Komatsu Galeo PC270LL-7L Logging Excavator Shop Manual CEBM014600 – PDF DOWNLOAD

Komatsu Galeo PC270LL-7L Logging Excavator Shop Manual CEBM014600 – PDF DOWNLOAD

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Komatsu Galeo PC270LL-7L Logging Excavator Shop Manual CEBM014600 – PDF DOWNLOAD

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Komatsu Galeo PC270LL-7L Logging Excavator Shop Manual CEBM014600 – PDF DOWNLOAD

SERIAL NUMBERS PC270LL-7L A85001 and UP

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1 .Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

•  Always wear safety glasses when hitting parts with a hammer.
•  Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.PREPARATIONS FOR WORK:
1. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels to
prevent the machine from moving.
2. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible,
use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.
3. When disassembling or assembling, support the machine with blocks, jacks or stands before starting
work.
4. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

TABLE OF CONTENTS:

Komatsu Galeo PC270LL-7L Logging Excavator Shop Manual CEBM014600 – PDF DOWNLOAD

MAIN MENU………………………………………………………………………. 0
COVER………………………………………………………………………….. 1
CONTENTS……………………………………………………………………….. 2
FOREWORD……………………………………………………………………….. 2
SAFETY……………………………………………………………………… 5
SAFETY NOTICE……………………………………………………………. 5
IMPORTANT SAFETY NOTICE…………………………………………………… 5
GENERAL PRECAUTIONS………………………………………………………. 5
PREPARATIONS FOR WORK…………………………………………………….. 5
PRECAUTIONS DURING WORK…………………………………………………… 5
GENERAL…………………………………………………………………….. 7
HOW TO READ THE SHOP MANUAL…………………………………………………… 8
VOLUMES…………………………………………………………………. 8
DISTRIBUTION AND UPDATING…………………………………………………. 8
FILING METHOD……………………………………………………………. 8
REVISED EDITION MARK……………………………………………………… 8
REVISIONS……………………………………………………………….. 8
SYMBOLS…………………………………………………………………. 8
HOISTING INSTRUCTIONS………………………………………………………… 9
HOISTING………………………………………………………………… 9
WIRE ROPES………………………………………………………………. 9
COATING MATERIALS……………………………………………………………. 10
STANDARD TIGHTENING TORQUE……………………………………………………. 12
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS………………………………… 12
TIGHTENING TORQUE OF HOSE NUTS…………………………………………….. 13
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…………………………………….. 13
TIGHTENING TORQUE FOR FLARED NUTS………………………………………….. 13
ELECTRIC WIRE CODE…………………………………………………………… 14
CLASSIFICATION BY THICKNESS……………………………………………….. 14
CLASSIFICATION BY COLOR AND CODE…………………………………………… 14
CONVERSION TABLES……………………………………………………………. 15
METHOD OF USING THE CONVERSION TABLE……………………………………….. 15
01 GENERAL……………………………………………………………………… 21
SPECIFICATION DIMENSION DRAWINGS………………………………………………. 22
PC270LL-7L………………………………………………………………. 22
DIMENSIONS………………………………………………………………. 22
WORKING RANGES…………………………………………………………… 24
WEIGHT TABLE………………………………………………………………… 27
FUEL, COOLANT AND LUBRICANTS………………………………………………….. 29
PC270LL-7L………………………………………………………………. 29
10 STRUCTURE AND FUNCTION………………………………………………………… 31
ENGINE RELATED PARTS…………………………………………………………. 33
RADIATOR . OIL COOLER . AFTERCOOLER……………………………………………. 34
POWER TRAIN…………………………………………………………………. 35
FINAL DRIVE…………………………………………………………………. 37
SWING CIRCLE………………………………………………………………… 41
TRACK FRAME . RECOIL SPRING…………………………………………………… 43
IDLER………………………………………………………………………. 45
TRACK ROLLER………………………………………………………………… 47
TRACK SHOE………………………………………………………………….. 48
