Komatsu PC1100-6, PC1100SP-6, PC1100LC-6 Hydraulic Excavator Shop Manual (10001 and up) - SEBM014207

This Complete Service Repair Workshop Manual PDF Download for the PC1100-6, PC1100SP-6, PC1100LC-6 Komatsu Hydraulic Excavator (10001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC1100-6 - S/N: 10001 and up
Komatsu PC1100SP-6 - S/N: 10001 and up
Komatsu PC1100LC-6 - S/N: 10001 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM014207
Total Pages : 885


This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.

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CONTENTS

01 GENERAL
SPECIFICATION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS

10 STRUCTURE AND FUNCTION
PTO
PTO LUBRICATION SYSTEM
RADIATOR, OIL COOLER, AFTERCOOLER
POWER TRAIN
SWING MACHINERY
SWING CIRCLE
FINAL DRIVE
TRACK FRAME
TRACK SHOE
AIR PIPING DIAGRAM
AIR CIRCUIT DIAGRAM
AIR GOVERNOR
AIR TANK
SAFETY VALVE
HORN VALVE
GREASE PUMP
HYDRAULIC PIPING DRAWING
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK
HYDRAULIC PUMP
NO. 1 PUMP
NO. 2 PUMP
NO. 3 PUMP
LINE OIL FILTER
PILOT OIL FILTER
RETURN OIL FILTER
DRAIN OIL FILTER
L. H. 5-SPOOL CONTROL VALVE
R.H. 4-SPOOL CONTROL VALVE
SWING 4-SPOOL CONTROL VALVE
STRAIGHT-TRAVEL VALVE
BOOM LOWER REGENERATION VALVE
SWING MOTOR
CENTER SWIVEL JOINT
TRAVEL MOTOR
PPC CONTROL RELIEF VALVE
SAFETY LOCK VALVE
ACCUMULATOR
VALVE CONTROL
WORK EQUIPMENT, SWING PPC VALVE
TRAVEL PPC VALVE
SOLENOID VALVES
WORK EQUIPMENT
AIR CONDITIONER
ACTUAL ELECTRIC WIRING DIAGRAM
ELECTRIC CIRCUIT DIAGRAM
ENGINE CONTROL
MACHINE CONTROL SYSTEM
MACHINE MONITOR SYSTEM

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING FAN BELT TENSION
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR
ADJUSTING ENGINE SPEED SENSOR
TESTING CLEARANCE OF SWING CIRCLE BEARING
MEASURING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING PISTON PUMP CONTROL
MEASURING SERVO PISTON STROKE
MEASURING PPC VALVE OUTPUT PRESSURE AND TESTING PPC SHUTTLE VALVE
TESTING SOLENOID VALVE OUTPUT PRESSURE
ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING TRAVEL DEVIATION
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT
MEASURING OIL LEAKAGE
BLEEDING AIR
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
ORDER OF TROUBLESHOOTING WHEN CARRYING OUT TROUBLESHOOTING
METHOD OF USING JUDGEMENT TABLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF COMMUNICATION ABNORMAILITY SYSTEM (N MODE)
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM OF N MODE SYSTEM
N-1 [E117, E118 OCCUR AT SAME TIME] MONITOR PANEL COMMUNICATION ABNORMALITY
N-2 [E117, E218 OCCUR AT SAME TIME] ENGINE CONTROLLER COMMUNICATION ABNORMALITY
N-3 [E118, E507 OCCUR AT SAME TIME] PUMP CONTROLLER COMMUNICATION ABNORMALITY
TROUBLESHOOTING OF ENGINE CONTROLLER & APS CONTROLLER SYSTEM (E MODE)
