Komatsu Hydraulic Excavator PC1100, PC1100LC, PC1100SP Repair Service Manual

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Price: US$ 65.00

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-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: 1,233 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

SEAM018304T-00 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 avance Operation & Maintenance Manual.pdf
SEAW001100 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 Field Assembly Manual.pdf
SEBM014207 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 Shop Manual.pdf

MAIN SECTIONS
SEAM018304T-00 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 avance Operation & Maintenance Manual....2
  COVER....2
  1. FOREWORD....3
  2. SAFETY INFORMATION....6
  3. INTRODUCTION....7
  4. LOCATION OF PLATES,TABLE TO ENTER SERIAL NUMBER AND DISTRIBUTOR....8
  5. CONTENTS....9
  SAFETY....13
    6. GENERAL PRECAUTIONS....14
    7. PRECAUTIONS DURING OPERATION....22
      7.1 BEFORE STARTING ENGINE....22
      7.2 AFTER STARTING ENGINE....23
      7.3 TRANSPORTATION....29
      7.4 BATTERY....30
      7.5 TOWING....32
    8. SAFETY MAINTENANCE INFORMATION....33
      8.1 BEFORE CARRYING OUT MAINTENANCE....33
    9. POSITION FOR ATTACHING SAFETY LABELS....39
      9.1 POSITION FOR ATTACHING SAFETY LABELS....39
      9.2 CONTENT AND USE OF WARNING PLATES....43
  OPERATION....44
    10. GENERAL VIEW....45
      10.1 GENERAL VIEW OF MACHINE....45
      10.2 GENERAL VIEW OF CONTROLS AND GAUGES....46
    11. EXPLANATION OF COMPONENTS....47
      11.1 MACHINE MONITOR....47
      11.2 SWITCHES....59
      11.3 CONTROL LEVERS,PEDALS....65
      11.4 DOOR LOCK....67
      11.5 CAP,COVER WITH LOCK....68
      11.6 EMERGENCY EXIT FROM OPERATOR'S CAB....69
      11.7 HOT AND COOL BOX....69
      11.8 LUGGAGE BOX....69
      11.9 ASHTRAY....69
      11.10 POWER SUPPLY SOCKET....69
      11.11 FUSE....70
      11.12 FUSIBLE LINK....71
      11.13 CONTROLLERS....71
      11.14 TOOL HOLDER (CLOTH BAG)....71
      11.15 HANDLING GREASE PUMP....71
      11.16 HANDLING ACCUMULATOR....74
    12. OPERATION....76
      12.1 CHECK BEFORE STARTING ENGINE....76
      12.2 STARTING ENGINE....89
      12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....92
      12.4 MOVING MACHINE OFF....99
      12.5 STEERING MACHINE....102
      12.6 STOPPING MACHINE....104
      12.7 SWINGING....105
      12.8 OPERATION OF WORK EQUIPMENT....106
      12.9 HANDLING WORKING MODE....107
      12.10 PROHIBITIONS FOR OPERATION....108
      12.11 PRECAUTIONS FOR OPERATION....110
      12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS....111
      12.13 HOW TO ESCAPE FROM MUD....113
      12.14 WORK POSSIBLE USING HYDRAULIC....114
      12.15 REPLACEMENT OF BUCKET....115
      12.16 PARKING MACHINE....117
      12.17 CHECK AFTER FINISHING WORK....118
      12.18 STOPPING ENGINE....119
      12.19 CHECK AFTER STOPPING ENGINE....120
      12.20 LOCKING....120
    13. TRANSPORTATION....121
      13.1 PRECAUTIONS FOR TRANSPORTATION....121
      13.2 METHOD OF LIFTING MACHINE....121
      13.3 PRECAUTIONS FOR LOADING....123
      13.4 TRANSPORTATION....124
    14. COLD WEATHER OPERATION....130
      14.1 PRECAUTIONS FOR LOW TEMPERATURE....130
      14.2 PRECAUTIONS AFTER COMPLETION OF WORK....132
      14.3 AFTER COLD WEATHER....132
    15. LONG-TERM STORAGE....133
      15.1 BEFORE STORAGE....133
      15.2 DURING STORAGE....134
      15.3 AFTER STORAGE....134
      15.4 STARTING MACHINE AFTER LONG-TERM STORAGE....134
    16. TROUBLESHOOTING....135
      16.1 WHEN MACHINE RUNS OUT OF FUEL....135
      16.2 PHENOMENA THAT ARE NOT FAILURES ....135
      16.3 METHOD OF TOWING MACHINE....135
      16.4 PRECAUTIONS ON PARTICULAR JOBSITES....135
      16.5 IF BATTERY IS DISCHARGED....136
      16.6 OTHER TROUBLE....141
  MAINTENANCE....147
    17. GUIDES TO MAINTENANCE....148
    18. OUTLINES OF SERVICE....150
      18.1 OUTLINE OF OIL,FUEL,COOLANT....150
      18.2 OUTLINE OF ELECTRIC SYSTEM....154
