Komatsu PC650-5 PC710-5 Shop Manual(SEBM000607) – PDF DOWNLOAD

Komatsu PC650-5 PC710-5 Shop Manual(SEBM000607) – PDF DOWNLOAD

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Komatsu PC650-5 PC710-5 Shop Manual(SEBM000607) – PDF DOWNLOAD

SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual are both
effective and safe. Some of these techniques require the use of tools specially designed by
Komatsu for the specific purpose.
To prevent injury to workers, the sym bol 丛is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed care­
fully. If any dangerous situation arises or may possibly arise, first consider safety, and take
the necessary actions to deal with the situation.
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 grind­ ing 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, al­ ways wear welding gloves, apron, hand
shield, cap and other clothes suited for weld­ ing work.
4. When carrying out any operation with two or more workers, always agree on the oper­
ating procedure before starting. Always in­ form 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 smok­ ing.
Never smoke while working.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the machine on hard, level ground, and
block the wheels or tracks to prevent the machine from moving.
8. 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 warn­
ing signs on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands
before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the
ma­ chine. 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 PC650-5 PC710-5 Shop Manual(SEBM000607) – PDF DOWNLOAD

COVER……………………………………………………………………………………………………………………………….. 1
CONTENTS…………………………………………………………………………………………………………………………….. 2
01 GENERAL…………………………………………………………………………………………………………………………… 23
ASSEMBLY DRAWING………………………………………………………………………………………………………………….. 24
SPECIFICATIONS……………………………………………………………………………………………………………………. 30
WEIGHT TABLE……………………………………………………………………………………………………………………… 36
LIST OF LUBRICANT AND WATER………………………………………………………………………………………………………… 42
10 STRUCTURE AND FUNCTION……………………………………………………………………………………………………………… 43
PTO (POWER TAKE-OFF)………………………………………………………………………………………………………………. 44
PTO LUBRICATION SYSTEM…………………………………………………………………………………………………………….. 45
RADIATOR AND OIL COOLER……………………………………………………………………………………………………………. 46
POWER TRAIN………………………………………………………………………………………………………………………. 47
SWING MACHINERY…………………………………………………………………………………………………………………… 48
SWING CIRCLE……………………………………………………………………………………………………………………… 49
FINAL DRIVE………………………………………………………………………………………………………………………. 50
TRACK FRAME………………………………………………………………………………………………………………………. 51
IDLER CUSHION…………………………………………………………………………………………………………………….. 53
IDLER……………………………………………………………………………………………………………………………. 53
TRACK ROLLER……………………………………………………………………………………………………………………… 54
CARRIER ROLLER……………………………………………………………………………………………………………………. 54
TRACK SHOE……………………………………………………………………………………………………………………….. 55
AIR PIPING……………………………………………………………………………………………………………………….. 56
AIR CIRCUIT DIAGRAM……………………………………………………………………………………………………………….. 57
AIR COMPRESSOR……………………………………………………………………………………………………………………. 57
AIR GOVERNOR……………………………………………………………………………………………………………………… 58
AIR TANK…………………………………………………………………………………………………………………………. 58
SAFETY VALVE……………………………………………………………………………………………………………………… 59
HORN VALVE……………………………………………………………………………………………………………………….. 59
GREASE PUMP………………………………………………………………………………………………………………………. 60
HYDRAULIC UNIT LOCATION……………………………………………………………………………………………………………. 61
HYDRAULIC CIRCUIT DIAGRAM………………………………………………………………………………………………………….. 63
HYDRAULIC TANK……………………………………………………………………………………………………………………. 66
NO.1 PUMP………………………………………………………………………………………………………………………… 67
NO.2 PUMP………………………………………………………………………………………………………………………… 86
SWING PUMP……………………………………………………………………………………………………………………….. 91
