Komatsu PW180-7E0 Hydraulic Excavator Service Repair Shop Manual (H55051 and up) - VEBM400100

This Complete Service Repair Workshop Manual PDF Download for the PW180-7E0 Komatsu Hydraulic Excavator (S/N: H55051 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 PW180-7E0 - S/N: H55051 and up


TABLE OF CONTENTS :

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


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : VEBM400100
Total Pages : 1148


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 !!!!

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VEBM400100 PW180-E0

SAFETY
SAFETY NOTICE

01 GENERAL
SPECIFICATION DIMENSION DRAWINGS
DIMENSIONS
WORKING RANGES
1 PIECE BOOM
2 PIECE BOOM
SPECIFICATIONS
FUEL, COOLANT AND LUBRICANTS
WEIGHT TABLE
1 PIECE BOOM
2 PIECE BOOM
HOISTING INSTRUCTIONS
HOW TO READ THE SHOP MANUAL
COATING MATERIALS
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
TIGHTENING TORQUE OF HOSE NUTS
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
TIGHTENING TORQUES FOR HOSES (Taper seal type and face seal type)
TIGHTENING TORQUE FOR 107 ENGINE SERIES (BOLTS AND NUTS)
TIGHTENING TORQUE FOR 107 ENGINE SERIES (EYE JOINTS)
TIGHTENING TORQUE FOR 107 ENGINE SERIES (TAPERED SCREWS)
ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
UNITS
DIMENSIONS
2 PIECE BOOM

10 STRUCTURE, FUNCTION AND MAINTENANCE
ENGINE RELATED PARTS
RADIATOR . OIL COOLER . CHARGE AIR COOLER
POWER TRAIN
SWING CIRCLE
SWING MACHINERY & MOTOR
SWING MOTOR
Operation of swing lock
RELIEF VALVE PORTION
UNDERCARRIAGE
TRANSMISSION
TRAVEL MOTOR
OPERATION OF TRAVEL MOTOR
CLUTCH CONTROL CIRCUIT
AXLE
SUSPENSION LOCK CYLINDER
BRAKING SYSTEM
BRAKE/STEER PUMP
PRIORITY VALVE
POWER BRAKE VALVE
ACCUMULATOR FOR BRAKE VALVE
STEERING SYSTEM
STEERING COLUMN
ORBITROL VALVE
HYDRAULIC EQUIPMENT LAYOUT DRAWINGS
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK
HYDRAULIC PUMP
LS VALVE
PC VALVE
LS(PC)-EPC VALVE
PILOT PRESSURE CONTROL (PPC) SYSTEM
CONTROL VALVE
PW180-7E0
CLSS
OUTLINE OF CLSS
BASIC PRINCIPLE
OPERATION FOR EACH FUNCTION AND VALVE
1. Unload valve
2. Introduction of LS pressure
3. LS Bypass plug
4. Pressure compensation valve
5. Area ratio of pressure compensation valve
6. Boom regeneration circuit
7. Arm regeneration circuit
8. Swing bleeding valve
9. Variable type pressure compensation valve (for service)
10. LS select valve
CENTRE SWIVEL JOINT
TRAVEL PPC PEDAL
WORK EQUIPMENT . SWING PPC VALVE
SOLENOID VALVE BLOCK
SOLENOID VALVE BLOCK
BOOM SAFETY VALVE
HYDRAULIC CYLINDER
OUTRIGGER CYLINDER
DOZER CYLINDER
WORK EQUIPMENT
Work Equipment
1. DIMENSION OF ARM
AIR CONDITIONER
AIR CONDITIONER PIPING
ELECTRICAL WIRING DIAGRAM
ELECTRICAL SYSTEM
ELECTRONIC CONTROL SYSTEM
MACHINE CONTROL SYSTEM DIAGRAM
MACHINE MONITOR SYSTEM
OVERLOAD WARNING DEVICE
OUTLINE
SENSOR
1st ATTACHMENT CIRCUIT HYDRAULIC PERFORMANCE (MAIN VALVE BYPASSED)
TRAVEL SYSTEM
TRAVEL CIRCUIT
OPERATIONAL AND CONTROL FEATURES
STEERING SYSTEM
OPERATING PRINCIPLES
SERVICE BRAKE AND SUSPENSION SYSTEM
BRAKING SYSTEM
OPERATION

