Komatsu PC600-8R1,PC600LC-8R1,PC700LC-8R Excavator Shop Manual PDF

Description

Komatsu PC600-8R1,PC600LC-8R1,PC700LC-8R Hydraulic Excavator Shop Manual SEN05660-09 – PDF DOWNLOAD

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Komatsu PC600-8R1,PC600LC-8R1,PC700LC-8R Hydraulic Excavator Shop Manual SEN05660-09 – PDF DOWNLOAD

Language : English
Pages :1378
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu PC600-8R1,PC600LC-8R1,PC700LC-8R Hydraulic Excavator Shop Manual SEN05660-09 – PDF DOWNLOAD

• SERIAL NUMBERS 70001 and up

Cover . 1
00 Index and foreword . 3
Table of Contents . 4
Foreword, safety and general information 14
Important safety notice . 14
How to read the shop manual . 21
Explanation of terms for maintenance standard . 23
Handling equipment of fuel system devices . 25
Handling of intake system parts . 26
Handling of hydraulic components 27
Method of disconnecting and connecting push-pull type coupler . 29
Handling of electric equipment 32
How to read electric wire code 41
Precautions when performing operation . 44
Practical use of KOMTRAX 47
Precautions when performing work 48
Standard tightening torque table 51
List of abbreviation 55
Conversion table 60
01 Specification 65
Contents 66
Specifications 68
Specifications drawing 68
Working range drawings 70
Specifications 72
Table of weight . 80
Table of fuel, coolant and lubricants . 86
10 Structure and function . 89
Contents 90
Engine and cooling system . 91
Engine related parts 91
PTO . 92
Cooling system 93
Power train system 94
Power train . 94
Swing circle 96
Swing machinery . 98
Final drive . 100
Undercarriage and frame . 102
Track frame and idler cushion . 102
Hydraulic system 104
Hydraulic component layout 104
Valve control . 106
Hydraulic tank and filter . 108
Hydraulic pump (piston pump) 110
Cooling fan pump 138
Cooling fan motor . 146
Control valve . 152
Swing motor . 168
Travel motor 176
PPC valve . 197
Solenoid valve 205
PPC shuttle valve . 212
Boom drift prevention valve . 213
Boom LOWER regeneration valve . 217
Arm regeneration valve 220
Quick return valve 223
Line oil filter . 226
Center swivel joint . 227
Accumulator . 228
Electrical system . 229
Engine control 229
Electrical control system . 237
Monitor system 267
KOMTRAX system 293
Sensors . 295
20 Standard value table . 299
Contents 300
Standard value table 301
Standard value table for engine . 301
Standard value table for machine 302
30 Testing and adjusting 325
Contents 326
Tool for testing, adjusting and troubleshooting . 327
Tools for testing, adjusting, and troubleshooting . 327
Engine and cooling system . 331
Testing engine speed 331
Testing intake air pressure (boost pressure) 333
Testing exhaust gas temperature . 334
Testing exhaust gas color . 335
Testing and adjusting valve clearance . 336
Testing compression pressure 337
Testing blowby pressure . 339
Testing engine oil pressure . 340
Handling fuel system parts 341
Releasing remaining pressure from fuel system . 342
Testing fuel pressure . 343
Cylinder cut-out test mode 344
No-injection cranking . 345
Testing fuel return rate and leakage 346
Bleeding air from fuel circuit 349
Testing fuel circuit for leakage 351
Testing and adjusting alternator belt tension . 352
Testing and adjusting air conditioner compressor belt tension . 353
Undercarriage and frame . 354
Testing swing circle bearing clearance 354
Checking and adjusting track tension 355
Hydraulic system 356
Testing and adjusting oil pressure in work equipment, swing and travel circuits . 356
Testing and adjusting control circuit oil pressure 361
Testing and adjusting control oil pressure of piston pump . 363
Testing servo piston movement . 369
Testing PPC valve output pressure . 370
Testing output pressure of solenoid valve and PPC shuttle valve . 374
Adjusting play of work equipment and swing PPC vavles . 380
Isolating the parts causing hydraulic drift in work equipment . 381
