5695026-Komatsu Service Pc100-6 Pc120-6 Shop Manual Excavator Repair Book PDF
5695026-Komatsu Service Pc100-6 Pc120-6 Shop Manual Excavator Repair Book PDF
5695026-Komatsu Service Pc100-6 Pc120-6 Shop Manual Excavator Repair Book PDF
This shop manual may contain attachments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
2000
All Rights Reserved 00-1
Printed in Japan 03-01(02) 7
CONTENTS
No. of page
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol a. IS used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19. Be sure to assemble all parts again in their
original places.
11. When removing the oil filler cap, drain plug Replace any damaged parts with new parts.
or hydraulic pressure measuring plugs, . When installing hoses and wires, be sure
loosen them slowly to prevent the oil from that they will not be damaged by contact
spurting out. with other parts when the machine is be-
Before disconnecting or removing compo- ing operated.
nents of the oil, water or air circuits, first
20. When installing high pressure hoses, make
remove the pressure completely from the
sure that they are not twisted. Damaged
circuit.
tubes are dangerous, so be extremely care-
12. The water and oil in the circuits are hot ful when installing tubes for high pressure
when the engine is stopped, so be careful circuits. Also, check that connecting parts
not to get burned. are correctly installed.
Wait for the oil and water to cool before
21. When assembling or installing parts, always
carrying out any work on the oil or water
use the specified tightening torques. When
circuits.
installing protective parts such as guards,
13. Before starting work, remove the leads from or parts which vibrate violently or rotate at
the battery. Always remove the lead from high speed, be particularly careful to check
the negative (-) terminal first. that they are installed correctly.
14. When raising heavy components, use a hoist 22. When aligning two holes, never insert your
or crane. fingers or hand. Be careful not to get your
Check that the wire rope, chains and hooks fingers caught in a hole.
are free from damage.
23. When measuring hydraulic pressure, check
Always use lifting equipment which has
that the measuring tool is correctly assem-
ample capacity.
bled before taking any measurements.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
24. Take care when removing or installing the
slowly to prevent the component from hit-
tracks of track-type machines.
ting any other part. Do not work with any
When removing the track, the track sepa-
part still raised by the hoist or crane.
rates suddenly, so never let anyone stand at
15. When removing covers which are under in- either end of the track.
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop 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 shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
I I
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs. They are divided as follows: (@@@....) is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one
Attachments volume: volume to cover all REVISIONS
1 models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
1. See the page number on the bottom of the Symbol Item Remarks
page. File the pages in correct order.
Special safety precautions are
A
2. Following examples show how to read the
Safety necessary when performing
page number. the work.
Example 1 (Chassis volume):
Special technical precautions
10 - 3
or other precautions for pre-
* Caution serving standards are neces-
Item number (IO. Structure sary when performing the
and Function) work.
:Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
IO-4 12-203
IO-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
A Heavy parts (25 kg or more) must be
lifted with a hoist, etc. In the DISAS-
cause the rope to slip off the hook during
hoisting, and a serious accident can re-
SEMBLY AND ASSEMBLY section, sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
I I I I I
2) Sling wire ropes from the middle portion
30 60 90 120 150
of the hook. Lifting angle (degree) SAD00480
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 1 Type 2
1) Hold the mouthpiece of the tightening por- 1) Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end. end.
CWPO6391 CWPO6392
2) Hold in the condition in Step I), and push 2) Hold in the condition in Step I), and turn
until cover (3) contacts contact surface a of lever (4) to the right (clockwise).
the hexagonal portion at the male end.
;
4
%!
.z
n
3 CWPO6393 CWPO6394
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
CWPO6395 CWPO6396
00-8
F O R EW OR D METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 1 Type 2
Hold the mouthpiece of the tightening por- Hold the mouthpiece of the tightening por-
tion and push body (2) in straight until slid- tion and push body (2) in straight until slid-
ing prevention ring (1) contacts contact sur- ing prevention ring (1) contacts contact sur-
face a of the hexagonal portion at the male face a of the hexagonal portion at the male
end to connect it. end to connect it.
Connection
00-9
F O R EW OR D COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
00-10
F O R EW OR D COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
00-11
F O R EW OR D STANDARD TIGHTENING TORQUE
mm mm Nm kgm
6 10 13.2 1.4 1.35 0.15
8 13 31 3 3.2 0.3
10 17 66 7 6.7 0.7
12 19 113 10 11.5 1
14 22 177 19 18 2
16 24 279 30 28.5 3
18 27 382 39 39 4
20 30 549 59 56 6
22 32 745 83 76 8.5
24 36 927 103 94.5 10.5
27 41 1320 140 135 15
30 46 1720 190 175 20
33 50 2210 240 225 25
36 55 2750 290 280 30
39 60 3290 340 335 35
mm mm Nm kgm
6 10 7.85 1.95 0.8 0.2
8 13 18.6 4.9 1.9 0.5
10 14 40.2 5.9 4.1 0.6
12 27 82.35 7.85 8.4 0.8
Sealing surface
00-12
FOREWORD STANDARD TIGHTENING TORQUE
00-l 3
FOREWORD STANDARD TIGHTENING TORQUE
00-l 4
FOREWORD ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cal;kziD. Curre&rating
number Number of Dia. of strands Cross section Applicable circuit
strands (mm) (mm?
\-\
Circuit:
Prior- Charging Ground Starting Lighting 1 Instrument 1 Signal 1 Other
ity Classi-
fication I I
w I I
1
I t
pri_
mav
Color
Code
White
WR
B
Black
-
Black
BW
B R
Red
RW
I
Yellow
YR
y I G
Green
GW
I
Blue
LW
L
White & Red I - IBlack &White Red & White IYellow & Red IGreen & WhitelBlue &White
WB BY RB YB GR LR
White & Black - Black & Yello\n Red & Black Yellow & Black Green & Red Blue & Red
4
WL 1 - 1 BR RY I YG I GY I LY
White & Blue - Black & Red Red & Yellow Yellow & Green Green &Yellow Blue & Yellow
WG RG YL GB LB
00-l 5
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line
down from @I.
(3) Take the point where the two lines cross as 0. This point @ gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
0 1 2 3 4 6 7 8 9
...50
.. ... . .. ..1.969
... .. .. .. .2.008
......... .2.047
. .. ... . ... . 2.087 2.126
.. ... .. ...I I.......... y&%YJ 2.205 2.244 2.283 2.323
@..
60 2.362 2.402 2.441 2.480 2.520 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2:953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-l 6
FOREWORD CONVERSIONTABLE
Millimetersto Inches
1 mm = llfl1917 in
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
\\
4
0 1 2 3 4 5 6 7 8 9
+
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
+
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-l 7
FOREWORD CONVERSIONTABLE
0 1 2 3 4 5 6 7 8 9
\\
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-l 8
FOREWORD CONVERSIONTABLE
kgm to ft. lb
1 kqm = 7.233ft.lb
0 1 2 3 4 5 6 7 8 9
\\
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 012.6 019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 084.9 092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 157.3 164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 129.6 236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 301.9 309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 374.3 381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-l 9
FOREWORD CONVERSIONTABLE
kg/cm2 to lb/in2
Ikg/cm2 = 14.2233 lb/in*
0 1 2 3 4 5 6 7 8 9
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ;a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with lnternatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { I.
Example:
N {kg1
Nm IkgmI
MPa {kg/cm21
kPa {mmHzO}
kPa ImmHgI
kw/rpm {HP/t-pm)
gfkwh {g/HPhl
00-22
01 GENERAL
01-l
0
GENERAL ASSEMBLY DRAWING
GENERAL
7170 6
e-- 2110
5060
2330
L 7590
7720
7750
7675
202FOM)OZ
GENERAL GENERAL ASSEMBLY DRAWING
PC120-6 Unit: mm
202FC6003A
L 8325
8445 202FO6004
01-3
@I
GENERAL SPECIFICATIONS
SPECIFICATIONS
I
Bucket capacity (SAE) m3 0.44 0.50
Gradeability deg. 35 35
Ground pressure
(standard shoe width: 500 mm) kPa{kg/cm*} 37.27IO.38) 38.2510.39)
01-4
GENERAL SPECIFICATIONS
Machine model
Serial Number
Model S4D95L-1
: Maximum torque Im/rpm{kgm/rpm: 299/I ,500 {30.5/l ,500) 299/l ,500 {30.5/1,500~
E High idling speed rpm 2,300 2,400
0
t Low idling speed 900 900
rpm
d
Min. fuel consumption ratio g/kWhIg/HPhI 211{1551 211 (1551
Carrier roller
Track roller
Track shoe
I
.o Type x no. Variable displacement piston type x 1 + gear type x 1
7
2 Q Delivery Q/min 197 + 32.9 I 206 + 34.5
oE
2 z Set pressure MPaIkg/cm21 Piston type: 31.9 (3251, gear type: 2.9 I301
I I
i5 Type x no. 6-spool type x 1
za
:-$ Control method Hydraulic type
U>
.o Travel motor
Variable displacement piston type
-5 (with brake valve,parking brake) x2
(0
+jB
Swing motor Fixed displacement piston type
fE (with safety valve,parking brake) x 2
I
01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling component. Unit : kg
Control valve 89 89 89 89
01-6
GENERAL WEIGHT TABLE
Unit : kg
Machine model
T PC1 00-6
Standard triple grouser shoe (500 mm) 705 x 2 705 x 2 705 x 2 705 x 2
Wide triple grouser shoe (600 mm) 790 x 2 790 x 2 790 x 2 790 x 2
Wide triple grouser shoe (700 mm) 880 x 2 880 x 2 880 x 2 790 x 2
Wide triple grouser shoe (750 mm) - -
01-7
0
GENERAL WEIGHT TABLE
Unit : kg
Machine model
l- PC120-6
Control valve 89 89 89 89
01-8
@
GENERAL WEIGHT TABLE
Unit : kg
Standard triple grouser shoe (500 mm) 740 x 2 740 x 2 740x2 740x2
Wide triple grouser shoe (600 mm) 830x2 830 x 2 830 x 2 830x2
Wide triple grouser shoe (700 mm) 925 x 2 925 x 2 925x2 925 x 2
Wide triple grouser shoe (750 mm) 970 x 2 970 x 2 970x2 970 x 2
Rubber pad shoe (500 mm) 845x2 845x2 845x2 845x2
Flat shoe (480 mm) 760x2 760x2 760x2 760 x 2
Swamp shoe (750 mm) 875x2 875 x 2 875x2 875 x 2
Rubber shoe (500 mm) 342x2 342x2 683x2 683x2
Road riner (rubber pad type) (500 mm) 804x2 804x2 804x2 804x2
01-9
@
LIST OF LUBRICANT AND WATER
01-10
a
10 STRUCTURE AND FUNCTION
Radiator and oil cooler .................................... IO- 2 Travel motor .................................................. IO- 94
PTO (Coupling) ................................................ IO- 4 Valve control .................................................. IO-101
Power train ....................................................... IO- 5 Work equipment l Swing PPC valve ........... IO-102
Swing circle.. .................................................... IO- 6 Travel PPC valve ............................................ IO-106
Swing machinery.. ........................................... lo- 7 Service PPC valve .......................................... IO-I IO
Track frame ...................................................... IO- 8 Safety lock valve ............................................ IO-I 13
Idler.. ................................................................. IO-IO PPC accumulator ........................................... IO-I 13
Idler cushion .................................................... IO-IO PPC shuttle l Travel junction valve ........... ..10-114
Carrier roller ..................................................... IO-I 1 EPC l Solenoid valve .................................... IO-I 18
Track roller ....................................................... 10-I 1 Boom holding valve ...................................... IO-124
Track shoe ........................................................ IO-12 Hydraulic cylinder.. ........................................ IO-127
Hydraulic piping drawing.. .............................. IO-15 Accumulator for breaker ............................... IO-129
Hydraulic circuit diagram ................................ IO-16 Additional filter for breaker.. ......................... IO-130 .
Hydraulic tank .................................................. IO-22 Work equipment ............................................ IO-131
Hydraulic pump ............................................... IO-23 Electrical wiring diagram .............................. IO-132
Control valve.. .................................................. IO-44 Electrical circuit diagram ............................... IO-134
CLSS ................................................................. IO-57 Engine control system.. ................................. IO-137
Swing motor .................................................... IO-90 Electronic control system.. ............................ IO-142
Center swivel joint ........................................... IO-93 Machine monitor system .......................... 10-166-2
10-l
0
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
; 6
1o-2
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
Oi I
IN -
OUT-
SAP01382
1o-3
STRACTURE AND FUNCTION RADIATOR AND OIL COOLER
. - --l.._
- - -?y--y-_-------
______c--.
1P
__-__-
br_-.----*y-- _-=__-_==
. ~_ y.-__~..__.. _ -__-
---_--_-
10-3-l
0
STRACTURE AND FUNCTION RADIATOR AND OIL COOLER
a
I
Di I
IN -
OUT-
SAP01383
1 O-3-2
0
PTO (COUPLING)
A-A
A-I
_:,5-
_/f
--A
L- :
202CDO6013
1 o-4
POWER TRAIN
1 2 3 4 5 6 7 0
10
202FO6009
IO-5
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
PClOO-6 Serial No. : 40001 -42156
PC120-6 Serial No. : 45001 - 52400
-A
31
2-
1' A-A
202CD0601'1
1O-6
@
STRACTURE AND FUNCTION SWING CIRCLE
I----
A-A
a. Inner race soft zone S position Amount of grease: 6.5 !?(Grease: G2-LI)
b. Outer race soft zone 9 position
10-6-l
0
SWING MACHINERY
CJ)
A-A 1 /
\
13
202COO6010
1. Swing pinion (No. of teeth: 11) 10. No. 1 planetary gear (No. of teeth: 24)
2. Case 11. No. 2 planetary gear (No. of teeth: 22)
3. No. 2 sun gear (No. of teeth: 17) 12. Drain plug
4. No. 2 planetary carrier (No. of teeth: 17) 13. Swing circle
5. Ring gear (No. of teeth: 61)
6. No. 1 planetary carrier (No. of teeth: 17)
7. No. 1 sun gear (No. of teeth: 14) SPECIFICATION
8. Oil level gauge/ oil filler port
14+ 61
9. Swing motor Reduction ratio:7 x v = 24.58
1o-7
0
TRACK FRAME
PCIOO-6
\
\
\
8 7 6
1. Idler 5. Sprocket
2. Track frame 6. Track shoe
3. Carrier roller 7. Track roller
4. Travel motor 8. Recoil spring
1 O-8
PC1 20-6
202CD06018
1. Idler 5. Sprocket
2. Track frame 6. Track shoe
3. Carrier roller 7. Track roller
4. Travel motor 8. Recoil spring
1 o-9
IDLER
1. Idler
2. Floating seal
3. Shaft
4. Support
202FO5013
IDLER CUSHION
1. Yoke
2. Seal
3. Front support
(cylinder)
4. Recoil spring
5. Wear ring
6. Packing
7. Rear support
8. Nut
1 2 3 4 5 6 7 8 9 9. Lubricator
\I/// I//
SPECIFICATION
Amount of grease
(when applying track
tension):
Approx. 140 cc (G2-LI)
IO-IO
CARRIER ROLLER
F020203305A
TRACK ROLLER
205F2452
IO-I 1
TRACK SHOE
TRIPLE GROUSER SHOE, SWAMP SHOE, FLAT SHOE, RUBBER PAD SHOE
1 2 3 4 5 6
202CD06014
IO-12
SELECTION OF TRACK SHOE
l Select the most suitable track shoe from the following table.
PC 100-6 PC120-6
Model
Soecifications Cateaorv Specifications Category
Rocky ground, l Travel in Lo speed when traveling on rough ground with obstacles
A
normal river soil such as large boulders and fallen trees.
land to avoid traveling over obstacles, lower the travel speed to approx.
half of Lo speed.
l Use only for ground where A and B sink and are impossible to
use.
Extremely soft l Cannot be used on rough ground where there are large obstacles
C ground (swampy such as boulders and fallen trees.
ground) l Travel in Hi speed only on flat ground, and when it is impossible
to avoid traveling over obstacles, lower the travel speed to approx.
half of Lo speed.
D Paved surface l The shoes are flat, so they have low gradeability.
F Chip operations
* Categories B and C are wide shoes, so * When selecting the shoe width, select the nar-
there are restrictions on their use. Therefore, rowest shoe possible within the range that will
before using, check the restrictions and con- give no problem with flotation and ground
sider carefully the conditions of use before pressure. If a wider shoe than necessary is
recommending a suitable shoe width. If nec- used, there will be a large load on the shoe,
essary, give the customer guidance in their and this may lead to bending of the shoe,
use. cracking of the links, breakage of the pins,
loosening of the shoe bolts, or other prob-
lems.
IO-13
ADDITIONAL ATTACHMENT CIRCUIT
Breaker (I service valve, 60% flow) * If the B/O (breaker) mode is selected for the working
mode, the pump flow is reduced to 60%.
h-
I Breaker
Selector
I
valve B2 A2
1 Safety valve
Accumulator
I I
I
------_I
Service 1 A7
A--
From control pump
t
To cooler
a
m*)
Control valve
Telescopic are
t (50% flow)
To cooler SEPOOOll
10-19
0
Crusher (1 service valve, 100% flow)
?i-
Safety vale
I
17 2MPa
(17%g/cmz)
Ql
I --e-f--
From control pump
Control valve
I
Tl
1
Crusher (100% flow)
To cooler
82 A2 Selector valve
Safety valve
I
I/Cm?)
I- Accumulat
I
I_______
m
rr
I
& 1i -p Control valve
Fiterm
1O-20
0
Log hunter (2 service valve)
k- , -1
Y L
I___
I---____7 1
--
Service 1 PPC valve -&--
*I- ;
* Remarks
l When switching the attachment with the first
service valve, operate the selector valve.
l The flow of the pump for the first service
valve is set at 100%.
l When using a 50%-flow attachment, fit a stop-
per to the control pedal. However, when us-
ing the breaker, select B/O(Breaker operation)
mode on the working mode on the monitor
panel and use the control pedal over the full
stroke.
l The oil flow from the pump for the second
service valve is set at 50%.
. It is possible to add up to a third service valve.
10-21
0
HYDRAULIC TANK
A-A
-6
II //
ds 1.J
=__;;_=,==ii_-__~~-_-__=,
___________,
12
__A_----_____
202CD06009
1 o-22
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
PCIOO-6 Serial No. : 40001 - 41400
PC120-6 Serial No. : 45001 - 50200
1 b
1o-23
al
STRACTURE AND FUNCTION HYDRAULIC PUMP
a I b
CZ
w
e f 0 h
SKP01167
10-23-l
@
STRACTURE AND FUNCTION HYDRAULIC PUMP
a b
_ \
202FO6022
a. Port PdF (Drain) d. Port PAZ (Pump delivery pressure outlet port)
b. Port PA (Delivery) e. Port PAI (Pump delivery pressure outlet port)
c. Port Pen (WC l LS valve signal pressure inlet f. Port PS (Suction)
port)
1O-23-2
0
STRUCTURE AND FUNCTION
HYDRAULIC PUMP
E-E
202FO6023
1 O-24
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
SKPOl168
1o-25
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION
I
8
?
li 11 ill
202F6024
a 12 II IO
SKP01169
STRUCTURE
. Cylinder block (7) is supported to shaft (I) by . Piston (6) carries out relative movement in the
spline a, and shaft (I) is supported by the axial direction inside each cylinder chamber of
front and rear bearings. cylinder block (7).
. The tip of piston (6) is a concave ball, and . Cylinder block (7) seals the pressure oil to
shoe (5) is caulked to it to form one unit. Pis- valve plate (8) and carries out relative rotation.
ton (6) and shoe (5) form a spherical bearing. This surface is designed so that the oil pres-
. Locker cam (4) has flat surface A, and shoe (5) sure balance is maintained at a suitable level.
is always pressed against this surface while The oil inside each cylinder chamber of cylin-
sliding in a circular movement. Rocker cam der block (7) is sucked in and discharged
(4) brings high pressure oil at cylindrical sur- through valve plate (8).
face B with cradle (2), which is secured to the
case, and forms a static pressure bearing
when it slides.
1 O-26
0
OPERATION
1. Operation of pump
1) Cylinder block (7) rotates together with
shaft (I), and shoe (5) slides on flat surface
A. When this happens, rocker cam (4)
moves along cylindrical surface B, so
angle a between center line X of rocker
tam(4) and the axial direction of cylinder
block (7) changes. (Angle a is called the
swash plate angle.)
,
202FO6025
1 7 E
202FO6027
1 O-27
2. Control of discharge amount
. If swash plate angle a becomes larger, the
difference in volumes E and F becomes
larger and discharge volume 0 increases.
Swash plate angle a is changed by servo
piston (11).
. Servo piston (11) moves in a reciprocal
movement (- ) under the signal pres-
sure of the TVC and LS valves. This
straight line movement is transmitted
through rod (12) to rocker cam (41, and
rocker cam (4), which is supported by the
cylindrical surface to cradle (21, slides in a
rotating movement in direction ( ( 1.
l With servo piston (1 I), the area receiving
the pressure is different on the left and
right, so main pump discharge pressure
(self pressure) Pp is always brought to the
pressure chamber on the small diameter
piston side (front).
202FO6028
Output pressure Pen of the LS valve is
brought to the pressure chamber at the
large diameter piston end (rear).The rela-
tionship in the size of pressure Pp at the
small diameter piston end and pressure
Pen at the large diameter piston end, and
the ratio between the area receiving the
pressure of the small diameter piston and
the large diameter piston controls the
movement of servo piston (11).
IO-28
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. WC l LS VALVE
202FO6029
a. Port Pm (Pump delivery pressure inlet port) d. Port PLS (Control valve LS pressure inlet port)
b. Port Pen (TVC l LS valve signal pressure outlet e. Pot-t PSIG(LS control EPC valve pressure inlet
port) port)
c. Port PAI (Pump delivery pressure inlet port)
1O-30
0
A-A
B-B
8 4
202F06030
IO-31
STRACTURE AND FUNCTION HYDRAULIC PUMP
d e
SKP01170
a. Port PAZ (Pump delivery pressure inlet port) d. Port PLS (Control valve LS pressure inlet port)
b. Port Pen (TVC LS valve signal pressure out-
l e. Port PSIG (LS control EPC valve pressure inlet
let port) port)
c. Port Pni (Pump delivery pressure inlet port) f. Port PVAR (Variable throttle valve selector
pressure inlet pot-t)
10-31-l
0
STRACTURE AND FUNCTION HYDRAULIC PUMP
A-A
I 2 3 4 5 6 7 6 9 IO II 12 I3 14 I5
B-B c-c
SKP01171
10-31-2
0
FUNCTION
LS VALUE
The LS valve detects the load and controls the (! /min)
discharge amount.
2.94 MPa (30 kg/cm)
This valve controls main pump discharge
amount 0 according to differential pressure :
APLS (=PP-PLS) (the difference between main 5
pump pressure Pp and control valve outlet %
&
port pressure PLS) {called the LS differential
pressure}.
Main pump pressure Pp, pressure PLS {called
II I
the LS pressure} coming from the control I
O&37(6.5) 2.11f21.5) (MPa (kg/cm))
valve output, and pressure PSIG {called the LS
LS differential pressure APLS
selection pressure) from the proportional sole-
noid valve enter this valve.
202FO6031
The relationship between discharge amount Q
and differential pressure APLs, (the difference
between main pump pressure Pp and LS
pressure PLS) (= PP-PLS) changes as shown in
the diagram on the right according to LS se-
lection pressure PSIG.
When PSIG changes between 0 and 2.94 MPa
(0 and 30 kg/cm?, the set pressure of the
spring changes according to this, and the se-
lector point for the pump discharge amount
changes at the rated central value between
0.637 and 2.11 MPa (6.5 and 21.5 kg/cm*.)
Tut VALUE
When the pump discharge pressure Pp is
high, the TVC valve controls the pump so that
no more oil than the constant flow (in accor-
dance with the discharge pressure) flows even
if the stroke of the control valve becomes
larger.
In this way it carries out equal horsepower
control so that the horsepower absorbed by
the pump does not exceed the engine horse-
Pump discharge pressure PP
power.
In other words, if the load during the opera-
202FO6032
tion becomes larger and the pump discharge
pressure rises, it reduces the discharge
amount from the pump; and if the pump dis-
charge pressure drops, it increases the dis-
charge amount from the pump.
The relationship between pump discharge
pressure Pp and pump discharge amount Q
when this happens is shown on the right, with
the current given to the TVC valve solenoid amount to allow the speed to recover. In
shown as a parameter. other words, when the load increases and the
However, in the heavy-duty operation mode, engine speed drops below the set value, the
there are cases where it is given the function command to the TVC valve solenoid from the
of sensing the actual speed of the engine, and controller increases according to the drop in
if the speed drops because of an increase in the engine speed to reduce the pump swash
the load, it reduces the pump discharge plate angle.
IO-32
STRACTURE AND FUNCTION HYDRAULIC PUMP
3. VARIABLE VALVE
sy
valve selector pressure) = 0 MPa (0 kg/
/Active mode (PvAR=OMPa (Oks/cm*) 1
cm*))
This changes the area of the opening of
the flow circuit which controls the swash
plate angle of the pump according to
pump discharge pressure PP.
In other words, it acts to make the swash
plate switching time faster at the low
pressure end in order to increase the op-
Pump discharge pressure PP (Mpa (kg/cm'))
erating speed, and to make the swash
plate switching time slower at the high
fT-
pressure end in order to reduce any flut-
tering of the work equipment.
