Komatsu Wheeled Excavator PW200-7E0, PW220-7E0 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheeled Excavator PW200-7E0, PW220-7E0, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Wheeled Excavator PW200-7E0, PW220-7E0 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: 1,242 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
VEBM949100 - Wheeled Excavator PW200-7E0, PW220-7E0 Shop Manual.pdf
MAIN SECTIONS
PW200/220-7E0 VEBM949100...1
CONTENTS...3
FOREWORD...5
Safety...7
Safety notice...7
General precautions...7
Preparations for work...8
Precautions during work...8
List of revised pages...11
General...17
General...17
Structure and function...17
Testing, adjusting and troubleshooting...17
Disassembly and assembly...17
Maintenance standard...17
How to read the shop manual...18
Volumes...18
Distribution and updating...18
Filing method...18
Revised edition mark...18
Revisions...19
Symbols...19
Hoisting instructions...20
Hoisting...20
Coating materials...22
Standard tightening torque...24
Standard tightening torque of bolts and nuts...24
Tightening torque of hose nuts...25
Tightening torque of split flange bolts...25
Tightening torques for hoses (taper seal type and face seal type)...26
Tightening torque for 107 engine series (bolts and nuts)...26
Tightening torque for 107 engine series (eye joints)...27
Tightening torque for 107 engine series (tapered screws)...27
Electric wire code...28
Classification by thickness...28
Classification by color and code...28
Conversion tables...29
Method of using the conversion table...29
Temperature...34
Units...35
GENERAL...37
Specification dimension drawings...39
Dimensions...39
1 Piece boom...39
Dimensions...41
2 Piece boom...41
Working ranges...43
1 Piece boom...43
2 Piece boom...44
Specifications...45
PW200-7E0, PW220-7E0...45
Weight table...47
W200-7E0, PW220-7E0...47
1 Piece boom...48
2 Piece boom...49
Fuel, coolant and lubricants...50
STRUCTURE AND FUNCTION, MAINTENANCE STANDARD...53
Engine related parts...55
Radiator - Oil cooler - Charge air cooler...56
Power train...57
Swing circle...58
Swing machinery and motor...60
Swing motor...63
Operation of swing lock...66
Relief valve portion...67
Operation...67
Undercarriage...68
Transmission...70
Travel motor...73
Operation of travel motor...75
Clutch control circuit...78
Axle...80
Front axle...80
Rear Axle...82
Suspension lock cylinder...84
Circuit...84
Axle oscillation...85
Braking system...86
Brake/steer pump...88
Priority valve...89
Power brake valve...90
Accumulator for brake system...92
Steering system...93
Steering column...94
Orbitrol valve...95
Hydraulic equipment layout drawings...96
Hydraulic circuit diagram...98
Hydraulic tank...99
Hydraulic pump...100
HPV95 + 95 (PW200-7E0 )...100
LS valve...106
PC valve...106
Pilot pressure control (PPC) system...121
Control valve...122
PW200E0/220-7E0...122
CLSS...136
Outline of CLSS...136
Basic Principle...137
Main relief valve...139
Variable pressure compensation valve...140
Centre swivel joint...142
Travel PPC pedal...143
Work equipment - Swing PPC valve...145
Solenoid valves...150
Solenoid valve block...154
2 Position 3 way valve...154
2 Position 4 way valve...156
LS (PC)-EPC valve...158
Attachment EPC valve...161
Boom Safety valve...164
Hydraulic cylinder...166
PW200-7E0, PW200-7E0...166
Boom cylinder...166
Arm cylinder...166
Bucket cylinder...166
Adjust cylinder...167
Outrigger cylinder...168
Dozer cylinder...170
Work equipment...172
PW200-7E0/PW220-7E0...173
Work equipment...173
1. Dimension of arm...174
2. Dimension of bucket...176
Air conditioner...178
Air conditioner piping...178
Electrical wiring diagram...180
Electrical system...181
Engine control...181
Engine controller...183
CN-CE01...183
CN-CE01...184
CN-CE02...184
CN-CE03...185
Engine control system...188
Machine control system diagram...190
1. Engine and pump control function...192
2. Pump/valve control function...197
3. One-touch power maximizing function...199
4. Auto-deceleration function...201
5. Auto-warm-up/overheat and white smoke prevention function...203
6. Swing control function...205
7. Travel control function...207
8. ATT flow control, circuit selector function (option)...209
9. System component parts...210
Machine monitor system...213
Monitor panel...214
Monitor gauge displays...218
Keypad layout...221