TRIPLE GROUSER SHOE………………………………………………………….. 50
HYDRAULIC EQUIPMENT………………………………………………………….. 51
HYDRAULIC TANK………………………………………………………………. 53
HYDRAULIC PUMP………………………………………………………………. 55
HPV95 + 95………………………………………………………………. 55
LS VALVE………………………………………………………………… 60
PC VALVE………………………………………………………………… 60
LS(PC)-EPC VALVE…………………………………………………………. 73
CONTROL VALVE……………………………………………………………….. 77
SELF PRESSURE REDUCING VALVE………………………………………………….. 93
MAIN RELIEF VALVE………………………………………………………… 96
VARIABLE PRESSURE COMPENSATION VALVE……………………………………….. 97
CLSS……………………………………………………………………….. 99
SWING MOTOR………………………………………………………………….100
RELIEF VALVE PORTION………………………………………………………103
SWING LOCK……………………………………………………………….104
REVERSE PREVENTION VALVE………………………………………………………105
CENTER SWIVEL JOINT…………………………………………………………..108
TRAVEL MOTOR……………………………………………………………..110
PARKING BRAKE…………………………………………………………….115
TRAVEL JUNCTION VALVE……………………………………………………..121
VALVE CONTROL………………………………………………………………..123
CONNECTIONS………………………………………………………………123
LEVER POSITIONS…………………………………………………………..124
WORK EQUIPMENT . SWING PPC VALVE……………………………………………….125
TRAVEL PPC VALVE……………………………………………………………..130
SERVICE VALVE………………………………………………………………..139
SOLENOID VALVE……………………………………………………………….142
ATTACHMENT SOLENOID VALVE……………………………………………………..143
PPC ACCUMULATOR………………………………………………………………145
BOOM HYDRAULIC DRIFT PREVENTION VALVE…………………………………………..146
LIFT CHECK VALVE……………………………………………………………..149
HYDRAULIC CYLINDERS…………………………………………………………..150
BOOM CYLINDER…………………………………………………………….150
ARM CYLINDER……………………………………………………………..150
BUCKET CYLINDER…………………………………………………………..150
WORK EQUIPMENT……………………………………………………………….152
100 HOURS………………………………………………………………..153
500 HOURS………………………………………………………………..153
DIMENSION OF ARM………………………………………………………….154
DIMENSION OF BUCKET……………………………………………………….156
AIR CONDITIONER………………………………………………………………158
PIPING…………………………………………………………………..158
ENGINE CONTROL……………………………………………………………….159
FUEL CONTROL DIAL…………………………………………………………161
GOVERNOR MOTOR……………………………………………………………162
ENGINE THROTTLE AND PUMP CONTROLLER…………………………………………164
INPUT AND OUTPUT SIGNALS…………………………………………………..165
ELECTRONIC CONTROL SYSTEM……………………………………………………..167
MACHINE CONTROL SYSTEM DIAGRAM……………………………………………..168
ENGINE AND PUMP CONTROL FUNCTION……………………………………………170
SWING CONTROL FUNCTION WITH SOFT SWING………………………………………185
MULTI MONITOR SYSTEM………………………………………………………….193
MONITOR PANEL…………………………………………………………….194
MONITOR CONTROL, DISPLAY PORTION MONITOR PORTION……………………………..196
MONITOR ITEMS AND DISPLAY………………………………………………….197
MAINTENANCE FUNCTION………………………………………………………206
SENSORS……………………………………………………………………..211
ENGINE OIL LEVEL SENSOR……………………………………………………212
ENGINE OIL PRESSURE SENSOR (FOR LOW PRESSURE)………………………………..212
COOLANT TEMPERATURE SENSOR…………………………………………………212
HYDRAULIC OIL TEMPERATURE SENSOR……………………………………………212
FUEL LEVEL SENSOR…………………………………………………………213
AIR CLEANER CLOGGING SENSOR………………………………………………..213
CAB RISER AND RELATED PARTS……………………………………………………214
POWER CONTROL…………………………………………………………….215
CAB RISER HYDRAULIC SYSTEM…………………………………………………….216
20 TESTING, ADJUSTING AND TROUBLESHOOTING…………………………………………..231
STANDARD VALUE TABLES…………………………………………………………219
ENGINE…………………………………………………………………..219
CHASSIS………………………………………………………………….220
TESTING AND ADJUSTING…………………………………………………………231
SERVICE TOOLS…………………………………………………………….233
ENGINE…………………………………………………………………..234
COMPRESSION PRESSURE…………………………………………………..234
BLOW-BY PRESSURE………………………………………………………234