2) In normal mode {PVAR = 2.9 MPa (30 kg/
cm? (H/O, G/O, F/O, L/O modes)}
When 2.9 MPa (30 kg/cm*) is input to
PVAR, the flow circuit which controls the
Active mode (PvAR=OMPa (Oks/cm*) 1
swash plate angle of the pump is fixed at Normal mode (PvAR=~. 9Mpa (30ks/cm*))
a constant area of opening. As a result,
the swash plate switching time becomes
slower at the low pressure end and
slightly faster at the high pressure end.
SKPOlZlO
Therefore, the movement of the work
equipment is softer than in the active
mode.
10-32-l
Co
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
TVC valve n
_-_-_
7
Large diameter
end -
I +-2
Minimum direction
SLPO1211
1. LS VALVE
I) When control valve is at neutral posi- terconnected with the drain circuit
tion through the control valve spool.) At this
. The LS valve is a three-way selector valve, point, spool (4) is pushed to the left, and
with pressure PLS (LS pressure) from the port d and port c are connected. Pump
outlet port of the control valve brought to pressure PP enters the large diameter end
spring chamber i, and main pump dis- of the piston from port h, and the same
charge pressure PP brought to chamber j pump pressure PP also enters the small
of plug (6). The size of this LS pressure diameter end of the piston, so the swash
PLS + force F of spring (3) and the main plate is moved to the minimum angle by
pump pressure (self pressure) PP deter- the difference in area of piston (1).
mines the position of spool (4). However,
7 1 2
the size of the output pressure PSIG (the
LS selection pressure) of the EPC valve for
the LS valve entering port e also changes
r----k I /
the position of spool (4). (The set pres-
sure of the spring changes.)
. Before the engine is started, servo piston
(I) is pushed to the right by spring (7) in-
stalled to rod (2). (See the diagram on the
right)
. When the engine is started and the control
lever is at the NEUTRAL position, LS
pressure PLS is 0 MPa (0 kg/cm2.) (It is in-
- 202FO6034
A-A
10-33
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
TVC valve
PLS PS
@---I -
Maximum direction
SLPO1.212
2) Operation in maximum direction for For this reason, the pressure at the large
pump discharge amount piston diameter end of servo piston (I) be-
. When the difference between main pump comes drain pressure Pt, and pump pres-
pressure PP and LS pressure PLS, in other sure PP enters the small diameter end, so
words, LS differential pressure APw, be- servo piston (I) is pushed to the right.
comes smaller (for example, when the Therefore,rod (2) moves to the right and
area of opening of the control valve be- moves the swash plate in the direction to
comes larger and pump pressure PP make the discharge amount larger.
drops), spool (4) is pushed to the right by If the output pressure of the EPC valve for
the combined force of LS pressure PLS the LS valve enters port e, this pressure
and the force of spring (3). creates a force to move piston (5) to the
. When spool (4) moves, port b and port c left. If piston (5) is pushed to the left, it
are joined and connected to the TVC valve. acts to make the set pressure of spring (3)
When this happens, the TVC valve is con- weaker, and the difference between PLS
nected to the drain port, so circuit c - h and PP changes when ports b and c of
becomes drain pressure Pt. (The operation spool (4) are connected.
of the NC valve is explained later.)
STRUCTURE AND FUNCTION HYDRAULIC PUMP
Minimum direction
SLPO1213
31 Operation in minimum direction for pump . Main pump pressure PP also enters the
discharge amount small piston diameter end, but because of
. The following explains the situation if the difference in area between the large
servo piston (I) moves to the left (the dis- piston diameter end of servo piston (1)
charge amount becomes smaller). When and the small piston diameter end, servo
LS pressure APLS becomes larger (for ex- piston (I) is pushed to the left. As a result,
ample, when the area of opening of the rod (2) moves in the direction to make the
control valve becomes smaller and pump swash p!ate angle smaller.
pressure PP rises), pump pressure PP . lf LS selection pressure PSIG enters port e,
pushes spool (4) to the left. it acts to make the set pressure of spring
. When spool (4) moves, main pump pres- (3) weaker.
sure PP flows from port d to port c, and
from port h, it enters the large piston di-
ameter end.
1o-35
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
//I,,,,,,,,,,,
7
:
:
cl :
:
/ e s
::w ::::
/ , f ::::,I, I
Large diameter
'mend _
/
h
SLPO1214
4) When servo piston is balanced At this point, the relationship between the
. Let us take the area receiving the pressure area receiving the pressure at both ends
at the large piston diameter end as Al, the of piston (I) is AO:Al = 1:2, so the pres-
area receiving the pressure at the small di- sure applied to both ends of the piston
ameter end as AO, and the pressure flow- when it is balanced becomes Pp:Pen +
ing into the large piston diameter end as 2:l.
Pen. If the main pump pressure PP of the The position where spool (4) is balanced
LS valve and the combined force of force and stopped is the standard center, and
F of spring (3) and LS pressure PLS are the force of spring (3) is adjusted so that it
balanced, and the relationship is A0 x PP = is determined when PP - PLS = 2.11 MPa
Al x Pen, servo piston (1) will stop in that (21.5kg/cm2). However, if PSIG (the output
position, and the swash plate will be kept pressure of 0 - 2.94 MPa (0 - 30 kg/cm*)
at an intermediate position. (It will stop at of the EPC valve of the LS valve) is applied
a position where the opening from port b to port e, the balance stop position will
to port c and from port d to port c of spool change in proportion to pressure PSIG be-
(4) is approximately the same.) tween PP - PLS = 2.11-0.637 MPa (21.5
~6.5 kg/cm2).
lo-36
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PT
Iriable
irott le valve
(Maximum direction)
ProI ix switch
1
SLPOl215 202FO6139
2. NCUALUE
1) When pump controller is normal
a. When the load on the actuator is small . The size of command current X is deter-
and pump pressure PP is low mined by the nature of the operation (le-
(I) Movement of solenoid (I) ver operation), the selection of the work-
. The command current from the pump ing mode, and the set value and actual
controller flows to solenoid (1). This com- value for the engine speed.
mand current changes the internal force
pushing solenoid push pin (11).
. On the opposite side to the force pushing
this solenoid push pin (II) is the spring
set pressure of springs (3) and (4) and
pump pressure PP. Piston (2) stops at a
position where the combined force push-
ing piston (2) is balanced, and the pres-
sure (pressure of port c) output from the
TVC valve changes according to this posi-
tion.
1o-37
0
(2) Movement of spring
l The spring load of springs (3) and (4) in the TVC
valve is determined by the swash plate posi-
tion.
l When servo piston (9) moves, cam (7), which is
connected to rod (8), also moves. When this
happens, lever (6) is rotated by the angle of
cam (71, and piston (5) moves to the right and
left.
. If piston (5) moves to the right, spring (3) is
compressed, and if it moves further to the right,
spring (4) contacts seat (IO), so both spring (3)
and spring (4) function. In other words, the
spring load is changed by piston (5) extending
or contracting springs (3) and (4).
. If the command current input to solenoid (I)
changes further, the force pushing solenoid
push pin (II) changes, and the spring load of
springs (3) and (4) also changes according to
the value of the solenoid command current.
. Port c of the TVC valve is connected to port e of
the LS valve (see 1. LS valve). Self pressure PP
enters port b, the small piston diameter end of
servo piston (91, and port a.
l When pump pressure PP is small, piston (2) is
on the right. At this point, port c and port d are
connected,and the pressure entering the LS
valve becomes drain pressure Pt. If port h and
port e of the LS valve are connected (see 1. LS
valve), the pressure entering the large piston di-
ameter end from port f becomes drain pressure
Pt, and servo piston (9) moves to the right. In
this way, the pump discharge amount moves in
the direction of .increase.
l As servo piston (9) moves further, piston (5) is
moved to the left by rod (8), cam (7), and lever
(6). Springs (3) and (4) expand and the spring
force becomes weaker. When the spring force
becomes weaker, piston (2) moves to the left,
so the connection between port c and port d is
cut, and the pump discharge pressure is con-
nected to port b. As a result, the pressure at
port c rises, and the pressure at the large piston
diameter end also rises, so the. movement of
piston (9) to the right is stopped. In other
words, the stop position for piston (9) (= pump
discharge amount) is decided at the point
where for the force of springs (3) and (4) and
the pushing force from the solenoid and the
pushing force created by pressure PP acting on
piston (2) are in.balance.
1 O-38
STRUCTURE AND FUNCTION HYDRAULIC PUMP
LS valve
I I I
diameter
(Minimum direction)
prolix snitch
SLPOl216 202FO6139
b. When load on actuator is small and pump . If main pump pressure PP increases fur-
discharge pressure is high ther and piston (2)moves further to the
. When the load is large and pump dis- left, main pump pressure PP flows to port
charge pressure PP is high, the force push- c and acts to make the discharge amount
ing piston (2) to the left becomes larger the minimum. When piston (9) moves to
and piston (2) moves to the position the left, piston (5) is moved to the right by
shown in the diagram above. When this cam (7) and lever (6). For this reason,
happens, as shown in the diagram above, springs (3) and (4) are compressed and
part of the pressurized oil from port b push back piston(2). Because of this
flows out to port d and the pressure oil force, piston (2) cuts off the connection
flowing from port c to the LS valve be- from port b to port c, and port c and port d
comes approximately half of main pump are connected. As a result, the pressure at
pressure PP. port c (= f) drops, and piston (9) stops
. When port h and port e of the LS valve are moving to the left. The position in which
connected (see 1. LS valve), the pressure piston (9) stops when this happens is fur-
from port f enters the large piston diam- ther to the left than the position when
eter end of servo piston (9), and servo pis- pump pressure PP is low.
ton (9) stops.
1o-39
0
l The relation of pump pressure PP and the
position of servo piston (9) forms a bent
line because of the double-spring effect of
springs (3) and (4). The relationship be-
tween pump pressure PP and pump dis-
charge amount Q is shown in the figure on
the right.
202FO6040
202FO6041
1 O-40
STRUCTURE AND FUNCTION HYDRAULIC PUMP
(Maximum direction)
TVC
prohx switch
// A
//
ON1
SLPO1217 202FO6139
2) When pump controller is abnormal and . If main pump pressure PP is low, the com-
TVC prolix switch is ON. bined force of the pump pressure and the
a. When load on main pump is light force of solenoid (I) is weaker than the
. If there is a failure in the pump controller, spring set force, so piston (2) is balanced
turn TVC prolix switch ON to switch to at a position to the right.
the resistor side. In this case, the power . At this point, port c is connected to the
source is taken directly from the battery. drain pressure of port d, and the large pis-
But if the current is used as it is, it is too ton diameter end of servo piston (9) also
large, so use the resistor to control the becomes the drain pressure Pt through
current flowing to solenoid (1). the LS valve. When this happens, the pres-
. When this is done, the current becomes sure at the small piston diameter end is
constant, so the force pushing solenoid large, so servo piston (9) moves in the di-
push pin (11) is also constant. rection to make the discharge amount
larger.
10-41
0
STRUCTURE AND FUNCTION HYDRAULIC PUMP
e I
triable
lrott Ie valve I
(Minimum direction)
202FO6139
SLPO1218
lo-42
0
STRACTURE AND FUNCTION HYDRAULIC PUMP
(Maximum direction)
SKP01219
3. VARIABLE THRO-ITLE VALVE . When this happens, the area of the open-
I) Movement to large pump discharge ing at portion A becomes larger, so the
a. In active mode (PVAR = 0 MPa (0 kg/cm*)) flow of oil from port b through port c from
. Main pump pressure PP enters the vari- the large diameter end of service piston
able throttle valve through port a. (I) is not controlled, and the movement of
. When main pump pressure PP is high, if servo piston (I) becomes faster.
the difference in the cross sectional area
of spool (4) of chamber e overcomes the
force of spring (3), spool (4) moves to the
right.
. When spool (4) moves to the right, the
area of the opening from port c to port b
is throttled by the cut-out part at portion
A, so the oil flowing from the large diam-
eter end of servo piston (I) is reduced,
and the movement of servo piston (I) be-
comes slower.
. When main pump pressure PP is low,
even if main pump pressure PP enters
chamber e from port a, the pressure is
low, so the force pushing spring (3) is
weak and the movement of spool (4) to
the right is small.
10-42-l
0
STRACTURE AND FUNCTION HYDRAULIC PUMP
;;,,,,,,I,,,,,,,/,,,,,,;
&r+
SKPO
In normal mode (PVAR = 2.9 MPa (30 kg/cm211 . The area of opening of throttle B is smaller
In the normal mode, main pump pressure PP than the area of opening of portion A of spool
enters port a. Variable throttle valve switch- (4) when the main pump pressure PP is low,
ing pressure PVAR (= 2.9 MPa (30 kg/cm*)) en- so even when piston (I) is at low pressure, it
ters port d. moves more slowly than in the active mode.
In order for the force of PVAR pressure enter-
ing chamber f from port d and pushing spool
(4) to overcome the force pushing the differ
ence in cross sectional area of spool (4) be-
cause of main pump pressure PP, spool (4) is
pushed to the left and stops at the point
where it contacts plug (7).
When spool (4) moves to the left, the flow of
oil from the large diameter end of servo pis-
ton (I) passes through port c and then
through the inside of spool (41, and flows
through throttle B.
10-42-2
0
STRACTURE AND FUNCTION HYDRAULIC PUMP
(Minimum direction)
SKP01221
2) Movement of pump discharge in minimum di- . The area of the opening of the check valve
rection (Same for both normal and active is larger than portion A (cut-out) of spool
modes) (4) and throttle B, so the movement from
. The pressure from the LS valves enters large + small of servo piston (I) for the
port b and flows inside spool (4). swash plate angle becomes faster.
. This flow becomes stronger than check
valve spring (5) and pushes check valve
poppet (6) open.
. For this reason, the output from the LS
valve flows from port b -+ passage inside
spool (4) + check valve + port c + large
diameter end of servo piston (I), regard-
less of main pump pressure PP and vari-
able throttle valve selector pressure PVAR.
. Therefore, when the pump swash plate
angle moves from large + small, the oil
does not flow through throttle B because
of the flow described above, so the speed
of movement of servo piston (1) is the
same for both the active mode and the
normal mode.
1o-42-3
0
3. CONTROL PUMP
A-A
B-B
202FO6045
1. Body SPECIFICATIONS
2. Driven gear
3. Cover Type: BAR16
4. Drive gear Theoretical delivery: 16.0 cc/rev
5. Relief valve Set pressure: 3.23 MPa (33 kg/cm2)
6. Filter
1 o-43
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
PCIOO-6 Serial No : 40001- 41229
PC120-6 Serial No : 45001 - 49820
PI pk
Pi
Pj
Pg
r+ k
Pe
I
Pf PC
g
pd PO
pb bb
d
2
a
1
x w
z
Y
4 ee
202FO6046
1 o-45
7-SPOOL VAVLE (STANDARD + 1 SERVICE VALVE)
pk
PI Pi
Pj Pg
Pe
Ph
PC
Pf
Pa
pb d
CC
Pd b
ee
202FO6047
1 O-46
&SPOOL VAVLE (STANDARD + 2 SERVICE VALVE1
i--Y P
\
.cc
l-11 t dd
202FO6048
1 o-47
9-SPOOL VAVLE (STANDARD + 3 SERVICE VALVE)
Pg
Pr PO
PP
Pm
P
Pk
PI Pi
Pg
Pj+
Pe
ph
PC
Pf
Pa
Pd
Pb -cc
202FO6049
1 O-48
CROSS-SECTIONAL DRAWING
* The cross section is given only for the 6-spool valve (standard). The cross-sectional structure of the
service valves in the 7-spool, 8-spool,and 9-spool valves is the same as the structure for the bucket
valve, so refer to the bucket valve for details.
1 A-A
202FO6050
1 o-49
10
B-B
202FO6051
1 O-50
202FO6052
IO-51
1
D-D
202FO6053
1 O-52
E-E
F-F 8
16 G-G 13 i2
202FO6054
1. Cooler bypass valve SWING VALVE L.H. AND R.H. TRAVEL VALVES
2. LS bypass valve 5. Pressure compensation valve 9. Pressure compensation valve
3. Main relief valve (LEFT) (FORWARD)
4. Lift check valve 6. LS select valve 10. LS shuttle valve
7. Pressure compensation valve 11. Pressure compensation valve
(RIGHT) (REVERSE)
8. Spool 12. Suction valve
13. Spool
14. Suction valve
1 o-53
J-J
lj 12 ii ill
\
19 K-K
18
202FO6055
1 o-54
M-M
202FO6056
1 o-55
STRACTURE AND FUNCTION CONTROL VALVE
OUTLINE
There are the following four types of control Port PLS (to pump LS valve)
valve: batPort (from 2-stage relief solenoid valve)
PXI
6-spool valve (standard) Port Px2
(from LS bypass solenoid valve)
7-spool valve (standard + 1 service valve) dcdc:
Port Bp (from PPC shuttle valve)
S-spool valve (standard + 2 service valve) ee. Pressure sensor port
9-spool valve (standard + 3 service valve) (pressure sensor installed)
* Each service valve is a single add-on type, so ffl. Port PAI (from active mode solenoid valve)
it is possible to add or remove the extra ff2. Port PAZ (from active mode solenoid valve)
valves at any time. W. Port T (to tank)
Details of the external appearance of every type is Pa. Port PI (from swing LEFT PPC valve)
given here. Pb. Port P2 (from swing RIGHT PPC valve)
The cross section is given only for the 7-spool PC. Port P3
valve (standard + 1 service valve). (from L.H. travel FORWARD PPC valve)
Pd. Port P4
GENERAL LOCATIONS AND NAMES OF PORTS (from L.H. travel REVERSE PPC valve)
(common for each external view diagram) Pe. Port P5
1. 6-spool valve sub assembly (from R.H. travel FORWARD PPC valve)
2. Cover A (main relief valve, LS bypass valve) Pf. Port P6
3. Cover B (unload valve) (from R.H. travel REVERSE PPC valve)
4. No. 1 service valve pg. Port P7 (from boom RAISE PPC valve)
5. No. 2 service valve Ph. Port P8 (from boom LOWER PPC valve)
6. No. 3 service valve Pi. Port P9 (from arm OUT PPC valve)
Pj. Port PI0 (from arm IN PPC valve)
Port Pp (from main pump) Pk. Port PI1 (from bucket DUMP PPC valve)
:: Port Al (to swing motor MB) PI. Port P12 (from bucket CURL PPC valve)
Port Bl (to swing motor MA) Pm. Port P-l (from service 1 PPC valve)
dc: Port A2 (to L.H. travel motor A) Pn. Port P-2 (from service 1 PPC valve)
e. Port B2 (to L.H. travel motor B) PO. Port P-3 (from service 2 PPC valve)
f. Port A3 (to R.H. travel motor B) Pp. Port P-4 (from service 2 PPC valve)
9, Port B3 (to R.H. travel motor A) Pq. Port P-5 (from service 3 PPC valve)
h. Port A4 (to boom cylinder bottom) Pr. Port P-6 (from service 3 PPC valve)
i. Port B4 (to boom cylinder head)
Port A5 (to arm cylinder head)
;: Port B5 (to arm cylinder bottom)
I. Port A6 (to bucket cylinder head)
m. Port B6 (to bucket cylinder bottom)
n. Port A7 (to attachment I)
0. Port B7 (to attachment 1)
P. Port A8 (to attachment 2)
q. Port B8 (to attachment 2)
r. Port A9 (to attachment 3)
S. Port B9 (to attachment 3)
t. Port Tsw (to swing motor)
U. Port Tc (to oil cooler)
V. Port T (to tank)
W. Port AE2 (to travel junction valve)
X. Port BE2 (to travel junction valve)
Y. Port AE3 (to travel junction valve)
2. Port BE3 (to travel junction valve)
STRACTURE AND FUNCTION CONTROL VALVE
EXTERNAL VIEW
Dj Di
oh DO
of De
DC
Od
Da
aa dd t
SKP01184
1O-55-2
0
STRACTURE AND FUNCTION CONTROL VALVE
oj
DP
De
DC
Da
ob
bb
A
aa dd t
SKPOl 185
1o-55-3
0
STRACTURE AND FUNCTION CONTROL VALVE
.O\ &llhi- 0
A
om
.ok
oi
oh DO
oe
DC
od
oa
ob
-//_l-.l-+-TA ai
//I
dd i
L-D
bb
cc
SKPOI 186
1o-55-4
0
STRACTURE AND FUNCTION CONTROL VALVE
.DO
om
ok
oj oi
oh
00
oe
DC
ob oa
bb
l--e
L C aa dd t
ee
SKP01187
1o-55-5
Co
STRACTURE AND FUNCTION CONTROL VALVE
CROSS-SECTIONAL DRAWING
* The cross section shows a 7-spool valve (standard + 1 service valve).
The cross-sectional structure of the service valve for the 8-spool valve and 9-spool valve is the same
as the structure of the service valve for the 7-spool valve, so refer to the 7-spool valve.
A-A
SKPOll88
10-55-6
0
STRACTURE AND FUNCTION CONTROL VALVE
B-B SKP01189
1o-55-7
0
STRACTURE AND FUNCTION CONTROL VALVE
c-c SKP01190
1O-55-8
0
STRACTURE AND FUNCTION CONTROL VALVE
D-Q
SKPOlI91
1o-55-9
0
STRACTURE AND FUNCTION CONTROL VALVE
I 4
E-E
SKP01192
1O-55 10
0
STRACTURE AND FUNCTION CONTROL VALVE
I8 K-K
17 I6 SKP01193
10-55-11
0
STRACTURE AND FUNCTION CONTROL VALVE
SKPOI 194
SERVICE VALVE
1. Pressure compensation valve 7. LS bypass plug
2. LS shuttle valve 8. Unload valve
3. Pressure compensation valve
4. Safety-suction valve
5. Spool
6. Safety-suction valve
10-55-12
CD
SAFETY-SUCTION VALVE FOR SERVICE VALVE
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve
8. Sleeve
9. Adjustment screw
10. Locknut
202FO6057
SPECIFICATIONS
1 O-56
CLSS
1. OUTLINE
Features
CLSS stands for Closed center Load Sensing System, and has the following features.
I) Fine control not influenced by load
2) Control enabling digging even with fine control
3) Ease of compound operation ensured by flow divider function using area of opening of spool during
compound operations
4) Energy saving using variable pump control
Structure
l The CLSS consists of a variable displacement single piston pump, control valve, and actuators.
l The pump body consists of the main pump, TVC valve and LS valve.
I
I
I
I 0
I I
I
I l-l
I
I I
I I 0
I
L- --me
&
PP
I
I
Servo
piston
202~06058
1 o-57
STRUCTURE AND FUNCTION CLSS
2. BASIC PRINCIPLE
I
I
I
I
I
Min. Max. I
I I
I
Servo II
piston I
I
APLS ;; I
t- -I I
I
differential pressure
iIZ!!!!&e current
SBP00200
LS differential pressureAPLS
SAP00384
1 O-58
0
STRUCTURE AND FUNCTION CLSS
2) Pressure compensation
. A pressure compensation valve is installed to the outlet port side of the control valve to balance the
load.
When two actuators are operated together, this valve acts to make pressure difference AP between the
upstream (inlet port) and downstream (outlet port) of the spool of each valve the same regardless of
the size of the load (pressure).
In this way, the flow of oil from the pump is divided (compensated) in proportion to the area of open-
ing Sl and S2 of each valve.
Load
Load
jI AP
Pump
SBP00201
1o-59
0
STRUCTURE AND FUNCTION CLSS
BE3
PS
____x
PP
Liz- :
BE?
PI
c !_________
. . I_ -1 ~
t 4
____________------
- __I
_--_-_-_-_-_-_-_-)I+-_
___ _________________________________............ 7
j _q=---
1 iTs,
I
_____.________~__-_-.-._~ I
:Px2 202FO6062
1 O-60
0
STRACTURE AND FUNCTION CLSS
1. Unload valve
(LS pressure + 2.45 MPa
(25 kg/cm2))
2. Safety-suction valve
(service valve)
(24.5 MPa (250 kg/cm211
3. Pressure compensation valve
4. LS shuttle valve
P14 5. Safety-suction valve
(35.8 MPa (365 kg/cm2))
6. Safety-suction valve
(33.3 MPa (340 kg/cm?)
7. Suction valve
8. LS bypass valve
(7.84 MPa (80 kg/cm2),
Oil pleasure aenaor port
when pressure rises:
36.26 MPa (370 kg/cm211
9. Main relief valve
(normal: 31.85 MPa (325 kg/cm2),
when pressure rises:
34.79 MPa (355 kg/cm2))
10. Lift check valve
(cracking pressure:
0.2 MPa (2.0 kg/cm*))
11. Bypass check valve
12. LS select valve
I
ion valve
P4
PZ
P LSI
Px2-
PXl -
SKP01222
10-60-l
0
1) Unload valve
Function
1. When the control valve is at neutral, pump discharge amount Q discharged by the minimum swash
plate angle is released To the tank circuit.
When this happens, pump discharge pressure Pp is set at 2.45MPa (25 kg/cm*) by spring (3) inside the
valve. (LS pressure PLS: OMPa (0 kg/cm?)
PLS
PP
202FO6063
Operation
IO-61
2. During fine control of the control valve, when the demand flow for the actuator is within the amount
discharged by the minimum swash plate angle of the pump, pump discharge pressure Pp is set to LS
pressure PLS + 2.45MPa (25 kg/cm?.
When the differential pressure between pump discharge pressure Pp and LS pressure PLS reaches the
load of spring (3) (2.45MPa (25 kg/cm?), the unload valve opens, so LS differential pressure APLS be-
comes 2.45 MPa (25 kg/cm*).
