Service manual Komatsu PC24MR-5, PC26MR-5 | SEN06893-00

Komatsu PC24MR-5, PC26MR-5 SEN06893-00 (Preview)

00 INDEX AND FOREWORD
– INDEX
– FOREWORD, SAFETY, BASIC INFORMATION
— HOW TO READ THE SHOP MANUAL
— SAFETY NOTICE FOR OPERATION
— PRECAUTIONS TO PREVENT FIRE
— ACTIONS IF FIRE OCCURS
— PRECAUTIONS WHEN YOU DISPOSE OF WASTE MATERIALS
— PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
— PRECAUTIONS WHEN YOU DISCONNECT AND CONNECT PIPINGS
— PRECAUTIONS WHEN YOU HANDLE ELECTRICAL EQUIPMENT
— PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
— PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
— PRACTICAL USE OF KOMTRAX
— DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER
— METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER
— METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER
— METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER
— PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
— METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
— METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
— METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
— METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
— METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
— STANDARD TIGHTENING TORQUE TABLE
— CONVERSION TABLE
— ABBREVIATION LIST
01 SPECIFICATION
– CONTENTS
– SPECIFICATIONS
— SPECIFICATION DRAWING
— SPECIFICATION DRAWING: PC24MR-5
— SPECIFICATION DRAWING: PC26MR-5
— WORKING RANGE DRAWINGS
— WORKING RANGE DRAWINGS: PC24MR-5
— WORKING RANGE DRAWINGS: PC26MR-5
— SPECIFICATIONS
— SPECIFICATIONS: PC24MR-5
— SPECIFICATIONS: PC26MR-5
— WEIGHT TABLE
— WEIGHT TABLE: PC24MR-5
— WEIGHT TABLE: PC26MR-5
— FUEL, COOLANT, LUBRICANT
— USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE
10 STRUCTURE AND FUNCTION
– CONTENTS
– BOOT-UP SYSTEM
— LAYOUT DRAWING OF BOOT-UP SYSTEM
— SYSTEM OPERATING LAMP SYSTEM
— SYSTEM DIAGRAM OF SYSTEM OPERATING LAMP SYSTEM
— FUNCTION OF SYSTEM OPERATING LAMP SYSTEM
— OPERATION OF SYSTEM OPERATING LAMP SYSTEM
— BATTERY DISCONNECT SWITCH
— FUNCTION OF BATTERY DISCONNECT SWITCH
— OPERATION OF BATTERY DISCONNECT SWITCH
– ENGINE SYSTEM
— LAYOUT DRAWING OF ENGINE SYSTEM
— ENGINE CONTROL SYSTEM
— SYSTEM DIAGRAM OF ENGINE CONTROL SYSTEM
— OPERATION OF ENGINE CONTROL SYSTEM
— ENGINE SYSTEM
— PTO
– COOLING SYSTEM
— LAYOUT DRAWING OF COOLING SYSTEM
— SPECIFICATIONS OF COOLING SYSTEM
– CONTROL SYSTEM
— LAYOUT DRAWING OF CONTROL SYSTEM
— MACHINE MONITOR SYSTEM
— SYSTEM DIAGRAM OF MACHINE MONITOR
— FUNCTION OF MACHINE MONITOR SYSTEM
— KOMTRAX SYSTEM
— KOMTRAX SYSTEM DIAGRAM
— FUNCTION OF KOMTRAX SYSTEM
— CONTROL SYSTEM
— MACHINE MONITOR
— KOMTRAX TERMINAL
— MACHINE CONTROLLER
— FUEL ADJUSTMENT LEVER
– HYDRAULIC SYSTEM
— LAYOUT DRAWING OF HYDRAULIC SYSTEM
— CLSS
— SYSTEM DIAGRAM OF CLSS
— FUNCTION OF CLSS
