure code [CA386] Sens Supply 1 Volt High Error.................................................................. 579 Failure code [CA441] Battery Voltage Low Error...................................................................... 581 Failure code [CA442] Battery Voltage High Error..................................................................... 581 Failure code [CA449] Rail Press Very High Error..................................................................... 582 Failure code [CA451] Rail Press Sensor High Error................................................................... 583 Failure code [CA452] Rail Press Sensor Low Error.................................................................... 585 Failure code [CA553] Rail Press High Error.......................................................................... 585 Failure code [CA554] Rail Press Sensor In Range Error............................................................... 586 Failure code [CA559] Rail Press Low Error........................................................................... 587 Failure code [CA689] Eng Ne Speed Sensor Error...................................................................... 591 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................................................ 593 Failure code [CA757] All Persistent Data Lost Error................................................................. 594 Failure code [CA778] Engine Bkup Speed Sensor Error................................................................. 595 Failure code [CA1228] EGR Valve Servo Error 1....................................................................... 597 Failure code [CA1625] EGR Valve Servo Error 2....................................................................... 598 Failure code [CA1626] BP Valve Sol Current High Error............................................................... 599 Failure code [CA1627] BP Valve Sol Current Low Error................................................................ 601 Failure code [CA1628] Bypass Valve Servo Error 1.................................................................... 602 Failure code [CA1629] Bypass Valve Servo Error 2.................................................................... 603 Failure code [CA1631] BP Valve Pos Sens High Error.................................................................. 604 Failure code [CA1632] BP Valve Pos Sens Low Error................................................................... 606 Failure code [CA1633] KOMNET Datalink Timeout Error................................................................. 607 Failure code [CA1642] EGR Inlet Press Sens Low Error................................................................ 610 Failure code [CA1653] EGR Inlet Press Sens High Error............................................................... 611 Failure code [CA2185] Throt Sens Sup Volt High Error................................................................ 613 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................. 615 Failure code [CA2249] Rail Press Very Low Error..................................................................... 616 Failure code [CA2271] EGR Valve Pos Sens High Error................................................................. 617 Failure code [CA2272] EGR Valve Pos Sens Low Error.................................................................. 619 Failure code [CA2351] EGR Valve Sol Current High Error.............................................................. 621 Failure code [CA2352] EGR Valve Sol Current Low Error............................................................... 623 Failure code [CA2555] Grid Htr Relay Volt Low Error................................................................. 624 Failure code [CA2556] Grid Htr Relay Volt High Error................................................................ 625 Troubleshooting by failure code (Display of code), Part 3............................................................... 628 Failure code [D110KB] Battery Relay Drive S/C....................................................................... 631 Failure code [D163KB] Flash Light Relay S/C......................................................................... 633 Failure code [D195KB] Step Light Relay S/C.......................................................................... 635 Failure code [DA25KP] Press. Sensor Power Abnormality............................................................... 637 Failure code [DA2SKQ] Model Selection Abnormality................................................................... 639 Failure code [DA80MA] Auto. Lub Abnormal............................................................................ 641 Failure code [DA2RMC] Pump Comm. Abnormality........................................................................ 643 Failure code [DAFRMC] Monitor Comm. Abnormality..................................................................... 645 Failure code [DGE5KY] Ambi. Temp. Sensor S/C........................................................................ 647 Failure code [DGE5KY] Ambi. Temp. Sensor S/C........................................................................ 649 Failure code [DGH2KB] Hydr. Oil Temp. Sensor S/C.................................................................... 650 Failure code [DHPAMA] F pump P. Sensor Abnormality.................................................................. 651 Failure code [DHPBMA] R pump P. Sensor Abnormality.................................................................. 653 Failure code [DV20KB] Travel Alarm S/C.............................................................................. 655 Failure code [DW43KA] Travel Speed Sol. Disc........................................................................ 657 Failure code [DW43KB] Travel Speed Sol. S/C......................................................................... 659 Failure code [DW45KA] Swing Brake Sol. Disc......................................................................... 661 Failure code [DW45KB] Swing Brake Sol. S/C.......................................................................... 663 Failure code [DW48KA] CO Cancel Sol. Disc........................................................................... 665 Failure code [DW48KB] CO Cancel Sol. S/C............................................................................ 667 Failure code [DW7BKA] Fan Reverse Sol. Disc......................................................................... 669 Failure code [DW7BKB] Fan Reverse Sol. S/C.......................................................................... 670 Failure code [DW4XKA] Bucket Curl Hi Cancel Sol. Disc............................................................... 671 Failure code [DW4XKB] Bucket Curl Hi Cancel Sol. S/C................................................................ 673 Failure code [DWK0KA] 2-stage Relief Sol. Disc...................................................................... 675 Failure code [DWK0KB] 2-stage Relief Sol. S/C....................................................................... 677 Failure code [DX16KA] Fan Pump EPC Sol. Disc........................................................................ 679 Failure code [DX16KB] Fan Pump EPC Sol. S/C......................................................................... 681 Failure code [DXA0KA] TVC Sol. Disc................................................................................. 683 Failure code [DXA0KB] TVC Sol. S/C.................................................................................. 685 Failure code [DY20KA] Wiper Working Abnormality..................................................................... 