PLS
PP
202FO6064
Operation
1 O-62
3. When the control valve is being operated and the demand flow for the actuator becomes greater than
the pump discharge from the minimum swash plate angle, the flow of the oil out to tank circuit T is cut
off, and all of pump discharge amount Q flows to the actuator circuit.
PLS
- q
PP
202FO6065
Operation
1 O-63
2) Introduction of LS pressure
Function
. LS pressure PLS is the actuator load pressure at the outlet port end of the control valve.
l Actually, it brings the upstream pressure of the pressure compensation valve (the downstream pres-
sure of the spool meter-in) inside spool (3) and sends it to LS shuttle valve (2).
When this happens, LS circuit PLS is interconnected with actuator circuit A through check valve (4), and
LS pressure PLS = actuator load pressure.
. In addition, intake hole a of spool (3) and hole c at the tip of LS shuttle valve (2) are designed as small
diameter holes to give them a throttling function.
202FO6066
Operation
l When spool (3) is operated, pump discharge 1. Pressure compensation valve
pressure Pp starts to flow to actuator circuit A. 2. LS shuttle valve
. First, this pump discharge pressure Pp passes 3. Spool
through intake hole a of spool (3) and goes to 4. Check valve
LS circuit PLS.
l When the pump discharge pressure Pp rises Pp: Pump circuit (pressure)
and actuator circuit pressure A also rises to A: Actuator circuit (pressure)
the necessary pressure, check valve (4) inside PLS: LS circuit (pressure)
spool (3) opens and the high pressure of LS
circuit PLS flows to actuator circuit A.
. In this way, LS pressure PLS becomes almost
the same pressure as actuator circuit pressure
A.
1 O-64
3) LS bypass plug
Outline
1. This releases the residual pressure of LS pressure PLS.
2. This makes the speed of the rise in pressure of LS pressure PLS more gentle.
In addition, with this discarded throttled flow, it creates a pressure loss in the throttled amount of the
spool or shuttle valve, and increases the stability by lowering the effective LS differential pressure.
202FO6067
Operation
l The pressurized oil for LS circuit PLS passes 1. LS bypass plug
from clearance filter a (formed by the clear-
ance between LS bypass plug (1) and the PLS: LS circuit (pressure)
valve body) through orifice b and flows to the T: Tank circuit (pressure)
tank circuit.
1 O-65
4) LS bypass valve
Function
l When the travel and another actuator are operated at the same time, the LS throttle amount that is
discarded is increased and the drop in the travel speed is kept small by relaxing the pressure compen-
sation precision in the travel circuit.
. During normal operations, the pilot pressure (2.94MPa (30 kg/cm*)) acts on pilot circuit Px2 from the LS
bypass solenoid valve, but when the travel + another actuator are operated at the same time, the pilot
pressure does not have any effect.
F20206001
Operation
Normal operation
. LS pressure PLS passes through clearance fil- 1. LS bypass valve
ter a and two-stage throttle b, and acts on pop- 2. Spring
pet (3). 3. Poppet
. Poppet (3) is being pushed to the right in the 4. Piston
direction of the arrow by the load of spring (2). 5. LS bypass solenoid valve
. In addition, during normal operation, the pres-
sure from the LS bypass solenoid valve acts PLS: LS pressure
on pilot circuit PXZ, and pushes piston (4) to Px2: LS bypass pilot pressure
the right in the direction of the arrow. T: Tank pressure
. In other words, poppet (3) is pushed to the
right in the direction of the arrow by the load
of spring (2) (which is set by piston (4)), so it
normally does not open, and LS circuit PLS
and tank circuit T are not interconnected.
1 O-66
202FO6069
1 O-67
5) Pressure compensation valve
Function
1. If the maximum load pressure is generated during individual operations or compound operations,
and the load pressure becomes higher than other actuators, this acts as a load check valve to prevent
the oil in the circuit from flowing back.
Operation
. If pump discharge pressure Pp and LS pres- 1. Pressure compensation valve
sure PLS become lower than actuator circuit 2. Spring
pressure A, shuttle valve (4) inside pressure 3. Piston
compensation valve (I) moves to the left in 4. Shuttle valve
the direction of the arrow, and connects actua- 5. Valve
tor circuit A and the spring chamber.
l When this happens, the movement of piston Pp: Pump circuit (pressure)
(3) becomes free, so piston (3) is pushed to the Ppn: Pump outlet port circuit (pressure)
right in the direction of the arrow by spring PLS: LS circuit (pressure)
(2). A: Actuator circuit (pressure)
l As a result, valve (5) is also pushed to the right T: Tank circuit (pressure)
in the direction of the arrow by piston (3),
closes pump outlet port circuit PpA, and pre-
vents the oil from flowing back from actuator
circuit A to pump outlet port circuit Ppn.
1 O-68
2. During compound operations, if the load pressure becomes lower than the other actuators, and the oil
flow tries to increase, compensation is received. In this case, the load pressure at the other actuator
end becomes higher and the oil flow tries to decrease.
202FO6071
Operation
. 1. Pressure compensation valve
During compound operations, if the load pres-
2. Spring
sure becomes higher at the other actuator
3. Piston
end, the oil flow in actuator circuit A tries to
increase. 4. Shuttle valve
. 5. Valve
In this case, LS pressure PLS at the other ac-
tuator end also becomes higher. LS pressure
Pp: Pump circit (pressure)
PLS then pushes shuttle valve (4) of pressure
PLS: Pump outlet port circuit (pressure)
compensation valve (1) to the right in the di-
PLs: LS circuit (pressure)
rection of the arrow, so the oil passes through
A: Actruator circuit (pressure)
passage inside piston (3) and flows into the
T: Tank circuit (pressure)
spring chamber.
l As a result, piston (3) and valve (5) are pushed
to the right in the direction of the arrow, the
outlet port end of pump circuit Pp is closed,
and outlet port pressure PLS (spool meter-in
downstream pressure) becomes the same as
the outlet port pressure of the other actuator.
l Pump discharge pressure Pp (spool meter-in
upstream pressure) is the same as between all
actuators, so pump discharge pressure Pp and
outlet port PPn become the same as all the
spools that are operated. Therefore, the flow
of oil from the pump is distributed in propor-
tion to the area of the opening of each spool.
1 O-69
STRUCTURE AND FUNCTION CLSS
6A) Shuttle valve inside pressure compensation valve (work equipment, swing valve)
Function
. When holding pressure A in the actuator circuit is higher than LS pressure PLS, holding pressure A is
taken from shuttle valve (4) to the spring chamber to prevent piston (3) and valve (5) from separating.
202FO6072
Time
202FO6073 202FO6074
1O-70
0
Pressure compensation valve without shuttle valve (travel valve)
l The travel circuit is different from the work equipment and swing circuit because no holding pressure
is generated in holding circuit A. This means that piston (3) is not pushed back to the left by holding
pressure A. Therefore, piston (3) and valve (4) always follow, and no shuttle valve is installed.
202FO6075
IO-71
STRACTURE AND FUNCTION CLSS
1. Valve Function
2. Spring . It is possible to adjust the division of the oil
3. Sleeve flow to the service valve when the service
4. Poppet valve (for attachment) is operated together
5. Spring with the main control valve (boom RAISE,
6. Screw etc.).
7. Locknut (Variable in proportion to surface area)
8. Plastic cap . The pump pressure leaving the service valve
spool acts on the left end of valve (I), and at
the same time passes through throttle a and
enters chamber g.
The maximum LS pressure passes through
throttle d and enters chamber e. At the same
time, the cylinder port pressure passes
through passage c and throttle f, and goes to
chamber h.
In addition, the force of spring (2) acts on
valve (I), and the force of spring (5) acts on
poppet (4). The force of spring (5) can be ad-
justed with screw (6).
10-71-l
0
STRACTURE AND FUNCTION CLSS
Operation
10-71-2
0
STRUCTURE AND FUNCTION CLSS
Function
. The pressure compensation valve determines the compensation characteristics by carrying out fine
adjustment of the area ratio (A2/Al) between area A2 of piston (3) and area Al of valve (4) to match
the characteristics of each actuator.
Al PPB
/w 202FO6076
lo-72
0
8) Boom regeneration circuit
Function
1. When the boom is being lowered, if bottom pressure A of cylinder (I) is higher than head pressure B,
and there is hydraulic drift, this sends the return oil flow at the bottom end to the head end to increase
the cylinder speed by that amount.
202~06077
Operation
l When there is hydraulic drift when lowering 1. Boom cylinder
the boom, pressure A at the bottom end of 2. Boom spool
boom cylinder (I) becomes higher than pres- 3. Check valve
sure Bat the head end.
l When this happens, part of the return oil at the Pp: Pump circuit (pressure)
bottom end passes through regeneration pas- A: Bottom circuit (pressure)
sage a of boom spool (I), pushes check valve B: Head circuit (pressure)
(3) open, and flows to the head end. T: Tank circuit (pressure)
l As a result, the boom lowering speed is in-
creased.
1o-73
2. When lowering the boom, if head pressure B of cylinder (1) is greater than bottom pressure A, and the
work equipment is in the digging process, check valve (3) closes and shuts off the circuit between the
head and bottom ends.
202FO6078
Operation
l When the boom is lowered, if the work equip- 1. Boom cylinder
ment is in the digging process, pressure B at 2. Boom spool
the head end of cylinder (1) becomes higher 3. Check valve
than pressure A at the bottom end.
l When this happens, check valve (3) is closed Pp: Pump circuit (pressure)
by the spring and pressure B at the head end, A: Bottom circuit (pressure)
so the circuit between the head circuit and B: Head circuit (pressure)
bottom circuit is shut off. T: Tank circuit (pressure)
1 o-74
STRUCTURE AND FUNCTION CLSS
Function
1. When the arm is being moved in, if head pressure A of cylinder (I) is higher than bottom pressure B,
and there is hydraulic drift, this sends the return oil flow at the head end to the bottom end to increase
the cylinder speed by that amount.
3. T. 4 5
202FO6079
Operation
. When there is hydraulic drift when moving the 1. Arm cylinder
arm in, pressure A at the head end of arm cyl- 2. Arm spool
inder (I) becomes higher than pressure B at 3. Counterbalance valve
the bottom end. 4. Check valve
. When this happens, part of the return oil at 5. Spool
the head end passes through regeneration
passage a of arm spool (2), pushes open check Pp: Pump circuit (pressure)
valve (3) of counterbalance valve, and flows to A: Head circuit (pressure)
the bottom end. B: Bottom circuit (pt%SSUrd
. As a result, the arm IN speed is increased. T: Tank circuit (pressure)
1o-75
0
2. When the arm is being moved in, if bottom pressure B of cylinder (1) is greater than head pressure A,
and the work equipment is in the digging process, check valve (4) closes and shuts off the circuit be-
tween the head and bottom ends.
If pressure B at the bottom end rises further and exceeds 17.64MPa (180 kg/cm? , spool (5) of counter-
balance valve (3) is actuated to maintain the area of the meter-out opening at the head end in order to
ensure the digging force.
202FO6080
Operation
l When the arm is being moved in, if the work 1. Arm cylinder
equipment is in the digging process, and pres- 2. Arm spool
sure B at the bottom end of cylinder (1) rises, 3. Counterbalance valve
check valve (4) closes and the circuit between 4. Check valve
the head circuit and bottom circuit is shut off. 5. Spool
. If pressure B at the bottom end rises further,
spool (5) of counterbalance valve (3) is pushed Pp: Pump circuit (pressure)
to the left in the direction of the arrow by pres- A: Head circuit (pressure)
sure B. The oil from the regeneration circuit is B: Bottom circuit (pressure)
connected to the tank circuit, and the area of T: Tank circuit (pressure)
the meter-out opening at the head end is
made larger to ensure the digging force.
1 O-76
STRACTURE AND FUNCTION CLSS
Function
1. When the arm is being moved in, if head pressure A of cylinder (I) is higher than bottom pressure B,
and there is hydraulic drift, this sends the return oil flow at the head end to the bottom end to in-
crease the cylinder speed by that amount.
SKP01196
Operation
When there is hydraulic drift when moving 1. Arm cylinder
the arm in, pressure A at the head end of arm 2. Arm spool
cylinder 11) becomes higher than pressure B 3. Check valve
at the bottom end.
When this happens, part of the return oil at Pp: Pump circuit (pressure)
the head end passes through regeneration A: l-lead circuit (PreSSUre)
passage a of arm spool (2), pushes open B: Bottom circuit (pressure)
check valve (31, and flows to the bottom end.
As result, the arm IN speed is increased.
10-76-l
0
STRACTURE AND FUNCTION CLSS
2. When the arm is being moved in, if bottom pressure B of cylinder (I) is greater than head pressure A,
and the work equipment is in the digging process, check valve (3) closes and shuts off the circuit be-
tween the head and bottom ends.
SKPOl197
Operation
When the arm is being moved in, if the work 1. Arm cylinder
equipment is in the digging. process, and 2. Arm spool
pressure B at the bottom end of cylinder (1) 3. Check valve
rises, check valve (3) closes and the circuit be-
tween the head circuit and bottom circuit is Pp: Pump circuit (pressure)
shut off. A: Head circuit (pressure)
B: Bottom circuit (pressure)
1O-76-2
0
101 LS select valve
Function
. When the swing + boom RAISE, or swing + travel are operated together, this valve prevents the high
pressure which is generated when driving the swing, and prevents swing LS pressure a from flowing
into LS circuit PLS.
202FO6081
IO-77
202FO6082
1 O-78
11) Cut-off function
Function
l This function uses the TVC valve, pump controller, and pump pressure sensor, and if pump discharge
pressure Pp exceeds the set pressure, it makes pump discharge amount Q the minimum.
u Control valve
IIMin. - Max.
202FO6083
Operation
. If the pump pressure sensor detects that the u
pump discharge pressure Pp has gone above 5
t I
the set pressure, it sends this information to E200
m
the pump controller.
%
l When the pump controller receives this signal, &
it increases the signal current to TVC valve (I),
and makes the pump discharge amount
(swash plate angle) Q the minimum.
9.8 (100) 19.8 (2001 29.4 (300) 34.3 1350)
2. Solenoid 202FO6084
1 o-79
STRACTURE AND FUNCTION CLSS
Boom LOWER
PPC Pressure
Arm IN
PPC PreSSUre
SKP01223
Operation
1. When active mode is OFF
Pilot pressure PA passes through port A and B
and acts on the right end face of piston (2), so
piston (2) is pushed fully to the left in the di-
rection of the arrow. When this happens, the
maximum stroke of spools (I) and (5) be-
comes StO.
10-79-l
0
STRACTURE AND FUNCTION CLSS
Arm IN drain
PPC OreSSUre -cuit
SKP01224
1O-79-2
0
4. OPERATION OF SYSTEM AS A WHOLE 1. Hydraulic tank
1) When all control valves are at neutral
Hydraulic pump
. Pump discharge amount 0 all flows from un-
2. Main pump
load valve (6) to tank (I).
3. TVC valve
. Non of the spools (7A to 12A) is being oper-
4. LS valve
ated, so the LS pressure PLS is not generated.
At the same time, the LS pressure PLS is con- Control valve
nected to the tank circuit by LS bypass plug 5. LS bypass valve
(5), so it is the tank pressure. 6. Unload valve
. In this condition, LS differential pressure APLS 7. Bucket valve
becomes the unload pressure - tank pres- 7A. Spool
sure, and becomes higher than the LS set 7B. Pressure compensation valve (DUMP)
pressure of LS valve (4), so main pump (2) is 7C. Pressure compensation valve (CURL)
set to the minimum swash plate angle. 7D. LS shuttle valve
8. Arm valve
8A. Spool
8B. Pressure compensation valve (OUT)
8C. Pressure compensation valve (IN)
8D. LS shuttle valve
9. Boom valve
9A. Spool
9B. Pressure compensation valve (RAISE)
9C. Pressure compensation valve (LOWER)
9D. LS shuttle valve
9E. Check valve
10. R.H. travel valve
IOA. Spool
IOB. Pressure compensation valve
(FORWARD)
IOC. Pressure compensation valve (REVERSE)
IOD. LS shuttle valve
11. L.H. travel valve
1 IA. Spool
11 B. Pressure compensation valve
(FORWARD)
I I C. Pressure compensation valve (REVERSE)
11 D. LS shuttle valve
12. Swing valve
12A. Spool
12B. Pressure compensation valve (LEFT)
l2C. Pressure compensation valve (RIGHT)
13. LS select valve
14. LS bypass valve
15. Main relief valve
16. Cooler bypass valve
17. Lift check valve
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. L.H. travel motor
22. R.H. travel motor
23. Swing motor
1 O-80
9B
202FO6085
IO-81
When boom RAISE is operated independently 1. Hydraulic tank
When boom spool (9A) is operated to the
Hydraulic pump
RAISE position, pump discharge amount 0
2. Main pump
flows to the bottom end of boom cylinder (20),
3. TVC valve
and at the same time, LS pressure PLS is gen-
4. LS valve
erated and unload valve (6) closes.
LS pressure PLS becomes.the boom holding Control valve
pressure, and the area of the opening of boom 5. LS bypass valve
spool (9A) is larger than the other spools 6. Unload valve
(oversize opening), so the difference between 7. Bucket valve
pump discharge pressure Pp and LS pressure 7A. Spool
PLS (LS differential pressure APLS) becomes 7B. Pressure compensation valve (DUMP)
smaller. 7C. Pressure compensation valve (CURL)
This LS differential pressure APLS is lower 7D. LS shuttle valve
than the LS set pressure of LS valve (4), so 8. Arm valve
main pump (2) is held at the maximum swash 8A. Spool
plate angle. 8B. Pressure compensation valve (OUT)
8C. Pressure compensation valve (IN)
8D. LS shuttle valve
9. Boom valve
9A. Spool
9B. Pressure compensation valve (RAISE)
9C. Pressure compensation valve (LOWER)
9D. LS shuttle valve
9E. Check valve
10. R.H. travel valve
IOA. Spool
IOB. Pressure compensation valve
(FORWARD)
IOC. Pressure compensation valve (REVERSE)
IOD. LS shuttle valve
11. L.H. travel valve
IIA. Spool
11 B. Pressure compensation valve
(FORWARD)
11 C. Pressure compensation valve (REVERSE)
11 D. LS shuttle valve
12. Swing valve
12A. Spool
12B. Pressure compensation valve (LEFT)
12C. Pressure compensation valve (RIGHT)
13. LS select valve
14. LS bypass valve
15. Main relief valve
16. Cooler bypass valve
17. Lift check valve
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. L.H. travel motor
22. R.H. travel motor
23. Swing motor
1 O-82
PLS
II I I 8881
I I 118fl
202FO6086
1 O-83
When swing is operated independently 1. Hydraulic tank
When swing spool (12A) is operated, pump
Hydraulic pump
discharge amount 0 flows to swing motor (23)
2. Main pump
and, at the same time, LS pressure PLS is gen-
3. TVC valve
erated and unload valve (4) closes.
4.4LS valve
LS pressure PLS becomes the load pressure of
swing motor (23). Control valve
In the swing circuit, the bifference between 5. LS bypass valve
pump discharge pressure Pp and LS pres- 6. Unload valve
sure PLS (LS differential pressure APLs) be- 7. Bucket valve
comes the same pressure as the LS set pres- 7A. Spool
sure of LS valve (4). 7B. Pressure compensation valve (DUMP)
As a result, the swash plate of main pump (2) 7C. Pressure compensation valve (CURL)
is kept at a position midway between the mini- 7D. LS shuttle valve
mum and maximum swash plate angle, and 8. Arm valve
the main pump discharges the demand flow 8A. Spool
(approx. 50%) for the swing circuit. 8B. Pressure compensation valve (OUT)
When the swing is operated independently, 8C. Pressure compensation valve (IN)
pump discharge amount 0 does not become 8D. LS shuttle valve
100%. 9. Boom valve
9A. Spool
9B. Pressure compensation valve (RAISE)
9C. Pressure compensation valve (LOWER)
9D. LS shuttle valve
9E. Check valve
10. R.H. travel valve
IOA. Spool 8
IOB. Pressure compensation valve g
(FORWARD) :
IOC. Pressure compensation valve (REVERSE)
IOD. LS shuttle valve
11. L.H. travel valve
IIA. Spool
11 B. Pressure compensation valve
(FORWARD)
1 IC. Pressure compensation valve (REVERSE)
11 D. LS shuttle valve
12. Swing valve
12A. Spool
12B. Pressure compensation valve (LEFT)
12C. Pressure compensation valve (RIGHT)
13. LS select valve
14. LS bypass valve
15. Main relief valve
16. Cooler bypass valve
17. Lift check valve
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. L.H. travel motor
22. R.H. travel motor
23. Swing motor
1 O-84
PLS
II&
1 I
16 17
202FO6087
1 O-85
When boom and arm are operated simulta- 1. Hydraulic tank
neously
Hydraulic pump
If boom spool (9A) is operated to the RAISE
2. Main pump
position and arm spool (8A) is operated to the
3. TVC valve
OUT position, pump discharge amount Q
4. LS valve
flows to cylinders (20) and (19).
When this happens, the load pressure of Control valve
boom cylinder (20) is greater than the load 5 LS bypass valve
pressure of arm cylinder (19), so the oil tries to 6 Unload valve
flow to arm cylinder (19), where the load pres- 7 Bucket valve
sure is lower. However, the pressure at the 7A. Spool
downstream side of arm spool (8A) is com- 7B. Pressure compensation valve (DUMP)
pensated by pressure compensation valve 7C. Pressure compensation valve (CURL)
(7B), which receives the load pressure (= max. 7D. LS shuttle valve
LS pressure PLS) of the boom. 8. Arm valve
As a result, the upstream pressure and down- 8A. Spool
stream pressure of boom spool (9A) and arm 8B. Pressure compensation valve (OUT)
spool (8A) become equal, so the oil flow from 8C. Pressure compensation valve (IN)
main pump (2) is divided in proportion to the 8D. LS shuttle valve
area of opening of each spool. 9. Boom valve
In the same way as when the boom is oper- 9A. Spool
ated independently, the area of the opening of 9B. Pressure compensation valve (RAISE)
boom spool (9A) is a large oversize opening, 9C. Pressure compensation valve (LOWER)
so the difference between pump discharge 9D. LS shuttle valve
pressure Pp and LS pressure PLS (LS differen- 9E. Check valve
tial pressure APLs)becomes smaller. 10. R.H. travel valve
This LS differential pressure APLS is lower IOA. Spool
than the LS set pressure of LS valve (4), so IOB. Pressure compensation valve
main pump (2) is held at the maximum swash (FORWARD)
plate angle. IOC. Pressure compensation valve (REVERSE)
IOD. LS shuttle valve
11. L.H. travel valve
IIA. Spool
11 B. Pressure compensation valve
(FORWARD)
11 C. Pressure compensation valve (REVERSE)
11 D. LS shuttle valve
12. Swing valve
12A. Spool
12B. Pressure compensation valve (LEFT)
12C. Pressure compensation valve (RIGHT)
13. LS select valve
14. LS bypass valve
15. Main relief valve
16. Cooler bypass valve
17. Lift check valve
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. L.H. travel motor
22. R.H. travel motor
23. Swing motor
1 O-86
-
-
PLS
, tr
15
16 17
202FO6088
IO-87
When circuit is relieved at end on boom 1. Hydraulic tank
stroke
Hydraulic pump
When boom cylinder (20) reaches the end of
2. Main pump
its stroke, main relief valve (15) opens and
3. TVC valve
pump discharge amount Q is relieved to tank
4. LS valve
(I).
When pump discharge pressure Pp comes Control valve
close to the relief pressure, the pump control- 5. LS bypass valve
ler sends a signal to the solenoid of TVC valve 6. Unload valve
(3) to carry out the cut-off function to make 7. Bucket valve
pump discharge amount 0 the minimum. 7A. Spool
The cylinder is at the end of its stroke, so no 7B. Pressure compensation valve (DUMP)
oil flows to the upstream or downstream side 7C. Pressure compensation valve (CURL)
of boom spool (9A). Pump discharge pressure 7D. LS shuttle valve
Pp and LS pressure PLS are the same pres- 8. Arm valve
sure, and LS differential pressure APLS be- 8A. Spool
comes 0. 8B. Pressure compensation valve (OUT)
LS differential pressure APLS is lower than the 8C. Pressure compensation valve (IN)
LS set pressure of LS valve (4), so LS valve (4) 8D. LS shuttle valve
acts to make the pump swash plate angle the 9. Boom valve
maximum. However, because of the mecha- 9A. Spool
nism, the operation of TVC valve (3) is given 9B. Pressure compensation valve (RAISE)
priority over the operation of LS valve (4), so 9C. Pressure compensation valve (LOWER)
the pump is kept at the minimum swash plate 9D. LS shuttle valve
angle by the cut-off function of TVC valve (3). 9E. Check valve
10. R.H. travel valve
IOA. Spool
IOB. Pressure compensation valve
(FORWARD)
IOC. Pressure compensation valve (REVERSE)
IOD. LS shuttle valve
11. L.H. travel valve
IIA. Spool
11 B. Pressure compensation valve
(FORWARD)
11 C. Pressure compensation valve (REVERSE)
11 D. LS shuttle valve
12. Swing valve
12A. Spool
12B. Pressure compensation valve (LEFT)
12C. Pressure compensation valve (RIGHT)
13. LS select valve
14. LS bypass valve
15. Main relief valve
16. Cooler bypass valve
17. Lift check valve
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. L.H. travel motor
22. R.H. travel motor
23. Swing motor
I O-88
PLS
I
16 17
202FO6089
I I
1 O-89
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
KMF40AB-2
d c
202FO6090
SPECIFICATIONS
a. Port T (to tank)
b. Port S (from control valve) Type : KMF40AB-2
c. Port MA (from control valve) Theoretical delivery : 40.2 cc/rev
d. Port MB (from control valve) Safety valve set pressure : 26.97MPa (275 kg/cm21
e. Port B (from swing brake solenoid valve) Rated speed : 2,413 rpm
Brake releasing pressure : 1.37MPa 114 kg/cm*}
1O-90
0
202FO6091
IO-91
SWING HOLDING BRAKE
OPERATION
I) When swing brake solenoid valve is deacti-
vated
When the swing brake solenoid valve is deac-
tivated, the pressurized oil from the control
pump is shut off and port B is connected to
the tank circuit.
