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Komatsu PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8 PC240NLC-8 Hydraulic Excavator Shop Manual PDF
Komatsu PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Hydraulic Excavator Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : UEN00084-01
Total Pages : 1062
DESCRIPTION:
Komatsu PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Hydraulic Excavator Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts
TABLE OF CONTENTS:
Komatsu PC210-8, PC210LC-8, PC210NLC-8, PC230NHD-8, PC240LC-8, PC240NLC-8 Hydraulic Excavator Shop Manual
00 Index and foreword........................................................................................ 3 Index.................................................................................................... 3 Organization list of the shop manual................................................................. 4 Table of contents.................................................................................... 6 00 Index and foreword........................................................................................ 15 Foreword and general information......................................................................... 15 Foreword and general information..................................................................... 16 Safety notice.................................................................................... 16 How to read the shop manual...................................................................... 20 Explanation of terms for maintenance standard.................................................... 22 Handling electric equipment and hydraulic component.............................................. 24 How to read electric wire code................................................................... 32 Method of disassembling and connecting push-pull type coupler.................................... 35 Standard tightening torque table................................................................. 38 Conversion table................................................................................. 42 01 Specification............................................................................................. 49 Specification and technical data......................................................................... 49 Specification and technical data..................................................................... 50 Specification dimension drawings................................................................. 50 Working range diagram............................................................................ 51 Specifications................................................................................... 52 Weight table..................................................................................... 56 Table of fuel, coolant and lubricants............................................................ 60 10 Structure, function and maintenance standard.............................................................. 63 Engine and cooling system................................................................................ 63 Engine and cooling system............................................................................ 64 Engine related parts............................................................................. 64 Radiator, oil cooler, aftercooler and fuel cooler................................................ 65 10 Structure, function and maintenance standard.............................................................. 67 Power train.............................................................................................. 67 Power train.......................................................................................... 68 Power train...................................................................................... 68 Final drive...................................................................................... 70 Swing machinery.................................................................................. 72 Swing circle..................................................................................... 76 10 Structure, function and maintenance standard.............................................................. 79 Undercarriage and frame.................................................................................. 79 Undercarriage and frame.............................................................................. 80 Track frame and recoil spring.................................................................... 80 Idler............................................................................................ 82 Carrier roller................................................................................... 84 Track roller..................................................................................... 85 Track shoe....................................................................................... 86 10 Structure, function and maintenance standard.............................................................. 93 Hydraulic system, Part 1................................................................................. 93 Hydraulic system, Part 1............................................................................. 94 Hydraulic equipment layout drawing............................................................... 94 Hydraulic tank and filter............................................................................ 96 Hydraulic pump................................................................................... 97 Hydraulic pump................................................................................... 98 Pilot oil filter................................................................................. 121 10 Structure, function and maintenance standard.............................................................. 123 Hydraulic system, Part 2................................................................................. 123 Hydraulic system, Part 2............................................................................. 124 Control valve.................................................................................... 124 CLSS............................................................................................. 137 Functions and operation by valve................................................................. 142 Hydraulic drift prevention valve................................................................. 168 10 Structure, function and maintenance standard.............................................................. 181 Hydraulic system, Part 3................................................................................. 181 Hydraulic system, Part 3............................................................................. 183 Swing motor...................................................................................... 183 Center swivel joint.............................................................................. 192 Travel motor..................................................................................... 195 PPC valve........................................................................................ 