Komatsu Galeo PC300LL-7E0 Logging Road Builder Excavator Shop Manual CEBM017800 – PDF DOWNLOAD

Komatsu Galeo PC300LL-7E0 Logging Road Builder Excavator Shop Manual CEBM017800 – PDF DOWNLOAD

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Komatsu Galeo PC300LL-7E0 Logging Road Builder Excavator Shop Manual CEBM017800 – PDF DOWNLOAD

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Komatsu Galeo PC300LL-7E0 Logging Road Builder Excavator Shop Manual CEBM017800 – PDF DOWNLOAD

SERIAL NUMBERS PC300LL-7E0 A86001 and UP

GENERAL PRECAUTIONS 00
Mistakes in operation are extremely dangerous. Read the OPERATION & 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 operating 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 00
1. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the
machine from moving.
2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert
the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers
and hang warning signs 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 PC300LL-7E0 Logging Road Builder Excavator Shop Manual CEBM017800 – PDF DOWNLOAD

COVER…………………………………………………………………………………….. 1
CONTENTS………………………………………………………………………………….. 3
FOREWORD………………………………………………………………………………….. 2
SAFETY………………………………………………………………………………… 4
SAFETY NOTICE………………………………………………………………………. 4
IMPORTANT SAFETY NOTICE………………………………………………………….. 4
GENERAL PRECAUTIONS……………………………………………………………… 4
PREPARATIONS FOR WORK……………………………………………………………. 4
PRECAUTIONS DURING WORK………………………………………………………….. 5
01 GENERAL………………………………………………………………………………… 6
HOW TO READ THE SHOP MANUAL……………………………………………………………… 9
VOLUMES……………………………………………………………………………. 9
DISTRIBUTION AND UPDATING……………………………………………………………. 9
FILING METHOD………………………………………………………………………. 9
REVISED EDITION MARK………………………………………………………………… 9
REVISIONS………………………………………………………………………….. 9
SYMBOLS……………………………………………………………………………. 10
HOISTING INSTRUCTIONS…………………………………………………………………… 11
HOISTING…………………………………………………………………………… 11
WIRE ROPES…………………………………………………………………………. 11
PUSH PULL COUPLER………………………………………………………………………. 13
TYPE 1…………………………………………………………………………….. 13
DISCONNECTION…………………………………………………………………… 13
CONNECTION……………………………………………………………………… 13
TYPE 2…………………………………………………………………………….. 14
DISCONNECTION…………………………………………………………………… 14
CONNECTION……………………………………………………………………… 14
TYPE 3…………………………………………………………………………….. 15
DISCONNECTION…………………………………………………………………… 15
CONNECTION……………………………………………………………………… 15
EXPLANATION OF MAINTENANCE STANDARD TERMS…………………………………………………. 16
STANDARD TIGHTENING TORQUE………………………………………………………………. 18
BOLTS AND NUTS……………………………………………………………………… 18
TIGHTENING TORQUE OF HOSE NUTS……………………………………………………….. 19
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS……………………………………………….. 19
TIGHTENING TORQUE FOR FLARED NUTS…………………………………………………….. 19
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS……………………………………….. 20
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS………………………………………. 20
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)……………………………… 20
ELECTRIC WIRE CODE……………………………………………………………………… 8
CLASSIFICATION BY THICKNESS………………………………………………………….. 8
CLASSIFICATION BY COLOR AND CODE……………………………………………………… 8
HOW TO READ ELECTRIC WIRE CODE……………………………………………………….. 21
CONVERSION TABLES………………………………………………………………………. 24
METHOD OF USING THE CONVERSION TABLE………………………………………………….. 24
COATING MATERIALS………………………………………………………………………. 30
SPECIFICATIONS…………………………………………………………………………. 32
DIMENSIONS…………………………………………………………………………. 32
ROAD BUILDER……………………………………………………………………. 32
LOG LOADER – 42 FT KOMATSU FOREST FRONT……………………………………………. 32
WORKING RANGES……………………………………………………………………… 34
ROAD BUILDER……………………………………………………………………. 34
LOG LOADER – 42 FT KOMATSU FOREST FRONT……………………………………………. 36
WEIGHT TABLE…………………………………………………………………………… 41
FUEL, COOLANT, AND LUBRICANTS……………………………………………………………. 43
10 STRUCTURE AND FUNCTION…………………………………………………………………… 45
ENGINE RELATED PARTS……………………………………………………………………. 48
RADIATOR . OIL COOLER . AFTERCOOLER………………………………………………………. 49
POWER TRAIN……………………………………………………………………………. 50
FINAL DRIVE……………………………………………………………………………. 51
SPROCKET………………………………………………………………………………. 55
SPROCKET TOOL………………………………………………………………………. 56
