Komatsu Hydraulic Excavator PC400LC-LK, PC400HD-LK Series Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC400LC-6LK, PC400HD-6LK, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC400LC-6LK, PC400HD-6LK avance workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,123 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM002901 - Hydraulic Excavator PC400LC-6LK, PC400HD-6LK avance Operation & Maintenance Manual.pdf
CEBM002502 - Hydraulic Excavator PC400LC-6LK, PC400HD-6LK avance Shop Manual.pdf
MAIN SECTIONS
MAIN MENU....0
COVER....1
CONTENTS....2
FOREWORD....13
SAFETY....13
SAFETY NOTICE....13
IMPORTANT SAFETY NOTICE....13
GENERAL PRECAUTIONS....13
PREPARATIONS FOR WORK....13
PRECAUTIONS DURING WORK....13
GENERAL....15
HOW TO READ THE SHOP MANUAL....16
VOLUMES....16
DISTRIBUTION AND UPDATING....16
FILING METHOD....16
REVISED EDITION MARK....16
REVISIONS....16
SYMBOLS....16
HOISTING INSTRUCTIONS....17
HOISTING....17
WIRE ROPES....17
COATING MATERIALS....18
STANDARD TIGHTENING TORQUE....20
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS....20
TIGHTENING TORQUE OF HOSE NUTS....21
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....21
TIGHTENING TORQUE FOR FLARED NUTS....21
ELECTRIC WIRE CODE....22
CLASSIFICATION BY THICKNESS....22
CLASSIFICATION BY COLOR AND CODE....22
CONVERSION TABLES....23
METHOD OF USING THE CONVERSION TABLE....23
01 GENERAL....29
SPECIFICATION DRAWINGS....30
MACHINE....30
WORK EQUIPMENT....32
SPECIFICATIONS....34
WEIGHT TABLE....36
FUEL COOLANT AND LUBRICANTS....38
10 STRUCTURE AND FUNCTION....39
PARTS RELATED TO ENGINE....43
ENGINE MOUNT TORQUES....45
RADIATOR, OIL COOLER....47
RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (1/4)....48
RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (2/4)....49
RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (3/4)....50
RADIATOR AND OIL COOLER SPECIFICATIONS AND TORQUES (4/4)....52
POWER TRAIN....53
FINAL DRIVE....55
FINAL DRIVE SPECIFICATIONS AND TORQUES....56
SWING CIRCLE....58
SWING CIRCLE SPECIFICATIONS AND TORQUES....59
SWING MACHINERY....61
SWING MACHINERY SPECIFICATIONS AND TORQUES....62
TRACK FRAME, RECOIL SPRING....64
PC400LC-6LK....64
TRACK FRAME, RECOIL SPRING TORQUES PC400LC-6LK....65
PC400LC-6LK - VARIABLE GAUGE....66
TRACK FRAME, RECOIL SPRING TORQUES PC400LC-6LK - VARIABLE GAUGE....67
PC400HD-6LK....68
TRACK FRAME, RECOIL SPRING TORQUES PC400HD-6LK....69
TRACK SHOE....71
TRACK SHOE SPECIFICATIONS....74
CARRIER ROLLER....75
IDLER....76
TRACK ROLLER....78
HYDRAULIC PIPING DRAWING....80
HYDRAULIC CIRCUIT DIAGRAM....82
HYDRAULIC TANK, HYDRAULIC FILTER....83
HYDRAULIC PUMP....84
HPV 160 + 160....84
HYDRAULIC PUMP TORQUES....87
TVC, LS VALVE....91
LS VALVE - OPERATION....94
TVC VALVE - OPERATION....98
HYDRAUIC CYLINDER....106
BOOM, BUCKET CYLINDER - THREADED PISTON....106
BOOM, BUCKET CYLINDER - CLAMPED PISTON....106
ARM CYLINDER - THREADED PISTON....106
ARM CYLINDER - CLAMPED PISTON....106