206 Valve control.................................................................................... 228 Solenoid valve................................................................................... 230 PPC Accumulator.................................................................................. 232 Return oil filter................................................................................ 233 Attachment circuit selector valve................................................................ 234 Hydraulic cylinder............................................................................... 236 10 Structure, function and maintenance standard.............................................................. 241 Work equipment........................................................................................... 241 Work equipment....................................................................................... 242 Dimensions of components......................................................................... 242 10 Structure, function and maintenance standard.............................................................. 249 Cab and its attachments.................................................................................. 249 Cab and its attachments.............................................................................. 250 Air conditioner piping........................................................................... 250 10 Structure, function and maintenance standard.............................................................. 253 Electrical system........................................................................................ 253 Electrical system.................................................................................... 254 Engine control................................................................................... 254 Electrical control system........................................................................ 262 Monitor system................................................................................... 282 Sensor........................................................................................... 309 KOMTRAX terminal system.......................................................................... 312 20 Standard value table...................................................................................... 315 Standard service value table............................................................................. 315 Standard service value table......................................................................... 316 Standard value table for engine related parts.................................................... 316 Standard value table for chassis related parts................................................... 318 30 Testing and adjusting..................................................................................... 337 Testing and adjusting, Part 1............................................................................ 337 Testing and adjusting, Part 1........................................................................ 339 Tools for testing, adjusting, and troubleshooting................................................ 339 Measuring engine speed........................................................................... 342 Measuring intake air pressure (boost pressure)................................................... 343 Checking exhaust gas color....................................................................... 344 Adjusting valve clearance........................................................................ 345 Measuring compression pressure................................................................... 347 Measuring blow-by pressure....................................................................... 349 Measuring engine oil pressure.................................................................... 350 Handling fuel system parts....................................................................... 351 Releasing residual pressure from fuel system..................................................... 351 Measuring fuel pressure.......................................................................... 352 Measuring fuel return rate and leakage........................................................... 354 Bleeding air from fuel circuit................................................................... 356 Checking fuel circuit for leakage................................................................ 358 Checking and adjusting air conditioner compressor belt tension................................... 359 Measuring swing circle bearing clearance......................................................... 360 Checking and adjusting track shoe tension........................................................ 361 Measuring and adjusting oil pressure in work equipment, swing, and travel circuits............... 363 Measuring control circuit basic pressure......................................................... 367 Measuring and adjusting oil pressure in pump PC control circuit.................................. 368 Measuring and adjusting oil pressure in pump LS control circuit.................................. 372 Measuring solenoid valve output pressure......................................................... 378 Measuring PPC valve output pressure.............................................................. 381 Adjusting play of work equipment and swing PPC valves............................................ 383 Checking parts which cause hydraulic drift of work equipment..................................... 384 Releasing residual pressure from hydraulic circuit............................................... 386 Measuring oil leakage............................................................................ 387 Bleeding air from each part...................................................................... 390 Checking cab tipping stopper..................................................................... 393 Adjusting mirrors................................................................................ 394 30 Testing and adjusting..................................................................................... 397 Testing and adjusting, Part 2............................................................................ 397 Testing and adjusting, Part 2........................................................................ 398 Special functions of machine monitor............................................................. 398 30 Testing and adjusting..................................................................................... 455 Testing and adjusting, Part 3............................................................................ 455 Testing and adjusting, Part 3........................................................................ 456 Handling high-voltage circuit of engine controller............................................... 456 Preparation work for troubleshooting of electrical system........................................ 457 Procedure for testing diodes..................................................................... 461 Pm Clinic service................................................................................ 463 Warning.......................................................................................... 