Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator GALEO PC400LC-7E0, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavators GALEO PC400LC-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEAM017001 – Hydraulic Excavator GALEO PC400LC-7E0 Operation & Maintenance Manual.pdf
CEBM016902 – Hydraulic Excavator GALEO PC400LC-7E0 Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,185 pages
File Format: PDF
Language: English
CEAM017001 – Hydraulic Excavator GALEO PC400LC-7E0 Operation & Maintenance Manual…..2
COVER…..2
INTRODUCTION…..4
FOREWORD…..5
SAFETY INFORMATION…..6
INTRODUCTION…..7
INTENDED USE…..7
FEATURES…..7
DIRECTIONAL REFFERENCE OF MACHINE…..7
BREAKING IN A NEW MACHINE…..8
PLATE LOCATIONS…..8
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…..8
ENGINE SERIAL NUMBER PLATE…..9
SERVICE METER LOCATION…..9
TABLE TO ENTER SERIAL NUMBERS AND DISTRIBUTOR…..10
TABLE OF CONTENTS…..11
SAFETY…..22
SAFETY AND WARNING DECALS…..23
LOCATION OF THE SAFETY DECALS…..23
SAFETY LABELS…..24
OPTIONAL SYSTEMS DECAL…..30
GENERAL SAFETY RULES AND PRECAUTIONS…..33
GENERAL SAFETY RULES…..33
UNAUTHORIZED MODIFICATIONS…..34
GENERAL SAFETY AT JOB SITE…..34
WORKING ON LOOSE GROUND…..34
SAFETY FEATURES…..35
PERSONAL PROTECTIVE EQUIPMENT…..35
FIRE AND EXPLOSION PREVENTION…..36
FIRE CAUSED BY FUEL OR OIL…..36
FIRE CAUSED BY ACCUMULATION OF FLAMMABLE MATERIAL…..36
FIRE COMING FROM ELECTRIC WIRING…..36
FIRE COMING FROM HYDRAULIC LINE…..37
WINDSHIELD WASHER FLUID…..37
ACTION IF FIRE OCCURS…..37
DUST HAZARD PRECAUTIONS…..37
ASBESTOS HAZARD ALERT…..38
KEEP OPERATOR'S COMPARTMENT CLEAN…..38
LEAVING OPERATOR'S SEAT WITH LOCK…..38
MOUNTING AND DISMOUNTING…..39
FIRE EXTINGUISHER AND FIRST AID KIT…..39
INSIDE OPERATOR’S COMPARTMENT…..40
PROTECTION AGAINST FALLING OR FLYING OBJECTS…..40
PRECAUTIONS FOR ATTACHMENTS…..41
QUICK COUPLER ATTACHMENT…..41
LARGE ATTACHMENTS AND COMBINATIONS…..41
PRECAUTIONS BEFORE STARTING OPERATIONS…..42
PRE-OPERATIONAL CHECKS…..42
STARTING YOUR WORK OPERATIONS…..42
WORK SITE HAZZARDS…..43
AVOIDING DANGEROUS SITUATIONS…..43
DIGGING HARD ROCKY GROUND…..47
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…..47
WORKING CLEARANCES…..47
OPERATIONS ON SLOPES…..48
OPERATIONS ON SNOW…..48
RULES FOR ROAD TRAVEL…..49
TRAVELING WITH CARRAGE REVERSED…..49
TRAVEL ON SLOPES…..50
PARKING THE MACHINE…..51
PRECAUTIONS DURING MAINTENANCE OPERATIONS…..52
WARNING TAGS…..52
EQUIPMENT STORAGE…..52
WORKING UNDER THE MACHINE…..53
USING DROP LAMPS…..53
KEEPING THE MACHINE CLEAN…..53
PERFORMING GENERAL MAINTENANCE PROCEDURES…..54
RUNNING THE ENGINE DURING MAINTENANCE…..55
PROPER TOOLS…..55
WELDING, GRINDING OR CUTTING…..56
ADJUSTING TRACK TENSION…..56
DO NOT DISASSEMBLE RECOIL SPRINGS…..56
WHEN USING HAMMER…..56
RULES FOR REFUELING THE MACHINE…..57
COOLING SYSTEM PRECAUTIONS…..57
BATTERY PRECAUTIONS…..58
STARTING ENGINE WITH BOOSTER CABLES…..58
STARTING PRECAUTIONS…..58
HIGH PRESSURE HOSES…..59
SAFETY HANDLING HIGH-PRESSURE HOSES…..59
PRECAUTION FOR HIGH FUEL PRESSURE…..59
HIGH TEMPERATURES AREAS…..59
DISPOSAL OF WASTE MATERIALS…..60
ACCUMULATOR…..60
CRITICAL PARTS…..60
HIGH VOLTAGE…..61
TOWING…..61
SAFETY RULES FOR TOWING…..61
OPERATION…..62
GENERAL VIEWS…..63
VIEW OF MACHINE…..63
VIEW CONTROLS AND GAUGES…..64
MACHINE MONITOR SYSTEM…..65
MONITOR BEZEL LAYOUT…..65
BASIC OPERATION OF MACHINE MONITOR…..66
ABNORMALITY OCCURS WHEN STARTING THE ENGINE…..67
ABNORMALITY OCCURS DURING OPERATION…..68
COLOR WARNING OR ALERT SYSTEM…..69
MONITOR CHECK ITEMS…..70
EMERGENCY ALERTS…..70
ENGINE COOLANT TEMPERATURE MONITOR…..70
HYDRAULIC OIL TEMPERATURE MONITOR…..71
ENGINE OIL PRESSURE MONITOR…..71
WARNING ALERTS…..72
ENGINE COOLANT TEMPERATURE MONITOR…..72
HYDRAULIC OIL TEMPERATURE MONITOR…..73
FUEL LEVEL MONITOR…..73
CHARGE MONITOR…..73
AIR CLEANER CLOGGING MONITOR…..73
CHECK ALERTS…..74
COOLANT LEVEL MONITOR…..74
ENGINE OIL LEVEL MONITOR…..75
MAINTENANCE INTERVAL MONITOR…..75
METER DISPLAY…..76
PILOT DISPLAYS…..76
GAUGES…..79
MONITOR SWITCHES…..81
SWITCH LAYOUT VIEW…..81
WORKING MODE SELECTOR SWITCH…..82
AUTO-DECELERATION SWITCH…..83
TRAVEL SPEED SELECTOR SWITCH…..84
WIPER SWITCH…..85
WINDOW WASHER SWITCH…..85
MAINTENANCE SWITCH…..86
SELECT SWITCH…..88
BACK SWITCH…..90
UP SWITCH, DOWN SWITCH…..90
INPUT CONFIRMATION SWITCH…..91
