Komatsu Material Handler PW400MH-6 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Material Handler PW400MH-6, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Material Handler PW400MH-6 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: 913 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
CEAM008300 - Material Handler PW400MH-6 Operation & Maintenance Manual.pdf
CEBM005600 - Material Handler PW400MH-6 Shop Manual.pdf
MAIN SECTIONS
CEAM008300 - Material Handler PW400MH-6 Operation & Maintenance Manual.....2
COVER.....2
INTRODUCTION.....8
FOREWORD.....9
SAFETY INFORMATION.....9
INTRODUCTION.....10
INTENDED USE.....10
FEATURES.....10
BREAKING IN THE MACHINE.....10
LOCATION OF PLATES, TABLE TO ENTER P.I.N. AND DISTRIBUTOR.....11
P.I.N. PLATE LOCATION.....11
ENGINE SERIAL NO. PLATE LOCATION.....11
TABLE TO ENTER NUMBERS AND DISTRIBUTOR.....11
TABLE OF CONTENTS.....12
SAFETY.....18
WARNING LABELS.....19
GENERAL PRECAUTIONS.....25
SAFETY RULES.....25
SAFETY FEATURES.....25
UNAUTHORIZED MODIFICATION.....25
INSIDE OPERATORS COMPARTMENT.....26
CLOTHING AND PERSONAL PROTECTIVE ITEMS.....26
ALWAYS APPLY LOCK WHEN LEAVING OPERATORS SEAT.....26
MOUNTING AND DISMOUNTING.....27
INJURY FROM WORK EQUIPMENT.....27
FIRE PREVENTION FOR FUEL AND OIL.....27
PRECAUTIONS AT HIGH TEMPERATURES.....28
ASBESTOS DUST HAZARD PREVENTION.....28
FIRE EXTINGUISHER AND FIRST AID KIT.....28
CAB GLASS.....29
WINDOW WASHER FLUID.....29
ESCAPE FROM FIRE.....29
PROTECTION AGAINST FALLING OR FLYING OBJECTS.....29
MACHINES WITH ACCUMULATOR.....30
PRECAUTIONS FOR ATTACHMENTS.....30
INDOOR VENTILATION.....30
EMERGENCY EXIT FROM OPERATORS CAB.....30
PRECAUTIONS DURING OPERATION.....31
BEFORE STARTING ENGINE.....31
SAFETY AT WORK SITE.....31
FIRE PREVENTION.....31
VENTILATION FOR ENCLOSED AREAS.....31
IN OPERATORS CAB.....31
PRECAUTIONS FOR MIRROR AND LIGHTS.....32
WHEN STARTING ENGINE.....32
OPERATING MACHINE.....33
WHEN STARTING ENGINE.....33
CHECK DIRECTION BEFORE STARTING MACHINE.....33
CHECK THAT NO ONE IS IN AREA BEFORE SWINGING OR TRAVELING IN REVERSE.....33
NEVER LET ANYONE RIDE ON ATTACHMENT.....33
PRECAUTIONS WHEN TRAVELING.....34
OPERATE CAREFULLY ON SNOW.....34
TRAVELING ON SLOPES.....35
PROHIBITED OPERATIONS.....35
PRECAUTIONS FOR OPERATION.....36
DO NOT GO CLOSE TO HIGH VOLTAGE CABLES.....36
WORKING ON LOOSE GROUND.....37
PARKING THE MACHINE.....37
PRECAUTIONS IN COLD WEATHER.....37
TRANSPORTATION.....38
LOADING AND UNLOADING.....38
PRECAUTIONS WHEN LIFTING.....38
SHIPPING.....38
BATTERY.....39
BATTERY HAZARD PREVENTION.....39
STARTING WITH BOOSTER CABLES.....39
CHARGING BATTERY.....40
TOWING.....41
PRECAUTIONS WHEN TOWING.....41
PRECAUTIONS FOR MAINTENANCE.....42
BEFORE CARRYING OUT MAINTENANCE.....42
CONTACT WHEN THERE IS FAILURE.....42
WARNING TAG.....42
CLEAN BEFORE INSPECTION OR MAINTENANCE.....42
NEAT CLEAN WORK PLACE.....42
FOLLOW LEADER IN OPERATIONS WITH OTHER WORKERS.....42
RADIATOR COOLANT LEVEL.....43
PROPER TOOLS.....43
STOP ENGINE PRIOR TO INSPECTION AND MAINTENANCE.....43
SUPPORT FOR WORK EQUIPMENT.....43
PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS.....44
USE OF LIGHTING.....44
FIRE PREVENTION.....44
RULES TO FOLLOW WHEN ADDING FUEL OR OIL.....44
DURING MAINTENANCE.....45
PERSONNEL.....45
REMOVAL, INSTALLATION AND STORAGE OF ATTACHMENTS.....45
WORK UNDER THE MACHINE.....45
NOISE.....45
WHEN WORKING ON MACHINE.....45
LOCK INSPECTION COVERS.....45
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING.....46
DO NOT DROP TOOLS OR PARTS INSIDE MACHINE.....46
FLYING PIECES WITH HAMMER WORK.....46
KEEP THE MACHINE CLEAN.....46
WELDING REPAIRS.....47
REMOVE BATTERY TERMINALS.....47
ACTION WHEN ABNORMALITY IS FOUND DURING INSPECTION.....47
RULES TO FOLLOW WHEN ADDING FUEL.....47
HANDLING HIGH PRESSURE HOSES.....48
PRECAUTIONS WITH HIGH PRESSURE OIL.....48
PRECAUTIONS FOR MAINTENANCE AT HIGH TEMPERATURE OR PRESSURE.....48
WASTE MATERIALS.....49
CHECKS AFTER INSPECTION AND MAINTENANCE.....49
MAINTENANCE FOR AIR CONDITIONER.....49
MAGNET SAFETY.....50
READ THE MAGNET INSTRUCTIONS.....50
BEWARE OF HIGH VOLTAGE.....50
HANDLE MAGNET WITH CARE.....50
OPERATION.....52
GENERAL.....53
GENERAL VIEW OF MACHINE.....53
GENERAL VIEW OF OPERATORS COMPARTMENT.....54
GENERAL VIEW OF MONITOR PANEL.....55
GENERAL VIEW OF OUTRIGGER PANEL.....56
GENERAL VIEW OF MAGNET PANEL.....57
EXPLANATION OF COMPONENTS.....58