SWING MACHINERY………………………………………………………………………… 57
SWING CIRCLE……………………………………………………………………….. 61
TRACK FRAME . RECOIL SPRING……………………………………………………………… 62
IDLER…………………………………………………………………………………. 64
TRACK ROLLER/CARRIER ROLLER……………………………………………………………… 66
TRACK SHOE…………………………………………………………………………….. 68
TRIPLE GROUSER SHOE…………………………………………………………………….. 71
DOUBLE GROUSER SHOE…………………………………………………………………….. 72
HYDRAULIC EQUIPMENT…………………………………………………………………….. 73
HYDRAULIC TANK AND FILTER……………………………………………………………….. 75
HYDRAULIC PUMP…………………………………………………………………………. 76
HPV125 + 125……………………………………………………………………….. 76
LS VALVE…………………………………………………………………………… 82
PC VALVE…………………………………………………………………………… 87
LS(PC)-EPC VALVE……………………………………………………………………. 94
VARIABLE VOLUME VALVE……………………………………………………………….. 98
CONTROL VALVE…………………………………………………………………………..100
CLSS…………………………………………………………………………………..112
VALVE FUNCTIONS AND OPERATION…………………………………………………………….116
UNLOADER VALVE………………………………………………………………………….118
INTRODUCTION OF LS PRESSURE………………………………………………………………120
LS BYPASS VALVE…………………………………………………………………………121
PRESSURE COMPENSATION VALVE………………………………………………………………122
PRESSURE COMPENSATION VALVE INNER SHUTTLE………………………………………………125
BOOM REGENERATION CIRCUIT…………………………………………………………….127
ARM REGENERATION CIRCUIT……………………………………………………………..129
MERGE-DIVIDER VALVE……………………………………………………………………..131
LS SELECT VALVE…………………………………………………………………………133
SELF PRESSURE REDUCING VALVE……………………………………………………………..134
TRAVEL JUNCTION VALVE……………………………………………………………………137
TRAVEL PPC SHUTTLE VALVE…………………………………………………………………139
BOOM DRIFT PREVENTION VALVE………………………………………………………………141
ARM DRIFT PREVENTION VALVE……………………………………………………………….144
QUICK RETURN VALVE………………………………………………………………………148
LIFT CHECK VALVE………………………………………………………………………..150
MAIN RELIEF VALVE……………………………………………………………………….151
2-STAGE SAFETY-SUCTION VALVE……………………………………………………………..152
VARIABLE PRESSURE COMPENSATION VALVE………………………………………………………154
CONTROL VALVE…………………………………………………………………………..156
PPC VALVE………………………………………………………………………………157
WORK EQUIPMENT AND SWING PPC VALVE…………………………………………………….157
TRAVEL PPC VALVE…………………………………………………………………….163
PRESSURE REDUCING VALVE………………………………………………………………….166
STRAIGHT TRAVEL PPC VALVE…………………………………………………………….172
PPC ACCUMULATOR……………………………………………………………………..174
SOLENOID VALVE………………………………………………………………………….175
ATTACHMENT SOLENOID VALVE………………………………………………………………..176
CENTER SWIVEL JOINT……………………………………………………………………..178
TRAVEL MOTOR……………………………………………………………………………179
TYPE: KMV200ADT-2……………………………………………………………………179
OPERATION OF MOTOR…………………………………………………………………..182
PARKING BRAKE…………………………………………………………………………..184
BRAKE VALVE OPERATION………………………………………………………………..186
SAFETY VALVE……………………………………………………………………………188
SWING MOTOR…………………………………………………………………………….191
TYPE: KMF230ABE-5……………………………………………………………………191
SWING HOLDING BRAKE………………………………………………………………….194
RELIEF VALVE PORTION…………………………………………………………………195
REVERSE PREVENTION VALVE…………………………………………………………………196
EXPLANATORY DRAWING OF EFFECTS………………………………………………………..197
HYDRAULIC CYLINDERS – EXCAVATOR WORK EQUIPMENT……………………………………………..200
BOOM CYLINDER……………………………………………………………………….200
ARM CYLINDER………………………………………………………………………..200
BUCKET CYLINDER……………………………………………………………………..201
WORK EQUIPMENT PIVOT POINT MEASUREMENTS……………………………………………………202
BOSS BUSHING/PINS – EXCAVATOR WORK EQUIPMENT……………………………………………202
DIMENSION OF ARM – EXCAVATOR WORK EQUIPMENT…………………………………………….204
DIMENSION OF BUCKET………………………………………………………………….206
CAB AND ATTACHMENTS……………………………………………………………………..208
AIR CONDITIONER PIPING……………………………………………………………….208
ELECTRICAL SYSTEM……………………………………………………………………….209
ENGINE CONTROL………………………………………………………………………209
ELECTRONIC COMPONENTS……………………………………………………………………211
FUEL CONTROL DIAL……………………………………………………………………211
ENGINE CONTROLLER……………………………………………………………………212
COOLANT TEMPERATURE SENSOR……………………………………………………………216
OIL PRESSURE SWITCH………………………………………………………………….216
ENGINE SPEED SENSOR………………………………………………………………….217
BOOST PRESSURE AND TEMPERATURE SENSOR………………………………………………….217
WIF (WATER-IN-FUEL DETECTION) SENSOR…………………………………………………..218
ENGINE OIL LEVEL SENSOR………………………………………………………………218
ELECTRONIC CONTROL SYSTEM………………………………………………………………..219
CONTROL FUNCTION…………………………………………………………………….219
