Komatsu PC600-8E0 PC600LC-8E0 PC650-8E0 PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual PDF

Description

Komatsu PC600-8E0 PC600LC-8E0 PC650-8E0 PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual SEN05377-10 – PDF DOWNLOAD

FILE DETAILS:

Komatsu PC600-8E0 PC600LC-8E0 PC650-8E0 PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual SEN05377-10 – PDF DOWNLOAD 

Language : English
Pages : 1387
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC600-8E0 PC600LC-8E0 PC650-8E0 PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual SEN05377-10 – PDF DOWNLOAD 

SERIAL NUMBERS 65001 and up

COVER 1
Notice of revision 3
00 Index and foreword 11
Table of Contents 12
Foreword and general information 22
Safety notice 22
How to read the shop manual 27
Explanation of terms for maintenance standard 29
Handling of hydraulic components 31
Method of disconnecting and connecting push-pull type coupler 33
Handling of electric equipment 36
How to read electric wire code 46
Precautions when performing work 49
Standard tightening torque table 52
List of abbreviation 56
Conversion table 60
01 Specification 65
Contents 66
Specifications 68
Specifications drawing 68
Working range drawings 70
Specifications 72
Table of weight 82
Table of fuel, coolant and lubricants 90
10 Structure and function 93
Contents 94
Engine and cooling system 95
Engine related parts 95
PTO 96
Cooling system 97
Power train system 98
Power train 98
Swing circle 100
Swing machinery 102
Final drive 104
Undercarriage and frame 106
Track frame and idler cushion 106
Hydraulic system 108
Hydraulic component layout 108
Valve control 110
Hydraulic tank and filter 112
Hydraulic pump (piston pump) 114
Cooling fan pump 142
Cooling fan motor 150
Control valve 156
Swing motor 172
Travel motor 180
PPC valve 201
Solenoid valve 209
PPC shuttle valve 216
Boom drift prevention valve 217
Boom LOWER regeneration valve 221
Arm regeneration valve 224
Quick return valve 227
Line oil filter 230
Center swivel joint 231
Accumulator 232
Electrical system 233
Engine control 233
Electrical control system 243
Monitor system 273
KOMTRAX system 299
Sensors 301
20 Standard value table 305
Contents 306
Standard value table 307
Standard value table for engine 307
Standard value table for machine 308
30 Testing and adjusting 331
Contents 332
Tool for testing, adjusting and troubleshooting 333
Tools for testing, adjusting, and troubleshooting 333
Engine and cooling system 337
Testing engine speed 337
Testing intake air pressure (boost pressure) 339
Testing exhaust gas temperature 340
Testing exhaust gas color 341
Testing and adjusting valve clearance 342
Testing compression pressure 343
Testing blowby pressure 345
Testing engine oil pressure 346
Testing EGR valve and bypass valve drive pressure 347
Handling fuel system parts 348
Releasing remaining pressure from fuel system 349
Testing fuel pressure 350
Cylinder cut-out test mode 351
No-injection cranking 352
Testing fuel return rate and leakage 353
Bleeding air from fuel circuit 356
Testing fuel circuit for leakage 358
Testing and adjusting alternator belt tension 359
Testing and adjusting air conditioner compressor belt tension 360
Undercarriage and frame 361
Testing swing circle bearing clearance 361
Checking and adjusting track tension 362
Hydraulic system 363
Testing and adjusting oil pressure in work equipment, swing and travel circuits 363
Testing and adjusting control circuit oil pressure 368
Testing and adjusting control oil pressure of piston pump 370
Testing servo piston movement 376
Testing PPC valve output pressure 378
Testing output pressure of solenoid valve and PPC shuttle valve 382
Adjusting play of work equipment and swing PPC vavles 388
Isolating the parts causing hydraulic drift in work equipment 389
Testing and adjusting travel deviation 391
Testing fan speed 393
Testing fan circuit oil pressure 394
Releasing remaining pressure from hydraulic circuit 395
Testing oil leakage 396