LIQUID CRYSTAL ADJUSTMENT SWITCH…..91
ALARM BUZZER STOP SWITCH…..92
CONSOLE CONTROL SWITCHES…..93
SWITCH LAYOUT VIEW…..93
IGNITION SWITCH…..94
ENGINE SPEED CONTROL DIAL…..94
CIGARETTE LIGHTER…..94
SWING LOCK SWITCH…..95
LAMP SWITCH…..95
MACHINE PUSH-UP SWITCH…..95
HORN SWITCH…..96
POWER MAX SWITCH…..96
CAB LAMP SWITCH…..96
EMERGENCY PUMP DRIVE SWITCH…..97
SWING BRAKE CANCEL SWITCH…..97
CONTROL LEVERS AND PEDALS…..98
LEVER LAYOUT VIEW…..98
SAFETY LOCK LEVER…..98
TRAVEL LEVERS…..99
WORK EQUIPMENT CONTROL LEVER…..100
WINDOW SYSTEM…..101
CEILING WINDOW…..101
WHEN OPENING…..101
WHEN CLOSING…..101
FRONT WINDOW…..102
WHEN OPENING…..102
WHEN CLOSING…..104
REMOVING FRONT BOTTOM WINDOW…..106
CAB EMERGENCY EXIT WINDOW…..106
SAFETY LOCKS AND SECURITY…..107
DOOR LOCK…..107
CAP, COVER WITH LOCK…..107
OPENING AND CLOSING CAP WITH LOCK…..108
OPENING AND CLOSING COVER…..108
LOCKABLE AREAS…..108
ADDTIONAL FEATURES AND ACCESSORIES…..110
HOT AND COOL BOX…..110
STORAGE BOX WITH CUP HOLDER…..110
ASHTRAY…..110
AUTO-TEMP AIR CONDITIONER…..111
GENERAL DESCRIPTION OF CONTROL PANEL…..111
SUNLIGHT SENSOR…..115
A/C SYSTEM OPERATION…..115
PRECAUTIONS WHEN USING AIR CONDITIONER…..122
MAINTAIN MACHINE EQUIPPED WITH AIR CONDITIONER…..122
SELF-DIAGNOSTIC FUNCTION…..122
RADIO…..124
EXPLANATION OF FEATURES…..124
CONTROLS ON RADIO…..126
TOOLBOX…..128
GREASE GUN HOLDER…..128
AUXILIARY POWER PORTS…..128
24V POWER SOURCE…..128
12V POWER SOURCE (IF EQUIPPED)…..128
FUSES AND FUSE LINKS…..129
FUSES…..129
FUSE CAPACITIES AND CIRCUIT NAMES…..129
FUSIBLE LINK…..130
CONTROLLER…..130
PRECAUTIONS BEFORE STARTING WORK OPERATIONS…..131
PRE-OPERATIONAL CHECKS…..131
WALK-AROUND CHECKS…..131
CHECKS BEFORE STARTING…..132
ADJUSTMENTS BEFORE OPERATION…..137
REARVIEW MIRRORS…..138
VISIBILITY FROM OPERATORS SEAT…..139
SEAT BELT…..140
SYSTEM “ON” CHECKS…..140
STARTING THE ENGINE…..143
NORMAL OR COLD START PROCEDURES…..143
OPERATIONS AND CHECKS AFTER STARTING ENGINE…..146
BREAKING IN THE MACHINE…..146
WARMING UP ENGINE…..146
WARMING UP HYDRAULIC EQUIPMENT…..148
AFTER WARMING-UP OPERATIONS…..152
STOPPING THE ENGINE…..153
CHECK AFTER SHUTING OFF ENGINE…..153
MOVING, STOPPING AND PARKING THE MACHINE…..154
PREPARATIONS FOR MOVING THE MACHINE…..154
MOVING MACHINE FORWARD…..155
MOVING MACHINE BACKWARD…..156
STOPPING MACHINE…..157
TURNING THE MACHINE…..158
TURNING THE MACHINE WHEN STOPPED…..158
CHANGING DIRECTION OF THE MACHINE…..159
COUNTER-ROTATION TURN (SPIN TURN)…..159
SWINGING…..160
GENERAL TRAVELING…..161
TRAVELING OVER OBSTACLES…..161
HIGH SPEED TRAVEL…..161
PERMISSIBLE WATER DEPTH…..161
TRAVELING ON SLOPES…..162
TRAVELING DOWNHILL…..163
ENGINE STOPPED ON SLOPE…..163
PRECAUTIONS ON SLOPES…..163
ESCAPING FROM MUD…..164
ONE SIDE OF TRACK STUCK…..164
BOTH SIDES OF TRACKS STUCK…..164
PARKING MACHINE…..165
CLEARING THE MACHINES TRACKS…..165
PARKING…..165
MACHINE INSPECTION AFTER DAILY WORK…..167
STARTING YOUR WORK OPERATIONS…..168
AVOIDING DANGEROUS SITUATIONS…..168
DIGGING HARD ROCKY GROUND…..171
SUDDEN LEVER SHIFTING HIGH SPEED TRAVEL…..171
WORKING CLEARANCES…..172
OPERATIONS ON SLOPES…..172
OPERATIONS ON SNOW…..173
WORK EQUIPMENT OVERVIEW…..174
ARM CONTROL…..174
SWING CONTROL…..174
BOOM CONTROL…..174
BUCKET CONTROL…..174
OPERATING MODES…..175
WORKING MODE…..175
ONE-TOUCH POWER MAX. SWITCH…..175
EXCAVATING PROCEDURES…..176
WORK EQUIPMENT ANGLES…..177
DITCHING WORK…..177
LOADING WORK…..177
SEVERE JOB CONDITIONS…..177
BUCKET REPLACEMENT AND INVERSION…..178
BUCKET REPLACEMENT…..178
BUCKET INVERSION…..179
TRANSPORTING THE MACHINE…..180
LOADING AND UNLOADING A TRAILER…..180
LOADING THE MACHINE…..181
SECURING MACHINE…..183
UNLOADING THE MACHINE…..184
LIFTING THE MACHINE…..186
DISSEMBLY TRANSPORTATION POSTURE…..188
POSTURE FOR EACH PART…..188
TOWING THE MACHINE…..191
LIGHTWEIGHT TOWING HOOK…..192
SEVERE JOB CONDITION…..192
INCREASING OR REDUCING TRACK FRAME GAUGE…..193
REDUCING TRACK GAUGE…..193
INCREASING TRACK GAUGE…..194
COLD WEATHER OPERATION…..195
FUEL AND LUBRICANTS…..195
COOLING SYSTEM COOLANT…..195
BATTERY…..196
MONITOR…..197
PRECAUTIONS ON PARTICULAR JOBSITES…..198
DISCHARGED BATTERY…..198
REMOVAL AND INSTALLATION OF BATTERY…..199
BATTERY CHARGES…..199
STARTING ENGINE WITH BOOSTER CABLES…..200
GENERAL TROUBLESHOOTING…..202
AFTER RUNNING OUT OF FUEL…..202