JUDGEMENT TABLE FOR ENGINE CONTROLLER, APS CONTROLLER, AND ENGINE RELATED PARTS
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-SHOOTING OF ENGINE CONTROLLER SYSTEM
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM OF E MODE SYSTEM
E- 1 [E501] ABNORMALITY IN ENGINE CONTROLLER POWER SOURCE SYSTEM IS DISPLAYED
E- 2 [E502] ABNORMALITY IN ENGINE CONTROLLER IS DISPLAYED
E- 3 [E521] DISCONNECTION IN GOVERNOR CONTROL SOLENOID SYSTEM IS DISPLAYED
E- 4 [E522] SHORT CIRCUIT IN GOVERNOR CONTROL SOLENOID SYSTEM IS DISPLAYED
E- 5 [E531] ABNORMALITY IN GOVERNOR SERVO IS DISPLAYED
E- 6 [E537] ABNORMALITY IN CONTROLLER SOLENOID POWER SUPPLY SYSTEM IS DISPLAYED
E- 7 [E508] ABNORMALITY IN RACK SENSOR POWER SOURCE SYSTEM IS DISPLAYED
E- 8 [E511] ABNORMALITY IN RACK SENSOR SIGNAL SYSTEM IS DISPLAYED
E- 9 [E515] DISCONNECTION IN PRESTROKE CONTROL SOLENOID SYSTEM IS DISPLAYED
E- 10 [E516] SHORT CIRCUIT IN PRESTROKE CONTROL SOLENOID SYSTEM IS DISPLAYED
E- 11 [E513] ABNORMALITY IN ENGINE SPEED SENSOR (1) SYSTEM IS DISPLAYED
E- 12 [E514] ABNORMALITY IN ENGINE SPEED SENSOR (2) SYSTEM IS DISPLAYED
E- 13 [E525] DISCONNECTION IN GOVERNOR CUT RELAY SYSTEM IS DISPLAYED
E- 14 [E526] SHORT CIRCUIT IN GOVERNOR CUT RELAY SYSTEM IS DISPLAYED
E- 15 [E505] ABNORMALITY IN FUEL CONTROL DIAL VOLTAGE IS DISPLAYED
E- 16 [E503] MISTAKEN CONNECTION OF CONNECTOR IS DISPLAYED
E- 17 [504] ENGINE OVERRUN IS DISPLAYED
E- 18 [E535] ABNORMALITY IN ENGINE CONTROLLER BACKUP POWER SUPPLY SYSTEM IS DISPLAYED
E- 19 [E536] ABNORMALITY IN CONTROLLER POWER SUPPLY SYSTEM IS DISPLAYED
E- 20 ENGINE DOES NOT START
E- 21 ENGINE DOES NOT STOP
E- 22 DEFECTIVE ACTUATION OF APS
E-23 [E534] ABNORMALITY IN MACHINE SELECTION INPUT TO ENGINE CONTROLLER IS DISPLAYED
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
S- 1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S- 2 ENGINE DOES NOT START
A) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT ( FUEL NOT BEING INJECTED
B) EXHAUST SMOKE COMES OUT, BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
S- 3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
S- 4 ENGINE STOPS DURING OPERATIONS
S- 5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S- 6 ENGINE LACKS OUTPUT (NO POWER)
S- 7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S- 8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S- 9 OIL BECOMES CONTAMINATED QUICKLY
S- 10 FUEL CONSUMPTION IS EXCESSIVE
S- 11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
S- 12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S- 13 OIL LEVEL RISES
S- 14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S- 15 ABNORMAL NOISE IS MADE
S- 16 VIBRATION IS EXCESSIVE
TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM (C MODE)
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC (MECHANICAL) RELATED PARTS
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING OF PUMP CONTROLLER SYSTEM