Liquid crystal monitor adjustment switch...232
Overload warning device...238
Outline...238
Sensor...239
Coolant temperature sensor...240
Oil pressure switch...240
Rotation sensor...241
Boost pressure and temperature sensor...241
WIF (Water-In-Fuel detection) sensor...242
Engine oil level sensor...242
Coolant level sensor...243
Coolant temperature sensor...243
Hydraulic oil temperature sensor...244
Fuel level sensor...244
Air cleaner clogging sensor...245
Overload Caution sensor...245
Swing proximity sensor...245
Travel PPC sensor...245
PPC pressure sensor...246
Park brake pressure sensor...246
Brake accumulator low pressure sensor...246
Brake stop light sensor...246
1st attachment circuit hydraulic performance (main valve bypassed)...247
Travel circuit...248
Operational and control features...249
1. Travel motor...251
2. Travel pedal...259
3. Forward/neutral/reverse switch (F-N-R)...260
4. Forward/reverse travel solenoid...261
5. Travel/neutral solenoid...262
6. Travel creep solenoid...263
7. 2-stage relief solenoid...264
8. Hi/Lo solenoid valve...266
9. Back pressure solenoid...267
Steering system...268
Operating principles...268
Condition 1...269
Condition 2...269
Condition 3...270
Condition 4...270
Condition 5...271
Condition 6...271
OLS priority valve...272
Load sensing steering unit...272
Service brake and suspension system...278
Braking system...278
Operation...281
Quick coupler control valve...284
Specification...284
Operation...284
Shematic...285
ATT EPC valve assembly...286
KOMTRAX terminal system...287
KOMTRAX terminal...288
Standard value table for engine related parts...293
Standard value table for chassis related parts...294
Flow control characteristic of PC valve (STD)...307
TESTING AND ADJUSTING...291
Preparations for troubleshooting of electrical system...430
TESTING AND ADJUSTING...309
Measuring engine speed...311
Measuring intake air pressure (boost pressure)...313
Measurement of exhaust gas color...315
Adjusting valve clearance...317
Measuring compression pressure...319
Measurement of blow-by pressure...322
Measure engine oil pressure...324
Handling fuel system parts...325
Releasing residual pressure from fuel system...326
Measuring fuel pressure...327
Measuring fuel return rate and leakage...329
Bleeding air from fuel circuit...332
Checking fuel circuit for leakage...333
Checking and adjusting air conditioner compressor belt tension...335
Replacing the fan belt...336
Measurement of clearance in swing circle bearings...337
Inspection and adjustment of hydraulic oil pressure in hydraulic circuit for work equipment, swing and travel...338
Inspection and adjustment of control circuit oil pressure...343
Procedure for pressure reducing adjustment...345
Inspection and adjustment of pump pc (valve inlet) control oil pressure...346
Inspection and adjustment of pump ls valve control oil pressure...350
Measurement of solenoid valve output pressure...357
7 - Stage solenoid block...359
4 - Stage solenoid block...361
2 - Stage solenoid block...362
Measurement of PPC valve output pressure...363
Checking Proportional Control PPC Circuit...364
Adjustment of work equipment and swing PPC valve...365
Measuring and adjusting quick coupler control valve output pressure...366
Testing travel motor relief pressure...368
Measuring travel motor Relief pressure...368
Adjusting travel motor relief pressure...369
Testing propshaft speed...370
Measuring rotating speed of propshaft...370
Testing transmission clutch control circuit...371
Description...371
Inspection of locations of hydraulic drift of work equipment...373
Release of remaining pressure in hydraulic circuit...375
Measurement of oil leakage amount...377
Air bleeding of various parts...380
Inspection procedures for diode...382
Special function of monitor panel...384
Operation of operators menu and display (outline)...387
Table for failure code no...394
Operation and display of service menu...398
Way of switching to Service Menu...398
Table for monitoring items...401
Procedure for turning on KOMTRAX terminal...419
KOMTRAX terminal lamp indications...423
TESTING AND ADJUSTING...433
Troubleshooting...433
Points to remember when troubleshooting...435
Sequence of events in troubleshooting...437
Points to remember when carrying out maintenance...438
Points to remember when handling electric equipment...438