CHARGING AND PTO LUBRICATING PUMP…………………………………………………………………………………………………… 96
LINE OIL FILTER…………………………………………………………………………………………………………………… 97
PILOT OIL FILTER………………………………………………………………………………………………………………….. 97
RETURN OIL FILTER…………………………………………………………………………………………………………………. 98
DRAIN OIL FILTER………………………………………………………………………………………………………………….. 98
L.H. 5-SPOOL CONTROL VALVE…………………………………………………………………………………………………………. 99
R.H. 4-SPOOL CONTROL VALVE………………………………………………………………………………………………………….103
SWING CONTROL VALVE………………………………………………………………………………………………………………..108
SWING MOTOR……………………………………………………………………………………………………………………….111
CENTER SWIVEL JOINT………………………………………………………………………………………………………………..115
TRAVEL MOTOR………………………………………………………………………………………………………………………116
CONTROL RELIEF VALVE……………………………………………………………………………………………………………….123
SAFETY LOCK VALVE………………………………………………………………………………………………………………….124
ACCUMULATOR……………………………………………………………………………………………………………………….126
PPC VALVE…………………………………………………………………………………………………………………………127
SOLENOID VALVE ASSEMBLY…………………………………………………………………………………………………………….131
EPC VALVE…………………………………………………………………………………………………………………………136
AUTO-DECELERATION CYLINDER………………………………………………………………………………………………………….138
PPC SHUTTLE VALVE………………………………………………………………………………………………………………….139
HYDRAULIC CYLINDER…………………………………………………………………………………………………………………140
WORK EQUIPMENT…………………………………………………………………………………………………………………….144
ELECTRICAL WIRING DIAGRAM…………………………………………………………………………………………………………..147
ELECTRICAL CIRCUIT DIAGRAM………………………………………………………………………………………………………….153
ENGINE CONTROL…………………………………………………………………………………………………………………….169
MACHINE CONTROL SYSTEM……………………………………………………………………………………………………………..171
WORK EQUIPMENT CONTROL SYSTEM……………………………………………………………………………………………………….201
MACHINE MONITORING SYSTEM…………………………………………………………………………………………………………..206
20 TESTING AND ADJUSTING……………………………………………………………………………………………………………….227
TABLE OF JUDGEMENT STANDARD VALUE……………………………………………………………………………………………………228
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM……………………………………………………………………………………………245
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING………………………………………………………………………………………254
MEASURING ENGINE SPEED……………………………………………………………………………………………………………..255
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)………………………………………………………………………………………..256
MEASURING EXHAUST GAS TEMPERATURE……………………………………………………………………………………………………257
MEASURING EXHAUST GAS COLOR…………………………………………………………………………………………………………258
ADJUSTING VALVE CLEARANCE…………………………………………………………………………………………………………..259
MEASURING COMPRESSION PRESSURE………………………………………………………………………………………………………260
MEASURING BLOW-BY PRESSURE………………………………………………………………………………………………………….261
TESTING AND ADJUSTING FUEL INJECTION TIMING…………………………………………………………………………………………..262
MEASURING ENGINE OIL PRESSURE……………………………………………………………………………………………………….264
TESTING AND ADJUSTING ALTERNATOR BELT TENSION…………………………………………………………………………………………265
TESTING AND ADJUSTING FAN BELT TENSION……………………………………………………………………………………………….265
ADJUSTING FUEL CONTROL LINKAGE………………………………………………………………………………………………………266
ADJUSTING ENGINE SPEED SENSOR……………………………………………………………………………………………………….271
CHECKING SWING CIRCLE BEARING CLEARANCE………………………………………………………………………………………………272
TESTING AND ADJUSTING TRACK SHOE TENSION……………………………………………………………………………………………..273
TESTING AND ADJUSTING WORK EQUIPMENT, SWING, TRAVEL CIRCUIT PRESSURE…………………………………………………………………….274
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE………………………………………………………………………………………..277
TESTING AND ADJUSTING PISTON PUMP CONTROL PRESSURE…………………………………………………………………………………….279
MEASURING STROKE OF SERVO PISTON…………………………………………………………………………………………………….285
TESTING AND ADJUSTING TRAVEL DEVIATION……………………………………………………………………………………………….286
MEASURING OIL LEAKAGE………………………………………………………………………………………………………………288
