Komatsu Hydraulic Excavators PC1000, PC1000LC, PC1000SE, PC1000SP Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC1000-1, PC1000LC-1, PC1000SE-1, PC1000SP-1, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC1000-1, PC1000LC-1, PC1000SE-1, PC1000SP-1 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: 1,734 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
SEBM021N0107 - Hydraulic Excavator PC1000-1, PC1000LC-1, PC1000SE-1, PC1000SP-1 Shop Manual.pdf
SEAM007701 - Hydraulic Excavator PC1000-1, PC1000LC-1, PC1000SE-1 Operation & Maintenance Manual.pdf
SEAM008701 - Hydraulic Excavator PC1000-1, PC1000LC-1, PC1000SE-1 Operation & Maintenance Manual.pdf
SEAM018300 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 avance Operation & Maintenance Manual.pdf
SEAW0021N0103 - Hydraulic Excavator PC1000-1 Field Assembly Manual.pdf
MAIN SECTIONS
SEAM007701 - Hydraulic Excavator PC1000-1, PC1000LC-1, PC1000SE-1 Operation & Maintenance Manual....2
COVER....2
1. FOREWORD....7
2. SAFETY INFORMATION....8
3. INTRODUCTION....9
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....10
5. CONTENTS....11
SAFETY....15
6. GENERAL PRECAUTIONS....16
7. PRECAUTIONS DURING OPERATION....22
7.1 BEFORE STARTING ENGINE....22
7.2 OPERATING MACHINE....24
7.3 TRANSPORTATION....29
7.4 BATTERY....30
7.5 BUCKET WITH HOOK....31
8. PRECAUTIONS FOR MAINTENANCE....34
8.1 BEFORE CARRYING OUT MAINTENANCE....34
8.2 DURING MAINTENANCE....37
9. POSITION FOR ATTACHING SAFETY LABELS....41
OPERATION....45
10. GENERAL VIEW....46
10.1 GENERAL VIEW OF MACHINE....46
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....47
11. EXPLANATION OF COMPONENTS....48
11.1 MACHINE MONITOR....48
11.2 LAMP....58
11.3 SWITCHES....59
11.4 CONTROL LEVERS, PEDALS....64
11.5 CEILING WINDOW....67
11.6 FRONT WINDOW....68
11.7 DOOR LOCK....70
11.8 DUST INDICATOR....70
11.9 AIR CONDITIONER....71
11.10 RADIO....74
11.11 FUSE....76
11.12 CONTROLLERS....77
11.13 TOOL BOX....77
11.14 GREASE PUMP....77
11.15 HANDLING GREASE PUMP....78
11.16 HANDLING ACCUMULATOR....80
12. OPERATION....81
12.1 CHECK BEFORE STARTING ENGINE....81
12.2 STARTING ENGINE....90
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....94
12.4 MOVING MACHINE OFF....96
12.5 STEERING MACHINE....100
12.6 STOPPING MACHINE....102
12.7 SWINGING....104
12.8 OPERATION OF WORK EQUIPMENT....105
12.9 WORKING MODE SELECTION....106
12.10 PROHIBITIONS FOR OPERATION....107
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 EXCAVATOR....114
12.15 PARKING MACHINE....115
12.16 CHECK AFTER FINISHING WORK....116
12.17 STOPPING ENGINE....117
12.18 CHECK AFTER STOPPING ENGINE....118
12.19 LOCKING....118
13. TRANSPORTATION....119
13.1 PRECAUTIONS FOR TRANSPORTATION....119
13.2 PARTS FOR TRANSPORT....120
13.3 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....123
14. COLD WEATHER OPERATION....125
14.1 PRECAUTIONS FOR LOW TEMPERATURE....125
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....127
14.3 AFTER COLD WEATHER....127
15. LONG-TERM STORAGE....128
15.1 BEFORE STORAGE....128
15.2 DURING STORAGE....129
15.3 AFTER STORAGE....129
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE....129
16. TROUBLESHOOTING....130
16.1 PHENOMENA THAT ARE NOT FAILURES....130
16.2 PRECAUTIONS ON PARTICULAR JOBSITES....130
16.3 IF BATTERY IS DISCHARGED....131
16.4 OTHER TROUBLE....135
MAINTENANCE....143
17. GUIDES TO MAINTENANCE....144
18. OUTLINES OF SERVICE....147
18.1 OUTLINE OF OIL, FUEL, COOLANT....147
18.2 OUTLINE OF ELECTRICAL SYSTEM....150
18.3 OUTLINE OF HYDRAULIC SYSTEM....151
18.4 RELEASING PRESSURE....152
18.5 BLEEDING AIR FROM CIRCUIT....154
18.6 OIL FILLER AND LEVEL GAUGE POSITIONS....159
19. CONSUMABLE PARTS LIST....160
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....161
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....165
21.1 INTRODUCTION OF NECESSARY TOOLS....165
21.2 TORQUE LIST....166
22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS....167
23. MAINTENANCE SCHEDULE CHART....170
23.1 MAINTENANCE SCHEDULE CHART....170
24. SERVICE PROCEDURE....174
24.1 INITIAL 100 HOURS SERVICE....174
CLEAN STRAINER OF PTO LUBRICATING OIL FILTER....174
24.2 INITIAL 250 HOURS SERVICE....174
REPLACE FUEL FILTER CARTRIDGE....174
CHANGE OIL OF SWING MACHINERY CASE....174
CHANGE OIL OF PTO CASE....174
CHANGE OIL OF FINAL DRIVE CASE....174
CHECK ENGINE VALVE CLEARANCE, ADJUST....174
24.3 WHEN REQUIRED....175
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT....175
CLEAN INSIDE OF COOLING SYSTEM....177
CHECK AND TIGHTEN TRACK SHOE BOLTS....181
CHECK AND ADJUST TRACK TENSION....182
CHECK ELECTRICAL INTAKE AIR HEATER....185
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)....186
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)....189
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID....190
CHECK AND ADJUST AIR CONDITIONER....191
CLEAN LINE FILTER....192
REPLACEMENT OF FAN BELT AND ADJUSTMENT OF AUTO TENSIONER....193
CHECK APS (AUTOMATIC PRIMING SYSTEM)....194
24.4 CHECK BEFORE STARTING....195
CHECK COOLANT LEVEL, ADD WATER....195
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL....195
CHECK FUEL LEVEL, ADD FUEL....196
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....197
CHECK DUST INDICATOR....198
CHECK ELECTRIC WIRING....198
DRAIN WATER AND SEDIMENT FROM FUEL TANK....199
CHECK MONITOR SYSTEM....199
CHECK OIL LEVEL IN PTO CASE....199
CHECK OIL LEVEL IN SWING MACHINERY CASE....199
24.5 CHECK EVERY 10 HOURS SERVICE....200
LUBRICATING....200
BOOM CONCENTRATION LUBRICATING BLOCK....200
BOOM CYLINDER FOOT PIN (2 POINTS)....201
ARM CONCENTRATION LUBRICATING BLOCK (4 POINTS)....201
BUCKET CYLINDER ROD END PIN (2 POINTS)....201
BUCKET CYLINDER ROD END LINK COUPLING PIN (4 POINTS)....201
BUCKET CYLINDER FOOT PIN (2 POINTS)....201
BUCKET-LINK COUPLING PIN (2 POINTS)....201
