Komatsu PC75UU-3 Hydraulic Excavator Shop Manual 15001 and up – PDF DOWNLOAD

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Komatsu PC75UU-3 Hydraulic Excavator Shop Manual

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Komatsu PC75UU-3 Hydraulic Excavator Shop Manual

Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC75UU-3
Serial Number: 15001 and up
Book Code: SEBM016404
Language: English
Pages: 631
File Format: Portable Document Format (PDF)

KOMATSU PC75UU-3 HYDRAULIC EXCAVATOR SHOP MANUAL 15001 AND UP – PDF DOWNLOAD:

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu PC75UU-3 Hydraulic Excavator Shop Manual

FOREWORD:
GENERAL:

• This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
• This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

TABLE OF CONTENTS:

Komatsu PC75UU-3 Hydraulic Excavator Shop Manual

COVER......................................................................................................................................................  1
CONTENTS...................................................................................................................................................  2
01 GENERAL................................................................................................................................................. 26
	GENERAL ASSEMBLY DRAWING............................................................................................................................... 27
	WORK EQUIPMENT RANGE DRAWING........................................................................................................................... 32
	SPECIFICATIONS......................................................................................................................................... 35
	WEIGHT TABLE .......................................................................................................................................... 41
	LIST OF LUBRICANT AND WATER............................................................................................................................ 45
10 STRUCTURE AND FUNCTION.................................................................................................................................. 48
	RADIATOR,OIL COOER..................................................................................................................................... 49
	PTO (COUPLING)......................................................................................................................................... 51
	POWER TRAIN............................................................................................................................................ 53
	SWING MACHINERY........................................................................................................................................ 54
	SWING CIRCLE........................................................................................................................................... 55
	TRACK FRAME............................................................................................................................................ 56
	HYDRAULIC EQUIPMENT LAYOUT............................................................................................................................. 57
	HYDRAULIC TANK......................................................................................................................................... 59
	HYDRAULIC PUMP......................................................................................................................................... 60
	CONTROL VALVE.......................................................................................................................................... 86
	SELF-PRESSURE REDUCING VALVE........................................................................................................................... 97
	CLSS...................................................................................................................................................101
	SWING MOTOR............................................................................................................................................119
	CENTER SWIVEL JOINT....................................................................................................................................130
	TRAVEL MOTOR...........................................................................................................................................134
	VALVE CONTROL..........................................................................................................................................140
	PPC VALVE..............................................................................................................................................141
	SOLENOID VALVE.........................................................................................................................................152
	SOLENOID VALVE,EPC VALVE...............................................................................................................................154
	WORK EQUIPMENT.........................................................................................................................................158
	AIR CONDITIONER PIPING.................................................................................................................................159
	ELECTRIC WIRING DIAGRAM................................................................................................................................160
	ENGINE CONTROL.........................................................................................................................................163
	FOUR SYSTEM (4 SYSTEM).................................................................................................................................171
	ELECTRICAL CONTROL SYSTEM..............................................................................................................................189
	MONITOR SYSTEM.........................................................................................................................................196
20 TESTING AND ADJUSTING...................................................................................................................................202
	STANDARD VALUE TABLE FOR ENGINE RELATED PARTS..........................................................................................................203
	STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS.........................................................................................................204
	STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS......................................................................................................211
	TESTING AND ADJUSTING..................................................................................................................................219
		TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING..................................................................................................220
		MEASURING ENGINE SPEED.............................................................................................................................221
		MEASURING EXHAUST COLOR............................................................................................................................222
		ADJUSTING VALVE CLEARANCE..........................................................................................................................223
		MEASURING COMPRESSION PRESSURE.....................................................................................................................224
		MEASURING BLOW-BY PRESSURE.........................................................................................................................225
		TESTING AND ADJUSTING FUEL INJECTION TIMING........................................................................................................226