Testing and adjusting travel deviation 383
Testing fan speed . 385
Testing fan circuit oil pressure 386
Releasing remaining pressure from hydraulic circuit . 387
Testing oil leakage . 388
Bleeding air from each part . 392
Electrical system . 395
Special functions of machine monitor 395
Handling of voltage circuit of engine controller 439
Preparatory work for troubleshooting of electrical system . 440
Inspection procedure of diode . 445
Pm clinic . 446
Pm Clinic service . 446
UNDERCARRIAGE INSPECTION REPORT . 458
40 Troubleshooting 461
Contents 462
General information on troubleshooting 468
Points to remember when troubleshooting . 468
Sequence of events in troubleshooting . 469
Checks before troubleshooting . 470
Classification and procedures for troubleshooting . 494
Failure codes table . 497
Symptom and troubleshooting numbers . 501
Information in troubleshooting table 504
Troubleshooting method for open circuit in wiring harness of pressure sensor system . 506
Connector list and layout . 508
Connection table for connector pin numbers 518
T- branch box and T- branch adapter table . 554
Fuse locations 557
Troubleshooting by failure code . 560
Failure code [989L00] Engine Controller Lock Caution 1 560
Failure code [989M00] Engine Controller Lock Caution 2 561
Failure code [989N00] Engine Controller Lock Caution 3 562
Failure code [AA10NX] Air Cleaner Clogging 563
Failure code [AB00KE] Charge Voltage Low 564
Failure code [B@BAZG] Eng Oil Press Low . 566
Failure code [B@BAZK] Eng Oil Level Low . 567
Failure code [B@BCNS] Eng Water Overheat 568
Failure code [B@BCZK] Eng Water Level Low . 570
Failure code [B@HANS] Hyd Oil Overheat 572
Failure code [CA111] ECM Critical Internal Failure 574
Failure code [CA115] Eng Ne and Bkup Speed Sens Error . 576
Failure code [CA122] Chg Air Press Sensor High Error 578
Failure code [CA123] Chg Air Press Sensor Low Error . 580
Failure code [CA131] Throttle Sensor High Error . 582
Failure code [CA132] Throttle Sensor Low Error 584
Failure code [CA135] Eng Oil Press Sensor High Error 586
Failure code [CA141] Eng Oil Press Sensor Low Error . 588
Failure code [CA144] Coolant Temp Sens High Error . 590
Failure code [CA145] Coolant Temp Sens Low Error 592
Failure code [CA153] Chg Air Temp Sensor High Error . 594
Failure code [CA154] Chg Air Temp Sensor Low Error 596
Failure code [CA187] Sens Supply 2 Volt Low Error . 598
Failure code [CA221] Ambient Press Sens High Error 600
Failure code [CA222] Ambient Press Sens Low Error . 602
Failure code [CA227] Sens Supply 2 Volt High Error 604
Failure code [CA234] Eng Overspeed 605
Failure code [CA238] NE Speed Sens Supply Volt Error 606
Failure code [CA263] Fuel Temp Sensor High Error 608
Failure code [CA265] Fuel Temp Sensor Low Error . 610
Failure code [CA271] IMV/PCV1 Short Error . 612
Failure code [CA272] IMV/PCV1 Open Error 613
Failure code [CA273] PCV2 Short Error . 614
Failure code [CA274] PCV2 Open Error 615
Failure code [CA322] Inj #1(L#1) Open/Short Error . 616
Failure code [CA323] Inj #5 (L#5) Open/Short Error 618
Failure code [CA324] Inj #3(L#3) Open/Short Error . 620
Failure code [CA325] Inj #6 (L#6) Open/Short Error 622
Failure code [CA331] Inj #2(L#2) Open/Short Error . 624
Failure code [CA332] Inj #4 (L#4) Open/Short Error 626
Failure code [CA342] Calibration Code Incompatibility . 628
Failure code [CA351] Injectors Drive Circuit Error 629
Failure code [CA352] Sens Supply 1 Volt Low Error . 630
Failure code [CA386] Sens Supply 1 Volt High Error 632
Failure code [CA441] Battery Voltage Low Error 632
Failure code [CA442] Battery Voltage High Error . 633
Failure code [CA449] Rail Press Very High Error . 633
Failure code [CA451] Rail Press Sensor High Error . 634
Failure code [CA452] Rail Press Sensor Low Error 636
Failure code [CA553] Rail Press High Error 638
Failure code [CA554] Rail Press Sensor In Range Error . 638
