Komatsu Hydraulic Excavator PC450-6K, PC450LC-6K Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC450-6K, PC450LC-6K, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC450-6K, PC450LC-6K 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: 2,143 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
EEBM001304 - Hydraulic Excavator PC450-6K, PC450LC-6K Shop Manual.pdf
UEBM001301 - Hydraulic Excavator PC450-6K, PC450LC-6K Shop Manual.pdf
EEAM008402 - Hydraulic Excavator PC450-6K, PC450LC-6K Operation & Maintenance Manual.pdf
EEAM008404 - Hydraulic Excavator PC450LC-6K Operation & Maintenance Manual.pdf
MAIN SECTIONS
EEAM008402 - Hydraulic Excavator PC450-6K, PC450LC-6K Operation & Maintenance Manual....2
EEAM008404 - Hydraulic Excavator PC450LC-6K Operation & Maintenance Manual....264
COVER....264
1. FOREWARD....265
2. SAFETY INFORMATION....266
2.1 SAFETY MESSAGES....266
2.2 NOISE....267
2.3 VIBRATION....267
3. INTRODUCTION....268
3.1 INTENDED USE....268
3.2 FEATURES....268
3.3 BREAKING IN YOUR NEW MACHINE....268
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....269
4.1 MACHINE SERIAL NO. PLATE POSITION....269
4.2 ENGINE SERIAL NO. PLATE POSITION....269
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....269
4.4 MACHINE SERIAL PLATE....270
5. CONTENTS....271
SAFETY....275
6. GENERAL PRECAUTIONS....276
7. PRECAUTIONS DURING OPERATION....282
7.1 BEFORE STARTING ENGINE....282
7.2 OPERATING MACHINE....284
7.3 LOADING AND UNLOADING....289
7.4 BATTERY....290
7.5 TOWING....291
7.6 BUCKET WITH HOOK....292
7.6.1 GENERAL PRECAUTIONS....292
7.6.2 PRECAUTIONS FOR LIFTING OPERATION....294
8. PRECAUTIONS FOR MAINTENANCE....295
8.1 BEFORE CARRYING OUT MAINTENANCE....295
8.2 DURING MAINTENANCE....298
9. POSITION FOR ATTACHING SAFETY LABELS....302
OPERATION....307
10. GENERAL VIEW....308
10.1 GENERAL VIEW OF MACHINE....308
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....309
11. EXPLANATION OF COMPONENTS....310
11.1 MACHINE MONITOR....310
11.2 SWITCHES....321
11.3 CONTROL LEVERS, PEDALS....325
11.4 ROOF HATCH....330
11.5 FRONT WINDOW....331
11.6 DOOR LOCK....333
11.7 CAP, COVER WITH LOCK....334
11.8 LUGGAGE TRAY....335
11.9 ASHTRAY....335
11.10 AIR CONDITIONER....336
11.11 CAB RADIO (OPTION)....339
11.12 FUSE....340
11.13 FUSIBLE LINK....341
11.14 CONTROLLERS....341
11.15 TOOL BOX/GREASE GUN HOLDER....341
11.16 REFUELLING PUMP (OPTION)....341
11.17 HANDLING THE ACCUMULATOR....342
12. OPERATION....344
12.1 CHECK BEFORE STARTING ENGINE....344
12.2 STARTING ENGINE....354
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....357
12.4 MOVING MACHINE OFF....363
12.5 STEERING MACHINE....366
12.6 STOPPING MACHINE....368
12.7 SWINGING....369
12.8 OPERATION OF WORK EQUIPMENT....370
12.9 HANDLING ACTIVE MODE....371
12.10 WORKING MODE SELECTION....372
12.11 PROHIBITIONS FOR OPERATION....374
12.12 PRECAUTIONS FOR OPERATION....376
12.13 PRECAUTIONS WHEN TRAVELLING UP OR DOWN HILLS....377
12.14 HOW TO ESCAPE MUD....379
12.15 WORK POSSIBLE USING HYDRAULIC EXCAVATOR....380
12.16 REPLACEMENT AND INVERSION OF BUCKET....381
12.17 PARKING THE MACHINE....383
12.18 CHECK AFTER FINISHING WORK....384
12.19 STOPPING ENGINE....385
12.20 CHECK AFTER STOPPING ENGINE....386
12.21 LOCKING....386
12.22 OVERLOAD WARNING DEVICE....386
13. TRANSPORTATION....387
13.1 LOADING, UNLOADING WORK....387
13.2 PRECAUTIONS FOR LOADING....389
13.3 PRECAUTIONS FOR TRANSPORTATION....389
13.4 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....390
13.5 METHOD OF LIFTING MACHINE....391
14. COLD WEATHER OPERATION....392
14.1 PRECAUTIONS FOR LOW TEMPERATURE....392
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....393
14.3 AFTER COLD WEATHER....393
15. LONG-TERM STORAGE....394
15.1 BEFORE STORAGE....394
15.2 DURING STORAGE....395
15.3 AFTER STORAGE....395
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE....395
16. TROUBLESHOOTING....396
16.1 PHENOMENA THAT ARE NOT FAILURES....396
16.2 METHOD OF TOWING MACHINE....396
16.3 USING METHOD FOR LIGHT-WEIGHT TOWING HOLE....396
16.4 PRECAUTIONS ON PARTICULAR JOBSITES....397
16.5 IF BATTERY IS DISCHARGED....397
16.6 OTHER TROUBLE....401
MAINTENANCE....407
17. GUIDES TO MAINTENANCE....408
18. OUTLINES OF SERVICE....411
18.1 OUTLINE OF OIL, FUEL, COOLANT....411
18.2 OUTLINE OF ELECTRIC SYSTEM....415
18.3 OUTLINE OF HYDRAULIC SYSTEM....416
19. WEAR PARTS LIST....417
20. USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....418
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....422
21.1 INTRODUCTION OF NECESSARY TOOLS....422
21.2 TORQUE LIST....423
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....424
23. MAINTENANCE SCHEDULE CHART....426
23.1 MAINTENANCE SCHEDULE CHART....426
23.2 MAINTENANCE WHEN USING HYDRAULIC BREAKER....428
24. SERVICE PROCEDURE....429
24.1 INITIAL 250 HOURS SERVICE (ONLY AFTER THE FIRST 250 HOURS)....429
REPLACE FUEL FILTER CARTRIDGE....468
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....464
CHECK ENGINE VALVE CLEARANCE, ADJUST....479
24.2 WHEN REQUIRED....430
24.2.1 CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....430
24.2.2 CLEAN INSIDE OF COOLING SYSTEM....432
24.2.3 CHECKING COOLANT LEVEL....436
24.2.4 CLEANING THE SYSTEM....437
24.2.5 FILLING THE SYSTEM....437
24.2.6 REFILLING AN OVERHEATED SYSTEM....438
24.2.8 CLEANING THE RADIATOR PRE-SCREEN....438
24.2.9 REMOVAL/INSTALLATION OF THERMOSTAT ASSEMBLY....439
24.2.10 CHECK AND TIGHTEN TRACK SHOE BOLTS....440
24.2.11 CHECK AND ADJUST TRACK TENSION....441
24.2.12 CHECK ELECTRICAL INTAKE AIR HEATER....443
24.2.13 CHECK ALTERNATOR....443
24.2.14 CHECK STARTER MOTOR....443
24.2.15 REPLACE BUCKET SIDE CUTTERS....444
24.2.16 REPLACE BUCKET TEETH....444
24.2.17 INSTALLATION OF BUCKET TEETH (ESCO VERTALOK TYPE)....445
24.2.18 REMOVAL OF BUCKET TEETH (ESCO VERTALOK TYPE)....447
24.2.19 ADJUST BUCKET CLEARANCE....449
24.2.20 CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....450
24.2.21 CHECK, MAINTAIN AIR CONDITIONER....451
24.2.22 CLEAN INLINE FILTER....452
24.3 CHECK BEFORE STARTING....453
24.3.1 CHECK COOLANT LEVEL, ADD COOLANT....453
24.3.2 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL....453
24.3.3 CHECK FUEL LEVEL, ADD FUEL....454
24.3.4 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....455
