50 Disassembly and assembly SEN02637-00

PC300, 350-8 7

2] Under the above condition, measuredimension (a).

3] Measure thickness (b) off the inde-pendent nut (24).

4] Determine Calculate a – b = c5] Using tool D1, tighten nut (24) until

dimension (d) becomes the value of(c) calculated above.

6] Using push-pull scale [5], measuretangential force of the hub to themotor case in the rotation direction.a Tangential force:

Max. 490 N {50 kg}a The tangential force denotes the

maximum force at start of therotation.

7] Install lockplate (23).

a When installing the lockplate, avoid notch(j) of the travel motor and fit it to the splinetotally (under the condition of (k))

2 Thread of mounting bolt:Adhesive (LT-2)

3 Mounting bolt:49 – 74 Nm {6 – 7.5 kgm}

a Do not apply the adhesive (LT-2) to thetapped portion of the nut.

3. No.2 carrier assembly1) Assemble No. 2 carrier assembly as fol-

lows.a Replace thrust washers (19) and (22)

as well as pin (16) with new ones.a There are traces of expansion on the

end surface of carrier side hole (e)which were originally caused whenthe pin was inserted. Make such theend surfaces are smooth enoughbefore reassembly.

1] Assemble bearing (21) to gear (20), fittop and bottom thrust washers (19)and (22) and then set the gearassembly on carrier (18).

SEN02637-00 50 Disassembly and assembly

8 PC300, 350-8

2] Align the position of pin holes on theshaft and carrier, then tap with a plas-tic hammer to install shaft (17).a Install the shaft, rotating the plan-

etary gear. Take care so thatthrust washer is not damaged.

3] Insert pin (16).a When inserting the pin, take care

that the 3 claws (parts (f)) on theperiphery of the pin will not beplaced on the thin parts of thecarrier (parts (g)).Since the thin parts may be onthe opposite side, confirm themon each carrier.If there is a groove, avoid placingthe claws on that groove.

a After inserting the pin, caulk thepin portion of the carrier.

a After assembling the carrierassembly, check that gear (20)rotates smoothly.

2) Install No.2 carrier assembly (15).a Align the position so that the 3 tips of

the gear shafts of carrier assembly(15) enter the 3 hollows in the endface of the motor case, then install.

4. Ring gearFit the O-ring to the hub. Using eyebolts [3],sling ring gear (14) and install it to the hub,matching their bolt holes to each other.a Remove all grease and oil from the mating

surface of the ring gear and hub.a Do not put any gasket sealant on the mat-

ing surface of the ring gear and hub underany circumstances.

50 Disassembly and assembly SEN02637-00

PC300, 350-8 9

5. Thrust washerInstall thrust washer (13).

6. No.2 sun gearInstall No. 2 sun gear (12).

7. No.1 carrier assembly1) Assemble No. 1 carrier assembly as fol-

lows.a Replace thrust washers (7) and (10)

as well as pin (4) with new ones (Forpin (4), see the next page).

a There are remains of caulking whenthe pin is inserted at the end face ofhole (h) at the side of the carrier.Remove the caulked metal from theinside diameter of the hole beforestarting to assemble.

1] Assemble bearing (9) to gear (8), fittop and bottom thrust washers (7)and (10) and then set the gearassembly on carrier (6).

2] Align the position of pin holes on theshaft and carrier, then tap with a plas-tic hammer to install shaft (5).a Install the shaft, rotating the plan-

etary gear. Take care so thatthrust washer is not damaged.

3] Insert pin (4).a When inserting the pin, take care

that the 3 claws (parts (f)) on theperiphery of the pin will not beplaced on the thin parts of thecarrier (parts (g)).Since the thin parts may be onthe opposite side, confirm themon each carrier.If there is a groove, avoid placingthe claws on that groove.

a After inserting the pin, caulk thepin portion of the carrier.

a After assembling the carrierassembly, check that gear (8)rotates smoothly.

2) Install No.2 carrier assembly (3).