465 Pm Clinic service................................................................................ 469 40 Troubleshooting........................................................................................... 477 General information on troubleshooting................................................................... 477 General information on troubleshooting............................................................... 478 Points to remember when troubleshooting.......................................................... 478 Sequence of events in troubleshooting............................................................ 479 Check before troubleshooting..................................................................... 480 Classification and procedures for troubleshooting................................................ 481 How to read electric wire code................................................................... 485 Connection table for connector pin numbers....................................................... 488 T-boxes and T-adapters table..................................................................... 511 40 Troubleshooting........................................................................................... 515 Troubleshooting by failure code (Display of code), Part 1................................................ 515 Troubleshooting by failure code (Display of code), Part 1............................................ 517 Failure codes table.............................................................................. 517 Before carrying out troubleshooting when failure code is displayed............................... 522 Information in troubleshooting table............................................................. 526 Failure code [989L00] Engine Controller Lock Caution 1........................................... 528 Failure code [989M00] Engine Controller Lock Caution 2........................................... 528 Failure code [989N00] Engine Controller Lock Caution 3........................................... 529 Failure code [AA10NX] Air Cleaner Clogging....................................................... 529 Failure code [AB00KE] Charge Voltage Low......................................................... 530 Failure code [B@BAZG] Eng Oil Press. Low......................................................... 532 Failure code [B@BAZK] Eng Oil Level Low.......................................................... 532 Failure code [B@BCNS] Eng Water Overheat......................................................... 533 Failure code [B@BCZK] Eng Water Level Low........................................................ 533 Failure code [B@HANS] Hydr Oil Overheat.......................................................... 534 Failure code [CA111] EMC Critical Internal Failure............................................... 534 Failure code [CA115] Eng Ne and Bkup Speed Sens 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............................................................... 561 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................. 562 Failure code [CA271] IMV/PCV1 Short Error........................................................ 563 Failure code [CA272] IMV/PCV1 Open Error......................................................... 564 Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................... 566 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................... 568 Failure code [CA324] Inj #3 (L#3) Open/Short Error............................................... 570 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................... 572 Failure code [CA331] Inj #2 (L#2) Open/Short Error............................................... 574 Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................... 576 40 Troubleshooting........................................................................................... 579 Troubleshooting by failure code (Display of code), Part 2................................................ 579 Troubleshooting by failure code (Display of code), Part 2............................................ 581 Failure code [CA342] Calibration Code Incompatibility............................................ 581 Failure code [CA351] Injectors Drive Circuit Error............................................... 582 Failure code [CA352] Sens Supply 1 Volt Low Error................................................ 584 Failure code [CA386] Sens Supply 1 Volt High Error............................................... 586 Failure code [CA428] Water in Fuel Sensor High Error............................................. 588 Failure code [CA429] Water in Fuel Sensor Low Error.............................................. 590 Failure code [CA435] Eng Oil Press Sw Error...................................................... 592 Failure code [CA441] Battery Voltage Low Error................................................... 593 Failure code [CA442] Battery Voltage High Error.................................................. 596 Failure code [CA449] Rail Press Very High Error.................................................. 598 Failure code [CA451] Rail Press Sensor High Error................................................ 600 Failure code [CA452] Rail Press Sensor Low Error................................................. 602 Failure code [CA488] Chg Air Temp High Torque Derate............................................. 604 Failure code [CA553] Rail Press High Error....................................................... 604 Failure code [CA559] Rail Press Low Error........................................................ 605 Failure code [CA689] Eng Ne Speed Sensor Error................................................... 606 Failure code [CA731] Eng Bkup Speed Sens Phase Error............................................. 608 Failure code [CA757] All Continuous Data Lost Error.............................................. 610 Failure code [CA778] Eng Bkup Speed Sensor Error................................................. 612 Failure code [CA1633] KOMNET Datalink Timeout Error.............................................. 614 Failure code [CA2185] Throt Sens Sup Volt High Error............................................. 616 Failure code [CA2186] Throt Sens Sup Volt Low Error.............................................. 617 Failure code [CA2249] Rail Press Very Low Error.................................................. 618 Failure code [CA2311] IMV Solenoid Error......................................................... 620 Failure code [CA2555] Grid Htr Relay Volt High Error............................................. 622 Failure code [CA2556] Grid Htr Relay Volt Low Error.............................................. 624 Failure code [D19JKZ] Personal Code Relay Abnormality............................................ 626 Failure code [D862KA] GPS Antenna Discon......................................................... 628 Failure code [DA25KP] 5V Sensor 1 Power Abnormality.............................................. 629 Failure code [DA29KQ] Model Selection Abnormality................................................ 636 40 Troubleshooting........................................................................................... 641 Troubleshooting by failure code (Display of code), Part 3................................................ 