SYSTEM DIAGRAM…………………………………………………………………..220
ENGINE AND PUMP CONTROL FUNCTION………………………………………………………222
PUMP AND VALVE CONTROL……………………………………………………………….226
LS CONTROL FUNCTION………………………………………………………………227
CUT-OFF FUNCTION…………………………………………………………………227
2-STAGE RELIEF FUNCTION…………………………………………………………..227
POWER MAXIMIZING AND MACHINE PUSH-UP…………………………………………………..228
AUTO-DECELERATION……………………………………………………………………230
AUTO-WARM-UP AND OVERHEAT PREVENTION…………………………………………………..231
SWING CONTROL……………………………………………………………………….233
TRAVEL CONTROL………………………………………………………………………235
ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR (IF EQUIPPED)……………………………….237
SYSTEM COMPONENTS……………………………………………………………………….238
PPC OIL PRESSURE SWITCH………………………………………………………………238
OIL PRESSURE SENSOR………………………………………………………………….239
PUMP PRESSURE SENSOR (HIGH PRESSURE)…………………………………………………..240
PUMP CONTROLLER……………………………………………………………………..241
MONITOR SYSTEM………………………………………………………………………….245
MACHINE MONITOR……………………………………………………………………..246
MONITOR CONTROL AND DISPLAY………………………………………………………………249
MONITOR…………………………………………………………………………….249
DISPLAY…………………………………………………………………………….250
SWITCHES……………………………………………………………………………….254
BRIGHTNESS, CONTRAST ADJUSTMENT……………………………………………………….262
SERVICE METER CHECK FUNCTION………………………………………………………….263
DISPLAY LCD CHECK FUNCTION……………………………………………………………263
USER CODE DISPLAY FUNCTION……………………………………………………………264
SENSOR…………………………………………………………………………………266
HYDRAULIC OIL LEVEL SENSOR……………………………………………………………266
HYDRAULIC OIL AND COOLANT TEMPERATURE SENSOR……………………………………………266
FUEL LEVEL SENSOR……………………………………………………………………267
AIR CLEANER CLOGGING SENSOR…………………………………………………………..268
KOMTRAX TERMINAL SYSTEM………………………………………………………………….269
KOMTRAX TERMINAL…………………………………………………………………….270
20 TESTING, ADJUSTING ANDTROUBLESHOOTING………………………………………………………273
TESTING AND ADJUSTING……………………………………………………………………274
STANDARD VALUE TABLES………………………………………………………………..277
ENGINE RELATED…………………………………………………………………..277
CHASSIS RELATED………………………………………………………………….278
SERVICE TOOLS……………………………………………………………………….286
ENGINE SERVICE TOOLS……………………………………………………………..286
CHASSIS SERVICE TOOLS…………………………………………………………….287
ENGINE……………………………………………………………………………..288
AIR BOOST PRESSURE……………………………………………………………….288
AIR COMPRESSOR BELT TENSION……………………………………………………….288
BLOW-BY PRESSURE…………………………………………………………………288
COMPRESSION PRESSURE……………………………………………………………..288
ENGINE OIL PRESSURE………………………………………………………………288
ENGINE SPEED…………………………………………………………………….288
EXHAUST GAS COLOR………………………………………………………………..288
FUEL CIRCUIT FOR LEAKAGE………………………………………………………….288
FUEL CIRCUIT FOR BLEEDING AIR……………………………………………………..288
FUEL PRESSURE……………………………………………………………………288
FUEL RETURN RATE…………………………………………………………………288
FUEL INJECTION TIMING…………………………………………………………….288
VALVE CLEARANCE………………………………………………………………….288
ENGINE FUNCTIONS…………………………………………………………………….289
MEASURE ENGINE SPEED WITH MACHINE MONITOR…………………………………………..289
PREPARATION………………………………………………………………….289
MEASURING LOW IDLE SPEED………………………………………………………289
MEASURING HIGH IDLE SPEED……………………………………………………..289
MEASURING THE ENGINE SPEED WHEN 2-PUMPS ARE RELIEVED……………………………..289
MEASURING THE ENGINE SPEED AT 2-PUMP RELIEF AND POWER MAXIMIZING (NEAR RATED SPEED)….289
MEASURING THE SPEED WHEN AUTO-DECELERATION SPEED IS IN OPERATION…………………..289
CYLINDER CUT-OUT OPERATION………………………………………………………..290
NO INJECTION CRANKING OPERATION……………………………………………………290
REFRIGERANT COMPRESSOR BELT…………………………………………………………..291
INSPECTION………………………………………………………………………291
ADJUSTMENT………………………………………………………………………291
SWING CIRCLE BEARING CLEARANCE………………………………………………………..292
TRACK SHOE TENSION…………………………………………………………………..293
INSPECTION………………………………………………………………………293
ADJUSTMENT………………………………………………………………………293
OIL PRESSURE IN WORK EQUIPMENT………………………………………………………..294
OIL PRESSURE IN SWING………………………………………………………………..294
OIL PRESSURE IN TRAVEL CIRCUIT………………………………………………………..294
MEASURING……………………………………………………………………….294
ADJUSTING……………………………………………………………………….296
CONTROL CIRCUIT OIL PRESSURE………………………………………………………….299
MEASURING……………………………………………………………………….299
PUMP PC CONTROL CIRCUIT OIL PRESSURE…………………………………………………..300
MEASURING……………………………………………………………………….300