Because of this, brake piston (6) is pushed
down in the direction of the arrow by brake
spring (71, so disc (4) and plate (5) are pushed
together and the brake is applied.
202FO50498.1
:
2
g
202F05050EL1
1 o-92
.
STRACTURE AND FUNCTION SWING MOTOR
KMF40AB-3
kl I
e
d C
SAD01385
1 O-92-2
@
SWING MOTOR
STRACTURE AND FUNCTION
A-A
SAD01366
1 O-92-3
@
STRACTURE AND FUNCTION SWING MOTOR
OPERATION
1) When swing brake solenoid valve is DEACTI-
VATED
When the swing brake solenoid valve is DE-
ACTIVATED the pressurized oil from the con-
trol pump is shut off and port B is connected
to the tank circuit.
Because of this, brake piston (7) is pushed
down in the direction of the arrow by brake
spring (8), so disc (4) and plate (5) are pushed
together and the brake is applied.
SAP01470
SAP01471
1 O-92-4
0
CENTER SWIVEL JOINT
Bl
El
T2
Tl
A2
202FO6094
IO-93
PCIOO-6 Serial No : 40001 - 40623
PC120-6 Serial No : 45001 - 47570
SPECIFICATIONS
1o-94
0
i : / I: ; I I \ I \ \
6 5 4 3 30 29 20 27 26 25 24 23 22
202FO6096
IO-95
PCIOO-6 Serial No : 40624 and up
PC120-6 Serial No : 47571 and up
SDP00018
8
10-95-l
0
1 2 3 8 9 10 11 12 13 14 15 16 17 18 19
SEP00019
1 O-95-2
0
OPERATION OF MOTOR
1) Motor swash plate angle (capacity) at maximum
8
2
c-4
0
202FO6098
. The solenoid valve is deactivated, so the pilot l The pressurized oil in chamber a of regulator
pressure oil from the control pump does not piston (23) passes through passage b in regu-
flow to port D. lator valve (8) and is drained to the motor
For this reason, regulator valve (8) is pushed case.
to the left in the direction of the arrow by . As a result, swash plate (14) is pushed in the
spring (9). maximum swash plate angle direction by the
Because of this, it pushes check valve (31), and main pressure oil inside cylinder chamber P,
the main pressure oil from the control valve to the motor capacity becomes maximum.
end cover (7) is closed by regulator valve (8).
1 O-96
2) Motor swash plate angle (capacity) at minimum
solenoid valve
202FO6097
l The solenoid valve is excited, so the pilot pres- l As a result swash plate (14) moves in the mini-
sure oil from the control pump flows to port D, mum swash plate angle direction, the motor
and pushes regulator valve (8) is pushed to capacity becomes minimum.
the right in the direction of the arrow.
. Because of this, the main pressure oil from the
control valve passes through passage c in
regulator valve (8) enters regulator piston (23)
at the bottom, and pushes regulator piston
(23) to the left in the direction of the arrow.
1 o-97
OPERATION 10 11 26 27
1) When starting to travel
When the travel lever is operated, the pressur-
ized oil from the pump actuates counterbal-
ance valve spool (5), the circuit to the parking
brake is opened, and opened check valve (30)
and the oil flows into chamber a of brake pis-
ton (II), overcomes the force of spring (IO),
and pushes piston (11) to the left in the direc-
tion of the arrow. When this happens, the
force pushing plate (26) and disc (27) together
is lost, so plate (26) and disc (27) separate and
the brake is released.
$
202FO6099
s
202F06100
1 O-98
BRAKE VALVE
J
valve
(Fig. I)
202FO5058
(Fig. 3) 202FO5060
1o-99
a
Operation of brake when traveling downhill
. If the machine tries to run away when
traveling downhill, the motor will turn un- Control valve
der no load, so the pressure at the motor
inlet port will drop, and the pressure in
chamber Sl through orifice El will also
drop.
When the pressure in chamber Sl drops
below the spool switching pressure, spool
(5) is returned to the left in the direction of
the arrow by spring (61, and outlet port
MB is throttled. As a result, the pressure
at the outlet port side rises, resistance is
generated to the rotation of the motor,
and this prevents running away.
In other words, the spool is moved to a
position where the pressure at outlet port
MB balances the pressure at the inlet port
and the force generated by the weight of
the machine. It throttles the outlet port cir- (Fig. 4) 202FO5061
cuit and controls the speed according to
the discharge volume of the pump (Fig. 4)
2) Safety valve
Function
l When travel is stopped (or when traveling
downhill), the circuit at the inlet and outlet
ports of the motor are closed by the coun-
terbalance valve, but the motor is rotated
by inertia, so the pressure at the outlet
port of the motor will become abnormally
high and damage the motor or piping. The 202FO5062
Operation
. When stopping travel (or when traveling
downhill), chamber a (or chamber b) in
the outlet port circuit is closed by the
check valve of the counterbalance valve,
but the pressure at the outlet port rises be- 4 3
cause of inertia. (Fig. 5)
. When the pressure goes above the set (Fig. 6) 202F05063
pressure, the pressurized oil in chamber a
overcomes the force of spring (3), pushes
spool (4) to the right in the direction of the
arrow, so the pressurized oil flows to
chamber b on the opposite side.
(When the pressure in chamber a is high.)
(Fig. 6)
l When the pressure goes above the set
pressure, the pressurized oil flows into
chamber d through orifice c in spool (4). It
overcomes the force of spring (3), pushes
spool (4) to the right in the direction of the
arrow, so the pressurized oil flows to
chamber a on the opposite side.
(When the pressure in chamber b is high.1
(Fig. 7) (Fig. 7) 202FO5064
10-100
Control valve
BRAKE VALVE
1Safetyvaive(j s!ooo22
*
SEP00024
10-100-1
0
ACTUATION OF BRAKES ON DOWNHILL SLOPE
2) SAFETY VALVE
Function
l When the machine is stopped (or when it
is traveling downhill), the circuits at the
inlet and outlet ports of the motor are
closed by the counterbalance valve. How-
ever, the motor is rotated by the inertia,
so the pressure at the outlet port of the
motor becomes abnormally high, and the
motor or piping will be damaged.
To prevent this, the abnormally high pres-
sure is released to the inlet port side of
the motor to protect the equipment from
damage.
Operation
l When the machine is stopped, the supply
of pressure oil from port PA also stops.
When this happens, counterbalance valve
(I), which was moved to the right, is re-
turned to the left (neutral position) by the
force of spring (2).
l Chamber A in the circuit on the outlet port
side is closed by counterbalance valve (I 1,
but the motor is rotated by the inertia, so
the pressure in chamber A rises.
SEP00072
1O-l 00-2
0
l When the pressure in chamber A rises, the
pressure oil in chamber A passes through
throttle b of valve (3) and flows from
chamber c into chamber d. The pressure
oil entering chamber d moves piston (4) to
the left. While this is happening, valve (3)
is pushed open by the pressure oil in
chamber A, so the pressure oil in chamber
A flows from port e to chamber F. There-
fore, the pressure oil in chamber A flows
at a lower pressure than the oil in cham-
ber F. In this way the pressure in chamber
A is controlled and cavitation in chamber
F is prevented.
1o- 100-3
0
VALVE CONTROL
202FO6110
10-101
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
Rl
SYD00313
a. Port P (from control pump) d. Port P4 (L.H.: Swing LEFT/ R.H.: Bucket DUMP)
b. Port T (to tank) e. Port PI (L.H.: Arm OUT/ R.H.: Boom LOWER)
c. Port PZ (L.H.: Arm IN / R.H.: Boom RAISE) f. Port P3 (L.H.: Swing RIGHT/ R.H.: Bucket CURL)
10-102
0
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
7
5
4
8
III
A-A B-B
D-D
E-E
1. Spool
2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Piston 9. Retainer
5. Disc 10. Body
6. Nut (for connecting lever) 11. Filter
10-103
0
STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
OPERATION
1) At neutral
Ports A and B of the control valve and ports PI
and P2 of the PPC valve are connected to drain
chamber D through fine controle hole f in
spool (I). (Fig. I)
(Fig. 1) SBPO1472
10-104
@
STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
4) At full stroke
When disc (5) pushes down piston (41, and re-
tainer (9) pushes down spool (I), fine control
hole f is shut off from drain chamber D, and
is connected with pump pressure chamber Pp.
Therefore, the pilot pressure from the control
pump passes through fine control hole f and
flows to chamber A from port PI, and pushes
the control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f and flows
to drain chamber D. (Fig. 4)
(F i g. 4) SBPO1475
10-105 .
@
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
Z
/
a
/
b
SBPOO279
10-106
@
TRAVEL PPC VALVE
STRUCTURE AND FUNCTION
A-A B-B
D-D
SEPOO280
5. Valve
1. Piston
6. Metering spring
2. Plate
7. Centering spring
3. Collar
8. Bolt
4. Body
10-107
@
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
OPERATION
1. At neutral
Ports A and B of the control valve and ports PI
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
(Fig. 2)
SBPO1477
lo-108
@
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
SBPOl478
$
8
8
4) At full stroke
Disc (5) pushes down piston (4), and retainer
(9) pushes down spool (1). Fine control hole f
is shut off from drain chamber D, and is con-
nected to pump pressure chamber Pp.
Therefore, the pilot pressure oil from the con-
trol pump passes through fine control hole f
and flows to chamber A from port PI to push
the control valve spool.
The return oil from chamber B passes from
port P2 through fine control hole f and flows
to drain chamber D. (Fig. 4)
(F i g. 4)
SBP01479
10-109
@
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
f
A
C-4
C d
f e
SAP01249
10-109-l
@
STRUCTURE AND FUNCTION TRAVEL PPC VALVE
B-0 A-A
D-D
SAP01250
5. Metering spring
1. Plate
6. Centering spring
2. Body
7. Valve
3. Piston
8. Bolt
4. Collar
lo- 109-2
@
STRUCTURE AND FUNCTION SERVICE PPC VALVE
P
c. Port A
d. PortB
____ Pin
1.
2. Cam
3. Ball
4. Piston
5. Cover
6. Sleeve
7. Centering spring
8. Metering spring
9. Spool
10. Body
8
8
8
10-110
aI
STRUCTURE AND FUNCTION SERVICE PPC VALVE
OPERATION
At neutral
. The pressurized oil from the control pump en-
ters from port P and is blocked by spool (9).
. Port A and B of the control valve and port a
and b of the PPC valve are connected to drain
port T through fine control hole X of spool (9).
Y
SBPO1480
When operated
. When cam (2) is moved, metering spring (8) is
pushed by ball (3), piston (4), and sleeve (6),
and spool (9) is also pushed down by this.
. As a result, fine control hole X is shut off from
the drain circuit. At almost the same time,
fine control portion Y is connected with port a,
and the pressurized oil from port P flows from
port a to port A of the control valve.
SElPOl481
10-111
@I
STRUCTURE AND FUNCTION SERVICE PPC VALVE
10-112
@I
STRUCTURE AND FUNCTION SERVICE PPC VALVE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
I I
6. Plate
7. Retainer
8. Body
A-A
SAP01389
10-112-l
@
STRUCTURE AND FUNCTION SAFETY LOCK VALVE. PPC ACCUMULATOR
1. Lever
2. Body
3. Seat
4. Ball
5. End cap
2
I\\\ 3 4 5
SBPOO289
$
:
0
PPC ACCUMULATOR
* FOR MACHINE EQUIPPED WITH PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATIONS
Gas capacity: 300 CC
SBP00290
10-l 13
0
PPC SHUTTLE . TRAVEL JUNCTION VALVE
P12
P22
P32 P42
P62
P52
P02 P72
PB2 PA2
P92
PC2
202FO6119
IO-114
b-AA
AA
F-F A-A
G-G
N-N
9
BB-BE
J-J
(2PLACES)
8
x
K-K
D-D
(2PLACES)
AA-AA
202FO6120
IO-115
STRAIGHT-TRAVEL SYSTEM
FUNCTION OPERATION
Travel junction valves are installed between During straight travel
the travel valve and travel motor to compen- When the L.H. and R.H. travel levers are oper-
sate for the error in the oil flow in the left and ated to travel forward, the pilot pressure from
right travel circuits when the machine is trav- the PPC valve flows to the L.H. and R.H. travel
eling in a straight line. valves. The flow of oil from the main pump
As a result, when the machine is traveling in a flows to the L.H. and R.H. travel motors.
straight line, the flow of oil to the left and At the same time, the pilot pressure passing
right travel motors is almost the same, so through the PPC shuttle valve goes to the pilot
there is no travel deviation. chamber at both ends of the travel junction
The travel junction valve connects the travel valve, and keeps the travel junction valve at
circuits when the straight travel is operated in- the neutral position.
dependently, or when the straight travel is op- In this way, the L.H. travel FORWARD circuit
erated together with another actuator. and R.H. travel FORWARD circuit, and the L.H.
When steering, if the difference in the amount travel REVERSE circuit and R.H. travel RE-
the left and right travel levers are operated ex- VERSE circuit are interconnected inside the
ceeds more than approx. IO mm, the travel travel junction valve.
junction valve is switched and the left and
right travel circuits are shut off.
-BucketCURL
-Bucket DUMP
.H. PPC valve! ! ~j 1 -.
H. travel
L--- ---~----+~$--BcJNIJRAISE
3vel PPC valve t I
L.H. travel
R.H. travel r-i=
REVERSE
L.H. travel
FORWARD
R.H. travel
FORWARD
L.H. travel
REVERSE
T3 1 I
Tl
202F06i 21
IO-116
When operating travel on one side or when
operating travel steering
l When operating the travel on one side or
when operating the travel steering, if the dif-
ference between the amount that the L.H. and
R.H. travel levers are operated is more than
approx. 10 mm, a difference in pressure is
generated in the L.H. and R.H. travel PPC pres-
sure.
l The PPC pressure becomes larger on the side
where the lever is operated further, so the
travel junction valve cannot keep the neutral
position and switches to one side because of
this difference in pressure.
l As a result, the L.H. and R.H travel circuits are
shut off, and steering can be carried out.
- Bucket CURL
r,
-6ucketDUMP
L.H. PPC valve //
-Boom LOWER
OUT
---Boom RAISE
ravel PPC valve I L.H. travel
REVERSE
-_ .-
202FO6122
IO-I 17
EPC . SOLENOID VALVE
202FO6123
IO-118
LS CONTROL EPC VALVE
1 a 2 3 4 5 6
A-A
202FO6124
10-I 19
FUNCTION
l The EPC valve consists of the proportional so-
lenoid portion and the hydraulic valve portion.
l When it receives signal current i from the 2.94_
(30)
pump controller, it generates EPC output pres-
sure P in proportion to the size of the signal,
2 2.45_
and outputs it to the control valve. E (25)
Y
0,
Y
m 1.96
2 (20)-
a
p 1.47_
; (15)
2
a
2 0.98
,a (IO)
s
0.49_
(5)
Current i (mA)
202FO6113
OPERATION
1. When signal current is 0 (coil deactivated)
l There is no signal current flowing from the
controller to coil (5), coil (5) is deactivated.
. For this reason, spool (2) is pushed to the
right in the direction of the arrow by spring
(3).
l As a result, port P closes and the pressurized
oil from the control pump does not flow to the
LS valve.
At the same time, the pressurized oil from the
LS valve passes from port C through port T
and is drained to the tank.
202FO6125
IO-120
When signal current is very small (coil ex-
cited)
When a very small signal current flows to coil
(51, coil (5) is excited, and a propulsion force is
generated, which pushes plunger (6) to the
left in the direction of the arrow.
Push pin (4) pushes spool (2) to the left in the
direction of the arrow, and pressurized oil
flows from port P to port C.
When the pressure at port C rises and the load
of spring (3) + the force acting on surface a of
spool (2) becomes greater than the proportion
force of plunger (61, spool (2) is pushed to the
right in the direction of the arrow. The circuit
between port P and port C is shut off, and at
the same time, port C and port T are con-
nected.
As a result, spool (2) is moved to the left or
right until the propulsion force of plunger (6)
is balanced with the load of spring (3) + pres-
sure of port C.
Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in
proportion to the size of the signal current.
202FO6126
8
z
s1 3. When signal current is maximum (coil ex-
cited)
l When the signal current flows to coil (5), coil
(5) is excited.
l When this happens, the signal current is at its
maximum, so the propulsion force of plunger
(6) is also at its maximum.
. For this reason, spool (I) is pushed to the left
in the direction of the arrow by push pin (4).
l As a result, the maximum flow of pressurized
oil from port P flows at its maximum to port
C, and the circuit pressure between the EPC
valve and LS valve becomes the maximum.
At the same time, port T closes and stops the
oil from flowing to the tank.
202FO6127
IO-121
LS BYPASS SOLENOID VALVE
L.Pl 1. Nut
2. Plunger
3. Coil
4. Connector
5. Push pin
6. Spring
7. Spool
8. Block
202FO6126
OPERATION
When solenoid is deactivated
l The signal current does not flow from the con-
troller, so coil (3) is deactivated.
l For this reason, spool (7) is pushed to the left
in the direction of the arrow by spring (6).
l As a result, the pressurized oil from the con-
trol pump flows from port A to port B, and
then flows to the actuator.
At the same time, port C is closed, and this
stops the oil from flowing to the tank.
202FO6129
202FO6130
IO-122
TRAVEL SPEED, SWING BRAKE, 2-STAGE RELIEF SOLENOID VALVE
4-----E 1.
2.
Nut
Plunger
3. Coil
4. Connector
5. Push pin
6. Spring
7. Spool
8. Block
202FO6131
OPERATION
When solenoid is deactivated
l The signal current does not flow from the con-
troller, so coil (3) is deactivated.
. For this reason, spool (7) is pushed to the left
in the direction of the arrow by spring (6).
l As a result, port A closes and the pressurized
oil from the control pump does not flow to the
actuator.
At the same time, the pressurized oil from the
actuator flows from port B to port C, and is
then drained to the tank.
202FO6132
When solenoid is excited
l When the signal current flows from the con-
troller to coil (3), coil (3) is excited, and a pro-
pulsion force is generated in plunger (2) to the
right in the direction of the arrow.
l For this reason, spool (7) is pushed to the
right in the direction of the arrow by push pin
(5).
l As a result, the pressurized oil from the con-
trol pump flows from port A to port B, and
then flows to the actuator.
At the same time, port C is closed, and this
stops the oil from flowing to the tank.
202FO6133
IO-123
BOOM HOLDING VALVE
* For machine equipped with arm holding valve, the structure and function of arm holding valve is the
same as this valve.
2 3
i
B-B
A-A
202FO5925
IO-124
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
OPERATION
1) At boom RAISE
When the boom is RAISED, the main pressure
from the control valve pushes poppet (5) up in
the direction of the arrow.
Because of this, the main pressure from the
control valve passes through the valve and
flows to the bottom end of the boom cylinder.
SEP01484
SEPOl485
10425
0
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
3) At boom LOWER
When the boom is LOWERED, the pilot pres-
sure from the PPC valve pushes pilot spool (3)
and the pressurized oil in chamber b inside
the poppet is drained.
When the pressure at port B rises because of
the pressurized oil from the bottom end of the
boom cylinder, the pressure of the pressurized
oil in chamber b is lowered by orifice a.
If the pressure in chamber b drops below the
pressure at port A, poppet (5) opens, the pres- Control lever
surized oil flows from port B to port A, and
then flows to the control valve.
If any abnormal pressure is generated in the
circuit at the bottom end of the boom cylinder,
safety valve (I) is actuated.
SEP01486
8
8
8
lo-126
0
HYDRAULIC CYLINDER
BOOM CYLINDER
202FO6104
ARM CYLINDER
li 17 i6
202FO6105
BUCKET CYLINDER
202FO6106
IO-127
1. Rod bushing 8. Head tube 15. Bottom bushing
2. Piston rod 9. Cast iron ring 16. Bottom cushion plunger
3. Cylinder head 10. Piston ring 17. Ball
4. Rod packing 11. Wear ring 18. Collar
5. Buffer ring 12. Piston 19. Head cushion plunger
6. Wear ring 13. Piston nut
7. Cylinder 14. Bottom tube
Specifications
Unit: mm
Cylinder I Boom I Arm I Bucket
Item PC100 PC120 PC100 PC120 PC100 PC120
Inside diameter of cylinder 95 105 115 115 90 95
Outside diameter of piston rod 65 70 75 75 60 65
Stroke 980 990 1,005 1,175 885 885
Max. stroke 2,470 2,490 2,877 2,877 2,263 2,263
Min. stroke 1,490 1,500 1,702 1,702 1,378 1,378
Width across flats of piston nut 70 80 85 85 65 70
IO-128
ACCUMULATOR FOR BREAKER
1. Cap
2. Core
3. Guard rubber
4. Lid
5. Bladder
6. Shell
SPECIFICATION
Gas capacity: 480 cc
202FO6108
IO-129
ADDITIONAL FILTER FOR BREAKER
202FO6109
SPECIFICATIONS
1. Head cover
Rated pressure : 6.86MPa (70 kg/cm*)
2. Element
Flow : 107 Q/min.
3. Case
4. Drain plug
Safety valve set pressure : 3.43kO.49 MPa
5. Safety valve
(3.5-tO.5 kg/cm?
6. Spring
Filter mesh size :6pm
7. Plug
Filtration area : 3160 cm*
IO-130
WORK EQUIPMENT
.
202FO6134
1. Bucket
2. Link
3. Bucket cylinder
4. Arm
5. Arm cylinder
6. Boom
7. Boom cylinder
IO-131
ELECTRICAL WIRING DIAGRAM
1. Fuse box 12
2. Light relay
3. Additional light relay
4. Caution buzzer
5. Starting switch
6. Fuel control dial
7. Radio
8. Cigarette lighter
9. Swing lock switch
10. Wiper switch
11. Light switch
12. Buzzer cancel switch
13. Air conditioner control panel
14. Service meter
15. Speaker
16. Engine throttle controller
17. L.H. knob switch
18. Pump controller
19. TVC prolix resistor
20. Wiper motor controller
21. Horn switch
22. Monitor panel
23. Swing lock prolix switch
24. TVC prolix switch
25. Working light
26 Fuel level sensor
27 Additional head light
28 Room lamp
29 Travel speed solenoid valve
30 Swing brake solenoid valve
31 2-stage relief solenoid valve
32. LS bypass solenoid valve
33 LS control EPC valve
34 Antenna
35 Engine speed sensor
36 Engine oil pressure sensor (Hi)
37 Engine oil pressure sensor (Lo)
38 Alternaotor
39. Pump pressure sensor
40. Coolant level sensor
41. Fusible link (x 3)
42. Battery relay
43. Air cleaner clogging sensor
44. Battery
45. PPC oil pressure switch (x 8)
46. Horn
47. Wiper motor
48. Window washer
49. Head light
50. Heater relay
51. Governor motor
52. Starting motor
53. Coolant temperature sensor
54. Engine oil level sensor \
2i l8 17
202F06135A
IO-132
39
/40
51
/
A5*
202F06136A
IO-133
ELECTRICAL CIRCUIT DIAGRAM PCIOO-6 Serial No : 40001 - 41229 (l/2) PC120-6 Serial No : 45001 - 49820 (l/2)
i
PCIOO-6 Serial No : 40001 - 41229 (2/2) PC120-6 Serial NO : 45001 - 49820 (2/2)
(TO l/2)
(TO l/2)
(TO l/2
(TO 112)
CN-HO5
q
(TO l/2)
I r------ IIIII
(TO 1 /2),
r-----------
202CD06030
10-135
0
ENGINE CONTROL SYSTEM
202FO6148
FUNCTION
IO-137
1. OPERATION OF SYSTEM
1) Starting engine
l When the starting switch is turned to the
START position, the starting signal flows to
the starting motor, and the starting motor Fuecontrodia
turns to start the engine.
l When this happens, the engine throttle con-
troller checks the signal from the fuel control
dial and sets the engine speed to the speed
set by the fuel control dial.
202FO5860
3) Stopping engine
l When the starting switch is turned to the
Fuel control dial
STOP position, the engine throttle controller
drives the governor motor so that the gover-
nor lever is set to the NO INJECTION position.
l When this happens, to maintain the electric
power in the system until the engine stops
completely, the engine throttle controller itself
drives the battery relay.
202FO5862
IO-138
2. COMPONENTS OF SYSTEM
1) FUEL CONTROL DIAL
1. Knob
2. Dial
3. Spring
4. Ball
Front of machine 5. Potentiometer
6. Connector
6A
+I21 ;
B
3G--I) 3
A-A I
Composition of circuit
202FO5105
FUNCTION
l The fuel control dial is installed to the con-
sole.
l A potentiometer is installed under the knob,
and when the knob is turned, it rotates the po-
tentiometer shaft.
l The power source voltage of 5V flows from
the engine throttle controller.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the voltage changed in this way 025 1 4 475 5
Voltage (V)
is sent as a signal to the engine throttle con-
Characteristics of throttle voltage
troller.
202FO5 106
l The range excluding the shaded area in the
graph on the right is accepted as the signal.