641 Troubleshooting by failure code (Display of code), Part 3............................................ 644 Failure code [DA2RMC] CAN Discon (Pump Con Detected)............................................. 644 Failure code [DAFGMC] GPS Module Error........................................................... 646 Failure code [DAFRMC] CAN Discon (Monitor Detected).............................................. 648 Failure code [DGH2KB] Hydr Oil Sensor Short...................................................... 650 Failure code [DHPAMA] F Pump Press Sensor Abnormality............................................ 652 Failure code [DHPBMA] R Pump Press Sensor Abnormality............................................ 654 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality...................................... 656 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality................................... 658 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality.................................... 660 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality...................................... 662 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality...................................... 664 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality................................... 666 Failure code [DHX1MA] Overload Sensor Abnormality (Analog)....................................... 668 Failure code [DW43KA] Travel Speed Sol Discon.................................................... 670 Failure code [DW43KB] Travel Speed Sol Short..................................................... 672 Failure code [DW45KA] Swing Brake Sol Discon..................................................... 674 Failure code [DW45KB] Swing Brake Sol Short...................................................... 676 Failure code [DW91KA] Travel Junction Sol Discon................................................. 678 Failure code [DW91KB] Travel Junction Sol Short.................................................. 680 Failure code [DWA2KA] Service Sol Discon......................................................... 682 Failure code [DWA2KB] Service Sol Short.......................................................... 683 Failure code [DWK0KA] 2-stage Relief Sol Discon.................................................. 684 Failure code [DWK0KB] 2-stage Relief Sol Short................................................... 686 40 Troubleshooting........................................................................................... 689 Troubleshooting by failure code (Display of code), Part 4................................................ 689 Troubleshooting by failure code (Display of code), Part 4............................................ 692 Failure code [DXA8KA] PC-EPC (F) Sol Discon...................................................... 692 Failure code [DXA8KB] PC-EPC (F) Sol Short....................................................... 694 Failure code [DXA9KA] PC-EPC (R) Sol Discon...................................................... 696 Failure code [DXA9KB] PC-EPC (R) Sol Short....................................................... 698 Failure code [DXE0KA] LS-EPC Sol Discon.......................................................... 700 Failure code [DXE0KB] LS-EPC Sol Short........................................................... 702 Failure code [DXE4KA] Service Current EPC Discon................................................. 704 Failure code [DXE4KB] Service Current EPC Short.................................................. 706 Failure code [DXE5KA] Merge-divider Main Sol Discon.............................................. 708 Failure code [DXE5KB] Merge-divider Main Sol Short............................................... 710 Failure code [DXE6KA] Merge-divider LS Sol Discon................................................ 712 Failure code [DXE6KB] Merge-divider LS Sol Short................................................. 714 Failure code [DY20KA] Wiper Working Abnormality.................................................. 716 Failure code [DY20MA] Wiper Parking Abnormality.................................................. 718 Failure code [DY2CKA] Washer Drive Discon........................................................ 720 Failure code [DY2CKB] Washer Drive Short......................................................... 722 Failure code [DY2DKB] Wiper Drive (For) Short.................................................... 724 Failure code [DY2EKB] Wiper Drive (Rev) Short.................................................... 726 40 Troubleshooting........................................................................................... 729 Troubleshooting of electrical system (E-mode)............................................................ 729 Troubleshooting of electrical system (E-mode)........................................................ 731 Before carrying out troubleshooting of electrical system......................................... 731 Information in troubleshooting table............................................................. 733 E-1 When starting switch turned ON, machine monitor displays nothing............................. 734 E-2 When starting switch turned ON (before starting engine), basic check item lights up.......... 736 E-3 Engine does not start (Engine does not turn)................................................. 739 E-4 Preheater does not operate................................................................... 742 E-5 Automatic warm-up system does not operate (in cold season)................................... 744 E-6 All work equipment, swing, and travel mechanism do not move or cannot be locked.............. 746 E-7 Precaution lights up while engine is running................................................. 748 E-8 Emergency stop item lights up while engine is running........................................ 753 E-9 Engine coolant temperature gauge does not indicate normally.................................. 754 E-10 Hydraulic oil temperature gauge does not indicate normally.................................. 755 E-11 Fuel level gauge does not indicate normally................................................. 757 E-12 Contents of display by machine monitor are different from applicable machine................ 759 E-13 Machine monitor does not display some items................................................. 759 E-14 Function switch does not work............................................................... 759 E-15 Auto-decelerator does not operate normally.................................................. 760 E-16 Working mode does not change................................................................ 761 E-17 Travel speed does not change................................................................ 762 E-18 Alarm buzzer cannot be stopped.............................................................. 763 E-19 Windshield wiper and window washer do not operate........................................... 764 E-20 Power maximizing function does not operate normally......................................... 766 E-21 Swing holding brake does not operate normally............................................... 768 E-22 Travel alarm does not sound or does not stop sounding....................................... 