SEN02637-00 50 Disassembly and assembly

10 PC300, 350-8

8. No.1 sun gear shaftAssemble No. 1 sun gear shaft (11).

9. SpacerInstall spacer (2).a After installing the spacer, measure the

dimension (i). If the dimension (i) is 15 mmor greater, the assembly is not done cor-rectly. Check the assembly procedureagain.

10. Cover1) Using eyebolts [2], install cover (1).2 Cover mounting surface:

Gasket sealant (LG-6)

2) Tighten the mounting bolts according tothe following procedure.

3 Mounting bolt:1st step : 98 Nm {10 kgm}2nd step: Using tool D4, retighten each

mounting bolt by 100 – 110°.a If tool D4 is not available, make a

match mark on the cover and the boltwith paint and then tighten the bolt by100 – 110°.

11. Refilling with oilTighten the drain plug and feed engine oilthrough oil filler.

5 Final drive case: 12 la Do a final check of the oil level at the

determined position after installing thefinal drive assembly to the chassis.

50 Disassembly and assembly SEN02637-00

PC300, 350-8 11

Removal and installation of swing motor and swing machinery assemblyRemovalk Release the remaining pressure in the

hydraulic circuit. For details, see Testingand adjusting, "Release of remaining pres-sure in hydraulic circuit".

k Lower the work equipment to the groundfor safety. After stopping the engine, loosenthe oil filler cap on the hydraulic tank torelease the residual pressure inside thetank and move the work equipment locklever to the LOCK position.

1. Disconnect 5 swing motor hoses (1) through (5).q (1): Between the swing motor and con-

trol valve (port MA)q (2): Between the swing motor and con-

trol valve (port MB)q (3): Suction hose (port S)q (4): Drain hose (port T)q (5): Pilot hose for relieving swing brake

(port B)

2. Disconnect arm cylinder hoses (6).

3. Remove the mounting bolts.

4. Tighten a forcing screw in position (a) shown inthe following figure to separate the swingmotor and swing machinery assembly. [*1]

5. Lift and remove swing motor and swingmachinery assembly (7).a When lifting off the swing motor and swing

machinery assembly for removal, do soslowly so that the hoses and other partsmay not be damaged.

a Take care in the lift until you can pull outthe pilot.

4 Swing motor and swing machineryassembly: 550 kg

Installationq Installation is done in the reverse order of

removal.

[*1]3 Mounting bolt:

824 – 1,030 Nm {84 – 105 kgm}

q Refilling with oil (hydraulic tank)Refill hydraulic oil through the oil filler port tothe specified level. Let the oil circulate in thehydraulic system by starting the engine. Thencheck the oil level again.

q Air bleedingBleed the air from the circuit between the valveand the hydraulic cylinder. For details, seeTesting and adjusting, "Bleeding air from vari-ous parts".

COVER00 INDEX AND FOREWORDINDEXCOMPOSITION OF SHOP MANUALTABLE OF CONTENTS

FOREWORD AND GENERAL INFORMATIONSAFETY NOTICEHOW TO READ THE SHOP MANUALEXPLANATION OF TERMS FOR MAINTENANCE STANDARDHANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTHANDLING OF CONNECTORS NEWLY USED FOR ENGINESHOW TO READ ELECTRIC WIRE CODEPRECAUTIONS WHEN CARRYING OUT OPERATIONMETHOD OF DISASSEMBLING AND CONNECTING PUSH-PULL TYPE COUPLERSTANDARD TIGHTENING TORQUE TABLECONVERSION TABLE

01 SPECIFICATIONSPECIFICATION AND TECHNICAL DATASPECIFICATION DIMENSION DRAWINGSSPECIFICATIONSWEIGHT TABLETABLE OF FUEL, COOLANT AND LUBRICANTS

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARDENGINE AND COOLING SYSTEMENGINE RELATED PARTSRADIATOR, OIL COOLER AND AFTERCOOLER