24.3.5 CHECK AIR CLEANER FOR CLOGGING....455
24.3.6 CHECK ELECTRIC WIRINGS....456
24.3.7 CHECK FUNCTION OF HORN....456
24.3.8 CHECK FOR WATER AND SEDIMENT IN WATER SEPARATOR, DRAIN WATER....456
24.4 EVERY 50 HOURS SERVICE....457
24.4.1 LUBRICATING....457
1. BOOM CYLINDER FOOT PIN (2 POINTS)....458
2. BOOM FOOT PIN (2 POINTS)....458
3. ARM LINK COUPLING PIN (1 POINT)....458
4. ARM BUCKET COUPLING PIN (1 POINT)....458
5. LINK COUPLING PIN (2 POINTS)....458
6. BUCKET CYLINDER ROD END (1 POINT)....458
7. BUCKET LINK COUPLING PIN (1 POINT)....458
24.5 EVERY 100 HOURS SERVICE....459
24.5.1 LUBRICATING....459
1. BOOM CYLINDER FOOT PIN (2 POINTS)....459
2. BOOM CYLINDER ROD PIN (2 POINTS)....459
3. ARM CYLINDER FOOT PIN (1 POINT)....459
4. BOOM ARM COUPLING PIN (1 POINT)....459
5. ARM CYLINDER ROD END (1 POINT)....459
6. BUCKET CYLINDER FOOT PIN (1 POINT)....459
24.5.2 CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL....460
24.5.3 DRAIN WATER AND SEDIMENT FROM FUEL TANK....461
24.6 EVERY 250 HOURS SERVICE....462
24.6.1 CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL....462
24.6.2 CHECK LEVEL OF BATTERY ELECTROLYTE....463
24.6.3 CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....464
24.6.4 LUBRICATE SWING CIRCLE (2 POINTS)....465
24.6.5 CHECK FAN BELT TENSION, ADJUST....466
24.6.6 CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT....467
24.7 EVERY 500 HOURS SERVICE....468
24.7.1 REPLACE FUEL FILTER CARTRIDGE....468
24.7.2 CHECK SWING PINION GREASE LEVEL, ADD GREASE....469
24.7.3 CLEAN AND INSPECT RADIATOR FINS, OIL COOLER FINS AND CONDENSER FINS....470
24.7.4 CLEAN FRESH/RECIRC AIR FILTERS OF AIR CONDITIONER....471
24.7.5 REPLACE HYDRAULIC TANK BREATHER ELEMENT....472
24.7.6 REPLACE HYDRAULIC FILTER ELEMENT....473
24.8 EVERY 1000 HOURS SERVICE....474
24.8.1 CHANGE OIL IN SWING MACHINERY CASE....474
24.8.2 CHECK OIL LEVEL IN DAMPER CASE, ADD OIL....475
24.8.3 CHECK ALL TIGHTENING PARTS OF TURBOCHARGER....475
24.8.4 CHECK PLAY OF TURBOCHARGER ROTOR....475
24.8.5 REPLACE CORROSION RESISTOR CARTRIDGE....476
24.9 EVERY 2000 HOURS SERVICE....477
24.9.1 CHANGE OIL IN FINAL DRIVE CASE....477
24.9.2 CLEAN HYDRAULIC TANK STRAINER....478
24.9.3 CLEAN ENGINE BREATHER....479
24.9.4 CLEAN, CHECK TURBOCHARGER....479
24.9.5 CHECK ALTERNATOR, STARTING MOTOR....479
24.9.6 CHECK ENGINE VALVE CLEARANCE, ADJUST....479
24.9.7 CHECK VIBRATION DAMPER....479
24.10 EVERY 4000 HOURS SERVICE....480
24.10.1 CHECK WATER PUMP....480
24.10.2 CHANGE ANTI FREEZE....480
24.11 EVERY 5000 HOURS SERVICE....481
24.11.1 CHANGE OIL IN HYDRAULIC TANK....481
SPECIFICATIONS....485
25.1 MACHINE SPECIFICATIONS....486
25.2 EXPLANATION OF LIFTING CAPACITY CHART....489
OPTIONS, ATTACHMENTS....491
26. GENERAL PRECAUTIONS....492
26.1 PRECAUTIONS RELATED TO SAFETY....492
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....493
27. HANDLING BUCKET WITH HOOK....494
27.1 CHECKING FOR DAMAGE TO BUCKET....494
27.2 PROHIBITED OPERATIONS....494
27.3 PRECAUTIONS DURING OPERATIONS....494
28. MACHINES READY FOR ATTACHMENTS....495
28.1 EXPLANATION OF COMPONENTS....495
28.2 HYDRAULIC CIRCUIT....497
28.3 ATTACHMENT MOUNTING/DISMOUNTING PROCEDURE....499
28.4 OPERATION....501
28.5 LONG TERM STORAGE....502
28.6 SPECIFICATIONS....502
29. INTRODUCTION OF ATTACHMENTS....503
29.1 SPECIFICATION, USE....503
29.2 ATTACHMENT INSTALLATION COMBINATION TABLE....504
29.3 SELECTION OF TRACK SHOES....505
29.4 SELECTION OF BUCKET TEETH....506
29.5 HANDLING TRAPEZOIDAL BUCKET....507
29.6 HANDLING THE CLAMSHELL BUCKET....508
30. EXTENDING MACHINE SERVICE LIFE....509
30.1 HYDRAULIC BREAKER....509
30.2 POWER RIPPER....512
30.3 FORK GRAB....513
30.4 GRAPPLE BUCKET....514
30.5 SCRAP GRAPPLE....515
30.6 CRUSHER & SMASHER....516
30.7 HYDRAULIC PILE DRIVER....517
30.8 HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE....518
EEBM001304 - Hydraulic Excavator PC450-6K, PC450LC-6K Shop Manual....519
COVER....519
CONTENTS....520
SAFETY....525
SAFETY NOTICE....525
FOREWARD....527
GENERAL....527
HOW TO READ THE SHOP MANUAL....528
HOISTING INSTRUCTIONS....529
COATING MATERIALS....530
STANDARD TIGHTENING TORQUE....531
ELECTRIC WIRE CODE....533
CONVERSION TABLE....534
01 GENERAL....541
SPECIFICATION DRAWINGS....542
SPECIFICATIONS....543
WEIGHT TABLE....545
FUEL, COOLANT AND LUBRICANTS....547
10 STRUCTURE AND FUNCTION....550
PARTS RELATED TO ENGINE....551
RADIATOR, OIL COOLER....553
POWER TRAIN....554
FINAL DRIVE....555
SWING CIRCLE....556
SWING MACHINERY....557
TRACK FRAME, RECOIL SPRING....558
TRACK SHOE....559
HYDRAULIC PIPING DRAWING....560
HYDRAULIC CIRCUIT DIAGRAM....561
HYDRAULIC TANK, HYDRAULIC FILTER....562
HYDRAULIC PUMP....563
CONTROL VALVE....585
SUCTION SAFETY VALVE....593
CLSS....594
SWING MOTOR....635
CENTER SWIVEL JOINT....639
TRAVEL MOTOR....640
VALVE CONTROL....649
WORK EQUIPMENT, SWING PPC VALVE....650
TRAVEL PPC VALVE....654
SERVICE PPC VALVE....658
PPC SAFETY LOCK VALVE....661
PPC ACCUMULATOR....661
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE....662
EPC SOLENOID VALVE....669
FOR LS SELECT, BOOM HI 2 STAGE SAFETY VALVE, MERGE/FLOW DIVIDER, TRAVEL SPEED, SWING BRAKE....669
FOR LS VALVE CONTROL....671
BOOM SAFETY VALVE....674
HYDRAULIC CYLINDER....677
OVERLOAD WARNING DEVICE....678
WORK EQUIPMENT....682
ACTUAL ELECTRIC WIRING DIAGRAM....684
ELECTRIC CIRCUIT DIAGRAM....686
ENGINE CONTROL....688
ELECTRONIC CONTROL SYSTEM....694
MACHINE MONITOR SYSTEM....718
BREAKER MODE HYDRAULIC PERFORMANCE....726
20 TESTING AND ADJUSTING....729
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS....730
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....731
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....739
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....747
MEASURING EXHAUST COLOR....748
VALVES AND INJECTORS....749
MEASURING BLOW-BY PRESSURE....755
TESTING AND ADJUSTING FUEL INJECTION TIMING....757
MEASURING ENGINE OIL PRESSURE....763
TESTING AND ADJUSTING FAN BELT TENSION....764
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR....764
ADJUSTING ENGINE SPEED SENSOR....765
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....766
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE....767
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....768
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)....771