MACHINE MONITOR.....58
MONITOR LIGHT GROUP.....60
METER DISPLAY PORTION.....62
SWITCHES.....65
OUTRIGGER PANEL.....66
MAGNET GRAPPLE PANEL.....68
SWITCHES.....69
RIGHT CONTROL PANEL.....69
LEFT CONTROL HANDLE.....73
RIGHT CONTROL HANDLE.....73
PILOT PRESSURE SAFETY SHUTOFF SWITCH.....73
STEERING.....74
STEERING WHEEL.....74
COLUMN TILT LEVER.....74
CONTROL LEVERS AND PEDALS.....75
SAFETY LOCK - LEFT CONTROL STAND.....75
LEFT CONTROL HANDLE.....75
RIGHT CONTROL HANDLE.....76
FOOT PEDALS.....76
OPERATORS SEAT.....77
SEAT BELT.....78
ROOF VENT.....79
WHEN OPENING.....79
WHEN CLOSING.....79
FRONT WINDOW.....79
WHEN OPENING.....79
WHEN CLOSING.....81
FRONT BOTTOM WINDOW.....82
DOOR LOCK.....82
OPERATOR EASE.....82
HOT AND COOL BOX.....82
STORAGE BOX.....82
CAP, COVER WITH LOCK.....83
METHOD OF OPENING AND CLOSING LOCK CAP.....83
METHOD OF OPENING AND CLOSING COVER LOCK.....83
AIR CONDITIONER.....84
GENERAL LOCATIONS ON CONTROL PANEL.....84
PRECAUTIONS WHEN USING AIR CONDITIONER.....86
CHECK, MAINTAIN MACHINE WITH AIR CONDITIONER.....86
AM/FM RADIO.....87
EXPLANATION OF COMPONENTS.....87
METHOD OF OPERATION.....89
PRECAUTIONS WHEN USING.....91
SPECIFICATIONS.....91
ELECTRIC POWER TAKE OUT ADAPTER.....91
FUSE.....92
FUSIBLE LINK.....93
CONTROLLERS.....93
TOOL BOX.....93
GREASE GUN HOLDER.....93
OPERATION.....94
CHECK BEFORE STARTING ENGINE.....94
WALK AROUND CHECK.....94
CHECK BEFORE STARTING.....95
ADJUST OPERATORS SEAT AND BELT.....99
ADJUSTMENT OF MONITOR PANEL ANGLE.....99
OPERATIONS AND CHECKS BEFORE STARTING ENGINE.....100
STARTING ENGINE.....102
NORMAL STARTING.....102
STARTING IN COLD WEATHER.....103
OPERATIONS AND CHECKS AFTER STARTING ENGINE.....105
WHEN NORMAL.....105
IN COLD AREAS (AUTOMATIC WARM UP OPERATION).....108
CANCELING AUTOMATIC WARM UP OPERATION.....110
MOVING AND STEERING MACHINE.....111
MOVING MACHINE.....111
STOPPING MACHINE.....113
SWINGING.....114
OPERATION OF WORK EQUIPMENT.....115
WORKING MODES.....115
PERMISSIBLE WATER DEPTH.....115
PARKING MACHINE.....116
CHECK AFTER FINISHING WORK.....117
STOPPING ENGINE.....117
CHECK AFTER STOPPING ENGINE.....117
LOCKING.....117
TRANSPORTATION.....118
TRANSPORTATION PROCEDURE.....118
COLD WEATHER OPERATION.....120
PRECAUTIONS FOR LOW TEMPERATURE.....120
FUEL AND LUBRICANTS.....120
COOLANT.....120
BATTERY.....120
PRECAUTIONS AFTER COMPLETION OF WORK.....121
AFTER COLD WEATHER.....121
LONG TERM STORAGE.....122
BEFORE STORAGE.....122
DURING STORAGE.....122
AFTER STORAGE.....122
MACHINE START AFTER STORAGE.....123
METHOD OF TOWING DISABLED MACHINE.....123
DISCHARGED BATTERY.....124
REMOVING AND INSTALLING BATTERY.....124
PRECAUTIONS FOR CHARGING BATTERY.....124
STARTING ENGINE WITH BOOSTER CABLE.....125
OTHER TROUBLE.....127
ELECTRICAL SYSTEM.....127
CHASSIS.....127
ENGINE.....128
ELECTRONIC CONTROL SYSTEM.....129
MAINTENANCE.....130
GUIDES TO MAINTENANCE.....131
OUTLINES OF SERVICE.....133
OUTLINE OF OIL, FUEL, COOLANT.....133
OIL.....133
FUEL.....133
COOLANT.....134
GREASE.....134
STORING OIL AND FUEL.....134
FILTERS.....134
RELATING TO ELECTRICAL SYSTEM.....134
OUTLINE OF HYDRAULIC SYSTEM.....135
WEAR PARTS LIST.....136
USE OF FUEL, COOLANT AND LUBRICANTS.....137
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS.....137
ABBREVIATIONS.....138
ENGINE OIL SPECIFICATIONS.....138
NORMAL OPERATION.....138
ARCTIC OPERATION.....138
DAMPER, SWING MACHINERY AND HYDRAULIC SYSTEM OIL SPECIFICATIONS.....139
FUEL SYSTEM.....139
FRONT AND REAR AXLE HOUSING OIL SPECIFICATIONS.....139
COOLING SYSTEM.....140
GENERAL.....140
WATER.....140
ANTIFREEZE.....140
INHIBITORS/CONDITIONERS.....141
SUPPLEMENTAL COOLANT ADDITIVES.....141
STANDARD TIGHTENING TORQUES.....145
INTRODUCTION OF NECESSARY TOOLS.....145
BOLT IDENTIFICATION CHART.....146
PERIODIC REPLACEMENT OF CRITICAL PARTS.....147
MAINTENANCE SCHEDULE CHART.....148
SERVICE PROCEDURE.....151
INITIAL 100 HOURS SERVICE.....151
CHANGE FRONT AXLE OIL.....151
CHANGE REAR AXLE OIL.....151
AXLE LUBRICATION.....152
INITIAL 250 HOURS SERVICE.....153
FUEL FILTER CARTRIDGE.....153
ENGINE VALVE CLEARANCE.....154
WHEN REQUIRED.....155
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT.....155
DRAIN, FLUSH AND REFILL COOLING SYSTEM.....157
CHECK AND TIGHTEN WHEEL HUB NUTS.....160
CHECK OIL LEVEL IN AXLES, WHEEL HUBS AND REDUCTION BOXES, ADD OIL.....160
REPLACE AXLE BREATHERS.....161