Points to remember when troubleshooting electric circuits...444
Points to remember when handling hydraulic equipment...444
Checks before troubleshooting...446
Classification and steps for troubleshooting...447
Steps for troubleshooting...447
Connector location chart and electrical circuit diagram by system...454
Connection table for connector pin numbers...479
T-boxes and T-adapters table...508
Information contained in troubleshooting table...515
Relative electrical circuit diagram...516
Failure code [6B2JMA] - Abnormality in travel PPC switch hydraulics...517
Failure code [989L00] - Engine controller lock caution 1...518
Failure code [989M00] - Engine controller lock caution 2...518
Failure code [989N00] - Engine controller lock caution 3...519
Failure code [AA10NX] - Air cleaner clogging...520
Failure code [AB00KE] - Charging voltage abnormally low...522
Failure code [B@BAZG] - Abnormally lowered engine oil pressure...524
Failure code [B@BAZK] - Abnormally lowered engine oil level...526
Failure code [B@BCNS] - Engine cooling water overheating...528
Failure code [B@BCZK] - Abnormally low radiator water level...530
Failure code [B@HANS] - Hydraulic oil overheating...532
Failure code [CA111] - EMC critical internal failure...534
Failure code [CA115] - Engine neutral and backup speed sensor error...535
Failure code [CA122] - Chg air press sensor high error...536
Failure code [CA123] - Chg air press sensor low error...538
Failure code [CA131] - Throttle sensor high error...540
Failure code [CA132] - Throttle sensor low error...542
Failure code [CA144] - Coolant temp sens high error...544
Failure code [CA145] - Coolant temp sens low error...546
Failure code [CA153] - Chg air temp sensor high error...548
Failure code [CA154] - Chg air temp sensor low error...550
Failure code [CA155] - Chg air temp high speed derate...552
Failure code [CA187] - Sens supply 2 volt low error...554
Failure code [CA221] - Ambient press sens high error...556
Failure code [CA222] - Ambient press sens low error...558
Failure code [CA227] - Sens supply 2 volt high error...560
Failure code [CA234] - Eng overspeed...562
Failure code [CA238] - Ne speed sens supply volt error...564
Failure code [CA271] - IMV/PCV1 short error...566
Failure code [CA272] - IMV/PCV1 open error...568
Failure code [CA322] - Inj #1 (L#1) open/short error...570
Failure code [CA323] - Inj #5 (L#5) open/short error...572
Failure code [CA324] - Inj #3 (L#3) open/short error...574
Failure code [CA325] - Inj #6 (L#6) open/short error...576
Failure code [CA331] - Inj #2 (L#2) open/short error...578
Failure code [CA332] - Inj #4 (L#4) open/short error...580
Failure code [CA342] - Calibration code incompatibility...582
Failure code [CA351] - Injectors drive circuit error...584
Failure code [CA352] - Sens supply 1 volt low error...586
Failure code [CA386] - Sens supply 1 volt high error...588
Failure code [CA428] - Water in fuel sensor high error...590
Failure code [CA429] - Water in fuel sensor low error...592
Failure code [CA435] - Eng oil press sw error...594
Failure code [CA441] - Battery voltage low error...596
Failure code [CA442] - Battery voltage high error...600
Failure code [CA449] - Rail press very high error...602
Failure code [CA451] - Rail press sensor high error...604
Failure code [CA452] - Rail press sensor low error...606
Failure code [CA488] - Chg air temp high torque derate...608
Failure code [CA553] - Rail press high error...608
Failure code [CA559] - Rail press low error...609
Failure code [CA689] - Eng ne speed sensor error...612
Failure code [CA731] - Eng bkup speed sens phase error...614
Failure code [CA757] - All continuous data lost error...616
Failure code [CA778] - Eng G speed sensor error...618
Failure code [CA1633] - KOMNET datalink timeout error...620
Failure code [CA2185] - Throttle sensor supply voltage high error...622
Circuit diagram related to fuel control dial...622
Failure code [CA2186] - Throttle sensor supply voltage low error...623
Circuit diagram related to fuel control dial...623
Failure code [CA2249] - Rail press very low error...624
Failure code [CA2311] - IMV solenoid error...626
Failure code [CA2555] - Grid htr relay volt high error...628
Failure code [CA2556] - Grid heater relay volt low error...630
Failure code [D110KB] - Short-circuiting in battery relay...632