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE....773
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE....776
TESTING SOLENOID VALVE OUTPUT PRESSURE....778
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE....780
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE....782
TESTING TRAVEL DEVIATION....783
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT....784
MEASURING OIL LEAKAGE....786
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....788
TESTING CLEARANCE OF SWING CIRCLE BEARING....789
TESTING AND ADJUSTING TRACK SHOE TENSION....790
BLEEDING AIR....791
TROUBLESHOOTING....793
POINTS TO REMEMBER WHEN TROUBLESHOOTING....794
SEQUENCE OF EVENTS IN TROUBLESHOOTING....795
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....796
CHECKS BEFORE TROUBLSHOOTING....804
CONNECTOR TYPES AND MOUNTING LOCATIONS....806
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....810
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....820
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL....821
METHOD OF USING JUDGEMENT TABLE....829
METHOD OF USING TROUBLESHOOTING CHARTS....831
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE....833
SERVICE CODE TABLE....838
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)....839
N-1 [E218] COMMUNICATION ABNORMALITY....840
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)....843
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM....844
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....846
JUDGEMENT TABLE FOR GOVERNOR, PUMP GOVERNOR (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS....850
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM....852
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)....854
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED....855
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED....856
E-4 [E318] (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED....857
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED....858
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED....859
E-7 [E316] ABNORMALITY (STEP OUT) IN MOTOR IS DISPLAYED....860
E-8 ENGINE DOES NOT START....862
E-9 ENGINE SPEED IS IRREGULAR....864
a) IDLING SPEED IS IRREGULAR....864
b) THERE IS HUNTING....866
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)....868
E-11 ENGINE DOES NOT STOP....870
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)....872
TROUBLESHOOTING OF ENGINE (S MODE)....875
TROUBLESHOOTING PROCEDURES AND TECHNIQUES....876
TROUBLESHOOTING SYMPTOMS CHARTS....876
ALTERNATOR NOT CHARGING OR INSUFFICIENT CHARGING....877
ALTERNATOR OVERCHARGING....878
COOLANT LOSS - EXTERNAL....879
COOLANT TEMPERATURE ABOVE NORMAL - SUDDEN OVERHEAT (CONTINUED)....880
COOLANT TEMPERATURE BELOW NORMAL....881
CRANKCASE GASES (BLOWBY) - EXCESSIVE....882
ENGINE ACCELERATION/RESPONSE POOR....883
ENGINE CRANKS BUT WILL NOT START (NO SMOKE FROM EXHAUST)....885
ENGINE DECELERATES SLOWLY....888
ENGINE DIFFICULT TO START OR WILL NOT START - EXHAUST SMOKE PRESENT....889
ENGINE NOISE EXCESSIVE*....891
ENGINE NOISE EXCESSIVE - COMBUSTION KNOCKS....894
ENGINE NOISE EXCESSIVE - CONNECTING ROD*....895
ENGINE NOISE EXCESSIVE - MAIN BEARING*....896
ENGINE NOISE EXCESSIVE - PISTON*....897
ENGINE NOISE EXCESSIVE - TURBOCHARGER*....899
ENGINE POWER OUTPUT LOW - BASICS....900
ENGINE POWER OUTPUT - PERFORMANCE MEASUREMENT....902
ENGINE RUNS ROUGH AT IDLE....904
ENGINE RUNS ROUGH OR MISFIRES....906
ENGINE SHUTS OFF UNEXPECTEDLY OR DIES DURING DECELERATION....908
ENGINE SPEED SURGES AT LOW IDLE....909
ENGINE SPEED SURGES (OTHER THAN LOW IDLE)....910
ENGINE VIBRATION - EXCESSIVE....911
ENGINE WILL NOT CRANK OR CRANKS SLOWLY (ELECTRIC STARTING MOTOR)....912
ENGINE WILL NOT SHUT OFF....914
ENGINE WILL START BUT WILL NOT KEEP RUNNING....915
FUEL IN COOLANT....917
FUEL IN LUBRICATING OIL....918
INTAKE MANIFOLD AIR TEMPERATURE ABOVE SPECIFICATION....919
LUBRICATING OIL CONSUMPTION EXCESSIVE....920
LUBRICATING OIL CONTAMINATED....922
LUBRICATING OIL PRESSURE - HIGH....923
LUBRICATING OIL PRESSURE - LOW....924
LUBRICATING OIL SLUDGE IN THE ENGINE CRANKCASE EXCESSIVE....926
LUBRICATING OIL TEMPERATURE ABOVE SPECIFICATION....928
LUBRICATING OIL IN THE COOLANT....929
SMOKE, BLACK - EXCESSIVE....930
SMOKE, BLACK - EXCESSIVE - PERFORMANCE MEASUREMENT....931
SMOKE, WHITE - EXCESSIVE....933
TURBOCHARGER BOOST PRESSURE LOW....935
TURBOCHARGER LEAKS - ENGINE OIL OR FUEL....936
ENGINE NOISE DIAGNOSTIC PROCEDURES - GENERAL INFORMATION....937
MAIN BEARING NOISE....937
CONNECTING ROD BEARING NOISE....937
PISTON NOISE....937
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)....938
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM....939
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE - CONTINUED....941
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS....945
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE....947
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)....948
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED....949
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED....951
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED....953
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED....955
C-6 [E202] SHORT CIRCUIT IN LS SELECT SOLENOID SYSTEM IS DISPLAYED....957
C-7 [E212] DISCONNECTION IN LS SELECT SOLENOID SYSTEM IS DISPLAYED....958
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED....959
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED....961
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED....963
C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED....964
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED....965
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED....966
C-14 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED....967
C-15 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED....969
C-16 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED....970
C-17 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED....971
C-18 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED....972
C-19 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED....973
C-20 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED....974