CHECK ELECTRICAL INTAKE AIR HEATER.....161
CHECK WINDOW WASHER FLUID, ADD FLUID.....161
CHECK, MAINTAIN AIR CONDITIONER.....162
CLEAN IN LINE FILTERS.....163
CHECK BEFORE STARTING.....164
CHECK COOLANT LEVEL, ADD COOLANT.....164
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL.....164
CHECK FUEL LEVEL, ADD FUEL.....165
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL.....166
CHECK AIR CLEANER FOR CLOGGING.....167
CHECK ELECTRIC WIRING.....167
CHECK FUNCTION OF HORN.....167
CHECK FOR WATER AND SEDIMENT IN FUEL FILTER.....168
EVERY 10 HOURS SERVICE - DAILY.....169
GREASE LUBRICATION.....169
EVERY 50 HOURS SERVICE.....171
EVERY 100 HOURS SERVICE.....172
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL.....172
DRAIN WATER AND SEDIMENT FROM FUEL TANK.....172
EVERY 250 HOURS SERVICE.....173
CHECK LEVEL OF BATTERY ELECTROLYTE.....173
CHANGE ENGINE OIL, REPLACE FILTER CARTRIDGE.....173
LUBRICATE SWING CIRCLE (3 POINTS).....175
CHECK FAN BELT TENSION, ADJUST.....175
CHECK, ADJUST TENSION OF A/C COMPRESSOR BELT.....176
EVERY 500 HOURS SERVICE.....178
REPLACE FUEL FILTER CARTRIDGE.....178
CHECK SWING PINION GREASE LEVEL, ADD GREASE.....179
CLEAN AND INSPECT RADIATOR, OIL COOLER, AFTER COOLER AND CONDENSER.....180
CLEAN FILTERS OF AIR CONDITIONER.....180
REPLACE HYDRAULIC TANK BREATHER ELEMENT.....181
REPLACE HYDRAULIC FILTER ELEMENT.....181
REPLACE STEERING AND GENERATOR PUMP FILTERS.....182
REPLACE GENERATOR MOTOR CASE DRAIN FILTER.....182
EVERY 1000 HOURS SERVICE.....183
CHANGE OIL IN SWING MACHINERY CASE.....183
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL.....183
CHECK OIL LEVEL IN PUMP GEAR CASE.....184
CHECK TIGHTENING PARTS OF TURBOCHARGER.....184
CHECK PLAY OF TURBOCHARGER ROTOR.....184
REPLACE CORROSION RESISTOR CARTRIDGE.....184
REPLACE HYDRAULIC TANK BREATHER.....185
CHANGE OIL IN FRONT AND REAR AXLES, WHEEL HUBS AND REDUCTION BOXES.....186
EVERY 2000 HOURS SERVICE.....187
CLEAN HYDRAULIC TANK STRAINER.....187
CLEAN ENGINE BREATHER.....187
CLEAN, CHECK TURBOCHARGER.....188
CHECK ALTERNATOR, STARTING MOTOR.....188
CHECK ENGINE VALVE CLEARANCE, ADJUST.....188
CHECK VIBRATION DAMPER.....188
CHECK, ADJUST FUEL INJECTION NOZZLES.....188
EVERY 4000 HOURS SERVICE.....189
CHECK WATER PUMP.....189
REPLACE FUEL INJECTION NOZZLE TIPS.....189
EVERY 5000 HOURS SERVICE.....190
CHANGE OIL IN HYDRAULIC TANK.....190
SPECIFICATIONS.....192
SPECIFICATIONS AND DIMENSIONS.....193
SPECIFICATIONS.....193
DIMENSIONS.....193
LIFTING CAPACITIES.....195
OUTRIGGERS DOWN.....195
OUTRIGGERS UP.....196
TRANSPORT.....197
MACHINE SYSTEMS.....198
HYDRAULIC SCHEMATIC.....199
CAB RISER VALVES.....201
UPPER STEERING.....203
UPPER BRAKE.....205
UPPER TRAVEL.....207
ACCUMULATOR CHARGE AND PRIORITY VALVE.....209
PARKING BRAKE AXLE LOCK.....211
UPPER OUTRIGGERS.....213
TRAVEL - VALVE TO SWIVEL.....215
OUTRIGGER PANEL SCHEMATIC.....217
CARRIER ELECTRICAL.....219
CAB ELECTRICAL.....221
STEERING AND GENERATOR PUMPS.....223
GENERATOR AND CONTROLLER PACKAGE.....225
GENERATOR VALVING AND PIPING.....227
MAGNET 230 VOLT ELECTRICAL.....229
MAGNET 24 VOLT ELECTRICAL.....231
GENERATOR HYDRAULIC COMPONENTS.....233
MAGNET DISCONNECT SWITCH AND CONTROLLER.....235
CONTROL HANDLES AND CONNECTIONS.....237
GRAPPLE CONTROL GROUP.....239
GRAPPLE CONTROL MAIN VALVE.....241
OPEN, CLOSE AND ROTATION FLOW CONTROL VALVE.....243
DOI -GRAPPLE- CONTROL VALVE.....245
FRONT AND REAR AXLES.....247
CEBM005600 - Material Handler PW400MH-6 Shop Manual.....252
COVER.....252
CONTENTS.....253
SAFETY.....256
SAFETY NOTICE.....256
IMPORTANT SAFETY NOTICE.....256
GENERAL PRECAUTIONS.....256
PREPARATIONS FOR WORK.....256
PRECAUTIONS DURING WORK.....256
FOREWORD.....258
GENERAL.....258
HOW TO READ THE SHOP MANUAL.....259
VOLUMES.....259
DISTRIBUTION AND UPDATING.....259
FILING METHOD.....259
REVISED EDITION MARK.....259
REVISIONS.....259
SYMBOLS.....259
HOISTING INSTRUCTIONS.....260
HOISTING.....260
WIRE ROPES.....260
COATING MATERIALS.....261
STANDARD TIGHTENING TORQUE.....263
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS.....263
TIGHTENING TORQUE OF HOSE NUTS.....264
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS.....264
TIGHTENING TORQUE FOR FLARED NUTS.....264
ALTERNATIVE FASTENERS.....265
BOLT IDENTIFICATION CHART.....265
GRADE 5 AND 8 NON PHOSPHATE COATED HARDWARE.....266
GRADE 8 PHOSPHATE COATED HARDWARE.....267
STANDARD METRIC FASTENERS.....267