Failure code [CA559] Supply Pump Press Low Error 1 639
Failure code [CA689] Eng NE Speed Sensor Error 642
Failure code [CA731] Eng Bkup Speed Sens Phase Error 644
Failure code [CA757] All Continuous Data Lost Error . 645
Failure code [CA778] Eng Bkup Speed Sensor Error 646
Failure code [CA1633] KOMNET Datalink Timeout Error . 648
Failure code [CA2185] Throt Sens Sup Volt High Error 650
Failure code [CA2186] Throt Sens Sup Volt Low Error . 652
Failure code [CA2249] Rail Press Very Low Error . 653
Failure code [CA2555] Grid Htr Relay Open Circuit Error . 654
Failure code [CA2556] Grid Htr Relay Short Circuit Error 656
Failure code [D110KB] Battery Relay Drive Short Circuit . 658
Failure code [D163KB] Flash Light Relay Short Circuit . 660
Failure code [D195KA] Step Light Relay Open Circuit . 662
Failure code [D195KB] Step Light Relay Short Circuit 664
Failure code [D19JKZ] Personal code relay abnormality . 666
Failure code [D862KA] GPS Antenna Open Circuit 669
Failure code [DA22KK] Pump Solenoid Power Low Error . 670
Failure code [DA25KP] 5V Sensor1 Power Abnormality 672
Failure code [DA29KQ] Model Selection Abnormality . 674
Failure code [DA2RMC] CAN Discon (Pump Con Detected) 676
Failure code [DA80MA] Auto. Lub. Abnormal . 680
Failure code [DAF8KB] Camera Power Supply Short Circuit . 682
Failure code [DAFGMC] GPS Module Error 684
Failure code [DAFRMC] CAN Discon (Monitor Detected) . 685
Failure code [DGE5KB] Ambi. Temp Sensor Short Circuit . 690
Failure code [DGH2KB] Hyd Oil Sensor Short 692
Failure code [DHPAMA] F Pump Press Sensor Abnormality . 694
Failure code [DHPBMA] R Pump Press Sensor Abnormality . 696
Failure code [DV20KB] Travel alarm short circuit 698
Failure code [DW43KA] Travel Speed Sol Open Circuit . 700
Failure code [DW43KB] Travel Speed Sol Short Circuit 702
Failure code [DW45KA] Swing Brake Sol Open Circuit 704
Failure code [DW45KB] Swing Brake Sol Short Circuit . 706
Failure code [DW48KA] CO Cancel Sol Open Circuit 708
Failure code [DW48KB] CO Cancel Sol Short Circuit . 710
Failure code [DW4XKA] Bucket Curl Hi Cancel Sol Open Circuit 712
Failure code [DW4XKB] Bucket Curl Hi Cancel Sol Short Circuit . 714
Failure code [DW7BKA] Fan Reverse Sol Open Circuit 716
Failure code [DW7BKB] Fan Reverse Sol Short Circuit . 718
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit . 720
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 722
Failure code [DX16KA] Fan Pump EPC Sol Open Circuit . 724
Failure code [DX16KB] Fan Pump EPC Sol Short Circuit 725
Failure code [DXA0KA] TVC Sol Open Circuit 726
Failure code [DXA0KB] TVC Sol Short Circuit . 728
Failure code [DY20KA] Wiper Working Abnormality . 730
Failure code [DY20MA] Wiper Parking Abnormality . 734
Failure code [DY2CKA] Washer Drive Open Circuit . 736
Failure code [DY2CKB] Washer Drive Short Circuit 738
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit . 740
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit . 744
Failure code [DY2FMA] Upper Wiper Working Abnormality . 748
Failure code [DY2GKM] Wiper Select Abnormality 750
Troubleshooting of electrical system (E-mode) . 754
E-1 Engine does not start (Engine does not crank) . 754
E-2 Preheater does not operate 759
E-3 When starting switch is turned to ON position, machine monitor displays nothing . 763
E-4 When starting switch is turned to ON position (before starting engine), basic check monitor lights up . 766
E-5 Precaution item lights up while engine is running . 768
E-6 Emergency stop item lights up while engine is running . 770
E-7 Engine coolant temperature gauge does not indicate properly . 771
E-8 Fuel gauge does not indicate properly . 772
E-9 Hydraulic oil temperature gauge does not indicate properly 774
E-10 Content of display on machine monitor is different from that of actual machine . 776
E-11 Some areas of machine monitor screen are not displayed . 776