CHECKING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT……………………………………………………………………………292
MEASURING PPC VALVE OUTPUT PRESSURE………………………………………………………………………………………………….293
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE…………………………………………………………………………………………….294
MEASURING SOLENOID VALVE OUTLET PRESSURE……………………………………………………………………………………………..295
BLEEDING AIR………………………………………………………………………………………………………………………296
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT……………………………………………………………………………………..298
TROUBLESHOOTING……………………………………………………………………………………………………………………299
POINTS TO REMEMBER WHEN TROUBLESHOOTING…………………………………………………………………………………………..300
SEQUENCE OF EVENTS IN TROUBLESHOOTING…………………………………………………………………………………………….301
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…………………………………………………………………………………..302
CHECKS BEFORE TROUBLESHOOTING……………………………………………………………………………………………………310
ELECTRICAL CIRCUIT DIAGRAM………………………………………………………………………………………………………311
POSITION OF CONNECTORS FOR TROUBLESHOOTING………………………………………………………………………………………..336
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS………………………………………………………………………………………..340
SELF-DIAGNOSTIC DISPLAY OF CONTROLLERS……………………………………………………………………………………………350
METHOD OF USING JUDGEMENT TABLE………………………………………………………………………………………………….351
METHOD OF USING TROUBLESHOOTING CHART…………………………………………………………………………………………….353
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)……………………………………………………………………………………..355
JUDGEMENT TABLE FOR ELECTRICAL SYSTEM OR HYDRAULIC, MECHANICAL SYSTEM…………………………………………………………….356
E-1. EXCESSIVE DEVIATION WHEN TRAVEL (CONSTANT DEVIATION)……………………………………………………………………….358
E-2. SPEED OF WORK EQUIPMENT, SWING, TRAVEL IS EXTREMELY SLOW OR LACKS POWER………………………………………………………361
E-3. ENGINE STALLS DURING OPERATIONS, OR ENGINE SPEED DROPS……………………………………………………………………..365
E-4. EVEN WHEN MODE SELECTOR SWITCH IS SWITCHED, OUTPUT DOES NOT CHANGE…………………………………………………………..368
E-5. AUTO-DECELERATION FUNCTION DOES NOT WORK PROPERLY (THERE IS NO DECELERATION, OR DECELERATION STAYS ON)…………………………..375
E-6. UPPER STRUCTURE DOES NOT SWING…………………………………………………………………………………………..383
E-7. EXCESSIVE HYDRAULIC DRIFT OF SWING……………………………………………………………………………………….388
E-8. TRAVEL SPEED DOES NOT CHANGE…………………………………………………………………………………………….392
E-9. EXCESSIVE TRAVEL DEVIATION DURING COMPOUND OPERATIONS (BUT ONLY FOR COMBINATION OF TRAVEL AND WORK EQUIPMENT)…………………….394
E-10. DEFECTIVE OPERATION OF HEAVY LIFT FUNCTION……………………………………………………………………………….405
E-11. MACHINE PUSH UP FUNCTION IS NOT ACTUATED…………………………………………………………………………………413
E-12. ENGINE DOES NOT START………………………………………………………………………………………………….420
E-13. ENGINE DOES NOT STOP…………………………………………………………………………………………………..423
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)…………………………………………………………………………425
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTME (H MODE)…………………………………………………………………426
H-1. EXCESSIVE TRAVEL DEVIATION (GOES OUTSIDE STANDARD ONLY DURING TRAVEL OPERATIONS, WHEN TRAVEL LEVER IS OPERATED TO END OF STROKE)……429
H-2. EXCESSIVE TRAVEL DEVIATION DURING COMPOUND OPERATIONS………………………………………………………………………433
H-3. EXCESSIVE DEVIATION WHEN STARTING………………………………………………………………………………………..434
H-4. CONTROL LEVERS ARE EXTREMELY HEAVY……………………………………………………………………………………….436
H-5. WORK EQUIPMENT, TRAVEL, SWING START TO MOVE SUDDENLY (IN FINE CONTROL RANGE)………………………………………………….437
H-6. SPEED OF WORK EQUIPMENT, SWING, TRAVEL IS EXTREMELY SLOW OR LACKS POWER ……………………………………………………..438
H-7. ENGINE STALLS OR ENGINE SPEED DROPS DURING OPERATION……………………………………………………………………….442
H-8. OUTPUT DOES NOT CHANGE WHEN MODE SELECTOR SWITCH IS OPERATED………………………………………………………………..443
H-9. AUTO-DECELERATION FUNCTION DOES NOT WORK PROPERLY (THERE IS NO DECELERATION OR DECELERATION STAYS ON )…………………………..443