— HYDRAULIC SYSTEM
— HYDRAULIC TANK
— MAIN PUMP
— CONTROL VALVE
– WORK EQUIPMENT SYSTEM
— LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
— STRUCTURE OF VALVE CONTROL
— PPC LOCK SYSTEM
— SYSTEM DIAGRAM OF PPC LOCK SYSTEM
— FUNCTION OF PPC LOCK SYSTEM
— WORK EQUIPMENT DOUBLE LOCK SYSTEM
— FUNCTION OF WORK EQUIPMENT DOUBLE LOCK SYSTEM
— OPERATION OF WORK EQUIPMENT DOUBLE LOCK SYSTEM
— WORK EQUIPMENT SYSTEM
— WORK EQUIPMENT AND SWING PPC VALVE
— ATTACHMENT PPC VALVE
— BLADE PPC VALVE
— BOOM SWING PPC VALVE
— BIPARTITE SOLENOID VALVE
— BOOM ANTI-DROP VALVE
— ARM ANTI-DROP VALVE
— PILOT CIRCUIT ACCUMULATOR
– SWING SYSTEM
— LAYOUT DRAWING OF SWING SYSTEM
— SWING SYSTEM
— SWING MOTOR
— SWING CIRCLE
– TRAVEL SYSTEM
— LAYOUT DRAWING OF TRAVEL SYSTEM
— SYSTEM DIAGRAM OF TRAVEL CONTROL SYSTEM
— FUNCTION OF TRAVEL CONTROL SYSTEM
— TRAVEL SYSTEM
— TRAVEL MOTOR
— TRAVEL PPC VALVE
— CENTER SWIVEL JOINT
– UNDERCARRIAGE AND FRAME
— LAYOUT DRAWING OF UNDERCARRIAGE
— SPECIFICATIONS OF UNDERCARRIAGE
— IDLER CUSHION
— STRUCTURE OF IDLER CUSHION
— SPECIFICATIONS OF IDLER CUSHION
– WORK EQUIPMENT
— STRUCTURE OF WORK EQUIPMENT
— FUNCTION OF WORK EQUIPMENT
— WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
— FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
– CAB RELATED PARTS
— ROPS CAB
— STRUCTURE OF ROPS CAB
— FUNCTION OF ROPS CAB
20 STANDARD VALUE TABLE
– CONTENTS
– STANDARD VALUE TABLE FOR ENGINE
— STANDARD VALUE TABLE FOR ENGINE: PC24MR-5
— STANDARD VALUE TABLE FOR ENGINE: PC26MR-5
– STANDARD VALUE TABLE FOR MACHINE
— STANDARD VALUE TABLE FOR MACHINE: PC24MR-5
— STANDARD VALUE TABLE FOR MACHINE: PC26MR-5
— GEAR PUMP: PC24MR-5
— PISTON PUMP: PC24MR-5
— GEAR PUMP: PC26MR-5
— PISTON PUMP: PC26MR-5
— MACHINE POSTURE AND PROCEDURES TO MEASURE PERFORMANCE
30 TESTING AND ADJUSTING
– CONTENTS
– RELATED INFORMATION ON TESTING AND ADJUSTING
— TOOLS FOR TESTING AND ADJUSTING
– ENGINE AND COOLING SYSTEM
— TEST ENGINE SPEED
— TEST ENGINE SPEED
— TEST EXHAUST GAS COLOR
— TEST EXHAUST GAS COLOR BY HANDY SMOKE CHECKER
— TEST EXHAUST GAS COLOR BY SMOKE METER
— CHECK AND ADJUST VALVE CLEARANCE
— TEST VALVE CLEARANCE
— ADJUST VALVE CLEARANCE
— TEST COMPRESSION PRESSURE
— TEST COMPRESSION PRESSURE
— TEST ENGINE OIL PRESSURE
— TEST ENGINE OIL PRESSURE
— TEST AND ADJUST FUEL INJECTION TIMING
— TEST FUEL INJECTION TIMING
— ADJUST FUEL INJECTION TIMING
— BLEED AIR FROM FUEL SYSTEM
— BLEED AIR FROM FUEL SYSTEM
— TEST FUEL CIRCUIT FOR LEAKAGE
— TEST FUEL CIRCUIT FOR LEAKAGE
— TEST AND ADJUST ALTERNATOR BELT TENSION
— TEST AND ADJUST ALTERNATOR BELT
– POWER TRAIN
— TEST SWING CIRCLE BEARING CLEARANCE
— TEST SWING CIRCLE BEARING CLEARANCE
– UNDERCARRIAGE AND FRAME
— TEST AND ADJUST TRACK TENSION
— TEST TRAVEL DEVIATION
— ADJUST TRACK TENSION
– HYDRAULIC SYSTEM
— RELEASE PRESSURE REMAINED IN HYDRAULIC CIRCUIT