IO-139
2) GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
pi=?+
ComDosition of circuit
202FO6149
FUNCTION OPERATION
l The motor is rotated and the governor lever of Motor stationary
the fuel injection pump is controlled by the . Both A phase and B phase of the motor are
drive signal from the engine throttle control- continuous, and a holding torque is generated
ler. in the motor.
. A stepping motor is used for the motor which Motor rotating
provides the motive power. l A pulse current is applied to the A phase and
. In addition, a potentiometer for giving feed- B phase from the engine throttle controller to
back is installed to allow observation of the give synchronous rotation with the pulse.
operation of the motor.
The rotation of the motor is transmitted to the
potentiometer through a gear.
IO-140
3) ENGINE THROTTLE CONTROLLER
Y
-
0
0
-1
CN-EOI
202FO6150
Input/ Input/
IO. Name of signal
output r40. Name of signal output
1 Controller power source (24V) - -
12 GND
2 Controller power source (24V) -
13 Battery relay drive output
16 Potentiometer GND -
10-141
0
ENGINE THROTTLE . PUMP CONTROLLER
CN-3 CN-5
CN-1 CN-2
SAP00327
10-141-l
0
input and output signals
1 3 / Swing holding brake solenoid 1Output 1 3 Pump F pressure input Input 3 GND Input
4 NC _
I 4 IThrottle potentiometer input Input 1 4 IGND I Input I
5 NC _ 1Swing
1 5 pressure switch I Input I
6 GND Input
a LS divider solenoid/speed output I 8 I Starting switch IACC) 1 Input Radiator water level sensor
mode solenoid
9 Travel selector solenoid output I 9 I Knobswitch I Input
11 NC _
I Input
I
:I,.......
I 12 IGND 12 Bucket DUMP pressure switch Input
CN-2
r
PIi- InPUtI
NO. Name of signal output
/ 17 / Potentiometer GND I I flout Air cleaner clogging sensor
1 Solenoid power source (+24V) Input
1 18 / Starting switch (terminal Cl I Input
2 Governor motor phase A (+) Output
:
Automatic greasing controller
3 Governor motor phase A ( ) Output
w
4 Governor motor phase B (+) Output
13 NC -
30 Boom LOWER pressure switch Input
14 NC -
31 Arm OUT pressure switch Input
15 NC -
32 S-NET (+) Input,
_. output
16 NC
10-141-2
0
ELECTRONIC CONTROL SYSTEM
1
CONTROL FUNCTION
I I
r
Pump & engine mutual control function
c Auto-deceleration function
Self-diagnostic function
* 8. Active mode function is available from the following serial numbers. 202FO6151
lo-142
0
020206
Boom Bucket
III
Solenoid valve
Control valve
Arm swlr
i i --cl (IN) j
I i lvalve
I d R.H. travel
r-&LEFT) 1 Swing
9
_.H.
(nob
W&l
controller
I i /, h
I II I / Il-
I I
I
I ,,
I
II
I II
I I,
Starting switch
/ $jRe*
Swing lock
prolix switch,
Travel motor
I I,
I ;,
II I
I II
1 Boom
^ Bucket lllll
I
maid valve I
Swin
L.t
I
Oilpc;lessure I
--
--
-4 I
Engine throttle *
pump controller
Starting switch
e
Fuel
Q
control dial
Swing lock
prolix switch
020206
1. PUMP & ENGINE MUTUAL CONTROL FUNCTION
202F6153
O,.,.-
ucket
L
(Network circ,)it) 1 SEPOO614
lo- 143-2
0
FUNCTION
. There are five modes available for selection l Engine torque curve
with the working mode switch on the monitor
panel. These modes are the heavy-duty op- YO B/O
Engine speed N
202FO6155
202FO6156
10-144
0
1) Control method in each mode
Heavy-duty operation (H/O) mode
. Matching point in heavy-duty operation mode:
Model I PC100 I PC120 I
Rated output point
l When the load on the pump rises and the Heavy-duty 58 kW (79 HP) 62 kW (84 HP)
pressure rises, the engine speed goes down. operation (H/O) /2,100 rpm /2,200 rpm
When this happens, the pump discharge
amount is reduced, and the engine speed is
controlled so that it becomes the rated speed.
l If the reverse happens and the pressure goes
down, the system is controlled so that the
pump discharge amount is increased until the
engine speed reaches the rated speed.
By repeating this control, the engine can al-
ways be used at near the rated output point.
IO-145
Liftinq operation (L/O) mode
. Matching point in lifting operation mode:
Model PC100 PC120
50% partial output point / I
l When the lifting operation mode is selected, Lifting 29 kW (39 HP) 33 kW (44 HP)
the engine speed is automatically lowered to operation (L/O) /I,500 rpm /I,600 rpm
the partial position.
. In this condition, control is carried out in the
same way as for the general operation and fin-
ishing operation modes to match the load on
the pump.
. In this way, the fuel consumption is reduced
and the fine control ability is improved.
202FO6166 202FO6168
202FO6167
IO-146
2) Pump control function when traveling
. If the travel is operated in any working mode
other than the heavy-duty operation (H/O)
mode, the working mode and engine speed
are kept as they are, and the pump absorption
torque is increased to the maximum horse-
power at that speed.
Engine speed N
202FO6169
202F06170
202FO6172
IO-147
2. PUMP AND VALVE CONTROL FUNCTION
202F6173
Solenoid valve
Engine throttle *
n~lmncontroller
lo-148
0
FUNCTION
l The following functions are available to pro-
vide the optimum matching under various
working conditions: a cut-off function which
reduces the relief loss; a function which can-
cels the cut-off function and prevents the
speed from dropping; a 2stage relief function
which increases the digging power; and a fine
control mode function which improves the
ease of fine control.
10-149
0
* Quick warming up for hydraulic oil when
swing lock switch is ON:
When the swing lock switch is turned ON,
the cut-off function is canceled.
If the work equipment is relieved in this
condition, the temperature of the hydrau-
lic oil can be raised more quickly to re-
duce the warming up time.
r
50 100 100 50 50
operation
(G/O)
Finishing t
operation 80 50 60 80 40 40
T
(F/O)
Llftlng
operation 100 100 100 50 50
6) LS bypass function
mode (L/O)
l When the travel is operated at the same L
10-150
a
3. POWER MAXIMIZING AND SWIFT SLOW-DOWN FUNCTION
PCIOO-6 Serial No : 40001 - 41229
PC120-6 Serial No : 45001 - 49820
202F6177
I Control valve I
Engine
Monitor panel
Engine
speed
SeSOr
L.H.
knob
switch
t (Network circuit)
SEP00616
10-151
a
FUNCTION
8
8
8
Actuated
Heavy-duty operation Automatically canceled
Canceled (31.85 - 34.79MPa)
(H/O) (325 - 355 kg/cm? after 8.5 set
10-152
0
4. AUTO-DECELERATION FUNCTION
PCIOO-6 Serial No : 40001 - 41229
PC120-6 Serial No : 45001 - 49820
202F6178
Boom Bucket
0 0
Engine
Fuel control
Monitor Dane1
- pump
I Engine throttle controller
F----------1!
i (Network circuit)
SEP00617
10-153
0
. If all the control levers are at neutral when
waiting for work or waiting for a dump truck,
the engine speed is automatically reduced to a
midrange speed to reduce fuel consumption
and noise.
. If any lever is operated, the engine speed re-
turns immediately to the set speed.
OPERATION
Speel
No. 1 deceleration
I--
1 \ No. 2 decelerqtjon (1400)
-Time (set)
l-
Levers at neutral Lever cPCtrated
202FO6179
10-154
0
5. AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION
PCIOO-6 Serial No : 40001 - 41229
PC120-6 Serial No : 45001 - 49820
clControl valve
I
Pump controller
202F6180
L---J
Control
valve
(Network circuit) 1
10-155
a
FUNCTION
10-156
0
2) Engine overheat prevention function
l This function protects the engine by lowering
the pump load and engine speed to prevent
overheating when the engine coolant tem-
perature has risen too far.
l This system is actuated in two stages. The
first stage is when the coolant temperature is
between 102C and 105X, and the second
stage is when the coolant temperature is
105C and above.
Normal operation
(coolant temperature below 102C)
Actuation condition 1
Coolant tempera-
ture: Below 102C
(Coolant tempera-
ture gauge:
Green range)
w
._ 1st stage (Coolant temperature between 102C and 105C)
-
II
overheat prevention func-
tion was actuated (manual
reset).
10-157
0
6. SYVING CONTROL FUNCTION
PCIOO-6 Serial No : 40001 - 41229 r------ 1
I Swina brake
Swim
I ,- , -1 Pump controller
202F6181
Controlvalve
Engine throttle -
pump controller
lo-158
a
FUNCTION
I) Swing lock, swing holding brake function l Swing lock switch and swing lock, holding
l The swing lock (manual) can be locked at brake
any desired position, and the swing hold-
ing brake (automatic) is interconnected Lock Lock
switch lamp Operation
with the swing, so it prevents any hydrau-
I
lic drift after the swing is stopped. When swing lever is placed at
Swing neutral, swing brake is applied after
holding approx. 4 set; when swing lever is
OFF OFF brake operated, brake is canceled and
swing can be operated freely.
% Operation of swing lock prolix switch Swing lock ON (when controller OFF (when controller
. If any abnormality should occur in the prolix switch is abnormal) is normal)
I I
10-159
0
7. TRAVEL CONTROL FUNCTION
PCIOO-6 Serial No : 40001 - 41229
PC120-6 Serial No : 45001 - 49820
202F6183
Control valve
(Network circuit)
SEP00620
10-160
0
l When traveling, the pump control is carried
out, and the travel speed can be selected
manually or automatically to give a travel per-
formance that suits the nature of the work or
the jobsite.
lo-161
0
iii) Automatic selection according to pump discharge
pressure
If the machine is traveling with the travel speed
switch at Hi, and the load increases, such as when
traveling up a steep hill, if the travel pressure con-
tinues at 26.46MPa (270 kg/cm*) for more than 0.2
set, the motor volume is automatically switched
and the travel speed changes to Mi.
(The travel speed switch stays at Hi.)
The machine continues to travel in Mi, and when
the load is reduced, such as when the machine trav-
els again on flat ground or goes downhill, and the
travel pressure stays at 17.64MPa (180 kg/cm? or I
17.E 180) 26.46 (270)
less for more than 0.06 set, the motor volume is
automatically switched and the travel speed returns Travel pressure (MPa(kg/cmz))
to Hi. 202FO6184
10-161-l
a
8. ACTIVE MODE FUNCTION
Engine
!7-
Monitor panel
Function
. If the active mode switch on the monitor panel
is turned ON (lights up), the speed is in-
creased when there is a light load and the load
is detected when there is a heavy load. This
makes it possible to speed up the operation.
* The active mode functions only when the en-
gine idling speed is more than 2,100 rpm.
10-161-3
0
1) 2-stage boom LOWER, arm IN speed function
When the active mode switch is turned ON
(the active mode solenoid is OFF), the control
valve spool stroke when lowering the boom or
when moving the arm in is changed from 8
mm to 9.5 mm, and the speed is increased.
SOP00622
Engine speed
10-161-4
0
9. COMPONENTS OF SYSTEM
1) ENGINE SPEED SENSOR
0
$2%-D
Composition of circuit
202FO6185
1. Wire FUNCTION
2. Magnet l The engine speed sensor is installed to the
3. Terminal ring gear portion of the engine flywheel. It
4. Housing counts electrically the number of gear teeth
5. Connector that pass in front of the sensor, and sends the
results to the pump controller.
l This detection is carried out by a magnet, and
an electric current is generated every time the
gear tooth passes in front of the magnet.
1 2 3
1. Plug
2. Switch
3. Connector
--- -
--- -
Lilt--b
SPECIFICATIONS
Composition of points: N.O. points
Actuation (ON) pressure:
0.49kO.l MPa (5.Okl.O kg/cm*)
Reset (OFF) pressure:
0.29+0.05 MPa (3.OkO.5 kg/cm*)
FUNCTION
There are 8 switches installed to
the PPC shuttle valve. The oper-
tczg)
ating condition of each actuator
Composition of circuit is detected from the PPC pres-
sure, and this is sent to the
202FO6t 86
pump controller.
10-162
0
3) PUMP PRESSURE SENSOR
1 2 3 1. Plug
I 3.
2. Connector
Sensor
L
Composition of circuit
202FO6187
1. Sensor
2. Connector
SBPOO367
1o-1 63
0
FUNCTION Insulation layer
l This sensor is installed to the inlet port circuit
of the control valve. It converts the pump dis-
charge pressure to a voltage and sends this to
the controller.
OPERATION
When the pressurized oil entering from the
pressure introduction portion pressurizes the
diaphragm of the pressure detection portion, (stainless steel)
the diaphragm deflects and changes shape. SAP00368
10-163-l
0
4) PUMP CONTROLLER
PCIOO-6 Serial No : 40001 - 41229
PC120-6 Serial No : 45001 - 49820
202FO6189
_
n D^^_ DAlCCnr.;+rh I.. .- - _
4 Pump merge-divider solenord 24
25 Auto deceleration output
_
I
-7
__-
1 27 1Network circuit (monitor +) 1 - 1
r-
7 LS control EPC (-1 output
_
8 TVCIO output 3*
L Monitor circuit (engine +I
-I
34 Speedsensorf Input
-~
35 Network circut ( i _
36 Network circuit ( 1 _
lo- 163-2
0
ENGINE THROTTLE. PUMP CONTROLLER
CN-3 CN-5
f
x
+++++
++++++
II I _,Til!
3
EEg +++++
+++++
/;
LA J
CN-1 CN-2
SAP00327
10-164
0
Input and output signals
I 5 INC 5 INC
I - I 5 Swing pressure switch Input
6 r;;;c;re sensor power source Outputh
6 GND Input 6 Servicevalvepressureswitch Input
/ 13 / Power source (+24V) I Input I 13 Pump R pressure input Input 13 Travel pressure switch Input
21 IPGND I InputI
lo-165
0
5) TVC PROLIX RESISTOR
i
J 202FO6216
1. Resistor FUNCTION
2. Connector l This resistor acts to allow a suitable current to
flow to the TVC solenoid when the TVC prolix
SPECIFICATION switch is ON.
Resistance: 30 s2 . No current flows when the TVC prolix switch
is OFF.
10-166
0
PC1 00-6 Serial No : 40001 - 41229
PC120-6 Serial No : 45001 - 49820
Monltor panel
Network
circuit
r
a Engine thronle .
Pump confroller
Sensor signal
Power source
Buzzer
Battery
SEP00712
lo- 166-2
a
FUNCTION
10-167
0
1. MONITOR PANEL
PCIOO-6 Serial No : 40001 - 41229
PC120-6 Serial No : 45001 - 49820
CN-PO2
CN-PO1
202FO6265
-1
17 Engine oil pressure Lo Input
10-168
a
PCIOO-6 Serial No : 41230 and up
PC120-6 Serial No : 49821 and up
/
CN-PO1
SDP00713
16 NC
19 Start signal
20 NC
10-169
0
TIME DISPLAY, MONITOR DISPLAY
PClOO-6 Serial No : 40001 - 41229
PC120-6 Serial No : 45001 - 49820 1. Clock
2. Coolant temperature gauge
3. Fuel gauge
4. Engine oil level caution lamp
5. Preheating pilot lamp
6. Swing lock pilot lamp
7. Charge level caution lamp
/-----I 8. Air cleaner clogging caution lamp
9. Engine oil pressure caution lamp
10. Coolant level caution lamp
-3
-4
202FO6266
Content of display
Symbol Display item Display range When engine is stopped When engine is running
Below 1,500 rpm: 0.05MPa(0.5kg/cm2) Lrghts up when normal Flashes and buzzer sounds
00 Engine Oil pressure Above 1,500 rpm: 0.15MPa(1.5kg/cmz) (goes out when engine starts) when abnormal
Engine oil level Below low level Flashes when abnormal OFF
Coolant temperature Flashes when above lOZC, flashes and buzzer sounds
when above 105C
202FO6267
202FO6268
l When the starting switch is turned ON, the buzzer sounds for 1 second, all the monitor display lamps
light up for 3 seconds, and after this, all lamps except Engine oil pressure and Charge level go
out.
The Engine oil pressure and Charge level go out when the engine is started.
10-170
0
PCIOO-6 Serial No : 41230 and up
PC120-6 Serial No : 49821 and up
llllllllllllJ 6.
7.
Preheating pilot lamp
Swing holding brake pilot lamp
H 4
llllllllllll&
14 8. Battery charge caution lamp
9. Air cleaner clogging caution lamp
13 F IO. PPC oil pressure caution lamp
11. Over load caution lamp
12. Coolant level caution lamp
12 5
13. Engine oil pressure caution lamp
14. Fuel level caution lamp
15. Coolant temperature caution lamp
II 10 9 8 7 6
SDP00714
Content of display
Display item Display range When engine is stopped When engine is running
I
Flashes and buzzer sounds
Coolant level Below low level Flashes when abnormal when abnormal
Engine oil level Below low level Flashes when abnormal OFF
10-170-l
0
Symbol Display item Display range When engine is stopped When engine is running
I
AC 1 I
4h* 1PPC oil pressure ~Below low level OFF Flashes when abnormal
QQ I Parking
(Swing lock)
When swing is locked Lights up when swing lock switch
swing lock prolix swatch is ON
is ON, flashes when
1 O-l 70-2
a
MODE SELECTION SWITCHES
202FO6269
Note 1: If the working mode is operated F/O + G/O or L/O + B/O, the auto-deceleration switch is auto-
matically turned ON if it is OFF. (If it is already ON, it stays ON.)
Conversely, if it is operated G/O + F/O or B/O + L/O, the auto-deceleration switch is automati-
cally turned OFF if it is ON.
1o-1 70-3
0
PCIOO-6 Serial No : 41230 and up
PC120-6 Serial No : 49821 and up
Hi Mi
0 0 II
SOP00691
8
Switch actuation table 8
8
l The bold letters indicate the default position of the switch when the starting switch is turned ON.
Switch
c Item Action
LEVER SWITCH
(POWER UPI (SPEED DOWN) SOP00694
SOP00693
TRAVEL SPEED Hi H Mi t3 Lo
SOP00696
GD@ SOP00697
ACTIVE MODE ON w OFF (Note 2)
Note 1: If the working mode is operated F/O + G/O or L/O + B/O, the auto-deceleration switch is auto-
matically turned ON if it is OFF. (If it is already ON, it stays ON.)
Conversely, if it is operated G/O + F/O or B/O + L/O, the auto-deceleration switch is automati-
cally turned OFF if it is ON.
Note 2: Even if it is ON, when the working mode switch is pressed, it is automatically turned OFF.
1o-1 70-4
0
2. SENSORS
l The signals from the sensors are input directly to the monitor panel.
l There are two types of sensors: contact type and resistance type.
The contact.type sensors are always connected at one end to the chassis GND.
1. Subtank
2. Float
3. Sensor
4. Connector
no
0
Composition of circuit
205FO5166
IO-171
2) ENGINE OIL LEVEL SENSOR
1. Connector
2. Float
3. Sensor
4. Switch
Composition of circuit
202FO6272
3) ENGINE OIL PRESSURE SENSOR (Lo, Hi) 1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
1. Boss
2. Filter
3. Spring
4. Guide
5. Diaphragm
6. Case
7. Hose
8. Connector
0
0
Composition of circuit
202FO6273
IO-172
5) COOLANT TEMPERATURE SENSOR
1 2 3
1. Connector
2. Plug
I 3. Thermistor
i...
.P:
@ L
-
Composition of circuit
198FO2046
1. Float
2. Connector
3. Cover
4. Variable resistor
b
Composition of circuit
3 \4
A-A
202FO6275
IO-173
20 TESTING AND ADJUSTING
Table of judgement standard value ................ 20- 2 Testing and adjusting LS valve output pressure
Standard value table for electrical parts.........20-12 (Servo piston input pressure) and LS
Tools for testing, adjusting, and differential pressure ................................. .20-35-8
troubleshooting ........................................... .20-21 Testing and adjusting variable throttle
Measuring engine speed ................................ .20-22 valve .......................................................... .20-40-l
Measuring exhaust gas color ......................... .20-23 Testing and adjusting control pump circuit
Adjusting valve clearance.. ............................. .20-24 oil pressure .................................................. .20-41
Measuring compression pressure ................. .20-25 Testing EPC valve solenoid valve output
Measuring blowby pressure.. ......................... .20-25 pressure ....................................................... .20-43
Testing and adjusting fuel injection timing.. . .20-26 Measuring PPC valve output pressure and
Measuring engine oil pressure ...................... .20-27 testing PPC shuttle valve.. ........................... .20-45
Testing and adjusting fan belt tension .......... .20-28 Adjusting work equipment l swing PPC
Testing and adjusting belt tension for valve ............................................................. .20-47
air conditioner compressor ........................ .20-28 Adjusting travel lever.. .................................... .20-48
Adjusting engine speed sensor.. .................... .20-29 Testing travel deviation .................................. .20-49
Testing and Adjusting governor motor Testing locations causing hydraulic drift of
lever stroke .................................................. .20-30 work equipment .......................................... .20-50
Testing clearance of swing circle bearing ..... .20-31 Measuring oil leakage.. ................................... .20-52
Testing and adjusting track shoe tension ...... .20-32 Releasing remaining pressure in hydraulic
Testing and adjusting hydraulic pressure in circuit ........................................................ .20-53-l
work equipment, swing, travel circuit.. ...... .20-33 Bleeding air ..................................................... .20-54
Testing and adjusting TVC valve output pressure Troubleshooting.. ............................................ .20-57
(Servo piston input pressure) .................. .20-35-4
A When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
A When checking the water level, always wait for the water to cool down.
moved when the water is still hot, the water will spurt out and cause burns.
If the radiator cap is re-
A Be careful not to get caught in the fan, fan belt or other rotating parts.
20-l
0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
- +M) -
High idling vm 2,300 6o
1W 2,400-,00
Bosch
At sudden acceleration Max. 5.5 7.5 Max. 5.5 7.5
index
Exhaust gas color
Bosch
At high idling Max. 1.0 2.0 Max. 1.0 2.0
index
$
8
Oil temperature: MPa Min. 2.94 2.06 Min. 2.94 2.16
(Min. 30) 8
Compression pressure 40 - 60C (kg/cm; (Min. 30) (21) (22)
(SAE30 oil)
<engine speed> <rpm: :320-360) <320-360) :320--360) :320--360)
(Coolant temperature:
Blowby pressure Pa Max. 490 980 Max. 490 980
(SAE30 oil) Operating range)
:mmHzC (Max. 50) (100) (Max. 50) (100)
At rated output
(Coolant temperature:
Operating range)
0.34-0.69 0.26 0.34-0.69 0.26
At high idling
(3.5-7.0) (2.7) (3.5-7.0) (2.7)
Oil pressure
At low idling MPa Min. 0.1 0.07 Min. 0.1 0.07
(SAESO) (kg/cm (Min. 1.0) (0.7) (Min. 1.0) (0.7)
At low idling Min. 0.08 0.07 Min. 0.08 0.07
(SAEI OW) (Min. 0.8) (0.7) (Min. 0.8) (0.7)
Deflection Fan -
when alternator 8 6-10 8 6-10
pressed
Belt tension with finger mm
force of Crankshaft
approx. - air com- 12-15 12-15 12-15 12-15
58.8N(6kg). pressor
20-2
0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
. FOR CHASSIS
* The standard values and permissible values shown in this table are all values for H/O (heavy-duty op-
eration) mode.
PC100 PC120
At pump relief l Hydraulic oil temperature: 45 - 55C
Coolant temperature:
---I--Y-
l
lin. 2,100 Min. 2,201
Within operating range
Pump relief: Arm relief rpn
At pump relief l
I
Swing control valve 202F2302
I
* The figures in ( ) show the value
Travel control valve
when the active mode is actuated.
-
112+15 112f15
lOf5 1025
-
15.7f2.9 Max. 24.5
Engine at high idling
(1.6f0.3) (Max. 2.5)
Hydraulic oil temperature: 45 - 55C
Fit push-pull scale to center of control 15.7Ib2.9 Max. 24.5
(1.6kO.3) (Max. 2.5)
lever knob to measure
Measure max. value to end of travel 12.7k2.9 Max. 21.6
Bucket control lever l
. Tip of pedal (I .3f0.3) (Max. 2.2)
N
kg) 12.7f2.9 Max. 21.6
Swing control lever
(1.3kO.3) (Max. 2.2)
26.95-29.9 24.99-30.38
Swing
(275-305) (255-310)
I
Overrun when
F20206003 dw
stopping swing mn 55*10 75flO Max. 70 Max. 90
l Engine at high idling
j30~1001 730+100) IMax. 680 Max. 870)
l Hydraulic oil temperature: 45 - 55C
l Stop after swinging one turn and
measure distance that swing
circle moves
l ( 1: Distance of movement on outside
circumference of swing circle
1
l Engine at high idling
l Hydraulic oil temperature:
45 - 55C 180 3 3 7.5 7.5
l In H/O mode
l Time taken to swing 90 and
180 from starting position
20-4
Machine model
- T PCIOO, 120-6
?,,,,,,,D
)
///////c//z
Time taken to swing set
F20206003
15.3k2.t 25+2.4 3.0-27.E 0.5-30.0
l Engine at high idling
l Hydraulic oil temperature: 45 - 55C
l In H/O mode
l Swing one turn, and measure time
taken to swing next 5 turns
-
LC 1 14.2-48.0 40.1-55.0
////////////////////// I
ciec.