		MEASURING ENGINE OIL PRESSURE......................................................................................................................227
		ADJUSTING ENGINE STOP SOLENOID LINKAGE TESTING.....................................................................................................228
		ADTUSTING FUEL CONTROL LINKAGE.....................................................................................................................229
		TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT..................................................................230
		MEASURING LS DIFFERENTIAL PRESSURE AND ADJUSTING LS VALVE..........................................................................................232
		ADJUSTING PC VALVE.................................................................................................................................233
		MEASURING CONTROL CIRCUIT OIL PRESSURE (REDUCED PUMP DISCHARGE SELF-PRESSURE)......................................................................234
		MEASURING PPC VALVE OUTPUT PRESSURE................................................................................................................235
		TESTING SOLENOID VALVE OUTPUT PRESSURE.............................................................................................................236
		ADJUSTING WORK EQUIPMENT, SWING PPC VALVE..........................................................................................................238
		TESTING TRAVEL DEVIATION...........................................................................................................................239
		TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT........................................................................................240
		MEASURING SWING, TRAVEL MOTOR OIL LEAKAGE..........................................................................................................241
		RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT..................................................................................................241
		TESTING CLEARANCE OF SWING CIRCLE BEARING..........................................................................................................242
		TESTING WEAR OF SPROCKET...........................................................................................................................243
		TESTING AND ADJUSTING TRACK SHOE TENSION...........................................................................................................244
		BLEEDING AIR.......................................................................................................................................245
		PROCEDURE FOR RESETTING ELECTRICAL SYSTEM INPUT/ OUTPUT SIGNALS AND CHECKING OPERATION.............................................................247
		PROCEDURE FOR ADJUSTMENT WHEN INSTALLING LONG ARM, SLIDE ARM (TELESCOPIC ARM)......................................................................259
		PROCEDURE FOR REPLACING POTENTIOMETER..............................................................................................................260
		PROCEDURE FOR CHECKING DIODE.......................................................................................................................261
	TROUBLESHOOTING........................................................................................................................................262
		POINTS TO REMEMBER WHEN TROUBLESHOOTING............................................................................................................263
		SEQUENCE OF EVENTS IN TROUBLESHOOTING..............................................................................................................264
		POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...................................................................................................265
		CHECKS BEFORE TROUBLESHOOTING......................................................................................................................273
		CONNECTOR TYPES AND MOUNTING LOCATIONS.............................................................................................................274
		CONNECTOR ARRANGEMENT DIAGRAM......................................................................................................................276
		CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.........................................................................................................279
		EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM.............................................................................................289
		DISPLAY METHOD FOR MONITOR PANEL,CONTROLLER........................................................................................................293
		METHOD OF USING JUDGEMENT TABLE....................................................................................................................297
		METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................................................298
		TROUBLESHOOTING OF ENGINE (S MODE).................................................................................................................300
			METHOD OF USING TROUBLESHOOTING CHART..........................................................................................................301
			S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)..................................................................................305
			S-2 ENGINE DOSE NOT START......................................................................................................................307
				(1) ENGINE DOSE NOT TURN...................................................................................................................307
				(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...............................................................308
				(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOSE NOT START(FUEL IS BEING INJECTED)..............................................................309
			S-3 ENGINE DOSE NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).......................................................................................310
			S-4 ENGINE STOPS DURING OPERATIONS.............................................................................................................311
			S-5 ENGINE DOSE NOT ROTATE SMOOTHLY (HUNTING)..................................................................................................312
			S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).......................................................................................................313
			S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).............................................................................................314
			S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)....................................................................................315
			S-9 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................................316
			S-10 FUEL CONSUMPTION IS EXCESSIVE.............................................................................................................317
			S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN.....................................................................318
			S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)................................................................................319
			S-13 OIL LEVEL RISES (WATER,FUEL IN OIL).......................................................................................................320
			S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..........................................................................................321
			S-15 ABNORMAL NOISE IS MADE....................................................................................................................322
			S-16 VIBRATION IS EXCESSIVE....................................................................................................................323
		TROUBLESHOOTING OF CONTROLLER,ELECTRICAL SYSTEM(E MODE)............................................................................................324