CONTROL VALVE....108
10 SPOOL VALVE - STD. AND 3 SERVICE VALVES....108
9 SPOOL VALVE - STD AND 2 SERVICE VALVES....114
8 SPOOL VALVE - STD AND 1 SERVICE VALVES....115
7 SPOOL VALVE - STD....116
CONTROL VALVE SPECIFICATIONS AND TORQUES....118
10 SPOOL VALVE....118
SELF REDUCING PRESSURE VALVE....124
SELF REDUCING PRESSURE VALVE SPECIFICATIONS....124
SUCTION SAFETY VALVE....130
FOR SERVICE....130
SUCTION SAFETY VALVE SPECIFICATIONS AND TORQUES....131
CLSS....132
OUTLINE OF CLSS....132
BASIC PRINCIPLE....133
CONTROL OF PUMP SWASH PLATE ANGLE....133
PRESSURE COMPENSATION....134
OPERATION FOR EACH FUNCTION OF CLSS....135
SYSTEM DIAGRAM....136
WHEN UNLOAD VALVE IS ACTUATED....137
OPERATION OF RELIEF VALVE....138
CUT-OFF CONTROL ACTUATED....138
CUT-OFF CANCELED....138
INTRODUCTION OF LS PRESSURE....139
LS BYPASS VALVE....140
PRESSURE COMPENSATION VALVE....141
SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE....144
VARIABLE TYPE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE)....146
VARIABLE PRESSURE COMPENSATION VALVE SPECIFICATIONS AND TORQUES....147
BOOM REGENERATION CIRCUIT....148
ARM REGENERATION CIRCUIT....150
MERGE FLOW DIVIDER VALVE....152
LS SELECT VALVE....154
2-STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD)....155
OPERATION OF CLSS SYSTEM AS A WHOLE....156
WHEN ALL WORK EQUIPMENT IS AT NEUTRAL....156
WHEN PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY....157
WHEN PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY....157
WHEN PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY....157
WHEN PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY....158
WHEN PUMP DIVIDED, TRAVEL OPERATED INDEPENDENTLY....158
WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY....158
WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY....159
WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY....159
WHEN PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY....159
SWING MOTOR....160
SWING MOTOR SPECIFICATIONS AND TORQUES....162
SUCTION-SAFETY VALVE....163
SWING BRAKE....164
CENTER SWIVAL JOINT....165
CENTER SWIVEL JOINT SPECIFICATIONS....166
TRAVEL MOTOR....168
MOTOR OPERATION....172
AT LOW SPEED....172
AT HIGH SPEED....173
PARKING BRAKE OPERATION....174
BRAKE VALVE OPERATION....174
SAFETY VALVE....176
VALVE CONTROL....179
WORK EQUIPMENT PPC VALVE....180
OPERATION....182
AT NEUTRAL....182
DURING FINE CONTROL (NEUTRAL ? FINE CONTROL)....182
DURING FINE CONTROL (WHEN LEVER IS RETURNED)....183
AT FULL STROKE....183
WORK EQUIPMENT AND SWING PPC VALVE SPECIFICATIONS AND TORQUES....184
TRAVEL PPC VALVE....185
OPERATION....187
AT NEUTRAL....187
FINE CONTROL (NEUTRAL --> FINE CONTROL)....187
FINE CONTROL (CONTROL LEVER RETURNED)....188
AT FULL STROKE....188
TRAVEL PPC VALVE SPECIFICATIONS AND TORQUE....190
SERVICE PPC VALVE....192
SERVICE PPC VALVE SPECIFICATIONS AND TORQUES....194
PPC SAFETY LOCK VALVE....195
PPC ACCUMULATOR....196