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE SYSTEM
C-1 ABNORMALITY IN CONTROLLER POWER SOURCE SYSTEM (CONTROLLER LED IS OFF)
C-2 [E232] SHORT CIRCUIT IN TVC SOLENOID SYSTEM IS DISPLAYED
C-3 [E233] DISCONNECTION IN TVC SOLENOID SYSTEM IS DISPLAYED
C-4 [E203] SHORT CIRCUIT IN SWING HOLDING BRAKE SOLENOID RELAY SYSTEM IS DISPLAYED
C-5 [E213] DISCONNECTION IN SWING HOLDING BRAKE SOLENOID RELAY SYSTEM IS DISPLAYED
C-6 [E201] SHORT CIRCUIT IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED
C-7 [E211] DISCONNECTION IN CO CANCEL SOLENOID SYSTEM IS DISPLAYED
C-8 [E202] SHORT CIRCUIT IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED
C-9 [E212] DISCONNECTION IN STRAIGHT-TRAVEL SOLENOID SYSTEM IS DISPLAYED
C-10 [E204] SHORT CIRCUIT IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED
C-11 [E214] DISCONNECTION IN 2-STAGE RELIEF SOLENOID SYSTEM IS DISPLAYED
C-12 [E205] SHORT CIRCUIT IN SWING PRIORITY SOLENOID SYSTEM IS DISPLAYED
C-13 [E215] DISCONNECTION IN SWING PRIORITY SOLENOID SYSTEM IS DISPLAYED
C-14 [E206] SHORT CIRCUIT IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED
C-15 [E216] DISCONNECTION IN TRAVEL SPEED SOLENOID SYSTEM IS DISPLAYED
C-16 [E217] MODEL SELECTION INPUT ERROR IS DISPLAYED
C-17 [E227] ABNORMALITY IN ENGINE SPEED SENSOR (2) SYSTEM IS DISPLAYED
C-18 [E228] ABNORMALITY IN AUTO-DECELERATION OUTPUT SYSTEM IS DISPLAYED
C-19 ABNORMALITY IN SWING HOLDING BRAKE SYSTEM (NO SERVICE CODE IS DISPLAYED)
C-20 ABNORMALITY IN MACHINE PUSH-UP SOLENOID SYSTEM (NO SERVICE CODE IS DISPLAYED)
C-21 ABNORMALITY IN BOOM SHOCKLESS SOLENOID SYSTEM (NO SERVICE CODE IS DISPLAYED)
TROUBLESHOOTING OF PUMP CONTROLLER INPUT SIGNAL SYSTEM (F MODE)
ELECTRICAL CIRCUIT DIAGRAM OF F MODE
F-1 [BIT PATTERN 20-(1)] (SWING TO RIGHT OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-2 [BIT PATTERN 20-(2)] (R.H. TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-3 [BIT PATTERN 20-(3)] (BOOM LOWER OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-4 [BIT PATTERN 20-(4)] (BOOM RAISE OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-5 [BIT PATTERN 20-(5)] (ARM IN OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-6 [BIT PATTERN 20-(6)] (ARM OUT OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-7 [BIT PATTERN 21-(1)] (BUCKET CURL OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-8 [BIT PATTERN 21-(2)] (BUCKET DUMP OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-9 [BIT PATTERN 21-(5)] (L.H. TRAVEL OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-10 [BIT PATTERN 26-(5)] SWING TO LEFT OIL PRESSURE SWITCH) DOES NOT LIGHT UP
F-11 [BIT PATTERN 21-(3)] (SWING LOCK SWITCH) DOES NOT LIGHT UP
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
TABLE OF FAILURE MODES AND CAUSES
BEFORE CARRYING OUT TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE)