— RELEASE REMAINING PRESSURE FROM HYDRAULIC TANK
— RELEASE REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT
— RELEASE REMAINING PRESSURE FROM SWING MOTOR CIRCUIT
— RELEASE REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT
— TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS
— TEST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS
— ADJUST OIL PRESSURE IN WORK EQUIPMENT, TRAVEL, AND BOOM SWING CIRCUITS
— TEST AND ADJUST OIL PRESSURE IN SWING AND BLADE CIRCUITS
— TEST OIL PRESSURE IN SWING AND BLADE CIRCUITS
— ADJUST OIL PRESSURE IN SWING AND BLADE CIRCUITS
— TEST AND ADJUST OIL PRESSURE IN CONTROL CIRCUIT
— TEST OIL PRESSURE OF CONTROL CIRCUIT
— ADJUST OIL PRESSURE IN CONTROL CIRCUIT
— TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
— TEST LS DIFFERENTIAL PRESSURE
— ADJUST LS VALVE
— TEST OUTLET PRESSURE IN SOLENOID VALVE
— TEST OUTLET PRESSURE IN SOLENOID VALVE
— TEST OUTLET PRESSURE IN PPC VALVE
— TEST OUTLET PRESSURE IN PPC VALVE
— ADJUST PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
— ADJUST PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
— TEST RELEASE PRESSURE IN SWING PARKING BRAKE
— TEST RELEASE PRESSURE IN SWING PARKING BRAKE
— TEST TRAVEL DEVIATION
— TEST TRAVEL DEVIATION
— TEST THE PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT
— TEST PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER
— TEST PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER
— TEST PARTS THAT CAUSE HYDRAULIC DRIFT OF PPC VALVE
— TEST OIL LEAKAGE
— TEST OIL LEAKAGE FROM BOOM CYLINDER
— TEST OIL LEAKAGE FROM ARM CYLINDER
— TEST OIL LEAKAGE FROM BUCKET CYLINDER
— TEST OIL LEAKAGE FROM BOOM SWING CYLINDER
— TEST OIL LEAKAGE FROM BLADE CYLINDER
— BLEED AIR FROM HYDRAULIC SYSTEM
— BLEED AIR FROM HYDRAULIC SYSTEM
— BLEED AIR FROM WORK EQUIPMENT CYLINDER
— BLEED AIR FROM SWING MOTOR
— BLEED AIR FROM TRAVEL MOTOR
— PRESSURIZE HYDRAULIC TANK
— PRESSURIZE HYDRAULIC TANK
– ELECTRICAL SYSTEM
— START UP KOMTRAX TERMINAL
— STOP USING OF KOMTRAX TERMINAL (MACHINE WITH KOMTRAX TERMINAL)
— DISPLAY OF KOMTRAX TERMINAL LAMPS
— BATTERY DISCONNECT SWITCH
— TEST DIODES
— TEST DIODES BY DIGITAL TESTER
— TEST DIODES BY ANALOG TESTER
– Pm-CLINIC
— Pm CLINIC SERVICE
— Pm CLINIC CHECK SHEET: PC24MR-5
— Pm CLINIC CHECK SHEET: PC26MR-5
40 TROUBLESHOOTING
– CONTENTS
– RELATED INFORMATION TO TROUBLESHOOT
— GENERAL TROUBLESHOOTING POINTS
— SEQUENCE OF EVENTS IN TROUBLESHOOTING
— CHECKS BEFORE TROUBLESHOOTING
— INSPECTION PROCEDURE BEFORE TROUBLESHOOTING
— WALK-AROUND CHECK
— TEST IN ACCORDANCE WITH TESTING PROCEDURE
— CHECK OF FUEL LEVEL AND TYPE
— CHECK FUEL FILTER ELEMENT, DRAIN WATER AND SEDIMENT
— CHECK FUEL FILTER ELEMENT
— CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)
— CHECK COOLANT LEVEL (RESERVOIR TANK)