E-12 Function switch does not operate . 776
E-13 Automatic warm-up system does not operate (in cold season) . 777
E-14 Auto-decelerator does not operate properly . 778
E-15 Working mode does not change . 779
E-16 Travel speed does not change . 780
E-17 Alarm buzzer cannot be canceled 781
E-18 When starting switch is turned OFF, service meter is not displayed . 781
E-19 Service mode cannot be selected 781
E-20 Any of work equipment, swing and travel does not work or cannot be locked 782
E-21 Machine push-up function does not work or cannot be canceled . 784
E-22 Boom shockless function does not operate normally 786
E-23 Swing brake does not operate normally 788
E-24 Windshield wiper and window washer do not operate 790
E-25 Travel alarm does not sound or does not stop sounding 793
E-26 BOOM RAISE indicator is not displayed properly with monitoring function 794
E-27 BOOM LOWER indicator is not displayed properly with monitoring function 796
E-28 ARM IN indicator is not displayed properly with monitoring function 798
E-29 ARM DUMP indicator is not displayed properly with monitoring function 800
E-30 BUCKET CURL indicator is not displayed properly with monitoring function . 802
E-31 BUCKET DUMP indicator is not displayed properly with monitoring function . 804
E-32 Swing indicator is not displayed properly with monitoring function . 806
E-33 Travel indicator is not displayed properly with monitoring function 808
E-34 “Service” is not displayed normally by monitoring function . 810
E-35 Electric grease gun does not operate . 812
E-36 KOMTRAX system does not operate normally . 813
E-37 Bottom dump does not operate properly 814
E-38 Horn does not sound or does not stop sounding 817
E-39 Step light does not light up or go off . 820
Troubleshooting of hydraulic and mechanical system (H-mode) . 824
Before troubleshooting for hydraulic and mechanical systems . 824
Information in troubleshooting table (H-mode) . 829
H-1 All of work equipment, travel and swing work slow or lack power . 830
H-2 Engine speed lowers significantly or engine stalls 832
H-3 Any of work equipment, swing and travel does not work . 834
H-4 Unusual noise is heard from around hydraulic pump . 836
H-5 Auto-decelerator is not canceled 837
H-6 Speed or power of boom is low . 838
H-7 Speed or power of arm is low 840
H-8 Speed or power of bucket is low . 841
H-9 Boom does not move 842
H-10 Arm does not move 842
H-11 Bucket does not move . 843
H-12 Bottom dump does not move 843
H-13 Hydraulic drift of work equipment is large . 844
H-14 Time lag of work equipment is large 845
H-15 One-touch power maximizing function does not work or is not canceled . 846
H-16 Machine push-up function does not work or is not canceled 846
H-17 Boom/bucket speed is low at combined operation of arm and boom or bucket . 846
H-18 Speed of boom, arm, swing and travel is low at combined operation of bucket and boom, arm, swing and travel 847
H-19 Swing speed is low at combined operation of arm and swing 847
H-20 Machine deviates during travel . 848
H-21 Machine deviates significantly at start 851
H-22 Machine deviates significantly during combined operation . 852
H-23 Travel speed or travel power is low 853
H-24 One of tracks does not run (on 1 side alone) . 854
H-25 Travel speed does not change . 855
H-26 Upper structure does not swing . 856
H-27 Swing speed is low or acceleration is poor . 857
H-28 Upper structure overruns excessively when it stops swinging 858
H-29 Shock is large when upper structure stops swinging . 859
H-30 Large unusual noise is heard when upper structure stops swinging . 860
H-31 Hydraulic drift of swing is large 861
Troubleshooting of engine (S-mode) 862
Method of using troubleshooting chart . 862
S-1 Startability is poor 866
S-2 Engine does not start . 867
S-3 Engine does not pick up smoothly 870
S-4 Engine stops during operation . 871