770 E-23 Air conditioner does not operate normally (including air conditioner abnormality record).... 772 E-24 When starting switch is turned OFF, service meter is not displayed.......................... 784 E-25 Machine monitor cannot be set in service mode............................................... 784 E-26 Monitoring function does not display lever control signal normally.......................... 785 E-27 KOMTRAX system does not operate normally.................................................... 794 40 Troubleshooting........................................................................................... 797 Troubleshooting of hydraulic and mechanical system (H-mode).............................................. 797 Troubleshooting of hydraulic and mechanical system (H-mode).......................................... 800 System diagram of hydraulic and mechanical system................................................ 800 Information in troubleshooting table............................................................. 802 H-1 Speed or power of whole work equipment, swing, and travel is low............................. 803 H-2 Engine speed lowers extremely or engine stalls............................................... 805 H-3 Work equipment, swing, and travel systems do not work........................................ 806 H-4 Abnormal sound comes out from around hydraulic pump.......................................... 806 H-5 Auto-decelerator does not operate............................................................ 807 H-6 Fine control performance or response is low.................................................. 807 H-7 Speed or power of boom is low................................................................ 808 H-8 Speed or power of arm is low................................................................. 809 H-9 Speed or power of bucket is low.............................................................. 810 H-10 Work equipment does not move singly......................................................... 810 H-11 Hydraulic drift of work equipment is large.................................................. 811 H-12 Time lag of work equipment is large......................................................... 813 H-13 When part of work equipment is relieved singly, other parts of work equipment move.......... 813 H-14 Power maximizing function does not work..................................................... 814 H-15 In compound operation of work equipment, speed of part loaded more is low................... 814 H-16 When machine swings and raises boom simultaneously, boom rising speed is low................ 815 H-17 When machine swings and travels simultaneously, travel speed lowers largely................. 815 H-18 Machine deviates during travel.............................................................. 816 H-19 Travel speed is low......................................................................... 817 H-20 Machine is not steered well or steering power is low........................................ 818 H-21 Travel speed does not change or travel speed is low/high.................................... 819 H-22 Travel system does not move (only one side)................................................. 820 H-23 Upper structure does not swing.............................................................. 821 H-24 Swing acceleration or swing speed is low.................................................... 823 H-25 Upper structure overruns remarkably when it stops swinging.................................. 824 H-26 Large shock is made when upper structure stops swinging..................................... 825 H-27 Large sound is made when upper structure stops swinging..................................... 825 H-28 Hydraulic drift of swing is large........................................................... 826 H-29 Attachment circuit is not changed........................................................... 827 H-30 Oil flow in attachment circuit cannot be controlled......................................... 827 40 Troubleshooting........................................................................................... 829 Troubleshooting of engine (S-mode)....................................................................... 829 Troubleshooting of engine (S-mode)................................................................... 831 Method of using troubleshooting chart............................................................ 831 S-1 Starting performance is poor................................................................. 834 S-2 Engine does not start........................................................................ 835 S-3 Engine does not pick up smoothly............................................................. 838 S-4 Engine stops during operations............................................................... 839 S-5 Engine does not rotate smoothly.............................................................. 840 S-6 Engine lack output (or lacks power).......................................................... 841 S-7 Exhaust smoke is black (incomplete combustion)............................................... 842 S-8 Oil consumption is excessive (or exhaust smoke is blue)...................................... 843 S-9 Oil becomes contaminated quickly............................................................. 844 S-10 Fuel consumption is excessive............................................................... 845 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....................... 846 S-12 Oil pressure drops.......................................................................... 847 S-13 Oil level rises (Entry of coolant/fuel)..................................................... 848 S-14 Coolant temperature becomes too high (overheating).......................................... 849 S-15 Abnormal noise is made...................................................................... 850 S-16 Vibration is excessive...................................................................... 851 50 Disassembly and assembly.................................................................................. 853 Disassembly and assembly related information............................................................. 853 Disassembly and assembly related information......................................................... 854 How to read this manual.......................................................................... 854 List of adhesives................................................................................ 856 Special tool list................................................................................ 859 Sketches of special tools........................................................................ 864 50 Disassembly and assembly.................................................................................. 869 Engine cooling related................................................................................... 869 Engine cooling related............................................................................... 870 Removal and installation of fuel supply pump assembly............................................ 870 Removal and installation of fuel injector assembly............................................... 