      18.3 OUTLINE OF HYDRAULIC SYSTEM....155
    19. WEAR PARTS LIST....156
    20. USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....157
    21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....161
      21.1 INTRODUCTION OF NECESSARY TOOLS....161
      21.2 TORQUE LIST....162
    22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....163
    23. MAINTENANCE SCHEDULE CHART....165
      23.1 MAINTENANCE SCHEDULE CHART....165
    24. SERVICE PROCEDURE....169
      24.1 INITIAL 100 HOURS SERVICE....169
      24.2 INITIAL 250 HOURS SERVICE....169
      24.3 WHEN REQUIRED....170
      24.4 CHECK BEFORE STARTING....191
      24.5 EVERY 10 HOURS SERVICE....192
      24.6 EVERY 100 HOURS SERVICE....194
      24.7 EVERY 250 HOURS SERVICE....195
      24.8 EVERY 500 HOURS SERVICE....206
      24.9 EVERY 1000 HOURS SERVICE....214
      24.10 EVERY 2000 HOURS SERVICE....221
      24.11 EVERY 4000 HOURS SERVICE....225
  SPECIFICATIONS....226
    25. SPECIFICATIONS....227
  OPTION PARTS,ATTACHMENTS....233
    26. GENERAL PRECAUTIONS....234
      26.1 PRECAUTIONS REPLATED TO SAFETY....234
      26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....235
    27. HANDLING BUCKET WITH HOOK....236
      27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK....236
      27.2 PROHIBITED OPERATIONS....236
      27.3 PRECAUTIONS DURING OPERATIONS....236
    28. USING SEAT BELT....237
      28.1 SEAT BELT....237
    29. INTRODUCTION OF OPTIONAL PARTS,ATTACHMENTS....239
      29.1 COMBINATIONS OF WORK EQUIPMENT....239
      29.2 SELECTION OF TRACK SHOES....241
    30. HANDLING AIR CONDITIONER....243
      30.1 HANDLING AIR CONDITIONER....243
    31. HANDLING CAR RADIO....246
      31.1 HANDLING CAR RADIO....246
    32. AUTO-GREASING SYSTEM....251
      32.1 GENERAL LOCATIONS....251
      32.2 EXPLANATION OF EQUIPMENT....252
      32.3 GREASING POINTS FOR AUTO-GREASING SYSTEM....254
      32.4 OPERATION....255
      32.5 TROUBLESHOOTING....258
      32.6 MAINTENANCE....259
  LOADING SHOVEL....265
    33. GENERAL LOCATIONS....266
    34. INSTRUMENTS AND CONTROLS....267
      34.1 SWITCH....267
    35. OPERATIONS....269
      35.1 OPERATION OF WORK EQUIPMENT....269
    36. PRECAUTIONS FOR MACHINE OPERATION....271
      36.1 PRECAUTIONS DURING OPERATION....271
    37. PRECAUTIONS WHEN DISASSEMBLING MACHINE....274
    38. MAINTENANCE....275
      38.1 CHECK BEFORE STARTING....275
      38.2 EVERY 10 HOURS SERVICE....276
      38.3 EVERY 2000 HOURS SERVICE....279
    39. EXCAVATOR WORK....281
    40. TRANSPORTATION....282
      40.1 TRANSPORTATION....282
    41. CONSUMABLE PARTS LIST....284
    42. SPECIFICATIONS....285
    43. COMBINATIONS OF WORK EQUIPMENT....288
      43.1 COMBINATIONS OF WORK EQUIPMENT....288
SEAW001100 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 Field Assembly Manual....290
  COVER....290
  CONTENTS ....291
  Outline of work processes....292
  Tool list....293
  Transportation posture, dimensions and weights of main components ....294
  Outline of size of work place ....299
  Precautions during operation ....300
  List of parts sent individually....304
  Detailed procedure for parts assembly work....313
  Procedure for flushing hydraulic circuit....350
  Procedure for bleeding air from hydraulic circuit....354
  Procedure for adjusting track link....358
  Procedure for inspecting oil, water, fuel....361
  APPENDIX....369
    FIELD ASSEMBLY INSPECTION REPORT....369
SEBM014207 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 Shop Manual....395
  COVER....395
  CONTENTS....396
  01 GENERAL....422
    SPECIFICATION DRAWINGS....423
    SPECIFICATIONS....426
    WEIGHT TABLE....430
    FUEL, COOLANT AND LUBRICANTS....434
  10 STRUCTURE AND FUNCTION....436
    PTO....437
    PTO LUBRICATION SYSTEM....438
    RADIATOR, OIL COOLER, AFTERCOOLER....439
    POWER TRAIN....441
    SWING MACHINERY....443
    SWING CIRCLE....444
    FINAL DRIVE....445
    TRACK FRAME....446
    TRACE SHOE....447
    AIR PIPING DIAGRAM....448