HYDRAULIC TUBES AND FITTINGS.....268
HOSE CLAMPS.....268
SPLIT FLANGE CONNECTIONS.....268
ELECTRIC WIRE CODE.....269
CLASSIFICATION BY THICKNESS.....269
CLASSIFICATION BY COLOR AND CODE.....269
CONVERSION TABLES.....270
METHOD OF USING THE CONVERSION TABLE.....270
01 GENERAL.....276
SPECIFICATIONS AND DRAWING.....278
SPECIFICATIONS.....279
LIFTING PERFORMANCE.....280
LIFTING CAPACITY.....281
TRANSPORTATION.....282
MAIN CARRIER TRANSPORTATION DATA.....283
FUEL COOLANT AND LUBRICANTS.....284
ENGINE OIL SPECIFICATIONS.....285
NORMAL OPERATION.....285
ARCTIC OPERATION.....285
FINAL DRIVE OIL SPECIFICATIONS.....286
DIESEL FUEL SPECIFICATIONS.....286
COOLANT SPECIFICATIONS.....287
10 STRUCTURE AND FUNCTION.....294
ENGINE COMPONENTS.....296
TURBO INTAKE PIPING AND ENGINE MOUNTS.....296
DRIVE PLATES AND ENGINE MOUNTS.....297
RADIATOR AND OIL COOLER.....298
POWER TRAIN.....299
DRIVE SYSTEM.....300
FINAL DRIVE.....300
WHEEL FRAME.....300
TRAVEL MOTOR.....300
TRAVEL CONTROL SYSTEM.....300
STRAIGHT-TRAVEL SYSTEM.....300
TRAVEL JUNCTION VALVE.....300
SWING CIRCLE.....301
SWING MACHINERY.....302
HYDRAULIC PIPING DRAWING.....303
HYDRULIC PIPING SCHEMATIC.....304
HYDRAULIC TANK AND FILTER.....305
HYDRULIC PUMP.....306
MAIN PUMP.....307
TVC AND LS VALVE.....312
CONTROL VALVE.....325
MAIN STRUCTURE OF 9 SPOOL VALVE (1/4).....326
MAIN STRUCTURE OF 9 SPOOL VALVE (2/4).....327
MAIN STRUCTURE OF 9 SPOOL VALVE (3/4).....328
MAIN STRUCTURE OF 9 SPOOL VALVE (4/4).....329
SELF REDUCING PRESSURE VALVE.....331
STRUCTURE.....331
SUCTION SAFETY VALVE.....336
FOR SERVICE VALVE.....336
CLSS.....337
CLSS HYDRAULICS.....340
SYSTEM DIAGRAM.....341
WHEN UNLOAD VALVE IS ACTUATED.....342
RELIEF VALVE.....343
CUT-OFF CONTROL ACTUATED.....343
CUT-OFF CANCELED.....343
INTRODUCTION OF LS PRESSURE.....344
LS BYPASS VALVE.....345
PRESSURE COMPENSATION VALVE.....346
SHUTTLE VALVE INSIDE PRESSURE COMPENSATION VALVE.....349
VARIABLE PRESSURE COMPENSATION VALVE (FOR SERVICE VALVE.....351
BOOM REGENERATION CIRCUIT.....352
ARM REGENERATION CIRCUIT.....354
MERGE FLOW DIVIDER VALVE.....355
LS SELECT VALVE.....357
2-STAGE SAFETY VALVE (INSTALLED TO BOOM CYLINDER HEAD).....358
SWING SYSTEM.....359
CENTER SWIVEL JOINT.....359
COUNTERBALANCE VALVE.....359
SAFETY VALVE.....359
SWING MOTOR.....360
PW400MH-6 APPLICATION.....360
SUCTION-SAFETY VALVE.....362
PARKING BRAKE.....363
VALVE CONTROL.....364
PPC VALVE.....365
SERVICE PPC VALVE.....365
PPC SAFETY LOCK VALVE.....365
TRAVEL PPC VALVE.....365
BOOM HOLDING VALVE.....365
WORK EQUIPMENT.....365
AUTO DECELERATION SYSTEM.....365
WORK EQUIPMENT PPC VALVE.....366
PPC ACCUMULATOR.....368
PPC SHUTTLE VALVE VIEW.....369
PPC SHUTTLE VALVE PORT LOCATIONS.....370
LS-EPC VALVE.....372
SOLENOID VALVE.....375
AIR CONDITIONER.....377
AIR CONDITIONER PIPING.....377
ACTUAL ELECTRICAL WIRING DIAGRAM.....378
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2).....381
ENGINE CONTROL.....382
COMPONENTS OF SYSTEM.....384
ELECTRONIC CONTROL SYSTEM.....388
CONTROL FUNCTION.....388
PUMP AND ENGINE MUTUAL CONTROL SYSTEM.....390
CONTROL METHOD IN EACH MODE.....391
PUMP AND VALVE CONTROL FUNCTION.....392
AUTOMATIC WARM-UP AND ENGINE OVERHEAT PROTECTION.....394
SWING CONTROL SYSTEM.....396
SWING LOCK AND SWING HOLDING BRAKE.....397
COMPONENTS OF SYSTEM.....398
MACHINE MONITOR SYSTEM.....401
MONITOR PANEL FRONT AND BACK VIEW.....402
MONITOR DISPLAY.....403
CONTENT OF DISPLAY.....404
OIL MAINTENANCE FUNCTION.....405
MODE SELECTION SWITCHES.....406
SENSORS.....407
COOLANT LEVEL SENSOR.....407
COOLANT TEMPERATURE SENSOR.....408
OIL PRESSURE AND LEVEL SENSOR.....409
FUEL LEVEL SENSOR.....410
20 TESTING, ADJUSTING AND TROUBLESHOOTING.....412
STANDARD VALUE TABLE FOR ENGINE.....413
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS.....414
STANDARD VALUE TABLE FOR ELECTRICAL PARTS.....418
SERVICE TOOLS TABLE.....423
ENGINE COMPONENTS.....424
ADJUSTING ENGINE STOP LINKAGE.....424
ADJUSTING ENGINE STOP SOLONOID.....424
MEASURING AND ADJUSTING VALVE CLEARANCE.....424
MEASURING BLOW-BY PRESSURE.....424
MEASURING COMPRESSION PRESSURE.....424
MEASURING COOLANT TEMPERATURE.....424
MEASURING ENGINE LUBRICATING PRESSURE.....424
MEASURING ENGINE SPEEDS.....424
MEASURING ENGINE EXHAUST SMOKE.....424
MEASURING EXHAUST GAS TEMPERATURE.....424
MEASURING FUEL FILTER INLET RESTRICTION.....424
TESTING AND ADJUSTING BELT TENSIONS.....424