ADJUSTING……………………………………………………………………….302
PUMP LS CONTROL CIRCUIT OIL PRESSURE…………………………………………………..303
MEASURING……………………………………………………………………….303
ADJUSTING……………………………………………………………………….307
SOLENOID VALVE OUTPUT PRESSURE………………………………………………………..308
ATTACHMENT SOLENOID VALVE OUTPUT………………………………………………………311
PPC VALVE OUTPUT…………………………………………………………………….313
ATTACHMENT PPC VALVE OUTPUT…………………………………………………………..314
WORK EQUIPMENT AND SWING PPC VALVES……………………………………………………315
HYDRAULIC DRIFT IN WORK EQUIPMENT……………………………………………………..316
BOOM AND BUCKET CYLINDERS INSPECTION……………………………………………….316
ARM CYLINDER INSPECTION…………………………………………………………..316
BOOM LOCK VALVE INSPECTION………………………………………………………..317
PPC VALVE INSPECTION……………………………………………………………..317
RELEASE REMAINING PRESSURE IN HYDRAULIC CIRCUIT…………………………………………318
OIL LEAKAGE AMOUNT……………………………………………………………….318
BLEEDING AIR FROM VARIOUS SYSTEMS……………………………………………………..321
DIODE INSPECTION PROCEDURES…………………………………………………………..323
MACHINE MONITOR – SPECIAL FUNCTIONS……………………………………………………324
ORDINARY AND SPECIAL FUNCTIONS…………………………………………………….325
OPERATORS MENU AND DISPLAY (OUTLINE)……………………………………………….326
SERVICE MENU OPERATION AND DISPLAY…………………………………………………….334
SWITCHING TO SERVICE MENU…………………………………………………………334
MONITORING [01] FUNCTION………………………………………………………….335
FUNCTION OF ABNORMALITY RECORD [02]………………………………………………..340
FUNCTION OF MAINTENANCE RECORD [03]………………………………………………..342
FUNCTION OF MAINTENANCE MODE CHANGE [04]……………………………………………343
FUNCTION OF PHONE NUMBER ENTRY [05]………………………………………………..345
FUNCTION OF DEFAULT [06]………………………………………………………….346
FUNCTION OF ADJUSTMENT [07]……………………………………………………….348
FUNCTION OF CYLINDER CUT OUT OPERATION [08]…………………………………………349
FUNCTION OF NO INJECTION CRANKING [09]……………………………………………..351
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…………………………………………..353
PROCEDURE FOR TURNING ON KOMTRAX TERMINAL………………………………………………354
KOMTRAX TERMINAL LAMP INDICATIONS……………………………………………………..357
TROUBLESHOOTING ELECTRICAL SYSTEM……………………………………………………..360
PM-CLINIC INSPECTION TABLE……………………………………………………………363
TROUBLESHOOTING (GENERAL)………………………………………………………………..369
POINTS TO REMEMBER WHEN TROUBLESHOOTING………………………………………………..370
SEQUENCE OF EVENTS IN TROUBLESHOOTING………………………………………………….372
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE………………………………………………373
PRECAUTIONS WHEN HANDLING ELECTRICAL EQUIPMENT………………………………………373
HANDLING ELECTRONIC CONTROL UNIT…………………………………………………..378
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRICAL CIRCUITS…………………………..379
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…………………………………381
CATEGORIES AND METHOD OF USING TROUBLESHOOTING CHARTS………………………………..384
TROUBLESHOOTING INDIVIDUAL ELECTRICAL CIRCUITS………………………………………385
TROUBLESHOOTING INDIVIDUAL HYDRAULIC CIRCUITS……………………………………….387
POSSIBLE PROBLEMS WHEN TROUBLESHOOTING A MODE…………………………………………..389
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS……………………………………………..392
T-ADAPTER TABLE……………………………………………………………………..414
TROUBLESHOOTING OF ELECTRICALSYSTEM (E-MODE)……………………………………………….417
CONNECTOR TYPES AND LOCATIONS…………………………………………………………420
CONNECTOR LAYOUT DRAWINGS…………………………………………………………….426
TROUBLESHOOTING BY FAILURE CODE……………………………………………………….432
BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED…………………….435
LOCATION OF FUSE BOX AND FUSE NUMBERS………………………………………………436
INFORMATION CONTAINED IN TESTING PROCEDURES…………………………………………….438
A000N1 – ENGINE OVER SPEED……………………………………………………………441
AA10NX – AIR CLEANER CLOG SENSOR SYSTEM………………………………………………..442
AB00KE – CHARGE VOLTAGE IS LOW………………………………………………………..444
B@BAZG – ENGINE OIL PRESSURE DROP……………………………………………………..446
B@BAZK – ENGINE OIL LEVEL DROP………………………………………………………..448
B@BCNS – COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT (NS)……………………………450
B@BCZK – ENGINE COOLANT LEVEL DROP…………………………………………………….452
B@HANS – HYDRAULIC OIL OVERHEAT CONDITION………………………………………………453
CA111 – CRITICAL INTERNAL FAILURE……………………………………………………..454
CA115 – ENGINE NE AND BACKUP SPEED SENSOR ERROR…………………………………………455
CA122 – CHARGE AIR PRESSURE SENSOR HIGH ERROR…………………………………………..456
CA123 – CHARGE AIR PRESSURE SENSOR LOW ERROR……………………………………………458
CA131 – THROTTLE SENSOR HIGH ERROR…………………………………………………….460