    AIR CIRCUIT DIAGRAM....449
    AIR GOVERNOR....450
    AIR TANK....450
    SAFETY VALVE....451
    HORN VALVE....451
    GREASE PUMP....452
    HYDRAULIC PIPING DRAWING....453
    HYDRAULIC CIRCUIT DIAGRAM....458
    HYDRAULIC TANK....459
    HYDRAULIC PUMP....460
    NO.1 PUMP....461
    NO.2 PUMP....484
    NO.3 PUMP....489
    LINE OIL FILTER....498
    PILOT OIL FILTER....499
    RETURN OIL FILTER....500
    DRAIN OIL FILTER ....501
    L.H.5-SPOOL CONTROL VALVE....502
    R.H.4-SPOOL CONTROL VALVE....504
    SWING 4-SPOOL CONTROL VALVE....506
    STRAIGHT-TRAVEL VALVE....508
    BOOM LOWER REGENERATION VALVE....511
    SWING MOTOR....514
    CENTER SWIVEL JOINT....516
    TRAVEL MOTOR....517
    PPC CONTROL RELIEF VALVE....527
    SAFETY LOCK VALVE....528
    ACCUMULATOR....529
    VALVE CONTROL....530
    WORK EQUIMENT, SWING PPC VALVE....531
    TRAVLE PPC VALVE....535
    SOLENOID VALVES....539
    WORK EQUIPMENT....541
    AIR CONDITIONER....542
    ACTUAL ELECTRIC WIRING DIAGRAM....543
    ELECTRICAL CIRCUIT DIAGRAM....548
    ENGINE CONTROL....549
    MACHINE CONTROL SYSTEM....559
    MACHINE MONITOR SYSTEM....588
  20 TESTING AND ADJUSTING....595
    STANDARD VALUE TABLE FOR ENGINE RELATED PARTS....596
    STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....597
    STANDARD VALUE TABLE FOR ELECTRICAL PARTS....614
    TESTING AND ADJUSTING....629
      TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....630
      MEASURING ENGINE SPEED....631
      MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)....632
      MEASURING EXHAUST TEMPERATURE....633
      MEASURING EXHAUST COLOR....634
      ADJUSTING VALVE CLEARANCE....635
      MEASURING COMPRESSION PRESSURE....636
      MEASURING BLOW-BY PRESSURE....637
      TESTING AND ADJUSTING FUEL INJECTION TIMING....638
      MEASURING ENGINE OIL PRESSURE....639
      TESTING AND ADJUSTING FAN BELT TENSION....640
      TESTING AND ADJUSTING ALTERNATOR BELT TENSION....640
      TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR....641
      ADJUSTING ENGINE SPEED SENSOR....641
      TESTING CLEARANCE OF SWING CIRCLE BEARING....642
      MEASURING WEAR OF SPROCKET....643
      TESTING AND ADJUSTING TRACK SHOE TENSION ....644
      TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT....645
      TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE....650
      TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE....651
      MEASURING SERVO PISTON STROKE....659
      MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE....660
      TESTING SOLENOID VALVE OUTPUT PRESSURE....664
      ADJUSTING WORK EQUIPMENT, SWING PPC VALVE....666
      TESTING TRAVEL DEVIATION....667
      TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT....668
      MEASURING OIL LEAKAGE....669
      BLEEDING AIR....673
      RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....675
    TROUBLESHOOTING....676
      POINTS TO REMEMBER WHEN TROUBLESHOOTING....677
      SEQUENCE OF EVENTS IN TROUBLESHOOTING....678
      POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....679
      CHECKS BEFORE TROUBLESHOOTING....687
      CONNECTOR TYPES AND MOUNTING LOCATIONS....688
      COONECTION TABLE FOR CONNECTIOR PIN NUMBERS....694
      EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM....705
      DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL....706
      ORDER OF TROUBLESHOOTING WHEN CARRYING OUT TROUBLESHOOTING....721
      METHOD OF USING JUDGEMENT TABLE....723
      METHOD OF USING TROUBLESHOOTING CHARTS....725
      TROUBLESHOOTING OF COMMUNICATION ABNORMALITY SYSTEM (N MODE)....727
        ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....728
        ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM....730
          N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY....731
          N-2 [E117, E218 OCCUR AT SAME TIME] ENGINE CONTROLLER COMMUNICATION ABNORMALITY....733
          N-3 [E118, E507 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY....735