C-21 ABNORMALITY IN MACHINE 2 - STAGE PRESSURE RELIEF SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)....975
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)....977
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE....978
F-1 BIT PATTERN 20-(1) SWING OIL PRESSURE SWITCH DOES NOT LIGHT UP....979
F-2 BIT PATTERN 20-(2) TRAVEL OIL PRESSURE SWITCH DOES NOT LIGHT UP....980
F-3 BIT PATTERN 20-(3) BOOM LOWER OIL PRESSURE SWITCH DOES NOT LIGHT UP....981
F-4 BIT PATTERN 20-(4) BOOM RAISE OIL PRESSURE SWITCH DOES NOT LIGHT UP....982
F-5 BIT PATTERN 20-(5) ARM IN OIL PRESSURE SWITCH DOES NOT LIGHT UP....983
F-6 BIT PATTERN 20-(6) ARM OUT OIL PRESSURE SWITCH DOES NOT LIGHT UP....984
F-7 BIT PATTERN 21-(1) BUCKET CURL OIL PRESSURE SWITCH DOES NOT LIGHT UP....985
F-8 BIT PATTERN 21-(2) BUCKET DUMP OIL PRESSURE SWITCH DOES NOT LIGHT UP....986
F-9 BIT PATTERN 21-(3) SWING LOCK SWITCH DOES NOT LIGHT UP....987
F-11 BIT PATTERN 22-(6) L.H. KNOB SWITCH DOES NOT LIGHT UP....988
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)....990
PUMP MERGE/DIVIDER LOGIC, LS SELECT LOGIC, SOLENOID ACTUATION TABLE....991
TABLE OF FAILURE MODES AND CAUSES....993
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS....997
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE....998
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)....998
H-5 AUTO-DECELERATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)....999
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR....999
H-7 BOOM IS SLOW OR LACKS POWER....1001
H-8 ARM IS SLOW OR LACKS POWER....1003
H-9 BUCKET IS SLOW OR LACKS POWER....1005
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)....1006
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)....1006
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)....1007
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED....1007
H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED....1008
H-15 DEFECTIVE ACTUATION OF MACHINE 2 STAGE PRESSURE RELIEF FUNCTION....1008
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW....1008
H-17 IN SWING + BOOM RAISE, BOOM RAISE IS SLOW....1009
H-18 IN SWING + ARM, ARM IS SLOW....1009
H-19 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY....1009
H-20 TRAVEL DEVIATION....1010
H-21 TRAVEL SPEED IS SLOW....1011
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER....1013
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED....1015
H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)....1015
H-25 DOES NOT SWING....1016
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW....1017
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING....1019
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)....1020
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....1020
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING....1021
H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED....1022
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)....1025
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....1027
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM....1029
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED, [E102] ERROR IN CLOCK DATA IS DISPLAYED....1030
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED....1031
M-3 [E104] AIR CLOGGING DETECTED IS DISPLAYED....1032
M-4 [E106] DROP IN ENGINE OIL PRESSURE DETECTED IS DISPLAYED....1032
M-5 [E108] ENGINE WATER TEMPERATURE 105 C DETECTED IS DISPLAYED....1033
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF THE LAMPS ON THE MONITOR PANEL LIGHT UP FOR 3 SECONDS....1034
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIT UP AND DO NOT GO OUT....1036
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIT UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)....1036
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASHES....1037
M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MOTOR) LIGHTS UP....1040
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH....1041
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE L....1043
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (THEN THERE IS NO ABNORMAL....1045
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER D....1048
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS....1048
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)....1049
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE....1050
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)....1050
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL....1051
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY....1051
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP....1052
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH....1052
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING....1053
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED....1053
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM....1054
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM....1055
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM....1056
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM....1057
M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM....1058
M-30 WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED....1059
M-31 WORKING LIGHT, PANEL LIGHTING DO NOT LIGHT UP, OR SWITCH IS NOT BEING USED BUT LIGHTS UP....1063
30 DISASSEMBLY AND ASSEMBLY....1065
METHOD OF USING MANUAL....1067
PRECAUTIONS WHEN CARRYING OUT OPERATION....1069
SPECIAL TOOL LIST....1071
SKETCHES OF SPECIAL TOOLS....1078
STARTING MOTOR ASSEMBLY....1086
REMOVAL AND INSTALLATION....1086
ALTERNATOR ASSEMBLY....1087
REMOVAL AND INSTALLATION....1087
NOZZLE HOLDER ASSEMBLY....1088
REMOVAL AND INSTALLATION....1088
THERMOSTAT ASSEMBLY....1096
REMOVAL AND INSTALLATION....1096
CYLINDER HEAD ASSEMBLY....1097
REMOVAL....1097
INSTALLATION....1099
HYDRAULIC COOLER ASSEMBLY....1105
REMOVAL....1105
INSTALLATION....1106
RADIATOR, HYDRAULIC COOLER ASSEMBLY....1107
REMOVAL....1107
INSTALLATION....1109
ENGINE, MAIN PUMP ASSEMBLY....1110
REMOVAL....1110
INSTALLATION....1113
DAMPER ASSEMBLY....1114
REMOVAL AND INSTALLATION....1114
FUEL TANK ASSEMBLY....1115
REMOVAL AND INSTALLATION....1115
CENTER SWIVEL JOINT ASSEMBLY....1116
REMOVAL AND INSTALLATION....1116
DISASSEMBLY AND ASSEMBLY....1117
FINAL DRIVE ASSEMBLY....1118