H-10. ABNORMAL NOISE COMES FROM AROUND PUMP……………………………………………………………………………………444
H-11. SWING SPEED IS SLOW, OR THERE IS EXCESSIVE OVERRUN WHEN STOPPING SWING………………………………………………………445
H-12. UPPER STRUCTURE DOES NOT SWING………………………………………………………………………………………….446
H-13. EXCESSIVE HYDRAULIC DRIFT OF SWING………………………………………………………………………………………447
H-14. EXCESSIVE HYDRAULIC DRIFT OF WORK EQUIPMENT………………………………………………………………………………447
H-15. EXCESSIVE TIME LAG OF WORK EQUIPMENT…………………………………………………………………………………….448
H-16. TRAVEL SPEED DOES ONT CHANGE……………………………………………………………………………………………449
H-17. DEFECTIVE ACTUATION OF HEAVY-LIFT FUNCTION (BOOM RAISE SET PRESSURE DOES NOT INCREASE, OR INCREASES BUT DOES NOT GO DOWN)…………450
H-18. DEFECTIVE ACTUATION OF MACHINE PUSH UP FUNCTION (BOOM LOWER SET PRESSURE DOES NOT INCREASE, OR INCRESES BUT DOES NOT GO DOWN)……..450
TABLE OF FAILURE MODES AND CAUSES…………………………………………………………………………………………….451
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)…………………………………………………………………………………453
M-1. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT APPEAR……………………………………………………..454
M-2. WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT……………………………………………………..454
M-3. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH. (FLUID LEVEL OF CHECK ITEMS ARE CORRECT)…………………..455
M-4. WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH……………………………………………………458
M-5. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH………………………………………………………460
M-6. WHEN STARTING SWITCH IS TURNED ON AMD ENGINE IS STARTED, CAUTION ITEMS FLASH………………………………………………….461
M-7. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) FOR 1 SECOND, OR WHEN CAUTION ITEMS ARE FLASHING, WARNING BUZZER DOES NOT SOUND….466
M-8. NO ABNORMAL DISPLAY ON MONITOR BUT WARNING BUZZER SOUNDS……………………………………………………………………467
M-9. PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)…………………………………………..468
M-10. WHEN ENGINE IS STARTED, SERVICE METER DOES NOT MOVE, WHEN ENGINE IS STOPPED, SERVICE METER MOVES……………………………….470
M-11. COOLANT TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE…………………………………………………………………472
M-12. COOLANT TEMPERATURE GAUGE GIVES NO DISPLAY……………………………………………………………………………….473
M-13. FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL……………………………………………………………………………………474
M-14. FUEL LEVEL GAUGE GIVES NO DISPLAY……………………………………………………………………………………….475
M-15. HEAD LAMP, WORKING LAMP DO NOT LIGHT UP………………………………………………………………………………….476
M-16. WIPERS DO NOT WORK…………………………………………………………………………………………………….479
30 DISASSEMBLY AND ASSEMBLY…………………………………………………………………………………………………………….481
METHOD OF USING MANUAL……………………………………………………………………………………………………………..483
PRECAUTIONS WHEN CARRYING OUT OPERATION………………………………………………………………………………………………484
SPECIAL TOOL LIST………………………………………………………………………………………………………………….486
STARTING MOTOR…………………………………………………………………………………………………………………….494
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..494
ALTERNATOR………………………………………………………………………………………………………………………..495
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..495
NOZZLE HOLDER……………………………………………………………………………………………………………………..496
REMOVAL……………………………………………………………………………………………………………………….496
INSTALLATION…………………………………………………………………………………………………………………..497
ENGINE OIL COOLER………………………………………………………………………………………………………………….498
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..498
FUEL INJECTION PUMP………………………………………………………………………………………………………………..499
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..499
WATER PUMP………………………………………………………………………………………………………………………..500
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..500
TURBOCHARGER………………………………………………………………………………………………………………………501
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..501
HYRDAULIC COOLER…………………………………………………………………………………………………………………..502
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..502