      TROUBLESHOOTING OF ENGINE CONTROLLER & APS CONTROLLER SYSTEM (E MODE)....737
        JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS....738
        POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF ENGINE CONTROLLER SYSTEM....741
        ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....742
        ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM....750
          E-1 [E501] ABNORMALITY IN ENGINE CONTROLLER POWER SOURCE SYSTEM IS DISPLAYED....754
          E-2 [E502] ABNORMALITY IN ENGINE CONTROLLER IS DISPLAYED....755
          E-3 [E521] DISCONNECTION IN GOVERNOR CONTROL SOLENOID SYSTEM IS DISPLAYED....756
          E-4 [E522] SHORT CIRCUIT IN GOVERNOR CONTROL SOLENOID SYSTEM IS DISPLAYED....757
          E-5 [E531] ABNORMALITY IN GOVERNOR SERVO IS DISPLAYED....758
          E-6 [E537] ABNORMALITY IN CONTORLLER SOLENOID POWER SUPPLE SYSTEM IS DISPLAYED....759
          E-7 [E508] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM IS DISPLAYED....760
          E-8 [E511] ABNORMALITY IN RACK SENSOR SIGNAL SYSTEM IS DISPLAYED....761
          E-9 [E515] DISCONNECTION IN PRESTROKE CONTROL SOLENOID SYSTEM IS DISPLAYED....762
          E-10 [E516] SHORT CIRCUIT IN PRESTROKE CONCTOR SOLENOID SYSTEM IS DISPLAYED....763
          E-11 [E513] ABNORMALITY IN ENGINE SPEED (1) SYSTEM IS DISPLAYED....764
          E-12 [E514] ABNORMALITY IN ENGINE SPEED SENSOR (2) SYSTEM IS DISPLAYED....765
          E-13 [E525] DISCONNECTION IN GOVERNOR CUT RELAY SYSTEM IS DISPLAYED....766
          E-14 [E526] SHORT CIRCUIT IN GOVERNOR CUT RELAY SYSTEM IS DISPLAYED....767
          E-15 [E505] ABNORMALITY IN FUEL CONTROL DIAL VOLTAGE IS DISPLAYED....768
          E-16 [E503] MISTAKEN CONNECTION OF CONNECTOR IS DISPLAYED....769
          E-17 [E504] ENGINE OVERRUN IS DISPLAYED....770
          E-18 [E535] ABNORMALITY IN ENGINE CONTORLLER BACKUP POWER SUPPLE SYSTEM IS DISPLAYED....771
          E-19 [E536] ABNORMALITY IN CONTROLLER POWER SUPPLE SYSTEM IS DISPLAYED....772
          E-20 ENGINE DOES NOT START....773
          E-21 ENGINE DOES NOT STOP....776
          E-22 DEFECTIVE ACTUATION OF APS....777
          E-23 [E534] ABNORMALITY IN MACHINE SELECTION INPUT TO ENGINE CONTROLLER IS DISPLAYED....784
      TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....785
        METHOD OF USING TROUBLESHOOTING CHARTS....786
        S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....790
        S-2 ENGINE DOES NOT START....791
        S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)....793
        S-4 ENGINE STOPS DURING OPERATIONS....794
        S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)....795
        S-6 ENGINE LACKS OUTPUT(NO POWER)....796
        S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)....797
        S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE)....798
        S-9 OIL BECOMES CONTAMINATED QUICKLY....799
        S-10 FUEL CONSUMPTION IS EXCESSIVE....800
        S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN ....801
        S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)....802
        S-13 OIL LEVEL RISES....803
        S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING)....804
        S-15 ABNORMAL NOISE IS MADE....805
        S-16 VIBRATION IS EXCESSIVE....806
      TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM(C MODE)....807
        JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC(MECHANICAL)RELATED PARTS....808
        POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM....811
        ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....812
        ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM....818
        C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM(CONTROLLER LED IS OFF)....820
        C-2 [E232] SHORT CIRCUIT IN TVC SOLENOID SYSTEM IS DISPLAYED....821
        C-3 [E233] DISCONNECTION IN TVC SOLENOID SYSTEM IS DISPLAYED....823
        C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID RELAY SYSTEM IS DISPLAYED....825