POWER TRAINPOWER TRAINSWING CIRCLESWING MACHINERYFINAL DRIVESPROCKET

UNDERCARRIAGE AND FRAMETRACK FRAME AND RECOIL SPRINGIDLERCARRIER ROLLERTRACK ROLLERTRACK SHOE

HYDRAULIC SYSTEM, PART 1HYDRAULIC EQUIPMENT LAYOUT DRAWINGHYDRAULIC TANK AND FILTERHYDRAULIC PUMP

HYDRAULIC SYSTEM, PART 2CONTROL VALVECLSSFUNCTIONS AND OPERATION BY VALVEMERGE-DIVIDER VALVEATTACHMENT CIRCUIT SELECTOR VALVEHYDRAULIC DRIFT PREVENTION VALVE

HYDRAULIC SYSTEM, PART 3VALVE CONTROLPPC VALVESOLENOID VALVEPPC ACCUMULATORRETURN OIL FILTERCENTER SWIVEL JOINTTRAVEL MOTORSWING MOTORHYDRAULIC CYLINDER

WORK EQUIPMENTWORK EQUIPMENTDIMENSIONS OF COMPONENTS

CAB AND ITS ATTACHMENTSAIR CONDITIONER PIPING

ELECTRICAL SYSTEMENGINE CONTROLELECTRONIC CONTROL SYSTEMMONITOR SYSTEMSENSORKOMTRAX TERMINAL SYSTEM

20 STANDARD VALUE TABLESTANDARD SERVICE VALUE TABLE STANDARD VALUE TABLE FOR ENGINE RELATED PARTSSTANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

30 TESTING AND ADJUSTINGTESTING AND ADJUSTING, PART 1 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTINGMEASURING ENGINE SPEEDMEASURING AIR BOOST PRESSUREMEASURING EXHAUST GAS COLOR ADJUSTING VALVE CLEARANCE MEASURING COMPRESSION PRESSUREMEASURING BLOW-BY PRESSUREMEASURING ENGINE OIL PRESSUREMEASURING FUEL PRESSUREHANDLING DURING CYLINDER CUT-OUT OPERATION HANDLING DURING NO INJECTION CRANKING OPERATION MEASURING FUEL RETURN RATE AND LEAKAGEBLEEDING AIR FROM FUEL CIRCUIT CHECKING FUEL CIRCUIT FOR LEAKAGETESTING AND ADJUSTING AIR COMPRESSOR BELT TENSION MEASURING CLEARANCE IN SWING CIRCLE BEARINGSTESTING AND ADJUSTING TRACK SHOE TENSIONTESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING AND TRAVEL CIRCUITTESTING AND ADJUSTING CONTROL CIRCUIT OIL PRESSURETESTING AND ADJUSTING PUMP PC CONTROL CIRCUIT OIL PRESSURETESTING AND ADJUSTING PUMP LS CONTROL CIRCUIT OIL PRESSURE MEASURING SOLENOID VALVE OUTPUT PRESSUREMEASURING PPC VALVE OUTPUT PRESSURE ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVESINSPECTING LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT MEASURING OIL LEAKAGE AMOUNT BLEEDING AIR FROM VARIOUS PARTS DIODE INSPECTION PROCEDURES

TESTING AND ADJUSTING, PART 2 SPECIAL FUNCTIONS OF MACHINE MONITOR

TESTING AND ADJUSTING, PART 3 HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLERPREPARATION WORK FOR TROUBLESHOOTING OF ELECTRICAL SYSTEMPROCEDURE FOR TESTING DIODESPM CLINIC SERVICE

40 TROUBLESHOOTINGFAILURE CODE TABLE AND FUSE LOCATIONSFAILURE CODES TABLEFUSE LOCATIONS

GENERAL INFORMATION ON TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTINGSEQUENCE OF EVENTS IN TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTINGCLASSIFICATION AND TROUBLESHOOTING STEPSINFORMATION IN TROUBLESHOOTING TABLECONNECTION TABLE FOR CONNECTOR PIN NUMBERST-ADAPTER BOX AND T-ADAPTER TABLE

TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 1 FAILURE CODE [A000N1] ENG. HI OUT OF STDFAILURE CODE [AA10NX] AIR CLEANER CLOGGINGFAILURE CODE [AB00KE] CHARGE VOLTAGE LOWFAILURE CODE [B@BAZG] ENG OIL PRESS. LOWFAILURE CODE [B@BAZK] ENG OIL LEVEL LOW FAILURE CODE [B@BCNS] ENG. WATER OVERHEATFAILURE CODE [B@BCZK] ENG WATER LEVEL LOWFAILURE CODE [B@HANS] HYDR OIL OVERHEAT FAILURE CODE [CA111] EMC CRITICAL INTERNAL FAILURE FAILURE CODE [CA115] ENG NE AND BKUP SPEED SENS ERRORFAILURE CODE [CA122] CHG AIR PRESS SENSOR HIGH ERRORFAILURE CODE [CA123] CHG AIR PRESS SENSOR LOW ERRORFAILURE CODE [CA131] THROTTLE SENSOR HIGH ERRORFAILURE CODE [CA132] THROTTLE SENSOR LOW ERROR FAILURE CODE [CA144] COOLANT TEMP SENS HIGH ERRORFAILURE CODE [CA145] COOLANT TEMP SENS LOW ERRORFAILURE CODE [CA153] CHG AIR TEMP SENSOR HIGH ERRORFAILURE CODE [CA154] CHG AIR TEMP SENSOR LOW ERRORFAILURE CODE [CA187] SENS SUPPLY 2 VOLT LOW ERRORFAILURE CODE [CA221] AMBIENT PRESS SENS HIGH ERRORFAILURE CODE [CA222] AMBIENT PRESS SENS LOW ERRORFAILURE CODE [CA227] SENS SUPPLY 2 VOLT HIGH ERROR FAILURE CODE [CA234] ENG OVERSPEED FAILURE CODE [CA238] NE SPEED SENS SUPPLY VOLT ERRORFAILURE CODE [CA271] IMV/PCV1 SHORT ERRORFAILURE CODE [CA272] IMV/PCV1 OPEN ERROR FAILURE CODE [CA322] INJ #1 OPEN/SHORT ERRORFAILURE CODE [CA323] INJ #5 OPEN/SHORT ERRORFAILURE CODE [CA324] INJ #3 OPEN/SHORT ERRORFAILURE CODE [CA325] INJ #6 OPEN/SHORT ERROR FAILURE CODE [CA331] INJ #2 OPEN/SHORT ERROR FAILURE CODE [CA332] INJ #4 OPEN/SHORT ERROR

TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 2 FAILURE CODE [CA342] CALIBRATION CODE INCOMPATIBILITYFAILURE CODE [CA351] INJECTORS DRIVE CIRCUIT ERRORFAILURE CODE [CA352] SENS SUPPLY 1 VOLT LOW ERRORFAILURE CODE [CA386] SENS SUPPLY 1 VOLT HIGH ERRORFAILURE CODE [CA428] WATER IN FUEL SENSOR HIGH ERROR FAILURE CODE [CA429] WATER IN FUEL SENSOR LOW ERRORFAILURE CODE [CA441] BATTERY VOLTAGE LOW ERRORFAILURE CODE [CA442] BATTERY VOLTAGE HIGH ERRORFAILURE CODE [CA449] RAIL PRESS VERY HIGH ERRORFAILURE CODE [CA451] RAIL PRESS SENSOR HIGH ERRORFAILURE CODE [CA452] RAIL PRESS SENSOR LOW ERRORFAILURE CODE [CA553] RAIL PRESS HIGH ERRORFAILURE CODE [CA559] RAIL PRESS LOW ERROR FAILURE CODE [CA689] ENG NE SPEED SENSOR ERRORFAILURE CODE [CA731] ENG BKUP SPEED SENS PHASE ERROR FAILURE CODE [CA757] ALL PERSISTENT DATA LOST ERRORFAILURE CODE [CA778] ENG BKUP SPEED SENSOR ERROR FAILURE CODE [CA1633] KOMNET DATALINK TIMEOUT ERRORFAILURE CODE [CA2185] THROT SENS SUP VOLT HIGH ERROR FAILURE CODE [CA2186] THROT SENS SUP VOLT LOW ERRORFAILURE CODE [CA2249] RAIL PRESS VERY LOW ERROR FAILURE CODE [CA2265] ELECTRIC LIFT PUMP HIGH ERROR FAILURE CODE [CA2266] ELECTRIC LIFT PUMP LOW ERRORFAILURE CODE [CA2555] GRID HTR RELAY VOLT HIGH ERROR FAILURE CODE [CA2556] GRID HTR RELAY VOLT LOW ERROR FAILURE CODE [D110KB] BATTERY RELAY DRIVE S/CFAILURE CODE [DA25KP] 5V SENSOR 1 POWER ABNORMALITY FAILURE CODE [DA2RMC] PUMP COMM. ABNORMALITYFAILURE CODE [DA2SKQ] MODEL SELECTION ABNORMALITY

TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE), PART 3 FAILURE CODE [DAFRMC] CAN DISCON (MONITOR DETECTED) FAILURE CODE [DHPAMA] F PUMP PRESS SENSOR ABNORMALITY FAILURE CODE [DHPBMA] R PUMP PRESS SENSOR ABNORMALITYFAILURE CODE [DHS3MA] ARM CURL PPC SEN. ABNORMALITYFAILURE CODE [DHS4MA] BUCKET CURL PPC PRESS SENSOR ABNORMALITY FAILURE CODE [DW43KA] TRAVEL SPEED SOL. DISC.FAILURE CODE [DW43KB] TRAVEL SPEED SOL. S/CFAILURE CODE [DW45KA] SWING BRAKE SOL. DISC. FAILURE CODE [DW45KB] SWING BRAKE SOL. S/CFAILURE CODE [DW91KA] TRAVEL JUNCTION SOL. DISC.FAILURE CODE [DW91KB] TRAVEL JUNCTION SOL. S/CFAILURE CODE [DWJ0KA] MERGE-DIVIDER SOL. DISC. FAILURE CODE [DWJ0KB] MERGE-DIVIDER SOL. S/CFAILURE CODE [DWK0KA] 2-STAGE RELIEF SOL. DISC.FAILURE CODE [DWK0KB] 2-STAGE RELIEF SOL. S/CFAILURE CODE [DXA0KA] PC-EPC SOL. DISC.FAILURE CODE [DXA0KB] PC-EPC SOL. S/CFAILURE CODE [DXE0KA] LS-EPC SOL. DISC.FAILURE CODE [DXE0KB] LS-EPC SOL. S/CFAILURE CODE [DXE4KA] SERVICE CURRENT EPC DISC.FAILURE CODE [DXE4KB] SERVICE CURRENT EPC S/CFAILURE CODE [DY20KA] WIPER WORKING ABNORMALITY FAILURE CODE [DY20MA] WIPER PARKING ABNORMALITY FAILURE CODE [DY2CKB] WASHER DRIVE SHORT FAILURE CODE [DY2DKB] WIPER DRIVE (FOR) SHORTFAILURE CODE [DY2EKB] WIPER DRIVE (REV) SHORT