TESTING AND ADJUSTING FUEL INJECTION TIMING.....424
GOVERNOR MOTOR LEVER STROKE.....425
WORK AND SWING EQUIPMENT.....426
TVC VALVE OUTPUT PRESSURE.....429
LS VALVE OUTPUT AND DIFFERENTIAL PRESSURE.....431
CONTROL CIRCUIT OIL PRESSURE.....434
SOLENOID VALVE OUTPUT PRESSURE.....435
PPC VALVE OUTPUT PRESSURE AND SHUTTLE VALVE.....438
WORK EQUIPMENT, SWING PPC VALVE.....440
TRAVEL DEVIATION.....441
LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT.....442
MEASURING OIL LEAKAGE.....444
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.....446
TESTING CLEARANCE OF SWING CIRCLE BEARING.....447
BLEEDING AIR.....448
TROUBLESHOOTING - GENERAL.....452
POINTS TO REMEMBER WHEN TROUBLESHOOTING.....454
SEQUENCE OF EVENTS IN TROUBLESHOOTING.....456
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.....457
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT.....457
HANDLING CONTROL BOX.....462
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT.....463
CHECKS BEFORE TROUBLESHOOTING.....465
JUDGEMENT OF POWER TRAIN.....466
PRECAUTIONS WHEN TROUBLESHOOTING.....467
SAFETY.....467
METHODS FOR TROUBLESHOOTING.....467
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING.....469
PREVENTING RECURRENCE OF TROUBLE.....470
HYDRAULIC EQUIPMENT.....470
OIL CHECKS.....470
CLEANING FRAGMENTS OFF DAMAGED PARTS.....470
METHOD OF USING TROUBLESHOOTING CHARTS.....471
CATEGORY OF TROUBLESHOOTING CODE NUMBER.....471
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE.....471
METHOD OF USING MATRIX TROUBLESHOOTING TABLES.....473
METHOD OF USING ENGINE RELATED CHARTS.....475
TROUBLESHOOTING ELECTRICAL CONNECTORS.....480
CONNECTOR TYPES AND MOUNTING LOCATIONS.....481
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.....484
CONTROL MECHANISM FOR ELECTRICAL SYSTEM.....494
MACHINE CONTROL FUNCTIONS.....494
DISPLAY METHOD AND SPECIAL FUNCTION OF MONITORING PANEL.....495
DISPLAY ON MACHINE MONITOR.....495
RECORDING SERVICE CODES AND USER CODE.....495
MACHINE DATA MONITORING FUNCTION.....496
METHOD OF DISPLAYING MONITORING CODE.....497
TABLE OF MACHINE MONITORING CODES.....498
BIT PATTERN CHART.....499
GOVERNOR MOTOR ADJUSTMENT MODE.....501
TIME ADJUSTMENT MODE.....501
WORKING MODE DEFAULT SETTING MODE.....502
METHOD OF USING JUDGEMENT TABLE.....503
WHEN USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYS-TEM] AND ENGINE RE......503
EXAMPLE TABLE.....503
USING JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER [GOVERNOR CONTROL SYSTEM] AND HYDRAULIC RELAT......505
EXAMPLE TABLE.....505
METHOD OF USING TROUBLESHOOTING CHARTS.....507
CATEGORY OF TROUBLESHOOTING CODE NUMBER.....507
GENERAL PRECAUTIONS.....507
DETAILS OF TROUBLESHOOTING AND PROCEDURE.....510
PROCEDURE FOR CHECKING MONITOR PANEL OUTPUT SIGNAL.....512
CHECKING INPUT SIGNAL OF GOVERNOR, PUMP CONTROLLER.....513
SERVICE CODE TABLE.....515
TROUBLESHOOTING COMMUNICATION SYSTEM (N-MODE).....516
N-1 [E218] COMMUNICATION ABNORMALITY.....517
TROUBLESHOTING GOVERNOR PUMP CONTROLLER AND SYSTEM (E-MODE).....520
POINTS TO REMEMBER WHEN TROUBLESHOOTING GOVERNOR, PUMP CONTROLLER SYSTEM.....521
E-1 ABNORMALITY IN GOVERNOR, PUMP CONTROLLER POWER SOURCE, (CONTROLLER LED IS OFF).....526
E-2 [E308] ABNORMALITY IN FUEL CONTROL DIAL INPUT (VALUE IS DISPLAYED).....527
E-3 [E317] ABNORMALITY, DISCONNECTION IN MOTOR DRIVE SYSTEM IS DISPLAYED.....528
E-4 [E318] ABNORMALITY, SHORT CIRCUIT IN MOTOR DRIVE SYSTEM IS DISPLAYED.....529
E-5 [E306] ABNORMALITY IN FEEDBACK POTENTIOMETER SYSTEM IS DISPLAYED.....530
E-6 [E315] SHORT CIRCUIT IN BATTERY RELAY OUTPUT SYSTEM IS DISPLAYED.....531
E-7 [E316] ABNORMALITY, STEP OUT IN MOTOR DISPLAYED.....533
E-8 ENGINE DOES NOT START.....534
(A) IDLE SPEED IS IRRERGULAR.....536
(B) ENGINE SPEED HUNTING.....537
E-10 LACK OF OUTPUT, ENGINE HIGH IDLE SPEED IS LOW.....538
E-11 ENGINE DOES NOT STOP.....539
E-12 FAULTY OPERATION OF BATTERY RELAY SYSTEM, (ENGINE DOES NOT STOP).....540
TROUBLESHOOTING ENGINE SYSTEM (S-MODE).....543
METHOD OF USING ENGINE CHARTS.....544
S-1 ENGINE STARTING PERFORMANCE IS POOR.....549
S-2 ENGINE DOES NOT START.....550
S-3 ENGINE STARTS ROUGH.....553
S-4 ENGINE QUITS DURING OPERATION.....554
S-5 ENGINE SPEED IS HUNTING.....555
S-6 ENGINE POWER OUTPUT IS POOR.....556
S-7 EXHAUST GAS IS BLACK (POOR COMBUSTION).....557
S-8 ENGINE OIL CONSUMPTION IS EXCESSIVE (EXHAUST GAS IS BLUE).....558