        C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID RELAY SYSTEM IS DISPLAYED....827
        C-6 [E201] SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED....829
        C-7 [E211] DISCONNECTION IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED....830
        C-8 [E202] SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED....831
        C-9 [E212] DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED....832
        C-10 [E204] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED....833
        C-11 [E214] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED....834
        C-12 [E205] SHORT CIRCUIT IN SWING PRIORITY SOLENOID SYSTEM IS DISPLAYED....835
        C-13 [E215] DISCONNECTION IN SWING PRIORITY SOLENOID SYSTEM IS DISPLAYED....836
        C-14 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED....837
        C-15 [E216] DISCONNECTION IN TRAVELE SPEED SOLENOID SYSTEM IS DISPLAYED....838
        C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED....839
        C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR(2)SYSTEM IS DISPLAYED....841
        C-18 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED....842
        C-19 ABNORMALITY IN SWING HOLDING BRAKE SYSTEM(NO SERVICE CODE IS DISPLAYED)....843
        C-20 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM(NO SERVICE CODE IS DISPLAYED)....845
        C-21 ABNORMALITY IN BOOM SHOCKLESS SOLENOID SYSTEM(NO SERVICE CODE IS DISPLAYED)....847
      TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTE(F MODE)....850
        ELECTRICAL CIRCUIT DIAGRAM OF F MODE....851
        F-1 [BIT PATTERN 20-(1)] (SWING TO RIGHT OIL PRESSURE SWITCH)DOES NOT LIGHT UP....853
        F-2 [BIT PATTERN 20-(2)] (R.H.TRAVEL OIL PRESSURE SWITCH)DOES NOT LIGHT UP....854
        F-3 [BIT PATTERN 20-(3)] (BOOM LOWER OIL PRESSURE SWITCH)DOES NOT LIGHT UP....855
        F-4 [BIT PATTERN 20-(4)] (BOOM RAISE OIL PRESSURE SWITCH)DOES NOT LIGHT UP....856
        F-5 [BIT PATTERN 20-(5)] (ARM IN OIL PRESSURE SWITCH)DOES NOT LIGHT UP....857
        F-6 [BIT PATTERN 20-(6)] (ARM OUT OIL PRESSURE SWITCH)DOES NOT LIGHT UP....858
        F-7 [BIT PATTERN 21-(1)] (BUCKET CURL OIL PRESSURE SWITCH)DOES NOT LIGHT UP....859
        F-8 [BIT PATTERN 21-(2)] (BUCKET DUMP OIL PRESSURE SWITCH)DOES NOT LIGHT UP....860
        F-9 [BIT PATTERN 21-(5)] (L.H.TRAVEL OIL PRESSURE SWITCH)DOES NOT LIGHT UP....861
        F-10 [BIT PATTERN 26-(5)] (SWING TO LEFT OIL PRESSURE SWITCH)DOES NOT LIGHT UP....862
        F-11 [BIT PATTERN 21-(3)] (SWING LOCK SWITCH)DOES NOT LIGHT UP....863
      TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE)....864
        TABLE OF FALIURE MODES AND CAUSES....865
        BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM(H MODE)....867
        H-1 SPEEDS OF ALL WORK EQUIPMENT,SWING,TRAVEL ARE SLOW OR LACK POWER....872
        H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED,OR ENGINE STALLS....874
        H-3 NO WORK EQUIPMENT,TRAVEL,SEWING MOVE....876
        H-4 ABNORMAL NOISE GENERATED(FORM AROUND PUMP)....877
        H-5 BOOM IS SLOW OR LACKS POWER....878
        H-6 ARM IS SLOW OR LACKS POWER....880
        H-7 BUCKET IS SLOW OR LACKS POWER....880
        H-8 BOOM DOES NOT MOVE....881
        H-9 ARM DOES NOT MOVE ....881
        H-10 BUCKET DOES NOT MOVE....881
        H-11 EXCESSIVE HYDRAULIC DRIFT....882
        H-12 EXCESSIVE TIME LAG....882
        H-13 BOOM SHOCKLESS FUNCTION IS NOT ACTUATED OR CANNOT BE CANCELED....883
        H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS....884
        H-15 DEVIATION IS EXCESSIVE WHEN STRARTING....886
        H-16 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS....887
        H-17 TRAVEL SPEED IS SLOW OR LACKS POWER....887
        H-18 TRAVEL DOES NOT MOVE(ONE SIDE ONLY)....888
        H-19 TRAVEL SPEED DOES NOT SWITCH....889
        H-20 DOES NOT SWING ....890
        H-21 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR....891