			ACTION TAKEN BY SELF-DIAGNOSTIC FUNCTION AND PROBLEMS ON MACHINE...............................................................................326
			JUDGEMENT TABLE FOR 4 SYSTEM...................................................................................................................332
			JUDGEMENT TABLE FOR CHASSIS RELATED PARTS......................................................................................................334
			ELECTRICAL CIRCUIT DIAGRAM FOR CONTROLLER SYSTEM...............................................................................................336
			POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF CONTROLLER SYSTEM......................................................................341
			PRECAUTIONS WHEN HANDLING CANCEL SWITCH WHEN ABNORMALITY DISPLAY IS GIVEN AND WORK EQUIPMENT STOPS.............................................344
			E-1 ERROR CODE [EE] (ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM OR COMMUNICATIONS SYSTEM)...................................................345
				a) ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM...........................................................................................345
				b) ABNORMALITY IN COMMUNICATIONS SYSTEM....................................................................................................346
			E-2 ERROR CODE [21] (ABNORMALITY IN MODEL SELECTION SYSTEM)....................................................................................347
			E-3 ERROR CODE [22] (ABNORMALITY IN WORK EQUIPMENT SELECTION SYSTEM)...........................................................................348
			E-4 ERROR CODE [31] (ABNORMALITY IN BOOM POTENTLOMETER SYSTEM).................................................................................349
			E-5 ERROR CODE [32] (ABNORMALITY IN ARM POTENTIOMETER SYSTEM)..................................................................................350
			E-6 ERROR CODE [34] (ABNORMALITY IN OFFSET POTENTIOMETER SYSTEM)...............................................................................351
			E-7 ERROR CODE [37] (ABNORMALITY IN POTENTIOMETER POWER SOURCE SYSTEM) IS DISPLAYED............................................................352
			E-8 ERROR CODE [38] (ABNORMALITY IN SLIDE ARM LENGTH SENSOR SYSTEM) IS DISPLAYED...............................................................353
			E-9 ERROR CODE [41] (ABNORMALITY IN PPC LOCK SOLENOID SYSTEM)..................................................................................354
			E-10 ERROR CODE [42] (ABNORMALITY IN LEFT OFFSET STOP SOLENOID STSTEM).........................................................................355
			E-11 ERROR CODE [44] (ABNORMALITY IN BOOM LOWER STOP SOLENOID SYSTEM)..........................................................................356
			E-12 ERROR CODE [51] (ABNORMALITY IN BOOM RAISE STOP SOLENOID SYSTEM)..........................................................................357
			E-13 ERROR CODE [52] (ABNORMALITY IN ARM IN STOP EPC SOLENOID SYSTEM) IS DISPLAYED.............................................................358
			E-14 ERROR CODE [61] (VALVE OPEN) IS DISPLAYED.................................................................................................358
			E-15 DEPTH MODE, HEIGHT MODE,OFFSET MODE DO NOT WORK PROPERLY (GO BEYOND SET POSITION BEFORE STOPPING OR STOP BEFORE REACHING SET POSITION)....359
			E-16 IMPOSSIBLE TO SELECT AND SET DEPTH DISPLAY 0 SET MODE,DEPTH MODE,HEIGHTMODE,OFFSET MODE...................................................361
			E-17 CANCEL SWITCH IS NOT TURNED ON,BUT ALARM BUZZER SOUNDS FOR 7 SECONDS AND ELECTRIC SYSTEM CAUTION LAMP FLASHES.............................362
			E-18 AUTOMATIC STOP IS NOT CARRIED OUT FOR BOOM RAISE,ARM IN,LEFT OFFSET(WHEN ERROR CODE [61] IS NOT DISPLAYED)................................363
				a) ALL OPERATIONS STOP IMMEDIATELY BOFORE INTERFERENCE.....................................................................................363
				b) THERE IS INTERFERENCE...................................................................................................................363
			E-19 WHEN TELESCOPIC ARM IS EXTENDED (MORE THAN 200 MM) AUTOMATIC STOP DISTANCE IS NEAR........................................................364
			E-20 WHEN SLIDE ARM IS RETRACTED (LESS THAN 200 MM) AUTOMATIC STOP DISTANCE IS FAR ............................................................365
			E-21 WORK EQUIPMENT DOSE MOVE WHEN WORK EQUIPMENT LOCK LEVER IS SET TO FREE POSITION...........................................................366
			E-22 WORK EQUIPMENT DOSE MOVE WHEN WORK EQUIPMENT LOCK LEVER IS SET TO FREE POSITION...........................................................367
			E-23 DOSE NOT SWING............................................................................................................................368
			E-24 EXCESSIVE HYDRAULIC DRIFT OF SWING (SWING BRAKE HAS NO EFFECT)............................................................................371
			E-25 EVEN WHEN TRAVEL BOOST PEDAL IS OPERATED (DEPRESSED),SPEED DOSE NOT INCREASE..............................................................374
			E-26 TRAVEL BOOST PEDAL IS NOT BEING OPERATED (NOT DEPRESSED) BUT SPEED REMAINS BOOSTED........................................................375
			E-27 POWER MODE DOSE NOT SWITCH................................................................................................................376
				a) WHEN ENGINE SPEED IS AT MID-RANGE SPEED OR ABOVE (LIMIT SWITCH ON) BUT WORK EQUIPMENT SPEED SLOW........................................376
				b) EXCESSIVE DROP IN ENGINE SPEED WHEN ENGINE SPEED IS BELOW MID-RANGE SPEED (LIMIT SWITCH ON).............................................377
			E-28 WIPER DOSE NOT WORK.......................................................................................................................378
			E-29 ENGINE DOSE NOT START ....................................................................................................................379
				a) STARTING MOTOR DOSE NOT TURN............................................................................................................379
				b) ENGINE STOP SOLENOID DOSE NOT WORK (STARTING MOTOR TURNS)...............................................................................382
			E-30 ENGINE DOSE NOT STOP......................................................................................................................383
			E-31 DEFECTIVE ENGINE CONTROL..................................................................................................................384
				a) DOSE NOT WORK,OR WORKS AND THEN STOPS WORKING...........................................................................................384
				b) WORKS,BUT DOSE NOT WORKS SMOOTHLY (CABLE WORK ABNORMAL OR INSUFFICIENT STROKE)..........................................................386
				c) SWIFT SLOW-DOWN DOSE NOT WORK...........................................................................................................388
				d) WORKS AT NEAR IDLING BUT DOSE NOT WORK UP TO FULL (LOAD BECOMES LARGER).................................................................389
		TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)............................................................................................390
			TABLE OF FAILURE MODES AND CAUSES..............................................................................................................391
			H-1 SPEEDS OF ALL WORK EQUIPMENT,TRAVEL,AND SWING ARE SLOW OR LACK POWER.......................................................................393
				a) SPEEDS OF ALL WORK EQUIPMENT,TRAVEL,AND SWING ARE ALL SLOW OR LACK POWER................................................................393
				b) SPEEDS OF SWING AND BLADE ARE ALL SLOW OR LACK POWER (BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE NORMAL).....................................393
				c) SPEEDS OF BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE ALL SLOW OR LACK POWER (SWING AND BLADE ARE NORMAL).....................................394