OIL PRESSURE………………………………………………………….234
RPM………………………………………………………………….234
SPEED SENSOR………………………………………………………….234
EXHAUST GAS COLOR……………………………………………………..234
FUEL INJECTION TIMING………………………………………………….234
VALVE CLEARANCE……………………………………………………….234
BELT TENSION – AIR COMPRESSOR………………………………………………235
EMERGENCY ESCAPE FROM ENGINE CONTROL FAILURE…………………………………236
SWING CIRCLE BEARINGS……………………………………………………..237
TRACK SHOE TENSION………………………………………………………..238
SPROCKET…………………………………………………………………238
OIL PRESSURE……………………………………………………………..239
WORK EQUIPMENT, SWING AND TRAVEL………………………………………..239
CONTROL CIRCUIT……………………………………………………….243
PUMP PC CONTROL CIRCUIT………………………………………………..244
PUMP LS CONTROL CIRCUIT………………………………………………..247
SOLENOID VALVE OUTPUT PRESSURE………………………………………….252
TABLE FOR FUNCTIONING CONDITIONS………………………………………..253
PPC LOCK SOLENOID VALVE………………………………………………..253
SWING AND PARKING BRAKE SOLENOID………………………………………..253
TRAVEL INTERCONNECTION SOLENOID VALVE……………………………………253
ATTACHMENT SOLENOID VALVE OUTPUT………………………………………..256
PPC VALVE OUTPUT PRESSURE………………………………………………….257
ATTACHMENT PPC VALVE OUTPUT…………………………………………….258
WORK EQUIPMENT AND SWING PPC VALVE………………………………………….259
WORK EQUIPMENT – HYDRAULIC DRIFT……………………………………………260
RELEASING PRESSURE IN HYDRAULIC CIRCUIT……………………………………..262
OIL LEAKAGE………………………………………………………………263
AIR BLEEDING OF VARIOUS PARTS………………………………………………266
SOFT SWING ADJUSTMENTS…………………………………………………….268
DIODE INSPECTION PROCEDURES………………………………………………..269
CAB DOOR STOP ADJUSTMENT…………………………………………………..271
MULTI-MONITOR PANEL……………………………………………………….272
TABLE FOR SERVICE AND FAILURE CODE NUMBERS……………………………….279
SERVICE MENU………………………………………………………….281
WAY OF SWITCHING TO SERVICE MENU………………………………………..281
ELECTRICAL SYSTEM TROUBLESHOOTING…………………………………………..297
PM TUNE UP SERVICE………………………………………………………..298
TROUBLESHOOTING………………………………………………………………303
TROUBLESHOOTING GENERAL……………………………………………………303
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………….305
SEQUENCE OF EVENTS IN TROUBLESHOOTING……………………………………307
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE………………………….308
CHECKS BEFORE TROUBLESHOOTING…………………………………………..316
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING……………………………..317
CLASSIFICATION OF TROUBLESHOOTING……………………………………317
STEPS FOR TROUBLESHOOTING…………………………………………..317
FAILURE-LOOKING PHENOMENON AND TROUBLESHOOTING NO……………………..318
CONNECTOR LOCATION CHART……………………………………………….321
CONNECTOR TABLE……………………………………………………321
CONNECTOR LOCATION DIAGRAM………………………………………….328
ELECTRICAL CIRCUIT DIAGRAMS…………………………………………….333
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS……………………………….334
CONNECTOR REPAIR PROCEDURES…………………………………………….357
CONTACT TERMINAL REMOVAL (HD30 TYPE)…………………………………357
STRIPPING INSULATION……………………………………………….358
CRIMPING CONTACT TERMINAL (HD30 TYPE)………………………………..359
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…………………………….360
CONTACT TERMINAL REMOVAL (DT TYPE)…………………………………..361
STRIPPING INSULATION……………………………………………….362
CRIMPING CONTACT TERMINAL (DT TYPE)………………………………….363
INSERTION OF CONTACT TERMINAL (DT TYPE)………………………………364
TROUBLESHOOTING ELECTRICAL SYSTEM (E-MODE)…………………………………..365
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM……………………………369
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF…………..369
USER CODE MEMORY RETENTION FUNCTION………………………………….369
INFORMATION CONTAINED IN TESTING PROCEDURES………………………………370
(E101)……………………………………………………………….372