ARM-BUCKET COUPLING PIN (2 POINTS)....201
ARM-LINK COUPLING PIN (2 POINTS)....201
BUCKET HINGE PIN (2 POINTS)....202
BOTTOM DUMP CYLINDER FOOT PIN (2 POINTS)....202
BOTTOM DUMP CYLINDER ROD END PIN (2 POINTS)....202
24.6 EVERY 100 HOURS SERVICE....203
CLEAN STRAINER OF PTO LUBRICATION FILTER....203
LUBRICATING SWING CIRCLE....203
DRAIN WATER AND SEDIMENT FROM FUEL TANK....203
24.7 EVERY 250 HOURS SERVICE....204
LUBRICATING....204
FAN PULLEY ASSEMBLY....204
TENSION PULLEY ASSEMBLY....204
CHANGE OIL AND FINAL DRIVE CASE....204
CHECK LEVEL OF BATTERY ELECTROLYTE....205
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE....206
REPLACE HYDRAULIC FILTER ELEMENT....207
CHECK ALTERNATOR DRIVE BELT TENSION, ADJUST....208
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST....209
CHECK, CLEAN FUEL STRAINER....210
CHECK AND TIGHTEN TRACK SHOE BOLTS....210
CHECK AND TIGHTEN TRACK FRAME AND AXLE CONNECTING BOLTS....210
24.8 EVERY 500 HOURS SERVICE....211
CLEAN HYDRAULIC TANK STRAINER....211
CHECK AND CLEAN RADIATOR FINS....212
CLEAN PILOT FILTER STRAINER....212
CLEAN STRAINER OF PTO LUBRICATION OIL FILTER....212
CHANGE FUEL FILTER....213
CHECK FAN BELT....213
CHECK INSPECTION OF WELDINGS STRUCTURE (COLOR CHECK)....214
24.9 EVERY 100 HOURS SERVICE....218
CHANGE OIL IN SWING MACHINERY CASE....218
CHECK TURBOCHARGER CLAMPING JOINT....218
LUBRICATING OF TENSION PULLEY (2 POINTS)....218
CHANGE OIL IN PTO CASE....219
REPLACE CORROSION RESISTOR CARTRIDGE....219
REPLACE HYDRAULIC TANK BREATHER ELEMENT....220
24.10 EVERY 2000 HOURS SERVICE....221
CHANGE OIL IN FINAL DRIVE CASE....221
CHANGE OIL IN HYDRAULIC TANK, CLEAN STRAINER....222
CLEAN, CHECK TURBOCHARGER....222
CHECK TURBOCHARGER ROTOR PLAY....222
CHECK SWING PINION GREASE LEVEL, ADD GREASE....223
CLEAN ENGINE BREATHER....224
CHECK ALTERNATOR, STARTING MOTOR....224
CHECK ENGINE VALVE CLEARANCE, ADJUST....224
CHECK VIBRATION DAMPER....224
24.11 EVERY 4000 HOURS SERVICE....225
CHECK WATER PUMP....225
CHECK FAN PULLEY AND TENSION PULLEY....225
CHECK AIR COMPRESSOR, ADJUST....225
SPECIFICATIONS....227
25. SPECIFICATIONS....228
OPTIONS, ATTACHMENTS....231
26. GENERAL PRECAUTIONS....232
26.1 PRECAUTIONS RELATED TO SAFETY....232
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....233
27. HANDLING BUCKET WITH HOOK....234
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK....234
27.2 PROHIBITED OPERATIONS....234
27.3 PRECAUTIONS DURING OPERATIONS....234
28. USING SEAT BELT....235
28.1 SEAT BELT....235
29. INTRODUCTION OF ATTACHMENTS....237
29.1 SPECIFICATION, USE....237
BACK HOE TYPE SHOVEL....239
30. GENERAL LOCATIONS....240
31. INSTRUMENTS AND CONTROLS....241
31.1 SWITCH....241
31.2 CONTROL LEVERS....242
31.3 CONTROL BOX....244
31.4 FUSE BOX....245
32. OPERATION....246
32.1 OPERATION OF WORK EQUIPMENT....246
32.2 CHECK BEFORE STARTING ENGINE....248
33. PRECAUTIONS FOR MACHINE OPERATION....251
33.1 PRECAUTIONS DURING OPERATION....251
34. PRECAUTIONS WHEN DISASSEMBLING MACHINE....253
35. MAINTENANCE....254
35.1 OIL FILLER AND LEVEL GAUGE POSITION....254
35.2 ADJUST BUCKET CLEARANCE....255
35.3 CHECK BEFORE STARTING....256
35.4 EVERY 10 HOURS SERVICE....257
36. EXCAVATOR WORK....260
37. TRANSPORTATION....261
38. INTRODUCTION OF ATTACHMENTS....264
38.1 ATTACHMENT INSTALLATION COMBINATION TABLE....264
38.2 SPECIFICATION, USE....265
39. SPECIFICATIONS....266
SEAM008701 - Hydraulic Excavator PC1000-1, PC1000LC-1, PC1000SE-1 Operation & Maintenance Manual....271
COVER....271
1. FOREWARD....272
2. SAFETY INFORMATION....273
3. INTRODUCTION....274
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....275
5. CONTENTS....276
SAFETY....280
6. GENERAL PRECAUTIONS....281
7. PRECAUTIONS DURING OPERATION....287
7.1 BEFORE STARTING ENGINE....287
7.2 OPERATING MACHINE....289
7.3 TRANSPORTATION....294
7.4 BATTERY....295
7.5 LIFTING OPERATION....296
8. PRECAUTIONS FOR MAINTENANCE....297
8.1 BEFORE CARRYING OUT MAINTENANCE....297
8.2 DURING MAINTENANCE....300
9. POSITION FOR ATTACHING SAFETY LABELS....304
OPERATION....308
10. GENERAL VIEW....309
10.1 GENERAL VIEW OF MACHINE....309
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....310
11. EXPLANATION OF COMPONENTS....311
11.1 MACHINE MONITOR....311
11.2 LAMP....321
11.3 SWITCHES....322
11.4 CONTROL LEVERS, PEDALS....327
11.5 CEILING WINDOWS....330
11.6 FRONT WINDOW....331
11.7 DOOR LOCK....333
11.8 DUST INDICATOR....333
11.9 AIR CONDITIONER....334
11.10 RADIO....337
11.11 FUSE....339
11.12 CONTROLLERS....340
11.13 TOOL BOX....340
11.14 GREASE PUMP....340
11.15 HANDLING GREASE PUMP....341
11.16 HANDLING ACCUMULATOR....343
11.17 LUGGAGE BOX....345
11.18 METHOD OF RELEASING PRESSURE IN CONTROL CIRCUIT ON MACHINE EQUIPPED WITH ACCUMULATOR....345
11.19 LOCATION OF FIRE EXTINGUISHER....345
12. OPERATION....346
12.1 CHECK BEFORE STARTING ENGINE....346
12.2 STARTING ENGINE....356
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE ....360
12.4 MOVING MACHINE OFF....362
12.5 STEERING MACHINE....366
12.6 TOPPING MACHINE....368
12.7 SWINGING....370
12.8 OPERATION OF WORK EQUIPMENT....371
12.9 WORKING MODE SELECTION....372
12.10 PROHIBITIONS FOR OPERATION....373
12.11 PRECAUTIONS FOR OPERATION....376
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS....377
12.13 HOW TO ESCAPE FROM MUD....379
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR....380
12.15 PARKING MACHINE....381
12.16 CHECK AFTER FINISHING WORK....382
12.17 STOPPING ENGINE....383
12.18 CHECK AFTER STOPPING ENGINE....384
12.19 LOCKING....384
13. TRANSPORTATION....385
13.1 LOADING UNLOADING WORK....385
13.2 PRECAUTION FOR TRANSPORTATION....272
13.3 PARTS FOR TRANSPORT....386
13.4 PROCEDURE FOR RAISING CHASSIS....389
13.5 SECURING MACHINE....392
13.6 PROCEDURE FOR INCREASING OR REDUCING TRACK FRAME GAUGE....393
14. COLD WEATHER OPERATION....395