				d) SPEEDS OF ALL WORK EQUIPMENT (BOOM,ARM,BUCKET,OFFSET) ARE ALL SLOW OR LACK POWER (TRAVEL AND AWING ARE NORMAL)..........................396
			H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS...................................................................................397
			H-3 NONE OF WORK EQUIPMENT,TRAVEL,OR SWING MOVE................................................................................................398
				a) NONE OF WORK EQUIPMENT,TRAVEL,OR SWING MOVE.............................................................................................398
				b) NONE OF BOOM,ARM,BUCKET,OFFSET,OR TRAVEL MOVE (SWING AND BLADE ARE NORMAL)..............................................................398
				c) SWING AND BLADE DO NOT MOVE (BOOM,ARM,BUCKET,OFFSET,AND TRAVEL ARE NORMAL)..............................................................398
			H-4 ABNORMAL NOISE GENERATED FROM AROUND PUMP..................................................................................................399
			H-5 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR (BOOM,ARM,BUCKET,OFFSET)..................................................................399
			H-6 BOOM IS SLOW OR LACKS POWER................................................................................................................400
			H-7 ARM IS SLOW OR LACKS POWER ................................................................................................................402
			H-8 BUCKET IS SLOW OR LACKS POWER..............................................................................................................404
			H-9 BLADE IS SLOW OR LACKS POWER...............................................................................................................404
			H-10 WORK EQUIPMENT DOSE NOT MOVE (ONE OF BOOM,ARM,BUCKET,OFFSET,BLADE DOSE NOT MOVE)..........................................................405
			H-11 EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT...............................................................................................406
				a) EXCESSIVE HYDRAULIC DRIFT OF BOOM,ARM,BUCKET............................................................................................406
				b) EXCESSIVE HYDRAULIC DRIFT OF BLADE......................................................................................................406
			H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING).................................................................................................407
			H-13 IN COMPOUND OPERATIONS,WORK EQUIPMENT WITH LARGER LOAD IS SLOW............................................................................407
			H-14 IN SWING + BOOM RAISE,BOOM RAISE IS SLOW..................................................................................................408
			H-15 IN TRAVEL + BOOM RAISE,TRAVEL SPEED DROPS EXCESSIVELY.....................................................................................408
			H-16 WHEN MACHINE IS TRAVELING,IT DEVIATES NATURALLY TO ONE SIDE (DEVIATION IS EXCESSIVE WHEN TRAVELING).......................................409
				a) DEVIATES IN SAME DIRECTION IN BOTH FORWARD AND REVERSE..................................................................................409
				b) DEVIATES IN DIFFERENT DIRECTION IN FORWARD AND REVERSE..................................................................................410
			H-17 EXCESSIVE DEVIATION WHEN STARTING.........................................................................................................411
			H-18 TRAVEL SPEED IS SLOW OR LACKS POWER ......................................................................................................411
			H-19 STEERING IS DIFFICULT TO TURN.............................................................................................................412
			H-20 TRAVEL SPEED DOSE NOT SWITCH..............................................................................................................413
			H-21 TRACK DOSE NOT MOVE (ONE SIDE ONLY).......................................................................................................413
			H-22 UPPER STRUCTURE DOSE NOT SWING............................................................................................................414
				a) DOSE NOT SWING TO EITHER LEFT OR RIGHT..................................................................................................414
				b) DOSE NOT SWING IN ONE DIRECTION (EITHER LEFT OR RIGHT)..................................................................................414
			H-23 SWING ACCELERATION IS POOR OR SPEED IS SLOW...............................................................................................415
			H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING.....................................................................................................417
				a) OVERRUN IN ONE DIRECTION ONLY...........................................................................................................417
				b) OVERRUN IN BOTH DIRECTIONS..............................................................................................................417
			H-25 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY0..................................................................................418
			H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING..............................................................................................418
			H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING........................................................................................................419
				a) WHEN SWING HOLDING BRAKE IS RELEASED....................................................................................................419
				b) WHEN SWING HOLDING BRAKE IS APPLIED.....................................................................................................419
		TROUBLESHOOTING 0F MACHINE MONITOR SYSTEM (M MODE).................................................................................................420
			ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM..........................................................................................421
			M-1 WHEN THE STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN (LAMPS DO NOT LIGHT UP FOR 3 SECONDS)............................................422
			M-2 WHEN STARTING SWITCH IS TURNED ON,LAMPS LIGHT UP FOR 3 SECONDS,BUT THEN DO NOT GO OUT......................................................422
			M-3 WHEN STARTING SWITCH IS TURNED ON,SOME LAMPS DO NOT LIGHT UP FOR 3 SECONDS.................................................................423
				a) NO GAUGE LIGHT UP PREHEATING PILOT DOSE NOT LIGHT UP....................................................................................423
				b) BATTERY ELECTROLYTE LEVEL CAUTION LAMP DOSE NOT LIGHT UP ELECTRIC SYSTEM CAUTION LAMP DOSE NOT LIGHT UP.................................423
				c) CHARGE CAUTION DOSE NOT LIGHT UP........................................................................................................423
				d) ENGINE OIL PRESSURE CAUTION LAMP DOSE NOT LIGHT UP......................................................................................423
			M-4 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHARGE CAUTION LAMP DOSE NOT LIGHT UP.........................................................424
			M-5 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), ENGINE OIL PRESSURE CAUTION LAMP DOSE NOT LIGHT UP ...........................................424
			M-6 DURING PREHEATING ,PREHEATING PILOT DOSE NOT LIGHT UP .....................................................................................425
			M-7 WHEN ENGINE IS RUNNING, ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP (ENGINE OIL PRESSURE IS NORMAL).........................................425
			M-8 WHEN ENGINE IS RUNNING, CHARGE CAUTION LAMP LIGHTS UP......................................................................................426
			M-9 ABNORMALITY DISPLAY ON COOLANT TEMPERATURE GAUGE...........................................................................................426