Bleeding air from each part 400
Electrical system 403
Special functions of machine monitor 403
Handling of voltage circuit of engine controller 447
Preparatory work for troubleshooting of electrical system 448
Inspection procedure of diode 453
Pm clinic 454
Pm Clinic service 454
UNDERCARRIAGE INSPECTION REPORT 468
40 Troubleshooting 471
Contents 472
General information on troubleshooting 478
Points to remember when troubleshooting 478
Sequence of events in troubleshooting 479
Checks before troubleshooting 480
Classification and procedures for troubleshooting 504
Failure codes table 507
Symptom and troubleshooting numbers 511
Information in troubleshooting table 514
Troubleshooting method for open circuit in wiring harness of pressure sensor system 516
Connector list and layout 518
Connection table for connector pin numbers 528
T- branch box and T- branch adapter table 564
Fuse locations 567
Troubleshooting by failure code 570
Failure code [989L00] Engine Controller Lock Caution 1 570
Failure code [989M00] Engine Controller Lock Caution 2 571
Failure code [989N00] Engine Controller Lock Caution 3 572
Failure code [AA10NX] Air Cleaner Clogging 573
Failure code [AB00KE] Charge Voltage Low 574
Failure code [B@BAZG] Eng Oil Press Low 576
Failure code [B@BAZK] Eng Oil Level Low 577
Failure code [B@BCNS] Eng Water Overheat 578
Failure code [B@BCZK] Eng Water Level Low 580
Failure code [B@HANS] Hyd Oil Overheat 582
Failure code [CA111] ECM Critical Internal Failure 584
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 586
Failure code [CA122] Chg Air Press Sensor High Error 588
Failure code [CA123] Chg Air Press Sensor Low Error 590
Failure code [CA131] Throttle Sensor High Error 592
Failure code [CA132] Throttle Sensor Low Error 594
Failure code [CA135] Eng Oil Press Sensor High Error 596
Failure code [CA141] Eng Oil Press Sensor Low Error 598
Failure code [CA144] Coolant Temp Sens High Error 600
Failure code [CA145] Coolant Temp Sens Low Error 602
Failure code [CA153] Chg Air Temp Sensor High Error 604
Failure code [CA154] Chg Air Temp Sensor Low Error 606
Failure code [CA187] Sens Supply 2 Volt Low Error 608
Failure code [CA221] Ambient Press Sens High Error 610
Failure code [CA222] Ambient Press Sens Low Error 612
Failure code [CA227] Sens Supply 2 Volt High Error 614
Failure code [CA234] Eng Overspeed 615
Failure code [CA238] Ne Speed Sens Supply Volt Error 616
Failure code [CA263] Fuel Temp Sensor High Error 618
Failure code [CA265] Fuel Temp Sensor Low Error 620
Failure code [CA271] IMV/PCV1 Short Error 622
Failure code [CA272] IMV/PCV1 Open Error 623
Failure code [CA273] PCV2 Short Error 624
Failure code [CA274] PCV2 Open Error 625
Failure code [CA322] Inj #1(L#1) Open/Short Error 626
Failure code [CA323] Inj #5 (L#5) Open/Short Error 628
Failure code [CA324] Inj #3(L#3) Open/Short Error 630
Failure code [CA325] Inj #6 (L#6) Open/Short Error 632
Failure code [CA331] Inj #2(L#2) Open/Short Error 634
Failure code [CA332] Inj #4 (L#4) Open/Short Error 636
Failure code [CA342] Calibration Code Incompatibility 638
Failure code [CA351] Injectors Drive Circuit Error 639
Failure code [CA352] Sens Supply 1 Volt Low Error 640
Failure code [CA386] Sens Supply 1 Volt High Error 642
Failure code [CA441] Battery Voltage Low Error 642
Failure code [CA442] Battery Voltage High Error 643
Failure code [CA449] Rail Press Very High Error 643
Failure code [CA451] Rail Press Sensor High Error 644
Failure code [CA452] Rail Press Sensor Low Error 646
Failure code [CA553] Rail Press High Error 648
Failure code [CA554] Rail Press Sensor In Range Error 648
Failure code [CA559] Supply Pump Press Low Error 1 649
Failure code [CA689] Eng Ne Speed Sensor Error 652
Failure code [CA731] Eng Bkup Speed Sens Phase Error 654
Failure code [CA757] All Continuous Data Lost Error 655
Failure code [CA778] Eng Bkup Speed Sensor Error 656
Failure code [CA1228] EGR Valve Servo Error 1 658
Failure code [CA1625] EGR Valve Servo Error 2 659