14.1 PRECAUTIONS FOR TRANSPORTATION....395
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....397
14.3 AFTER COLD WEATHER....397
15. LONG-TERM STORAGE....398
15.1 BEFORE STORAGE....398
15.2 DURING STORAGE....399
15.3 AFTER STORAGE....399
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE....399
16. TROUBLESHOOTING....400
16.1 PHENOMENA THAT ARE NOT FAILURES....400
16.2 METHOD OF TOWING MACHINE....400
16.3 PRECAUTIONS ON PARTICULAR JOBSITES....401
16.4 IF BATTERY IS DISCHARGED....402
16.5 OTHER TROUBLE....406
MAINTENANCE....414
17. GUIDES TO MAINTENANCE....415
18. OUTLINES OF SERVICE....418
18.1 OUTLINE OF OIL, FUEL, COOLANT....418
18.2 OUTLINE OF ELECTRICAL SYSTEM....421
18.3 OUTLINE OF HYDRAULIC SYSTEM....422
18.4 RELEASING PRESSURE....423
18.5 BLEEDING AIR FROM CIRCUIT....425
18.6 OIL FILTER AND LEVEL GAUGE POSITIONS....430
19. CONSUMABLE PARTS LIST....431
20. USE FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERANCE....432
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....436
21.1 INTROUCTION OF NECESSARY TOOLS....436
21.2 TORQUE LIST....437
22. PERIODIC REPLACEMENT OF CRITICAL SAFETY PARTS....438
23. MAINTENANCE SCHEDULE CHART....444
23.1 MAINTENANCE SCHEDULE CHART....444
24. SERVICE PROCEDURE....448
24.1 INTIAL 100 HOURS SERVICE....448
24.2 INTIAL 250 HOURS SERVICE....448
24.3 WHEN REQUIRED....449
24.4 CHECK BEFORE STARTING....469
24.5 EVERY 10 HOURS SERVICE....474
24.6 EVERY 100 HOURS SERVICE....477
24.7 EVERY 250 HOURS SERVICE....478
24.8 EVERY 500 HOURS SERVICE....485
24.9 EVERY 1000 HOURS SERVICE....492
24.10 EVERY 2000 HOURS SERVICE....495
24.11 EVERY 4000 HOURS SERVICE....499
SPECIFICATIONS....500
25. SPECIFICATIONS....501
OPTIONS, ATTACHMENTS....504
26. GENERAL PRECAUTIONS....505
26.1 PRECAUTIONS RELATED TO SAFETY....505
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....506
27. USING SEAT BELT....507
27.1 SEAT BELT....507
28. INTRODUCTION OF ATTACHMENTS....509
28.1 SPECIFICATION, USE....509
BACK HOE TYPE SHOVEL....510
29. GENERAL LOCATIONS....511
30. INSTRUMENTS AND CONTROLS....512
30.1 SWITCH....512
30.2 CONTROL LEVERS....513
30.3 CONTROL BOX....515
30.4 FUSE BOX....516
31. OPERATION....517
31.1 OPERATION OF WORK EQUIPMENT....517
31.2 CHECK BEFORE STARTING ENGINE....519
32. PRECAUTIONS FOR MACHINE OPERATION....522
32.1 PRECAUTIONS DURING OPERATION....522
33. PRECAUTIONS WHEN DISASSEMBLING MACHINE....524
34. MAINTENANCE....525
34.1 OIL FILTER AND LEVEL GAUGE POSITION....525
34.2 ADJUST BUCKET CLEARANCE....526
34.3 CHECK BEFORE STARTING....527
34.4 EVERY 10 HOURS SERVICE....528
35. EXCAVATOR WORK....531
36. TRANSPORTATION....532
37. INTRODUCTION OF ATTACHMENT....536
37.1 ATTACHMENT INSTALLATION COMBINATION TABLE....536
37.2 SPECIFICATION, USE....537
38. SPECIFICATIONS....538
SEAM018300 - Hydraulic Excavator PC1100-6, PC1100LC-6, PC1100SP-6 avance Operation & Maintenance Manual....542
COVER....542
1. FOREWORD....543
2. SAFETY INFORMATION....544
3. INTRODUCTION....545
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....546
5. CONTENTS....547
SAFETY....551
6. GENERAL PRECAUTIONS....552
7. PRECAUTIONS DURING OPERATION....561
7.1 BEFORE STARTING ENGINE....561
7.2 AFTER STARTING ENGINE....563
7.3 TRANSPORTATION....571
7.4 BATTERY....572
7.5 TOWING....574
7.6 LIFTING OPERATIONS....574
7.7 BUCKET WITH HOOK....575
8. PRECAUTIONS FOR MAINTENANCE....576
8.1 BEFORE CARRYING OUT MAINTENANCE....576
8.2 DURING MAINTENANCE....581
9. POSITION FOR ATTACHING SAFETY LABELS....588
OPERATION....593
10. GENERAL VIEW....594
10.1 GENERAL VIEW OF MACHINE....594
10.2 GENERAL VIEW OF CONTROLS AND GAUGES....595
11. EXPLANATION OF COMPONENTS....596
11.1 MACHINE MONITOR....596
11.2 SWITCHES....607
11.3 CONTROL LEVERS, PEDALS....612
11.4 DOOR LOCK....614
11.5 CAP, COVER WITH LOCK....615
11.6 HOT AND COOL BOX....616
11.7 LUGGAGE BOX....616
11.8 ASHTRAY....616
11.9 POWER SUPPLY SOCKET....616
11.10 FUSE....617
11.11 FUSIBLE LINK....618
11.12 CONTROLLERS....618
11.13 TOOL HOLDER (CLOTH bAG)....618
11.14 HANDLING GREASE PUMP....618
11.15 HANDLING ACCUMULATOR....621
12. OPERATION....623
12.1 CHECK BEFORE STARTING ENGINE....623
12.2 STARTING ENGINE....636
12.3 OPERATIONS AND CHECKS AFTER STARTING ENGINE....639
12.4 MOVING MACHINE OFF....646
12.5 STEERING MACHINE....649
12.6 STOPPING MACHINE....651
12.7 SWINGING....652
12.8 OPERATION OF WORK EQUIPMENT....653
12.9 HANDLING WORKING MODE....654
12.10 PROHIBITIONS FOR OPERATION....655
12.11 PRECAUTIONS FOR OPERATION....657
12.12 PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS....658
12.13 HOW TO ESCAPE FROM MUD....660
12.14 WORK POSSIBLE USING HYDRAULIC EXCAVATOR....661
12.15 REPLACEMENT OF BUCKET....662
12.16 PARKING MACHINE....663
12.17 CHECK AFTER FINISHING WORK....664
12.18 STOPPING ENGINE....665
12.19 CHECK AFTER STOPING ENGINE....666
12.20 LOCKING....666
13. TRANSPORTATION....667
13.1 PRECAUTIONS FOR TRANSPORTATION....667
13.2 METHOD OF LIFTING MACHINE....667
13.3 PRECAUTIONS FOR LOADING....669
13.4 TRANSPORTATION POSTURE....670
14. COLD WEATHER OPERATION....676
14.1 PRECAUTIONS FOR LOW TEMPERATURE....676
14.2 PRECAUTIONS AFTER COMPLETION OF WORK....678
14.3 AFTER COLD WEATHER....678
15. LONG-TERM STORAGE....679
15.1 BEFORE STORAGE....679
15.2 DURING STORAGE....680
15.3 AFTER STORAGE....680
15.4 STARTING MACHINE AFTER LONG-TERM STORAGE....680
16. TROUBLESHOOTING....681
16.1 WHEN MACHINE RUNS OUT OF FUEL....681
16.2 PHENOMENA THAT ARE NOT FAILURES....681
16.3 METHOD OF TOWING MACHINE....681
16.4 PRECAUTIONS ON PARTICULAR JOBSITES....681
16.5 IF BATTERY IS DISCHARGED....682
16.6 OTHER TROUBLE....687
MAINTENANCE....693
17. GUIDES TO MAINTENANCE....694
18. OUTLINES OF SERVICE....697
18.1 OUTLINE OF OIL, FUEL, COOLANT....697
18.2 OUTLINE OF ELECTRIC SYSTEM....700
18.3 OUTLINE OF HYDRAULIC SYSTEM....701
19. WEAR PARTS LIST....702