PROCEDURE FOR BLEEDING AIR…..202
PHENOMENA THAT ARE NOT FAILURES…..203
ELECTRICAL SYSTEM PROBLEMS…..204
CHASSIS PROBLEMS…..205
ENGINE PROBLEMS…..206
ELECTRONIC CONTROL SYSTEM…..207
MACHINE MONITOR TROUBLE DISPLAY…..207
TELEPHONE WHEN ERROR OCCURS…..208
LONG TERM STORAGE…..209
BEFORE STORAGE…..209
DURING STORAGE…..209
AFTER STORAGE…..209
STARTING MACHINE…..209
MAINTENANCE…..210
MAINTENANCE INFORMATION…..211
SERVICE METER READING…..211
KOMATSU GENUINE REPLACEMENT PARTS…..211
KOMATSU GENUINE LUBRICANTS…..211
WINDSHIELD WASHER FLUID…..211
FRESH AND CLEAN LUBRICANTS…..211
CHECK DRAINED OIL AND USED FILTER…..211
FUEL STRAINER…..211
WELDING INSTRUCTIONS…..211
DO NOT DROP THINGS INSIDE MACHINE…..211
SELECTING FUEL AND LUBRICANTS TO MATCH AMBIENT TEMPERATURE…..211
DUSTY JOBSITE…..212
AVOID MIXING LUBRICANTS…..212
LOCKING THE INSPECTION COVERS…..212
HYDRAULIC SYSTEM – AIR BLEEDING…..212
HYDRAULIC HOSE INSTALLATION…..212
CHECKS AFTER INSPECTION AND MAINTENANCE WORKS…..212
LUBRICANTS, COOLANT AND FILTERS…..213
OUTLINE OF SERVICE…..213
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…..213
OIL…..213
FUEL…..214
COOLING SYSTEM COOLANT…..214
GREASE…..214
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)…..215
OIL AND FUEL STORAGE…..215
FILTERS…..216
ELECTRIC SYSTEM MAINTENANCE…..217
HANDLING HYDRAULIC SYSTEM…..217
WEAR PARTS LIST…..218
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…..219
RECOMMENDED PRODUCTS OTHER THAN KOMATSU GENUINE OILS…..221
TIGHTENING TORQUE SPECIFICATIONS…..222
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..223
SAFETY RELATED CRITICAL PARTS…..224
MAINTENANCE SCHEDULE…..225
MAINTENANCE SCHEDULE CHART…..225
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER…..227
REPLACE HYDRAULIC FILTER ELEMENT…..227
CHANGE OIL IN HYDRAULIC TANK…..227
REPLACING ADDITIONAL FILTER ELEMENT FOR BREAKER (IF EQUIPPED)…..227
MAINTENANCE PROCEDURE…..228
INITIAL 1000 HOURS MAINTENANCE (ONLY AFTER THE FIRST 1000 HOURS)…..228
WHEN REQUIRED…..229
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…..229
CLEAN INSIDE OF COOLING SYSTEM…..234
CHECK AND TIGHTEN TRACK SHOE BOLTS…..237
CHECK AND ADJUST TRACK TENSION…..238
REPLACE BUCKET TEETH (VERTICAL PIN TYPE)…..240
REPLACE BUCKET TEETH (HORIZONTAL PIN TYPE)…..243
REPLACE BUCKET SIDE CUTTER, SHROUD…..244
ADJUST BUCKET CLEARANCE…..245
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..246
CHECK AND ADJUST AIR CONDITIONER…..246
CLEANING CAB FLOOR…..247
SETTING MACHINE AT AN ANGLE…..249
BLEEDING AIR FROM HYDRAULIC SYSTEM…..250
CHECK BEFORE STARTING…..252
EVERY 50 HOURS MAINTENANCE…..253
LUBRICATING…..253
EVERY 250 HOURS MAINTENANCE…..254
LUBRICATE SWING CIRCLE…..254
CHECK OIL LEVEL IN MACHINERY CASE, ADD OIL…..254
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…..255
CHECK LEVEL OF BATTERY ELECTROLYTE…..256
CHECK, ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…..258
CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST…..259
EVERY 500 HOURS MAINTENANCE…..260
LUBRICATING…..260
REPLACE FUEL PRE-FILTER CARTRIDGE…..261
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..264
CHANGING ENGINE OIL AND REPLACING ENGINE OIL FILTER CARTRIDGE…..265
CLEAN/INSPECT RADIATOR, OIL COOLER, AFTERCOOLER AND CONDENSER FINS…..266
CLEAN AIR CONDITIONER FRESH/RECIRC FILTERS…..267
REPLACE BREATHER ELEMENT IN HYDRAULIC TANK…..268
EVERY 1000 HOURS MAINTENANCE…..269
REPLACE FUEL MAIN FILTER CARTRIDGE…..269
REPLACE HYDRAULIC OIL FILTER ELEMENT…..271
CHANGE OIL IN SWING MACHINERY CASE…..272
CHECK OIL LEVEL IN DAMPER CASE, ADD OIL…..273
CHECK ALL TIGHTENING POINTS OF ENGINE EXHAUST PIPE CLAMPS…..273
REPLACE CORROSION RESISTOR CARTRIDGE (IF EQUIPPED)…..274
CHECK FAN BELT AND ALTERNATOR DRIVE BELT TENSION, REPLACE…..274
REPLACE HYDRAULIC TANK ADDITIONAL BREATHER ELEMENT…..275
CHECK NITROGEN GAS CHARGE PRESSURE IN ACCUMULATOR (FOR BREAKER)…..275
EVERY 2000 HOURS MAINTENANCE…..276
CHANGE OIL IN FINAL DRIVE CASE…..276
CLEAN HYDRAULIC TANK STRAINER…..277
CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)…..278
CHECKING FUNCTION OF ACCUMULATOR…..279
RELEASING PRESSURE IN HYDRAULIC CIRCUIT…..280
CHECK ALTERNATOR, STARTING MOTOR…..281
CHECK ENGINE VALVE CLEARANCE, ADJUST…..281
CHECK VIBRATION DAMPER…..281
EVERY 4000 HOURS MAINTENANCE…..282
CHECK WATER PUMP…..282