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE....197
PPC SHUTTLE VALVE....198
TRAVEL JUNCTION VALVE....201
STRAIGHT-TRAVEL SYSTEM....202
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE SPECIFICATIONS AND TORQUES....204
LS-EPC VALVE....205
LS-EPC VALVE SPECIFICATIONS AND TORQUES....208
SOLENOID VALVE....209
SOLENOID VALVE TORQUES....211
BOOM HOLDING VALVE....212
BOOM HOLDING VALVE SPECIFICATIONS AND TORQUES....215
WORK EQUIPMENT....217
WORK EQUIPMENT SPECIFICATIONS....218
DIMENSIONS OF WORK EQUIPMENT....220
ARM....220
BUCKET....222
AIR CONDITIONER....225
A/C PIPING....225
A/C ELECTRICAL WIRING DIAGRAM....226
ENGINE CONTROL....230
OPERATION....231
STARTING ENGINE....231
ENGINE SPEED CONTROL....231
STOPPING ENGINE....231
COMPONENTS....232
FUEL CONTROL DIAL....232
GOVERNOR MOTOR....234
GOVERNOR, PUMP CONTROLLER....236
INPUT OUTPUT SIGNALS....237
ELECTRONIC CONTROL SYSTEM....239
CONTROL FUNCTION....239
TOTAL SYSTEM DIAGRAM....239
PUMP AND ENGINE CONTROL SYSTEM....240
PUMP AND VALVE CONTROL FUNCTION....243
CUT-OFF FUNCTION....244
CUT-OFF CANCEL FUNCTION....244
FINE CONTROL MODE FUNCTION....245
POWER MAX. FUNCTION, SWIFT SLOW-DOWN FUNCTION....246
AUTO DECELERATION SYSTEM....247
AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION....249
SWING CONTROL SYSTEM....252
TRAVEL CONTROL SYSTEM....254
ACTIVE MODE FUNCTION....256
INCREASE IN ENGINE SPEED....257
COMPONENTS OF SYSTEM....258
ENGINE SPEED SENSOR....258
PPC HYDRAULIC SWITCH....258
PUMP PRESSURE SENSOR....259
TVC PROLIX RESISTOR....260
MACHINE MONITOR SYSTEM....262
MONITOR PANEL....263
MONITOR DISPLAY....264
CONTENT OF DISPLAY....265
OIL MAINTENANCE FUNCTION....266
MODE SELECTION SWITCHES....268
SWITCH ACTUATION TABLE....268
SENSORS....269
20 TESTING, ADJUSTING AND TROUBLESHOOTING....273
STANDARD VALUE TABLES....275
ENGINE RELATED PARTS....275
CHASSIS RELATED PARTS....276
ELECTRICAL PARTS....281
TESTING AND ADJUSTING....287
SERVICE TOOLS....289
ENGINE....290
BLOW BY PRESSURE....290
BOOST PRESSURE....290
COMPRESSION PRESSURE....290
ENGINE OIL PRESSURE....290
ENGINE SPEED SENSOR....290
ENGINE SPEED (rpm)....290
EXHAUST COLOR....290
FUEL INJECTION TIMING....290
VALVE CLEARANCE....290
GOVERNOR MOTOR LEVER S TROKE....291
FAN BELT TENSION....292
A/C COMPRESSOR BELT....292
WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....293
TVC VALVE OUTPUT PRESSURE....296
LS VALVE OUTPUT PRESSURE....298
LS DIFFERENTIAL PRESSURE....298
CONTROL CIRCUIT OIL PRESSURE....301
SOLENOID VALVE OUTPUT PRESSURE....302
PPC VALVE OUTPUT PRESSURE....305
PPC SHUTTLE VALVE....305
WORK EQUIPMENT, SWING PPC VALVE....307
WORK EQUIPMENT....309
HYDRAULIC DRIFT - LOCATIONS CAUSING....309
CYLINDER PACKING....309
BOOM LOCK VALVE....310
PPC VALVE....310
OIL LEAKAGE....311
WORK EQUIPMENT CYLINDER....311
SWING MOTOR....312
TRAVEL MOTOR....312
RELEASING REMAINING PRESSURE....313
TESTING CLEARANCE OF SWING CIRCLE BEARING....314
SPROCKET WEAR....315
TRACK SHOE TENSION....316