				a) AFTER ENGINE IS STARTED, LEVEL STAYS AT BOTTOM AND DOSE NOT MOVE........................................................................426
				b) AFTER ENGINE IS ATARTED, LEVEL IMMEDIATELY RISES ENGINE IS NOT OVERHEATING BUT INDICATOR ENTERS RED RANGE ..............................427
				c) WATER TEMPERATURE GAUGE GOSE OUT........................................................................................................427
			M-10 ABNORMALITY DISPTAY ON FUEL GAUGE.........................................................................................................428
				a) ALL FUEL GAUGE SEGMENTS GO OUT..........................................................................................................428
				b) EVEN WHEN FUEL LEVEL GOSE DOWN, FUEL GAUGE CONTINUES TO SHOW FULL.......................................................................428
				c) EVEN WHEN TANK IS FILLED, FUEL GAUGE DOSE NOT SHOW FULL.................................................................................429
			M-11 DEFECTIVE OPERATION OF ALARM BUZZER.......................................................................................................430
				a) BUZZER DOSE NOT SOUND...................................................................................................................430
				b) BUZZER CONTINUES TO SOUND AND DOSE NOT STOP.............................................................................................430
			M-12 WHEN ENGINE IS RUNING, SERVISE METER DOSE NOT ADVANCE.....................................................................................431
				a) WHEN CHARGE CAUTION LAMP DOES NOT LIGHT UP..............................................................................................431
				b) WHEN CHARGE CAUTION LAMP LIGHTS UP......................................................................................................431
			M-13 NIGHT LIGHTING DOSE NOT LIGHT UP..........................................................................................................432
				a) LIGHTING OF COOLANT TEMPERATURE GAUGE, FUEL GAUGE, DEPTH DISPLAY DOSE NOT LIGHT UP......................................................432
				b) LIGHTING OF SERVICE METER DOSE NOT LIGHT UP ............................................................................................432
			M-14 ELECTRIC SYSTEM CAUTION LAMP STAYS LIGHTED UP, AND DOSE NOT GO OUT (ON ABNORMALITY DISPLAY ON CONTROLLER, OPERATION IS NORMAL)............433
			M-15 HEATER DOSE NOT WORK......................................................................................................................434
				a) DOSE NOT WORK AT EITHER LO OR HI........................................................................................................434
				b) DOSE NOT WORK AT LO ONLY................................................................................................................434
				c) DOSE NOT WORK AT HI ONLY................................................................................................................434
30 DISASSEMBLY AND ASSEMBLY................................................................................................................................436
	SERIAL NO.:15001-19000 (MOUNT THE 4D95LE-2ENGINE)......................................................................................................437
		METHOD OF USING MANUAL.............................................................................................................................439
		PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................................................440
		SPECIAL TOOL LIST..................................................................................................................................442
		SCHEMATIC DRAWING OF SPECIAL TOOL..................................................................................................................446
		STARTING MOTOR.....................................................................................................................................447
			REMOVAL AND INSTALLATION.......................................................................................................................447
		ALTERNATOR ........................................................................................................................................448
			REMOVAL AND INSTALLATION.......................................................................................................................448
		FUEL INJECTION PUMP................................................................................................................................449
			REMOVAL .......................................................................................................................................449
			INSTALLATION...................................................................................................................................451
		WATER PUMP.........................................................................................................................................454
			REMOVAL AND INSTALLATION.......................................................................................................................454
		NOZZLE HOLDER .....................................................................................................................................455
			REMOVAL AND INSTALLATION.......................................................................................................................455
		THERMOSTAT.........................................................................................................................................456
			REMOVAL AND INSTALLATION.......................................................................................................................456
		ENGINE OIL COOLER CORE.............................................................................................................................457
			REMOVAL AND INSTALLATION.......................................................................................................................457
		CYLINDER HEAD......................................................................................................................................458
			REMOVAL........................................................................................................................................458
			INSTALLATION...................................................................................................................................462
		RADIATOR AND HYDRAULIC OIL COOLER .................................................................................................................465
			REMOVAL .......................................................................................................................................465
			INSTALLATION...................................................................................................................................466
		ENGINE AND MAIN PUMP...............................................................................................................................467
			REMOVAL........................................................................................................................................467
			INSTALLATION...................................................................................................................................471
		CENTER SWIVEL JOINT................................................................................................................................472
			REMOVAL .......................................................................................................................................472
			INSTALLATION...................................................................................................................................473
			DISASSEMBLY AND ASSEMBLY.......................................................................................................................474