S-5 Engine runs rough or is unstable 872
S-6 Engine lacks power 874
S-7 Exhaust smoke is black (incomplete combustion) 876
S-8 Oil consumption is excessive (or exhaust smoke is blue) . 877
S-9 Oil becomes contaminated early 878
S-10 Fuel consumption is excessive 879
S-11 Oil is in coolant (or coolant spurts or coolant level goes down) . 880
S-12 Oil pressure drops . 881
S-13 Oil level rises (coolant or fuel in oil) . 882
S-14 Coolant temperature rises too high (overheating) . 883
S-15 Unusual noise is made 884
S-16 Vibration is excessive . 885
50 Disassembly and assembly . 887
Contents 888
General information on disassembly and assembly . 890
How to read this manual . 890
Coating materials list 892
Special tools list 896
Sketches of special tools . 903
Engine and cooling system . 911
Removal and installation of fuel supply pump assembly . 911
Removal and installation of fuel injector assembly 917
Removal and installation of cylinder head assembly 920
Removal and installation of radiator assembly . 936
Removal and installation of hydraulic oil cooler assembly . 938
Removal and installation of aftercooler assembly 940
Removal and installation of engine front seal . 942
Removal and installation of engine rear seal 946
Removal and installation of engine, PTO and hydraulic pump assembly . 951
Removal and installation of cooling fan motor assembly 958
Removal and installation of fuel tank assembly 962
Power train . 963
Removal and installation of PTO assembly 963
Disassembly and assembly of PTO assembly 965
Disassembly and assembly of final drive assembly 968
Removal and installation of swing motor and swing machinery assembly 991
Disassembly and assembly of swing machinery assembly 993
Removal and installation of swing circle assembly .1008
Undercarriage and frame .1009
Separation and connection of track shoe assembly 1009
Disassembly and assembly of one link in field .1013
Removal and installation of idler assembly 1017
Disassembly and assembly of idler assembly 1019
Removal and installation of idler cushion assembly 1026
Disassembly and assembly of idler cushion assembly 1029
Removal and installation of track roller assembly .1033
Disassembly and assembly of track roller assembly .1035
Removal and installation of carrier roller assembly .1041
Disassembly and assembly of carrier roller assembly .1043
Removal and installation of revolving frame assembly 1049
Removal and installation of counterweight assembly 1051
Removal and installation of counterweight remover assembly 1053
Hydraulic system 1055
Removal and installation of center swivel joint assembly 1055
Disassembly and assembly of center swivel joint assembly 1056
Removal and installation of hydraulic tank assembly .1058
Removal and installation of hydraulic pump assembly .1060
Removal and installation of control valve assembly 1064
Disassembly and assembly of control valve assembly 1066
Removal and installation of swing motor assembly 1068
Disassembly and assembly of work equipment PPC valve assembly .1069
Disassembly and assembly of travel PPC valve assembly .1071
Disassembly and assembly of grease gun assembly .1073
Work equipment 1074
Removal and installation of bucket cylinder assembly 1074
Removal and installation of arm cylinder assembly .1078
Removal and installation of boom cylinder assembly 1082
Removal and installation of bottom dump cylinder assembly .1086
Removal and installation of bucket assembly .1088
Removal and installation of arm assembly 1092
Removal and installation of boom assembly .1095
Removal and installation of work equipment assembly .1099
Disassembly and assembly of work equipment cylinder assembly 1103
Cab and its attachments .1109
Removal and installation of operator’s cab assembly .1109
Removal and installation of operator’s cab glass (adhered window glass) .1113
Removal and installation of front window assembly .1123