CHECKING CHARGE PRESSURE IN ACCUMULATOR (FOR CONTROL CIRCUIT)…..282
CHECK HIGH-PRESSURE PIPING CLAMP, HARDENING OF RUBBER…..283
CHECK FUEL SPRAY PREVENTION CAP, HARDENING OF RUBBER…..283
EVERY 5000 HOURS MAINTENANCE…..284
CHANGE OIL IN HYDRAULIC TANK…..284
EVERY 8000 HOURS MAINTENANCE…..285
REPLACE HIGH-PRESSURE PIPING CLAMP…..285
REPLACE FUEL SPRAY PREVENTION CAP…..285
SPECIFICATIONS…..286
SPECIFICATIONS…..287
OPTIONS, ATTACHMENTS…..290
GENERAL PRECAUTIONS…..291
PRECAUTIONS RELATED TO SAFETY…..291
PRECAUTIONS FOR ATTACHMENT REMOVAL AND INSTALLATION…..291
PRECAUTIONS WHEN USING LARGE IMPLEMENTS…..292
HANDLING BUCKET WITH HOOK…..293
HOOK CONDITION…..293
PROHIBITED OPERATIONS…..293
MACHINES READY FOR ATTACHMENTS…..294
EXPLANATION OF COMPONENTS…..294
STOP VALVE…..294
SELECTOR VALVE…..295
ATTACHMENT CONTROL PEDAL…..295
LOCK PIN…..296
BREAKER CIRCUIT ADDITIONAL OIL FILTER…..296
HYDRAULIC CIRCUIT…..299
SWITCHING THE HYDRAULIC CIRCUIT…..299
ADJUSTING OIL FLOW…..299
SWITCHING BETWEEN BREAKER AND GENERAL ATTACHMENT…..299
HYDRAULIC CIRCUIT CONNECTION…..300
OIL FLOW…..301
REPLACE ADDITIONAL BREAKER FILTER ELEMENT…..302
ATTACHMENT INSTALLATION AND REMOVAL PROCEDURE…..303
REMOVAL PROCEDURE…..303
INSTALLATION PROCEDURE…..304
ATTACHMENT OPERATIONS…..305
WHEN USING BREAKER…..305
WHEN USING GENERAL ATTACHMENT SUCH AS CRUSHER…..305
LONG TERM STORAGE…..306
SPECIFICATIONS…..306
ATTACHMENT GUIDE…..307
COMBINATIONS OF WORK EQUIPMENT…..307
SELECTION OF TRACK SHOES…..309
SELECTING SHOES…..309
HYDRAULIC BREAKER…..310
MAIN APPLICATIONS…..310
PROHIBITED OPERATIONS…..311
GREASING…..313
CEBM016902 – Hydraulic Excavator GALEO PC400LC-7E0 Shop Manual…..314
COVER…..314
CONTENTS…..315
FOREWORD…..316
SAFETY…..324
SAFETY NOTICE…..324
GENERAL…..326
HOW TO READ THE SHOP MANUAL…..327
HOISTING INSTRUCTIONS…..328
PUSH PULL COUPLER…..329
EXPLANATION OF MAINTENANCE STANDARD TERMS…..332
STANDARD TIGHTENING TORQUE…..334
BOLTS AND NUTS…..334
TIGHTENING TORQUE OF HOSE NUTS…..335
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS…..335
TIGHTENING TORQUE FOR FLARED NUTS…..335
TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS…..336
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS…..336
TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)…..336
HOW TO READ ELECTRIC WIRE CODE…..338
CONVERSION TABLES…..341
METHOD OF USING THE CONVERSION TABLE…..341
Millimeters to Inches…..342
Kilogram to Pound…..342
Liter to U.S. Gallon…..343
Liter to U.K. Gallon…..343
kgm to ft. lb…..344
kg/cm2 to lb/in2…..345
Temperature…..346
COATING MATERIALS…..347
01 GENERAL…..350
SPECIFICATIONS…..351
DIMENSIONS…..352
FIXED GAUGE SPECIFICATION…..352
VARIABLE GAUGE SPECIFICATION…..352
WORKING RANGES…..352
WEIGHT TABLE…..357
FUEL COOLANT AND LUBRICANTS…..359
10 STRUCTURE AND FUNCTION…..362
ENGINE AND COOLING SYSTEM…..366
ENGINE RELATED PARTS…..366
RADIATOR, OIL COOLER AND AFTERCOOLER…..367
POWER TRAIN…..368
POWER TRAIN…..368
FINAL DRIVE…..369
SPROCKET…..371
SWING MACHINERY…..373
SWING CIRCLE…..375
UNDERCARRIAGE AND FRAME…..377
TRACK FRAME AND RECOIL SPRING…..377
IDLER…..379
CARRIER ROLLER…..381
TRACK ROLLER…..383
TRACK SHOE…..385
TRIPLE GROUSER SHOE…..388
HYDRAULIC SYSTEM…..389
HYDRAULIC PIPING DRAWING…..389
HYDRAULIC TANK AND FILTER…..391
HYDRAULIC PUMP…..393
LS VALVE…..399
PC VALVE…..404
LS(PC)-EPC VALVE…..411
VARIABLE VOLUME VALVE…..414
CONTROL VALVE…..415
CLSS (CLOSED CENTER LOAD SENSING SYSTEM)…..427
FUNCTIONS AND OPERATION BY VALVE…..431
UNLOAD VALVE…..433
LS BYPASS VALVE…..436
PRESSURE COMPENSATION VALVE…..437
PRESSURE COMPENSATION VALVE INNER SHUTTLE VALVE…..440
BOOM REGENERATION CIRCUIT…..442
ARM REGENERATION CIRCUIT…..444
MERGE-DIVIDER VALVE…..446
LS SELECT VALVE…..448
SELF PRESSURE REDUCING VALVE…..449
TRAVEL JUNCTION VALVE…..452
TRAVEL PPC SHUTTLE VALVE…..454
BOOM DRIFT PREVENTIVE VALVE…..456
ARM DRIFT PREVENTIVE VALVE…..459
QUICK RETURN VALVE…..463
LIFT CHECK VALVE…..465
MAIN RELIEF VALVE…..466
2-STAGE SAFETY-SUCTION VALVE…..467
VARIABLE PRESSURE COMPENSATION VALVE…..469
ATTACHMENT CIRCUIT SELECTOR VALVE…..475
VALVE CONTROL…..473
PPC VALVE…..475
TRAVEL PPC VALVE…..480
SERVICE PPC VALVE…..490
SOLENOID VALVE…..492
PPC ACCUMULATOR…..494
RETURN OIL FILTER…..495
CENTER SWIVEL JOINT…..496
TRAVEL MOTOR…..498
BRAKE VALVE…..506
SWING MOTOR…..512