BLEEDING AIR....317
BLEEDING AIR FROM HYDRAULIC CYLINDERS....318
BLEEDING AIR FROM SWING MOTOR....318
BLEEDING AIR FROM TRAVEL MOTOR....318
TROUBLESHOOTING GENERAL....319
POINTS TO REMEMBER WHEN TROUBLESHOOTING....321
SEQUENCE OF EVENTS IN TROUBLESHOOTING....323
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....324
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT....324
HANDLING WIRING HARNESSES AND CONNECTORS....324
REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES....326
HANDLING CONTROL BOX....329
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS....330
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT....330
CHECKS BEFORE TROUBLESHOOTING....332
CONNECTOR TYPES AND MOUNTING LOCATIONS....333
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....339
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....349
EXPLANATION OF MACHINE CONTROL FUNCTIONS....349
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL....350
DISPLAY ON MACHINE MONITOR....350
RECORDING OF SERVICE CODES AND USER CODE DISPLAY FUNCTION....350
METHOD OF DISPLAYING TROUBLE DATA....351
MACHINE DATA MONITORING FUNCTION....352
METHOD OF DISPLAYING MONITORING CODE....352
TABLE OF MACHINE MONITORING CODES....353
BIT PATTERN CHART....354
GOVERNOR MOTOR ADJUSTMENT MODE....356
TIME ADJUSTMENT MODE....356
WORKING MODE DEFAULT SETTING MODE....357
METHOD OF USING JUDGEMENT TABLE....358
METHOD OF USING TROUBLESHOOTING CHARTS....360
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE....360
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE....364
PROCEDURE FOR CHECKING MONITOR PANEL OUTPUT SIGNAL....366
CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER....367
PUMP CONTROL SYSTEM....367
GOVERNOR CONTROL SYSTEM....370
SERVICE CODE TABLE....371
TROUBLESHOOTING ELECTRICAL SYSTEM ON GOVERNOR PUMP CONTROLLER (C-MODE)....373
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....375
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF....375
USER CODE MEMORY RETENTION FUNCTION....375
INFORMATION CONTAINED IN TESTING PROCEDURES....376
(C-1)....378
CONTROLLER POWER SOURCE (LED) IS OFF....378
(C-2)....380
SHORT IN FRONT PUMP (TVC) SOLENOID SYSTEM....380
(C-3)....382
OPEN IN FRONT PUMP (TVC) SOLENOID SYSTEM....382
(C-4)....384
SHORT IN REAR PUMP (TVC) SOLENOID SYSTEM....384
(C-5)....386
OPEN IN REAR PUMP (TVC) SOLENOID SYSTEM....386
(C-6)....388
SHORT IN (LS) SELECT SOLENOID SYSTEM....388
(C-7)....389
OPEN IN (LS) SELECT SOLENOID SYSTEM....389
(C-8)....390
SHORT IN SWING BRAKE SOLENOID SYSTEM....390
(C-9)....392
OPEN IN SWING BRAKE SOLENOID SYSTEM....392
(C-10)....394
SHORT IN PUMP MERGE DIVIDER SOLENOID SYSTEM....394
(C-11)....396
OPEN IN PUMP MERGE DIVIDER SOLENOID SYSTEM....396
(C-12)....398
SHORT IN TRAVEL SPEED SOLENOID SYSTEM....398
(C-13)....400
OPEN IN TRAVEL SPEED SOLENOID SYSTEM....400
(C-14)....402
SHORT IN ACTIVE MODE, SWING, SOLENOID SYSTEM....402
(C-15)....404