Failure code [D19JKZ] - Personal code relay abnormality...634
Failure code [D862KA] - GPS antenna discon...636
Failure code [DA25KP] - Press. sensor power abnormality...638
Failure code [DA2RMC] - Pump comm. abnormality...640
Failure code [DA2SKA] - Disconnection of S-NET signal...642
Failure code [DA2SKQ] - Abnormality in inputting model code...644
Failure code [DA2SKQ] - Abnormality in inputting model code...646
Failure code [DAF0KT] - Abnormal data in error history...648
Failure code [DAFRMC] - Monitor comm. abnormality...650
Failure code [DDC3KZ] - Outrigger switch select abnormality...652
Failure code [DDHPAKP] - Abnormality in pump pressure sensor...654
Failure code [DDP4KX] - Abnormality in travel PPC pressure switch...656
Failure code [DDWCKZ] - Abnormality in travel direction control switch...658
Failure code [DFB1KZ] - Service lever potentio 1 abnormality...660
Failure code [DFB2KZ] - Service lever potentio 2 abnormality...662
Failure code [DFB3L8] - Service lever 1 potentio error...664
Failure code [DFB4L8] - Service lever 2 potentio error...665
Failure code [DGH2KB] - Hydr oil sensor short...667
Failure code [DH10KS] - Abnormality in pressure sensor power source...668
Failure code [DHPAKP] - Abnormality in F pump pressure sensor...670
Failure code [DHPAMA] - Abnormality in F pump pressure sensor...672
Failure code [DHPBMA] - Abnormality in R pump pressure sensor...674
Failure code [DHS5KX] - Abnormality in travel PPC sensor...676
Failure code [DHX1MA] - Abnormality in overload caution sensor...678
Failure code [DLE2MA] - Abnormality in engine rotation sensor in governor (pump controller system)...680
Failure code [DLT4KA] - Disconnection in transmission speed sensor in governor (pump controller syste)m)...682
Failure code [DW27KA] - Disconnection in transmission clutch solenoid...684
Failure code [DW27KB] - Short-circuiting in transmission clutch solenoid...686
Failure code [DW4CKA] - Disconnection in PPC lock solenoid...688
Failure code [DW4CKB] - PPC lock sol. S/C...690
Failure code [DW44KA] - Disconnection of travel F/R solenoid...692
Failure code [DW44KB] - Short-circuiting of travel F/R solenoid...694
Failure code [DW45KA] - Disconnection in swing parking brake solenoid...696
Failure code [DW4MKA] - Disconnection in creep solenoid...698
Failure code [DW4MKB] - Short-circuiting in creep solenoid...700
Failure code [DW91KA] - Disconnection in travel neutral solenoid...702
Failure code [DW91KB] - Short-circuiting in travel neutral solenoid...704
Failure code [DWK0KA] - Disconnection in 2-stage relief solenoid...706
Failure code [DWK0KB] - Short-circuiting in 2-stage relief solenoid...708
Failure code [DWK2KA] - Disconnection in 2-stage back pressure solenoid...710
Failure code [DWK2KB] - Short circuiting in 2-stage back pressure solenoid...712
Failure code [DXA0KA] - Disconnection in PC-EPC solenoid system...714
Failure code [DXE0KA] - Disconnection in LS-EPC solenoid system...716
Failure code [DXE0KB] - Short-circuiting in LS-EPC solenoid...718
Failure code [DXE4KA] - Service current EPC1 discon...720
Failure code [DXE4KB] - Service current EPC1 short...722
Failure code [DXE7KA] - Service current EPC2 disco...724
Failure code [DXE7KB] - Service current EPC2 short...726
Failure code [DXE8KA] - Service current EPC3 discon...728
Failure code [DXE8KB] - Service current EPC3 short...730
Failure code [DXE9KA] - Service current EPC4 discon...732
Failure code [DXE9KB] - Service current EPC4 short...734
Failure code [DY20KA] - Wiper working abnormality...736
Failure code [DY20MA] - Wiper parking abnormality...738
Failure code [DY2CKB] - Washer drive S/C...740
Failure code [DY2DKB] - Wiper drive (for) S/C...742
Failure code [DY2EKB] - Wiper drive (rev) S/C...744
TESTING AND ADJUSTING...511
Troubleshooting when service code "Electrical system" and failure code "Mechanical system" are indicated...511
Information contained in troubleshooting table...749
Relative electrical circuit diagram...750
E-1 - Engine does not start (engine does not rotate)...751
E-5 - Auto-decelerator does not work...755
E-6 - Auto engine warm-up device does not work...757
E-7 - Preheater does not operate...758
E-8 - All work equipment, swing and travel do not move...760
E-9 - One-touch power max switch does not work...762