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....703
21. STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....707
21.1 INTRODUCTION OF NECESSARY TOOLS....707
21.2 TORQUE LIST....708
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....709
23. MAINTENANCE SCHEDULE CHART....711
23.1 MAINTENANCE SCHEDULE CHART....711
24. SERVICE PRODEDURE....715
24.1 INITIAL 100 HOURS SERVICE....715
24.2 INITIAL 250 HOURS SERVICE....715
24.3 WHEN REQUIRED....716
24.4 CHECK BEFORE STARTING....732
24.5 EVERY 10 HOURS SERVICE....738
24.6 EVERY 100 HOURS SERVICE....740
24.7 EVERY 250 HOURS SERVICE....741
24.8 EVERY 500 HOURS SERVICE....751
24.9 EVERY 1000 HOURS SEVICE....759
24.10 EVERY 2000 HOURS SERVICE....767
24.11 EVERY 4000 HOURS SERVICE....775
SPECIFICATIONS....777
25. SPECIFICATIONS....778
OPTIONAL PARTS, ATTACHMENTS....785
26. GENERAL PRECAUTIONS....786
26.1 PRECAUTIONS RELATED TO SAFETY....786
26.2 PRECAUTIONS WHEN INSTALLING ATTACHMENTS....787
27. HANDLING BUCKET WITH HOOK....788
27.1 CHECKING FOR DAMAGE TO BUCKET WITH HOOK....788
27.2 PROHIBITED OPERATIONS....788
27.3 PRECAUTIONS DURING OPERATIONS....788
28. USING SEAT BELT....789
28.1 SEAT BELT....789
29. INTRODUCTION OF OPTIONAL PARTS, ATTACHMENTS....791
29.1 COMBINATIONS OF WORK EQUIPMENT....791
29.2 SELECTION OF TRACK SHOES....793
30. HANDLING AIR CONDITIONER....795
30.1 HANDLING AIR CONDITIONER....795
31. HANDLING CAR RADIO....798
31.1 HANDLING CAR RADIO....798
SEAW0021N0103 - Hydraulic Excavator PC1000-1 Field Assembly Manual....805
COVER PAGE....805
TABLE OF CONTENTS....806
A. GENERAL....809
A-1: BEFORE ASSEMBLY....809
A-2: LIST OF PARTS SENT INDIVIDUALLY....813
A-3: POINTS REGARDING LOCAL ASSEMBLY....834
A-4: PRECAUTIONS WHEN ASSEMBLING, TIGHTENING TORQUE OF BOLTS, SCREWS AND TAPER SEAL HOSES....835
A-5: TABLE OF TOOLS FOR LOCAL ASSEMBLY....838
A-6: PLACE TO SET (UNLOAD) EACH UNIT....839
B. ASSEMBLY OF MACHINE (PART I)....840
B-1: INSTALLATION OF LEFT, RIGHT TRACK FRAMES....841
B-2: INSTALLATION OF TRAVEL PIPING....843
B-3: EXCHAING RETURN FILTER (STANDARD PART - SPECIAL FLUSHING PART)....846
B-4: CHECK OF OIL AND WATER LEVELS....848
B-5: CHECK CENTRAL MONITOR....849
B-6: BLEEDING AIR FROM HYDRAULIC PUMP, SWING PUMP....850
B-7: FLUSHING TRAVEL CIRCUIT....851
B-8: INSTALLATION OF TRAVEL PIPING....852
C. ASSEMBLY OF MACHINE (PART II)....853
C-1: INSTALLATION OF LEFT SIDE STEP....854
C-2: INSTALLATION OF STEP....855
C-3: INSTALLATION OF HANDRAIL....856
C-4: INSTALLATION OF STEP (ONLY WHEN INSTALLING HIGH CAB)....857
C-5: INSTALLATION OF OPERATOR'S CAB ASSEMBLY....858
C-6: CONNECTION OF ELECTRICAL COMPONENTS IN OPERATOR'S CAB (ONLY WHEN INSTALLING HIGH CAB)....859
C-7: INSTALLATION OF AIR CONDITIONER (ONLY WHEN INSTALLING HIGH CAB)....860
C-8: INSTALLATION OF OPERATOR'S SEAT ASSEMBLY (ONLY WHEN INSTALLING HIGH CAB)....863
C-9: INSTALLATION OF ADDITIONAL REAR VIEW MIRROR (OPTION)....864
C-10: INSTALLATION OF FOPS (OPTION)....865
C-11: INSTALLATION OF MUFFLER TAIL PIPE....869
C-12: INSTALLATION OF COUNTERWEIGHT ASSEMBLY....871
C-13: EXCHANGING RETURN FILTER (STANDARD PART - SPECIAL FLUSHING PART)....872
C-14: CHECK OF OIL AND WATER LEVELS....873
C-15: CHECK CENTRAL MONITOR (CARRY OUT ONLY WHEN MACHINE IS DIVIDED INTO THREE PARTS FOR TRANSPORTATION)....873
C-16: BLEEDING AIR FROM TRAVEL MOTOR CIRCUIT....874
C-17: BLEEDING AIR FROM HYDRAULIC IDLER CUSHION CIRCUIT....875
C-18: ADJUSTMENT OF HYDRAULIC IDLER CUSHION CYLINDER....877
C-19: ADJUSTING TRACK TENSION....878
D. PROCEDURE FOR ASSEMBLY OF WORK EQUIPMENT (BACKHOE SPECIFICATION)....879
D-1: ASSEMBLY OF BOOM ASSEMBLY....880
D-2: RELEASING PRESSURE FROM HYDRAULIC CIRCUIT....881
D-3: WORK EQUIPMENT PIPING (BETWEEN CHASSIS AND BOOM) (BETWEEN CHASSIS AND BOOM CYLINDER)....882
D-4: FLUSHING WORK EQUIPMENT PIPING....885
D-5: INSTALLATION OF BOOM CYLINDER FOOT PIN....886
D-6: INSTALLING BOOM CYLINDER HOSES....887
D-7: INSTALLATION OF BOOM CYLINDER TOP PIN....888
D-8: INSTALLATION OF ARM CYLINDER FOOT PIN....889
D-9: WORK EQUIPMENT PIPING (ARM CYLINDER)....890
D-10: INSTALLATION OF ARM AND ARM CYLINDER TOP PIN....891
D-11: WORK EQUIPMENT PIPING (BOOM-BUCKET CYLINDER)....892
D-12: ASSEMBLY OF BUCKET ASSEMBLY....893
D-13: MAINTENANCE STANDARD....895
D-14: INSTALLATION OF WORK EQUIPMENT GREASE PIPING....897
D-15: INSTALLATION OF WORK EQUIPMENT WIRING AND WORK EQUIPMENT HOSE CLAMPS....899
D-16: BLEEDING AIR FROM CYLINDER....901
D-17: CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....902
E. PROCEDURE FOR ASSEMBLY OF WORK EQUIPMENT (FRONT LOADING SHOVEL SPECIFICATION)....903
E-1: INSTALLATION OF ARM CYLINDER FOOT PIN....904
E-2: CONNECTION OF BOOM AND ARM....905
E-3: INSTALLATION OF ARM CYLINDER TOP PIN....906
E-4: INSTALLATION OF BUCKET CYLINDER FOOT PIN....907
E-5: CONNECTION OF LINK AND BUCKET CYLINDER TOP PIN....908
E-6: ASSEMBLY OF BOOM ASSEMBLY....910
E-7: RELEASING PRESSURE FROM HYDRAULIC CIRCUIT....912
E-8: WORK EQUIPMENT PIPING (BETWEEN CHASSIS AND BOOM)....913
E-9: WORK EQUIPMENT PIPING....914
E-10: FLUSHING WORK EQUIPMENT PIPING....919
E-11: INSTALLATION OF BOOM CYLINDER FOOT PIN....921
E-12: INSTALLATION OF BOOM CYLINDER HOSES....922
E-13: INSTALLATION OF BOOM CYLINDER TOP PIN....923
E-14: INSTALLATION OF ARM CYLINDER HOSES....924
E-15: INSTALLATION OF BUCKET CYLINDER PIPING....925
E-16: INSTALLATION OF BOTTOM DUMP CYLINDER PIPING....926
E-17: INSTALLATION OF BUCKET ASSEMBLY....927
E-18: MAINTENANCE STANDARD....929
E-19: INSTALLATION OF BOTTOM DUMP CYLINDER PIPING....931
E-20: INSTALLATION OF WORK EQUIPMENT PIPING CLAMPS....932
E-21: INSTALLATION OF WORKING LAMP....934
E:22: INSTALLATION OF WORK EQUIPMENT GREASE PIPING....935
E-23: BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT....938
E-24: CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL....939