        H-22 IN COMPOUND OPERATIONS WITH BUCKET,SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR....892
        H-23 IN COMPOUND OPERATIONS WITH BOON WHEN SWING PRIORITY IS ON,SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR....892
        H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING....893
        H-25 EXCESSIVE SHOCK WHEN STOPPING SWING....894
        H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING....895
        H-27 EXCESSIVE HYDRAULIC DRIFT OF SWING....895
      TROUBLESHOOTING OF MACHINE MONITOR SYSTEM(M MODE)....896
        ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....897
        ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM....901
        M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED OR [E102]ABNORMALITY IN CLOCK DATA IS DISPLAYEED....903
        M-2 [E103] SHOT CIRCUIT IN BUZZER OUTPUT SYSTEM IS DISPLAYED....904
        M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED....905
        M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED....905
        M-5 [E108] ENGINE WATER TEMPERATURE 105C DETECTED IS DISPLAYED....906
        M-6 WHEN STARTING SWITCH IS TURNED ON,NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS....907
        M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHT UP AND DO NOT GO OUT....909
        M-8 WHEN STARTING SWITCH IS TURNED ON,ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM MACHINE....909
        M-9 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),BASIC CHECK ITEMS FLASH....910
        M-10 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),(PREHEATING MONITOR)DISPLAY IS NOT NORMAL....913
        M-11 WHEN ENGINE IS STARTED,BASIC CHECK ITEMS FLASH....914
        M-12 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH....916
        M-13 WHEN ENGINE IS STARTED,CAUTION ITEMS,EMERGENCY STOP ITEMS FLASH(BUT THERE IS NO ABNORMALITY IN ANY ITEM)....918
        M-14 WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED),BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND....923
        M-15 NO ABNORMALITY IS DISPLAYED NO MONITOR BUT BUZZER SOUNDS....923
        M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP....924
        M-17 ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE....925
        M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY(GAUGE DOES NOT EVEN DISPLAY 1ST LEAVE)....925
        M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL....926
        M-20 FUEL LEVEL GAUGE DOES NOT GIVE ANY DISPLAY(GAUGE DOSENOT EVEN DISPLAY 1ST LEVEN....926
        M-21 SWING LOCK SWITCH IS TURNED ON,BUT (SWING LOCK MONITOR) DOES NOT LIGHT UP ....927
        M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX),BUT (SWING LOCK MONITOR) DOES NOT FLASH....928
        M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING....929
        M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED,SERVICE METER DOES NOT GIVE DISPLAY....929
        M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM....930
        M-26 DEFECTIVE ENGINE WATER TEMPERATURE SENSOR SYSTEM AND DEFECTIVE HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM....931
        M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM AND DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM....932
        M-28 DEFECTIVE RADIATOR WATER LEVEL SENSOR SYSTEM....933
        M-29 DEFECTIVE OPERATION OF WIPER(INCLUDING CASES WHERE[E113]IS DISPLAYED]....934
        M-30 DEFECTIVE OPERATION OF WINDOW WASHER(INCLUDING CASES WHERE SERVICE CODE[E114]IS DISPLAYED)....937
  30 DISASSEMBLY AND ASSEMBLY....940
    METHOD OF USING MANUAL....942
    PRECAUTIONS WHEN CARRYING OUT OPERATION....944
    SPECIAL TOOL LIST....946
    SKETCHES OF SPECIAL TOOLS....953
    STARTING MOTOR ASSEMBLY....960
      REMOVAL AND INSTALLATION....960
    ALTERNATOR ASSEMBLY....961
      REMOVAL AND INSTALLATION....961
    NOZZLE HOLDER ASSEMBLY....962
      REMOVAL AND INSTALLATION....962
    ENGINE OIL COOLER ASSEMBLY....963
      REMOVAL AND INSTALLATION....963