— CHECK, CLEAN AND REPLACE AIR CLEANER
— CHECK HYDRAULIC OIL LEVEL
— CHECK HYDRAULIC OIL STRAINER
— CHECK HYDRAULIC OIL FILTER
— CHECK OF OIL LEVEL IN FINAL DRIVE CASE: PC24MR-5
— CHECK OF OIL LEVEL IN FINAL DRIVE CASE: PC26MR-5
— BLEED AIR FROM FUEL SYSTEM
— BLEED AIR FROM HYDRAULIC SYSTEM
— CHECK ELECTRIC EQUIPMENT
— PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM
— CONNECT ADAPTER FOR TROUBLESHOOTING MACHINE MONITOR
— CONNECT ADAPTER FOR TROUBLESHOOTING OF MACHINE CONTROLLER
— CONNECT ADAPTER FOR TROUBLESHOOTING KOMTRAX TERMINAL
— PROCEDURE FOR TROUBLESHOOTING
— SYMPTOM AND TROUBLESHOOTING NUMBERS
— INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
— CONNECTOR LIST AND LAYOUT (Cab)
— CONNECTOR LIST AND LAYOUT (Canopy)
— CONNECTOR CONTACT IDENTIFICATION
— T-BRANCH BOX AND T-BRANCH ADAPTER TABLE
— FUSE LOCATION TABLE
— TABLE OF FAILURE CODE AND USER CODE
– TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
— USER CODE [EOE]
— FAILURE CODE [6AZ0ZG]
— FAILURE CODE [DBH0MC]
— FAILURE CODE [DBH2KK]
— FAILURE CODE [DBH5KP]
— FAILURE CODE [DBHLKA]
— FAILURE CODE [DBHLKB]
— FAILURE CODE [DDWLKA]
— FAILURE CODE [DDWLKB]
— FAILURE CODE [DFB1KZ]
— FAILURE CODE [DFB2KZ]
— FAILURE CODE [DFB3L8]
— FAILURE CODE [DFB4L8]
— FAILURE CODE [DFB5KZ]
— FAILURE CODE [DFB6KZ]
— FAILURE CODE [DV50KB]
— FAILURE CODE [DV50KY]
— FAILURE CODE [DXE7KA]
— FAILURE CODE [DXE7KB]
— FAILURE CODE [DXE7KY]
— FAILURE CODE [DXE8KA]
— FAILURE CODE [DXE8KB]
— FAILURE CODE [DXE8KY]
— FAILURE CODE [DXE9KA]
— FAILURE CODE [DXE9KB]
— FAILURE CODE [DXE9KY]
— FAILURE CODE [DXEAKA]
— FAILURE CODE [DXEAKB]
— FAILURE CODE [DXEAKY]
– TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
— ENGINE DOES NOT START (ENGINE DOES NOT CRANK) (Cab)
— ENGINE DOES NOT START (ENGINE DOES NOT CRANK) (Canopy)
— ENGINE DOES NOT START (FUEL FEED PUMP SYSTEM)
— PREHEATING SYSTEM DOES NOT OPERATE
— WHEN YOU TURN STARTING SWITCH TO ON POSITION, ALL ITEMS OF MACHINE MONITOR DO NOT WORK, OR ONE OF ITEMS DO NOT WORK
— CHARGE LEVEL CAUTION LAMP LIGHTS UP WHILE ENGINE IS IN OPERATION
— FUEL LEVEL MONITOR PILOT LAMP LIGHTS UP WHILE ENGINE IS IN OPERATION
— ENGINE COOLANT TEMPERATURE MONITOR PILOT LAMP LIGHTS UP WHILE ENGINE IS IN OPERATION
— ENGINE OIL PRESSURE CAUTION LAMP LIGHTS UP WHILE ENGINE IS IN OPERATION
— FUEL GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
— FUEL GAUGE DOES NOT SHOW ACTUAL FUEL LEVEL
— COOLANT TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM
— COOLANT TEMPERATURE GAUGE DOES NOT SHOW CORRECT TEMPERATURE
— TRAVEL SPEED DOES NOT CHANGE EVEN WHEN YOU OPERATE THE OPERATION TO CHANGE TRAVEL SPEED
— TRAVEL ALARM DOES NOT MAKE SOUND (Cab)
— TRAVEL ALARM DOES NOT MAKE SOUND (Canopy)
— TRAVEL ALARM DOES NOT STOP WHEN MACHINE STOPS
— ALARM BUZZER DOES NOT MAKE SOUND
— ALARM BUZZER DOES NOT STOP WHEN MACHINE STOPS