687 Failure code [DY20MA] Wiper Parking Abnormality..................................................................... 689 Failure code [DY2CKB] Washer Drive S/C.............................................................................. 693 Failure code [DY2DKB] Wiper Drive (For) S/C......................................................................... 695 Failure code [DY2EKB] Wiper Drive (Rev) S/C......................................................................... 699 Troubleshooting of electrical system (E-mode)........................................................................... 700 E-1 Engine does not start (Engine does not rotate).................................................................. 702 E-2 Preheater does not operate...................................................................................... 705 E-3 Auto engine warm-up device does not work........................................................................ 707 E-4 Auto-decelerator does not operate............................................................................... 708 E-5 All work equipment, swing and travel do not move................................................................ 709 E-6 Power max. function does not operate............................................................................ 711 E-7 Machine push-up function does not operate normally.............................................................. 712 E-8 Any item is not displayed on machine monitor.................................................................... 714 E-9 Part of display on machine monitor is missing................................................................... 715 E-10 Machine monitor displays contents irrelevant to the model...................................................... 715 E-11 Fuel level monitor red lamp lights up while engine is running.................................................. 716 E-12 Engine coolant temperature gauge does not display correctly.................................................... 717 E-13 Hydraulic oil temperature gauge does not display correctly..................................................... 719 E-14 Fuel gauge does not display correctly.......................................................................... 720 E-15 Swing lock monitor does not display correctly.................................................................. 721 E-16 When monitor switch is operated, nothing is displayed.......................................................... 723 E-17 Wiper and window washer do not work............................................................................ 725 E-18 "Boom Raise" is not correctly displayed in monitoring function................................................. 733 E-19 "Boom Lower" is not correctly displayed in monitoring function................................................. 735 E-20 "Arm IN" is not correctly displayed in monitoring function..................................................... 737 E-21 "Arm OUT" is not correctly displayed in monitoring function.................................................... 738 E-22 "Bucket CURL" is not correctly displayed in monitoring function................................................ 739 E-23 "Bucket DUMP" is not correctly displayed in monitoring function................................................ 740 E-24 "Swing" is not correctly displayed in monitoring function...................................................... 741 E-25 "Travel" is not correctly displayed in monitoring function..................................................... 743 E-26 Air conditioner does not work.................................................................................. 745 E-27 Step light does not light up or go off......................................................................... 747 E-28 Electric grease gun does not operate........................................................................... 751 E-29 Travel alarm does not sound or does not stop sounding.......................................................... 753 E-30 Horn does not sound............................................................................................ 755 E-31 Bottom dump does not move...................................................................................... 757 Troubleshooting of hydraulic and mechanical system (H-mode)............................................................. 760 Before troubleshooting H-mode....................................................................................... 762 Information in troubleshooting table................................................................................ 767 H-1 Speed or power of all work equipment, travel, and swing is low.................................................. 769 H-2 Engine speed lowers remarkably or engine stalls................................................................. 771 H-3 All work equipment, travel, and swing systems do not work....................................................... 773 H-4 Abnormal sound is heard from around pump........................................................................ 775 H-5 Auto-decelerator is not reset................................................................................... 776 H-6 Boom speed or power is low...................................................................................... 777 H-7 Arm speed or power is low....................................................................................... 779 H-8 Bucket speed or power is low.................................................................................... 780 H-9 Boom does not move.............................................................................................. 781 H-10 Arm does not move.............................................................................................. 781 H-11 Bucket does not move........................................................................................... 782 H-12 Bottom dump does not move...................................................................................... 782 H-13 Hydraulic drift of work equipment is large..................................................................... 783 H-14 Time lag of work equipment is large............................................................................ 784 H-15 Power max. function does not operate or stop................................................................... 785 H-16 Machine push-up function does not operate or stop.............................................................. 785 H-17 When arm and boom, bucket are operated simultaneously, boom, bucket speed is low............................... 786 H-18 When bucket and boom, arm, swing, travel are operated simultaneously, boom, arm, swing, travel speed is low.... 786 H-19 When arm and swing are operated simultaneously, swing speed is low............................................. 787 H-20 Machine deviates in one direction.............................................................................. 