S-9 ENGINE OIL BECOMES CONTAMINATED QUICKLY.....559
S-10 EXCESS FUEL CONSUMPTION.....560
S-11 OIL IN COOLANT, COOLANT BLOWS OUT OF SYSTEM DURING OPERATION.....561
S-12 OIL PRESSURE LIGHT STAYS ON (OIL PRESSURE LOW).....562
S-13 OIL LEVEL RISES OR OIL LOOKS ABNORMAL.....563
S-14 HIGH COOLANT TEMPERATURES (OVERHEATING).....564
S-15 ABNORMAL NOISES COMING FROM ENGINE COMPARTMENT.....565
S-16 EXCESSIVE ENGINE VIBRATION.....566
TROUBLESHOOTING GOVERNOR PUMP AND CONTROL SYSTEM (C-MODE).....568
IMPORTANT POINTS WHEN TROUBLESHOOTING CONTROLLER SYSTEM.....569
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.....570
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.....574
ELECTRIC CIRCUIT DIAGRAM FOR (C MODE).....575
C1 ABNORMALITY IN CONTROLLER POWER SOURCE, LED IS OFF.....577
C-2 [232] SHORT CIRCUIT IN FRONT PUMP TVC SOLONOID IS DISPLAYED.....578
C-3 [E233] DISCONECTION IN FRONT PUMP TVC SOLENOID IS DISPLAYED.....579
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID IS DISPLAYED.....580
C-5 [E237] DISCONECT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....581
C-6 [E207] SHORT CIRCUIT IN LS SELECT SOLENOID SYSTEM IS DISPLAYED.....582
BLANK FAULT CODES.....583
C-7 [E208].....583
C-12 [E206].....583
C-13 [E216].....583
C-14 [E217].....583
C-15 [E235].....583
C23.....583
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.....584
C-9 [E213] DISCONECT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.....585
C-10 [E204] SHORT CIRCUIT IN PUMP MERGE DIVIDER SOLENOID IS DISPLAYED.....586
C-11 [E214] DISCONECT IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED.....587
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED.....588
C-16 RELATED ELECTRIC CIRCUIT DIAGRAM.....589
C-17 [E222] SHORT CIRCUIT IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.....590
C-18 [E224] DISCONECTION IN LS-EPC SOLENOID SYSTEM IS DISPLAYED.....591
C-19 [E224] ABNORMALITY IN FRONT FUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.....592
C-20 [E225] ABNORMALITY IN REAR PUMP PRESSURE SENSOR SYSTEM IS DISPLAYED.....593
C-21 [E226] ABNORMALITY IN PRESSURE SENSOR POWER SOURCE IS DISPLAYED.....594
C-22 [E227] ABNORMALITY IN ENGINE SPEED SYSTEM IS DISPLAYED.....595
TROUBLESHOOTING GOVERNOR PUMP CONTROLLER INPUT SIGNAL (F-MODE).....597
ELECTRIC CIRCUIT DIAGRAM FOR (F MODE).....599
F1 BIT PATTERN 20-[1] SWING OIL PRESSURE SWITCH LIGHT INNOPERATIVE.....600
F-2 BIT PATTERN 20-[2] NOT USED.....601
F-3 BIT PATTERN 20-[3] BOOM LOWER OIL PRESSURE SWITCH LIGHT INNOPERATIVE.....602
F-4 BIT PATTERN 20-[4] BOOM RAISE OIL PRESSURE SWITCH LIGHT INNOPERATIVE.....603
F-5 BIT PATTERN 20-[5] ARM IN OIL PRESSURE SWITCH LIGHT INNOPERATVE.....604
F-6 BIT PATTERN 20-[60] ARM OUT OIL PRESSURE SWITCH LIGHT INNOPERATIVE.....605
F-7 BIT PATTERN 12-[1] GRAPPLE OPEN OIL PRESSURE SWITCH LIGHT INNOPERATIVE.....606
F-8 BIT PATTERN 12-[2] GRAPPLE CLOSED OIL PRESSURE LIGHT INNOPERATIVE.....607
F-9 BIT PATTERN 21-[3] SWING LOCK OIL PRESSURE SWITCH LIGHT INNOPERATIVE.....608
F-10 BIT PATTERN 22-[5] MODE CONNECTION LIGHT INNOPERATIVE.....609
F-11 BIT PATTERN 22-[6] NOT USED.....610
TROUBLESHOOTING MACHINE MECHANICAL SYSTEM (H-MODE).....612
PUMP MERGE DIVIDER LOGIC.....613
SOLENOID ACTUATION TABLE.....613
TABLE OF FAILURE MODES AND CAUSES.....614
H-1 SPEEDS OF WORK EQUIPMENT ARE SLOW OR LACK POWER.....616
H-2 EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS.....617
H-3 NO WORK EQUIPMENT OR SWING MOVEMENT.....617
H-4 ABNORMAL NOISE GENERATED AROUNG PUMPS.....618
BLANK FAULT CODES.....619
H-5.....619
H-6.....619
H-9.....619
H-10.....619
H-14.....619
H-15.....619
H-16.....619
H-17.....619
H-19.....619
H-20.....619
H_21.....619
H-23.....619
H-24.....619
H-7 BOOM IS SLOW OR LACKS POWER.....620
H-8 ARM IS SLOW OR LACKS POWER.....621
H-11 EXCESSIVE HYDRAULIC DRIFT.....622
1) EXCESSIVE HYDRAULIC DRIFT OF BOOM.....622
2) EXCESSIVE HYDRAULIC DRIFT OF ARM.....622
H-12 EXCESSIVE TIME LAG (ENGINE AT IDLE).....623
H-13 OTHER EQUIPMENT MOVES WHEN SIGNAL CIRCUIT IS RELIEVED.....623
H-25 DOES NOT SWING.....624
H-26 SWING ACCELERATION IS POOR OR SLOW.....625
H-27 EXCESSIVE OVERRUN WHEN STIPPING SWING MOTION.....626
H-28 EXCESSIVE SHOCK WHEN STOPPING SWING (ONE DIRECTION ONLY).....627
H-29 ABNORMAL NOISE WHEN STOPPING SWING.....627
H-30 EXCESSIVE HYDRAULIC DRIFT OF SWING.....628
H-31 SWING SPEED FASTER THAN SPECIFIED SWING SPEED.....628