ABNORMAL DATA IN ERROR HISTORY………………………………………372
(E112)……………………………………………………………….374
SHORT IN WINDSHIELD WIPER MOTOR DRIVE FORWARD ROTATION…………………374
SHORT IN GUARD WIPER MOTOR DRIVE FORWARD ROTATION……………………..375
(E113)……………………………………………………………….377
SHORT IN WINDSHIELD WIPER MOTOR DRIVE REVERSE ROTATION…………………377
SHORT IN GUARD WIPER MOTOR DRIVE REVERSE ROTATION……………………..378
(E114)……………………………………………………………….380
SHORT OR OPEN IN WINDOW WASHER SYSTEM………………………………..380
SHORT OR OPEN IN GUARD WASHER SYSTEM…………………………………381
(E115)……………………………………………………………….383
ABNORMAL WINDSHIELD WIPER MOTION…………………………………….383
ABNORMAL GUARD WIPER MOTION…………………………………………384
(E116)……………………………………………………………….386
ABNORMALITY IN PARKING WIPER ARM…………………………………….386
ABNORMALITY IN PARKING WIPER ARM (GUARD)……………………………..387
(E201)……………………………………………………………….390
SHORT OR OPEN IN TRAVEL INTERLOCKING SOLENOID…………………………390
(E203)……………………………………………………………….392
SHORT IN SWING AND PARKING SOLENOID GOVERNOR SYSTEM……………………392
SHORT IN SWING AND PARKING SOLENOID CONTROLLER SYSTEM (WITH SOFT SWING)….394
(E204)……………………………………………………………….396
SHORT IN MERGE/DIVIDE SOLENOID………………………………………396
(E205)……………………………………………………………….398
SHORT IN 2 STAGE RELIEF SOLENOID…………………………………….398
(E206)……………………………………………………………….400
SHORT IN TRAVEL SPEED SHIFT SOLENOID…………………………………400
(E211)……………………………………………………………….402
OPEN IN TRAVEL INTERLOCKING SOLENOID…………………………………402
(E213)……………………………………………………………….404
OPEN IN SWING PARKING BRAKE SOLENOID…………………………………404
OPEN IN SWING PARKING BRAKE SOLENOID (WITH SOFT SWING)…………………406
NO CODE………………………………………………………………408
SHORT OR OPEN IN SOFT SWING SOLENOID SYSTEM…………………………..408
(E214)……………………………………………………………….412
OPEN OF MERGE/DIVIDE SOLENOID……………………………………….412
(E215)……………………………………………………………….414
OPEN IN 2 STAGE RELIEF SOLENOID……………………………………..414
(E216)……………………………………………………………….416
OPEN IN TRAVEL SPEED SOLENOID……………………………………….416
(E217)……………………………………………………………….418
ABNORMAL INPUT FOR MODEL CODE……………………………………….418
(E218)……………………………………………………………….420
OPEN IN S-NET SIGNAL……………………………………………….420
(E222)……………………………………………………………….422
SHORT IN LS-EPC SOLENOID……………………………………………422
(E223)……………………………………………………………….424
OPEN IN LS-EPC SOLENOID SYSTEM………………………………………424
(E224)……………………………………………………………….426
ABNORMAL F-PUMP PRESSURE SENSOR SIGNAL……………………………….426
(E225)……………………………………………………………….428
ABNORMAL R-PUMP PRESSURE SENSOR SIGNAL……………………………….428
(E226)……………………………………………………………….430
ABNORMAL PRESSURE SENSOR POWER SUPPLY………………………………..430
(E227)……………………………………………………………….432
ABNORMAL ENGINE RPM SIGNAL IN GOVERNOR PUMP CONTROLLER…………………432
(E228)……………………………………………………………….434
SHORT IN ATTACHMENT RETURN SWITCHING RELAY……………………………434
NO CODE………………………………………………………………436
SHORT OR OPEN IN ATTACHMENT SOLENOID SYSTEM…………………………..436
NO CODE………………………………………………………………440
OPEN IN CAB TILT SYSTEM…………………………………………….440
(E232)……………………………………………………………….442
SHORT IN PC-EPC SOLENOID……………………………………………442
(E233)……………………………………………………………….444
OPEN IN PC-EPC SOLENOID SYSTEM………………………………………444
(E238)……………………………………………………………….446
OPEN IN ATTACHMENT RETURN SWITCH RELAY……………………………….446
(E245)……………………………………………………………….448
SHORT IN ATTACHMENT OIL FLOW RATE EPC SYSTEM………………………….448
(E246)……………………………………………………………….450
OPEN IN ATTACHMENT OIL FLOW RATE EPC SYSTEM…………………………..450
(E256)……………………………………………………………….452
INCORRECT NON-VOLATILE MEMORY DATA…………………………………..452
(E306)……………………………………………………………….454