REVERSE PREVENTION VALVE…..518
WORK EQUIPMENT…..524
WORK EQUIPMENT…..524
DIMENSIONS OF COMPONENTS…..526
DIMENSION OF ARM…..526
DIMENSION OF BUCKET…..528
AIR CONDITIONER PIPING…..530
ELECTRICAL SYSTEM…..531
ENGINE CONTROL…..531
FUEL CONTROL DIAL…..532
ENGINE CONTROLLER…..534
SENSORS…..538
ROTATION SENSOR…..538
OIL PRESSURE SWITCH…..538
AMBIENT PRESSURE SENSOR…..539
BOOST PRESSURE SENSOR…..539
BOOST TEMPERATURE SENSOR…..540
COOLANT TEMPERATURE SENSOR…..540
HYDRAULIC OIL TEMPERATURE SENSOR…..540
EGR VALVE STROKE SENSOR…..541
ENGINE OIL LEVEL SENSOR…..542
ELECTRONIC CONTROL SYSTEM…..543
ENGINE AND PUMP COMPOSITE CONTROL FUNCTION…..546
PUMP AND VALVE CONTROL FUNCTION…..551
POWER MAXIMIZING AND MACHINE PUSH-UP FUNCTION…..553
AUTO-DECELERATION FUNCTION…..555
AUTO-WARM-UP AND OVERHEAT PREVENTION FUNCTION…..556
SWING CONTROL FUNCTION…..558
TRAVEL CONTROL FUNCTION…..560
ATTACHMENT FLOW CONTROL AND CIRCUIT SELECTOR FUNCTION…..562
SYSTEM COMPONENT PARTS…..563
PUMP PRESSURE SENSOR (HIGH PRESSURE)…..565
PUMP CONTROLLER…..566
MONITOR SYSTEM…..569
MACHINE MONITOR…..570
MONITOR PORTION…..572
SWITCHES…..577
MAINTENANCE FUNCTION…..584
SENSOR…..590
HYDRAULIC OIL LEVEL SENSOR…..590
HYDRAULIC OIL TEMPERATURE SENSOR…..590
COOLANT TEMPERATURE SENSOR…..590
FUEL LEVEL SENSOR…..591
AIR CLEANER CLOGGING SENSOR…..591
KOMTRAX TERMINAL SYSTEM…..593
KOMTRAX TERMINAL…..594
20 TESTING, ADJUSTING AND TROUBLESHOOTING…..596
STANDARD VALUE TABLES…..597
ENGINE RELATED…..597
TESTING AND ADJUSTING…..606
SERVICE TOOLS…..608
ENGINE SPEED…..610
ENGINE…..611
EXHAUST GAS COLOR…..612
FAN BELT AND ALTERNATOR BELT TENSION…..613
AIR CONDITIONER COMPRESSOR BELT TENSION…..614
SWING CIRCLE BEARING CLEARANCE…..615
TRACK SHOE TENSION…..616
WORK EQUIPMENT, SWING, AND TRAVEL OIL CIRCUITS…..617
CONTROL CIRCUIT – BASIC PRESSURE…..622
PUMP PC CONTROL CIRCUIT…..623
PUMP LS CONTROL CIRCUIT…..627
SOLENOID VALVE – OUTPUT PRESSURE…..632
PPC VALVE – OUTPUT PRESSURE…..635
WORK EQUIPMENT PPC VALVE – PLAY ADJUSTMENT…..637
SWING PPC VALVE – PLAY ADJUSTMENT…..637
WORK EQUIPMENT – HYDRAULIC DRIFT – CAUSE…..638
RELEASING RESIDUAL PRESSURE HYDRAULIC CIRCUIT…..640
MEASURING OIL LEAKAGE…..641
BLEEDING AIR FROM VARIOUS PARTS…..644
DIODE TESTING PROCEDURE…..647
MONITOR PANEL – SPECIAL FUNCTIONS…..648
OPERATOR’S MENU (OUTLINE)…..650
FAILURE CODES TABLE…..656
SERVICE MENU…..659
LIST OF MONITORING ITEMS…..662
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER…..676
PROCEDURE FOR TURNING ON KOMTRAX TERMINAL…..677
ELECTRICAL EQUIPMENT SYSTEM – PREPARATION WORK FOR TROUBLESHOOTING…..683
12 PM CLINIC SERVICE…..685
TROUBLESHOOTING GENERAL…..692
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..694
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..696
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..697
POINTS TO REMEMBER WHEN HANDLING ELECTRIC EQUIPMENT…..697
HANDLING WIRING HARNESSES AND CONNECTORS…..697
12 REMOVING, INSTALLING, AND DRYING CONNECTORS AND WIRING HARNESSES…..699
HANDLING CONTROL BOX…..702
POINTS TO REMEMBER WHEN TROUBLESHOOTING ELECTRIC CIRCUITS…..703
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT…..703
CHECKS BEFORE TROUBLESHOOTING…..705
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING…..706
CLASSIFICATION OF TROUBLESHOOTING…..706
STEPS FOR TROUBLESHOOTING…..706
POSSIBLE PROBLEMS AND TROUBLESHOOTING NO…..707
CONNECTOR ARRANGEMENT DIAGRAM…..710
ELECTRICAL CIRCUIT DIAGRAM…..721
See Section 90 for diagrams…..721
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..722
12 T-BOXES AND T-ADAPTERS TABLE…..744
TROUBLESHOOTING ERROR CODES AND FAILURE CODES…..748
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM…..752
POINTS TO REMEMBER IF ABNORMALITY RETURNS TO NORMAL BY ITSELF…..753
USER CODE MEMORY RETENTION FUNCTION…..753
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)…..754
FAILURE CODES TABLE…..754
BEFORE CARRYING OUT TROUBLESHOOTING WHEN FAILURE CODE IS DISPLAYED…..757
INFORMATION IN TROUBLESHOOTING TABLE…..761
A000N1 – ENG. HI OUT OF STD…..763
AA10NX – AIR CLEANER CLOGGING…..764
AB00KE – CHARGE VOLTAGE LOW…..765
B@BAZG – ENG OIL PRESS. LOW…..767
B@BAZK – ENG. OIL LEVEL LOW…..769
B@BCZK – ENG. WATER LVL LOW…..773
B@HANS – HYD. OIL OVERHEAT…..774
CA111 – ECM CRITICAL INTERNAL FAILURE…..775
CA115 – ENG NE AND BKUP SPEED SENS ERROR…..777