H-1 SPEEDS OF ALL WORK EQUIPMENT, SWING, TRAVEL ARE SLOW OR LACK POWER
H-2 THERE IS EXCESSIVE DROP IN ENGINE SPEED, OR ENGINE STALLS
H-3 NO WORK EQUIPMENT, TRAVEL, SWING MOVE
H-4 ABNORMAL NOISE GENERATED (FROM AROUND PUMP)
H-5 BOOM IS SLOW OR LACKS POWER
H-6 ARM IS SLOW OR LACKS POWER
H-7 BUCKET IS SLOW OR LACKS POWER
H-8 BOOM DOES NOT MOVE
H-9 ARM DOES NOT MOVE
H-10 BUCKET DOES NOT MOVE
H-11 EXCESSIVE HYDRAULIC DRIFT
H-12 EXCESSIVE TIME LAG
H-13 BOOM SHOCKLESS FUNCTION IS NOT ACTUATED OR CANNOT BE CANCELED
H-14 MACHINE DEVIATES NATURALLY TO ONE SIDE DURING TRAVEL OPERATIONS
H-15 DEVIATION IS EXCESSIVE WHEN STARTING
H-16 TRAVEL DEVIATION IS EXCESSIVE DURING COMPOUND OPERATIONS
H-17 TRAVEL SPEED IS SLOW OR LACKS POWER
H-18 TRAVEL DOES NOT MOVE (ONE SIDE ONLY)
H-19 TRAVEL SPEED DOES NOT SWITCH
H-20 DOES NOT SWING
H-21 SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR
H-22 IN COMPOUND OPERATIONS WITH BUCKET, SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR
H-23 IN COMPOUND OPERATIONS WITH BOOM WHEN SWING PRIORITY IS ON, SWING SPEED IS SLOW OR SWING ACCELERATION IS POOR
H-24 EXCESSIVE OVERRUN WHEN STOPPING SWING
H-25 EXCESSIVE SHOCK WHEN STOPPING SWING
H-26 EXCESSIVE ABNORMAL NOISE WHEN STOPPING SWING
H-27 EXCESSIVE HYDRAULIC DRIFT OR SWING
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
M-1 [E101] ABNORMALITY IN ERROR DATA IS DISPLAYED OR [E102] ABNORMALITY IN CLOCK DATA IS DISPLAYED
M-2 [E103] SHORT CIRCUIT IN BUZZER OUTPUT SYSTEM IS DISPLAYED
M-3 [E104] AIR CLEANER CLOGGING DETECTED IS DISPLAYED
M-4 [E106] DROP IN ENGINE OIL HI PRESSURE DETECTED IS DISPLAYED
M-5 [E108] ENGINE WATER TEMPERATURE 105C DETECTED IS DISPLAYED
M-6 WHEN STARTING SWITCH IS TURNED ON, NONE OF LAMPS ON MONITOR PANEL LIGHT UP FOR 3 SECONDS
M-7 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY LIGHTED UP AND DO NOT GO OUT
M-8 WHEN STARTING SWITCH IS TURNED ON, ITEMS LIGHTED UP ON MONITOR PANEL ARE DIFFERENT FROM MACHINE
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BASIC CHECKED ITEMS FLASH
M-10 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), (PREHEATING MONITOR) DISPLAY IS NOT NORMAL
M-11 WHEN ENGINE IS STARTED, BASIC CHECK ITEMS FLASH
M-12 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH
M-13 WHEN ENGINE IS STARTED, CAUTION ITEMS, EMERGENCY STOP ITEMS FLASH (BUT THERE IS NO ABNORMALITY IN ANY ITEM)
M-14 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR 1 SECOND CAUTION ITEM FLASHES BUT BUZ
M-15 NO ABNORMALITY IS DISPLAYED ON MONITOR BUT BUZZER SOUNDS
M-16 NIGHT LIGHTING ON MONITOR PANEL DOES NOT LIGHT UP
M-17 ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE
M-18 ENGINE WATER TEMPERATURE GAUGE DOES NOT GIVE ANY DISPLAY (GAUGE DOES NOT EVEN DISPLAY 1ST LEVEL)
M-19 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL
M-20 FUEL LEVEL GAUGE DOES NOT GIVE ANY DISPLAY (GAUGE DOES NOT EVEN DISPLAY 1ST LEVEL)
M-21 SWING LOCK SWITCH IS TURNED ON, BUT SWING LOCK MONITOR DOES NOT LIGHT UP
M-22 SWING PROLIX SWITCH IS TURNED ON (PROLIX), BUT SWING LOCK MONITOR DOES NOT FLASH
M-23 SERVICE METER DOES NOT ADVANCE WHILE ENGINE IS RUNNING
M-24 WHEN STARTING SWITCH IS AT OFF AND TIME SWITCH IS PRESSED, SERVICE METER DOES NOT GIVE DISPLAY
M-25 DEFECTIVE FUEL LEVEL SENSOR SYSTEM
M-26 DEFECTIVE ENGINE WATER TEMPERATURE SENSOR SYSTEM AND DEFECTIVE HYDRAULIC OIL TEMPERATURE SENSOR SYSTEM
M-27 DEFECTIVE ENGINE OIL LEVEL SENSOR SYSTEM AND DEFECTIVE HYDRAULIC OIL LEVEL SENSOR SYSTEM
M-28 DEFECTIVE RADIATOR WATER LEVEL SENSOR SYSTEM
M-29 DEFECTIVE OPERATION OF WIPER (INCLUDING CASES WHERE [E113] IS DISPLAYED)
M-30 DEFECTIVE OPERATION OF WINDOW WASHER (INCLUDING CASES WHERE SERVICE CODE [E114] IS DISPLAYED)

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR ASSEMBLY
REMOVAL AND INSTALLATION
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION
NOZZLE HOLDER ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE OIL COOLER ASSEMBLY
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP ASSEMBLY
REMOVAL
INSTALLATION
WATER PUMP ASSEMBLY
REMOVAL AND INSTALLATION
TURBOCHARGER ASSEMBLY
REMOVAL AND INSTALLATION
THERMOSTAT ASSEMBLY
REMOVAL AND INSTALLATION
AIR COMPRESSOR ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION
ENGINE REAR SEAL
REMOVAL AND INSTALLATION
CYLINDER HEAD ASSEMBLY
REMOVAL
INSTALLATION
AFTERCOOLER
REMOVAL AND INSTALLATION
RADIATOR, HYDRAULIC COOLER ASSEMBLY
REMOVAL
INSTALLATION
HYDRAULIC COOLER ASSEMBLY
REMOVAL AND INSTALLATION
ENGINE, PTO, HYDRAULIC PUMP ASSEMBLY
REMOVAL
INSTALLATION
PTO ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
FUEL TANK ASSEMBLY
REMOVAL AND INSTALLATION
FINAL DRIVE ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
REVOLVING FRAME ASSEMBLY
REMOVAL AND INSTALLATION
SWING MACHINERY ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
SWING CIRCLE
REMOVAL AND INSTALLATION
TRACK SHOE ASSEMBLY
REMOVAL
INSTALLATION
SPROCKET
REMOVAL AND INSTALLATION
IDLER ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
IDLER ADJUSTMENT CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
RECOIL SPRING ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
CARRIER ROLLER ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK ROLLER ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
HYDRAULIC TANK ASSEMBLY
REMOVAL
INSTALLATION
TVC VALVE ASSEMBLY
REMOVAL
INSTALLATION
SERVO VALVE ASSEMBLY
REMOVAL AND INSTALLATION
HYDRAULIC PUMP ASSEMBLY
REMOVAL AND INSTALLATION
NO. 1, 2 PUMP (HPV95+95)
DISASSEMBLY
ASSEMBLY
NO. 3 PUMP (HPV160+160_
DISASSEMBLY
ASSEMBLY
MAIN PUMP INPUT SHAFT OIL SEAL
REMOVAL AND INSTALLATION
MAIN RELIEF VALVE ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