OPEN IN ACTIVE MODE, SWING, SOLENOID SYSTEM....404
(C-16)....406
ABNORMAL INPUT FOR MODEL CODE....406
(C-17)....408
SHORT IN (LS-EPC) SOLENOID SYSTEM....408
(C-18)....409
OPEN IN (LS-EPC) SOLENOID SYSTEM....409
(C-19)....410
ABNORMAL FRONT PUMP PRESSURE SENSOR SIGNAL....410
(C-20)....412
BINOMIAL REAR PUMP PRESSURE SENSOR SIGNAL....412
(C-21)....414
ABNORMAL PRESSURE SENSOR POWER SUPPLY....414
(C-22)....416
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER....416
(C-23)....418
MACHINE PUSH-UP SOLENOID HAS NO RESPONSE....418
TROUBLESHOOTING ELECTRICAL SYSTEM ON GOVERNOR PUMP CONTROLLER (E-MODE)....421
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....423
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF....423
USER CODE MEMORY RETENTION FUNCTION....423
INFORMATION CONTAINED IN TESTING PROCEDURES....424
(E-1)....426
CONTROLLER POWER SOURCE (LED) IS OFF....426
(E-2)....428
INCORRECT FUEL CONTROL DIAL VALUE DISPLAYED....428
(E-3)....430
OPEN IN MOTOR DRIVE SYSTEM....430
(E-4)....432
SHORT IN MOTOR DRIVE SYSTEM....432
(E-5)....434
INCORRECT FEEDBACK IN POTENTIOMETER DISPLAYED....434
(E-6)....436
SHORT IN BATTERY RELAY OUTPUT SYSTEM....436
(E-7)....438
ABNORMALITY IN STEP OUT MOTOR SYSTEM....438
(E-8)....440
ENGINE WILL NOT CRANK....440
(E-9)....442
ENGINE SPEED IRREGULAR....442
ENGINE SPEED IS HUNTING....444
(E-10)....446
ENGINE OUTPUT IS LOW....446
(E-11)....448
ENGINE WILL NOT SHUT DOWN....448
(E-12)....450
FAULTY OPERATION OF RELAY OUTPUT SYSTEM....450
TROUBLSHOOTING GOVERNOR, PUMP CONTROLLER, INPUT SIGNAL (F-MODE)....453
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....454
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF....454
USER CODE MEMORY RETENTION FUNCTION....454
INFORMATION CONTAINED IN TESTING PROCEDURES....455
(F-1)....457
SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP....457
(F-2)....458
TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP....458
(F-3)....459
BOOM (LOWER) PRESSURE SWITCH DOES NOT LIGHT UP....459
(F-4)....460
BOOM (RAISE) PRESSURE SWITCH DOES NOT LIGHT UP....460
(F-5)....461
ARM (IN) PRESSURE SWITCH DOES NOT LIGHT UP....461
(F-6)....462
ARM (OUT) PRESSURE SWITCH DOES NOT LIGHT UP....462
(F-7)....463
BUCKET (CURL) PRESSURE SWITCH DOES NOT LIGHT UP....463
(F-8)....464
BUCKET (DUMP) PRESSURE SWITCH DOES NOT LIGHT UP....464
(F-9)....465
SWING LOCK SWITCH DOES NOT LIGHT UP....465
(F-10)....466
MODE CONNECTION DOES NOT LIGHT UP....466
(F-11)....468
LEFT KNOB SWITCH DOES NOT LIGHT UP....468
TROUBLESHOOTING HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)....471
PUMP MERGE DIVIDER LOGIC....473
SOLENOID ACTUATION TABLE....473
TABLE OF FAILURE MODES AND CAUSES....474
H-1....478
SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER....478
H-2....480
THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS....480
H-3....481
NO WORK EQUIPMENT, TRAVEL, SWING MOVEMENT....481
H-4....482
ABNORMAL NOISE GENERATED AROUND PUMP....482
H-5....483