E-25: INSTALLATION OF BOOM FOOT POTENTIOMETER....940
E-26: INSTALLATION AND ADJUSTMENT OF BOOM TOP POTENTIOMETER (BOOM - ARM JOINT)....942
E-27: INSTALLATION OF CLAMPS AND COVER FOR BOOM FOOT POTENTIOMETER....943
E-28: INSTALLATION OF CLAMPS AND COVER FOR BOOM TOP POTENTIOMETER....944
E-29: ADJUSTMENT OF WORK EQUIPMENT CONTROLLER (FOR AUTOMATIC CONTROL OF LOADING SHOVEL)....945
F. ASSEMBLY OF MACHINE (PART III)....951
F-1: EXTENDING TRACK FRAME GAUGE WIDTH (ONLY WHEN DIVIDED INTO THREE PARTS FOR TRANSPORTATION)....952
F-2: INSTALLATION OF TRAVEL PIPING COVERS....954
G. CHECK OF ALL PARTS DURING AND AFTER ASSEMBLY....956
H. PCIOOO-1 55C AUSTRALIA SPECIFICATION....957
APPENDIX....973
FIELD ASSEMBLY INSPECTION REPORT....973
SEBM021N0107 - Hydraulic Excavator PC1000-1, PC1000LC-1, PC1000SE-1, PC1000SP-1 Shop Manual....985
CONTENTS....986
LIST OF REVISED PAGES....987
SAFETY NOTICE....992
FOREWORD....994
HOW TO READ THE SHOP MANUAL....995
HOISTING INSTRUCTIONS....996
WIRE ROPES....996
COATING MATERIALS....997
STANDARD TIGHTENING TORQUE....999
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS....999
TIGHTENING TORQUE OF HOSE NUTS....999
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....999
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR....1000
TIGHTENING TORQUE OF O-RING BOSS CONNECTOR....1000
TIGHTENING TORQUES OF FLARE NUT....1000
TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS)....1001
TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS)....1001
TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS)....1001
ELECTRIC WIRE CODE....1002
CLASSIFICATION BY THICKNESS....1002
CLASSIFICATION BY COLOR AND CODE....1002
CONVERSION TABLE....1003
METHOD OF USING THE CONVERSION TABLE....1003
Millimeters to Inches....1004
Kilogram to Pound....1004
Liter to U.S. Gallon....1005
Liter to U.K. Gallon....1005
kgm to ft. lb....1006
kg/cm2 to lb/in2....1007
Temperature....1008
10 ENGINE....1012
11 STRUCTURE AND FUNCTION....1012
PTO (Power Take-Off)....1013
PTO LUBRICATION SYSTEM....1014
AUTO-DECELERATION SYSTEM....1015
OPERATION TABLE....1018
1. DECELERATOR CYLINDER....1019
2. SOLENOID VALVE....1020
OPERATION....1021
1. SOL A excited (engine running, control levers at NEUTRAL)....1021
2. SOL A, B deactivated (engine running, control levers at NEUTRAL)....1021
3. SOL B excited (engine running, control levers operated)....1021
3. OIL PRESSURE SWITCH....1022
4. AUTO-DECELERATOR SELECTOR SWITCH....1022
12 TESTING AND ADJUSTING....1023
STANDARD FOR TESTING AND ADJUSTING....1024
TESTING AND ADJUSTING TOOL LIST....1026
ADJUSTING VALVE CLEARANCE....1027
MEASURING COMPRESSION PRESSURE....1028
MEASURING BLOW-BY PRESSURE....1029
TESTING AND ADJUSTING FUEL INJECTION TIMING....1030
ADJUSTING FUEL CONTROL LEVER....1033
ADJUSTING AUTO-DECELERATION SYSTEM....1036
MEASURING EXHAUST GAS COLOR....1038
13 DISASSEMBLY AND ASSEMBLY....1039
STARTING MOTOR....1040
REMOVAL....1040
INSTALLATION....1040
ALTERNATOR....1040
REMOVAL....1040
INSTALLATION....1040
ENGINE OIL COOLER....1042
REMOVAL....1042
INSTALLATION....1042
WATER PUMP....1042
REMOVAL....1042
INSTALLATION....1042
FUEL INJECTION PUMP....1044
REMOVAL ....1044
INSTALLATION....1044
NOZZLE HOLDER....1046
REMOVAL....1046
INSTALLATION....1046
TURBOCHARGER....1048
REMOVAL....1048
INSTALLATION....1048
CYLINDER HEAD....1050
REMOVAL....1050
INSTALLATION Serial No.: 10001 - 10371....1061
INSTALLATION Serial No.: 10372 and up....1067
HYDRAULIC OIL COOLER....1073
REMOVAL....1073
INSTALLATION....1073
RADIATOR....1073
REMOVAL....1073
INSTALLATION....1073
ENGINE, PTO, HYDRAULIC PUMP....1075
REMOVAL....1075
INSTALLATION....1077
PTO....1083
REMOVAL....1083
INSTALLATION....1083
DISASSEMBLY....1085
ASSEMBLY....1085
AUTO-DECELERATION CYLINDER....1089
REMOVAL Serial No.: 10001 - 10371....1089
INSTALLATION Serial No.: 10001 - 10371....1089
REMOVAL Serial No.: 10372 and up....1089
INSTALLATION Serial No.: 10372 and up....1089
14 MAINTENANCE STANDARD....1091
PTO (Power Take-Off)....1092
20 POWER TRAIN....1093
21 STRUCTURE AND FUNCTION....1093
POWER TRAIN....1094
TRAVEL AND BRAKE SYSTEM....1095
1. TRAVEL CONTROL CIRCUIT SCHEMATICS....1095
2. TRAVEL CONTROL CIRCUIT....1096
3. STRAIGHT-TRAVEL SYSTEM....1097
4. CENTER SWIVEL JOINT....1102
5. TRAVEL MOTOR AND BRAKE VALVE....1103
6. FINAL DRIVE....1115
SWING SYSTEM....1117
1. SWING HYDRAULIC CIRCUIT SCHEMATICS....1117
2. SWING HYDRAULIC CIRCUIT....1118
3. SWING PUMP....1119
4. SWING CONTROL VALVE....1122
5. SWING MOTOR (WITH MECHANICAL BRAKE) AND SAFETY VALVE....1124
6. SWING BRAKE (AUTOMATIC) AND SWING PARKING BRAKE (MANUAL)....1128
7. FREE SWING SYSTEM....1132
8. SWING MACHINERY....1135
9. SWING CIRCLE....1137
23 DISASSEMBLY AND ASSEMBLY....1138
CENTER SWIVEL JOINT ASSEMBLY....1139
REMOVAL....1139
INSTALLATION....1139
DISASSEMBLY....1141
ASSEMBLY....1141
TRAVEL MOTOR, BRAKE VALVE....1143
REMOVAL....1143
INSTALLATION....1143
TRAVEL MOTOR....1145
DISASSEMBLY....1145
ASSEMBLY....1151
ASSEMBLY OF END COVER ASSEMBLY....1151
1. Servo piston assembly....1151
2. Valve plate....1151
ASSEMBLY OF BRAKE VALVE ASSEMBLY....1151
3. Suction valve....1151
4. Safety valve assembly....1151
5. Counterbalance valve....1153
ASSEMBLY OF MOTOR....1153
6. Bearing outer race....1153
7. Shaft assembly....1153
8. Disc, plate....1155
9. Piston, retainer....1155
10. Brake piston assembly....1157
11. Cylinder block....1157
12. Spring....1157
13. Motor case....1157
14. End cover assembly....1157
15. Block....1157
16. Measuring rotation torque....1157
17. Measuring brake torque....1159
FINAL DRIVE ASSEMBLY....1161
REMOVAL....1161
INSTALLATION....1161
DISASSEMBLY....1163
1. Case assembly....1163
2. Coupling, pinion gear....1163
3. Case, gear assembly....1163
4. Carrier assembly (small)....1163
5. Ring gear (small)....1165
8. Carrier assembly (large)....1165
7. Shaft....1165