TROUBLESHOOTING MACHINE MONITOR SYSTEM (M-MODE).....629
ACTIONS TAKEN BY MONITOR PANEL.....631
ELECTRIC CIRCUIT DIAGRAM FOR M MODE.....632
M-1 [E101] ABNORMALITY IN DATA OR IN CLOCK IS DISPLAYED.....633
M-2 [E103] SHORT CIRCUIT IN BUZZER DISPLAYED.....634
M-3 [E104] AIR CLEANER RESTRICTION DETECTION DISPLAYED.....635
M-4 [E106] MAJOR DROP IN ENGINE OIL PRESSURE IS DISPLAYED.....635
M-5 [E108] 105 ENGINE COOLANT TEMPERATURE IS DISPLAYED.....635
M-6 NO DISPLAY IN MONITOR PANEL WHEN IGNITION SWITCH IS IN THE "NO" POSITION.....636
M-7 WARNING LIGHTS ON MONITOR REMAIN ILLUMINATED WHILE MACHINE IS RUNNING.....638
M-8 MONITOR PANEL DISPLAYS INCORRECT INFORMATION AFTER MACHINE IS RUNNING.....638
M-9 WITH IGNITION SWITCH IN "ON" POSITION AND ENGINE OFF MONITOR PANEL DISPLAY FLASHES.....639
M-10 PREHEAT INDICATOR REMAINS ON AFTER ENGINE IS RUNNING.....642
M-11 WITH ENGINE RUNNING, MONITOR PANEL DISPLAY FLASHES.....643
M-12 WITH IGNITION SRITCH IN THE "ON" POSITION, ENGINE SPEED, CAUTION AND EMERGENCY ITEMS FLASH W......645
M-13 WITH ENGINE RUNNING, CAUTION AND EMERGENCY ITEMS FLASH DURING NORMAL OPERATION.....647
M-14 WITH IGNITION SWITCH ON, AND ENGINE OFF, CAUTION ITEMS FLASH BUT DO NOT SOUND.....650
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR PANEL BUT BUZZER SOUNDS.....651
M-16 DISPLAY ON MONITOR PANEL WORKS BUT NIGHT LIGHT ON PANEL DOES NOT ILLUMINATE.....652
M-17 COOLANT TEMPERATURE GAUGE DOES NOT RISE.....653
M-18 COOLANT TEMPERATURE GAUGE DOES NOT WORK DURING NORMAL OPERATION.....654
M-19 FUEL LEVEL GAUGE STUCK AT "FULL" INDICATION.....655
M-20 FUEL LEVEL GAUGE DOES NOT WORK.....656
M-12 SWING LOCK ON, BUT MONITOR PANEL DISPLAY DOES NOT WORK.....657
M-22 SWING PROLIX SEITCH IS ON, BUT MONITOR PANEL DISPLAY DOES NOT FLASH.....658
M-23 HOUR METER DOES NOT WORK WHILE ENGINE IS RUNNING.....659
M-24 WITH IGNITION SWITCH IN THE "OFF" POSITION, CLOCK AND HOUR METER ARE NOT DISPLAYED WHEN TIME......659
M-25 FAULTY FUEL LEVER SENSOR SYSTEM.....660
M-26 FAULTY COOLANT TEMPERATURE SENSOR SYSTEM.....661
M-27 FAULTY OIL LEVEL SENSOR SYSTEM.....662
M-28 FAULTY COOLANT LEVEL SENSOR SYSTEM.....663
M-29 FAULTY HYDRAULIC OIL LEVEL SENSOR SYSTEM.....664
M-30 [E112,113] WIPER OPERATION IS ABNORMAL WITH SWITCH IN THE "OFF" POSITION.....665
M-31 WASHER WORKS, BUT WIPER DOES NOT WORK.....669
30 DISASSEMBLY AND ASSEMBLY.....671
SPECIAL TOOL LIST.....675
SKETCHES OF SPECIAL TOOLS.....679
ENGINE COMPONENTS.....684
ALTERNATOR ASSEMBLY.....684
AFTERCOOLER CORE ASSEMBLY.....684
CYLINDER HEAD ASSEMBLY.....684
CRANKSHAFT DAMPER AND PULLYASSEMBLY.....684
ENGINE OIL COOLER ASSEMBLY.....684
ENGINE OIL PUMP ASSEMBLY.....684
FUEL INJECTION PUMP ASSEMBLY.....684
FUEL INJECTOR ASSEMBLY.....684
FRONT AND REAR ENGINE OIL SEAL ASSEMBLY.....684
GOVERNOR ASSEMBLY.....684
STARTER MOTOR ASSEMBLY.....684
THERMOSTAT ASSEMBLY.....684
TURBORCHARGER ASSEMBLY.....684
WATER PUMP ASSEMBLY.....684
OIL COOLER.....685
REMOVAL.....685
INSTALLATION.....686
RADIATOR, OIL COOLER AND AC CONDENSER.....687
REMOVAL.....687
INSTALLATION.....690
ENGINE WITH MAIN PUMP.....691
REMOVAL.....691
INSTALLATION.....694
DAMPER.....696
REMOVAL.....696
INSTALLATION.....696
FUEL TANK.....697
REMOVAL.....697
INSTALLATION.....697
CENTER SWIVEL JOINT.....698
REMOVAL.....698
INSTALLATION.....698
DISASSEMBLY.....699
ASSEMBLY.....699
SWING MOTOR.....700
REMOVAL.....700
INSTALLATION.....700
DISASSEMBLY.....701
ASSEMBLY.....703
SWING MACHINERY.....709
REMOVAL.....709
INSTALLATION.....709
DISASSEMBLY.....710
ASSEMBLY.....713
REVOLVING FRAME.....718
REMOVAL.....718
INSTALLATION.....719
SWING CIRCLE.....720
REMOVAL.....720
INSTALLATION.....720
TRAVEL AND CARRIER SYSTEM.....721
HYDRAULIC TANK AND PIPING.....721
TRAVEL SYSTEM HYDRAULICS.....721
TRAVEL MOTOR.....721
DRIVE AXLES REDUCTION BOXES.....721
STEERING SYSTEM.....721
BRAKING SYSTEM.....721
OUTRIGGER SYSTEM.....721
WORK SYSTEM.....722
ARM AND BOOM.....722
WORK EQUIPMENT.....722
BOOM CYLINDER AND PIPING.....722
ARM CYLINDER AND PIPING.....722
AUXILLURY PUMP SYSTEM.....722
GENERATOR AND ELECTRICAL SYSTEM.....722
EQUIPMENT CONTROLS.....722
MAIN PUMP.....723
REMOVAL.....723
INSTALLATION.....724
DISASSEMBLY.....725
PUMPS, FRONT AND REAR.....725
FRONT PUMP TAIR DOWN.....725
REAR PUMP TAIR DOWN.....730
ASSEMBLY.....734
FRONT PUMP.....734
MAIN PUMP OIL SEAL.....753
REMOVAL.....753
INSTALLATION.....753
CONTROL VALVE.....754