788 H-21 Machine deviates largely at start.............................................................................. 790 H-22 Travel deviation is large during compound operation............................................................ 791 H-23 Travel speed or power is low................................................................................... 792 H-24 Machine does not travel (only one track)....................................................................... 793 H-25 Travel speed does not change................................................................................... 794 H-26 Upper structure does not swing................................................................................. 795 H-27 Swing speed or acceleration is low............................................................................. 796 H-28 Upper structure overruns excessively when it stops swinging.................................................... 797 H-29 Large shock is made when upper structure stops swinging........................................................ 798 H-30 Large abnormal sound is made when upper structure stops swinging............................................... 799 H-31 Hydraulic drift of swing is large.............................................................................. 800 Troubleshooting of engine (S-mode)...................................................................................... 802 Method of using troubleshooting chart............................................................................... 804 S-1 Starting performance is poor.................................................................................... 807 S-2 Engine does not start........................................................................................... 809 S-3 Engine does not pick up smoothly................................................................................ 813 S-4 Engine stops during operations.................................................................................. 814 S-5 Engine does not rotate smoothly................................................................................. 815 S-6 Engine lacks output (or lacks power)............................................................................ 816 S-7 Exhaust smoke is black (incomplete combustion).................................................................. 817 S-8 Oil consumption is excessive (or exhaust smoke is blue)......................................................... 818 S-9 Oil becomes contaminated quickly................................................................................ 819 S-10 Fuel consumption is excessive.................................................................................. 820 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).......................................... 821 S-12 Oil pressure drops............................................................................................. 822 S-13 Oil level rises (Entry of coolant or fuel)..................................................................... 823 S-14 Coolant temperature becomes too high (overheating)............................................................. 825 S-15 Abnormal noise is made......................................................................................... 826 S-16 Vibration is excessive......................................................................................... 827 50 Disassembly and assembly................................................................................................. 0 General information on disassembly and assembly......................................................................... 830 How to read this manual............................................................................................. 831 Coating materials list.............................................................................................. 833 Special tools list.................................................................................................. 836 Sketches of special tools........................................................................................... 842 Engine and cooling system, Part 1....................................................................................... 850 Removal and installation of fuel supply pump assembly............................................................... 851 Removal and installation of cylinder head assembly.................................................................. 857 Removal and installation of fuel injector assembly.................................................................. 873 Removal and installation of engine front seal....................................................................... 876 Removal and installation of engine rear seal........................................................................ 880 Engine and cooling system, Part 2....................................................................................... 886 Removal and installation of engine, PTO and hydraulic pump assembly................................................. 887 Removal and installation of radiator assembly....................................................................... 894 Removal and installation of hydraulic oil cooler assembly........................................................... 896 Removal and installation of aftercooler assembly.................................................................... 898 Removal and installation of fan motor assembly...................................................................... 900 Removal and installation of fuel tank assembly...................................................................... 904 Power train............................................................................................................. 906 Removal and installation of PTO assembly............................................................................ 907 Disassembly and assembly of PTO assembly............................................................................ 909 Removal and installation of swing motor and swing machinery assembly................................................ 912 Disassembly and assembly of swing machinery assembly................................................................ 913 Removal and installation of swing circle assembly................................................................... 920 Disassembly and assembly of final drive assembly.................................................................... 921 Undercarriage and frame................................................................................................. 932 Removal and installation of track shoe assembly..................................................................... 933 Disassembly and assembly of 1 link in field......................................................................... 935 Removal and installation of idler, recoil spring assembly........................................................... 939 Disassembly and assembly of idler assembly.......................................................................... 940 Disassembly and assembly of recoil spring assembly.................................................................. 943 Removal and installation of track roller assembly................................................................... 