AUTO DECELERATION DOES NOT WORK WHEN PPC SHUTTLE VALVE IS CAUSE....483
H-6....483
FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR....483
H-7....484
BOOM IS SLOW OR LACKS POWER....484
H-8....486
ARM IS SLOW OR LACKS POWER....486
H-9....488
BUCKET IS SLOW OR LACKS POWER....488
H-10....490
WORK EQUIPMENT; BOOM, ARM, BUCKET, DOES NOT MOVE, BUT TRAVEL AND SWING ARE NORMAL....490
H-11....490
EXCESSIVE HYDRAULIC DRIFT, BOOM, ARM, BUCKET....490
EXCESSIVE HYDRAULIC DRIFT OF BOOM....490
EXCESSIVE HYDRAULIC DRIFT OF ARM OR BUCKET....490
H-12....491
EXCESSIVE TIME LAG, ENGINE AT LOW IDLING....491
H-13....491
OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED....491
H-14....492
IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED....492
H-15....492
MALFUNCTION OF MACHINE PUSH UP FUNCTION....492
H-16....492
IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW....492
H-17....493
IN SWING PLUS BOOM RAISE, BOOM RAISE IS SLOW....493
IN ACTIVE MODE....493
IN OTHER MODE....493
H-18....493
IN SWING PLUS ARM, ARM IS SLOW....493
H-19....493
IN SWING PLUS TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY....493
H-20....494
TRAVEL DEVIATION....494
WHEN THERE IS A DEVIATION IN NORMAL TRAVEL....494
EXCESSIVE DEVIATION WHEN STARTING....494
H-21....496
TRAVEL SPEED IS SLOW....496
H-22....498
STEERING DOES NOT TURN EASILY OR LACKS POWER....498
H-23....500
TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED....500
H-24....500
TRAVEL DOES NOT MOVE, ONE SIDE ONLY....500
H-25....501
DOES NOT SWING....501
DOES NOT SWING TO EITHER LEFT OR RIGHT....501
DOES NOT SWING IN ONE DIRECTION....501
H-26....502
SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW....502
H-27....504
EXCESSIVE OVERRUN WHEN STOPPING SWING....504
ONE DIRECTION ONLY....504
BOTH DIRECTIONS....504
H-28....505
EXCESSIVE SHOCK WHEN STOPPING SWING, ONE DIRECTION ONLY....505
H-29....505
EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....505
H-30....506
EXCESSIVE HYDRAULIC DRIFT OR SWING....506
WHEN SWING HOLDING BRAKE IS RELEASED....506
WHEN SWING HOLDING BRAKE IS APPLIED....506
H-31....507
SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED....507
TROUBLESHOOTING MACHINE MONITOR SYSTEM (M-MODE)....509
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....511
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF....511
USER CODE MEMORY RETENTION FUNCTION....511
INFORMATION CONTAINED IN TESTING PROCEDURES....512
(M-1)....514
ERROR IN DATA HISTORY....514
(M-2)....516
SHORT IN BUZZER OUTPUT DISPLAY....516
(M-3)....518
AIR CLEANER CLOG INDICATOR FAILURE....518
(M-4)....520
ABNORMAL ENGINE (HI) OIL PRESSURE....520
(M-5)....522
ENGINE COOLANT INDICATING OVERHEAT CONDITION....522
(M-6)....524
THREE SECOND DELAY ON MONITOR WHEN IGNITION KEY IS TURNED ?ON?....524
(M-7)....526
WHEN IGNITION SWITCH IS TURNED ?ON? ALL PANEL LAMPS STAY ILLUMINATED....526
(M-8)....526
WHEN IGNITION SWITCH IS TURNED ?ON? PANEL LIGHTS DO NOT MATCH THE MACHINE....526