		TRAVEL MOTOR.......................................................................................................................................475
			REMOVAL AND INSTALLATION.......................................................................................................................475
		SPROCKET...........................................................................................................................................476
			REMOVAL AND INSTALLATION.......................................................................................................................476
		SWING MOTOR AND SWING MACHINERY....................................................................................................................477
			REMOVAL........................................................................................................................................477
			INSTALLATION...................................................................................................................................478
		SWING MACHINERY....................................................................................................................................479
			DISASSEMBLY....................................................................................................................................479
			ASSEMBLY.......................................................................................................................................482
		REVOLVING FRAME....................................................................................................................................485
			REMOVAL........................................................................................................................................485
			INSTALLATION...................................................................................................................................486
		SWING CIRCLE.......................................................................................................................................487
			REMOVAL AND INSTALLATION.......................................................................................................................487
		IDLER AND RECOIL SPRING............................................................................................................................488
			REMOVAL AND INSTALLATION.......................................................................................................................488
		IDLER .............................................................................................................................................489
			DISASSEMBLY....................................................................................................................................489
			ASSEMBLY.......................................................................................................................................490
		RECOIL SPRING......................................................................................................................................492
			DISASSEMBLY....................................................................................................................................492
			ASSEMBLY ......................................................................................................................................493
		TRACK ROLLER.......................................................................................................................................494
			REMOVAL AND INSTALLATION.......................................................................................................................494
			DISASSEMBLY ...................................................................................................................................495
			ASSEMBLY.......................................................................................................................................497
		CARRIER ROLLER ....................................................................................................................................499
			REMOVAL AND INSTALLATION.......................................................................................................................499
			DISASSEMBLY AND ASSEMBLY.......................................................................................................................500
		RUBBER SHOE........................................................................................................................................501
			REMOVAL AND INSTALLATION.......................................................................................................................501
		STEEL SHOE AND ROAD LINER .........................................................................................................................502
			REMOVAL AND INSTALLATION.......................................................................................................................502
		MAIN PUMP..........................................................................................................................................503
			REMOVAL........................................................................................................................................503
			INSTALLATION...................................................................................................................................504
		MAIN PUMP INPUT SHAFT OIL SEAL ....................................................................................................................505
			REMOVAL AND INSTALLATION.......................................................................................................................505
		SELF PRESSURE  REDUCING VALVE......................................................................................................................506
			REMOVAL AND INSTALLATION.......................................................................................................................506
		CONTROL VALVE......................................................................................................................................507
			REMOVAL........................................................................................................................................507
			INSTALLATION...................................................................................................................................508
			DISASSEMBLY....................................................................................................................................509
			ASSEMBLY ......................................................................................................................................514
		MAIN RELIEF VALVE..................................................................................................................................520
			DISASSEMBLY AND ASSEMBLY.......................................................................................................................520
		SOLENOID VALVE.....................................................................................................................................521
			REMOVAL AND INSTALLATION.......................................................................................................................521
		WORK EQUIPMENT L. H. PPC VALVE.....................................................................................................................523
			REMOVAL AND INSTALLATION.......................................................................................................................523
		WORK EQUIPMENT R. H. PPC VALVE.....................................................................................................................524
			REMOVAL AND INSTALLATION.......................................................................................................................524
		WORK EQUIPMENT AND SWING PPC VALVE.................................................................................................................525