REMOVAL AND INSTALLATION....1118
DISASSEMBLY....1119
ASSEMBLY....1123
TRAVEL MOTOR ASSEMBLY....1128
DISASSEMBLY....1128
ASSEMBLY....1133
SPROCKET....1145
REMOVAL AND INSTALLATION....1145
SWING MOTOR ASSEMBLY....1146
DISASSEMBLY....1146
ASSEMBLY....1149
REMOVAL AND INSTALLATION....1156
SWING MACHINERY ASSEMBLY....1157
REMOVAL AND INSTALLATION....1157
DISASSEMBLY....1158
ASSEMBLY....1162
REVOLVING FRAME ASSEMBLY....1167
REMOVAL....1167
INSTALLATION....1168
SWING CIRCLE ASSEMBLY....1169
REMOVAL AND INSTALLATION....1169
IDLER, RECOIL SPRING ASSEMBLY....1170
REMOVAL AND INSTALLATION....1170
IDLER ASSEMBLY....1171
DISASSEMBLY....1171
ASSEMBLY....1172
RECOIL SPRING ASSEMBLY....1174
DISASSEMBLY....1174
ASSEMBLY....1175
TRACK ROLLER ASSEMBLY....1176
REMOVAL AND INSTALLATION....1176
DISASSEMBLY....1177
ASSEMBLY....1178
CARRIER ROLLER ASSEMBLY....1180
REMOVAL AND INSTALLATION....1180
DISASSEMBLY....1181
ASSEMBLY....1183
TRACK SHOE ASSEMBLY....1185
REMOVAL AND INSTALLATION....1185
HYDRAULIC TANK ASSEMBLY....1186
REMOVAL....1186
INSTALLATION....1187
CONTROL PUMP ASSEMBLY....1188
REMOVAL AND INSTALLATION....1188
MAIN PUMP ASSEMBLY....1189
REMOVAL....1189
INSTALLATION....1190
DISASSEMBLY....1198
ASSEMBLY....1204
MAIN PUMP INPUT SHAFT OIL SEAL....1213
REMOVAL AND INSTALLATION....1213
CONTROL VALVE ASSEMBLY....1214
REMOVAL....1214
INSTALLATION....1216
DISASSEMBLY....1217
ASSEMBLY....1221
PUMP MERGE/DEVIDER VALVE ASSEMBLY....1226
DISASSEMBLY AND ASSEMBLY....1226
PRESSURE COMPENSATION VALVE ASSEMBLY....1227
DISASSEMBLY AND ASSEMBLY....1227
SERVO VALVE ASSEMBLY FOR FRONT PUMP ....1228
REMOVAL AND INSTALLATION....1228
SERVO VALVE ASSEMBLY FOR REAR PUMP....1229
REMOVAL AND INSTALLATION....1229
LS-EPC SOLENOID VALVE ASSEMBLY....1230
REMOVAL AND INSTALLATION....1230
SOLENOID VALVE ASSEMBLY....1231
REMOVAL AND INSTALLATION....1231
WORK EQUIPMENT PPC VALVE ASSEMBLY....1232
REMOVAL AND INSTALLATION....1232
DISASSEMBLY....1233
ASSEMBLY....1234
TRAVEL PPC VALVE ASSEMBLY....1235
REMOVAL AND INSTALLATION....1235
DISASSEMBLY....1236
ASSEMBLY....1237
PPC SHUTTLE VALVE ASSEMBLY....1238
REMOVAL....1238
INSTALLATION....1239
DISASSEMBLY....1240
ASSEMBLY....1241
BOOM CYLINDER ASSEMBLY....1242
REMOVAL....1242
INSTALLATION....1243
ARM CYLINDER ASSEMBLY....1244
REMOVAL....1244
INSTALLATION....1245
BUCKET CYLINDER ASSEMBLY....1246
REMOVAL....1246
INSTALLATION....1247
HYDRAULIC CYLINDER ASSEMBLY....1248
DISASSEMBLY....1248
ASSEMBLY....1250
WORK EQUIPMENT ASSEMBLY....1252
REMOVAL....1252
INSTALLATION....1253
BUCKET ASSEMBLY....1254
REMOVAL....1254
INSTALLATION....1255
ARM ASSEMBLY....1256
REMOVAL....1256
INSTALLATION....1257
BUCKET, ARM ASSEMBLY....1258
REMOVAL....1258
INSTALLATION....1259
BOOM ASSEMBLY....1260
REMOVAL....1260
INSTALLATION....1261
OPERATOR'S CAB ASSEMBLY....1262
REMOVAL....1262
INSTALLATION....1263
COUNTERWEIGHT ASSEMBLY....1264
REMOVAL AND INSTALLATION....1264
GOVERNOR, PUMP CONTROLLER ASSEMBLY....1265
REMOVAL AND INSTALLATION....1265
MONITOR PANEL ASSEMBLY....1266
REMOVAL AND INSTALLATION....1266
CONTROL STAND CASE....1267
REMOVAL....1267
INSTALLATION....1268
40 MAINTENANCE STANDARD....1270
SWING MACHINERY....1271
SWING CIRCLE....1273
FINAL DRIVE....1274
TRACK FRAME AND RECOIL SPRING....1276
IDLER....1277
CARRIER ROLLER....1279
TRACK ROLLER....1280
TRACK....1281
HYDRAULIC PUMP....1284
CONTROL PUMP AND RELIEF VALVE....1286
CONTROL VALVE....1287
SUCTION SAFETY VALVE....1293
SWING MOTOR....1294
TRAVEL MOTOR....1295
WORK EQUIPMENT, SWING PPC VALVE....1296
TRAVEL PPC VALVE....1297
SERVICE PPC VALVE....1298
PPC SHUTTLE VALVE, TRAVEL JUNCTION....1299
EPC SOLENOID VALVE....1300
CENTER SWIVEL JOINT....1301
HYDRAULIC CYLINDER....1302
WORK EQUIPMENT....1303
DIMENSIONS OF WORK EQUIPMENT....1305
UEBM001301 - Hydraulic Excavator PC450-6K, PC450LC-6K Shop Manual....1308
COVER....1308
CONTENTS....1309
SAFETY....1314
SAFETY NOTICE....1314
FOREWARD....1316
GENERAL....1316
HOW TO READ THE SHOP MANUAL....1317
HOISTING INSTRUCTIONS....1318
COATING MATERIALS....1319
STANDARD TIGHTENING TORQUE....1321
ELECTRIC WIRE CODE....1324
CONVERSION TABLE....1325
01 GENERAL....1333
SPECIFICATION DRAWINGS....1334
SPECIFICATIONS....1335
WEIGHT TABLE (SERIAL NO'S 32001 and up)....1338
WEIGHT TABLE (SERIAL NO'S 34001 and up)....1342
FUEL, COOLANT AND LUBRICANTS....1344
10 STRCTURE AND FUNCTION....1348
PARTS RELATED TO ENGINE....1349
RADIATOR, OIL COOLER....1351
POWER TRAIN....1352
FINAL DRIVE....1353
SWING CIRCLE....1354
SWING MACHINERY....1355
TRACK FRAME, RECOIL SPRING....1356
TRACK SHOE....1357
HYDRAULIC PIPING DRAWING....1359
HYDRAULIC CIRCUIT DIAGRAM....1361
HYDRAULIC TANK, HYDRAULIC FILTER K32001 - K33999....1362
HYDRAULIC TANK, HYDRAULIC FILTER K34001 AND UP....1363
HYDRAULIC PUMP....1364
CONTROL VALVE....1385
SELF-REDUCING PRESSURE VALVE....1395
SUCTION SAFETY VALVE....1400
CLSS....1402
SWING MOTOR....1467
CENTER SWIVEL JOINT....1473
TRAVEL MOTOR....1475
VALVE CONTROL....1484
WORK EQUIPMENT * SWING PPC VALVE....1485
TRAVEL PPC VALVE....1489
SERVICE PPC VALVE....1493
PPC SAFETY LOCK VALVE....1496
PPC ACCUMULATOR....1496
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE....1498
LS-EPC VALVE....1505
SOLENOID VALVE....1509
BOOM SAFETY VALVE....1511
OVERLOAD WARNING DEVICE....1514
WORK EQUIPMENT....1516
AIR CONDITIONER....1517
ACTUAL ELECTRIC WIRING DIAGRAM....1518
ELECTRIC CIRCUIT DIAGRAM....1522
ENGINE CONTROL....1525
ELECTRONIC CONTROL SYSTEM....1532
MACHINE MONITOR SYSTEM....1559
BREAKER MODE HYDRAULIC PERFORMANCE....1570
20 TESTING AND ADJUSTING....1573
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS....1574
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....1575
STANDARD VALUE TABLE FOR ELECTRICAL PARTS....1583
TESTING AND ADJUSTING....1591
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....1592
MEASURING ENGINE SPEED....1593
MEASURING EXHAUST COLOR....1594
ADJUSTING VALVE CLEARANCE....1595
MEASURING COMPRESSION PRESSURE....1596
MEASURING BLOW-BY PRESSURE....1596
TESTING AND ADJUSTING FUEL INJECTION TIMING....1597
MEASURING ENGINE OIL PRESSURE....1599
TESTING AND ADJUSTING FAN BELT TENSION....1600
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR....1600
ADJUSTING ENGINE SPEED SENSOR....1601
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....1602