— SERVICE METER IS NOT SHOWN WHILE STARTING SWITCH IS IN OFF POSITION
— SERVICE METER DOES NOT OPERATE WHILE ENGINE IS IN OPERATION
— ALL WORK EQUIPMENT, SWING, TRAVEL DO NOT OPERATE (Cab)
— ALL WORK EQUIPMENT, SWING, TRAVEL DO NOT OPERATE (Canopy)
— ALL WORK EQUIPMENT, SWING, TRAVEL CANNOT BE LOCKED (Cab)
— ALL WORK EQUIPMENT, SWING, TRAVEL CANNOT BE LOCKED (Canopy)
— HORN DOES NOT MAKE SOUND
— HORN DOES NOT STOP
— WORKING LAMP DOES NOT LIGHT UP (Cab)
— WORKING LAMP DOES NOT LIGHT UP (Canopy)
— BEACON LAMP DOES NOT LIGHT UP (Cab)
— BEACON LAMP DOES NOT LIGHT UP (Canopy)
— KOMTRAX SYSTEM DOES NOT OPERATE CORRECTLY
– TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
— INFORMATION SHOWN IN TROUBLESHOOTING TABLE (H-MODE)
— ALL WORK EQUIPMENT, TRAVEL, SWING, BLADE DO NOT OPERATE
— All work equipment or travel does not operate.
— TRAVEL AND BLADE DO NOT OPERATE
— SWING AND BLADE DO NOT OPERATE
— ALL WORK EQUIPMENT, TRAVEL, SWING, BLADE SPEED IS LOW OR POWER IS LOW
— ALL WORK EQUIPMENT AND TRAVEL SPEED IS LOW OR POWER IS LOW
— TRAVEL AND BLADE SPEED IS LOW OR POWER IS LOW
— SWING AND BLADE SPEED OR POWER IS LOW
— FINE CONTROL PERFORMANCE OR RESPONSE IS UNSATISFACTORY
— THERE IS AN UNUSUAL NOISE FROM AROUND MAIN PUMP
— ENGINE SPEED FALLS LARGELY OR ENGINE STOPS
— ALL WORK EQUIPMENT SPEED OR POWER IS LOW
— ALL WORK EQUIPMENT AND BLADE SPEED IS LOW OR POWER IS LOW
— BLADE DOES NOT OPERATE
— ALL WORK EQUIPMENT DO NOT OPERATE
— ALL WORK EQUIPMENT AND BLADE DO NOT OPERATE
— BOOM SPEED OR POWER IS LOW
— ARM SPEED IS LOW OR POWER IS LOW
— BUCKET SPEED OR POWER IS LOW
— BLADE SPEED IS LOW OR POWER IS LOW
— BOOM SWING SPEED IS LOW OR POWER IS LOW
— WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION
— HYDRAULIC DRIFT OF BOOM IS LARGE
— HYDRAULIC DRIFT OF ARM IS LARGE
— HYDRAULIC DRIFT OF BUCKET IS LARGE
— HYDRAULIC DRIFT OF BLADE IS LARGE
— TIME LAG OF WORK EQUIPMENT IS LARGE
— IN COMBINED OPERATION OF WORK EQUIPMENT, WORK EQUIPMENT WITH HEAVIER LOAD MOVES SLOWER
— MACHINE DOES NOT TRAVEL STRAIGHT
— MACHINE DOES NOT MOVE OFF STRAIGHT
— MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW
— TRAVEL SPEED IS SLOW
— ONE OF TRACKS DOES NOT RUN
— TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST
— MACHINE DOES NOT SWING TO RIGHT OR LEFT
— SWINGS ONLY IN ONE DIRECTION
— SWING ACCELERATION OR SWING SPEED IS LOW IN TWO DIRECTIONS OF RIGHT AND LEFT
— SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION
— UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (RIGHT AND LEFT)
— UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING OPERATION (ONLY ONE DIRECTION)
— SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWING OPERATION
— THERE IS A LARGE UNUSUAL NOISE WHEN UPPER STRUCTURE STOPS SWING OPERATION
— SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)
— SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)
– TROUBLESHOOTING OF ENGINE (S-MODE)
— INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (S-MODE)
— ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
— ENGINE CRANKS BUT NO EXHAUST SMOKE COMES OUT
— FUEL IS INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)
— ENGINE STARTABILITY IS UNSATISFACTORY
— ENGINE DOES NOT PICK UP SMOOTHLY
— ENGINE STOPS DURING OPERATION
— ENGINE RUNNING IS NOT STABLE
— OUTPUT POWER IS LOW (POWER IS LOW)
— ENGINE OIL CONSUMPTION IS EXCESSIVE
— ENGINE OIL BECOMES CONTAMINATED QUICKLY
— FUEL CONSUMPTION IS EXCESSIVE
— OIL MIXES INTO COOLANT (OR SPURTS BACK, COOLANT LEVEL FALLS)
— ENGINE OIL PRESSURE FALLS
— FUEL MIXES INTO ENGINE OIL
— WATER MIXES INTO ENGINE OIL (MILKY)
— COOLANT TEMPERATURE RISES TOO HIGH (OVERHEAT)
— THERE IS AN UNUSUAL NOISE
— VIBRATION IS EXCESSIVE
— AIR CANNOT BE BLED FROM FUEL CIRCUIT
50 DISASSEMBLY AND ASSEMBLY
– CONTENTS
– RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
— HOW TO READ THIS MANUAL
– COATING MATERIALS LIST
– SPECIAL TOOLS LIST
– ENGINE AND COOLING SYSTEM
— DRAIN AND ADD COOLANT
— DRAIN COOLANT
— ADD COOLANT
— DRAIN AND ADD HYDRAULIC OIL
— DRAIN HYDRAULIC OIL
— ADD HYDRAULIC OIL
— REMOVE AND INSTALL RADIATOR ASSEMBLY
— REMOVE RADIATOR ASSEMBLY
— INSTALL RADIATOR ASSEMBLY
— REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
— REMOVE HYDRAULIC OIL COOLER ASSEMBLY
— INSTALL HYDRAULIC OIL COOLER ASSEMBLY
— REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
— REMOVE ENGINE AND MAIN PUMP ASSEMBLY
— INSTALL ENGINE AND MAIN PUMP ASSEMBLY
— REMOVE AND INSTALL FUEL TANK ASSEMBLY
— REMOVE FUEL TANK ASSEMBLY
— INSTALL FUEL TANK ASSEMBLY
– POWER TRAIN
— REMOVE AND INSTALL TRAVEL MOTOR ASSEMBLY (PC24MR-5)
— REMOVE TRAVEL MOTOR ASSEMBLY (PC24MR-5)
— INSTALL TRAVEL MOTOR ASSEMBLY (PC24MR-5)
— REMOVE AND INSTALL TRAVEL MOTOR ASSEMBLY (PC26MR-5)
— REMOVE TRAVEL MOTOR ASSEMBLY (PC26MR-5)
— INSTALL TRAVEL MOTOR ASSEMBLY (PC26MR-5)
— REMOVE AND INSTALL SWING MOTOR ASSEMBLY
— REMOVE SWING MOTOR ASSEMBLY
— INSTALL SWING MOTOR ASSEMBLY
— REMOVE AND INSTALL SWING CIRCLE ASSEMBLY
— REMOVE SWING CIRCLE ASSEMBLY
— INSTALL SWING CIRCLE ASSEMBLY
– UNDERCARRIAGE AND FRAME
— DISASSEMBLE AND ASSEMBLE RECOIL SPRING ASSEMBLY
— DISASSEMBLE RECOIL SPRING ASSEMBLY (PC24MR-5)
— DISASSEMBLE RECOIL SPRING ASSEMBLY (PC26MR-5)
— ASSEMBLE RECOIL SPRING ASSEMBLY (PC24MR-5)
— ASSEMBLE RECOIL SPRING ASSEMBLY (PC26MR-5)
— REMOVE AND INSTALL TRACK ASSEMBLY
— REMOVE TRACK ASSEMBLY
— INSTALL TRACK ASSEMBLY
— DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
— DISASSEMBLE IDLER ASSEMBLY (PC24MR-5)
— DISASSEMBLE IDLER ASSEMBLY (PC26MR-5)
— ASSEMBLE IDLER ASSEMBLY (PC24MR-5)
— ASSEMBLE IDLER ASSEMBLY (PC26MR-5)
— DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