E-10 - No display in monitor panel at all...763
E-11 - Part of display on monitor panel is missing...764
E-12 - Monitor panel displays contents irrelevant to the model...764
E-13 - Fuel level monitor red lamp lights up while engine is running...765
E-14 - Engine coolant temperature gauge does not indicate normally...766
E-15 - Hydraulic oil temperature gauge does not display correctly...768
E-16 - Fuel gauge does not display correctly...769
E-17 - Swing lock monitor does not display correctly...770
E-18 - When the monitor switch is operated, no display appears...772
E-19 - Windshield wiper and window washer do not operate...774
E-20 - Alarm buzzer cannot be stopped...776
E-21 - "Boom/stabiliser RAISE" is not correctly displayed in monitor function...777
E-22 - "Boom/stabiliser LOWER" is not correctly displayed in monitor function...778
E-23 - "Arm DIGGING" is not correctly displayed in monitor function...779
E-24 - "Arm DUMPING" is not correctly displayed in monitor function...780
E-25 - "Bucket DIGGING" is not correctly displayed in monitor function...781
E-26 - "Bucket DUMPING" is not correctly displayed in monitor function...782
E-27 - "SWING" is not correctly displayed in monitor function...784
E-28 - "TRAVEL" is not correctly displayed in monitor function...786
E-29 - "2 piece boom" is not correctly displayed in monitor function...788
E-30 - Air conditioner does not work...790
E-31 - Travel reverse alarm does not sound...792
E-32 - KOMTRAX system does not operate normally...794
TESTING AND ADJUSTING...747
Troubleshooting of electrical system (E-Mode)...747
Information contained in troubleshooting table...799
Radio cassette and telephone socket...800
PPC lock circuit...802
Brake light circuit...804
Undercarriage attachments - Mode selection...806
Undercarriage attachments - Front left outrigger...808
Undercarriage attachments - Front right outrigger...810
Undercarriage attachments - Rear left outrigger...812
Undercarriage attachments - Rear right outrigger...814
Heated seat does not warm up...816
Suspension lock...818
Lower wiper does not work (optional fitment)...820
Work lights (operator cab front left)...822
Work lights (operator cab front right)...823
Work lights (operator cab rear)...824
Work lights (boom, arm and counterweight)...826
Cab and counterweight beacon light...828
Air seat compressor (option - air suspension seat)...830
Operator cab interior light...832
Cigar lighter...834
Park brake (not activating)...836
Park brake (displayed symbol)...838
RH PPC lever clamshell roller switch pushed to the LH position...840
RH PPC lever clamshell roller switch pushed to the RH position...842
RH PPC lever clamshell roller switch pushed to the RH or LH position...844
Horns...846
Swing lock - Normal operation...848
Swing lock - Emergency operation...850
Neutral start (engine)...852
Neutral start (engine) contd (A)...853
Neutral start (engine) contd (B)...854
Neutral start (engine) contd (C)...855
Emergency travel control - Forward...858
Emergency travel control - neutral...860
Emergency travel control - Reverse...863
Emergency travel control - Reverse contd...864
Driving lights - Main beam...866
Driving lights - Main beam flash...868
Driving lights - Main beam dipped...870
Driving lights - Position lights...872
Driving lights - Position lights contd (1) and (2)...874
Indicators - Right hand...876
Indicators - Left hand...878
Hazard warning lights...880
Hazard warning lights contd (A)...882
Swing lock proximity switch...884
TESTING AND ADJUSTING...797
Troubleshooting of electrical system (Error checking of items without monitor codes)...797
System chart for hydraulic and mechanical systems...889
Information contained in troubleshooting table...893
H-1 - All work equipment lacks power, or travel and swing speeds are slow...894
H-2 - Engine speed sharply drops or engine stalls...895
H-3 - No work equipment, travel or swing move...896
H-4 - Abnormal noise is heard from around hydraulic pump...897
H-5 - Auto-decelerator does not work...898
H-6 - Fine control mode does not function...899
H-7 - Boom moves slowly or lacks power...900
H-8 - Arm moves slowly or lacks power...901
H-9 - Bucket moves slowly or lacks power...902
H-10 - Work equipment does not move in its single operation...903
H-11 - Work equipment hydraulic drift is too fast...904