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE....1603
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....1604
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE)....1607
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE....1609
TESTING CONTROL CIRCUIT OIL PRESSURE (OIL PRESSURE WHEN SELF PRESSURE IS REDUCED)....1612
TESTING SOLENOID VALVE OUTPUT PRESSURE....1613
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE....1616
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE....1618
TESTING TRAVEL DEVIATION....1619
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT....1620
MEASURING OIL LEAKAGE....1622
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....1624
TESTING CLEARANCE OF SWING CIRCLE BEARING....1625
TESTING WEAR OF SPROCKET....1626
TESTING AND ADJUSTING TRACK SHOE TENSION....1627
BLEEDING AIR....1628
TROUBLESHOOTING....1631
POINTS TO REMEMBER WHEN TROUBLESHOOTING....1632
SEQUENCE OF EVENTS IN TROUBLESHOOTING....1633
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....1634
CHECKS BEFORE TROUBLESHOOTING....1642
CONNECTOR TYPES AND MOUNTING LOCATIONS....1644
CONNECTOR ARRANGEMENT DIAGRAM....1646
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....1649
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....1659
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL....1660
METHOD OF USING JUDGEMENT TABLE....1669
METHOD OF USING TROUBLESHOOTING CHARTS....1671
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE....1673
SERVICE CODE TABLE....1678
TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)....1679
N-1 [E218] COMMUNICATION ABNORMALITY....1680
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) (E MODE)....1683
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER SYSTEM....1684
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....1686
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS....1690
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM....1692
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE (CONTROLLER LED IS OFF)....1694
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT VALUE IS DISPLAYED....1695
E-3 [E317] ABNORMALITY (DISCONNECTION) IN MOTOR DRIVE SYSTEM IS DISPLAYED....1696
E-4 [E318] ABNORMALITY (SHORT CIRCUIT) IN MOTOR DRIVE SYSTEM IS DISPLAYED....1697
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED....1698
E-6 [E315] ABNORMALITY (SHORT CIRCUIT) IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED....1699
E-7 [E316] ABNORMALITY (STEP-OUT) IN MOTOR IS DISPLAYED....1700
E-8 ENGINE DOES NOT START....1702
E-9 ENGINE SPEED IS IRREGULAR....1704
a) IDLING SPEED IN IRREGULAR....1704
b) THERE IS HUNTING....1706
E-10 LACK OF OUTPUT (ENGINE HIGH IDLING SPEED IS TOO LOW)....1708
E-11 ENGINE DOES NOT STOP....1710
E-12 DEFECTIVE OPERATION OF BATTERY RELAY SYSTEM (ENGINE DOES NOT STOP)....1712
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....1715
METHOD OF USING TROUBLESHOOTING CHARTS....1716
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....1720
S-2 ENGINE DOES NOT START....1721
(1) ENGINE DOES NOT TURN....1721
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)....1722
(3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)....1723
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW UP IS POOR)....1724
S-4 ENGINE STOPS DURING OPERATIONS....1725
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....1726
S-6 ENGINE LACKS OUTPUT (NO POWER)....1727
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)....1728
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)....1729
S-9 OIL BECOMES CONTAMINATED QUICKLY....1730
S-10 FUEL CONSUMPTION IS EXCESSIVE....1731
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN....1732
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)....1733
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)....1734
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....1735
S-15 ABNORMAL NOISE IS MADE....1736
S-16 VIBRATION IS EXCESSIVE....1737
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) (C MODE)....1739
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP CONTROLLER SYSTEM....1740
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....1742
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS....1750
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE....1752
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)....1754
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED....1755
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED....1757
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED....1759
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED....1761
C-6 [E207] SHORT CIRCUIT IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED....1763
C-7 [E208] DISCONNECTION IN ACTIVE MODE (BOOM) SOLENOID SYSTEM IS DISPLAYED....1764
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED....1765
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED....1767
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE/DIVIDER DOLENOID SYSTEM IS DISPLAYED....1769
C-11 [E214] DISCONNECTION IN PUMP MERGE/DIVIDER SOLENOID SYSTEM IS DISPLAYED....1770
C-12 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED....1771
C-13 [E216] DISCONNECTION IN TRAVEL SPEED SELECTOR SOLENOID SYSTEM IS DISPLAYED....1772
C-14 [E231] SHORT CIRCUIT IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED....1773
C-15 [E235] DISCONNECTION IN ACTIVE MODE (SWING) SOLENOID SYSTEM IS DISPLAYED....1774
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED....1775
C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED....1777
C-18 [E223] DISCONNECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED....1778
C-19 [E224] ABNORMALITY IN FRONT PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED....1779
C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED....1780
C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE SYSTEM IS DISPLAYED....1781
C-22 [E227] ABNORMALITY IN ENGINE SPEED SENSOR SYSTEM IS DISPLAYED....1782
C-23 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE DISPLAYED)....1783
C-24 [E234] DISCONNECTION IN OVERLOAD WARNING SYSTEM....1785
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER (INPUT SIGNAL SYSTEM) (F MODE)....1787
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE....1788