— DISASSEMBLE TRACK ROLLER ASSEMBLY
— ASSEMBLE TRACK ROLLER ASSEMBLY
— REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY
— REMOVE REVOLVING FRAME ASSEMBLY
— INSTALL REVOLVING FRAME ASSEMBLY
— REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY
— REMOVE COUNTERWEIGHT ASSEMBLY
— INSTALL COUNTERWEIGHT ASSEMBLY
– HYDRAULIC SYSTEM
— REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY (PC24MR-5)
— REMOVE CENTER SWIVEL JOINT ASSEMBLY (PC24MR-5)
— INSTALL CENTER SWIVEL JOINT ASSEMBLY (PC24MR-5)
— REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY (PC26MR-5)
— REMOVE CENTER SWIVEL JOINT ASSEMBLY (PC26MR-5)
— INSTALL CENTER SWIVEL JOINT ASSEMBLY (PC26MR-5)
— REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY (CANOPY SPECIFICATION)
— REMOVE HYDRAULIC TANK ASSEMBLY (CANOPY SPECIFICATION)
— INSTALL HYDRAULIC TANK ASSEMBLY (CANOPY SPECIFICATION)
— REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY (CAB SPECIFICATION)
— REMOVE HYDRAULIC TANK ASSEMBLY (CAB SPECIFICATION)
— INSTALL HYDRAULIC TANK ASSEMBLY (CAB SPECIFICATION)
— REMOVE AND INSTALL MAIN PUMP ASSEMBLY
— REMOVE MAIN PUMP ASSEMBLY
— INSTALL MAIN PUMP ASSEMBLY
– WORK EQUIPMENT
— REMOVE AND INSTALL BLADE ASSEMBLY
— REMOVE BLADE ASSEMBLY
— INSTALL BLADE ASSEMBLY
— REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY
— REMOVE WORK EQUIPMENT ASSEMBLY
— INSTALL WORK EQUIPMENT ASSEMBLY
— REMOVE AND INSTALL BOOM ANTI-DROP VALVE ASSEMBLY
— REMOVE BOOM ANTI-DROP VALVE ASSEMBLY
— INSTALL BOOM ANTI-DROP VALVE ASSEMBLY
— REMOVE AND INSTALL ARM ANTI-DROP VALVE ASSEMBLY
— REMOVE ARM ANTI-DROP VALVE ASSEMBLY
— INSTALL ARM ANTI-DROP VALVE ASSEMBLY
— DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY
— DISASSEMBLE ANTI-DROP VALVE ASSEMBLY
— ASSEMBLE ANTI-DROP VALVE ASSEMBLY
— DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY
— DISASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY
— ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY
– CAB RELATED PARTS
— REMOVE AND INSTALL OPERATOR CAB ASSEMBLY (CAB SPECIFICATION)
— REMOVE OPERATOR CAB ASSEMBLY (CAB SPECIFICATION)
— INSTALL OPERATOR CAB ASSEMBLY (CAB SPECIFICATION)
— REMOVE AND INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPECIFICATION)
— REMOVE FLOOR FRAME ASSEMBLY (CANOPY SPECIFICATION)
— INSTALL FLOOR FRAME ASSEMBLY (CANOPY SPECIFICATION)
— REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
— REMOVE OPERATOR CAB GLASS (ADHERED GLASS)
— INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
— REMOVE AND INSTALL FRONT WINDOW ASSEMBLY
— REMOVE FRONT WINDOW ASSEMBLY
— INSTALL FRONT WINDOW ASSEMBLY
— REMOVE AND INSTALL OPERATOR’S SEAT
— REMOVE OPERATOR’S SEAT
— INSTALL OPERATOR’S SEAT
— REMOVE AND INSTALL SEATBELT
— REMOVE SEATBELT
— INSTALL SEATBELT
– ELECTRICAL SYSTEM
— REMOVE AND INSTALL MACHINE CONTROLLER ASSEMBLY