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
Flow control characteristic of PC valve (STD)
MEASURING ENGINE SPEED
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASUREMENT OF EXHAUST GAS COLOUR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
HANDLING FUEL SYSTEM PARTS
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
MEASURING FUEL PRESSURE
MEASURING FUEL RETURN RATE AND LEAKAGE
BLEEDING AIR FROM FUEL CIRCUIT
Checking fuel circuit for leakage
CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE
INSPECTION AND ADJUSTMENT OF PUMP PC (VALVE INLET) CONTROL OIL PRESSURE
INSPECTION AND ADJUSTMENT OF PUMP LS VALVE CONTROL OIL PRESSURE
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE
Solenoid valve block
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE
TESTING TRAVEL MOTOR RELIEF PRESSURE
ADJUSTING TRAVEL MOTOR RELIEF PRESSURE
TESTING PROPSHAFT SPEED
TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT
MEASUREMENT OF OIL LEAKAGE
AIR BLEEDING OF VARIOUS PARTS
INSPECTION PROCEDURES FOR DIODE
SPECIAL FUNCTION OF MONITOR PANEL
OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE)
TABLE FOR FAILURE CODE NO.
OPERATION AND DISPLAY OF SERVICE MENU
Way of switching to Service Menu
Table for Monitoring Items
PREPARATIONS FOR TROUBLESHOOTING ELECTRICAL SYSTEM
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Classification of troubleshooting
Steps for troubleshooting
Failure-looking Phenomenon and Troubleshooting No.
How to read electric wire code
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM
CONNECTOR LOCATIONS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-boxes and T-adapters table
Before carrying out troubleshooting when failure code is displayed
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
Failure Code [6B2JMA] (Abnormality in travel PPC switch hydraulics)
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng Oil Press. Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@HANS] Hydr Oil Overheat
Failure code [CA111] EMC Critical Internal Failure
Failure code [CA115] Engine Neutral and Backup Speed Sensor Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3 (L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2 (L#2) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA553] Rail Press High Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng G Speed Sensor Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throttle Sensor Supply Voltage High Error
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2555] Grid Htr Relay Volt High Error
Failure code [CA2556] Grid Heater Relay Volt Low Error
Failure Code [D110KB] (Short-circuiting in battery relay)
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [DA25KP] Press. Sensor Power Abnormality
Failure code [DA2RMC] Pump Comm. Abnormality
Failure Code [DA2SKQ] (Abnormality in inputting model code)
Failure Code [DA2SKQ] (Abnormality in inputting model code)
Failure code [DAFRMC] Monitor Comm. Abnormality
Failure Code [DDHPAKP] (Abnormality in pump pressure sensor)
Failure Code [DDP4KX] (Abnormality in travel PPC pressure switch)
Failure Code [DDWCKZ] (Abnormality in travel direction control switch)
Electrical Circuit Diagram for Travel PPC Switch
Failure Code [DH1OKS] (Abnormality in Pressure sensor power source)
Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure Code [DHS5KX] (Abnormality in travel PPC sensor)
Failure Code [DHX1MA] (Abnormality in overload caution sensor)
Failure Code [DLT4KA] (Disconnection in transmission speed sensor in pump controller system)
Failure Code [DW27KA] (Disconnection in Transmission Clutch solenoid)
Failure Code [DW27KB] (Short-circuiting in Transmission Clutch solenoid)
Failure Code DW4AKA (Disconnection in suspension lock solenoid)
Failure Code [DW4AKB] (Short circuiting in suspension lock solenoid)
Failure Code [DW4CKA] (Disconnection in PPC lock solenoid)
Failure code [DW4CKB] PPC Lock Sol. S/C
Failure Code [DW4MKA] (Disconnection in Creep solenoid)
Electrical Circuit Diagram for Creep Solenoid in Pump Controller
Failure Code [DW4MKB] (Short-circuiting in Creep solenoid)
Electrical Circuit Diagram for Creep Solenoid in Pump Controller
Failure Code [DW44KA] (Disconnection of Travel F/R solenoid)
Failure Code [DW44KB] (Short-circuiting of Travel F/R solenoid)
Failure Code [DW45KA] (Disconnection in Swing Parking Brake solenoid)
Failure code [DW45KB] Swing Brake Sol. S/C