Failure code [CA1626] BP Valve Sol Current High Error 660
Failure code [CA1627] BP Valve Sol Current Low Error 662
Failure code [CA1628] Bypass Valve Servo Error 1 664
Failure code [CA1629] Bypass Valve Servo Error 2 665
Failure code [CA1631] BP Valve Pos Sens High Error 666
Failure code [CA1632] BP Valve Pos Sens Low Error 668
Failure code [CA1633] KOMNET Datalink Timeout Error 670
Failure code [CA2185] Throt Sens Sup Volt High Error 672
Failure code [CA2186] Throt Sens Sup Volt Low Error 674
Failure code [CA2249] Rail Press Very Low Error 675
Failure code [CA2271] EGR Valve Pos Sens High Error 676
Failure code [CA2272] EGR Valve Pos Sens Low Error 678
Failure code [CA2351] EGR Valve Sol Current High Error 680
Failure code [CA2352] EGR Valve Sol Current Low Error 682
Failure code [CA2555] Grid Htr Relay Open Circuit Error 684
Failure code [CA2556] Grid Htr Relay Short Circuit Error 686
Failure code [D110KB] Battery Relay Drive Short Circuit 688
Failure code [D163KB] Flash Light Relay Short Circuit 690
Failure code [D195KA] Step Light Relay Open Circuit 692
Failure code [D195KB] Step Light Relay Short Circuit 694
Failure code [D19JKZ] Personal code relay abnormality 696
Failure code [D862KA] GPS Antenna Open Circuit 698
Failure code [DA22KK] Pump Solenoid Power Low Error 700
Failure code [DA25KP] 5V Sensor1 Power Abnormality 702
Failure code [DA29KQ] Model Selection Abnormality 704
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 706
Failure code [DA80MA] Auto Lub Abnormal 710
Failure code [DAF8KB] Camera Power Supply Short Circuit 712
Failure code [DAFGMC] GPS Module Error 714
Failure code [DAFRMC] CAN Discon (Monitor Detected) 715
Failure code [DGE5KB] Ambi Temp Sensor Short Circuit 720
Failure code [DGH2KB] Hyd Oil Sensor Short 722
Failure code [DHPAMA] F Pump Press Sensor Abnormality 724
Failure code [DHPBMA] R Pump Press Sensor Abnormality 726
Failure code [DV20KB] Travel alarm short circuit 728
Failure code [DW43KA] Travel Speed Sol Open Circuit 730
Failure code [DW43KB] Travel Speed Sol Short Circuit 732
Failure code [DW45KA] Swing Brake Sol Open Circuit 734
Failure code [DW45KB] Swing Brake Sol Short Circuit 736
Failure code [DW48KA] CO Cancel Sol Open Circuit 738
Failure code [DW48KB] CO Cancel Sol Short Circuit 740
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Open Circuit 742
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol Short Circuit 744
Failure code [DW7BKA] Fan Reverse Sol Open Circuit 746
Failure code [DW7BKB] Fan Reverse Sol Short Circuit 748
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 750
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 752
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit 754
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit 755
Failure code [DXA0KA] TVC Sol Open Circuit 756
Failure code [DXA0KB] TVC Sol Short Circuit 758
Failure code [DY20KA] Wiper Working Abnormality 760
Failure code [DY20MA] Wiper Parking Abnormality 764
Failure code [DY2CKA] Washer Drive Open Circuit 766
Failure code [DY2CKB] Washer Drive Short Circuit 768
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 770
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 774
Failure code [DY2FMA] Upper Wiper Working Abnormality 778
Failure code [DY2GKM] Wiper Select Abnormality 780
Troubleshooting of electrical system (E-mode) 784
E-1 Engine does not start (Engine does not crank) 784
E-2 Preheater does not operate 789
E-3 When starting switch is turned to ON position, machine monitor displays nothing 793
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up 796
E-5 Precaution item lights up while engine is running 798
E-6 Emergency stop item lights up while engine is running 800
E-7 Engine coolant temperature gauge does not indicate properly 801
E-8 Fuel gauge does not indicate properly 802
E-9 Hydraulic oil temperature gauge does not indicate properly 804
E-10 Content of display on machine monitor is different from that of actual machine 806