8. Ring gear, housing assembly....1165
9. Case assembly....1165
ASSEMBLY....1167
1. Housing....1167
2. Case assembly....1167
3. Bearing....1167
4. Ring gear, housing assembly....1167
5. Preload adjustment, retainer....1167
6. Shaft....1169
7. Carrier assembly (large)....1169
8. Carrier assembly (small)....1171
9. Ring gear (small)....1171
10. Case and gear assembly....1171
11. Pinion gear....1173
12. Case assembly....1173
SPROCKET....1175
REMOVAL....1175
INSTALLATION....1175
SWING PUMP....1177
REMOVAL....1177
INSTALLATION....1177
DISASSEMBLY....1179
ASSEMBLY....1183
ASSEMBLY OF PUMP SUBASSEMBLY....1183
1. Cradle, piston assembly....1183
2. Cylinder block....1183
3. Shaft assembly....1185
4. Servo piston....1187
5. Pump subassembly....1189
6. Adjusting end play of bearing....1189
7. End cap....1189
8. Servo piston cap....1189
9. Impeller....1191
10. Servo and CO-NC valves....1193
11. Rear pump assembly....1193
CO-NC VALVE ASSEMBLY....1195
REMOVAL....1195
INSTALLATION....1195
SERVO VALVE....1195
REMOVAL....1195
INSTALLATION....1195
PPC VALVE....1197
REMOVAL....1197
INSTALLATION....1197
DISASSEMBLY....1197
ASSEMBLY....1197
SWING CONTROL VALVE....1199
REMOVAL....1199
INSTALLATION....1199
MAIN RELIEF VALVE....1199
REMOVAL....1199
INSTALLATION....1199
SWING CONTROL VALVE....1203
DISASSEMBLY....1201
ASSEMBLY....1203
FRONT SWING MOTOR....1205
REMOVAL....1205
INSTALLATION....1205
REAR SWING MOTOR....1205
REMOVAL....1205
INSTALLATION....1205
SWING MOTOR ASSEMBLY....1211
DISASSEMBLY....1207
ASSEMBLY....1211
1. Outer race....1211
2. Shaft assembly....1211
3. Belleville spring, spacer, bearing....1211
4. Spacer....1211
5. Cover....1211
6. Plate, disc....1211
7. Brake piston....1213
8. Piston, shaft....1213
9. Spring....1213
10. Cylinder block....1213
11. Valve plate....1213
12. Belleville spring....1213
13. Check valve....1213
14. Relief valve....1213
15. Valve case assembly ....1213
16. Inspection of rotating torque of drive shaft....1213
REVOLVING FRAME....1215
REMOVAL....1215
INSTALLATION....1215
SWING CIRCLE....1217
REMOVAL....1217
INSTALLATION....1217
FRONT SWING MACHINERY....1219
REMOVAL....1219
INSTALLATION....1219
REAR SWING MACHINERY....1221
REMOVAL....1221
INSTALLATION....1221
SWING MACHINERY....1223
DISASSEMBLY....1223
1. Cover....1223
2. Coupling....1223
3. Ring gear....1223
4. Thrust washer....1223
5. Sungear....1223
6. Carrier assembly....1223
7. Thrust washer....1223
8. Bolt, plate....1223
9. Gear assembly....1223
10. Shaft....1223
11. Spacer....1225
12. Snap ring, bearing....1225
13. Oil seal....1225
DISASSEMBLY OF CARRIER ASSEMBLY....1225
14. Shaft....1225
15. Gear assembly....1225
SWING MACHINERY ....1227
DISASSEMBLY Serial No. 10001-10077....1223
1. Cover....1223
2. Coupling....1223
3. Ring gear....1223
4. Thrust washer....1223
5. Sungear....1223
6. Carrier assembly....1223
7. Thrust washer....1223
8. Bolt, plate....1223
9. Gear assembly....1223
10. Shaft....1223
11. Spacer....1225
12. Snap ring, bearing....1225
13. Oil seal....1225
14. Shaft....1225
15. Gear assembly....1225
ASSEMBLY Serial No. 10001-10077....1227
1. Gear assembly....1227
2. Shaft....1227
3. Oil seal....1227
4. Bearing, snap ring....1227
6. Shaft....1227
6. Spacer....1227
7. Bearing....1229
8. Gear assembly....1229
9. Plate, bolt....1229
10. Thrust washer....1229
11. Carrier assembly, sun gear....1229
12. Thrust washer....1231
13. Ring gear....1231
14. Coupling....1231
15. Cover....1231
16. Refilling with oil....1231
DISASSEMBLY Serial No. 10078 and up....1233
1. Oil filler....1233
2. Cover....1233
3. No. 1 sun gear....1233
4. No. 1 carrier assembly....1233
5. Ring gear....1234
6. No. 2 carrier assembly....1235
7. Swing pinion....1236
8. Spacer....1237
9. Oil seal, bearing....1237
10. Bearing....1237
ASSEMBLY Serial No. 10078 and up....1238
1. Bearing, oil seal....1238
2. Swing pinion....1238
3. Retainer....1239
4. No. 2 carrier assembly....1239
5. Ring gear....1241
6. No. 1 carrier assembly....1241
7. No. 1 sun gear....1242
8. Cover....1243
9. Oil filler....1244
24 MAINTENANCE STANDARD....1245
TRAVEL MOTOR AND BRAKE VALVE....1246
TRAVEL RELIEF VALVE....1248
TRAVEL SHUTTLE VALVE....1249
STRAIGHT-TRAVEL VALVE....1250
FINAL DRIVE....1251
SWING CONTROL VALVE....1252
JET SENSOR....1253
CONNECTION VALVE....1254
SWING MOTOR....1255
SWING MACHINERY....1256
SWING CIRCLE....1258
30 UNDERCARRIAGE....1259
31 STRUCTURE AND FUNCTION....1259
TRACK FRAME....1260
IDLER CUSHION....1263
IDLER....1267
TRACK ROLLER....1268
CARRIER ROLLER....1268
TRACK SHOE....1269
33 DISASSEMBLY AND ASSEMBLY....1271
TRACK....1272
REMOVAL....1272
INSTALLATION....1272
IDLER....1274
REMOVAL....1274
INSTALLATION....1274
IDLER CUSHION....1274
REMOVAL....1274
INSTALLATION....1274
DISASSEMBLY....1276
ASSEMBLY....1276
IDLER ADJUSTMENT CYLINDER....1276
DISASSEMBLY....1276
ASSEMBLY....1276
TRACK ROLLER....1278
REMOVAL....1278
INSTALLATION....1278
CARRIER ROLLER....1278
REMOVAL....1278
INSTALLATION....1278
34 MAINTENANCE STANDARD....1280
TRACK FRAME....1281
TRACK ROLLER....1282
IDLER....1283
CARRIER ROLLER....1285
TRACK SHOE....1286
50 AIR SYSTEM....1288
51 STRUCTURE AND FUNCTION....1288
AIR PIPING....1289
AIR CIRCUIT DIAGRAM....1289
AIR GOVERNOR....1290
AIR TANK....1290
SAFETY VALVE....1291
HORN VALVE....1291
GREASE PUMP....1292
60 HYDRAULIC SYSTEM....1293
61 STRUCTURE AND FUNCTION....1293
HYDRAULIC SYSTEM LOCATION....1294
HYDRAULIC CIRCUIT DIAGRAM....1295
WORK EQUIPMENT CONTROL....1300
ELECTRONIC AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM....1319
HYDRAULIC TANK....1328
MAIN PUMP....1329
CHARGING AND PTO LUBRICATING PUMP....1346
HYDRAULIC OIL FILTER....1347
2-STAGE AND 3-STAGE MODE SELECTOR OLSS (Open center Load Sensing System)....1349
HYDRAULIC CONTROL VALVE....1367
PPC VALVE....1374
PPC ACCUMULATOR....1380
PPC SHUTTLE VALVE....1381
PILOT RELIEF VALVE....1383