ABNORMAL GOVERNOR POTENTIOMETER SIGNALS………………………………454
(E308)……………………………………………………………….456
ABNORMAL FUEL DIAL SIGNALS………………………………………….456
(E315)……………………………………………………………….458
SHORT IN BATTERY RELAY SYSTEM……………………………………….458
(E316)……………………………………………………………….460
STEP OUT IN GOVERNOR MOTOR………………………………………….460
(E317)……………………………………………………………….462
OPEN IN GOVERNOR MOTOR PHASE “A” AND “B”……………………………..462
(E318)……………………………………………………………….464
SHORT IN GOVERNOR MOTOR PHASE “A” AND “B”…………………………….464
(E501)……………………………………………………………….466
MODEL SELECTION FUNCTION NOT PROVIDED………………………………..466
(E502)……………………………………………………………….467
MODEL SELECTING SIGNAL FAULT………………………………………..467
(A000N1)……………………………………………………………..468
ENGINE SPEED OUT OF RANGE AT HIGH IDLE……………………………….468
(A000N2)……………………………………………………………..469
ENGINE SPEED OUT OF RANGE AT LOW IDLE………………………………..469
(AA10NX)……………………………………………………………..470
AIR CLEANER CLOG INDICATOR FAILURE…………………………………..470
(AB00KE)……………………………………………………………..472
LOW CHARGING VOLTAGE INDICATED………………………………………472
(B@BAZG)……………………………………………………………..474
ABNORMAL ENGINE OIL PRESSURE………………………………………..474
(B@BAZK)……………………………………………………………..476
ABNORMAL ENGINE OIL LEVEL…………………………………………..476
(B@BCNS)……………………………………………………………..478
ENGINE COOLANT INDICATING OVERHEAT CONDITION………………………….478
(B@BCZK)……………………………………………………………..480
ABNORMAL COOLANT LEVEL INDICATION……………………………………480
(B@HANS)……………………………………………………………..482
HYDRAULIC OIL OVERHEAT INDICATION……………………………………482
TROUBLESHOOTING MONITOR ELECTRICAL (E-MODE)………………………………….485
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM……………………………487
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF…………..487
USER CODE MEMORY RETENTION FUNCTION………………………………….487
INFORMATION CONTAINED IN TESTING PROCEDURES………………………………488
(E-1)………………………………………………………………..490
ENGINE WILL NOT CRANK………………………………………………490
(E-2)………………………………………………………………..492
ENGINE STOPS WHILE IN OPERATION……………………………………..492
(E-3)………………………………………………………………..494
ENGINE SPEED IRREGULAR, OR HUNTING…………………………………..494
(E-4)………………………………………………………………..496
ENGINE DOES NOT STOP……………………………………………….496
(E-5)………………………………………………………………..498
AUTO DECELERATOR DOES NOT WORK………………………………………498
(E-6)………………………………………………………………..499
AUTO ENGINE WARM UP DEVICE DOES NOT WORK……………………………..499
(E-7)………………………………………………………………..500
COLD START PREHEATER DOES NOT WORK…………………………………..500
(E-8)………………………………………………………………..502
ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE……………………502
(E-9)………………………………………………………………..504
ONE TOUCH POWER MAX SWITCH DOES NOT OPERATE…………………………..504
(E-10)……………………………………………………………….506
NO DISPLAY ON MONITOR PANEL…………………………………………506
(E-11)……………………………………………………………….508
PART OF DISPLAY ON MONITOR PANEL IS MISSING…………………………..508
(E-12)……………………………………………………………….509
MONITOR PANEL DISPLAYS CONTENTS IRRELEVANT TO THE MODEL………………..509
(E-13)……………………………………………………………….510
FUEL LEVEL INDICATOR LAMP LIGHTS UP WHEN FUEL TANK IS FULL……………..510
(E-14)……………………………………………………………….512
ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE CORRECTLY……………512
(E-15)……………………………………………………………….514
HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY……………..514
(E-16)……………………………………………………………….516
FUEL GAUGE DOES NOT DISPLAY CORRECTLY………………………………..516
(E-17)……………………………………………………………….518
SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY…………………………518
(E-18)……………………………………………………………….520
WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS………………..520
(E-19)……………………………………………………………….522