PILOT RELIEF VALVE ASSEMBLY
REMOVAL AND INSTALLATION
5-SPOOL CONTROL VALVE ASSEMBLY
REMOVAL
INSTALLATION
4-SPOOL CONTROL VALVE ASSEMBLY
REMOVAL
INSTALLATION
CONTROL VALVE
DISASSEMBLY
ASSEMBLY
SWING MOTOR ASSEMBLY
REMOVAL AND INSTALLATION
CENTER SWIVEL JOINT ASSEMLBY
REMOVAL AND INSTALLATION
DISASSEMBLY AND ASSEMBLY
TRAVEL MOTOR ASSEMBLY
REMOVAL AND INSTALLATION
WORK EQUIPMENT PPC VALVE ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRAVEL PPC VLAVE ASSEMBLY
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
BUCKET CYLINDER ASSEMBLY
BACKHOE
REMOVAL
INSTALLATION
LOADING SHOVEL
REMOVAL
INSTALLATION
ARM CYLINDER ASSEMBLY
BACKHOE
REMOVAL
INSTALLATION
LOADING SHOVEL
REMOVAL
INSTALLATION
BOOM CYLINDER ASSEMBLY
BACKHOE
REMOVAL
INSTALLATION
LOADING SHOVEL
REMOVAL
INSTALLATION
BOTTOM DUMP CYLINDER ASSEMBLY
LOADING SHOVEL
REMOVAL
INSTALLATION
BUCKET ASSEMBLY
BACKHOE
REMOVAL
INSTALLATION
LOADING SHOVEL
REMOVAL
INSTALLATION
ARM ASSEMBLY
BACKHOE
REMOVAL
INSTALLATION
LOADING SHOVEL
REMOVAL
INSTALLATION
BOOM ASSEMBLY
BACKHOE
REMOVAL
INSTALLATION
LOADING SHOVEL
REMOVAL
INSTALLATION
BUCKET, ARM ASSEMBLY
REMOVAL
INSTALLATION
WORK EQUIPMENT ASSEMBLY
BACKHOE
REMOVAL
INSTALLATION
LOADING SHOVEL
REMOVAL
INSTALLATION
CAB ASSEMBLY
REMOVAL
INSTALLATION
COUNTERWEIGHT ASSEMBLY
REMOVAL AND INSTALLATION
RECEIVER TANK ASSEMBLY
REMOVAL AND INSTALLATION
AIR CONDITIONER CONDENSER ASSEMBLY
REMOVAL AND INSTALLATION
AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVAL AND INSTALLATION
AIR CONDITIONER UNIT ASSEMLBY
REMOVAL
INSTALLATION
SOLENOID VALVE ASSEMBLY
REMOVAL INSTALLATION
GOVERNOR CONTROLLER ASSEMBLY
REMOVAL AND INSTALLATION
MONITOR
REMOVAL AND INSTALLATION
PUMP CONTROLLER ASSEMLBY
REMOVAL AND INSTALLATION
BOOM ROCK PREVENTION VALVE ASSEMBLY
REMOVAL AND INSTALLATION
ACCUMULATOR ASSEMBLY
REMOVAL AND INSTALLATION
BOOM LOWER REGENERATION VALVE ASSEMLBY
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
ENGINE MOUNT
PTO
SWING CIRCLE
SWING MACHINERY
FINAL DRIVE
TRACK FRAME
IDLER
CARRIER ROLLER
TRACK ROLLER
TRACK SHOE
HYDRAULIC PUMP
CONTROL, PTO LUBRICATING, AFTERCOOLER FAN DRIVE PUMP
L.H. 5-SPOOL CONTROL VALVE
R.H. 4-SPOOL CONTROL VALVE
SWING 4-SPOOL CONTROL VALVE
STRAIGHT-TRAVEL VALVE
BOOM LOWER REGENERATION VALVE
SWING MOTOR
TRAVEL MOTOR
CENTER SWIVEL JOINT
PPC CONTROL RELIEF VALVE
WORK EQUIPMENT SWING PPC VALVE
TRAVEL PPC VALVE
HYDRAULIC CYLINDER
FOR BACKHOE
FOR LOADING SHOVEL
WORK EQUIPMENT
FOR BACKHOE
FOR LOADING SHOVEL
DIMENSIONS OF WORK EQUIPMENT

90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM
FOR BACKHOE
FOR LOADING SHOVEL
ELECTRICAL CIRCUIT DIAGRAM (1/4)
FOR BACKHOE (1/4)
FOR BACKHOE (2/4)
FOR BACKHOE (3/4)
FOR BACKHOE (4/4)
FOR LOADING SHOVEL (1/4)
FOR LOADING SHOVEL (2/4)
FOR LOADING SHOVEL (3/4)
FOR LOADING SHOVEL (4/4)

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