    FUEL INJECTION PUMP ASSEMBLY....964
      REMOVAL....964
      INSTALLATION....965
    WATER PUMP ASSEMBLY....966
      REMOVAL AND INSTALLATION....966
    TURBOCHARGER ASSEMBLY....967
      REMOVAL AND INSTALLATION....967
    THERMOSTAT ASSEMBLY....968
      REMOVAL AND INSTALLATION....968
    AIR COMPRESSOR ASSEMBLY....969
      REMOVAL AND INSTALLATION....969
    ENGINE FRONT SEAL ....970
      REMOVAL AND INSTALLATION....970
    ENGINE REAR SEAL ....972
      REMOVAL AND INSTALLATION....972
    CYLINDER HEAD ASSEMBLY....974
      REMOVAL....974
      INSTALLATION....978
    AFTERCOOLER ASSEMBLY....980
      REMOVAL AND INSTALLATION....980
    RADIATOR,HYDRAULLIC COOLER ASSEMBLY....981
      REMOVAL....981
      INSTALLATION....982
    HYDRAULIC COOLER ASSEMBLY....983
      REMOVAL AND INSTALLATION....983
    ENGINE,PTO,HYDRAULIC PUMP ASSEMBLY....984
      REMOVAL....984
      INSTALLATION....987
    PTO ASSEMBLY....988
      REMOVAL....988
      INSTALLATION ....989
      DISASSEMBLY....990
      ASSEMBLY....992
    FUEL TANK ASSEMBLY....994
      REMOVAL AND INSTALLATION....994
    FINAL DRIVE ASSEMBLY....995
      REMOVAL AND INSTALLATION....995
      DISASSEMBLY....996
      ASSEMBLY....1000
    REVOLVING FRAME ASSEMBLY....1008
      REMOVAL AND INSTALLATION....1008
    SWING MACHINERY ASSEMBLY....1009
      REMOVAL AND INSTALLATION....1009
      DISASSEMBLY....1010
      ASSEMBLY....1014
    SWING CIRCLE ASSEMBLY....1019
      REMOVAL AND INSTALLATION....1019
    TRACK SHOE ASSEMBLY....1020
      REMOVAL....1020
      INSTALLATION....1021
    SPROCKET....1022
      REMOVAL AND INSTALLATION....1022
    IDLER ASSEMBLY....1023
      REMOVAL AND INSTALLATION....1023
      DISASSEMBLY....1024
      ASSEMBLY....1026
    IDLER ADJUSTMENT CYLINDER ASSEMBLY....1028
      DISASSEMBLY AND ASSEMBLY....1028
    RECOIL SPRING ASSEMBLY....1029
      REMOVAL AND INSTALLATION....1029
      DISASSEMBLY....1031
      ASSEMBLY....1032
    CARRIER ROLLER ASSEMBLY....1033
      REMOVAL AND INSTALLATION....1033
      DIAASSEMBLY....1034
      ASSEMBLY....1035
    TRACK ROLLER ASSEMBLY....1036
      REMOVAL AND INSTALLATION....1036
      DISASSEMBLY....1037
      ASSEMBLY....1038
    HYDRAULIC TANK ASSEMBLY....1040
      REMOVAL....1040
      INSTALLATION....1041
    TVC VALVE ASSEMBLY....1042
      REMOVAL AND INSTALLATION....1042
    SERVO VALVE ASSEMBLY....1043
      REMOVAL AND INSTALLATION....1043
    HYDEAULIC PUMP ASSEMBLY....1044
      REMOVAL AND INSTALLATION....1044
    NO.1, 2 PUMP (HPV95+95)....1045
      DISASSEMBLY ....1045
      ASSEMBLY....1055
    NO.3 PUMP (HPV160+160)....1071
      DISASSEMBLY....1071
      ASSEMBLY....1081
    MAIN PUMP INPUT SHAFT OIL SEAL....1096
      REMOVAL AND INSTALLATION....1096
    MAIN RELIEF VALVE ASSEMBLY....1097
      REMOVAL AND INSTALLATION....1097
      DISASSEMBLY AND ASSEMBLY....1098
    PILOT RELIEF VALVE ASSEMBLY....1099
      REMOVAL AND INSTALLATION....1099
    5-SPOOL CONTROL VALVE ASSEMBLY(NO.1)....1100
      REMOVAL....1100
      INSTALLATION....1101
    4-SPOOL CONTROL VALVE ASSEMBLY(NO.2)....1102
      REMOVAL....1102
      INSTALLATION....1103
    4-SPOOL CONTROL VALVE ASSEMBLY(NO.3)....1104
      REMOVAL....1104
      INSTALLATION ....1105
    CONTROL VALVE ASSEMBLY(NO.1)....1106
      DISASSEMBLY....1106
      ASSEMBLY....1107
    CONTROL VALVE ASSEMBLY(NO.2)....1109
      DISASSEMBLY....1109
      ASSEMBLY....1110
    CONTROL VAVLE ASSEMBLY(NO.3)....1113
      DISASSEMBLY....1113
      ASSEMBLY....1114
    SWING MOTOP ASSEMBLT....1117
      REMOVAL AND INSTALLATION....1117
    CENTER SWIVEL JOINT ASSEMBLY....1118
      REMOVAL AND INSTALLATION....1118
      DISASSEMBLY AND ASSEMBLY....1119
    TRAVEL MOTOR ASSEMBLY....1120
      REMOVAL AND INSTALLATION....1120
    WORK EQUIPMENT PPC VALVE ASSEMBLY....1121
      REMOVAL AND INSTALLATION....1121
      DISASSEMBLY....1122
      ASSEMBLY....1123
    TRAVEL PPC VALVE ASSEMBLY....1124
      REMOVAL AND INSTALLATION....1124
      DISASSEMBLY....1125