CA122 – CHG AIR PRESS SENSOR HIGH ERROR…..779
CA123 – CHG AIR PRESS SENSOR LOW ERROR…..781
CA131 – THROTTLE SENSOR HIGH ERROR…..783
CA132 – THROTTLE SENSOR LOW ERROR…..784
CA135 – ENG OIL PRESS SENSOR HIGH ERROR…..785
CA141 – ENG OIL PRESS SENSOR LOW ERROR…..786
CA144 – COOLANT TEMP SENS HIGH ERROR…..787
CA145 – COOLANT TEMP SENS LOW ERROR…..788
CA153 – CHG AIR TEMP SENSOR HIGH ERROR…..789
CA154 – CHG AIR TEMP SENSOR LOW ERROR…..791
CA187 – SENS SUPPLY 2 VOLT LOW ERROR…..792
CA221 – AMBIENT PRESS SENS HIGH ERROR…..793
CA222 – AMBIENT PRESS SENS LOW ERROR…..795
CA227 – SENS SUPPLY 2 VOLT HIGH ERROR…..797
CA234 – ENG OVERSPEED…..799
CA238 – NE SPEED SENS SUPPLY VOLT ERROR…..801
CA263 – FUEL TEMP SENSOR HIGH ERROR…..803
CA265 – FUEL TEMP SENSOR LOW ERROR…..805
CA271 – IMV/PCV1 SHORT ERROR…..806
CA272 – IMV/PCV1 OPEN ERROR…..807
CA273 – PCV2 SHORT ERROR…..809
CA274 – PCV2 OPEN ERROR…..810
CA322 – INJ #1 (L#1) OPEN/SHORT ERROR…..811
CA323 – INJ #5 (L#5) OPEN/SHORT ERROR…..812
CA324 – INJ #3 (L#3) OPEN/SHORT ERROR…..813
CA325 – INJ #6 (L#6) OPEN/SHORT ERROR…..814
CA331 – INJ #2 (L#2) OPEN/SHORT ERROR…..815
CA332 – INJ #4 (L#4) OPEN/SHORT ERROR…..816
CA342 – CALIBRATION CODE INCOMPATIBILITY…..817
CA351 – INJECTORS DRIVE CIRCUIT ERROR…..819
CA352 – SENS SUPPLY 1 VOLT LOW ERROR…..821
CA386 – SENS SUPPLY 1 VOLT HIGH ERROR…..823
CA441 – BATTERY VOLTAGE LOW ERROR…..825
CA442 – BATTERY VOLTAGE HIGH ERROR…..826
CA449 – RAIL PRESS VERY HIGH ERROR…..827
CA451 – RAIL PRESS SENSOR HIGH ERROR…..829
CA452 – RAIL PRESS SENSOR LOW ERROR…..831
CA553 – RAIL PRESS HIGH ERROR 1…..831
CA554 – RAIL PRESS SENSOR IN RANGE ERROR…..832
CA559 – RAIL PRESS LOW ERROR…..833
CA689 – ENG NE SPEED SENSOR ERROR…..837
CA731 – ENG BKUP SPEED SENS PHASE ERROR…..839
CA757 – ALL PERSISTENT DATA LOST ERROR…..840
CA778 – ENG BKUP SPEED SENSOR ERROR…..841
CA1228 – EGR VALVE SERVO ERROR 1…..843
CA1625 – EGR VALVE SERVO ERROR 2…..844
CA1633 – KOMNET DATALINK TIMEOUT ERROR…..845
CA2185 – THROT SENS SUP VOLT HIGH ERROR…..847
CA2186 – THROT SENS SUP VOLT LOW ERROR…..849
CA2249 – RAIL PRESS VERY LOW ERROR…..850
CA2271 – EGR VALVE LIFT SENS HIGH ERROR…..851
CA2272 – EGR VALVE LIFT SENS LOW ERROR…..853
CA2351 – EGR VALVE SOL CURRENT HIGH ERROR…..855
CA2352 – EGR VALVE SOL CURRENT LOW ERROR…..857
CA2555 – GRID HTR RELAY VOLT LOW ERROR…..858
CA2556 – GRID HTR RELAY VOLT HIGH ERROR…..859
D110KB – BATTERY RELAY DRIVE S/C…..861
D196KA – SERVICE RETURN RELAY DISC…..863
D196KB – SERVICE RETURN RELAY S/C…..865
DA25KP – PRESS. SENSOR POWER ABNORMALITY…..867
DA80MA – AUTO-LUBE ABNORMAL…..869
DA2RMC – PUMP COMM. ABNORMALITY…..871
DA2SKQ – MODEL SELECTION ABNORMALITY…..873
DAFRMC – MONITOR COMM. ABNORMALITY…..875
DHPAMA – F PUMP P. SENSOR ABNORMALITY…..877
DHPBMA – R PUMP P. SENSOR ABNORMALITY…..879
DHS3MA – ARM CURL PPC SEN. ABNORMALITY…..881
DHS4MA – BUCKET CURL PPC SEN. ABNORMALITY…..883
DW43KA – TRAVEL SPEED SOL. DISC…..885
DW43KB – TRAVEL SPEED SOL. S/C…..887
DW45KA – SWING BRAKE SOL. DISC…..889
DW45KB – SWING BRAKE SOL. S/C…..891
DW91KA – TRAVEL JUNCTION SOL. DISC…..893
DW91KB – TRAVEL JUNCTION SOL. S/C…..895
DWJ0KA – MERGE-DIVIDER SOL. DISC…..897
DWJ0KB – MERGE-DIVIDER SOL. S/C…..899
DWK0KA – 2-STAGE RELIEF SOL. DISC…..901
DWK0KB – 2-STAGE RELIEF SOL. S/C…..903
DXA0KA – PC-EPC SOL. DISC…..905
DXA0KB – PC-EPC SOL. S/C…..907
DXE0KA – LS-EPC SOL. DISC…..909
DXE0KB – LS-EPC SOL. S/C…..911
DXE4KA – SERVICE CURRENT EPC DISC…..913
DXE4KB – SERVICE CURRENT EPC S/C…..914
DY20KA – WIPER WORKING ABNORMALITY…..915
DY20MA – WIPER PARKING ABNORMALITY…..917
DY2CKB – WASHER DRIVE S/C…..919
DY2DKB – WIPER DRIVE (FOR) S/C…..921
DY2EKB – WIPER DRIVE (REV) S/C…..923
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…..926
BEFORE CARRYING OUT TROUBLESHOOTING…..927
CONNECTION TABLE OF FUSE BOX…..927
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..929
E-1 ENGINE DOES NOT START…..930
E-2 AUTO-DECELERATOR DOES NOT OPERATE…..933
E-3 AUTOMATIC WARMING-UP DOES NOT OPERATE…..934
E-4 PREHEATER DOES NOT OPERATE…..935
E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVE…..937
E-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATE…..939
E-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL…..940
E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMS…..941