CA132 – THROTTLE SENSOR LOW ERROR……………………………………………………..461
CA144 – COOLANT TEMPERATURE (HIGH) SENSOR OUT OF RANGE (KX)………………………………462
CA145 – COOLANT TEMPERATURE (LOW) SENSOR OUT OF RANGE (KX)……………………………….464
CA153 – CHARGE AIR PRESSURE SENSOR HIGH ERROR…………………………………………..466
CA154 – CHARGE AIR PRESSURE SENSOR LOW ERROR……………………………………………468
CA187 – SENSOR SUPPLY 2 VOLT LOW ERROR…………………………………………………470
CA221 – AMBIENT PRESSURE SENSOR HIGH ERROR……………………………………………..472
CA222 – AMBIENT PRESSURE SENSOR LOW ERROR………………………………………………474
CA227 – SENSOR SUPPLY 2 VOLT HIGH ERROR………………………………………………..476
CA234 – ENGINE OVER SPEED…………………………………………………………….478
CA238 – SPEED SENSOR SUPPLY VOLT ERROR…………………………………………………479
CA271 – UMV/PCV1 SHORT ERROR………………………………………………………….480
CA272 – UMV/PCV1 OPEN ERROR…………………………………………………………..481
CA322 – OPEN IN NO. 1 INJECTOR SOLENOID VALVE…………………………………………..482
CA323 – OPEN IN NO. 5 INJECTOR SOLENOID VALVE…………………………………………..484
CA324 – OPEN IN NO. 3 INJECTOR SOLENOID VALVE…………………………………………..486
CA325 – OPEN IN NO. 6 INJECTOR SOLENOID VALVE…………………………………………..488
CA331 – OPEN IN NO. 2 INJECTOR SOLENOID VALVE…………………………………………..490
CA332 – OPEN IN NO. 4 INJECTOR SOLENOID VALVE…………………………………………..492
CA342 – CALIBRATION CODE INCOMPATIBILITY……………………………………………….494
CA351 – INJECTOR DRIVE CIRCUIT ERROR…………………………………………………..496
CA352 – AMBIENT PRESSURE SENSOR 1 VOLT LOW ERROR………………………………………..498
CA386 – AMBIENT PRESSURE SENSOR 1 VOLT HIGH ERROR……………………………………….500
CA428 – WATER IN FUEL SENSOR HIGH ERROR………………………………………………..502
CA429 – WATER IN FUEL SENSOR LOW ERROR…………………………………………………504
CA441 – BATTERY VOLTAGE LOW ERROR……………………………………………………..506
CA442 – BATTERY VOLTAGE HIGH ERROR…………………………………………………….508
CA449 – RAIL PRESSURE VERY HIGH……………………………………………………….510
CA451 – RAIL PRESSURE SENSOR HIGH ERROR………………………………………………..514
CA452 – RAIL PRESSURE SENSOR LOW ERROR…………………………………………………516
CA553 – RAIL PRESSURE ERROR…………………………………………………………..518
CA559 – RAIL PRESSURE VERY LOW………………………………………………………..520
CA689 – ENGINE NE SPEED SENSOR ERROR…………………………………………………..522
CA731 – ENGINE BACK-UP SPEED SENSOR PHASE ERROR…………………………………………524
CA757 – PERSISTENT DATA LOSS ERROR…………………………………………………….526
CA778 – ENGINE BKUP SPEED SENSOR ERROR…………………………………………………528
CA1633 – (KOMNET) DATALINK HAS TIME-OUT ERROR…………………………………………..530
CA2185 – THROTTLE SENSOR HIGH ERROR……………………………………………………532
CA2186 – THROTTLE SENSOR LOW ERROR…………………………………………………….533
CA2249 – RAIL PRESSURE VERY LOW……………………………………………………….534
CA2265 – ELECTRIC LIFT PUMP HIGH ERROR…………………………………………………536
CA2266 – ELECTRIC LIFT PUMP LOW ERROR………………………………………………….537
CA2556 – GRID HEATER RELAY VOLT LOW ERROR………………………………………………538
CA2555 – GRID HEATER RELAY VOLT HIGH ERROR……………………………………………..540
D110KB – BATTERY RELAY DRIVE S/C………………………………………………………542
D196KA – SERVICE RETURN RELAY ERROR……………………………………………………544
D196KB – SERVICE RETURN RELAY ERROR……………………………………………………546
DA25KP – SENSOR POWER ERROR…………………………………………………………..548
DA2RMC – PUMP COMMUNICATION ERROR……………………………………………………..550
DA2SKQ – MODEL SELECTION ERROR………………………………………………………..552
DAFRMC – MONITOR COMMUNICATION ERROR…………………………………………………..554
DHPAMA – F PUMP PRESSURE SENSOR ERROR………………………………………………….556
DHPBMA – R PUMP PRESSURE SENSOR ERROR………………………………………………….558
DHS3MA – ARM CURL PRESSURE SENSOR ERROR………………………………………………..560
DHS4MA – CURL PPC PRESSURE SENSOR ERROR………………………………………………..562
DW43KA – TRAVEL SPEED SOLENOID ERROR…………………………………………………..564
DW43KB – TRAVEL SPEED SOLENOID ERROR…………………………………………………..566
DW45KA – SWING BRAKE SOLENOID ERROR……………………………………………………568
DW45KB – SWING BRAKE SOLENOID ERROR……………………………………………………571
DW91KA – TRAVEL JUNCTION SOLENOID ERROR………………………………………………..574
DW91KB – TRAVEL JUNCTION SOLENOID ERROR………………………………………………..576
DWJ0KA – MERGE-DIVIDER SOLENOID ERROR………………………………………………….578
DWJ0KB – MERGE-DIVIDER SOLENOID ERROR………………………………………………….580
DWK0KA – 2-STAGE RELIEF SOLENOID ERROR…………………………………………………582
DWK0KB – 2-STAGE RELIEF SOLENOID ERROR…………………………………………………584
DXA0KA – PC-EPC SOLENOID ERROR………………………………………………………..586
DXA0KB – PC-EPC SOLENOID ERROR………………………………………………………..588
DXE0KA – LS-EPC SOLENOID ERROR………………………………………………………..590