WINDSHIELD WIPER DOES NOT WORK………………………………………522
GUARD WIPER DOES NOT WORK…………………………………………..523
(E-20)……………………………………………………………….526
ALARM BUZZER CANNOT BE CANCELLED…………………………………….526
(E-21)……………………………………………………………….528
BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR…………………………528
(E-22)……………………………………………………………….530
BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR…………………………530
(E-23)……………………………………………………………….532
ARM EXTEND NOT CORRECTLY DISPLAYED ON MONITOR…………………………532
(E-24)……………………………………………………………….534
ARM RETRACT NOT CORRECTLY DISPLAYED ON MONITOR………………………..534
(E-25)……………………………………………………………….536
BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR………………………..536
(E-26)……………………………………………………………….538
BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR………………………..538
(E-27)……………………………………………………………….540
SWING NOT CORRECTLY DISPLAYED ON MONITOR……………………………..540
(E-28)……………………………………………………………….542
TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR…………………………….542
(E-29)……………………………………………………………….544
TRAVEL DIFFERENTIAL PRESSURE NOT CORRECTLY DISPLAYED ON MONITOR…………544
(E-30)……………………………………………………………….546
SERVICE NOT CORRECTLY DISPLAYED ON MONITOR……………………………546
(E-31)……………………………………………………………….548
AIR CONDITIONER SYSTEM DOES NOT WORK…………………………………548
(E-32)……………………………………………………………….552
TRAVEL ALARM DOES NOT SOUND…………………………………………552
30 DISASSEMBLY AND ASSEMBLY……………………………………………………….555
METHOD OF USING MANUAL………………………………………………………..559
PRECAUTIONS DURING OPERATION…………………………………………………..560
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK…………………………………..560
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK………………………………561
PRECAUTIONS WHEN COMPLETING THE OPERATIONS…………………………………..562
OTHER PRECAUTIONS…………………………………………………………562
SPECIAL TOOL LIST…………………………………………………………….563
SKETCHES OF SPECIAL TOOLS……………………………………………………..567
ENGINE………………………………………………………………………568
ALTERNATOR……………………………………………………………….568
CYLINDER HEAD…………………………………………………………….568
ENGINE FRONT SEAL…………………………………………………………568
ENGINE OIL COOLER…………………………………………………………568
ENGINE REAR SEAL………………………………………………………….568
FUEL INJECTION PUMP……………………………………………………….568
NOZZLE HOLDER…………………………………………………………….568
STARTING MOTOR……………………………………………………………568
THERMOSTAT……………………………………………………………….568
TURBOCHARGER……………………………………………………………..568
WATER PUMP……………………………………………………………….568
RADIATOR…………………………………………………………………….569
REMOVAL………………………………………………………………….569
INSTALLATION……………………………………………………………..570
HYDRAULIC OIL COOLER………………………………………………………….571
REMOVAL………………………………………………………………….571
INSTALLATION……………………………………………………………..572
ENGINE AND HYDRAULIC PUMPS…………………………………………………….573
REMOVAL………………………………………………………………….573
INSTALLATION……………………………………………………………..578
TRAVEL MOTOR AND FINAL DRIVE…………………………………………………..580
REMOVAL………………………………………………………………….580
INSTALLATION……………………………………………………………..580
FINAL DRIVE………………………………………………………………….581
DISASSEMBLY………………………………………………………………581
ASSEMBLY…………………………………………………………………586
REMOVAL………………………………………………………………….591
INSTALLATION……………………………………………………………..592
DISASSEMBLY………………………………………………………………593
ASSEMBLY…………………………………………………………………596
TRACK AND CARRIER ROLLER………………………………………………………602
REMOVAL………………………………………………………………….602
INSTALLATION……………………………………………………………..602
DISASSEMBLY………………………………………………………………603
ASSEMBLY…………………………………………………………………604
IDLER AND RECOIL SPRING……………………………………………………….607
REMOVAL………………………………………………………………….607
INSTALLATION……………………………………………………………..607
IDLER……………………………………………………………………608