1[ravel speed (2) Mi 18+2 18.9+2 5.0-22.0 16.9-23.0
l Engine at high idling F20206006
l Hydraulic oil temperature:
45 - 55C
l In H/O mode
l Run up for at least 10 m, and Hi 13.1+2 13.lfl l.l-17.01 12.1-16.0
measure time taken to travel next
20 m on flat ground.
-
20-5
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Machine model
- T PCIOO, 120-6
L J
///////////////////////// /
F20206006
I 20 m
205F2402
*Measure dimension x
-
Hydraulic drift of
travel nrr 0 0
F20206007
l Engine stopped
l Hydraulic oil temperature: 45 - 55C
l Stop machine on 12 slope with
sprocket facing straight up the slope.
l Measure the distance the machine
moves in 5 minutes.
Leakage of travel
mi Max. 5 Max. 10
motor Lock pin
F20206008
20-6
0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
-T-
Machine model
-
T PC1 00, 120-6
Standard Permissible
Item Measurement conditions Jnit
value value
-
Posture for measurement PC100 PC120
Total work
equipment
(hydraulic drift at
tip of bucket teeth Max. 460 Max. 700
Boom cylinder
(amount of retrac Max. IO Max. 8 Max. 12
tion of cylinder) F20206009
F20206010
I
l Engine at high idling 2.6kO.3 / 2.9f0.3 vlax. 3.0 Max. 3.5
Cylinder fully
l Hydraulic oil temperature:
extended
45 - 55C
Cylinder fully
retracted sec.
I F20206011
Fully extended l Engine at high idling Illax. 3.4 Max. 3.7
l Hydraulic oil temperature:
45 - 55T
Bucket
Cylinder fully
retracted
r>, Empty
vlax. 3.4
+
Max. 3.7
I-
J
Boom
I F20206010
2.420.3 2.920.3 Max. 3.0 Max. 3.5
Cylinder fully
extended 1 Engine at high idling
1 Hydraulic oil temperature:
45 - 55C
2.OkO.3 2.3kO.3 Max. 2.6 Max. 2.9
3.42; :
3.7kO.3 Max. 4.2 Max. 4.5
Cylinder fully
I
retracted ;ec.
Bucket
:-_,
2 6
.
2.4kO.3
+o.; 2.9kO.4
-0.2
2.720.3
-!-
Max. 3.4
Max. 3.2
Max. 3.7
Max. 3.5
Cylinder fully I, , i
retracted Empty c
/,,,,///,,,,////////////////////////////: I
1
4
F20206012
2.3kO.3 2.420.3 Max. 2.9 Max. 3.0
Fully extended
Engine at high idling
Hydraulic oil temperature:
45 - 55C
2.1~0.3 2.2kO.3 Max. 2.7 Max. 2.8
-
Note: PC DO-6 Serial No. : 41230 and up
PC 20-6 Serial No. : 49821 and up
20-8
0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Boom
\
,,,,,,,,,,,,,r
a Max. 3 Max. 4
' F20206013
l Lower boom and measure time taken
from point where bucket contacts
ground to point where chassis rises
from ground
l Engine at low idling
l Hydraulic oil temperature: 45 - 55C
sec.
Arm ;57////////////////////////////j/// / Max. 2 Max. 3
F20206014
l Stop arm suddenly and measure time
taken for arm to stop
l Engine at low idling
* Hydraulic oil temperature: 45 - 55C
205F2402
*Measure dimension X
-
20-9
0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
20-10
0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Cat1
PC100,120 Discharge amount of main piston pump (in H/O mode)
gcr
202FO6321
* The error is large near the point where the graph curves, so avoid measuring at this point.
* When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed with the fuel control dial, take the pump discharge amount and the engine speed at the
point of measurement, and use them as a base for calculating the pump discharge amount at the specified
speed.
20-11
0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
20-11-l
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
I) Turn starting
switch ON.
Warming-up There must be no network error message on
Network 2) Insert T-adapter.
signal the monitor display.
_
If the condition is as shown in the table belov y, I) Turn starting
it is normal switch ON.
Auto-decelera- 2) Insert T-adapter.
tion signal
I-
If the condition
it is normal
is as shown in the table belov y, I) Turn starting
switch ON.
Governor 2) Insert T-adapter.
I-
motor EOI
1 Between (IO) - (20) 1 1.8 - 4.6 V
If the condition
it is normal
is as shown in the table belov y,I) Turn starting
switch ON.
2) Insert T-adapter.
Between (13) - (12) 20 - 30 v
Battery relay 1
* This is only for 2.5 set after the startin 9
switch is operated ON -+ OFF; at othc :r
times it must be 0 V.
-
20-13
-
lspec-
SYS Component
Connector
ion Judgment table
Measurement
ten No. conditions
nethod
Engine speed
E07 Measure with AC range 1) Start engine.
sensor
2) Insert T-adapter.
Between (I) - (2) 0.5 - 3.0 v
_
If the condition is as shown in the table below, 1) Turn starting
it is normal switch OFF.
2) Disconnect
Swing lock switch CO2 (female: connector C02.
20-14
Inspec-
sys- Component
Connector tion
Judgment table
Measurement
tern No. conditions
method
Swing brake
I I
m??
If the condition
it is normal
is as shown in the table below, I) Turn starting
switch OFF.
2) Disconnect
solenoid valve Between (I) - (2) 20 - 60 R connector V04.
Between (2) - chassis Min. IMR
I I
0, p!
If the condition
it is normal
is as shown in the table below, 1) Turn starting
switch OFF.
z
E it is normal switch OFF.
LS bypass 2) Disconnect
2 VOI Between (I) - (2) 20 - 60 R
connector Vol.
L
solenoid valve
al Min. IMR
Between (2) - chassis
zL
E
8
If the condition is as shown in the table below, 1) Turn starting
E it is normal switch OFF.
2 2) Disconnect
LS control EPC _ I,.\
1
t II - w
4-1
20-15
nspec
Sy: Component
Connector
ion Judgment table
Measurement
ten No. conditions
nethot
Model selec-
CO2 (femalt
tion
20-16
nspec-
Connector Measurement
Component ion Judgment table
No. conditions
nethoc
2-stage relief
co1
solenoid valve
20-17
j-
T
sy:
ten
Component
onnector
No.
~~~~-
Judgment table Measurement
conditions
method
I,f the condition is as shown in the table below, it is normal Insert a dummy
-T resistance with
Display level resistance
Position of gauge the starting
[Monitor panel input
display switch OFF, or
resistance)
measure the
Starting switch ON Starting switch OFF resistance of the
sensor.
Min. - Max. kR
Right Check the display
side with the starting
E/ switch ON.
(Zoolant
I:emperature
!3auge
IVleasure
.esistance
Iletween
02 (female)
I 12) - PO1
(female) (I I) 5
-
Left
side El 4
3
2
1 34.927 - Disconnection
IFuel level
!gauge
IMeasure
Iresistance
Ibetween 37.00 - 44.60
IPO1 (female)
i111) - PO2
l[female) (I I) 1
Left
side
20-18
sys- Component
Connector I??- Judgment table
Measurement
tern No. conditions
method
I
If the condition is as shown in the table below, 1) Start engine.
it is normal 2) Disconnect PI 1,
P12.
Air cleaner PI1 (male)
clogging sensor P12 (female)
1) Start engine.
Engine speed Measure with AC range
E07 2) Insert T-adapter.
sensor
1 Between (1) - (2) I 0.5 - 3.0 v I
I I
1) Turn starting
If the condition is as shown in the table below, switch OFF.
it is normal 2) Disconnect
P $ connector P08.
Above LOW level in 3) Insert T-adapter
Coolant level Max. 1 R
PO8 (male) z+ : reservoir tank
sensor 3 .I into connector at
r! Below LOW level in sensor end, and
Min. 1 MD
reservoir tank
measure resis-
I I tance.
I) Turn starting
If the condition is as shown in the table below, switch OFF.
it is normal 2) Disconnect
connector P05.
II I I
3) Drain oil, then
remove sensor.
4) Insert T-adapter
Engine oil level into sensor, and
sensor II I measure resis-
tance.
I/ e f:Eyr 1 Min.lMR 1
* Connect the T-
1 I I adapter to the
connector and
sensor flange.
20-19
ispec- Measurement
sy: ;- Component
Zonnector Judgment table
ion
ten 1 No. conditions
nethod
_:
b+- *
i
float to
stopper
tance.
* Connect the T-
adapter to the
connector and
sensor flange.
20-20
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
lucketCURL SOt
i Between (male)
Min. 1 MQ
(I I,(2) - chassis
I
lucketDUMP SO7
wing SO8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
I I I I
em)Min.
Between(l), (2) - chassis I MS1 1
I
Active mode vo7 2) Disconnect
solenoid valve (male) Between (1) - (2) I 20 - 60 R connector V07.
20-20-2
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
20-20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
-
Name of CZonnector Measurement
Judgment table
comoonent i No. conditions
-
Ii the condition is as shown in the table 1) Start engine.
blelow, it is normal 2) Turn swing
lock switch
Swing lever OFF.
operated 3) Turn swing
(Solenoid ON: 20 - 3OV
lock prolix
swing holding switch OFF.
Swing hold- brake released) Between 4) Insert T-
ing brake co1 adapter.
(3) - (6),
solenoid Approx. 5 set
(12)
after swing
lever is placed
at neutral Q-3V
(Solenoid OFF:
swing holding
brake applied)
-
IIi the condition is as shown in the table I) Start engine.
blelow, it is normal 2) Insert T-
adapter.
Travel speed 3) Turn fuel
switch at Hi control dial to
(Solenoid ON: 20 - 3OV MAX position.
travel motor 4) Travel on level
swash plate ground.
Travel speed MINI Between
co1
solenoid (9) - (6).
Travel speed (12)
switch at Lo
(Solenoid OFF: o-3V
travel motor
swash plate
MAX)
-
Ii the condition is as shown in the table I) Start engine.
blelow, it is normal 2) Insert T-
adapter.
Swing + travel
lever operated
simultaneously
(Solenoid ON:
LS bypass
LS bypass
co1 solenoid actu- Between
solenoid
ated) (2) - (61,
(12)
All levers at
neutral (Sole-
noid OFF: LS Q-3V
bypass solenoid
released)
20-20-4
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Sy:;-
T
ter n
Name of
component T
IZonnector
No.
Judgment table
Measurement
conditions
- 1
I1i the condition is as shown in the table 1) Start engine.
hbelow, it is normal 2) Insert T-
adapter.
Active mode
switch ON and
engine speed 20 - 3ou
Active mode 2100 rpm or
co1 more (Solenoid
solenoid
ON: active Between
mode actuated) (8) - (61,
(12)
Active mode
switch OFF o-3u
(Solenoid OFF:
active mode
canceled)
20-20-5
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
-
i-
T
SYS
ten n
Name of
component
Zonnector
No.
-
ISPectiC
nethot -
Judgment table
Measurement
conditions
I Fthe condition is as shown in the table 1) Turn starting
t below, it is normal switch ON.
l-K l H/O mode 2) Turn fuel
solenoid valve control dial to
(default value) MAX position
Between (8) - 3) Turn prolix
(18) switch OFF.
[
-
I.F the condition is as shown in the table I) Turn starting
t lelow, it is normal switch ON.
LS-EPC l H/O mode 2) Turn fuel
solenoid valve control dial to
(default value) Between (7) - (17) 1 800 f 80 mA I MAX position
[ 3) All levers at
neutral.
[
Between (4),(12) - GND 1 4-8V -7 T - adapter.
-
I:F the condition is as shown in the table 1) Turn starting
t jelow, it is normal switch ON.
2) Insert1
Kerosene mode Cl7 T - adapter.
t
-
I.f the condition is as shown in the table 1) Stat-t engine.
L:jelow, it is normal 2) Set monitor-
High idling (rpm)
F ing code to IO
\ 1 PC100 / PC120
1 or 16 (com-
mand value).
H/O Approx. Approx. 3) Operate
2300 2400
working
Approx. Approx. mode switch
G/O
2000 2100 and L.H. knob
No. 2 throttle switch.
signal Approx. Approx.
F/O 2000 2100
20-20-6
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
sys Name of Zonnectol
Judgment table
Measurement
:omponent No. n&hoc conditions
-ter
If the condition is as shown in the table I) Turn starting
below, it is normal switch OFF.
2) Dis connect
PC100 connector.
Betweenselection
1 C17(5) - CO2(11) No continuity 3) Connect T -
adapter to
Between selection 2 C17(13) - CO2(11) No continuity wiring har-
Between selection 3 C17(6) - CO2(11) No continuity ness
PC120
20-20-7
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
BLP00003
20-20-8
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
PO6
.
JP- . , Raise float
to stopper
Approx. 12 c
or below
Disconnect
connector P06.
Drain fuel, then
remove sensor.
Fuel level sensor BLPOOOO4 Insert
(male) T - adapter into
sensor.
JJ=-Yh E.&g; 851;;.Q
Connect the
T - adapter to
BLPOOOO5 the connector
and sensor
flange.
20-20-9
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
-
Eonnector Inspection Measurement
Name of componeni Judgment table
No. method
- conditions
Between When engine is running (l/2 throttle or above I) Start engine.
alternator below, the sensor is defective.
Alternator terminal j27.5 - 29.5 V
R and * If the battery is old, or after starting in
chassis cold areas, the voltage may not rise for
some time.
-
Display level resistance kC 1) Insert a
Position of (Monitor panel input dummy
gauge display resistance) resistance with
the starting
Starting switch ON Starting switch OFF switch OFF, or
measure the
Min. - Max. resistance of
the sensor.
2) Check the
display with
the starting
switch ON.
Measure
resistance
4+--i
1
3.512
3.600
- 3.900
- 4.125
between
coolant 3.807 - 4.349
temperature Display i
gauge CO3 position
7
(female) (I 1 w
- co3
H
6
(female) (16) 5
1
4
8.502 - 10.774
1 45.52 - 55.14
Left
side
* Level 1 flashes.
20-20- 10
0
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Coolant and oil temperatures B 1 790-101-6000 1 Digital temperature gauge 1 -50 - 1,200C
-
Pressuregauge : 2.45(25), 5.88(60),
799-101-5002 Hydraulic tester 39.2(400), 58.8(600) MPa(kg/cm*)
1
Pressure gauge :
790-261-1203 Digital hydraulic tester
68.6 MPa (700 kg/cm21
6 - Hose
-
1 795-502-I 590 Compression gauge
0 - 6.86 MPa (0 - 70 kg/cm2)
Compression pressure D
2 795-502-I 370 Adapter Kit Part No.: 795-502-1205
-
Blowby pressure E 1 799-201-1504 1 Blowbychecker 1 0 - 4.9 KPa (0 - 500 mmHz0)
Commercially
Valve clearance F Feeler gauge
available
Discoloration 0 - 70%
1 799-201-9000 Handy Smoke Checker
(with standard color)
Exhaust color G (Discoloration % x l/IO =
2 Commercially
Smoke meter Bosch index)
available
Commercially
Stroke, hydraulic drift I Scale
available
Commercially
Work equipment speed J. Stop watch
available
Measuring voltage and
K 79A-264-0210 Tester
resistance values I
1 799-601-2600 T-adapter box
l Kit Part No.
Troubleshooting of wiring
L 2 Adapter assembly T-adaoter kit
harnesses and sensors I I
799-661-8000
3 Adapter
20-21
0
MEASURING ENGINE SPEED
.
Coolant temperature: Within operating range
Hydraulic oil temperature : 45 - 55C c
1.
c
Install sensor (1) of multi-tachometer A to speed
pick-up port, then connect to multi-tachometer
A.
t
I-
202FO6327
20-22
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
I
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
I 202FO5207
TDP00308
20-24
0
MEASURING COMPRESSION PRESSURE
MEASURING BLOWBY
PRESSURE
* Measure the blowby pressure under the follow-
ing conditions.
l Coolant temperature: Within operating range
l Hydraulic oil temperature: 45 - 55C
1. Install the nozzle of blowby checker E to blowby
hose (I ).
2. Connect the nozzle and gauge with the hose.
3. Set the working mode to the H/O mode, then run
the engine at high idling and relieve the arm cir-
cuit.
4. Measure the blowby at the point where the
gauge indicator remains steady.
202FO6333
TESTING AND ADJUSTING FUEL INJECTION TIMING
m Sleeve nut :
23.5 k 1.0 Nm (2.4 & 0.1 kgm) I
205FO52 I6
205FO52 I7
20-26
MEASURING ENGINE OIL PRESSURE
20-27
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
Alternator pulley
Q
Crankshaft pulley
BKP00329
Drive pulley
BKP00331
20-28
0
1. Screw in until the tip of sensor (1) contacts gear
(2).
2. When gear (2) contacts sensor (I), turn back one
turn.
Tighten locknut (3).
: Be particularly careful when securing the sensor
wiring to ensure that no excessive force is
brought to bear on the wiring.
* Be careful not to let the tip of the sensor be
scratched or to let any iron particles stick to the
sensor tip.
202FO6338
205FO5222
20-29
TESTING AND ADJUSTING GOVERNOR MOTOR LEVER
STROKE
TESTING
* Use the governor motor adjustment mode.
1. In the time mode display, keep the time switch +
travel speed R.H. switch + working mode R.H.
switch pressed for 2.5 seconds.
2. In this condition, check the governor lever and
spring rod.
3. After checking, repeat the procedure in Step 1 to
finish the governor motor adjustment mode.
ADJUSTING F20206019-K
1. Turn the starting switch OFF, then remove the
nut and disconnect joint (1) from governor lever
(4).
2. Repeat the procedure in Step 1 in MEASURING
above to set to the governor motor adjustment
mode.
3. Set governor lever (4) to a position where it con-
tacts the full speed stopper (5) of the injection
pump, then adjust the length of spring assembly
(2) and rod (3), and connect joint (I) with the nut.
4. From the above position, turn rod (3) back 2.5
turns (extend the rod approx. 3.1 mm), and se-
cure in position with locknut (6).
* Caution 205FO6287
When the spring assembly is removed and the
starting switch is at the OFF position, if the gov-
ernor motor lever is moved suddenly, the gover-
nor motor will generate electricity, and this may
cause afailure in the engine throttle controller.
20-30
TESTING CLEARANCE OF SWING
F20505395
F20505396
8
z
z
4. Set the arm more or less at right angles to the
ground surface, then lower the boom until the
front of the machine comes off the ground.
When this is done, the upper structure will tilt
back, so the front will rise and the rear will go
down.
carriage.
20-31
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING
1. Raise the track frame using the arm and boom,
Track frame
and measure the clearance between the bottom J
of the track frame and the top of the track shoe.
l Clearance: 240 + 20 mm
Measurement position
ADJUSTING
* If the track shoe tension is not within the stan-
dard value, adjust as follows.
20-32
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
MEASURING
20-33
0
2. When main relief pressure is raised (34.8
MPa (355 kg/cm?)
1) When travel is operated
Measure the oil pressure when the travel
is relieved on each side separately in H/O
mode with the engine at high idling.
j, To relieve the travel circuit, put block
0 under the track shoe grouser, or
put block @ between the sprocket
and frame to lock the track.
2) When power max. function is actuated
When measuring the oil pressure in G/O 20TF01116 20TF01117
20-34
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
ADJUSTING
w Locknut:
58.8 f. 4.9 Nm (6 Z!I 0.5 kgm)
m Locknut:
44.1 + 4.9 Nm (4.5 + 0.5 kgm)
20-35
0
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
MEASURING
20-35 1
0
TESTING AND ADJUSTING HYDRAULIC PRESSURE
TESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT
ADJUSTING
m Locknut:
44.1 z!z4.9 Nm (4.5 _+ 0.5 kgm)
202FO6345
20-35-3
0
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
MEASURING
* Hydraulic oil temperature when measuring:
45 - 55C
l Measure the oil pressure when the circuit is re-
lieved in the pressure rise mode.
1. Remove pressure measurement plugs (I) and (2)
(Thread dia.=lOmm, Pitch=l.25mm), and install oil
pressure gauge Cl.
* Install a 39.2 MPa (400 kg/cm*) gauge to the
202F -06346
servo end, and a 58.8 MPa (600 kg/cm*) gauge
to the pump outlet port end.
2. Set the swing lock switch ON.
3. Set the working mode to H/O mode.
4. Run the engine at high idling, push the L.H. knob
switch ON, and measure the oil pressure when the
arm IN circuit is relieved.
j, Check that the servo piston input pressure is
l/2 of the pump discharge pressure.
[Reference]
If there is any abnormality in the LS valve or servo
piston, the servo piston input pressure will be al-
most the same or 0 of the pump discharge pres-
sure.
202FO6340
20-35-4
0
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
ADJUSTING
n
* If the load becomes larger, the engine speed will J
drop. Or if the engine speed remains normal, the
work equipment speed will drop. In such cases, if
the pump discharge pressure and LS differential
pressure are normal, adjust the TVC valve as fol-
\ I!
Punch mark showing
lows. eccentric position
\
1. Loosen locknut (3), and if the speed is slow, turn
>
screw (4) to the left; if the engine speed drops,
turn the screw to the right.
* If the screw is turned to the left, the pump ab-
sorption torque will be increased, and if it is 202FO6349
turned to the right, the pump absorption
torque will be reduced.
* There is also a connection with the angle, so
see Note below.
* The adjustment range for the screw is a maxi-
mum of 90 to both the left and right.
2. After completing the adjustment, tighten the lock-
nut.
202FO6351
20-35-5
0
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
MEASURING
* Hydraulic oil temperature when measuring:
45 - 55C
. Measure the oil pressure when the circuit is re-
lieved in the pressure rise mode.
1. Remove pressure measurement plugs (I) and (2)
(Thread dia.=lOmm, Pitch=l.25mm), and install oil
pressure gauge Cl.
* Install a 39.2 MPa (400 kg/cm*) gauge to the
BLPOO335
servo end, and a 58.8 MPa (600 kg/cm*) gauge
to the pump outlet port end.
2. Set the swing lock switch ON.
3. Set the working mode to H/O mode.
4. Run the engine at high idling, push the L.H. knob
switch ON, and measure the oil pressure when the
arm IN circuit is relieved.
* Check that the servo piston input pressure is
,
II2 of the pump discharge pressure.
[Reference]
If there is any abnormality in the LS valve or servo
piston, the servo piston input pressure will be al-
most the same or 0 of the pump discharge pres-
sure.
202FO6341
20-35-6
0
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
ADJUSTING
* If the load becomes larger, the engine speed will
drop. Or if the engine speed remains normal, the
work equipment speed will drop. In such cases, if
the pump discharge pressure and LS differential
pressure are normal, adjust the TVC valve as fol-
lows.
1. Loosen locknut (3), and if the speed is slow, turn
screw (4) to the left; if the engine speed drops,
turn the screw to the right.
* If the screw is turned to the left, the pump ab-
sorption torque will be increased, and if it is 202FO6349
turned to the right, the pump absorption
torque will be reduced.
* There is also a connection with the angle, so
see Note below.
* The adjustment range for the screw is a maxi-
mum of 90 to both the left and right.
2. After completing the adjustment, tighten the lock-
nut.
-eccentric position
I I
202FO6351
20-35-7
0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
MEASURING
1. Measuring LS valve output pressure
(servo piston input pressure)
1) Remove pressure measurement plugs (I) and
(2) (Thread dia.=lOmm, Pitch=1.25mm), and
install oil pressure gauge Cl.
202FO6346
* Install a 39.2 MPa (400 kg/cm*) gauge to
the servo end, and a 58.8 MPa (600 kg/
cm? gauge to the pump outlet port end.
l Oil pressure when travel is rotating under no
load on one side
i) Set the working mode to H/O mode, and
turn the travel speed switch to Hi.
ii) Use the work equipment to raise the track
assembly on one side.
iii) Measure the oil pressure with the engine
at high idling and the travel lever operated
to the end of its stroke to rotate the track
under no load.
Run the engine at high idling, operate the
travel lever to the end of its stroke, and 202FO6347
measure the oil pressure when the work-
ing mode and travel speed are switched
as shown in Table 1.
Table 1
Pump Servo inlet
,k:ig Trave preSSUre port pressure Remarks
lever MPa(kg/cm*) MPa(kg/cmz)
About
2.9-to 2.9+0 same
H/O mode Neutral
(30+0) (30&O) pressure
About
7.8k2.0 3.9fl.O
H/O mode Full 112 of
(80+20) (40&O) pressure
202FO6341 202FO6340
20-35-8
0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
Table 2
202FO6352
II
gauge is available, a 39.2 MPa (400 kg/
cm*) pressure gauge can be used.
iii) Set to the conditions in Table 2 and mea-
sure the pump discharge pressure.
* Stand directly in front of the indicator
and be sure to read it correctly. Cl
lb
iv) Remove oil pressure gauge Cl, then in- C'
stall to the LS pressure measurement
v)
plug.
Set to the conditions in Table 2 and mea-
P :06353
20-36
0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
ADJUSTING
1. Adjusting LS valve
When the differential pressure is measured under
the conditions above, and the results show that
the differential pressure is not within the standard
value, adjust as follows.
1) Loosen locknut (4) and turn screw (5) to adjust
the differential pressure.
* Turn the screw to adjust the differential
pressure as follows.
l To INCREASE pressure, turn CLOCK-
WISE 202FO6355
l To DECREASE pressure, turn COUN-
TERCLOCKWISE
2) After adjusting, tighten locknut (4).
m Locknut:
29.4 + 4.9 Nm (3.0 & 0.5 kgm)
20-37
0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
MEASURING
1. Measuring LS valve output pressure
(servo piston input pressure)
1) Remove pressure measurement plugs (1) and
(2) (Thread dia.=lOmm, Pitch=1.25mm), and
2J.J
install oil pressure gauge Cl.