E-11 Some areas of machine monitor screen are not displayed 806
E-12 Function switch does not operate 806
E-13 Automatic warm-up system does not operate (in cold season) 807
E-14 Auto-decelerator does not operate properly 808
E-15 Working mode does not change 809
E-16 Travel speed does not change 810
E-17 Alarm buzzer cannot be canceled 811
E-18 When starting switch is turned OFF, service meter is not displayed 811
E-19 Service mode cannot be selected 811
E-20 Any of work equipment, swing and travel does not work or cannot be locked 812
E-21 Machine push-up function does not work or cannot be canceled 814
E-22 Boom shockless function does not operate normally 816
E-23 Swing brake does not operate normally 818
E-24 Windshield wiper and window washer do not operate 820
E-25 Travel alarm does not sound or does not stop sounding 823
E-26 BOOM RAISE indicator is not displayed properly with monitoring function 824
E-27 BOOM LOWER indicator is not displayed properly with monitoring function 826
E-28 ARM IN indicator is not displayed properly with monitoring function 828
E-29 ARM DUMP indicator is not displayed properly with monitoring function 830
E-30 BUCKET CURL indicator is not displayed properly with monitoring function 832
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function 834
E-32 Swing indicator is not displayed properly with monitoring function 836
E-33 Travel indicator is not displayed properly with monitoring function 838
E-34 “Service” is not displayed normally by monitoring function 840
E-35 Electric grease gun does not operate 842
E-36 KOMTRAX system does not operate normally 843
E-37 Bottom dump does not operate properly 844
E-38 Horn does not sound or does not stop sounding 847
E-39 Step light does not light up or go off 850
Troubleshooting of hydraulic and mechanical system (H-mode) 854
Before troubleshooting for hydraulic and mechanical systems 854
Information in troubleshooting table (H-mode) 859
H-1 All of work equipment, travel and swing work slow or lack power 860
H-2 Engine speed lowers significantly or engine stalls 862
H-3 Any of work equipment, swing and travel does not work 864
H-4 Unusual noise is heard from around hydraulic pump 866
H-5 Auto-decelerator is not canceled 867
H-6 Speed or power of boom is low 868
H-7 Speed or power of arm is low 870
H-8 Speed or power of bucket is low 871
H-9 Boom does not move 872
H-10 Arm does not move 872
H-11 Bucket does not move 873
H-12 Bottom dump does not move 873
H-13 Hydraulic drift of work equipment is large 874
H-14 Time lag of work equipment is large 875
H-15 One-touch power maximizing function does not work or is not canceled 876
H-16 Machine push-up function does not work or is not canceled 876
H-17 Boom/bucket speed is low at combined operation of arm and boom or bucket 876
H-18 Speed of boom, arm, swing and travel is low at combined operation of bucket and boom, arm, swing and travel 877
H-19 Swing speed is low at combined operation of arm and swing 877
H-20 Machine deviates during travel 878
H-21 Machine deviates significantly at start 881
H-22 Machine deviates significantly during combined operation 882
H-23 Travel speed or travel power is low 883
H-24 One of tracks does not run (on one side alone) 884
H-25 Travel speed does not change 885
H-26 Upper structure does not swing 886
H-27 Swing speed is low or acceleration is poor 887
H-28 Upper structure overruns excessively when it stops swinging 888
H-29 Shock is large when upper structure stops swinging 889
H-30 Large unusual noise is heard when upper structure stops swinging 890
H-31 Hydraulic drift of swing is large 891
Troubleshooting of engine (S-mode) 892
Method of using troubleshooting chart 892
S-1 Startability is poor 896
S-2 Engine does not start 898
S-3 Engine does not pick up smoothly 902
S-4 Engine stops during operation 903
S-5 Engine runs rough or is unstable 904
S-6 Engine lacks power 906