Failure Code [DW91KA] (Disconnection in Travel Neutral solenoid)
Failure Code [DW91KB] (Short-circuiting in Travel Neutral Solenoid)
Failure Code [DWK0KB] (Short-circuiting in 2-Stage Relief Solenoid)
Failure Code [DWK2KA] (Disconnection in 2-stage Back Pressure solenoid)
Failure Code [DWK2KB] (Short circuiting in 2-stage back pressure solenoid)
Failure Code [DXA0KA] (Disconnection in PC-EPC solenoid system)
Failure Code [DXA0KB] (Short-circuiting in PC-EPC solenoid)
Failure Code [DXE0KA] (Disconnection in LS-EPC solenoid system)
Failure Code [DXE0KB] (Short-circuiting in LS-EPC solenoid)
Failure Code [DXE4KA] (Disconnection in attachment oil flow rate adjusting EPC)
1st Service EPC Solenoid (Left Hand)
1st Service EPC Solenoid (Right Hand)
2nd Service EPC Solenoid (Left Hand)
2nd Service EPC Solenoid (Right Hand)
Failure Code [DXE4KB] (Short-circuiting in attachment oil flow rate adjusting EPC)
1st Service EPC Solenoid (Left Hand)
1st Service EPC Solenoid (Right Hand)
2nd Service EPC Solenoid (Left Hand)
2nd Service EPC Solenoid (Right Hand)
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive S/C
Failure code [DY2DKB] Wiper Drive (For) S/C
Failure code [DY2EKB] Wiper Drive (Rev) S/C
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
E-1 Engine does not start (Engine does not rotate)
Electrical Circuit Diagram for Engine Start, Stop and Battery Charging
E-5 Auto-decelerator does not work
E-6 Auto engine warm-up device does not work
E-7 Preheater does not operate
E-8 All work equipment, swing and travel do not move
Electrical Circuit Diagram for PPC Lock Solenoid
E-9 One-touch Power Max Switch does not work
Electric Circuit Diagram for One-Touch Power Max. Switch
E-10 No display in monitor panel at all
Electrical Circuit Diagram for Power Source in Monitor Panel
E-11 Part of display on monitor panel is missing
E-12 Monitor panel displays contents irrelevant to the model
E-13 Fuel level monitor red lamp lights up while engine is running
Electrical Circuit Diagram for Fuel Level Sensor
E14 Engine coolant temperature gauge does not indicate normally
E-15 Hydraulic oil temperature gauge does not display correctly
Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
E-16 Fuel gauge does not display correctly
Electrical Circuit Diagram for Fuel Level Sensor
E-17 Swing lock monitor does not display correctly
Electrical Circuit Diagram for Swing Lock Switch
E-18 When the monitor switch is operated, no display appears
E-19 Windshield wiper and window washer do not operate
E-20 Alarm buzzer cannot be stopped
E-21 "Boom/Stabiliser RAISE" is not correctly displayed in monitor function
Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
E-22 "Boom/Stabiliser LOWER" is not correctly displayed in monitor function
Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
E-23 "Arm DIGGING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Arm DIGGING PPC Hydraulic Switch
E-24 "Arm DUMPING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
E-25 "Bucket DIGGING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Bucket DIGGING PPC hydraulic Switch
E-26 "Bucket DUMPING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
E-27 "SWING" is not correctly displayed in monitor function
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
E-28 "TRAVEL" is not correctly displayed in monitor function
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
E-29 "2 Piece Boom" is not correctly displayed in monitor function
Electrical Circuit Diagram for 2 Pice Boom PPC hydraulic Switch
E-30 Air Conditioner does not work
Electrical Circuit Diagram for Air Conditioner
E-31 Travel reverse alarm does not sound
Electrical Circuit Diagram for Travel Reverse Alarm System
E-32 KOMTRAX system does not operate normally
TROUBLESHOOTING OF ELECTRICAL SYSTEM (Error checking of items without Monitor codes)
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
Relative Electrical Circuit Diagram
Radio Cassette & Telephone Socket
Electrical Circuit Diagram For Radio Cassette & Telephone Socket
PPC Lock Circuit
Circuit Diagram for PPC Lock Circuit
Brake Light Circuit
Circuit Diagram for Brake Light Circuit
Undercarriage Attachments - Mode Selection
Circuit Diagram for Undercarriage Attachments - Mode Selection
Undercarriage Attachments - Front Left Outrigger
Circuit Diagram for Undercarriage Attachments - Front Left Outrigger
Undercarriage Attacments - Front Right Outrigger