E-9 DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINE…..941
E-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNING…..942
E-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY…..943
E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY…..945
E-13 FUEL LEVEL GAUGE DOES NOT OPERATE NORMALLY…..946
E-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLY…..947
E-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHING…..949
E-16 WINDSHIELD WIPER DOES NOT OPERATE…..951
E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY…..955
E-18 MONITORING FUNCTION FAILS TO DISPLAY “BOOM RAISE” NORMALLY…..957
E-19 MONITORING FUNCTION FAILS TO DISPLAY “BOOM LOWER" NORMALLY…..958
E-20 MONITORING FUNCTION FAILS TO DISPLAY “ARM IN” NORMALLY…..959
E-21 MONITORING FUNCTION FAILS TO DISPLAY “ARM OUT” NORMALLY…..960
E-22 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET CURL" NORMALLY…..961
E-23 MONITORING FUNCTION FAILS TO DISPLAY “BUCKET DUMP" NORMALLY…..962
E-24 MONITORING FUNCTION FAILS TO DISPLAY “SWING” NORMALLY…..963
E-25 MONITORING FUNCTION FAILS TO DISPLAY “TRAVEL” NORMALLY…..965
E-26 MONITORING FAILS TO DISPLAY “TRAVEL DIFFERENTIAL PRESSURE" NORMALLY…..967
E-27 MONITORING FAILS TO DISPLAY “SERVICE” NORMALLY…..969
E-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…..971
E-29 AIR CONDITIONER DOES NOT OPERATE…..973
E-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING…..975
E-31 HORN DOES NOT SOUND…..977
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H-MODE)…..988
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS…..989
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..991
H-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOW…..992
H-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS…..993
H-3 NO WORK EQUIPMENT, TRAVEL OR SWING MOVE…..994
H-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP…..994
H-5 AUTO-DECELERATOR DOES NOT WORK…..995
H-6 FINE CONTROL MODE DOES NOT FUNCTION…..995
H-7 BOOM MOVES SLOWLY OR LACKS POWER…..996
H-8 ARM MOVES SLOWLY OR LACKS POWER…..997
H-9 BUCKET MOVES SLOWLY OR LACKS POWER…..998
H-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION…..998
H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFT…..999
H-12 WORK EQUIPMENT HAS BIG TIME LAG…..1000
H-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUIT…..1000
H-14 ONE-TOUCH POWER MAX. FUNCTION DOES NOT WORK…..1000
H-15 MACHINE PUSH-UP FUNCTION DOES NOT WORK…..1001
H-16 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY…..1001
H-17 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLY…..1002
H-18 IN SWING + TRAVEL, TRAVEL SPEED DROPS SHARPLY…..1002
H-19 MACHINE SWERVES IN TRAVEL…..1003
H-20 MACHINE TRAVELS SLOWLY…..1004
H-21 MACHINE CANNOT BE EASILY STEERED OR LACKS POWER…..1005
H-22 TRAVEL SPEED DOES NOT SHIFT, OR IT IS SLOWER OR FASTER THAN PRESET SPEED…..1006
H-23 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)…..1006
H-24 MACHINE DOES NOT SWING…..1007
H-25 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW…..1008
H-26 EXCESSIVE OVERRUN WHEN STOPPING SWING…..1009
H-27 THERE IS BIG SHOCK WHEN STOPPING SWING…..1010
H-28 LARGE SOUND CAUSED WHEN STOPPING SWING…..1010
H-29 SWING NATURAL DRIFT IS TOO LARGE…..1011
H-30 ATTACHMENT CIRCUIT DOES NOT CHANGE…..1012
H-31 FLOW RATE IN ATTACHMENT CIRCUIT CANNOT BE ADJUSTED…..1012
30 DISASSEMBLY AND ASSEMBLY…..1014
HOW TO READ THIS MANUAL…..1018
REMOVAL AND INSTALLATION OF PARTS…..1018
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES…..1020
PRECAUTIONS DURING OPERATION…..1022
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK…..1022
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK…..1023
PRECAUTIONS WHEN COMPLETING THE OPERATIONS…..1024
OTHER PRECAUTIONS…..1024
SPECIAL TOOL LIST…..1025
SKETCHES OF SPECIAL TOOLS…..1029
CONNECTOR REPAIR PROCEDURES…..1031
CONTACT TERMINAL REMOVAL (HD30 TYPE)…..1031
STRIPPING INSULATION…..1032
CRIMPING CONTACT TERMINAL (HD30 TYPE)…..1033
INSERTION OF CONTACT TERMINAL (HD30 TYPE)…..1034
CONTACT TERMINAL REMOVAL (DT TYPE)…..1035
CRIMPING CONTACT TERMINAL (DT TYPE)…..1036
INSERTION OF CONTACT TERMINAL (DT TYPE)…..1037
ENGINE…..1038
AFTERCOOLER…..1038
ALTERNATOR…..1038
CYLINDER HEAD…..1038
ENGINE FRONT SEAL…..1038
ENGINE OIL COOLER…..1038
ENGINE REAR SEAL…..1038