H-12 - Work equipment has big time lag...905
H-13 - Other work equipment moves when relieving single circuit...906
H-14 - One-touch power max. switch does not operate...907
H-15 - In compound operation, work equipment with larger load moves slowly...908
H-16 - In swing and boom RAISE operation, boom moves slowly...909
H-17 - In swing and travel, travel speed drops sharply...910
H-18 - Travel speed does not switch...911
H-19 - Travel speed does not shift, or it is too slow or fast...912
H-20 - Machine does not swing...913
H-21 - Swing acceleration is poor, or swing speed is slow...914
H-22 - Excessive overrun when stopping swing...915
H-23 - There is big shock when stopping swing...916
H-24 - There is loud abnormal noise caused when stopping swing...917
H-25 - Swing natural drift is too big...918
H-26 - Swing speed is faster than specified swing speed...919
Troubleshooting of engine (S-mode)...920
Method of using troubleshooting chart...920
S-1 - Starting performance is poor...923
S-2 - Engine does not start...924
S-3 - Engine does not pick up smoothly...927
S-4 - Engine stops during operations...928
S-5 - Engine does not rotate smoothly...929
S-6 - Engine lack output (or lacks power)...930
S-7 - Exhaust smoke is black (incomplete combustion)...931
S-8 - Oil consumption is excessive (or exhaust smoke is blue)...932
S-9 - Oil becomes contaminated quickly...933
S-10 - Fuel consumption is excessive...934
S-11 - Oil is in coolant (or coolant spurts back or coolant level goes down)...935
S-12 - Oil pressure drops...936
S-13 - Oil level rises (entry of coolant/fuel)...937
S-14 - Coolant temperature becomes too high (overheating)...938
S-15 - Abnormal noise is made...939
S-16 - Vibration is excessive...940
TESTING AND ADJUSTING...887
Troubleshooting of hydraulic and mechanical system (H-Mode)...887
How to read this manual...945
Removal and installation of assemblies...945
Special tools...945
Removal of parts...946
Installation of parts...946
Sketches of special tools...946
Coating materials list...947
Special Tools...950
Sketches of special tools...953
E1 push tool...953
E5 push tool...953
F2 push tool...954
List of tools...955
Precautions when performing operation...956
Removal and installation of starting motor...960
Removal...960
Installation...960
Removal and installation of fuel pump assembly...961
Removal...961
Installation...964
Removal and installation of fuel injector assembly...965
Special tools...965
Removal...965
Installation...970
Removal and installation of engine front seal...974
Special tools...974
Removal...974
Installation...976
Removing and installation of engine rear seal...977
Special tools...977
Removal...977
Installation...978
Removal and installation of cylinder head assembly...980
Special tools...980
Removal...980
Installation...988
Removal and installation of combination cooler...995
Removal...995
Installation...998
Removal and installation of engine and hydraulic pump assemblies...999
Special tools...999
Removal...999
Installation...1004
Removal and installation of fuel cooler assembly...1006
Removal...1006
Installation...1006
Removal and installation of transmission and travel motor...1007
Removal...1007
Installation...1009
Disassembly and assembly of transmission...1010
Special tools...1010
Disassembly...1010
Removal of travel motor...1010
Installation of travel motor...1011
Removal of transmission input shaft...1012
Installation of transmission input shaft...1022
Removal of output shaft...1023
Installation of output shaft...1026
Removal of pump shaft...1027
Installation of pump shaft...1029
Disassembly and assembly of travel motor assembly...1030
Disassembly...1031
Assembly...1033
Removal and installation of swing motor and swing machinery assembly...1035
Removal...1035
Installation...1036
Disassembly and assembly of swing motor and swing machinery assembly...1037
Special tools...1037
Disassembly...1037
Assembly...1040
Removal and installation of front axle...1046
Removal...1046
Installation...1047
Disassembly and assembly of front axle...1048
Disassembly of steering cylinder...1048
Assembly of steering cylinder...1053
Disassembly of epicyclic reduction gear and brake...1060
Assembly of epicyclic reduction gear and brake...1066
Disassembly of joint box...1075
Assembly of joint box...1082