945 Disassembly and assembly of track roller assembly................................................................... 946 Removal and installation of carrier roller assembly................................................................. 949 Disassembly and assembly of carrier roller assembly................................................................. 950 Removal and installation of revolving frame assembly................................................................ 953 Removal and installation of counterweight assembly.................................................................. 955 Removal and installation of counterweight remover assembly.......................................................... 956 Hydraulic system........................................................................................................ 960 Removal and installation of hydraulic tank assembly................................................................. 961 Removal and installation of hydraulic pump assembly................................................................. 963 Removal and installation of control valve and solenoid valve assembly............................................... 966 Disassembly and assembly of control valve assembly.................................................................. 968 Disassembly and assembly of main control valve assembly............................................................. 969 Removal and installation of swing motor assembly.................................................................... 973 Removal and installation of center swivel joint assembly............................................................ 974 Disassembly and assembly of center swivel joint assembly............................................................ 975 Disassembly and assembly of work equipment PPC valve assembly....................................................... 977 Disassembly and assembly of travel PPC valve assembly............................................................... 979 Disassembly and assembly of hydraulic cylinder assembly............................................................. 982 Disassembly and assembly of grease gun assembly..................................................................... 988 Work equipment.......................................................................................................... 990 Removal and installation of bucket cylinder assembly (Backhoe specification)........................................ 991 Removal and installation of bucket cylinder assembly (Loading shovel specification)................................. 993 Removal and installation of arm cylinder assembly (Backhoe specification)........................................... 995 Removal and installation of arm cylinder assembly (Loading shovel specification).................................... 997 Removal and installation of boom cylinder assembly (Backhoe specification).......................................... 999 Removal and installation of boom cylinder assembly (Loading shovel specification)...................................1001 Removal and installation of bottom dump cylinder assembly (Loading shovel specification)............................1003 Removal and installation of bucket assembly (Backhoe specification).................................................1004 Removal and installation of bucket assembly (Loading shovel specification)..........................................1006 Removal and installation of arm assembly (Backhoe specification)....................................................1007 Removal and installation of arm assembly (Loading shovel specification).............................................1009 Removal and installation of boom assembly (Backhoe specification)...................................................1010 Removal and installation of boom assembly (Loading shovel specification)............................................1012 Removal and installation of work equipment (Backhoe specification)..................................................1014 Removal and installation of work equipment (Loading shovel specification)...........................................1016 Cab and its attachments.................................................................................................1020 Removal and installation of operator’s cab..........................................................................1021 Removal and installation of operator’s cab glass (stuck glass)......................................................1024 Removal and installation of front window assembly...................................................................1034 Electrical system.......................................................................................................1040 Removal and installation of air conditioner unit assembly...........................................................1041 Removal and installation of engine controller assembly..............................................................1043 Removal and Installation of KOMTRAX terminal assembly...............................................................1045 Removal and installation of pump controller assembly................................................................1045 Removal and installation of monitor assembly........................................................................1046 90 Diagrams and drawings.................................................................................................... 0 Hydraulic diagrams and drawings.........................................................................................1048 Hydraulic circuit diagram (1/4) (Backhoe specification).............................................................1050 Hydraulic circuit diagram (2/4) (ATT specification).................................................................1051 Hydraulic circuit diagram (3/4) (Loading shovel specification)......................................................1052 Hydraulic circuit diagram (4/4) (Loading shovel specification)......................................................1053 Electrical diagrams and drawings........................................................................................1056 Electrical circuit diagram (1/6)....................................................................................1058 Electrical circuit diagram (2/6)....................................................................................1059 Electrical circuit diagram (3/6)....................................................................................1060 Electrical circuit diagram (4/6)....................................................................................1061 Electrical circuit diagram (5/6)....................................................................................1062 Electrical circuit diagram (6/6)....................................................................................1063 Connector arrangement diagram.......................................................................................1064 Electrical circuit diagram for air conditioner......................................................................1065
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⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
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