			DISASSEMBLY....................................................................................................................................525
			ASSEMBLY ......................................................................................................................................526
		TRAVEL PPC VALVE ..................................................................................................................................527
			REMOVAL AND INSTALLATION.......................................................................................................................527
			DISASSEMBLY ...................................................................................................................................528
			ASSEMBLY.......................................................................................................................................529
		BLAND PPC VALVE....................................................................................................................................530
			REMOVAL AND INSTALLATION.......................................................................................................................530
		OFFSET PPC VALVE ..................................................................................................................................531
			REMOVAL AND INSTALLATION.......................................................................................................................531
			DISASSEMBLY....................................................................................................................................532
			ASSEMBLY.......................................................................................................................................533
		ARM CYLINDER.......................................................................................................................................534
			REMOVAL........................................................................................................................................534
			INSTALLATION...................................................................................................................................535
		BUCKET CYLINDER ...................................................................................................................................536
			REMOVAL........................................................................................................................................536
			INSTALLATION...................................................................................................................................537
		BOOM CYLINDER......................................................................................................................................538
			REMOVAL .......................................................................................................................................538
			INSTALLATION...................................................................................................................................539
		OFFSET CYLINDER....................................................................................................................................540
			REMOVAL........................................................................................................................................540
			INSTALLATION...................................................................................................................................541
		BLADE CYLINDER.....................................................................................................................................542
			REMOVAL........................................................................................................................................542
			MOUNT..........................................................................................................................................543
		HYDRAULIC CYLINDER.................................................................................................................................544
			DISASSEMBLY....................................................................................................................................544
			ASSEMBLY.......................................................................................................................................546
		WORK EQUIPMENT ....................................................................................................................................549
			REMOVAL........................................................................................................................................549
			INSTALLATION...................................................................................................................................550
		BUCKET ............................................................................................................................................551
			REMOVAL AND INSTALLATION.......................................................................................................................551
		ARM ...............................................................................................................................................552
			REMOVAL........................................................................................................................................552
			INSTALLATION...................................................................................................................................553
		SECOND BOOM........................................................................................................................................554
			REMOVAL........................................................................................................................................554
			INSTALLATION...................................................................................................................................557
		BUCKET AND ARM ....................................................................................................................................558
			REMOVAL........................................................................................................................................558
			INSTALLATION...................................................................................................................................559
		FIRST BOOM.........................................................................................................................................560
			REMOVAL .......................................................................................................................................560
			INSTALLATION...................................................................................................................................562
		BLADE..............................................................................................................................................563
			REMOVAL AND INSTALLATION.......................................................................................................................563
		OPERATOR'S CAB ....................................................................................................................................564
			REMOVAL AND INSTALLATION.......................................................................................................................564
		FLOOR FRAME........................................................................................................................................565
			REMOVAL........................................................................................................................................565
			INSTALLATION...................................................................................................................................568