REMOVAL.....754
INSTALLATION.....756
DISASSEMBLY.....757
(1/3).....757
(2/3).....758
(3/3).....759
ASSEMBLY.....762
(1/3).....762
(2/3).....763
(3/3).....764
PUMP MERGE DIVIDER VALVE.....768
DISASSEMBLY.....768
ASSEMBLY.....768
PRESSURE COMPENSATION VALVE.....769
DISASSEMBLY.....769
ASSEMBLY.....769
FRONT PUMP SERVO VALVE.....770
REMOVAL.....770
INSTALLATION.....770
REAR PUMP SERVO VALVE.....771
REMOVAL.....771
INSTALLATION.....771
LS-EPC SOLENOID VALVE.....772
REMOVAL.....772
INSTALLATION.....772
SOLENOID VALVE.....773
REMOVAL.....773
INSTALLATION.....773
WORK EQUIPMENT PPC VALVE.....774
REMOVAL.....774
INSTALLATION.....774
DISASSEMBLY.....775
ASSEMBLY.....775
PPC SHUTTLE VALVE.....777
REMOVAL.....777
INSTALLATION.....778
DISASSEMBLY.....778
ASSEMBLY.....779
OPERATORS CAB.....780
REMOVAL.....780
INSTALLATION.....781
COUNTERWEIGHT.....782
REMOVAL.....782
INSTALLATION.....782
COMPRESSOR.....783
REMOVAL.....783
INSTALLATION.....783
CONDENSER.....784
REMOVAL.....784
INSTALLATION.....784
RECEIVER DRYER.....785
REMOVAL.....785
INSTALLATION.....785
AIR CONDITIONER UNIT.....786
REMOVAL.....786
INSTALLATION.....787
GOVERNOR, PUMP CONTROLLER.....788
REMOVAL.....788
INSTALLATION.....788
MONITOR PANEL.....789
REMOVAL.....789
INSTALLATION.....789
CONTROL STAND CASE.....790
REMOVAL.....790
TRAY.....790
BOOT.....790
UPPER CASE.....791
INSTALLATION.....791
40 MAINTENANCE STANDARD.....793
ENGINE MOUNTS.....795
RADIATOR AND OIL COOLER MOUNTINGS (1/2).....796
RADIATOR AND OIL COOLER MOUNTINGS (2/2).....797
SPECIFICATIONS FOR RADIATOR AND OIL COOLER MOUNTINGS.....798
SWING MACHINERY.....799
SWING CIRCLE.....801
HYDRAULIC PUMP.....802
CONTROL VALVE.....803
SELF REDUCING PRESSURE VALVE.....813
SUCTION SAFETY VALVE.....814
SWING MOTOR.....815
WORK EQUIPMENT SWING PPC VALVE.....816
LS-EPC VALVE.....818
SOLENOID VALVE.....819
CENTER SWIVEL JOINT.....820
90 OTHERS.....822
HYDRAULIC PIPING DRAWING.....824
HYDRAULIC PIPING SCHEMATIC.....826
DETAILS OF TROUBLESHOOTING, AND TROUBLESHOOTING PROCEDURE.....836
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART I).....838
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART II).....840
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER AND ENGINE RELATED PARTS.....842
ELECTRICAL CIRCUIT DIAGRAM FOR (E) MODE.....844
(E-8) ENGINE DOES NOT START.....846
(A) IDLE SPEED IS IRREGULAR.....848
(B) ENGINE SPEED IS HUNTING.....850
(E-10) LACK OF OUTPUT, ENGINE HIGH IDLE SPEED IS LOW.....852
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART I).....856
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART II).....858
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE (PART III).....860
ACTIONS TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS ON MACHINE ( PART IV).....862
(E-11) ENGINE DOES NOT STOP.....854
JUDGEMENT TABLE FOR GOVERNOR, PUMP CONTROLLER (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS.....864
ELECTRIC CIRCUIT DIAGRAM FOR (C) MODE.....866
C-2 [E232] SHORT CIRCUIT IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....868
C-3 [E233] DISCONNECTION IN FRONT PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....870
C-4 [E236] SHORT CIRCUIT IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....872
C-5 [E237] DISCONNECTION IN REAR PUMP TVC SOLENOID SYSTEM IS DISPLAYED.....874
C-8 [E203] SHORT CIRCUIT IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.....876
C-9 [E213] DISCONNECTION IN SWING BRAKE SOLENOID SYSTEM IS DISPLAYED.....878
C-11 [E214] DISCONNECTION IN PUMP MERGE DIVIDER SOLENOID SYSTEM IS DISPLAYED.....880
ELECTRIC CIRCUIT DIAGRAM FOR (F) MODE.....882
TABLE OF FAILURE MODES AND CAUSES (1/2).....884
TABLE OF FAILURE MODES AND CAUSES (2/2).....886
(H-1) SPEEDS OF ALL WORK EQUIPMENT, SWING, ARE SLOW OR LACK POWER.....888
(H-4) ABNORMAL NOISE GENERATED AROUND PUMP.....890
(H-7) BOOM IS SLOW OR LACKS POWER.....892
(H-26) SWING ACCELERATION IS POOR OR SLOW.....896
(H-8) ARM IS SLOW OR LACKS POWER.....894
ACTIONS TAKEN BY MONITOR WHEN ABNORMALITY OCCURS ON MACHINE.....898
ELECTRICAL CIRCUIT DIAGRAM FOR (M) MODE.....900
(M-30) WIPER OPERATION IS ABNORMAL WITH SWITCH NOT BEING USED [Include E112, E113].....902
(M-31) WIPER DOES NOT WORK OR SWITCH IS NOT BEING USED BUT WASHER MOTOR IS ACTUATED [Include E114].....906
RADIATOR AND OIL COOLER MOUNTINGS (1/2).....908
RADIATOR AND OIL COOLER MOUNTINGS (2/2).....910