CYLINDER HEAD……………………………………………………………………………………………………………………..503
REMOVAL……………………………………………………………………………………………………………………….503
INSTALLATION…………………………………………………………………………………………………………………..506
RADIATOR………………………………………………………………………………………………………………………….508
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..508
AFTER-COOLER CORE………………………………………………………………………………………………………………….509
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..509
ENGINE, PTO, HYDRAULIC PUMP…………………………………………………………………………………………………………510
REMOVAL……………………………………………………………………………………………………………………….510
INSTALLATION…………………………………………………………………………………………………………………..514
PTO………………………………………………………………………………………………………………………………515
REMOVAL……………………………………………………………………………………………………………………….515
INSTALLATION…………………………………………………………………………………………………………………..517
DISASSEMBLY……………………………………………………………………………………………………………………518
ASSEMBLY………………………………………………………………………………………………………………………519
FINAL DRIVE……………………………………………………………………………………………………………………….520
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..520
DISASSEMBLY……………………………………………………………………………………………………………………521
ASSEMBLY………………………………………………………………………………………………………………………525
REVOLVING FRAME……………………………………………………………………………………………………………………530
REMOVAL……………………………………………………………………………………………………………………….530
INSTALLATION…………………………………………………………………………………………………………………..531
SWING MACHINERY……………………………………………………………………………………………………………………532
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..532
DISASSEMBLY……………………………………………………………………………………………………………………533
ASSEMBLY………………………………………………………………………………………………………………………536
SWING CIRCLE………………………………………………………………………………………………………………………540
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..540
TRACK SHOE………………………………………………………………………………………………………………………..541
REMOVAL……………………………………………………………………………………………………………………….541
INSTALLATION…………………………………………………………………………………………………………………..542
ONE LINK………………………………………………………………………………………………………………………….543
FIELD DISASSEMBLY………………………………………………………………………………………………………………543
FIELD ASSEMBLY…………………………………………………………………………………………………………………545
SPROCKET………………………………………………………………………………………………………………………….547
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..547
IDLER…………………………………………………………………………………………………………………………….548
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..548
FRONT IDLER……………………………………………………………………………………………………………………….549
DISASSEMBLY……………………………………………………………………………………………………………………549
ASSEMBLY………………………………………………………………………………………………………………………551
IDLER ADJUSTMENT CYLINDER…………………………………………………………………………………………………………..553
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………..553
RECOIL SPRING……………………………………………………………………………………………………………………..554
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..554
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………..556
CARRIER ROLLER…………………………………………………………………………………………………………………….557
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..557
DISASSEMBLY……………………………………………………………………………………………………………………558
ASSEMBLY………………………………………………………………………………………………………………………559
TRACK ROLLER………………………………………………………………………………………………………………………561
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..561
DISASSEMBLY……………………………………………………………………………………………………………………562
ASSEMBLY………………………………………………………………………………………………………………………563
NO.1 PUMP…………………………………………………………………………………………………………………………565
REMOVAL……………………………………………………………………………………………………………………….565
INSTALLATION…………………………………………………………………………………………………………………..566
HYDRAULIC PUMP…………………………………………………………………………………………………………………….567
DISASSEMBLY……………………………………………………………………………………………………………………567
ASSEMBLY………………………………………………………………………………………………………………………572
SERVO VALVE……………………………………………………………………………………………………………………….583
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..583
TVC VALVE…………………………………………………………………………………………………………………………584