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) BEFORE CARRYING OUT TROUBLESHOOTING OF ELECTRICAL SYSTEMINFORMATION CONTAINED IN TROUBLESHOOTING TABLEE-1 ENGINE DOES NOT STARTE-2 AUTO-DECELERATOR DOES NOT OPERATE E-3 AUTOMATIC WARMING-UP SYSTEM DOES NOT OPERATE E-4 PREHEATER DOES NOT OPERATE E-5 ALL WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT MOVEE-6 POWER MAXIMIZING FUNCTION DOES NOT OPERATEE-7 MACHINE MONITOR DOES NOT DISPLAY AT ALL E-8 MACHINE MONITOR DOES NOT DISPLAY SOME ITEMSE-9 CONTENTS OF DISPLAY BY MACHINE MONITOR ARE DIFFERENT FROM APPLICABLE MACHINEE-10 FUEL LEVEL MONITOR WAS LIGHTED IN RED WHILE ENGINE RUNNINGE-11 ENGINE COOLANT TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY E-12 HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLYE-13 FUEL LEVEL GAUGE DOES NOT INDICATE NORMALLYE-14 SWING LOCK MONITOR DOES NOT INDICATE NORMALLYE-15 WHEN MONITOR SWITCH IS OPERATED, MONITOR DISPLAYS NOTHINGE-16 WINDSHIELD WIPER AND WINDOW WASHER DO NOT OPERATE E-17 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE NORMALLY E-18 MONITORING FUNCTION FAILS TO DISPLAY “ BOOM RAISE ” NORMALLY E-19 MONITORING FUNCTION FAILS TO DISPLAY “ BOOM LOWER ” NORMALLY E-20 MONITORING FUNCTION FAILS TO DISPLAY “ ARM IN ” NORMALLY E-21 MONITORING FUNCTION FAILS TO DISPLAY “ ARM OUT ” NORMALLY E-22 MONITORING FUNCTION FAILS TO DISPLAY “ BUCKET CURL ” NORMALLY E-23 MONITORING FUNCTION FAILS TO DISPLAY “ BUCKET DUMP ” NORMALLY E-24 MONITORING FUNCTION FAILS TO DISPLAY “ SWING ” NORMALLYE-25 MONITORING FUNCTION FAILS TO DISPLAY “ TRAVEL ” NORMALLY E-26 MONITORING FUNCTION FAILS TO DISPLAY “ TRAVEL DIFFERENTIAL PRESSURE ” NORMALLY E-27 MONITORING FUNCTION FAILS TO DISPLAY “ SERVICE ” NORMALLYE-28 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY E-29 AIR CONDITIONER DOES NOT OPERATEE-30 TRAVEL ALARM DOES NOT SOUND OR DOES NOT STOP SOUNDING E-31 HORN DOES NOT SOUND

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM INFORMATION CONTAINED IN TROUBLESHOOTING TABLEH-1 ALL WORK EQUIPMENT LACK POWER, OR TRAVEL AND SWING SPEEDS ARE SLOWH-2 ENGINE SPEED SHARPLY DROPS OR ENGINE STALLS H-3 NO WORK EQUIPMENT, SWING OR TRAVEL MOVEH-4 ABNORMAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMPH-5 AUTO-DECELERATOR DOES NOT WORKH-6 FINE CONTROL MODE DOES NOT FUNCTION OR RESPONDS SLOW H-7 BOOM MOVES SLOWLY OR LACKS POWER H-8 ARM MOVES SLOWLY OR LACKS POWERH-9 BUCKET MOVES SLOWLY OR LACKS POWERH-10 WORK EQUIPMENT DOES NOT MOVE IN ITS SINGLE OPERATION H-11 WORK EQUIPMENT HAS A BIT TOO FAST HYDRAULIC DRIFTH-12 WORK EQUIPMENT HAS BIG TIME LAGH-13 OTHER WORK EQUIPMENT MOVES WHEN RELIEVING SINGLE CIRCUITH-14 POWER MAX. SWITCH DOES NOT OPERATEH-15 IN COMPOUND OPERATION, WORK EQUIPMENT WITH LARGER LOAD MOVES SLOWLY H-16 IN SWING + BOOM RAISE OPERATION, BOOM MOVES SLOWLYH-17 IN SWING + TRAVEL OPERATION, TRAVEL SPEED DROPS SHARPLYH-18 MACHINE SWERVES IN TRAVELH-19 MACHINE TRAVELS SLOWLY H-20 MACHINE CANNOT BE EASILY STEERED OR LACKS POWERH-21 TRAVEL SPEED DOES NOT SHIFT, OR IT IS TOO SLOW OR FASTH-22 TRACK SHOE DOES NOT TURN (ON ONE SIDE ONLY)H-23 MACHINE DOES NOT SWINGH-24 SWING ACCELERATION IS POOR, OR SWING SPEED IS SLOW H-25 EXCESSIVE OVERRUN WHEN STOPPING SWINGH-26 THERE IS BIG SHOCK WHEN STOPPING SWING H-27 LARGE SOUND IS MADE WHEN UPPER STRUCTURE STOPS SWINGINGH-28 SWING HYDRAULIC DRIFT IS TOO BIG