Disassembly of beam trumpet and differential unit...1090
Assembly of beam trumpet and differential unit...1095
Disassembly of pinion group...1102
Assembly of pinion group...1105
Toe-in adjustment...1114
Removal and installation of rear axle...1116
Removal...1116
Installation...1117
Disassembly and assembly of rear axle...1118
Special tools...1118
Removal of epicyclic reduction gear and brake...1118
Installation of epicyclic reduction gear and brake...1125
Disassembly of beam trumpet and differential unit...1135
Installation of beam trumpet and differential unit...1139
Disassembly of pinion group...1140
Installation of pinion group...1144
Removal and installation of propshaft...1152
Removal...1152
Installation...1152
Removal and installation of wheel...1153
Removal...1153
Installation...1153
Removal and installation of suspension lock cylinder...1154
Removal...1154
Installation...1154
Disassembly and assembly of suspension lock cylinder...1155
Change rod seal...1155
Removal and installation of outrigger...1156
Removal...1156
Installation...1157
Disassembly and assembly of outrigger...1158
Disassembly...1158
Assembly...1159
Removal and installation of dozer blade...1160
Removal...1160
Installation...1160
Disassembly and assembly of dozer blade...1161
Disassembly...1161
Assembly...1162
Removal and installation of swing circle assembly...1163
Removal...1163
Installation...1163
Removal and installation of revolving frame assembly...1165
Removal...1165
Installation...1168
Removal and installation of centre swivel joint...1169
Removal...1169
Installation...1172
Disassembly and assembly of centre swivel joint...1173
Special tools...1173
Disassembly...1173
Assembly...1174
Removal and installation of hydraulic tank...1175
Removal...1175
Installation...1178
Removal and installation of fuel tank...1179
Removal...1179
Installation...1180
Removal and installation of control valve...1181
Removal...1181
Installation...1185
Removal and installation of LS select valve assembly...1186
Removal...1186
Installation...1186
Removal and installation of LS shuttle valve assembly...1187
Removal...1187
Installation...1187
Removal and installation of pressure compensation valve assembly...1188
Removal...1188
Installation...1188
Removal and installation of main relief valve assembly...1189
Removal...1189
Installation...1189
Removal and installation of LS control EPC valve assembly...1190
Removal...1190
Installation...1190
Removal and installation of EPC solenoid valve assembly...1191
Removal...1191
Installation...1191
Removal and installation of PPC valve block assembly...1192
Removal...1192
Installation...1192
Removal and installation of manifold block assembly...1193
Removal...1193
Installation...1193
Removal and installation of oil seal in hydraulic pump input shaft...1194
Special tools...1194
Removal...1194
Installation...1194
Disassembly and assembly of work equipment PPC valve...1195
Assembly...1196
Disassembly and assembly of hydraulic cylinder...1197
Special tools...1197
Disassembly of arm and bucket cylinders...1198
Assembly...1200
Removal and installation of monoboom work equipment...1205
Special tools...1205
Removal...1205
Installation...1207
Removal and installation of 2 piece boom work equipment...1208
Special tools...1208
Removal...1208
Installation...1210
Removal and installation of air conditioner unit...1211
Special tools...1211
Removal...1211
Installation...1215
Removal and installation of counterweight...1216
Removal...1216
Installation...1217
Removal and installation of operator cab assembly...1218
Removal...1218
Installation...1220
Removal and installation of monitor assembly...1221
Removal...1221
Installation...1222
Removal and installation of governor/pump controller assembly...1223
Removal...1223
Installation...1224
Removal and Installation of KOMTRAX terminal...1225
Removal...1225
Installation...1225
DISASSEMBLY AND ASSEMBLY...941
OTHER...1227
Lubrication...1229
Hydraulic circuit diagram (1/3)...1233
Hydraulic circuit diagram (2/3)...1234
Hydraulic circuit diagram (3/3)...1235
Electrical circuit diagram (1/7)...1236
Electrical circuit diagram (2/7)...1237
Electrical circuit diagram (3/7)...1238
Electrical circuit diagram (4/7)...1239
Electrical circuit diagram (5/7)...1240
Electrical circuit diagram (6/7)...1241
Electrical circuit diagram (7/7)...1242