DISASSEMBLY………………………………………………………………608
ASSEMBLY…………………………………………………………………609
RECOIL SPRING…………………………………………………………….612
DISASSEMBLY………………………………………………………………612
ASSEMBLY…………………………………………………………………613
TRACK ROLLER…………………………………………………………………614
REMOVAL………………………………………………………………….614
INSTALLATION……………………………………………………………..614
DISASSEMBLY………………………………………………………………615
ASSEMBLY…………………………………………………………………616
SPROCKET…………………………………………………………………….619
REMOVAL………………………………………………………………….619
INSTALLATION……………………………………………………………..619
TRACK SHOE…………………………………………………………………..620
EXPANSION OF TRACK SHOE……………………………………………………620
ASSEMBLY…………………………………………………………………621
SWING CIRCLE…………………………………………………………………622
REMOVAL………………………………………………………………….622
INSTALLATION……………………………………………………………..622
REVOLVING FRAME………………………………………………………………623
REMOVAL………………………………………………………………….623
INSTALLATION……………………………………………………………..625
CENTER SWIVEL JOINT…………………………………………………………..626
REMOVAL………………………………………………………………….626
INSTALLATION……………………………………………………………..627
DISASSEMBLY………………………………………………………………628
ASSEMBLY…………………………………………………………………629
HYDRAULIC TANK……………………………………………………………….630
REMOVAL………………………………………………………………….630
INSTALLATION……………………………………………………………..632
CONTROL VALVE………………………………………………………………..633
REMOVAL………………………………………………………………….633
INSTALLATION……………………………………………………………..636
DISASSEMBLY………………………………………………………………637
ASSEMBLY…………………………………………………………………638
HYDRAULIC PUMP……………………………………………………………….639
REMOVAL………………………………………………………………….639
INSTALLATION……………………………………………………………..641
HYDRAULIC PUMP INPUT SHAFT – OIL SEAL…………………………………………..642
REMOVAL………………………………………………………………….642
INSTALLATION……………………………………………………………..642
PPC VALVE……………………………………………………………………643
WORK EQUIPMENT……………………………………………………………643
ASSEMBLY…………………………………………………………………643
TRAVEL…………………………………………………………………..644
ASSEMBLY…………………………………………………………………644
HYDRAULIC CYLINDER……………………………………………………………645
DISASSEMBLY………………………………………………………………645
ASSEMBLY…………………………………………………………………647
WORK EQUIPMENT……………………………………………………………….651
REMOVAL………………………………………………………………….651
INSTALLATION……………………………………………………………..653
AIR CONDITIONER………………………………………………………………654
REMOVAL………………………………………………………………….654
INSTALLATION……………………………………………………………..657
COUNTERWEIGHT………………………………………………………………..658
REMOVAL………………………………………………………………….658
INSTALLATION……………………………………………………………..658
CAB…………………………………………………………………………659
REMOVAL………………………………………………………………….659
INSTALLATION……………………………………………………………..661
MONITOR……………………………………………………………………..662
REMOVAL………………………………………………………………….662
INSTALLATION……………………………………………………………..662
GOVERNOR PUMP CONTROLLER………………………………………………………663
REMOVAL………………………………………………………………….663
INSTALLATION……………………………………………………………..663
90 OTHERS……………………………………………………………………….665
ELECTRICAL…………………………………………………………………..667
CIRCUIT DIAGRAM SHEET 1 (PART 1 OF 3)……………………………………….667
CIRCUIT DIAGRAM SHEET 1 (PART 2 OF 3)……………………………………….669
CIRCUIT DIAGRAM SHEET 1 (PART 3 OF 3)……………………………………….671
CIRCUIT DIAGRAM SHEET 2 (PART 1 OF 1)……………………………………….673
CIRCUIT DIAGRAM SHEET 3 (PART 1 OF 2)……………………………………….675
CIRCUIT DIAGRAM SHEET 3 (PART 2 OF 2)……………………………………….677
CIRCUIT DIAGRAM SHEET 4 (PART 1 OF 2)……………………………………….679
CIRCUIT DIAGRAM SHEET 4 (PART 2 OF 2)……………………………………….681
HYDRAULIC……………………………………………………………………685
HYDRAULIC DIAGRAM (SHEET 1 OF 4) – FOLDOUT 11………………………………..685
HYDRAULIC DIAGRAM (SHEET 2 OF 4) – FOLDOUT 12………………………………..687
HYDRAULIC DIAGRAM (SHEET 3 OF 4) – FOLDOUT 13………………………………..689