(M-9)....528
ABNORMAL FLUID LEVEL INDICATIONS....528
ENGINE COOLANT LEVEL FLASHES....528
ENGINE OIL LEVEL FLASHES....530
HYDRAULIC OIL LEVEL FLASHES....531
(M-10)....532
PREHEATING INDICATION IS ?ON? WHEN SYSTEM IS OFF....532
(M-11)....534
WHEN ENGINE IS STARTED BASIC CHECK ITEMS FLASH....534
ALTERNATOR SYSTEM....534
ENGINE OIL PRESSURE....536
(M-12)....538
WHEN ENGINE IS STARTED CAUTION ITEMS FLASH....538
ALTERNATOR SYSTEM....538
ENGINE OIL PRESSURE....540
(M-13)....542
WHEN THE ENGINE IS STARTED CAUTION AND EMERGENCY ITEMS FLASH....542
ENGINE OIL PRESSURE FLASHES....542
COOLANT LEVEL FLASHES....542
BATTERY CHARGE INDICATOR FLASHES....542
COOLANT TEMPERATURE FLASHES....543
FUEL LEVEL FLASHES....544
AIR CLEANER CLOG INDICATOR FLASHES....545
(M-14)....546
WARNINGS FLASH BUT BUZZER IS DELAYED....546
(M-15)....548
BUZZER SOUNDS CONTINUOUSLY....548
(M-16)....550
NIGHT LIGHT ON MONITOR PANEL DOES NOT LIGHT-UP....550
(M-17)....552
ENGINE COOLANT TEMPERATURE DOES NOT RISE....552
(M-18)....554
ENGINE COOLANT TEMPERATURE GIVES NO DISPLAY....554
(M-19)....556
FUEL LEVEL GAUGE ALWAYS SHOWS ?FULL?....556
(M-20)....557
FUEL LEVEL GAUGE DOES NOT DISPLAY....557
(M-21)....558
SWING LOCK NOT INDICATED ON MONITOR WHEN ?ON?....558
(M-22)....560
SWING PROLOX NOT INDICATED ON MONITOR....560
(M-23)....562
SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING....562
(M-24)....563
WITH IGNITION SWITCH ?OFF?, WHEN THE TIME SWITCH IS PRESSED THE TIME AND SERVICE ARE NOT DISPLAYED....563
(M-25)....564
FAULTY FUEL LEVER SENSOR SYSTEM....564
(M-26)....565
COOLANT TEMPERATURE SENSOR SYSTEM....565
(M-27)....566
FAULTY ENGINE OIL LEVEL SENSOR SYSTEM....566
(M-28)....568
FAULTY ENGINE COOLANT LEVEL SENSOR SYSTEM....568
(M-29)....570
FAULTY HYDRAULIC OIL LEVEL SENSOR SYSTEM....570
(M-30)....572
WIPER DOES NOT WORK, OR REMAINS ?ON?....572
WIPER DOES NOT WORK....572
WIPER SWITCH IS IN THE "OFF" POSITION BUT WIPERS REMAIN ON....575
(M-13)....578
WASHER MOTOR WORKS WHEN SWITCH IS NOT BEING USED OR WASHER MOTOR DOES NOT WORK....578
TROUBLESHOOTING COMMUNICATION SYSTEM (N-MODE)....581
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....582
POINTS TO REMEMBER IF A PROBLEM RETURNS TO NORMAL BY ITSELF....582
USER CODE MEMORY RETENTION FUNCTION....582
INFORMATION CONTAINED IN TESTING PROCEDURES....583
(N-1)....585
COMMUNICATION ABNORMALITY....585
30 DISASSEMBLY AND ASSEMBLY....587
METHOD OF USING MANUAL....589
PRECAUTIONS DURING OPERATION....590
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK....590
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK....591
PRECAUTIONS WHEN COMPLETING THE OPERATIONS....592
OTHER PRECAUTIONS....592
SPECIAL TOOL LIST....593
SKETCHES OF SPECIAL TOOLS....598
ENGINE....606
AFTERCOOLER....606
ALTERNATOR....606
CYLINDER HEAD....606
ENGINE OIL COOLER....606
ENGINE REAR SEAL....606
FUEL INJECTION PUMP....606
NOZZLE HOLDER....606
STARTING MOTOR....606