DXE0KB – LS-EPC SOLENOID ERROR………………………………………………………..592
DXE4KA – SERVICE CURRENT EPC ERROR…………………………………………………….594
DXE4KB – SERVICE CURRENT EPC ERROR…………………………………………………….596
DY20KA – WINDSHIELD WIPER MOTOR DRIVE ERROR…………………………………………….598
DY20MA – WINDSHIELD WIPER MOTOR DRIVE ERROR…………………………………………….600
DY2CKB – WINDSHIELD WASHER DRIVE ERROR…………………………………………………602
DY2DKB – WINDSHIELD WIPER DRIVE ERROR………………………………………………….604
DY2EKB – WINDSHIELD WIPER DRIVE ERROR………………………………………………….606
E-1 – ENGINE WILL NOT CRANK…………………………………………………………..608
E-2 – AUTO DECELERATOR DOES NOT WORK…………………………………………………..610
E-3 – AUTO ENGINE WARM UP DEVICE DOES NOT WORK………………………………………….611
E-4 – COLD START PRE-HEATER DOES NOT WORK………………………………………………612
E-5 – ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT OPERATE………………………………..614
E-6 – POWER MAXIMIZING FUNCTION DOES NOT OPERATE………………………………………..616
E-7 – MACHINE MONITOR DOES NOT OPERATE…………………………………………………618
E-8 – MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS……………………………………….620
E-9 – MACHINE MONITOR DOES NOT DISPLAY ITEMS CORRECTLY…………………………………..621
E-10 – MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING………………………622
E-11 – COOLANT HIGH TEMPERATURE SENSOR SHOWING OVERHEAT………………………………….624
E-12 – HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT DISPLAY CORRECTLY…………………………626
E-13 – MONITOR FUEL LEVEL WAS INDICATING RED WHILE ENGINE IS RUNNING………………………628
E-14 – SWING LOCK MONITOR DOES NOT DISPLAY CORRECTLY…………………………………….630
E-15 – WHEN THE MONITOR SWITCH IS OPERATED, NO DISPLAY APPEARS……………………………632
E-16 – WINDSHIELD WIPER AND WASHER DO NOT OPERATE……………………………………….634
WINDSHIELD WASHER DRIVE ERROR……………………………………………………..636
E-17 – MACHINE PUSH-UP FUNCTION DOES NOT OPERATE………………………………………..638
E-18 – BOOM RAISE NOT CORRECTLY DISPLAYED ON MONITOR…………………………………….640
E-19 – BOOM LOWER NOT CORRECTLY DISPLAYED ON MONITOR…………………………………….642
E-20 – ARM IN NOT CORRECTLY DISPLAYED ON MONITOR………………………………………..644
E-21 – ARM OUT NOT CORRECTLY DISPLAYED ON MONITOR……………………………………….646
E-22 – BUCKET CURL NOT CORRECTLY DISPLAYED ON MONITOR……………………………………648
E-23 – BUCKET DUMP NOT CORRECTLY DISPLAYED ON MONITOR……………………………………650
E-24 – SWING NOT CORRECTLY DISPLAYED ON MONITOR…………………………………………652
E-25 – TRAVEL NOT CORRECTLY DISPLAYED ON MONITOR………………………………………..654
E-26 – TRAVEL DIFFERENTIAL NOT CORRECTLY DISPLAYED ON MONITOR…………………………….656
E-27 – SERVICE NOT CORRECTLY DISPLAYED ON MONITOR……………………………………….658
E-28 – KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…………………………………………660
E-29 – AIR CONDITIONER SYSTEM DOES NOT WORK…………………………………………….662
E-30 – TRAVEL ALARM DOES NOT SOUND…………………………………………………….664
E-31 – HORN DOES NOT SOUND……………………………………………………………666
TROUBLESHOOTING HYDRAULIC ANDMECHANICAL SYSTEM (H-MODE)……………………………………..669
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS……………………………………….670
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE………………………………………….672
H-1 – WORK EQUIPMENT, TRAVEL AND SWING SPEEDS ARE SLOW…………………………………..673
H-2 – ENGINE SPEED DROPS SHARPLY OR ENGINE STALLS……………………………………….674
H-3 – NO WORK EQUIPMENT, TRAVEL OR SWING MOVEMENT……………………………………….675
H-4 – ABNORMAL NOISE IS HEARD FROM HYDRAULIC PUMP……………………………………….675
H-5 – AUTO-DECELERATOR DOES NOT WORK…………………………………………………..676
H-6 – FINE CONTROL MODE DOES NOT FUNCTION………………………………………………676
H-7 – BOOM MOVES SLOWLY OR LACKS POWER…………………………………………………677
H-8 – WORK EQUIPMENT MOVES SLOWLY OR LACKS POWER………………………………………..678
H-9 – BUCKET MOVES SLOWLY OR LACKS POWER……………………………………………….679
H-10 – WORK EQUIPMENT DOES NOT MOVE IN A INDEPENDENT OPERATION……………………………679
H-11 – WORK EQUIPMENT HAS EXCESSIVE HYDRAULIC DRIFT……………………………………..680
H-12 – WORK EQUIPMENT HAS EXCESSIVE LAG TIME……………………………………………681
H-13 – OTHER WORK EQUIPMENT MOVES WHEN RELIEVING A SINGLE CIRCUIT…………………………681
H-14 – ONE-TOUCH POWER MAX. SWITCH DOES NOT OPERATE……………………………………..682
H-15 – IN A COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOADS MOVES SLOWLY………………682
H-16 – IN SWING AND BOOM RAISE OPERATION, BOOM MOVES SLOWLY………………………………682
H-17 – IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY…………………………………….683