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..584
CO・NC VALVE……………………………………………………………………………………………………………………….585
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..585
NO.2 PUMP…………………………………………………………………………………………………………………………586
REMOVAL……………………………………………………………………………………………………………………….586
INSTALLATION…………………………………………………………………………………………………………………..587
SWING PUMP………………………………………………………………………………………………………………………..588
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..588
DISASSEMBLY……………………………………………………………………………………………………………………589
ASSEMBLY………………………………………………………………………………………………………………………592
CHARGING, PTO LUBRICATION PUMP………………………………………………………………………………………………………603
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..603
MAIN RELIEF VALVE (FOR SWING CONTROL VALVE)…………………………………………………………………………………………..604
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..604
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………..605
MAIN CONTROL VALVE (FOR WORK EQUIPMENT,4-,5-SPOOL CONTROL VALVE)………………………………………………………………………..606
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..606
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………..607
SWING CONTROL VALVE………………………………………………………………………………………………………………..608
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..608
DISASSEMBLY……………………………………………………………………………………………………………………609
ASSEMBLY………………………………………………………………………………………………………………………610
CONTROL VALVE (WORK EQUIPMENT)………………………………………………………………………………………………………611
DISASSEMBLY……………………………………………………………………………………………………………………611
ASSEMBLY………………………………………………………………………………………………………………………613
SWING MOTOR……………………………………………………………………………………………………………………….615
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..615
DISASSEMBLY……………………………………………………………………………………………………………………616
ASSEMBLY………………………………………………………………………………………………………………………619
CENTER SWIVEL JOINT………………………………………………………………………………………………………………..624
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..624
DISASSEMBLY……………………………………………………………………………………………………………………625
ASSEMBLY………………………………………………………………………………………………………………………626
TRAVEL MOTOR………………………………………………………………………………………………………………………627
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..627
DISASSEMBLY……………………………………………………………………………………………………………………628
ASSEMBLY………………………………………………………………………………………………………………………638
CHARGING PUMP RELIEF VALVE………………………………………………………………………………………………………….650
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..650
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………..651
PPC VALVE (FOR TRAVEL)……………………………………………………………………………………………………………..652
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………..652
PPC VALVE (FOR WORK EQUIPMENT, SWING)………………………………………………………………………………………………..653
DISASSEMBLY AND ASSEMBLY………………………………………………………………………………………………………..653
AUTO-DECELERATION CYLINDER………………………………………………………………………………………………………….654
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..654
BOOM CYLINDER (BACK HOE)……………………………………………………………………………………………………………655
REMOVAL……………………………………………………………………………………………………………………….655
INSTALLATION…………………………………………………………………………………………………………………..656
ARM CYLINDER (BACK HOE)…………………………………………………………………………………………………………….657
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..657
BUCKET CYLINDER (BACK HOE)………………………………………………………………………………………………………….658
REMOVAL……………………………………………………………………………………………………………………….658
INSTALLATION…………………………………………………………………………………………………………………..659
BOOM CYLINDER (LOADING SHOVEL)………………………………………………………………………………………………………660
REMOVAL……………………………………………………………………………………………………………………….660
INSTALLATION…………………………………………………………………………………………………………………..661
ARM CYLINDER (LOADING SHOVEL)……………………………………………………………………………………………………….662
REMOVAL……………………………………………………………………………………………………………………….662
INSTALLATION…………………………………………………………………………………………………………………..663