      ASSEMBLY ....1126
    BUCKET CYLINDER ASSEMBLY....1127
      BACKHOE....1127
        REMOVAL....1127
        INSTALLATION....1128
      LOADING SHOVEL....1129
        REMOVAL....1129
        INSTALLATION....1130
    ARM CYLINDER ASSEMBLY....1131
      BACKHOE....1131
        REMOVAL....1131
        INSTALLATION....1132
      LOADING....1133
        REMOVAL....1133
        INSTALLATION....1134
    BOOM CYLINDER ASSEMBLY....1135
      BACKHOE....1135
        REMOVAL....1135
        INSTALLATION....1136
      LOADING....1137
        REMOVAL....1137
        INSTALLATION....1138
    BOTTOM DUMP CYLINDER ASSEMBLY....1139
      LOADING SHOVEL....1139
        REMOVAL....1139
        INSTALLATION....1140
    BUCKET ASSEMBLY....1141
      BACKHOE....1141
        REMOVAL....1141
        INSTALLATION....1142
      LOADING SHOVEL....1143
        REMOVAL....1143
        INSTALLATION....1144
    ARM ASSEMBLY....1145
      BACKHOE....1145
        REMOVAL....1145
        INSTALLATION....1146
      LOADING SHOVEL....1147
        REMOVAL ....1147
        INSTALLATION....1148
    BOOM ASSEMBLY....1149
      BACKHOE....1149
        REMOVAL....1149
        INSTALLATION....1150
      LOADING SHOVEL....1151
        REMOVAL....1151
        INSTALLATION....1153
    BUKET,ARM ASSEMBLY....1155
      REMOVAL....1155
      INSTALLATION ....1156
    WORK EQUIPMENT ASSEMBLY....1157
      BACKOE....1157
        REMOVAL....1157
        INSTALLATION....1158
      LOADING SHOVEL....1159
        REMOVAL ....1159
        INSTALLATION....1160
    CAB ASSEMBLY....1161
      REMOVAL....1161
      INSTALLATION....1162
    COUNTERWEIGHT ASSEMBLY....1163
      REMOVAL AND INSTALLATION....1163
    RECEIVER TANK ASSEMBLY....1164
      REMOVAL AND INSTALLATION....1164
    AIR CONDITIONER CONDENSER ASSEMBLY....1165
      REMOVAL AND INSTALLATION....1165
    AIR CONDITIONER COMPRESSOR ASSEMBLY....1166
      REMOVAL AND INSTALLATION....1166
    AIR CONDITIONER UNIT ASSEMBLY....1167
      REMOVAL ....1167
      INSTALLATION ....1168
    SOLENOID VAVLE ASSEMBLY....1169
      REMOVAL AND INSTALLATION....1169
    GOVERNOR CONTROLLER ASSEMBLY....1170
      REMOVAL AND INSTALLATION....1170
    MONITOR PANEL ASSEMBLY....1171
      REMOVAL AND INSTALLATION....1171
    PUMP CONTROLLER ASSEMBLY....1172
      REMOVAL AND INSTALLATION....1172
    BOOM ROCK PREVENTION VALVE ASSEMBLY....1173
      REMOVAL AND INSTALLATION....1173
    ACCUMULATOR ASSEMBLY....1174
      REMOVAL AND INSTALLATION....1174
    BOOM LOWER REGENERATION VALVE ASSEMBLY....1175
      REMOVAL AND INSTALLATION....1175
  40 MAINTENANCE STANDARD....1176
    ENGINE MOUNT....1177
    PTO....1178
    SWING CIRCLE....1179
    SWING MACHINERY....1180
    FINAL DRIVE....1182
    TRACK FRAME....1184
    IDLER....1185
    CARRIER ROLLER....1187
    TRACK ROLLER....1188
    TRACK SHOE....1189
    HYDRAULIC PUMP....1193
    CONTROL,PTO LUBRICATING,AFTERCOOLER FAN DRIVE PUMP....1195
    L.H.5-SPOOL CONTROL VALVE....1196
    R.H.4-SPOOL CONTROL VALVE....1198
    SWING 4-SPOOL CONTROL VALVE....1200
    STRAIGHT-TRAVEL VALVE....1203
    BOOM LOWER REGENERATION VALVE....1204
    SWING NOTOR....1205
    TRAVEL MOTOR....1206
    CENTER SWIVEL JOINT....1208
    PPC CONTROL RELIEF VALVE....1209
    WORK EQUIPMENTSWING PPC VALVE....1210
    TRAVEL PPC VALVE....1211
    HYDRAULIC CYLINDER ....1212
      FOR BACKHOE....1212
      FOR LOADING SHOVEL....1214
    WORK EQUIPMENT....1215
      FOR BACKHOE....1215
      FOR LOADING SHOVEL....1217
    DIMENSIONS OF WORK EQUIPMENT....1219
  90 OTHERS....1223
    HYDRAULIC CIRCUIT DIAGRAM....1224
      FOR BACKHOE....1224
      FOR LOADING SHOVEL....1225
    ELECTRICAL CIRCUIT DIAGRAM....1226
      FOR BACKHOE(1/4)....1226
      FOR BACKHOE(2/4)....1227
      FOR BACKHOE(3/4)....1228
      FOR BACKHOE(4/4)....1229
      FOR LOADING SHOVEL(1/4)....1230
      FOR LOADING SHOVEL(2/4)....1231
      FOR LOADING SHOVEL(3/4)....1232
      FOR LOADING SHOVEL(4/4)....1233

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