FUEL INJECTION PUMP…..1038
NOZZLE HOLDER…..1038
NOZZLE TIP…..1038
STARTING MOTOR…..1038
THERMOSTAT…..1038
TURBOCHARGER…..1038
WATER PUMP…..1038
RADIATOR ASSEMBLY…..1039
REMOVAL…..1039
INSTALLATION…..1040
HYDRAULIC OIL COOLER ASSEMBLY…..1041
REMOVAL…..1041
INSTALLATION…..1042
AFTERCOOLER ASSEMBLY…..1043
REMOVAL…..1043
INSTALLATION…..1044
ENGINE AND HYDRAULIC OIL PUMP ASSEMBLY…..1045
REMOVAL…..1045
INSTALLATION…..1053
FINAL DRIVE ASSEMBLY…..1054
DISASSEMBLY…..1056
REMOVAL…..1054
INSTALLATION…..1055
FINAL DRIVE ASSEMBLY…..1056
DISASSEMBLY…..1056
ASSEMBLY…..1060
SWING MOTOR AND SWING MACHINERY…..1066
DISASSEMBLY…..1068
REMOVAL…..1066
INSTALLATION…..1067
SWING MOTOR AND SWING MACHINERY…..1068
DISASSEMBLY…..1068
ASSEMBLY…..1071
SWING CIRCLE ASSEMBLY…..1077
REMOVAL…..1077
INSTALLATION…..1077
UNDERCARRIAGE AND FRAME…..1078
ASSEMBLY…..1078
TRACK ROLLER ASSEMBLY…..1080
ASSEMBLY…..1080
IDLER ASSEMBLY…..1081
DISASSEMBLY…..1081
ASSEMBLY…..1082
RECOIL SPRING ASSEMBLY…..1085
DISASSEMBLY…..1085
ASSEMBLY…..1086
SPROCKET…..1087
REMOVAL…..1087
INSTALLATION…..1087
TRACK SHOE ASSEMBLY…..1088
EXPANSION…..1088
INSTALLATION…..1088
REVOLVING FRAME ASSEMBLY…..1090
REMOVAL…..1090
INSTALLATION…..1092
COUNTERWEIGHT ASSEMBLY…..1093
REMOVAL…..1093
INSTALLATION…..1093
CENTER SWIVEL JOINT ASSEMBLY…..1094
REMOVAL…..1094
INSTALLATION…..1095
DISASSEMBLY…..1095
ASSEMBLY…..1096
HYDRAULIC TANK ASSEMBLY…..1097
REMOVAL…..1097
INSTALLATION…..1098
CONTROL VALVE ASSEMBLY…..1099
REMOVAL…..1099
INSTALLATION…..1102
DISASSEMBLY…..1102
REPLACEMENT PROCEDURE FOR PRESSURE COMPENSATION VALVE SEAL…..1102
ASSEMBLY…..1104
HYDRAULIC PUMP ASSEMBLY…..1107
REMOVAL…..1107
INSTALLATION…..1109
HYDRAULIC PUMP INPUT SHAFT…..1110
REMOVAL…..1110
INSTALLATION…..1110
WORK EQUIPMENT PPC VALVE ASSEMBLY…..1111
ASSEMBLY…..1111
TRAVEL PPC VALVE ASSEMBLY…..1112
DISASSEMBLY…..1112
ASSEMBLY…..1112
HYDRAULIC CYLINDER ASSEMBLY…..1113
DISASSEMBLY…..1113
ASSEMBLY…..1115
WORK EQUIPMENT ASSEMBLY…..1119
REMOVAL…..1119
INSTALLATION…..1120
CAB…..1122
REMOVAL…..1122
INSTALLATION…..1125
CAB GLASS (STUCK GLASS)…..1126
REMOVAL…..1127
INSTALLATION…..1127
WINDOW ASSEMBLY…..1137
REMOVAL…..1137
INSTALLATION…..1140
AIR CONDITIONER UNIT ASSEMBLY…..1145
REMOVAL…..1145
INSTALLATION…..1147
KOMTRAX TERMINAL ASSEMBLY…..1148
REMOVAL…..1148
INSTALLATION…..1148
MONITOR ASSEMBLY…..1149
REMOVAL…..1149
INSTALLATION…..1149
PUMP CONTROLLER…..1150
REMOVAL…..1150
INSTALLATION…..1150
90 OTHERS…..1152
REMOVAL…..1039
HYDRAULIC…..1154
HYDRAULIC DIAGRAM – PAGE 1 OF 2 – SHEET 1 OF 5…..1154
HYDRAULIC DIAGRAM – PAGE 1 OF 2 – SHEET 2 OF 5…..1155
HYDRAULIC DIAGRAM – PAGE 1 OF 2 – SHEET 3 OF 5…..1156
HYDRAULIC DIAGRAM – PAGE 1 OF 2 – SHEET 4 OF 5…..1157
HYDRAULIC DIAGRAM – PAGE 1 OF 2 – SHEET 5 OF 5…..1158
HYDRAULIC DIAGRAM – PAGE 2 OF 2 – SHEET 1 OF 6…..1159
HYDRAULIC DIAGRAM – PAGE 2 OF 2 – SHEET 2 OF 6…..1160
HYDRAULIC DIAGRAM – PAGE 2 OF 2 – SHEET 3 OF 6…..1161
HYDRAULIC DIAGRAM – PAGE 2 OF 2 – SHEET 4 OF 6…..1162
HYDRAULIC DIAGRAM – PAGE 2 OF 2 – SHEET 5 OF 6…..1163
HYDRAULIC DIAGRAM – PAGE 2 OF 2 – SHEET 6 OF 6…..1164
ELECTRICAL…..1165
ELECTRICAL DIAGRAM – PAGE 1 OF 6 – SHEET 1 OF 4…..1165
ELECTRICAL DIAGRAM – PAGE 1 OF 6 – SHEET 2 OF 4…..1166
ELECTRICAL DIAGRAM – PAGE 1 OF 6 – SHEET 3 OF 4…..1167
ELECTRICAL DIAGRAM – PAGE 1 OF 6 – SHEET 4 OF 4…..1168
ELECTRICAL DIAGRAM – PAGE 2 OF 6 – SHEET 1 OF 1…..1169
ELECTRICAL DIAGRAM – PAGE 3 OF 6 – SHEET 1 OF 2…..1170
ELECTRICAL DIAGRAM – PAGE 3 OF 6 – SHEET 2 OF 2…..1171
ELECTRICAL DIAGRAM – PAGE 4 OF 6 – SHEET 1 OF 2…..1172
ELECTRICAL DIAGRAM – PAGE 4 OF 6 – SHEET 2 OF 2…..1173
ELECTRICAL DIAGRAM – PAGE 5 OF 6 – SHEET 1 OF 2…..1174
ELECTRICAL DIAGRAM – PAGE 5 OF 6 – SHEET 2 OF 2…..1175
ELECTRICAL DIAGRAM – PAGE 6 OF 6 – SHEET 1 OF 2…..1176
ELECTRICAL DIAGRAM – PAGE 6 OF 6 – SHEET 2 OF 2…..1177
ELECTRICAL CONNECTORS LEGEND AND LOCATION – SHEET 1 OF 9…..1178
ELECTRICAL CONNECTORS – SHEET 2 OF 9…..1179
ELECTRICAL CONNECTORS – SHEET 3 OF 9…..1180
ELECTRICAL CONNECTORS – SHEET 4 OF 9…..1181
ELECTRICAL CONNECTORS – SHEET 5 OF 9…..1182
ELECTRICAL CONNECTORS – SHEET 6 OF 9…..1183
ELECTRICAL CONNECTORS – SHEET 7 OF 9…..1184
ELECTRICAL CONNECTORS – SHEET 8 OF 9…..1185
ELECTRICAL CONNECTORS – SHEET 9 OF 9…..1186
Komatsu Hydraulic Excavator GALEO PC400LC-E0 Series Repair Service Manuals