872 Removal and installation of engine front seal.................................................... 879 Removal and installation of engine rear seal..................................................... 882 Removal and installation of cylinder head assembly............................................... 885 Removal and installation of radiator assembly.................................................... 897 Removal and installation of assembly hydraulic oil cooler assembly............................... 900 Removal and installation of aftercooler assembly................................................. 902 Removal and installation of fuel cooler assembly................................................. 904 Removal and installation of engine and hydraulic pump assemblies................................. 905 50 Disassembly and assembly.................................................................................. 917 Power train.............................................................................................. 917 Power train.......................................................................................... 918 Removal and installation of final drive assembly................................................. 918 Disassembly and assembly of final drive assembly................................................. 920 Removal and installation of swing motor and swing machinery assembly............................. 936 Disassembly and assembly of swing motor and swing machinery assembly............................. 938 Removal and installation of swing circle assembly................................................ 948 50 Disassembly and assembly.................................................................................. 951 Under carriage and frame................................................................................. 951 Under carriage and frame............................................................................. 952 Disassembly and assembly of carrier roller....................................................... 952 Disassembly and assembly of track roller assembly................................................ 955 Disassembly and assembly of idler assembly....................................................... 957 Disassembly and assembly of recoil spring........................................................ 960 Removal and installation of sprocket............................................................. 962 Expansion and installation of track shoe assembly................................................ 963 Removal and installation of revolving frame assembly............................................. 965 Removal and installation of counterweight assembly............................................... 967 50 Disassembly and assembly.................................................................................. 969 Hydraulic system......................................................................................... 969 Hydraulic system..................................................................................... 970 Removal and installation of center swivel joint assembly......................................... 970 Disassembly and assembly of center swivel joint assembly......................................... 972 Removal and installation of hydraulic tank assembly.............................................. 973 Removal and installation of control valve assembly............................................... 976 Disassembly and assembly of control valve assembly............................................... 981 Removal and installation of hydraulic pump assembly.............................................. 985 Removal and installation of oil seal in hydraulic pump input shaft............................... 990 Disassembly and assembly of work equipment PPC valve assembly.................................... 991 Disassembly and assembly of travel PPC valve assembly............................................ 992 Disassembly and assembly of hydraulic cylinder assembly.......................................... 993 50 Disassembly and assembly..................................................................................1001 Work equipment...........................................................................................1001 Work equipment.......................................................................................1002 Removal and installation of the work equipment assembly..........................................1002 50 Disassembly and assembly..................................................................................1007 Cab related..............................................................................................1007 Cab related..........................................................................................1008 Removal and installation of operator's cab assembly..............................................1008 Removal and installation of operator cab glass (stuck glass).....................................1011 Removal and installation of front window assembly................................................1021 Removal and installation of floor frame assembly.................................................1028 50 Disassembly and assembly..................................................................................1033 Electric components......................................................................................1033 Electric components..................................................................................1034 Removal and installation of air conditioner unit assembly........................................1034 Removal and installation of KOMTRAX communication modem assembly.................................1037 Removal and installation of monitor assembly.....................................................1038 Removal and installation of pump controller assembly.............................................1040 Removal and installation of engine controller assembly...........................................1041 90 Diagrams and drawings.....................................................................................1043 Hydraulic diagrams and drawings..........................................................................1043 Hydraulic diagrams and drawings......................................................................1045 Hydraulic circuit diagram........................................................................1045 90 Diagrams and drawings.....................................................................................1049 Electrical diagrams and drawings.........................................................................1049 Electrical diagrams and drawings.....................................................................1051 Electrical circuit diagram (1/5).................................................................1051 Electrical circuit diagram (2/5).................................................................1053 Electrical circuit diagram (3/5).................................................................1055 Electrical circuit diagram (4/5).................................................................1057 Electrical circuit diagram (5/5).................................................................1059
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