S-7 Exhaust smoke is black (incomplete combustion) 908
S-8 Oil consumption is excessive (or exhaust smoke is blue) 910
S-9 Oil becomes contaminated early 911
S-10 Fuel consumption is excessive 912
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) 913
S-12 Oil pressure drops 914
S-13 Oil level rises (coolant or fuel in oil) 916
S-14 Coolant temperature rises too high (overheating) 918
S-15 Unusual noise is made 919
S-16 Vibration is excessive 920
50 Disassembly and assembly 921
Contents 922
General information on disassembly and assembly 924
How to read Disassembly and Assembly 924
Coating materials list 926
Special tools list 929
Sketches of special tools 936
Engine and cooling system 944
Removal and installation of fuel supply pump assembly 944
Removal and installation of fuel injector assembly 950
Removal and installation of cylinder head assembly 953
Removal and installation of radiator assembly 970
Removal and installation of hydraulic oil cooler assembly 972
Removal and installation of aftercooler assembly 974
Removal and installation of engine front seal 976
Removal and installation of engine rear seal 980
Removal and installation of engine, PTO and hydraulic pump assembly 985
Removal and installation of cooling fan motor assembly 993
Removal and installation of fuel tank assembly 997
Power train 998
Removal and installation of PTO assembly 998
Disassembly and assembly of PTO assembly 1000
Disassembly and assembly of final drive assembly 1003
Removal and installation of swing motor and swing machinery assembly 1026
Disassembly and assembly of swing machinery assembly 1028
Removal and installation of swing circle assembly 1043
Undercarriage and frame 1044
Separation and connection of track shoe assembly 1044
Disassembly and assembly of one link in field 1048
Removal and installation of idler assembly 1052
Disassembly and assembly of idler assembly 1054
Removal and installation of idler cushion assembly 1061
Disassembly and assembly of idler cushion assembly 1064
Removal and installation of track roller assembly 1068
Disassembly and assembly of track roller assembly 1070
Removal and installation of carrier roller assembly 1076
Disassembly and assembly of carrier roller assembly 1078
Removal and installation of revolving frame assembly 1084
Removal and installation of counterweight assembly 1086
Removal and installation of counterweight remover assembly 1087
Hydraulic system 1089
Removal and installation of center swivel joint assembly 1089
Disassembly and assembly of center swivel joint assembly 1090
Removal and installation of hydraulic tank assembly 1092
Removal and installation of hydraulic pump assembly 1094
Removal and installation of control valve assembly 1097
Disassembly and assembly of control valve assembly 1099
Removal and installation of swing motor assembly 1101
Disassembly and assembly of work equipment PPC valve assembly 1102
Disassembly and assembly of travel PPC valve assembly 1104
Disassembly and assembly of grease gun assembly 1106
Work equipment 1107
Removal and installation of bucket cylinder assembly 1107
Removal and installation of arm cylinder assembly 1111
Removal and installation of boom cylinder assembly 1115
Removal and installation of bottom dump cylinder assembly 1119
Removal and installation of bucket assembly 1121
Removal and installation of arm assembly 1125
Removal and installation of boom assembly 1128
Removal and installation of work equipment assembly 1132
Removal and installation of anti- drop valve assembly for boom 1136
Removal and installation of anti- drop valve assembly for arm 1139
Disassembly and assembly anti- drop valve assembly 1142
Disassembly and assembly of work equipment cylinder assembly 1144
Cab and its attachments 1150
Removal and installation of operator’s cab assembly 1150
Removal and installation of operator’s cab glass (adhered window glass) 1154
Removal and installation of front window assembly 1164
Removal and installation of air conditioner unit assembly 1171