H-18 – MACHINE SWERVES WHEN TRAVELING………………………………………………….684
H-19 – MACHINE TRAVELS SLOWLY…………………………………………………………685
H-20 – MACHINE CANNOT BE STEERED EASILY OR LACKS POWER…………………………………..686
H-21 – TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FAST DURING SHIFTING………………687
H-22 – TRACK SHOES DO NOT TURN (ON ONE SIDE ONLY)……………………………………….687
H-23 – MACHINE DOES NOT SWING…………………………………………………………688
H-25 – EXCESSIVE OVERRUN WHEN STOPPING SWING……………………………………………690
H-24 – SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW………………………………..689
H-26 – THERE IS A SUDDEN SHOCK WHEN STOPPING SWING………………………………………691
H-27 – ABNORMAL NOISE CAUSED WHEN STOPPING SWING………………………………………..691
H-28 – SWING NATURAL DRIFT IS EXCESSIVE………………………………………………..692
30 DISASSEMBLY AND ASSEMBLY………………………………………………………………….693
ENGINE COMPONENTS……………………………………………………………………….696
CYLINDER HEAD……………………………………………………………………….696
ENGINE FRONT SEAL……………………………………………………………………696
ENGINE REAR SEAL…………………………………………………………………….696
FUEL SUPPLY PUMP…………………………………………………………………….696
VALVES……………………………………………………………………………..696
SPECIAL TOOLS LIST…………………………………………………………………..697
CONNECTOR REPAIR PROCEDURES………………………………………………………………700
CONTACT TERMINAL REMOVAL (HD30 TYPE)…………………………………………………..700
STRIPPING INSULATION…………………………………………………………………701
CRIMPING CONTACT TERMINAL (HD30 TYPE)………………………………………………….702
INSERTION OF CONTACT TERMINAL (HD30 TYPE)………………………………………………703
CONTACT TERMINAL REMOVAL (DT TYPE)…………………………………………………….704
STRIPPING INSULATION…………………………………………………………………705
CRIMPING CONTACT TERMINAL (DT TYPE)……………………………………………………706
INSERTION OF CONTACT TERMINAL (DT TYPE)………………………………………………..707
ENGINE AND COOLING SYSTEM………………………………………………………………..708
RADIATOR ASSEMBLY……………………………………………………………………708
REMOVAL…………………………………………………………………………708
INSTALLATION…………………………………………………………………….709
HYDRAULIC OIL COOLER ASSEMBLY…………………………………………………………710
REMOVAL…………………………………………………………………………710
INSTALLATION…………………………………………………………………….711
AFTERCOOLER ASSEMBLY…………………………………………………………………712
REMOVAL…………………………………………………………………………712
INSTALLATION…………………………………………………………………….712
ENGINE AND HYDRAULIC PUMP ASSEMBLY…………………………………………………….713
REMOVAL…………………………………………………………………………713
INSTALLATION…………………………………………………………………….717
POWER TRAIN…………………………………………………………………………….719
FINAL DRIVE ASSEMBLY…………………………………………………………………719
REMOVAL…………………………………………………………………………719
INSTALLATION…………………………………………………………………….720
DISASSEMBLY……………………………………………………………………..720
ASSEMBLY………………………………………………………………………..725
SWING MOTOR AND SWING MACHINERY ASSEMBLY……………………………………………….731
REMOVAL…………………………………………………………………………731
INSTALLATION…………………………………………………………………….732
DISASSEMBLY……………………………………………………………………..733
ASSEMBLY………………………………………………………………………..736
SWING CIRCLE ASSEMBLY………………………………………………………………..742
REMOVAL…………………………………………………………………………742
INSTALLATION…………………………………………………………………….742
UNDERCARRIAGE AND FRAME………………………………………………………………….743
TRACK ROLLER ASSEMBLY AND CARRIER ROLLER ASSEMBLY……………………………………….743
DISASSEMBLY……………………………………………………………………..743
ASSEMBLY………………………………………………………………………..743
IDLER ASSEMBLY………………………………………………………………………745
DISASSEMBLY……………………………………………………………………..745
ASSEMBLY………………………………………………………………………..746
RECOIL SPRING……………………………………………………………………….749
DISASSEMBLY……………………………………………………………………..749
ASSEMBLY………………………………………………………………………..750
SPROCKET……………………………………………………………………………752
REMOVAL…………………………………………………………………………752
INSTALLATION…………………………………………………………………….752
TRACK SHOE ASSEMBLY………………………………………………………………….753
EXPANSION OF TRACK SHOE…………………………………………………………..753
INSTALLATION OF TRACK SHOE………………………………………………………..754
REVOLVING FRAME ASSEMBLY……………………………………………………………..755
REMOVAL…………………………………………………………………………755
INSTALLATION…………………………………………………………………….757
COUNTERWEIGHT ASSEMBLY……………………………………………………………….758
REMOVAL…………………………………………………………………………758
INSTALLATION…………………………………………………………………….758
HYDRAULIC SYSTEM………………………………………………………………………..759
CENTER SWIVEL JOINT ASSEMBLY………………………………………………………….759
REMOVAL…………………………………………………………………………759
INSTALLATION…………………………………………………………………….760
DISASSEMBLY……………………………………………………………………..761
ASSEMBLY………………………………………………………………………..761
HYDRAULIC TANK ASSEMBLY………………………………………………………………762