		FUEL TANK .........................................................................................................................................569
			REMOVAL AND INSTALLATION.......................................................................................................................569
		CONTROLLER ........................................................................................................................................570
			REMOVAL AND INSTALLATION.......................................................................................................................570
		MONITOR............................................................................................................................................571
			REMOVAL AND INSTALLATION.......................................................................................................................571
		COUNTERWEIGHT......................................................................................................................................572
			REMOVAL AND INSTALLATION.......................................................................................................................572
	SERIAL NO.: 19001 AND UP (MOUNT THE 4D95LE-2ENGINE.....................................................................................................573
		RADIATOR AND HYD RAULIC OIL COOLER ................................................................................................................574
			REMOVAL AND INSTALLATION.......................................................................................................................574
		ENGINE MAIN PUMP ..................................................................................................................................575
			REMOVAL........................................................................................................................................575
			INSTALLATION...................................................................................................................................579
		REVOLVING FRAME ...................................................................................................................................580
			REMOVAL........................................................................................................................................580
			INSTALLATION...................................................................................................................................581
		MAIN PUMP .........................................................................................................................................582
			REMOVAL .......................................................................................................................................582
			INSTALLATION...................................................................................................................................583
		FLOOR FRAME........................................................................................................................................584
			REMOVAL........................................................................................................................................584
			INSTALLATION...................................................................................................................................586
		COUNTERWEIGHT......................................................................................................................................587
			REMOVAL AND INSTALLATION.......................................................................................................................587
40 MAINTENANCE STANDARD....................................................................................................................................588
	SWING MACHINERY........................................................................................................................................589
	SWING CIRCLE...........................................................................................................................................590
	TRACK FRAME, RECOIL SPRING.............................................................................................................................591
	IDLER..................................................................................................................................................592
	TRACK ROLLER...........................................................................................................................................593
	CARRIER ROLLER.........................................................................................................................................594
	SPROCKET...............................................................................................................................................595
	TRACK SHOE.............................................................................................................................................596
	HYDRAULIC PUMP.........................................................................................................................................599
	CONTROL VALVE..........................................................................................................................................601
	SELF PRESSURE REDUCING VALVE...........................................................................................................................608
	SWING MOTOR............................................................................................................................................610
	CENTER SWIVEL JOINT....................................................................................................................................611
	WORK EQUIPMENT, SWING PPC VALVE........................................................................................................................612
	TRAVEL PPC VALVE.......................................................................................................................................613
	BLADE, OFFSET PPC VALVE................................................................................................................................614
	HYDRAULIC CYLINDER.....................................................................................................................................615
	WORK EQUIPMENT.........................................................................................................................................617
	DIMENSION OF WORK EQUIPMENT............................................................................................................................621
90 OTHERS..................................................................................................................................................625
	HYDRAULIC CIRCUIT DIAGRAM..............................................................................................................................626
		STANDERD SPEC......................................................................................................................................626
		SERVICE VALVE SPEC.................................................................................................................................627
		SLIDE ARM SPEC.....................................................................................................................................628
		MONO BOOM SPEC.....................................................................................................................................629
	ELECTRICAL CIRCUIT DIAGRAM.............................................................................................................................630
		STANDERD SPEC. ....................................................................................................................................630
		LONG ARM SPEC......................................................................................................................................631

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