Removal and installation of air conditioner unit assembly .1130
Removal and installation of work equipment control lever assembly .1134
Electrical system .1148
Removal and installation of air conditioner compressor assembly .1148
Removal and installation of air conditioner condenser assembly 1151
Removal and installation of engine controller assembly 1153
Removal and installation of pump controller assembly 1155
Removal and installation of KOMTRAX terminal assembly .1157
Removal and installation of machine monitor assembly 1158
60 Maintenance standard .1161
Contents 1162
Engine and cooling system .1163
Engine mount 1163
PTO .1165
Cooling system 1166
Power train .1167
Swing circle 1167
Swing machinery .1168
Final drive .1170
Sprocket 1172
Undercarriage and frame .1176
Track frame and idler cushion .1176
Idler .1178
Track roller 1182
Carrier roller 1185
Track shoe 1188
Hydraulic system 1198
Hydraulic pump 1198
Control valve .1208
Swing motor .1214
Travel motor 1215
PPC valve .1218
Boom drift prevention valve .1225
Regeneration valve (boom, arm) 1226
Center swivel joint .1227
Work equipment 1228
Work equipment 1228
Work equipment dimension 1232
Work equipment cylinder .1238
80 Appendix .1243
Table of contents .1244
Air conditioner .1245
Precautions for refrigerant .1245
Air conditioner component .1246
Configuration and function of refrigeration cycle .1248
Outline of refrigeration cycle 1249
Air conditioner unit 1252
Air conditioner controller 1257
Compressor 1258
Condenser .1259
Receiver drier 1260
Procedure for testing and troubleshooting .1262
Circuit diagram and arrangement of connector pins .1264
System diagram 1266
Detail of air conditioner unit 1268
Parts and connectors layout .1270
Testing air leakage (duct) 1273
Testing with self-diagnosis function 1274
Testing temperature control .1277
Testing vent (mode) changeover 1279
Testing FRESH/RECIRC air changeover .1282
Testing inner sensor 1284
Testing evaporator temperature sensor .1285
Testing sunlight sensor .1287
Testing (dual) pressure switch for refrigerant 1288
Testing relays 1289
Troubleshooting chart 1 .1290
Troubleshooting chart 2 .1292
Information in troubleshooting table 1294
Troubleshooting for power supply and CAN communication system (Air conditioner does not operate) 1296
Troubleshooting for compressor and refrigerant system (Air is not cooled) .1301
Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1305
Troubleshooting for temperature control .1309
Troubleshooting for vent (mode) changeover 1312
Troubleshooting for FRESH/RECIRC air changeover .1314
Troubleshooting for temperature sensor system .1316
Troubleshooting with gauge pressure .1317
Connection of service tool 1320
Precautions for disconnecting and connecting air conditioner piping .1322
Handling of compressor oil 1324
90 Diagrams and drawings 1327
Contents 1328
Hydraulic circuit diagram .1329
Symbols used in hydraulic circuit diagrams 1329
Hydraulic circuit diagram .1333
Electrical circuit diagram 1341
Symbols used in electric circuit diagrams .1341
Electrical circuit diagram 1345
Air conditioner electrical circuit diagram 1369

DESCRIPTION:

Komatsu PC600-8R1,PC600LC-8R1,PC700LC-8R Hydraulic Excavator Shop Manual SEN05660-09 – PDF DOWNLOAD

• SERIAL NUMBERS 70001 and up

• GENERAL PRECAUTIONS:
•  Inappropriate handling causes an extreme danger. Read and understand what is described in the operation and maintenance manual before operating the machine. Read and understand what is described in this manual before starting the work.
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the operation and maintenance manual.
• Locate a place in the repair workshop to keep the tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any work, always wear the safety shoes and helmet. Do not wear loose work cloths, or clothes with buttons missing.
• 1. Always wear the protective eyeglasses when hitting parts with a hammer.