SAFETY LOCK VALVE....1385
HYDRAULIC CYLINDER....1386
WORK EQUIPMENT....1393
62 TESTING AND ADJUSTING....1394
TABLE OF JUDGEMENT STANDARD VALUE....1395
TABLE OF JUDGEMENT STANDARD VALVE (FOR MACHINES EQUIPPED WITH 3-STAGE MODE SELECTOR OLSS)....1406
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE....1417
TESTING AND ADJUSTING TOOL LIST....1430
TESTING AND ADJUSTMENT OF RELIEF PRESSURE....1431
TESTING AND ADJUSTMENT OF CONTROL CIRCUIT PRESSURE....1433
BLEEDING AIR AND RELEASING PRESSURE....1436
CHARGING ACCUMULATOR WITH GAS....1440
CHECKING SWIVEL JOINT....1441
TESTING AND ADJUSTING OF TRAVEL CONTROL LEVER AND ROD....1443
ADJUSTMENT OF WORK EQUIPMENT POTENTIOMETER (LOADING SHOVEL)....1444
ADJUSTMENT OF WORK EQUIPMENT CONTROL BOX (LOADING SHOVEL)....1445
TROUBLESHOOTING....1450
ELECTRICAL CIRCUIT DIAGRAM....1451
3-STAGE MODE SELECTOR ELECTRONIC OLSS....1452
SWING PARKING BRAKE AND SWING BRAKE SYSTEM....1453
TRAVEL SPEED SELECTOR SYSTEM....1453
ELECTRONIC AUTOMATIC WORK EQUIPMENT CONTROL SYSTEM....1456
CNE9 (Engine potentiometer)....1457
CN5 (Intermediate connector)....1458
CN 13 (WC solenoid)....1459
CN23 (Intermediate connector)....1460
CN36 (Prolix circuit switch)....1461
CN46 (Auto-deceleration solenoid B)....1462
CN62 (Hydraulic pressure switch for ARM IN, BUCKET CURL and DUMP)....1463
OLSS control box....1464
POSITION OF CONNECTORS FOR TROUBLESHOOTING....1454
CONNECTION TABLE FOR CONNECTOR PINS....1465
TROUBLESHOOTING PROCEDURE....1469
CHECKS BEFORE TROUBLESHOOTING....1470
E. H MODE TROUBLESHOOTING....1473
ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY....1474
TROUBLESHOOTING....1475
E-1 Machine deviates excessively (always deviates)....1479
a) Self-testing display shows abnormality....1480
b) If cause is removed when switching to prolix circuit (when self-testing display shows normal)....1482
E-2 Work equipment, swing, travel speeds extremely slow, or lack of power....1483
a) Self-testing display shows abnormality....1483
b) If cause is removed when switching to prolix circuit (when self-testing display shows normal)....1485
E-3 Engine stalls during operations, or engine speed drops....1488
a) Self-testing display shows abnormality....1488
b) If cause is removed when switching to prolix circuit (when self-testing display shows normal)....1490
E-4 No change in output when mode switch is operated....1491
a) Self-testing display shows abnormality....1492
b) If cause is removed when switching to prolix circuit (when self-testing display shows normal)....1492
E-5 Auto-deceleration does not work....1497
a) Self-testing display shows abnormality....1497
b) Self-testing display shows normality....1501
E-6 Swing does not work....1503
E-7 Excessive hydraulic drift of swing....1505
E-8 Travel speed does not switch....1506
a) Speed does not increase when placed in Hi (does not switch to Hi)....1506
b) Speed does not decrease when placed in Lo....1506
H-1 Machine deviates excessively (deviates more than standard when only travel system is used, travel lever at FULL position)....1512
H-2 Excessive deviation in travel during simultaneous operations....1514
H-3 Machine deviates excessively when starting....1516
H-4 Control levers are extremely heavy....1518
a) If travel lever is heavy....1518
b) If work equipment levers are heavy....1518
H-5 Work equipment, travel, and swing start suddenly during fine control operations....1519
H-6 Speeds for work equipment, swing, and travel are all extremely slow, or there is no power....1520
a) Machine hardly moves....1520
b) Abnormality in some part (abnormality on one side)....1522
c) Individual symptoms....1522
d) If work equipment speed on either side is slow....1523
e) For failures except for those in (a), (b), (c) and (d). (Auto-deceleration is normal.)....1524
H-7 Engine stalls or engine speed drops during operations....1526
H-8 No change in output when mode selector switch is operated....1527
H-9 Auto-deceleration does not come on, or does not not go off....1527
H-10 Abnormal noise comes from around pump....1528
H-11 Swing speed is slow, or overrun when stopping swing is excessive....1529
H-12 Upper structure does not swing....1531
H-13 Excessive hydraulic drift....1533
H-16 Excessive time lag for work equipment....1533
H-17 Troubleshooting Chart....1534
FAILURE MODE AND COMPONENTS....1535
W. L MODE TROUBLESHOOTING....1536
ABNORMALITY JUDGEMENT CONDITIONS FOR SELF-TESTING DISPLAY....1537
TROUBLESHOOTING....1538
W-1 In arc digging mode, work equipment carries out horizontal digging, or there is bucket angle....1540
W-2 In horizontal digging mode, work equipment does not carry out horizontal digging....1541
a) Self-testing display does not show abnormality....1541
b) Self-testing display shows abnormality....1543
W-3 In horizontal digging mode, there is bucket angle compensation....1549
W-4 In horizontal digging + bucket angle compensation mode, work equipment carries out horizontal digging, but there is no.....1550
a) Self-testing display does not show abnormality....1550
b) Self-testing display shows abnormality....1552
W-5 In horizontal digging + bucket angle compensation mode, there is bucket angle compensation, but work equipment does not.....1554
a) Self-testing display does not show abnormality....1554
b) Self-testing display shows abnormality....1554
W-6 In horizontal digging + bucket angle compensation mode, work equipment does not carry out horizontal digging, and there.....1556
a) Self-testing display does not show abnormality....1556
b) Self-testing display shows abnormality....1557
L-1 Work equipment does not carry out horizontal digging or bucket angle compensation....1563
63 DISASSEMBLY AND ASSEMBLY....1564
CHARGING PUMP....1565
REMOVAL....1565
INSTALLATION....1565
NO. 1 PUMP....1567
REMOVAL....1567
INSTALLATION....1569
NO. 2 PUMP....1571