TROUBLESHOOTING OF ENGINE (S-MODE) METHOD OF USING TROUBLESHOOTING CHARTS-1 STARTING PERFORMANCE IS POORS-2 ENGINE DOES NOT STARTS-3 ENGINE DOES NOT PICK UP SMOOTHLY S-4 ENGINE STOPS DURING OPERATIONS S-5 ENGINE DOES NOT ROTATE SMOOTHLYS-6 ENGINE LACKS 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 QUICKLYS-10 FUEL CONSUMPTION IS EXCESSIVES-11 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) S-12 OIL PRESSURE DROPSS-13 OIL LEVEL RISES (ENTRY OF COOLANT OR FUEL)S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING) S-15 ABNORMAL NOISE IS MADES-16 VIBRATION IS EXCESSIVE

50 DISASSEMBLY AND ASSEMBLYGENERAL INFORMATION ON DISASSEMBLY AND ASSEMBLYHOW TO READ THIS MANUALCOATING MATERIALS LISTSPECIAL TOOLS LISTSKETCHES OF SPECIAL TOOLS

ENGINE AND COOLING SYSTEMREMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLYREMOVAL AND INSTALLATION OF ENGINE FRONT SEALREMOVAL AND INSTALLATION OF ENGINE REAR SEALREMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLYREMOVAL AND INSTALLATION OF RADIATOR ASSEMBLYREMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLYREMOVAL AND INSTALLATION OF AFTERCOOLER ASSEMBLYREMOVAL AND INSTALLATION OF ENGINE AND HYDRAULIC PUMP ASSEMBLY

POWER TRAINREMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLYDISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLYREMOVAL AND INSTALLATION OF SWING MOTOR AND SWING MACHINERY ASSEMBLYDISASSEMBLY AND ASSEMBLY OF SWING MOTOR AND SWING MACHINERY ASSEMBLY REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLY

UNDERCARRIAGE AND FRAMEDISASSEMBLY AND ASSEMBLY OF CARRIER ROLLERDISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLYDISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLYDISASSEMBLY AND ASSEMBLY OF RECOIL SPRING REMOVAL AND INSTALLATION OF SPROCKETEXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLYREMOVAL AND INSTALLATION OF REVOLVING FRAME ASSEMBLYREMOVAL AND INSTALLATION OF COUNTERWEIGHT ASSEMBLY

HYDRAULIC SYSTEM REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT ASSEMBLYDISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLYREMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLYREMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLYDISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLYREMOVAL AND INSTALLATION OF HYDRAULIC PUMP ASSEMBLYREMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC PUMP INPUT SHAFTDISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC VALVE ASSEMBLYDISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE ASSEMBLYDISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY

WORK EQUIPMENTREMOVAL AND INSTALLATION OF WORK EQUIPMENT ASSEMBLY

CAB AND ITS ATTACHMENTS REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLYREMOVAL AND INSTALLATION OF OPERATOR CAB GLASS (STUCK GLASS)REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLYREMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY

ELECTRICAL SYSTEMREMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLYREMOVAL AND INSTALLATION OF KOMTRAX COMMUNICATION MODEM ASSEMBLYREMOVAL AND INSTALLATION OF MONITOR ASSEMBLYREMOVAL AND INSTALLATION OF PUMP CONTROLLER ASSEMBLYREMOVAL AND INSTALLATION OF ENGINE CONTROLLER

90 DIAGRAMS AND DRAWINGSHYDRAULIC DIAGRAMS AND DRAWINGSHYDRAULIC CIRCUIT DIAGRAM

ELECTRICAL DIAGRAMS AND DRAWINGSELECTRICAL CIRCUIT DIAGRAMCONNECTOR ARRANGEMENT DIAGRAM