• 2. Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any work with two or more workers, always agree on the working procedure before starting. While working, always keep conversations of the work between your fellow workers and your self on any step of the work. During the work, hang the warning tag of “UNDER WORKING” in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification. q Keep the tools in good condition. And learn the correct way to use the tools, and use the proper ones among them. Before starting the work, thoroughly check the tools, forklift truck, service car, etc.
• If welding repairs is required, always have a trained and experienced welder with good knowledge of welding perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap, etc.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests with proper intervals to keep your body in good condition. Take a rest in a specified safe place.
• Preparation q Before adding oil or making any repairs, place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks to prevent the machine from moving.
• Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If it is not possible to lower the equipment to the ground, insert the lock pin or use blocks to prevent the work equipment from falling. And be sure to lock all the work equipment control levers and hang a warning tag on them
•  When performing the disassembling or assembling work, support the machine securely with blocks, jacks, or stands before starting the work.
• Remove all of mud and oil from the steps or other places used to get on and off the machine completely. Always use the handrails, ladders of steps when getting on or off the machine. Never jump on or off the machine. When the scaffold is not provided, use steps or stepladder to secure your footing.
• Precautions during work:
• For the machine equipped with the battery disconnect switch, check that the system operating lamp is turned off before starting the work. Then, turn the battery disconnect switch to the OFF (Q) position and remove the switch key. For the machine not equipped with the battery disconnect switch, remove the cable from the battery before starting the work. Be sure to remove the negative end (-) of the battery cable first.
• Release the remaining pressure in the circuits completely before the work when the parts in the circuits of oil, fuel, coolant and air are disconnected or removed. When the cap of the oil filter, drain plug or oil pressure pickup plug is removed, loose them slowly to prevent the oil from spurting out.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer after the engine is shut down and start the work after the remaining pressure is released from the fuel circuit.
• Immediately after the engine is shut down, the coolant and oil in the circuits are hot. Be careful not to get scalded by the hot coolant and oil. Start the work after checking that the coolant and oil are cooled down sufficiently.
• Start the work after the engine is shut down. Be sure to shut down the engine when working on or around the rotating parts in particular. When checking the machine without shutting down the engine (measuring oil pressure, engine speed, oil or coolant temperature), take extreme care not to get caught in the rotating parts or the working equipment.
• The hoist or crane must be used to sling the components weighing 25 kg or heavier. Check the slings (wire rope, nylon sling, chain and hook) for damage before the work. Use the slings with ample capacity and install them to the proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
• When removing the part which is under internal pressure or reaction force of the spring, always leave two bolts in diagonal positions. Loosen those two bolts gradually and alternately and release the pressure, then, remove the part.
• When removing the part, be careful not to break or damage the electrical wiring. The damaged wiring may cause electrical fires.
• When removing piping, prevent the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it off immediately. Fuel or oil on the floor can cause you to slip and can even cause fires.
• As a general rule, do not use gasoline to wash parts. Do not use gasoline to clean the electrical parts, in particular.
• Reinstall the parts removed to their original places. Replace the damaged parts and the parts which must not be used with new ones. When installing the hoses and wiring harnesses, be careful that they are not damaged by contacting with other parts when the machine is operated.
• When connecting the high pressure hoses and tubes, make sure that they are not twisted. The damaged high pressure hoses and tubes are very dangerous when they are installed. So, be extremely careful when connecting the high pressure pipings. In addition, check that their connections are correct.
• When assembling or installing the parts, be sure to tighten the bolts to the specified torque. When installing the protective parts such as guards, or the parts which vibrate violently or rotate at high speeds, be sure to check that they are installed correctly.
• When aligning two holes, never insert your fingers or hand into the holes. Align the holes with care so that your fingers are not caught in the hole.
• When measuring hydraulic pressure, check that the measuring tools are correctly installed.
• Pay attention to safety when removing and installing the tracks of the track type machines. When removing the track, it separates suddenly. The workers should not stand at either end of the track.
• If the engine is operated for a long time in a closed place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate the place well.

G.B 28/12/24