BUCKET CYLINDER (LOADING SHOVEL)…………………………………………………………………………………………………….664
REMOVAL……………………………………………………………………………………………………………………….664
INSTALLATION…………………………………………………………………………………………………………………..665
BOTTOM, DUMP CYLINDER (LOADING SHOVEL)……………………………………………………………………………………………….666
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..666
HYDRAULIC CYLINDER…………………………………………………………………………………………………………………667
DISASSEMBLY……………………………………………………………………………………………………………………667
ASSEMBLY………………………………………………………………………………………………………………………669
BUCKET (BACK HOE)………………………………………………………………………………………………………………….672
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..672
ARM (BACK HOE)…………………………………………………………………………………………………………………….673
REMOVAL……………………………………………………………………………………………………………………….673
INSTALLATION…………………………………………………………………………………………………………………..674
BOOM (BACK HOE)……………………………………………………………………………………………………………………675
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..675
BUCKET AND ARM (BACK HOE)…………………………………………………………………………………………………………..676
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..676
WORK EQUIPMENT (BACK HOE)…………………………………………………………………………………………………………..677
REMOVAL……………………………………………………………………………………………………………………….677
INSTALLATION…………………………………………………………………………………………………………………..678
BUCKET (LOADING SHOVEL)…………………………………………………………………………………………………………….679
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..679
ARM (LOADING SHOVEL)……………………………………………………………………………………………………………….680
REMOVAL……………………………………………………………………………………………………………………….680
INSTALLATION…………………………………………………………………………………………………………………..681
BOOM (LOADING SHOVEL)………………………………………………………………………………………………………………682
REMOVAL……………………………………………………………………………………………………………………….682
INSTALLATION…………………………………………………………………………………………………………………..683
WORK EQUIPMENT (LOADING SHOVEL)……………………………………………………………………………………………………..684
REMOVAL……………………………………………………………………………………………………………………….684
INSTALLATION…………………………………………………………………………………………………………………..685
OPERATOR’S CAB…………………………………………………………………………………………………………………….686
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..686
COUNTERWEIGHT……………………………………………………………………………………………………………………..687
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..687
MONITOR PANEL……………………………………………………………………………………………………………………..688
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..688
AUTO-DECELERATION・OLSS CONTROLLER……………………………………………………………………………………………………689
REMOVAL AND INSTALLATION………………………………………………………………………………………………………..689
40 MAINTENANCE STANDARD………………………………………………………………………………………………………………..690
PTO………………………………………………………………………………………………………………………………691
SWING CIRCLE………………………………………………………………………………………………………………………692
SWING MACHINERY……………………………………………………………………………………………………………………693
FINAL DRIVE……………………………………………………………………………………………………………………….695
TRACK FRAME AND RECOIL SPRING……………………………………………………………………………………………………….697
TRACK ROLLER………………………………………………………………………………………………………………………698
IDLER…………………………………………………………………………………………………………………………….699
CARRIER ROLLER…………………………………………………………………………………………………………………….701
TRACK SHOE………………………………………………………………………………………………………………………..703
CHARGING AND PTO LUBRICATION PUMP……………………………………………………………………………………………………704
L.H. 5-SPOOL CONTROL VALVE………………………………………………………………………………………………………….705
R.H. 4-SPOOL CONTROL VALVE………………………………………………………………………………………………………….709
SWING CONTROL VALVE………………………………………………………………………………………………………………..712
SWING MOTOR……………………………………………………………………………………………………………………….714
CENTER SWIVEL JOINT………………………………………………………………………………………………………………..715
PILOT RELIEF VALVE…………………………………………………………………………………………………………………716
PPC VALVE…………………………………………………………………………………………………………………………717
HYDRAULIC CYLINDER…………………………………………………………………………………………………………………719
WORK EQUIPMENT…………………………………………………………………………………………………………………….721

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