REMOVAL…………………………………………………………………………762
INSTALLATION…………………………………………………………………….764
CONTROL VALVE ASSEMBLY……………………………………………………………….765
REMOVAL…………………………………………………………………………765
INSTALLATION…………………………………………………………………….768
ASSEMBLY………………………………………………………………………..770
MAIN RELIEF VALVE ASSEMBLY………………………………………………………..771
HYDRAULIC PUMP ASSEMBLY………………………………………………………………772
REMOVAL…………………………………………………………………………772
INSTALLATION…………………………………………………………………….774
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT…………………………………………………775
REMOVAL…………………………………………………………………………775
INSTALLATION…………………………………………………………………….775
WORK EQUIPMENT PPC VALVE ASSEMBLY……………………………………………………..776
DISASSEMBLY……………………………………………………………………..776
ASSEMBLY………………………………………………………………………..776
TRAVEL PPC VALVE ASSEMBLY…………………………………………………………….777
DISASSEMBLY……………………………………………………………………..777
ASSEMBLY………………………………………………………………………..777
HYDRAULIC CYLINDER ASSEMBLY…………………………………………………………..778
DISASSEMBLY……………………………………………………………………..778
ASSEMBLY………………………………………………………………………..780
WORK EQUIPMENT………………………………………………………………………….784
WORK EQUIPMENT ASSEMBLY………………………………………………………………784
REMOVAL…………………………………………………………………………784
INSTALLATION…………………………………………………………………….785
CAB AND ITS ATTACHMENTS………………………………………………………………….787
OPERATOR’S CAB ASSEMBLY………………………………………………………………787
REMOVAL…………………………………………………………………………787
INSTALLATION…………………………………………………………………….789
OPERATOR’S CAB GLASS (STUCK GLASS)…………………………………………………….790
REMOVAL…………………………………………………………………………791
INSTALLATION…………………………………………………………………….792
FRONT WINDOW ASSEMBLY………………………………………………………………..801
REMOVAL…………………………………………………………………………801
INSTALLATION…………………………………………………………………….804
ELECTRICAL SYSTEM……………………………………………………………………….809
WORK EQUIPMENT ASSEMBLY………………………………………………………………809
REMOVAL…………………………………………………………………………809
INSTALLATION…………………………………………………………………….810
MACHINE MONITOR……………………………………………………………………..811
REMOVAL…………………………………………………………………………811
INSTALLATION…………………………………………………………………….811
PUMP CONTROLLER……………………………………………………………………..812
REMOVAL…………………………………………………………………………812
INSTALLATION…………………………………………………………………….812
KOMTRAX TERMINAL…………………………………………………………………….813
REMOVAL…………………………………………………………………………813
INSTALLATION…………………………………………………………………….813
ENGINE CONTROLLER……………………………………………………………………814
REMOVAL…………………………………………………………………………814
INSTALLATION…………………………………………………………………….814
90 OTHERS………………………………………………………………………………….815
ELECTRICAL CIRCUIT DIAGRAMS………………………………………………………………817
TO CABIN HARNESS…………………………………………………………………….817
CABIN HARNESS VIEW 1…………………………………………………………………819
CABIN HARNESS VIEW 2…………………………………………………………………821
CONTROLLER (CR700) VIEW………………………………………………………………823
FLOOR HARNESS VIEW…………………………………………………………………..825
MONITOR AND RADIO HARNESS VIEW………………………………………………………..827
LEFT CONSOLE, FUSE PANEL AND KOMTRAX CONTROLLER…………………………………………829
WARNING AND INDICATOR LAMPS…………………………………………………………..831
ENGINE AND DRIVE SYSTEM SENSORS AND CONTROLLERS…………………………………………833
ENGINE SENSORS AND CONTROLLERS………………………………………………………..835
FUEL INJECTOR SYSTEM VIEW…………………………………………………………….837
ELECTRICAL DIAGRAM – 1 OF 9…………………………………………………………..839
ELECTRICAL DIAGRAM – 2 OF 9…………………………………………………………..841
ELECTRICAL DIAGRAM – 3 OF 9…………………………………………………………..843
ELECTRICAL DIAGRAM – 4 OF 9…………………………………………………………..845
ELECTRICAL DIAGRAM – 5 OF 9…………………………………………………………..847
ELECTRICAL DIAGRAM – 6 OF 9…………………………………………………………..849
ELECTRICAL DIAGRAM – 7 OF 9…………………………………………………………..851
ELECTRICAL DIAGRAM – 8 OF 9…………………………………………………………..853
ELECTRICAL DIAGRAM – 9 OF 9…………………………………………………………..855
HYDRAULIC CIRCUIT DIAGRAMS……………………………………………………………….857
VIEW “A” – 1 OF 11…………………………………………………………………..857
VIEW “A” – 2 OF 11…………………………………………………………………..859
VIEW “A” – 3 OF 11…………………………………………………………………..861
VIEW “A” – 4 OF 11…………………………………………………………………..863
VIEW “A” – 5 OF 11…………………………………………………………………..865
VIEW “A” – 6 OF 11…………………………………………………………………..867
VIEW “A” – 7 OF 11…………………………………………………………………..869
VIEW “A” – 8 OF 11…………………………………………………………………..871
VIEW “A” – 9 OF 11…………………………………………………………………..873
VIEW “A” – 10 OF 11………………………………………………………………….875
VIEW “A” – 11 OF 11………………………………………………………………….877
VIEW “B” – 1 OF 1……………………………………………………………………879