* Install a 39.2 MPa (400 kg/cm*) gauge to I
the servo end, and a 58.8 MPa (600 kg/
cm*) gauge to the pump outlet port end.
l Oil pressure when travel is rotating under no
load on one side
i) Set the working mode to H/O mode, and
turn the travel speed switch to Hi.
ii) Use the work equipment to raise the track
assembly on one side.
iii) Measure the oil pressure with the engine
at high idling and the travel lever operated
to the end of its stroke to rotate the track
under no load.
Run the engine at high idling, operate the 8
8
travel lever to the end of its stroke, and
8
measure the oil pressure when the work-
ing mode and travel speed are switched
as shown in Table 1.
Table 1
/l-l/O
mode/ Full 1 7.8k2.0
(80+20)
202FO6341
20-38
0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
Table 2
Differential
Working ~~t$ pressure
mode Operation
dial (MPa(kg/cm2))
BLPOO338
2.74f 10
H/O mode MAX Levers at neutral
(28+10)
Travel speed: Hi
H/O mode MAX Travelcircuitunderno load 2.16*1.0
(lever fully operated) (22klO)
// i02~06354
20-39
0
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
ADJUSTING
1. Adjusting LS valve
When the differential pressure is measured under
the conditions above, and the results show that
the differential pressure is not within the standard
value, adjust as follows.
I) Loosen locknut (4) and turn screw (5) to adjust
the differential pressure.
* Turn the screw to adjust the differential
pressure as follows.
l To INCREASE pressure, turn CLOCK-
WISE
l To DECREASE pressure, turn COUN-
TERCLOCKWISE
2) After adjusting, tighten locknut (4).
m Locknut:
29.4 f 4.9 Nm (3.0 + 0.5 kgm)
20-40
0
TESTING AND ADJUSTING TESTING AND ADJUSTING VARIABLE THROTTLE VALVE
TESTING
* Check the actuation of the variable throttle valve
assembled to the servo valve assembly as follows.
1. Measure the work equipment speed under the fol-
lowing conditions for boom LOWER, arm IN, and
bucket CURL.
lMeasurement conditions
Working Active Work
Engine
mode mode equipment
BKP00341
Full H/O OFF No load
Adjusting
* If the measured values in the above Step 2 are not
within the standard value, adjust the variable
throttle valve as follows.
1. Loosen locknut (1) and turn adjustment screw (2)
to adjust.
* Turn the adjustment screw to adjust the work
equipment speed as follows.
l If speed is SLOW, turn CLOCKWISE.
l If speed is FAST, turn COUNTERCLOCK-
WISE.
* The adjustment screw changes the pressure
for starting operation (throttling) of the vari-
able throttle valve. BKP00343
BLP00344
20-40- 1
0
TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL
PRESSURE
MEASURING
* Hydraulic oil temperature when measuring:
45 - 55C
1. Remove pressure pick-up plug (I) (Thread
dia.=lOmm, Pitch=1.25mm), and install oil pres-
sure gauge Cl (5.88 MPa (60 kg/cm?).
2. Start the engine and measure with the engine at
high idling.
* When testing for internal leakage of the
equipment in the control circuit, use the
parts given below to shut off the circuit for
the following sections when measuring the
relief pressure.
Solenoid valve
Control pump
1
T
I Safety lock
1 $ u vave
Accumulator
202FO6358-1 K
20-41
ADJUSTING
1. Loosen locknut (2) and turn adjustment screw (3)
to adjust.
* Turn the adjustment screw as follows.
l To INCREASE pressure, turn CLOCK- ~~
WISE QQ
j__
&
l To DECREASE pressure, turn COUNTER-
CLOCKWISE
* Amount of adjustment for one turn of adjust-
ment screw: 0.53 MPa (5.4 kg/cm*)
20-42
TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE
MEASURING
* Hydraulic oil temperature when measuring:
45 - 55C
1. Measuring output pressure of LS control EPC sole-
noid valve
I) Disconnect output hose (I) of the LS control
EPC valve, then use adapter C3 in the oil pres-
sure gauge kit to install oil pressure gauge Cl
(5.9 MPa (60 kg/cm?).
2) Measure the output pressure under the condi-
tions in Table 1.
Table 1
20-43
0
2. Measuring output pressure of ON/OFF solenoid
valve
1) Disconnect outlet hose (2) of the solenoid
valve, then use adapter C3 in the oil pressure
gauge kit to install oil pressure gauge Cl (5.9
MPa (60 kg/cm*)).
2) Measure the output pressure under the con-
ditions in Table 2.
Table 2
I-
at Lo or engine speed 1500 Travel speed Lo OFF 0
rpm or below at maximum
-
Swing lock switch ON + work Pressure rise 2.94f0.49
ON
equipment lever operated (3Ok5)
3 2-stage reliel i
All levers at neutral Normal pressure OFF 0
-
Compound operation of travel + LS circuit pres-
work equipment or swing ON 0
sure bypassed
4 LS select
LS circuit pres- 2.94f0.49
Any operation except above sure not bypassed OFF
(3Ot-5) t-
-
* Operation of solenoid valve
ON: Continuous (oil pressure generated)
OFF: Not continuous (oil pressure: 0)
However, for LS bypass only:
ON: Continuous (oil pressure: 0)
OFF: Not continuous (oil pressure: 30)
Cl 202FO6362
20-44
TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE
MEASURING
* Hydraulic oil temperature when measuring:
45 - 55C
1. Measuring output pressure of LS control EPC sole-
noid valve
I) Disconnect output hose (I) of the LS control
EPC valve, then use adapter C3 in the oil pres-
sure gauge kit to install oil pressure gauge Cl
(5.9 MPa (60 kg/cm*)).
2) Measure the output pressure under the condi-
tions in Table 1.
able 1
Engine Output [Reference]
Operation speed pressure Current
(rpm) MPa(kg/cm*) (A)
All control Min. 1100 2.5 (26) 8OOk80
levers at neutral
Travel lever
op;;teJ travel Max. 1900 $zij 6
20-44-l
0
TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE
Table 2
20-44-2
0
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND TESTING PPC SHUlTLE VALVE
PPC
202FO6366
Pressure switch location diagram
Shuttle block seen from rear of machine
Bucket DUMP
(SO7)
Arm IN
(505)
Travel
(SOI)
202FO6367
l Circuit diagram
PPC shuttle *
-.
traveljunction valve
I
R.H. PPC valve (Bucket CURL) PPC shuttle valve
r-----------
+&r,
_A---$--______-
_- F20206017
20-46
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND TESTING PPC SHUTTLE VALVE
20-46 1
0
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND TESTING PPC SHUTTLE VALVE
Bucket DUMP
(s.07)
Arm IN
(505)
Boom LOWER
Travel
(SOI)
202FO6367
l Circuit diagram
PPCshuttle *
travel junction valve
c_._
F20206017
1. Swing PPC shuttle valve 4. Travel PPC shuttle valve
2. PPC shuttle valve for LS select 5. PPC shuttle valve for R.H. travel
3. PPC shuttle valve for L.H. travel FORWARD, L.H. travel REVERSE
FORWARD, R.H. travel REVERSE
20-46-2
0
ADJUSTING WORK EQUIPMENT l SWING PPC VALVE
20-47
TESTING AND ADJUSTING ADJUSTING TRAVEL LEVER
202FO6372
20-48
0
TESTING TRAVEL DEVIATION
8 Make a mark
8 at the 10 m midway point
8
202FO5258
20-49
TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK
EQUIPMENT
[Reference]
If the cause of the hydraulic drift is in the pack-
ing, and the above operation is carried out, the
downward movement becomes faster for the fol-
lowing reasons.
1) If the work equipment is set to the above 3) When the pressure is balanced, the down-
posture (holding pressure applied to the bot- ward movement becomes slower. If the le-
tom end), the oil at the bottom end leaks to ver is then operated according to the proce-
the head end. However, the volume at the dure given above, the circuit at the head end
head end is smaller than the volume at the is opened to the drain circuit (the bottom end
bottom end by the volume of the rod, so the is closed by the check valve), so the oil at the
internal pressure at the head end increases head end flows to the drain circuit and the
because of the oil flowing in from the bottom downward movement becomes faster.
end.
2) When the internal pressure at the head end
increases, the pressure at the bottom end
also rises in proportion to this. The balance
is maintained at a certain pressure (this dif-
fers according to the amount of leakage) by
repeating this procedure.
20-50
2. Checking boom holding valve
20-51
MEASURING OIL LEAKAGE
* Hydraulic oil temperature when measuring: Posture for measuring boom cylinder
45 - 55C
Disconnect hose
End of stroke @$
F201 C6006
Arm cylinder
202FO6376 202FO6375
20-52
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
3. Travel motor
1) Disconnect drain hose (2) from the travel PCIOO-6 Serial Nos. : 42157 and up
motor, then fit a blind plug at the hose end. PC120-6 Serial Nos. : 50401 and up
2) Fit block @ under the track shoe grouser, or
fit block @ between the sprocket and frame
to lock the track.
3) Start the engine and operate the travel relief
with the engine at high idling.
I 20TF01116 11 20TF01117
20-53
0
RELEASING REMAINING PRES-
SURE IN HYDRAULIC CIRCUIT
* No accumulator is installed, so the pressure re-
maining in the piping between the control valve
and the hydraulic cylinder or swing motor can-
not be released by operating the control levers.
Therefore, when removing the above piping, be
careful of the following points.
20-53-l
0
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
Note 1: Bleed the air from the swing and travel motors only when the oil inside the motor case has been
drained.
w Plug :
17.15 f 2.45 Nm (1.75 + 0.25 kgm)
D Plug :
17.15 X!Z2.45 Nm (1.75 + 0.25 kgm)
* Precautions when starting the engine * If the coolant temperature is low and
After completing the above procedure and automatic warming- up is carried out,
starting the engine, run the engine at low cancel it by using the fuel control dial
idling for 10 minutes. after starting the engine.
20-54
0
TESTING AND ADJUSTING BLEEDING AIR
w Plug :
17.15 k 2.45 Nm (1.75 f 0.25 kgm)
m Plug :
17.15 * 2.45 Nm (1.75 k 0.25 kgm)
20-55
0
TESTING AND ADJUSTING BLEEDING AIR
20-56
0
TESTING AND ADJUSTING BLEEDING AIR
202F05275A
20-56-l
0
TROUBLESHOOTING
Troubleshooting of engine throttle, pump controller (Governor control system) (E mode). ................ 20-132-I
Troubleshooting of engine throttle, pump controller (Pump control system) (C mode). ...................... 20-186-I
Troubleshooting of engine throttle, pump controller (Input signal system) IF mode) .......................... 20-200-I
20-57
0
POINTS TO REMEMBER WHEN TROUBLESHOOTING
l Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely
fitted.
l When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do
not allow any unauthorized person to come near.
l If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so
wait for the engine to cool down before starting troubleshooting.
l Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
l When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
l When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it prop-
erly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and
function. However, a short cut to effective troubleshooting is to ask the operator various questions to
form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not 3) Check the travel of the control levers.
hurry to disassemble the components. 4) Check the stroke of the control valve
If components are disassembled immediately spool.
any failure occurs: 5) Other maintenance items can be checked
. Parts that have no connection with the externally, so check any item that is con-
failure or other unnecessary parts will be sidered to be necessary.
disassembled. 4. Confirming failure
l It will become impossible to find the l Confirm the extent of the failure yourself,
cause of the failure. and judge whether to handle it as a real
It will also cause a waste of manhours, parts, failure or as a problem with the method of
or oil or grease, and at the same time, will operation, etc.
also lose the confidence of the user or opera- j, When operating the machine to reen-
tor. act the troubleshooting symptoms, do
For this reason, when carrying out trouble- not carry out any investigation or
shooting, it is necessary to carry out through measurement that may make the
prior investigation and to carry out trouble- problem worse.
shooting in accordance with the fixed proce- 5. Troubleshooting
dure. l Use the results of the investigation and in-
2. Points to ask user or operator spection in Items 2 - 4 to narrow down
1) Have any other problems occured apart the causes of failure, then use the trouble-
from the problem that had been reported? shooting flowchart to locate the position
2) Was there anything strange about the ma- of the failure exactly.
chine before tha failure occurred? * The basic procedure for troubleshoot-
3) Did the failure occur suddenly, or were ing is as follows.
there problems with the machine condi- 1) Start from the simple points.
tion before this? 2) Start from the most likely points.
4) Under what conditions did the failure oc- 3) Investigate other related parts or
cur? information.
5) Had any repairs been carried out before 6. Measures to remove root cause of failure
the failure? l Even if the dailure is repaired, if the root
When were these repairs carried out? cause of the failure is not repaired, the
6) Has the same kind of failure occurred be- same failure will occur again.
fore? To prevent this, always investigate why
3. Check before troubleshooting the problem occureed. Then, remove the
1) Check the oil level. root cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
20-58
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
TEW00180 m TEW00181
step 1
IExamination, confirmation of symptoms 1
1) When a request for repairs is received, first
ask the following points. Ring I Ring *
. Name of customer
. Type, serial number of machine
. Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
. Condition of failure
. Work being carried out at the time of the TEW00182
failure
. Operating environment
* Past history, details of maintenance, etc.
step 2
Determining probable location of cause TEW00183
TEW00184
1
step 3
I-
IPreparation of troubleshooting tools.1 --
-
TEW00186
Step 6
Reenacting failure
-!zY!Y TEW00188
the condition
failure.
and judge if there is really a
step
-1
4
dl II
1 step 5
Ask operator
failure.
questions to confirm details of
f
cc
.
.
.
Was there anything
chine before the failure
Did the failure
strange about the ma-
occurred?
occur suddenly?
Had any repairs been carried out before the
TEW00189 failure?
TEWOOlSl
JL
20-59
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
and is aimed at improving the quality of repairs. For this purpose, it gives sections on Handling
electric equipment and Handling hydraulic equipment (particularly gear oil and hydraulic oil).
TEW00192
i
TEW00193
. 20-60
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
0 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
\ TEW00194
20-61
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
l Disconnecting connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors held by a screw, loosen the screw fully,
then hold the male and female connectors
in each hand and pull apart. For connectors
which have a lock stopper, press down the
stopper with your thumb and pull the con-
TEW00197
nectors apart.
* Never pull with one hand.
I TBW00485
TEW00198
20-62
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
0 Connecting connectors
0 Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de- Clicks into position
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
* If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
t If there is any damage or breakage, re-
place the connector.
20-63
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
4i
tor.
TEW00202
20-64
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TEW00204
-- TEW00205
II TEW00206
20-65
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TEW00208
20-66
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3y) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
TEW00211
20-66-l
0
CHECKS BEFORE TROUBLESHOOTING
Judgement Remedy
Item
standard
6. Check engine oil level (Level of oil in oil pan) Add oil
20-67
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
;
Swing brake solenoid circuit
ti
,n Alarm buzzer
MO2 X 2 Starting motor M-l PO5 x 1 Engine oil level sensor L-l
MO6 M 3 Heater fan switch s-9 PO6 X 1 Fuel level sensor D-9
* The Address column in the table above shows the address in the connector arrangement drawing (2-
dimensional drawing).
* This table includes connectors that are not shown in the drawing.
20-68
0
Electrical component
* The Address column in the table above shows the address in the connector arrangement drawing (2.
dimensional drawing).
* This table includes connectors that are not shown in the drawing.
20-69
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
PCIOO-6 Serial No. : 40001-41229 PO6 MO9 M41 M40 V06 vo4 vo5 Cl0 E07
PC120-6 Serial No. : 45001-49820
M3i
202FO6385-1
20-70
0
MO7 PO3 M38 PI0 x01 x07 EOI M36 M36 HO4 Ml3 HOI M39 HO5 HO6
HO3
HO2
x05
D13
M21
DO5
M20
DO6
E06--_
DO1
PO4
D14
PO1
PO2
D17
DO2
R04
R05
M26
M45
Ml2
/ / / I / I I I I \ \
\
co5 W06 WI0 W08 CO6 co1 co3 co2 co9 M23 M23 M22
202FO6386-1
20-71
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Electrical component
20-72
0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
E?
CN ; :
Electrical component ?
No. X .
z
z g a
~
(machines wrth auto pull-up)
PO6 I X 2 I Fuel level sensor I c-9I
PO7 x 2 Engine coolant temperature l-5 WO8 I 070 I 18 I Wiper motor controller 1M-l
sensor I I I I
Wiper motor controller
PO8 X 2 Radiator water level sensor H-6 WO9 070 14 M-l
(machines with auto pull-up)
PI1 - 1 Air cleaner clogging sensor G-8 iN10 M 4 Rear limit switch -
Intermediate connector
PI2 - 1 Air cleaner clogging sensor G-8 WI0 M 4 (machines with auto pull-up)
L-l
R04 Shinagawa 5 Light relay L-4 X01 MIC 21 Intermediate connector N-9
R05 IShinagad 5 1 Light relay I L-6I X05 M 4 Swing lock switch L-9
20-72-l
0
CONNECTOR TYPES AND MOUNTING LOCATIONS
TROUBLESHOOTING
E05
M43 E04
MO8
M47
u
M28
\
Ml6 MO2
\
PO5
M34
20-72-2
0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
x05
DO1
M21
M20 D14
E06
M71 DO7
R05
PO4
DO8
PO1
PO2
DO2
Dll
D17
M70
D26
R04
018
M45
M26
W06
WI0 Wb9 W08 CO6 M46 CO2 co1 Cl7 CO3 M23 co9 M22 M23 Ml2
20-72-3
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TEW00221 TEW00222
I r
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
20-73
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T SWP type connector
3 6
TEW00235 6 3
BLWO033
4 8 4
TEW00237 TEW00238
m
1
1 4
___.__
______
;
0 5
12 0 5 8
9 9 12
1 4 8 11 II 84 1
14
3 7 IO i4
TEW00239
5 8
16
BLFUOO37
20-74
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
c I
i BLFOC038
TEW00243 TEW00244
1 3 3 1
4
ZZII m
2 4 4 2
TEW00245 TEW00246
1 A
3 6 TEWG3248
TEW00247
8 5
20-75
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
I I
4 8
TEW00249 TEW00.250
1 6
10
h 1
BLFu0042
1 6 6 1
12
I 1
5
8
i2
BLPoOO43 Ii
8
5
16
i l6 BLWOO44 16 7 TEW00256
20-76
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T MIC connector
BLP00046
i IIII 1 BLPOco47
7
1
13
8
13
H BLWOc49
9 /
ouo ououo ouo
BLPOOO50
00 0
17
10
17
L J
1 I BLWoo51 BLPWO52
11
21
21
I TEW00.259
TEW00260
20-77
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
8 4
BLPooO54
12 6
7 1 BLFOOO56
16 8
16
1 9
BLWOO57 TEW00232
20
ii i
TEW00234
20-78
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
1 7
6 4
BLwoo59 BLpoOO64
12
BLFtWO61 1 BLFOOO62
20-79
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T L type connector
B
2
TEwoo257
20-80
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T Automobile connector
1
BLW0054
1
1
2
3
ED B BLPOOO65
3 2
BLFQ0067
BLPoaO69 BLP00070
4 1
8
rI!D
BLPOOO71 BLPOO072
20-81
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T Relay connector
2 5
i:
1 3 6 5
BLFUOO73 BLFWO74
6 5
n ,
BLFUoO75 BLP00076
20-82
0
TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
I Travel oil
G0W?rllCN _-
potentiometer signal
5
G0W?rlVX
motor drive current :
~Motor
El
I
Fuel
control dial signal
o-
I -8
202FO6389
20-86
0
TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM
Boom Raise/Loner
Arm In/Out
Bucket Curl/Dump
TDPOOI 77
20-86- 1
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
* For details of the service codes included in the user code, see ACTION TAKEN BY THE CON-
TROLLER WHEN AN ABNORMALITY OCCURS, AND SYMPTOMS ON MACHINE or JUDGE-
MENT TABLE.
Component code
20-87
0
4) Display of service code
The monitor panel records both service codes which are included in the user code, and service
codes which are not included. This data can be displayed on the time display as follows.
* For details of the service codes that are not included in the user code, see ACTION TAKEN BY
CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE.
Working mode -
switch
\
-
L.H. travel
speed switch
202FO6391-I
Operation Display
20-88
Operation Display 1
2. To go to the next service code 3) If any abnormality exists at this time, the E mark is dis-
display, played.
Press the time switch + R.H.
working mode switch.
I---I s,:(/
-
3. To go back to the previous ser-
vice code display,
Press the time switch + L.H.
If there is en abnormality, or the controller is carrying out
working mode switch. self diagnosis, the output is shut off, and E is displayed.
8
z 3. Machine data monitoring mode function
z The input signals from the monitor panel and controller sensors and the output signals to drive the
solenoid can be checked by displaying them on the time display.
Working mode
switch
II
\
Lever switch
function switch
202F06391-IK
Front of monitor panel Rear of monitor panel
20-89
1) Method of displaying monitoring mode
Operation Display
1.. To set to the monitoring mode, 1. Goes off the time display, and display as follows.
do as follows.
Keep the time switch + lever 2. Example of display
switch function switch pressed 1) When pump controller engine speed is monitored
for 2.5 seconds.
20-90
2) Table of machine data monitoring codes
* For details of the B in the Unit column, see the bit pattern chart.
20-9 1
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
0
Monitoring code
205FO6382
:
Swing switch ON
Travel switch ON
.. . _
Input condltlon of pump controller Boom LOWER switch ON
20
PPC oil pressure switches Boom RAISE switch ON
Arm IN switch ON
g Arm OUT switch ON
Bucket CURL switch ON
; Bucket DUMP switch OFd
Input condition of pump controller
Swing lock switch ON
I
21 PPC oil pressure switches and other
g Service switch ON
switches _
5 (Blade) GND connected
ix switch ON
I
20-92
0
Code No. Content Bit Details (condition when lighted up)
I I m I
r
throttle controller
VYY
20-93
4. Governor motor adjustment mode
This is used when adjusting the linkage between the governor motor and the injection pump. For de-
tails of the procedure, see TESTING AND ADJUSTING.
Operation Display
20-94
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
to the monitor panel. When the monitor panel receives this data, it records the abnormality
data, and at the same time, depending on the nature of the abnormality, it displays the user
code on the time display panel or CALL on the service meter to advise the operator of the
action to take.
However, in cases of abnormalities which are not urgent and do not require the user code or
CALL to be displayed, only the content of the abnormality is recorded, and no display is given.
OFF OFF
OFF OFF
OFF OFF
OFF OFF
Y V
Telephone number display OFF
BKPO0227
20-94-l
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
.vice meter
Time di SPlaY
Time SW
Workins I mode
switch
Travel speed
switch
TOP001 78
1. To set to the trouble data display 1. On the time display and service meter display, the serv-
mode, ice code and number of hours (service meter hours)
Keep the TIME switch + L.H. travel that have elapsed since the occurrence of the abnor-
speed switch pressed for 2.5 sec- mality are displayed.
onds. . Example of display : When E212 has occurred 12
Note: It is possible to call it up at hours before (service meter)
the following times. I) Display of service code 2) Display of elapsed time
I) In the normal mode
2) In the user code display mode
3) In the machine data monitoring
mode
4) In the time adjustment mode
Y4JWVV-V
OFF OFF Service code OFF OFF Elapsed ON
time data
2. To go to the next service code dis- BKP00079
play, press the time switch + R.H.
woking mode switch.
3. To go back to the previous service 3) If any abnormality exists at this time, the E mark is
code display, press the time switch displayed.
+ L.H. woking mode switch. OFF
OFF
I
20-94-2
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Operation Display
4. To finish with the trouble data dis- 4) If there is no abnormality code in memory
play mode, keep the TIME switch
+ L.H. travel speed switch pressed
OFF OFF
for 2.5 seconds.
5. To erase the memory, keep the
time switch pressed, turn the start-
ing switch from OFF to ON, and
keep the time switch pressed for v-v-v
5 seconds. OFF - is displayed OFF - is displayed ON
BKP00081
!
Working mode
switch
Knob button
function switch
TDPOOISO
Operation Display
1. To set to the machine data moni- 1. On the time display and service meter display, the moni-
toring mode, do as follows. toring code and data are displayed.
Keep the time switch + knob but- . Example of display
ton function switch pressed for 2.5 1) When engine speed is monitored (monitoring code
seconds. IO)
Note: This is possible at the fol- OFF OFF
lowing times.
1) During the normal mode
2) During the user code display
mode
3) During the time adjustment v-w WV--&V
OFF OFF Monitoring OFF OFF Monitoring OFF OFF
mode code code data
4) During the trouble data display (example of 1950 rpm)
BKPOOOg3
mode
20-94-3
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Operation Display
switch.
4. To finish with the machine data
monitoring code mode, keep the
time switch + knob button func- w--v Lt : qJ
tion switch pressed for 2.5 sec- OFF OFF Displays OFF Displays bit 0Y 1;;~
monitoring pattern
onds. code BKW0084
02 Engine throttle l pump controller model code - Engine throttle l pump controller
I03 Engine throttle l pump controller model code I - I Engine throttle l pump controller
23 Engine throttle l pump controller solenoid actuation B Engine throttle * pump controller
30 Fuel control dial input value IOmV Engine throttle l pump controller
20-94-4
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Sr For details of the B in the Unit column, see the bit pattern chart in the next section.