Electrical system 1175
Removal and installation of air conditioner compressor assembly 1175
Removal and installation of air conditioner condenser assembly 1178
Removal and installation of engine controller assembly 1180
Removal and installation of pump controller assembly 1182
Removal and installation of KOMTRAX terminal assembly 1184
Removal and installation of machine monitor assembly 1185
60 Maintenance standard 1187
Contents 1188
Engine and cooling system 1189
Engine mount 1189
PTO 1191
Cooling system 1192
Power train 1193
Swing circle 1193
Swing machinery 1194
Final drive 1196
Sprocket 1198
Undercarriage and frame 1202
Track frame and idler cushion 1202
Idler 1204
Track roller 1208
Carrier roller 1211
Track shoe 1214
Hydraulic system 1224
Hydraulic pump 1224
Control valve 1234
Swing motor 1240
Travel motor 1241
PPC valve 1244
Boom drift prevention valve 1251
Regeneration valve (boom, arm) 1252
Center swivel joint 1253
Work equipment 1254
Work equipment 1254
Work equipment dimension 1258
Work equipment cylinder 1264
80 Appendix 1269
Table of contents 1270
Air conditioner 1271
Precautions for refrigerant 1271
Air conditioner component 1272
Configuration and function of refrigeration cycle 1274
Outline of refrigeration cycle 1275
Air conditioner unit 1278
Air conditioner controller 1283
Compressor 1284
Condenser 1285
Receiver drier 1286
Procedure for testing and troubleshooting 1288
Circuit diagram and arrangement of connector pins 1290
System diagram 1292
Detail of air conditioner unit 1294
Parts and connectors layout 1296
Testing air leakage (duct) 1299
Testing with self-diagnosis function 1300
Testing temperature control 1303
Testing vent (mode) changeover 1305
Testing FRESH/RECIRC air changeover 1308
Testing inner sensor 1310
Testing evaporator temperature sensor 1311
Testing sunlight sensor 1313
Testing (dual) pressure switch for refrigerant 1314
Testing relays 1315
Troubleshooting chart 1 1316
Troubleshooting chart 2 1318
Information in troubleshooting table 1320
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 1322
Troubleshooting for compressor and refrigerant system (Air is not cooled) 1327
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1331
Troubleshooting for temperature control 1335
Troubleshooting for vent (mode) changeover 1338
Troubleshooting for FRESH/RECIRC air changeover 1340
Troubleshooting for temperature sensor system 1342
Troubleshooting with gauge pressure 1343
Connection of service tool 1346
Precautions for disconnecting and connecting air conditioner piping 1348
Handling of compressor oil 1350
90 Diagrams and drawings 1353
Contents 1354
Hydraulic circuit diagram 1355
Symbols used in hydraulic circuit diagrams 1355
Hydraulic circuit diagram 1359
Electrical circuit diagram 1363
Symbols used in electric circuit diagrams 1363
Electrical circuit diagram 1367
Air conditioner electrical circuit diagram 1379
Index 1380
A 1380
B 1380
C 1380
D 1380
E 1380
F 1381
H 1382
I 1383
K 1383
L 1383
M 1383
N 1383
O 1383
P 1383
Q 1383
R 1383
S 1384
T 1384
U 1385
V 1385
W 1385

DESCRIPTION:

Komatsu PC600-8E0 PC600LC-8E0 PC650-8E0 PC650LC-8E0 PC700LC-8E0 Excavator Shop Manual SEN05377-10 – PDF DOWNLOAD 

SERIAL NUMBERS 65001 and up

How to read the shop manual
1. Composition of shop manual
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 contains the index, foreword, safety and basic information. If any revision is made, the LIST
OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding
for the structure of each component, but also serves as reference material for troubleshooting.
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 tools and measuring methods for testing and adjusting, as well as the
adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
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.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section
explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.

S.V 29/12/24