— REMOVE MACHINE CONTROLLER ASSEMBLY
— INSTALL MACHINE CONTROLLER ASSEMBLY
— REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
— REMOVE MACHINE MONITOR ASSEMBLY
— INSTALL MACHINE MONITOR ASSEMBLY
— REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY
— REMOVE KOMTRAX TERMINAL ASSEMBLY
— INSTALL KOMTRAX TERMINAL ASSEMBLY
60 MAINTENANCE STANDARD
– CONTENTS
– EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
– ENGINE AND COOLING SYSTEM
— MAINTENANCE STANDARD OF ENGINE MOUNT
— MAINTENANCE STANDARD OF PTO
— MAINTENANCE STANDARD OF COOLING SYSTEM
– POWER TRAIN
— MAINTENANCE STANDARD OF SWING CIRCLE
— MAINTENANCE STANDARD OF SPROCKET
– UNDERCARRIAGE AND FRAME
— MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION
— MAINTENANCE STANDARD OF IDLER
— MAINTENANCE STANDARD OF TRACK ROLLER
— MAINTENANCE STANDARD OF TRACK SHOE
— MAINTENANCE STANDARD OF DOUBLE SHOE
— MAINTENANCE STANDARD OF RUBBER SHOE
– HYDRAULIC SYSTEM
— MAINTENANCE STANDARD OF HYDRAULIC TANK
— MAINTENANCE STANDARD OF MAIN PUMP
— MAINTENANCE STANDARD OF SWING MOTOR
— MAINTENANCE STANDARD OF TRAVEL MOTOR
— MAINTENANCE STANDARD OF CONTROL VALVE
— MAINTENANCE STANDARD OF ANTI-DROP VALVE OF BOOM
— MAINTENANCE STANDARD OF ANTI-DROP VALVE OF ARM
— MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE
— MAINTENANCE STANDARD OF BLADE PPC VALVE
— MAINTENANCE STANDARD OF BOOM SWING PPC VALVE
— MAINTENANCE STANDARD OF TRAVEL PPC VALVE
— MAINTENANCE STANDARD OF ATTACHMENT PPC VALVE
— MAINTENANCE STANDARD OF CENTER SWIVEL JOINT
– WORK EQUIPMENT
— MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE
— DIMENSIONS OF ARM
— DIMENSIONS OF BUCKET
— MAINTENANCE STANDARD OF BOOM CYLINDER
— MAINTENANCE STANDARD OF ARM CYLINDER
— MAINTENANCE STANDARD OF BUCKET CYLINDER
— MAINTENANCE STANDARD OF BLADE CYLINDER
— MAINTENANCE STANDARD OF BOOM SWING CYLINDER
90 CIRCUIT DIAGRAMS
– CONTENTS
– HOW TO READ THE CODES FOR ELECTRIC CABLE
– HYDRAULIC CIRCUIT DIAGRAM
— SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
— HYDRAULIC CIRCUIT DIAGRAM (1/3)
— HYDRAULIC CIRCUIT DIAGRAM (2/3)
— HYDRAULIC CIRCUIT DIAGRAM (3/3)
— HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE OPERATION)
— HYDRAULIC CIRCUIT DIAGRAM (AT LEFT SWING OPERATION)
— HYDRAULIC CIRCUIT DIAGRAM (AT BOOM RAISE AND LEFT SWING OPERATION)
– ELECTRICAL CIRCUIT DIAGRAM
— SYMBOLS USED IN ELECTRIC CIRCUIT DIAGRAM
— ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATION) (1/3)
— ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATION) (2/3)
— ELECTRICAL CIRCUIT DIAGRAM (CANOPY SPECIFICATION) (3/3)
— ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (1/4)
— ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (2/4)
— ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (3/4)
— ELECTRICAL CIRCUIT DIAGRAM (CAB SPECIFICATION) (4/4)
INDEX