Circuit Diagram for Undercarriage Attachments - Front Right Outrigger
Undercariage Attachments - Rear Left Outrigger
Undercarriage Attachments - Rear Right Outrigger
Circuit Diagram for Undercarriage Attachments - Rear Right Outrigger
Heated Seat Does Not Warm Up
Circuit Diagram for the Heated Seat
Suspension Lock
Circuit Diagram for Suspension Lock
Lower Wiper Does Not Work (Optional Fitment)
Circuit Diagram for Lower Wiper
Work Lights (Operator Cab Front Left)
Work Lights (Operator Cab Front Right)
Work Lights (Operator Cab Rear)
Circuit Diagram for Work Lights
Worklights (Boom, Arm & Counterweight)
Circuit Diagram for Worklights (Boom & Counterweight)
Cab and Counterweight Beacon Light
Circuit Diagram for Cab & Counterweight Beacon Light
Air Seat Compressor (Option - Air Suspension Seat)
Circuit Diagram for Air Seat Compressor (Option - Air Suspension Seat)
Operator Cab Interior Light
Circuit Diagram for Operator Cab Interior Light
Cigar Lighter
Circuit Diagram for Cigar Lighter
Park Brake (Not Activating)
Circuit Diagram for Park Brake
Park Brake (Displayed Symbol)
Circuit Diagram for Park Brake
RH PPC Lever Clamshell Roller Switch Pushed to the LH Position
Circuit Diagram for Clamshell Control
RH PPC Lever Clamshell Roller Switch Pushed to the RH Position
Circuit Diagram for Clamshell Control
RH PPC Lever Clamshell Roller Switched Pushed to the RH or LH
Circuit Diagram for Clamshell Control
Horns
Circuit Diagram for Horn
Swing Lock - Normal Operation
Circuit Diagram for Swing Lock
Swing Lock - Emergency Operation
Circuit Diagram for Swing Lock - Emergency Operation
Neutral Start (Engine)
Neutral Start (Engine) cont’d (A)
Neutral Start (Engine) cont’d (B)
Neutral Start (Engine) cont’d (C)
Circuit Diagram for Neutral Start (Engine)
Emergency Travel Control - Forward
Circuit Diagram for Travel Direction Control
Emergency Travel Control - Neutral
Circuit Diagram for Travel Direction Control
Emergency Travel Control - Reverse
Emergency Travel Control - Reverse cont’d
Circuit Diagram for Travel Direction Control
Driving Lights - Main Beam
Circuit Diagram for Driving Lights
Driving Lights - Main Beam Flash
Circuit Diagram for Driving Lights
Driving Lights - Main Beam Dipped
Circuit Diagram for Driving Lights
Driving Lights - Position Lights
Circuit Diagram for Driving Lights
Driving Lights - Position Lights cont’d (1) and (2)
Circuit Diagram for Driving Lights
Indicators - Right Hand
Circuit Diagram for Indicators & Hazard Warning
Indicators - Left Hand
Circuit Diagram for Indicators & Hazard Warning
Hazard Warning Lights
Circuit Diagram for Indicators & Hazard Warning
Hazard Warning Lights cont’d (A)
Circuit Diagram for Indicators & Hazard Warning
Swing Lock Proximity Switch
Brake and Swing Lock Proximity Switches
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
H-1 All work equipment lacks power, or travel and swing speeds are slow
H-2 Engine speed sharply drops or engine stalls
H-3 No work equipment, travel or swing move
H-4 Abnormal noise is heard from around hydraulic pump
H-5 Auto-decelerator does not work
H-6 Fine control mode does not function
H-7 Boom moves slowly or lacks power
H-8 Arm moves slowly or lacks power
H-9 Bucket moves slowly or lacks power
H-10 Work equipment does not move in its single operation
H-11 Work equipment hydraulic drift is too fast
H-12 Work equipment has big time lag
H-13 Other work equipment moves when relieving single circuit
H-14 One-touch power max. switch does not operate
H-15 In compound operation, work equipment with larger load moves slowly
H-16 In swing + boom RAISE operation, boom moves slowly
H-17 In swing + travel, travel speed drops sharply
H-18 Travel speed does not switch
H-19 Travel speed does not shift, or it is too slow or fast.
H-20 Machine does not swing
H-21 Swing acceleration is poor, or swing speed is slow
H-22 Excessive overrun when stopping swing
H-23 There is big shock when stopping swing
H-24 There is loud abnormal noise caused when stopping swing
H-25 Swing natural drift is too big
H-26 Swing speed is faster than specified swing speed
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Starting performance is poor
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lack output (or lacks 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 in coolant (or coolant spurts back or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (Entry of coolant/fuel)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive

30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
Coating materials list
Special tools list
Sketches of special tools
LIST OF TOOLS
PRECAUTIONS WHEN PERFORMING OPERATION
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of cylinder head assembly
Removal and installation of combination cooler assembly
Removal and installation of fuel cooler assembly
Removal and installation of engine and hydraulic pump assemblies
Removal and installation of travel motor assembly
Disassembly and assembly of travel motor assembly
Removal and installation of swing motor and swing machinery
Disassembly and assembly of swing machinery
Disassembly and assembly of swing motor assembly
Removal and installation of front axle assembly
Disassembly and assembly of front axle
Removal and installation of rear axle and transmission
Disassembly and assembly of rear axle assembly
Disassembly and assembly of transmission
Removal and installation of propshaft assembly
Removal and installation of wheel assembly
Removal and installation of suspension lock cylinder assembly
Disassembly and assembly of suspension lock cylinder
Removal and installation of outrigger assembly
Disassembly and assembly of outriggers
Removal and installation of dozer blade assembly
Disassembly and assembly of dozer blade
Removal and installation of swing circle assembly
Removal and installation of revolving frame assembly
Removal and installation of centre swivel joint
Disassembly and assembly of centre swivel joint assembly
Removal and installation of fuel tank assembly
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Removal and installation of LS separation valve assembly
Removal and installation of pressure compensation valve assembly
Removal and installation of main relief valve assembly
Removal and installation of LS control EPC valve
Removal and installation of EPC solenoid valve assembly
Removal and installation of PPC solenoid valve block assembly
Removal and installation of oil seal in hydraulic pump input shaft
Disassembly and assembly of work equipment PPC valve
Disassembly and assembly of hydraulic cylinder
Removal and installation of monoboom work equipment
Removal and installation of 2 piece boom work equipment
Removal and installation of air conditioner unit
Removal and installation of counterweight
Removal and installation of operator cab assembly
Removal and installation of monitor assembly
Removal and installation of pump controller assembly

90 DIAGRAMS
HYDRAULIC CIRCUIT DIAGRAM (1/3)
HYDRAULIC CIRCUIT DIAGRAM (2/3)
HYDRAULIC CIRCUIT DIAGRAM (3/3)
ELECTRICAL CIRCUIT DIAGRAM (1/3)
ELECTRICAL CIRCUIT DIAGRAM (2/3)
ELECTRICAL CIRCUIT DIAGRAM (3/3)

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