REMOVAL....1571
INSTALLATION....1571
PISTON PUMP....1573
DISASSEMBLY (HPV160 + 160)....1573
DISASSEMBLY OF PUMP BODY....1573
DISASSEMBLY OF PUMP SUB-ASSEMBLY....1575
ASSEMBLY (HPV160 + 160)....1577
ASSEMBLY OF PUMP SUBASSEMBLY....1577
ASSEMBLY OF PUMP BODY....1579
CHECKING CONTACT BETWEEN CYLINDER BLOCK AND VALVE PLATE, AND ROCKER CAM AND CRADLE....1585
CONC VALVE ASSEMBLY (for No. 1 front pump)....1587
REMOVAL....1587
INSTALLATION....1587
CONC VALVE ASSEMBLY (for No. 1 rear pump with TVC valve)....1587
REMOVAL....1587
INSTALLATION....1587
TVC VALVE (for No. 1 rear pump)....1589
REMOVAL....1589
INSTALLATION....1589
SERVO VALVE (for No. 1 front pump)....1591
REMOVAL....1591
INSTALLATION....1591
SERVO VALVE (for No; 1 rear pump)....1591
REMOVAL....1591
INSTALLATION....1591
SERVO VALVE (for No. 2 front pump)....1591
REMOVAL....1591
INSTALLATION....1591
SERVO VALVE (for No. 2 rear pump)....1591
REMOVAL....1591
INSTALLATION....1591
L.H. 5-SPOOL CONTROL VALVE....1593
REMOVAL....1593
INSTALLATION....1595
R.H. 4-SPOOL CONTROL VALVE ASSEMBLY....1597
REMOVAL....1597
INSTALLATION....1599
CONTROL VALVE....1601
DISASSEMBLY....1601
ASSEMBLY....1601
MAIN RELIEF VALVE (for 4-, 5-SPOOL CONTROL VALVE)....1603
REMOVAL, DISASSEMBLY....1603
INSTALLATION, ASSEMBLY....1603
PILOT RELIEF VALVE....1605
REMOVAL, DISASSEMBLY....1605
ASSEMBLY, INSTALLATION....1605
PPC VALVE ASSEMBLY (for work equipment and swing)....1605
DISASSEMBLY, ASSEMBLY....1605
BOOM CYLINDER (BACKHOE)....1607
REMOVAL INSTALLATION....1607
ARM CYLINDER (BACKHOE)....1609
REMOVAL....1609
INSTALLATION....1609
BUCKET CYLINDER ASSEMBLY (BACKHOE)....1611
REMOVAL....1611
INSTALLATION....1611
BOOM CYLINDER ASSEMBLY (LOADING SHOVEL)....1613
REMOVAL....1613
INSTALLATION....1613
ARM CYLINDER ASSEMLBY (LOADING SHOVEL)....1615
REMOVAL....1615
INSTALLATION....1615
BUCKET CYLINDER ASSEMBLY (LOADING SHOVEL)....1617
REMOVAL....1617
INSTALLATION....1617
BOTTOM DUMP CYLINDER ASSEMBLY (LOADING SHOVEL)....1619
REMOVAL....1619
INSTALLATION....1619
HYDRAULIC CYLINDER....1621
DISASSEMBLY....1621
ASSEMBLY....1625
BUCKET ASSEMBLY (BACKHOE)....1629
REMOVAL....1629
INSTALLATION....1629
ARM (BACKHOE)....1631
REMOVAL....1631
INSTALLATION....1631
BOOM (BACKHOE)....1633
REMOVAL....1633
INSTALLATION....1633
BUCKET AND ARM (BACKHOE)....1635
REMOVAL....1635
INSTALLATION....1635
WORK EQUIPMENT (BACKHOE)....1637
REMOVAL....1637
INSTALLATION....1637
BUCKET (LOADING SHOVEL)....1639
REMOVAL....1639
INSTALLATION....1639
ARM (LOADING SHOVEL)....1641
REMOVAL....1641
INSTALLATION....1641
BOOM (LOADING SHOVEL)....1643
REMOVAL....1643
INSTALLATION....1645
WORK EQUIPMENT (LOADING SHOVEL)....1647
REMOVAL....1647
INSTALLATION....1647
POTENTIOMETER (LOADING SHOVEL)....1649
DISASSEMBLY....1649
ASSEMBLY....1649
COUNTERWEIGHT....1649
REMOVAL....1649
INSTALLATION....1649
64 MAINTENANCE STANDARD....1651
CHARGING AND PTO LUBRICATION PUMP....1652
PILOT RELIEF VALE....1653
L.H. 5-SPOOL CONTROL VALVE....1654
R.H. 4-SPOOL CONTROL VALVE....1656
PPC VALVE....1658
PPC SHUTTLE VALVE....1659
WORK EQUIPMENT SAFETY VALVE....1661
HYDRAULIC CYLINDER....1664
WORK EQUIPMENT....1666
80 ELECTRIC AND ELECTRONIC SYSTEM....1683
82 TESTING AND ADJUSTING....1683
ELECTRICAL CIRCUIT DIAGRAM....1684
POSITION OF CONNECTORS FOR TROUBLESHOOTING....1686
M MODE TROUBLESHOOTING....1696
M-1 When starting switch is turned ON, monitor panel display does not appear....1697
M-2 When starting switch is turned ON, monitor panel display does not go out....1697
M-3 When starting switch is turned ON (do not start engine), ....1698
a) (coolant level) flashes....1698
b) (engine oil level) flashes....1698
c) (hydraulic oil level) flashes....1699
M-4 APS switch is not being used, but APS monitor lights up....1701
M-5 When starting switch is turned ON, (engine started), CHECK BEFORE STARTING items flash....1702
a) Alternator system....1702
b) Engine oil pressure system....1702
M-6 When starting switch is turned ON, (do not start engine), CAUTION items flash....1704
M-7 When starting switch is ON (engine started), caution items flash....1705
a) (engine oil pressure) flashes....1705
b) (coolant level) flashes....1705
c) (coolant temperature gauge) flashes....1706
d) (charge level) flashes....1706
e) (hydraulic oil filter) flashes....1707
f) (hydraulic oil temperature) flashes....1707
M-8 When starting switch is turned ON (engine stopped) for 1 second, or when CAUTION items are flashing, warning buzzer does.....1710
M-9 No abnormal display on monitor but warning buzzer sounds....1710
M-10 Monitor panel lamps do not light up (Indication on monitor panel is correct)....1712
M-11 When engine is started, service meter does not move....1713
a) Service meter does not move, when engine is started....1713
b) Service meter does not stop moving, when engine is stopped....1713
M-12 Engine coolant temperature is high, but lowest level displayed....1715
M-13 Engine coolant temperature gauge gives no display....1715
M-14 Fuel tank is not full but display shows full tank....1717
M-15 No display is given for fuel level....1717
P MODE TROUBLESHOOTING....1719
P-1 APS fuse (4) is blown....1720
P-2 Even when APS switch is turned ON, monitor lamp does not start to flash....1723
P-3 When APS switch is turned ON, monitor lamp flashes, but time taken to change to ON is not 60 - 100 sec....1726
P-4 When APS switch is turned ON, flashing of monitor lamp changes to ON after approx. 80 sec. but engine does not start easily....1727
P-5 Engine can be started with APS, but when starting motor stops, engine immediately stalls....1730
P-6 Function of APS does not stop....1731
a) Function of APS is normal, but APS does not stop even when water temperature is more than 20C....1731
b) APS is actuated even when APS switch on panel is not turned ON....1731
FAILURE MODE AND COMPONENTS....1733