THERMOSTAT....606
TURBOCHARGER....606
WATER PUMP....606
GOVERNOR MOTOR....607
OIL COOLER....608
RADIATOR, OIL COOLER....610
ENGINE, MAIN HYDRAULIC PUMP....613
DAMPER....618
FUEL TANK....619
CENTER SWIVEL JOINT....620
FINAL DRIVE....622
TRAVEL MOTOR....633
SPROCKET....647
SWING MOTOR....648
SWING MACHINERY....658
REVOLVING FRAME....667
SWING CIRCLE....669
IDLER AND RECOIL SPRING....670
IDLER....671
RECOIL SPRING....675
TRACK ROLLER....677
CARRIER ROLLER....683
TRACK CHAIN....688
HYDRAULIC TANK....689
MAIN HYDRAULIC PUMP....691
DISASSEMBLY....693
PUMP ASSEMBLY....693
FRONT PUMP....693
REAR PUMP....698
ASSEMBLY....701
FRONT PUMP....701
REAR PUMP....709
MAIN PUMP OIL SEAL....720
CONTROL VALVE....721
PUMP MERGE DIVIDER VALVE....735
PRESSURE COMPENSATION VALVE....736
FRONT PUMP SERVO VALVE....737
REAR PUMP SERVO VALVE....738
LS-EPC SOLENOID VALVE....739
SOLENOID VALVE....740
WORK EQUIPMENT PPC VALVE....742
TRAVEL PPC VALVE....744
PPC SHUTTLE VALVE....747
BOOM LOCK VALVE....750
CYLINDER....752
BOOM....752
ARM....754
BUCKET....756
HYDRAULIC....758
BOLT ON TYPE PISTON....758
THREADED STYLE PISTON....762
WORK EQUIPMENT....768
BUCKET....770
ARM....772
BUCKET AND ARM....774
BOOM....776
OPERATORS CAB....778
COUNTERWEIGHT....780
AIR CONDITIONER....781
COMPRESSOR....781
CONDENSER....782
RECEIVER TANK....783
AIR CONDITIONER UNIT....784
GOVERNOR, PUMP CONTROLLER....786
MONITOR PANEL....787
CONTROL STAND CASE....788
90 OTHERS....791
ELECTRICAL....793
FOLDOUT 1 - CIRCUIT DIAGRAM SHEET 1 (Part 1 of 3)....793
FOLDOUT 2 - CIRCUIT DIAGRAM SHEET 1 (Part 2 of 3)....795
FOLDOUT 3 - CIRCUIT DIAGRAM SHEET 1 (Part 3 of 3)....797
FOLDOUT 4 - CIRCUIT DIAGRAM SHEET 2 (Part 1 of 2)....799
FOLDOUT 5 - CIRCUIT DIAGRAM SHEET 2 (Part 2 of 2)....801
FOLDOUT 6 - CIRCUIT DIAGRAM SHEET 3 (Part 1 of 1)....803
FOLDOUT 7 - ELECTRONIC CONTROL SYSTEM - TOTAL SYSTEM DIAGRAM....805
HYDRAULIC....807
FOLDOUT 8 - CIRCUIT DIAGRAM (Sheet 1 of 4)....807
FOLDOUT 9 - CIRCUIT DIAGRAM (Sheet 2 of 4)....809
FOLDOUT 10 - CIRCUIT DIAGRAM (Sheet 3 of 4)....811
FOLDOUT 11 - CIRCUIT DIAGRAM (Sheet 4 of 4)....813
CLSS OPERATION FOR EACH FUNCTION....815
FOLDOUT 12 - HYDRAULIC CIRCUIT DIAGRAM....815
FOLDOUT 13 - WHEN ALL WORK EQUIPMENT IS AT NEUTRAL....817
FOLDOUT 14 - WHEN PUMP FLOW MERGED, BUCKET CURL OPERATED INDEPENDENTLY....819
FOLDOUT 15 - WHEN PUMP FLOW MERGED, BOOM RAISE OPERATED INDEPENDENTLY....821
FOLDOUT 16 - WHEN PUMP FLOW MERGED, ARM IN OPERATED INDEPENDENTLY....823
FOLDOUT 17 - WHEN PUMP FLOW MERGED, ARM OUT OPERATED INDEPENDENTLY....825
FOLDOUT 18 - WHEN PUMP DIVIDED, TRAVEL OPERATED INDEPENDENTLY....827
FOLDOUT 19 - WHEN PUMP FLOW MERGED, ARM IN + BOOM RAISE OPERATED SIMULTANEOUSLY....829
FOLDOUT 20 - WHEN PUMP FLOW MERGED, SWING + BOOM RAISE OPERATED SIMULTANEOUSLY....831
FOLDOUT 21 - WHEN PUMP FLOW DIVIDED, TRAVEL + BOOM RAISE OPERATED SIMULTANEOUSLY....833
FOLDOUT 22 - WHEN PUMP FLOW DIVIDED, TRAVEL + ARM IN OPERATED SIMULTANEOUSLY....835S