F-1 BIT PATTERN 20-(1) (SWING OIL PRESSURE SWITCH) DOES NOT LIGHT UP....1790
F-2 BIT PATTERN 20-(2) (TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP....1791
F-3 BIT PATTERN 20-(3) (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP....1792
F-4 BIT PATTERN 20-(4) (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP....1793
F-5 BIT PATTERN 20-(5) (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP....1794
F-6 BIT PATTERN 20-(6) (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP....1795
F-7 BIT PATTERN 20-(7) (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP....1796
F-8 BIT PATTERN 21-(2) (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP....1797
F-9 BIT PATTERN 21-(3) (SWING LOCK SWITCH) DOES NOT LIGHT UP....1798
F-11 BIT PATTERN 22-(6) (L.H. KNOB SWITCH) DOES NOT LIGHT UP....1800
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)....1801
PUMP MERGE/DIVIDER LOGIC....1803
SOLENOID ACTUATION TABLE....1803
TABLE OF FAILURE MODES AND CAUSES (1/2)....1804
TABLE OF FAILURE MODES AND CAUSES (2/2)....1806
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER....1808
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS....1810
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE....1811
H-4 ABNORMAL NOISE GENERATED (AROUND PUMP)....1811
H-5 AUTO-DECLARATION DOES NOT WORK (WHEN PPC SHUTTLE VALVE IS CAUSE)....1812
H-6 FINE CONTROL ABILITY IS POOR OR RESPONSE IS POOR....1812
H-7 BOOM IS SLOW OR LACKS POWER....1814
H-8 ARM IS SLOW OR LACKS POWER....1816
H-9 BUCKET IS SLOW OR LACKS POWER....1818
H-10 WORK EQUIPMENT (BOOM, ARM, BUCKET) DOES NOT MOVE (BUT TRAVEL AND SWING ARE NORMAL)....1819
H-11 EXCESSIVE HYDRAULIC DRIFT (BOOM, ARM, BUCKET)....1819
H-12 EXCESSIVE TIME LAG (ENGINE AT LOW IDLING)....1820
H-13 OTHER EQUIPMENT MOVES WHEN SINGLE CIRCUIT IS RELIEVED....1820
H-14 IN L/O, F/O MODES, WORK EQUIPMENT SPEED IS FASTER THAN SPECIFIED SPEED....1821
H-15 DEFECTIVE ACTUATION OF MACHINE PUSH-UP FUNCTION....1821
H-16 IN COMPOUND OPERATIONS, WORK EQUIPMENT WITH LARGER LOAD IS SLOW....1821
H-17 IN SWING + BOOM RAISE IS SLOW....1822
H-18 IN SWING + ARM, ARM IS SLOW....1822
H-19 IN SWING + TRAVEL, TRAVEL SPEED DROPS EXCESSIVELY....1822
H-20 TRAVEL DEVIATION....1823
a) WHEN THERE IS DEVIATION IN NORMAL TRAVEL....1823
b) EXCESSIVE TRAVEL DEVIATION WHEN STARTING....1823
H-21 TRAVEL SPEED IS SLOW....1824
H-22 STEERING DOES NOT TURN EASILY OR LACKS POWER....1826
H-23 TRAVEL SPEED DOES NOT SWITCH OR IS FASTER THAN SPECIFIED SPEED....1828
H-24 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)....1828
H-25 DOES NOT SWING....1829
a) DOES NOT SWING TO EITHER LEFT OR RIGHT....1829
b) DOES NOT SWING IN ONE DIRECTION....1829
H-26 SWING ACCELERATION IS POOR OR SWING SPEED IS SLOW (BOTH LEFT AND RIGHT, ONE DIRECTION ONLY)....1830
a) SWING ACCELERATION IS POOR....1830
H-27 EXCESSIVE OVERRUN WHEN STOPPING SWING....1832
a) ONE DIRECTION ONLY....1832
b) BOTH DIRECTIONS....1832
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY)....1833
H-29 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....1833
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING....1834
a) WHEN SWING HOLDING BRAKE IS RELEASED....1834
b) WHEN SWING HOLDING BRAKE IS APPLIED....1834
H-31 SWING SPEED IS FASTER THAN SPECIFIED SWING SPEED....1835
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)....1837
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....1840
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM....1842
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED [E102] ERROR IN CLOCK DATA IS DISPLAYED....1844
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT OR CONTACT OF 24V WIRING HARNESS WITH BUZZER DRIVE HARNESS IS DISPLAYED....1845
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED....1846
M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED....1846
M-5 [E108] ENGINE WATER TEMPERATURE 105 C DETECTED IS DISPLAYED....1847
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS....1848
a) NONE OF LAMPS ON MONITOR PANEL LIGHT UP....1848
b) SOME OF LAMPS ON MONITOR PANEL DO NOT LIGHT UP....1848
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT....1850
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM ACTUAL MACHINE (MODEL)....1850
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECK ITEMS FLASH....1851
a) (COOLANT LEVEL) FLASHES....1851
b) (ENGINE OIL LEVEL) FLASHES....1852
c) (HYDRAULIC OIL LEVEL) FLASHES....1853
M-10 PREHEATING IS NOT BEING USED BUT (PREHEATING MONITOR) LIGHTS UP....1854
M-11 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, BASIC CHECK ITEMS FLASH....1855
a) ALTERNATOR SYSTEM....1855
b) ENGINE OIL PRESSURE SYSTEM....1856
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY ITEMS FLASH (BATTERY, ENGINE OIL PRESSURE L....1857
a) ALTERNATOR SYSTEM....1857
b) ENGINE OIL PRESSURE SENSOR SYSTEM....1858
M-13 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY ITEMS FLASH (WHEN THERE IS NO ABNORMAL....1859
a) (ENGINE OIL PRESSURE) FLASHES....1859
b) (COOLANT LEVEL) FLASHES....1859
b) (BATTERY CHARGE) FLASHES....1859
d) (COOLANT TEMPERATURE) FLASHES....1860
e) (FUEL LEVEL) FLASHES....1860
f) (AIR CLEANER CLOGGING) FLASHES....1861
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER D....1862
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS....1862
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)....1863
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE....1864
M-18 COOLANT TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (NONE OF GAUGE LAMPS LIGHT UP DURING OPERATION)....1864
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL....1865
M-20 FUEL LEVEL GAUGE DOES NOT GIVE DISPLAY....1865
M-21 SWING LOCK SWITCH IS TURNED ON (LOCK) BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP....1866
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT (SWING LOCK MONITOR) DOES NOT FLASH....1866
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING....1867
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, TIME AND SERVICE METER ARE NOT DISPLAYED....1867
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM....1868
M-26 DEFECTIVE COOLANT TEMPERATURE SENSOR SYSTEM....1869
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM....1870
M-28 DEFECTIVE COOLANT LEVEL SENSOR SYSTEM....1871
M-29 DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM....1872
M-30 WIPER DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WIPER IS ACTUATED (INCLUDE E112, E113)....1874
a) WIPER DOES NOT WORK....1874
b) WIPER SWITCH IS NOT BEING OPERATED BUT WIPER IS ACTUATED....1878
M-31 WASHER MOTOR DOES NOT WORK, OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED (INCLUDE E114)....1879
a) WASHER MOTOR DOES NOT WORK....1879
b) SWITCH IS NOT BEING OPERATED BUT WASHER IS ACTUATED....1880
M-32 ELECTRIC GREASE GUN DOES NOT WORK....1881
30 DISASSEMBLY AND ASSEMBLY....1884
METHOD OF USING MANUAL....1886
PRECAUTIONS WHEN CARRYING OUT OPERATION....1888
SPECIAL TOOL LIST....1890
SKETCHES OF SPECIAL TOOLS....1896
STARTING MOTOR ASSEMBLY....1901
REMOVAL AND INSTALLATION....1901
ALTERNATOR ASSEMBLY....1902
REMOVAL AND INSTALLATION....1902
ENGINE OIL COOLER ASSEMBLY....1903
REMOVAL AND INSTALLATION....1903
FUEL INJECTION PUMP ASSEMBLY....1904
REMOVAL....1904
INSTALLATION....1906
WATER PUMP ASSEMBLY....1907
REMOVAL AND INSTALLATION....1907
NOZZLE HOLDER ASSEMBLY....1908
REMOVAL AND INSTALLATION....1908
TURBOCHARGER ASSEMBLY....1909
REMOVAL AND INSTALLATION....1909
THERMOSTAT ASSEMBLY....1910
REMOVAL AND INSTALLATION....1910
ENGINE FRONT SEAL....1911
REMOVAL AND INSTALLATION....1911
ENGINE REAR SEAL....1912
REMOVAL....1912
INSTALLATION....1913
CYLINDER HEAD ASSEMBLY....1916
REMOVAL....1916
INSTALLATION....1920
GOVERNOR MOTOR ASSEMBLY....1923
REMOVAL AND INSTALLATION....1923
AFTERCOOLER ASSEMBLY....1924
REMOVAL AND INSTALLATION....1924
AFTERCOOLER CORE ASSEMBLY....1926
REMOVAL AND INSTALLATION....1926
HYDRAULIC COOLER ASSEMBLY....1927
REMOVAL....1927
INSTALLATION....1928
RADIATOR, HYDRAULIC COOLER ASSEMBLY....1929
REMOVAL....1929
INSTALLATION....1931
ENGINE, MAIN PUMP ASSEMBLY....1932
REMOVAL....1932
INSTALLATION....1935
DAMPER ASSEMBLY....1936
REMOVAL AND INSTALLATION....1936
FUEL TANK ASSEMBLY....1937
REMOVAL AND INSTALLATION....1937
CENTER SWIVEL JOINT ASSEMBLY....1938
REMOVAL AND INSTALLATION....1938
DISASSEMBLY AND ASSEMBLY....1939
FINAL DRIVE ASSEMBLY....1940
REMOVAL AND INSTALLATION....1940
DISASSEMBLY....1941
ASSEMBLY....1945
TRAVEL MOTOR ASSEMBLY....1951
DISASSEMBLY....1951
ASSEMBLY....1956
SPROCKET....1967
REMOVAL AND INSTALLATION....1967
SWING MOTOR ASSEMBLY....1968
REMOVAL AND INSTALLATION....1968
SWING MACHINERY ASSEMBLY....1969
REMOVAL AND INSTALLATION....1969
DISASSEMBLY....1970
ASSEMBLY....1974
REVOLVING FRAME ASSEMBLY....1979
REMOVAL....1979
INSTALLATION....1980
SWING CIRCLE ASSEMBLY....1981
REMOVAL AND INSTALLATION....1981
IDLER, RECOIL SPRING ASSEMBLY....1982
REMOVAL AND INSTALLATION....1982
IDLER ASSEMBLY....1983
DISASSEMBLY....1983
ASSEMBLY....1984
RECOIL SPRING ASSEMBLY....1986
DISASSEMBLY....1986
ASSEMBLY....1987
TRACK ROLLER ASSEMBLY....1988
REMOVAL AND INSTALLATION....1988
DISASSEMBLY....1989
ASSEMBLY....1990
CARRIER ROLLER ASSEMBLY....1992
REMOVAL AND INSTALLATION....1992
DISASSEMBLY....1993
ASSEMBLY....1995
TRACK SHOE ASSEMBLY....1997
REMOVAL AND INSTALLATION....1997
HYDRAULIC TANK ASSEMBLY....1998
REMOVAL....1998
INSTALLATION....1999
MAIN PUMP ASSEMBLY....2000
REMOVAL....2000
INSTALLATION....2001
DISASSEMBLY....2002
ASSEMBLY....2008
MAIN PUMP INPUT SHAFT OIL SEAL....2024
REMOVAL AND INSTALLATION....2024
CONTROL VALVE ASSEMBLY....2025
REMOVAL....2025
INSTALLATION....2027
DISASSEMBLY....2028
ASSEMBLY....2034
PUMP MERGE/DIVIDER VALVE ASSEMBLY....2041
DISASSEMBLY AND ASSEMBLY....2041
PRESSURE COMPENSATION VALVE ASSEMBLY....2042
DISASSEMBLY AND ASSEMBLY....2042
SERVO VALVE ASSEMBLY FOR FRONT PUMP....2043
REMOVAL AND INSTALLATION....2043
SERVO VALVE ASSEMBLY FOR REAR PUMP....2044
REMOVAL AND INSTALLATION....2044
LS-EPC SOLENOID VALVE ASSEMBLY....2045
REMOVAL AND INSTALLATION....2045
SOLENOID VALVE ASSEMBLY....2046
REMOVAL AND INSTALLATION....2046
WORK EQUIPMENT PPC VALVE ASSEMBLY....2047
REMOVAL AND INSTALLATION....2047
DISASSEMBLY....2048
ASSEMBLY....2049
TRAVEL PPC VALVE ASSEMBLY....2050
REMOVAL AND INSTALLATION....2050
DISASSEMBLY....2051
ASSEMBLY....2052
PPC SHUTTLE VALVE ASSEMBLY....2053
REMOVAL....2053
INSTALLATION....2054
DISASSEMBLY....2055
ASSEMBLY....2056
BOOM CYLINDER ASSEMBLY....2057
REMOVAL....2057
INSTALLATION....2058
ARM CYLINDER ASSEMBLY....2059
REMOVAL....2059
INSTALLATION....2060
BUCKET CYLINDER ASSEMBLY....2061
REMOVAL....2061
INSTALLATION....2062
HYDRAULIC CYLINDER ASSEMBLY....2063
DISASSEMBLY....2063
ASSEMBLY....2066
WORK EQUIPMENT ASSEMBLY....2070
REMOVAL....2070
INSTALLATION....2071
BUCKET ASSEMBLY....2072
REMOVAL....2072
INSTALLATION....2073
ARM ASSEMBLY....2074
REMOVAL....2074
INSTALLATION....2075
BUCKET, ARM ASSEMBLY....2076
REMOVAL....2076
INSTALLATION....2077
BOOM ASSEMBLY....2078
REMOVAL....2078
INSTALLATION....2079
OPERATOR'S CAB ASSEMBLY....2080
REMOVAL....2080
INSTALLATION....2081
COUNTERWEIGHT ASSEMBLY....2082
REMOVAL AND INSTALLATION....2082
AIR CONDITIONER COMPRESSOR ASSEMBLY....2083
REMOVAL AND INSTALLATION....2083
CONDENSER ASSEMBLY....2084
REMOVAL AND INSTALLATION....2084
RECEIVER TANK ASSEMBLY....2085
REMOVAL AND INSTALLATION....2085
AIR CONDITIONER UNIT ASSEMBLY....2086
REMOVAL....2086
INSTALLATION....2087
GOVERNOR, PUMP CONTROLLER ASSEMBLY....2088
REMOVAL AND INSTALLATION....2088
MONITOR PANEL ASSEMBLY....2089
REMOVAL AND INSTALLATION....2089
CONTROL STAND CASE....2090
REMOVAL....2090
INSTALLATION....2091
40 MAINTENANCE STANDARD....2093
ENGINE MOUNT....2094
SWING MACHINERY....2096
SWING CIRCLE....2098
FINAL DRIVE....2099
TRACK FRAME AND RECOIL SPRING....2101
IDLER....2103
CARRIER ROLLER....2105
TRACK ROLLER....2106
TRACK SHOE (TRIPLE GROUSER SHOE)....2107
HYDRAULIC PUMP....2111
CONTROL VALVE....2113
SELF-REDUCING PRESSURE VALVE....2120
SUCTION SAFETY VALVE....2121
SWING MOTOR....2122
TRAVEL MOTOR....2123
WORK EQUIPMENT, SWING PPC VALVE....2124
TRAVEL PPC VALVE....2125
SERVICE PPC VALVE....2126
PPC SHUTTLE VALVE, TRAVEL JUNCTION VALVE....2127
LS-EPC VALVE....2128
SOLENOID VALVE....2129
CENTER SWIVEL JOINT....2131
HYDRAULIC CYLINDER....2133
WORK EQUIPMENT....2135
DIMENSIONS OF WORK EQUIPMENT....2137
90 OTHERS....2142
HYDRAULIC CIRCUIT DIAGRAM....2143
ELECTRIC CIRCUIT DIAGRAM (1/3)....2144
ELECTRIC CIRCUIT DIAGRAM (2/3)....2145
ELECTRIC CIRCUIT DIAGRAM (3/3)....2146