No. Item Unit Name of component
20-94-5
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
OFF OFF
BKPCOO85
(3)
08 Connection of S-NET components
(4)
(5)
(6)
20-94-6
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
(6)
(1)
(2)
Input condition of engine throttle, (3)
36
pump controller (4)
(5) Starting switch ON
(6)
(2)
Output condition of engine throttle, (3)
37
pump controller (4)
(5)
(6)
(2)
(3) Wiper motor drive (RI actuated
47 Output condition 1 of monitor panel
(4) Wiper motor drive (L) actuated
(6)
20-94-7
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
(1)
(2) Wiper motor normal rotation relay output
When specified voltage is abnormal
(3) Wiper motor reverse rotation relay output
4c IInput condition 4 of monitor panel
When specified voltage is abnormal
(4) Window washer motor drive output
When specified voltage is abnormal
20-94-B
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Operation Display
w-+-J-v
OFF Displays g-SET OFF OFF OFF
BKP00086
Operation Display
20-94-9
0
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Operation Display
20-94-10
0
METHOD OF USING JUDGEMENT TABLE
This judgement table is a tool to determine if the problem with the machine is caused by an abnormality
in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are
then used to decide which troubleshooting table (E-00, S-00, C-00, F-00, H-00, M-00) matches the
symptoms.
The judgement table is designed so that it is easy to determine from the user code and service code which
troubleshootino table to go to.
* The abnormality display (caution) given by the monitor panel leads directly to troubleshooting of the
machine monitor (M- 00).
(See troubleshooting of the machine monitor system)
1. When using judgement table for engine throttle controller and engine related parts
l If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom
of the judgement table (E-00).
(A 0 mark is put at the places where the failure mode and service code match.)
l If a problem has appeared but no service code is displayed on the monitor panel, go to the point
where the failure mode matches the troubleshooting code on the right of the judgement table (E-
00 or S-00).
JUDGEMENT TABLE FOR ENGINE THROITLE CONTROLLER AND, ENGINE RELATED PARTS Figwe
in0 shows
pIttloofbllPatter
[Judgementl
1) If a service code is being displayed on the monitor panel ...
go to troubleshooting [E-00] for the engine throttle controller system.
2) If no service code is displayed on the monitor panel, and the engine does not start:
Starting motor rotates ...
l Check that starting
Go to troubleshooting S-2 of mechanical system
motor rotates
Starting motor does not rotate . . .
Go to troubleshooting E-l 1 of electrical system
20-96
2. When using judgement table for pump controller and hydraulic related parts
l If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom
of the judgement table (C-00).
(A 0 mark is put at the places where the failure mode and service code match.)
l If a problem has appeared but no service code is displayed on the monitor panel, go to the point
where the failure mode matches the input signal, and check the display for the input signal (the
display at the place with a 0 mark).
l If it is displayed normally, go to the troubleshooting code on the right of the judgement table
(H-00).
l If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (F-00).
[Judgementl
1) If a service code is being displayed on the monitor panel . ..
go to troubleshooting [C-O01 for the pump controller system.
2) If no service code is displayed on the monitor panel, and the auto-deceleration does not work:
There is a signal . ..
l Check pump con-
Go to troubleshooting H-5 of mechanical system
troller input signal -c
There is no signal . ..
Go to troubleshooting F-00 of electrical system
(F mode for applicable system)
20-97
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Troubleshooting
Component Service code
Code No.
20-98
0
<Example>
0
M-7 When starting switch is turned ON (engine stopped), check item flashes
@
* Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.
* Always connect any disconnected connectors before going on the next step.
* Check that the coolant is at the specified level before carrying out troubleshooting
Remedy
I
3 YES
- cjefective monitor panel ?eplace
connector IS con- Is continuit be-
netted to PO8 (fe- YES tween PO1 r female)
- (17) and (3) as -
2_ ;ho7wn in the ta- rjefective contact, or discon-
:lean (defec-
. Turn starting nection in wiring harness be-
:ive contact)
switch ON. Is there continuity tween PO8 (female) (1) -
x replace
_ between PO8 (fe- _ . Connect - NO FIO3 (11) - PO1 (female)
ND male) (2) and disconnect short (10)
chassis ground? connector to PO8
(female).
. Turn starting . Turn starting swtch ON.
switch OFF. * Disconnect POl.
rdefective contact, or discon- :lean (defec-
. Disconnect P08.
_ nectlon m wiring harness be- :ive contact)
NO
t ween PO8 (female) (2) - ,r replace
chassis ground
Table
Short connector Continuity
Connected Yes
Disconnected No
20-99
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accordance
with the judgement table for that type of failure (engine throttle controller, pump controller). For details of
the troubleshooting and troubleshooting procedure, refer to this flow chart.
When carrying out troubleshooting, ask the operator as much as possible about the condition of the ma-
chine, and check the following items before starting.
(I) Condition of controller connection (check with monitoring code 02 - 04)
(2) Blown fuses
(3) Battery voltage (monitoring code 32)
(4) Electricity generation (charge input), voltage (monitoring code 43)
The procedure for carrying out check items No. 3 and 4 in the flow chart below is given on the following
pages.
S z
8
Is engine
J-L
electrical
\I system for
whitch there
is no service
Is service code display
normal?
code dis- I
played on Carry out troubleshooting
Is problem
d
monitor Go to flow for engine electrical system
in engme
panel? chart for NO (E mode Ell-E15)
YES system orhy-
draulivmech section
anical sys- where is no
service code
- Operate and
4
tern?
display on
check service I iudaement
code Are engine . After ad- iabie.
throttle justing oil Carry out t!oubleshooting
contololler.
YES_ pump con- _
troller input
and output
3 signals nor-
_ mal?
* Check using
Are monitor monitoring
_ panel switch - mode.
signals out- . Governor
NO put corectly controller NO nal system
30.35,37
. Pump con-
. troller lo-23
. Check condi-
tion of S-
If the display is not given,
NET in
the controller is defective.
monitoring NO
code 08.
- Note (See
Text page)
20- 100
0
NOTE
If there is no abnormality display in the networking system transmitted in S-NET, it can be taken that the
output signal from the monitor panel has been transmitted. However, even if there is no abnormality
display, if the operation is defective, use the following procedure when checking directly.
If any abnormality occurs in the S-NET system, the system is automatically switched to the following de-
fault mode, so be careful when carrying out troubleshooting.
l Default mode
1. When networking cannot be carried out for the monitor and engine throttle controller + pump con-
troller
6. Travel sDeed Lo -
2. When networking cannot be carried out for the monitor and engine throttle controller
Only throttle signal is recognized as FULL; normal control is carried out for others.
2. Checking working mode signal (check No. 2 throttle signal at the same time)
1) Set to the monitoring mode and display monitoring code 40.
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
(rpm)
Engine speed (high idling)
Table 1 [The figures in ( ) are the rated speed1
1 Workina mode PC100 PC120
H/O Approx. 2300 (2100) Approx. 2400 (2200)
G/O, F/O Approx. 2000 (1850) Approx. 2100 (1900)
L/O Approx.1650 (1500) Approx. 1750 (1600)
20-101
l Checking input/output signal of engine throttle controller, pump controller
* Check the input signal for each controller as follows.
l Pump controller
20-102
DETAILS OF TROUBLESHOOTING AND
TROUBLESHOOTING TROUBLESHOOTING PROCEDURE
20-103
0
DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING
PROCEDURE
PCIOO-6 Serial No. : 41230 and up
PC120-6 Serial No. : 49821 and up
If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accord-
ante with the judgement table for that type of failure (engine throttle pump controller (governor l
The procedure for carrying out check items No. 3 and 4 in the flow chart below is given on the
following pages.
E02(TVCsystem)
* For details, see engine throttle l pump controller (governor control system) (pump control system)
in the JUDGEMENT TABLE.
20-104
0
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
If there is no abnormality display in the communications system transmitted in S-NET, it can be taken
that the output signal from the monitor panel has been transmitted. However, even if there is no
abnormality display, if the operation is defective, use the following procedure when checking directly.
If any abnormality occurs in the S-NET system, the system is automatically switched to the following
default mode, so be careful when carrying out troubleshooting.
Default Mode when communications cannot be carried out for the monitor and engine throttle
lpump controller
2. Checking working mode signal {check No. 2 throttle signal (monitoring code 16) at the same
time)
1) Set to the monitoring mode and display monitoring code 10.
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
20-l 04-l
0
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
. Pump controller
20-104-2
0
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
20-104-3
0
TROUBLESHOOTING SERVICE CODE TABLE
El01 Error memory data abnormal - E315 Short circuit in battery relay output system -
E,03 Short circuit in buzzer output, contact E317 Disconnection in governor motor system
with buzzer drive wiring harness 24V - E05
E318 Short circuit in governor motor system
El04 Air cleaner clogging detected -
I I
t
I I
20-104-4
0
TROUBLESHOOTING OF COMMUNICATION
ABNORMALITY SYSTEM
(N MODE)
20-104-5
0
TROUBLESHOOTING N-l
c Cause Remedy
1
I Clefective mating of moni-
t<or panel connector PO2 of
Ciefective monitor panel
leplace
Table 1
Display
Monitoring code
------- ~~:filj$Jljj
08 Network connection condition m @I 0
Code position
20- 104-6
0
TROUBLESHOOTING N-l
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
If the starting switch was turned off after the abnormality occurred, turn the starting switch on and
check that the service code displays E. (If it is not displayed, the problem has been removed.)
Before carrying out troubleshooting, check that all the re-
Cause Remedy
lated connectors are properly inserted.
Always connect any disconnected connectors before going
on the next step.
1
Iias been reset
4 YE!
1 Is resistance
5 lefective monitor panel Replace
YES between PO1 (4)
- (11) and chassis or -
_ 3 PO1 (4) (11) and
Disconnection is betweer
I I
Yf
When Cl7 is
disconnected,do
bits (1) and (21light
PO1 (12) normal?
* Disconnect
connector C17,
Nr 5;, POl(4) (11) and PO1 (12)
or chassis
Repair
F 1 ii!%%L!ode 1
*Turn starting
switch ON.
YES Defective engine throttle
Replace
5 pump controller
* See Table 2.
*Turn starting Is voltage
switch ON. bwtween Cl7 (4)
F , (12) and chassis 6 S
Defective monitor panel Replace
normal? _ Is resistance
*Turn starting between PO1(4),
switch ON. NO (11) and Cl7 (41,
* Min. 7.5 V (12) normal? Disconnection in wiring
Replace
* Disconnect Cl7 * Disconnect POl, 0 harness between POl(4).
and measure (11) and Cl7 (4), (12)
c17.
voltage at * Max. IQ
harness end.
I I
Table 1 1 Display ) l
When each controller is connected to the
n is displayed. If the correct
alphanumerics are not displayed (another
Table 2
Display
Monitoring code
. Light up when connected . Note: Checks can be carried out with code
(1) Engine throttle punp controller
l
08 only when there is a disconnection.
(2) Engine throttle punp controller
l
The display does not change when there
is a short circuit.
Therefore, checks when there is a short
circuit should be carried out basically US-
ing Table 1.
20-104-7
0
TROUBLESHOOTING N-l
Monitor panel
PO1(04020)
I
S-NETl+d; n HI4
@ (M6)
S-NET(+) @
C17(04016)
BKP00092
20- 104-8
0
TROUBLESHOOTING OF ENGINE THROTTLE
CONTROLLER SYSTEM (E MODE)
PCIOO-6 Serial No. : 40001-41229
PC120-6 Serial No. : 45001-49820 I
Points to remember when carrying out troubleshooting of engine throttle controller system .. . .. . .. . .. .. 20-106
Action taken by controller and condition of machine when abnormality occurs .. . ..._............................ 20-107
Judgement table for engine throttle controller and engine related parts . . .. .. .. ... . ..._............................... 20-109
E-l Abnormality in engine throttle controller power source system ..._............................................ 20-I 11
E-2 [E3:08] Abnormality in fuel control dial input value system is displayed . . .. .. . ... . .. .. . ... . . ... .. .. . ... . . 20-I 12
E-3 [E3:17] Abnormality (disconnection) in governor motor drive system is displayed .. . . ... . .. .. . .. . . 20-113
E-4 [E3:18] Abnormality (short circuit) in governor motor drive system is displayed ..................... 20-I 14
(D E-8 [E3:07] Abnormality in pump controller throttle system is displayed ........................................ 20-I 19
R
E-9 [E3:15] Abnormality (short circuit) in battery relay output system is displayed ........................ 20-I 19
E
E-10 [E3:16] Abnormality (step-out) in governor motor system is displayed .................................... 20-120
E-13 Lack of output (engine high idling speed is too low) .................................................................. 20-128
E-15 Defective operation of battery relay system (engine does not stop) .......................................... 20-132
20- 105
0
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-
SHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM
Points to remember when there is abnormality which is not displayed by user code
The engine is controlled by an engine throttle controller.
The problems that may occur with this system include the following.
1. Idling speed is too high (too low)
2. High idling speed is too low
3. Auto-deceleration speed is too high (too low)
4. Engine speed for automatic warming-up operation is too high (too low)
5. There is hunting
6. Engine does not stop
If any abnormality occurs, and the abnormality is displayed on the time display portion of the monitor
panel, use the troubleshooting table to determine the appropriate troubleshooting flow chart from El
to EIO. However, if there is any abnormality in the machine and no abnormality display is given, it is
necessary to determine whether the problem is in the mechanical system or in the electrical system.
If the linkage between the governor motor and the injection pump is not properly adjusted, problems
1 to 6 listed above may occur. Therefore, if there is no abnormality display, but one of problems 1 to
6 above has occurred, carry out troubleshooting as follows.
YES 2
YES Defective adjustment of governor motor
IIf
linkage
governok motor
See TESTING AND ADJUSTING.
and injection pump
I
If hnkaoe between - is disconnected, -
governo-i
motor does operation of
and injection pump governor motor be- NO Go to troubleshooting E-12-E-15 of
is disconnected and come normal? electrical system
pump lever is oper- - With starting switch at ON, operate fuel con-
ated by hand or is trol dial and working mode switch.
fixed with wire,
does condition re-
Go to troubleshooting S-l -S-16 of g
turn to normal?
engine system
r40
2
*If engine does not stop, push governor lever 0
to STOP posltion and check If engine stops.
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting
flow chart for the mechanical system or electrical system.
* For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
20-I 06
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
U ser Service Action by controller when Problem that appears on machine
C(,de code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) abnormality is detected when there is abnormality
-
1. Short circuit in wiring harness between EOI (5) - (16), Maintains engine speed at 1. Does not become partial
EOI (female) E06 (male) Resistance value
(5) - (17). (16) - (17) position of fuel control dial speed when set at high idling
(5) - (7) (1) - (2) 0.25 - 7 kR
2. Short circuit in wiring harness between E04 (I) - (2), immediately before abnormality position
(I) - (3). (2) - (3) (7) - (16) (2) - (3) 0.25 - 7 kS2 occurred 2. Does not reach high idling
3. Short circuit in wiring harness between E06 (1) - (2), (5) - (16) - 2-339 when set at partial speed
(I) - (3), (2) - (3) - 4-6kR 3. There are cases of hunting
(1) - (3)
4. Short circuit in wiring harness between EOI (5) - (7). 4. Lacks output (max. speed of
Between
E3. o8 Abnormality in fuel (7) - (16) each pin - Min. 1 kR
engine is too low)
control dial input value 5. Disconnection in wiring harness between EOI (5) - and chassis
X07 (6) - E06 (1)
6. Disconnection in wiring harness between EOI (7) -
x07 (5) - E06 (2)
7. Disconnection in wiring harness between EOI (16) -
x07 (4) - E06 (3)
8. Defective fuel control dial
9. Defective contact of EOI, X07, E06 connectors
1. Disconnection inside governor motor E05 (male) EOI (female) Resistance value Takes no particular action 1. When there is a disconnection
2. Disconnection in wiring harness between EOI (IO) - in both the A phase and B
(I) - (2) (IO) - (20) 2.5 - 7 kR
HO2 (4) - E05 (1) phase at the same time, the
3. Disconnection in wiring harness between EOI (I I) - (3) - (4) (11) - (21) 2.5 - 7 kR problem is the same.as for a
HO2 (7) - E05 (3) (1) - (3) (IO) - (11) Min. 1 kR short circuit in the governor
E : 05 4. Disconnection in wiring harness between EOI (20) - (IO) - (21) Min. 1 kR motor system
(1) - (4)
Abnormality (disconnec- HO2 (5) - E05 (2) 2. When there is a disconnection
Between pins Between pins
E3 : 17 tion) in governor motor 5. Disconnection in wiring harness between EOI (21) -
(I), G!), (31, (IO), (II),
in only one of A phase or B
drive system HO2 (8) - E05 (4) (201, (21) and Min. 1 kR phase
(4) and
6. Defective contact of EOI, H02, E05 connectors chassis chassis I) Engine does not stop
2) Stops moving at position
Motor drive current: Hold: 0.7 A
immediately before failure,
Start: 0.84 A
so engine speed cannot be
controlled
3) There are cases of hunting
1. Short circuit inside governor motor EOI (female) Resistance value Sets motor drive current to 0 1. If during operation
E05 (male)
2. Wiring harness between EOI (IO) - HO2 (4) - E05 (I) I) Sets to low idling
(1) - (2) (IO) - (20) 2.5 - 7 kR
short circuiting with wiring harness between EOI (20) 2) Engine does not stop
- HO2 (5) - E05 (2) (3) - (4) (11) - (21) 2.5 - 7 kR 3) There are cases of hunting
3. Wiring harness between EOI (11) - HO2 (7) - E05 (3) (I) - (3) (IO) - (11) Min. 1 kR 2. When stopped
Abnormality (short
short circuiting with wiring harness between EOI (21) Min. 1 kR 1) Engine starts, but stays at
E3 : 18 circuit) in governor (I) - (4) (IO) - (21)
- HO2 (8) - E05 (4) low idling
motor drive system Between pins Between pins
4. Wiring harness in Items 2 and 3 short circuiting with 2) Engine does not stop after
(I), (21, (31, (IO), (II), Min. 1 kR
ground (4) and (20), (21) and starting
chassis chassis 3) There are cases of hunting
Motor drive current: Hold: 0.7 A
Start: 0.84 A
1. Short circuit, disconnection in network wiring harness 1. When monitor panel and 1. When monitor panel and
2. Abnormality in pump controller pump controller cannot pump controller cannot
3. Abnormality in engine throttle controller receive signal receive signal
1) Working mode: H/O I) Even when working mode
Abnormality in network
E3: 01 2) Automatic warming-up: ON is switched, engine speed
reception system
3) Overheat signal: OFF does not change
2. Same as normal when only 2. Same as normal when only
pump controller cannot pump controller cannot
receive signal
20-I 07
User Service Action by controller when Problem that appears on machine
code code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) abnormality is detected when there is abnormality
1. Disconnection, short circuit in model selection wiring 1. PC100 Detects abnormality in input 1. In case of 1, when change
harness Resistance between 1) Retains data when starting occurs from midway point,
2. Abnormality in engine throttle controller EOI (81, (181, (9), (19) - GND : Min. 1 MR switch is ON initial data continues as it is, s(
3. Part No. for model selection connector is wrong 3. PC120 2) Functions as PC100 when non- there is no abnormal phenom-
Resistance between set conditions are input enon
- E3. o5 Abnormality in model
EOI (8) - GND : Max. 1 R 3) When model code set by 2. In case of 2, no particular
code
Resistance between controller is input, functions as abnormality
EOI (181, (91, (19) - GND : Min. 1 MR model that is input. 3. In case of 3, for example when
For PCIOO: PC120,200,220 controller recognizes PC100 as
( For PC120: PCIOO, 200,220 1 PC200, judges that there is a
disconnection and displays
E:02
1. Short circuit in wiring harness between EOI (5) - (16), EOI (female) E06 (male) Resistance value Calculates position of motor and 1. Precision of engine speed
(5) - (17), (16) - (17) carries out control from value of control may be reduced.
(5) - (17) (I) - (2) 0.25 - 7 kR
2. Short circuit in wiring harness between EOI (1) - (21, voltage immediately before For example:
(I) - (31, (2) - (3) (17) - (16) (2) - (3) 0.25 - 7 kC! abnormality occurred 1) Engine does not change to
3. Short circuit in wiring harness between E06 (I) - (21, (5) - (16) - 2-3kkR high idling speed (a little tot
(1) - (3), (2) - (3) - (I) - (3) 4-6kR low)
4. Short circuit in wiring harness between EOI (5) - (71, Between 2) Engine does not change to
(7) - (16) each pin - Min. 1 MS2 low idling speed (a little too
5. Disconnection in wiring harness between EOI (5) - and chassis high)
- E3. o6 Abnormality in governor HO2 (1) - E04 (I) 3) Defective engine speed for
potentiometer system 6. Disconnection in wiring harness between EOI (17) - auto-deceleration or auto-
HO2 (2) - E04 (2) matic warming-up (too high
7. Disconnection in wiring harness between EOI (16) - or too low)
HO2 (3) - E04 (3) 4) Engine may not stop
8. Defective governor potentiometer *The governor motor
9. Defective contact of EOI, H02, E04 connectors moves in the direction to
stop the engine, but
motor may not move
completely to the positioi
to stop the engine.
5) There are cases of hunting
1. If model selection input is different for the two con- Functions as PC100 when non-set No particular abnormality
Abnormality in pump trollers (pump controller and engine throttle control- conditions are input
- E3 : 07 controller throttle ler)
system 2. Controller part No. is different
(No. 2 throttle signal)
If excess current flows between EOI (13) and battery Between EOI (13) and chassis: 20 - 30 V Sets battery relay drive current to Engine does not stop
relay * Hold with the motor in the stop position for 2 - 2.5 0
Abnormality (short
* This occurs only when turning starting switch to OFF, set, return to the low idling position, then turn the
- E3 : 15 circuit) in battery relay and stopping engine battery relay OFF.
output system
1. Defective adjustment of rod or twisting of loose 1. Linkage adjustment correct 1. Displays when returning from Engine speed cannot be con-
spring 2. Must move lightly when connector is removed high idling to low idling trolled (particularly at high idlings
Abnormality (step-out) 2. Abnormality in governor motor * Start again (repeat step-out) so there is hunting
3. Normal
- E3 : 16 in governor motor 3. Abnormality in engine throttle controller 2. In some cases it may not
system display when returning from
partial speed to low idling
20-I 08
JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND, ENGINE RELATED PARTS Figure in 0 shows position of bit pattern
6 Engine speed does not change even when working mode % E-3
0 s-4
IS swrtched
Troubleshooting code when service code is displayed E-l E-2 E-3 E-4 E-5 E-6 E-7 E-8 E-9 E-16 _ _ _ _ _ _ _ _ _ _ _
Troubleshooting code when there is abnormality in --_- ------ C-15 E-15 - - - - - M-14 M-13 M-13 E-II
monitoring or machine monitor check
0 : This shows applicable item for service code 0 : This shows item to check with monitoring mode or machine monitor
.X : This shows item that needs only checking with monitoring mode
20-109
ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAM
Fuel control
dial
Governor motor
Pump controller
r------
r-----1
E04fX3) Potentiometer
0. B5WB . .
0. B5G
t
; sig
0. assw:, :
!
x07 I
I
(MIC17) E05tX3) Motor
D13tKESl
I I I
H02(S21)
0. 5WB, . 0. B5WB
0. 5GB ;. 0. B5G
0. 5BWz . 0. B5BW
c \ 0. 5B : 0. 758
I
- -II 0. 5G = 5= 0. 75G
- -,) - _.-----~---o~5-R-~ 6*~~_~~R--------__----------__-------_
-
- \ 0.5w* z. 0. 75w
- _ 2BR = g: 2BR
o 160
-
:n
m
is Fusible
III I N link
---_- El-i,
r-
Monitor panel
II I
60 ;
u
50 -<
40
30
20
F20206018
E-l Abnormality in engine throttle controller power source system
(engine speed stays at low idling)
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* C-heck that fuses 2 and 14 are not blown.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-l I.)
Cause Remedy
YES
Defective engine throttle con-
troller
I h,
Is voltage between
E01 (6) and (12) Defective contact, or discon-
normal? 3 YES nection in wiring harness be- Repair or
II tween starting switch ACC - replace
11
H
u 1 1 Is voltaoe between X07 (17) - EOl (female) (6)
1 - 20-30V starting-switch ter-
* Turn starting
switch ON. chassis normal?
Is voltage between Defective starting switch (be- Replace
E01 (1) (2) and * 20-30V tween B and ACC)
(12) normal?
* Turn starting
switch ON.
* 20-30V Defective contact, or discon-
4 YES
- I urn sramng I II nection in wiring harness be- Repair or
switch ON. tween fuse 2 and EOl (fe- replace
Is voltage between male) (1) (2)
fuse 2 outlet port
,* II
Defective contact, or discon-
nection in wiring harness be-
I I I Repair or
tween fuse 2 - HO6 (2) -
NO replace
.20-30V ;14 (2) (1) - battery relay
. Turn starting
switch ON.
X07(MIC17) FLXX
M14IL2)
switch ON signal
202CK06501
20-I 11
E-2 [E3:08] Abnormality in fuel control dial input value system is
displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
2 YES
Defective engine throttle con-
troller
Note: If E3:06 also occurs at the same time, check the wiring harness below.
l Wiring harness between EOI (female) (5) - HO2 (1) - E04 (female) (1) short circuiting with
ground, or contact with other wiring harness
Table 1
Governor
potentiometer
20-I 12
E-3 [E3:17] Abnormality (disconnection) in governor motor drive system
is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the
to its original position, if the service code is not displayed, the problem has been removed.
* During operation, if there is
1) a simultaneous disconnection in A phase and B phase:
0 the engine will run at low idling
@ the engine will not stop
2) a disconnection in either A phase or B phase:
the engine speed will remain the same as before the abnormality occurred
* If the problem occurs when the engine is stopped,
I) the engine can be started, but it stays in low idling, or
2) it will not stop after it is started.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
CC3M.e Remedy
2 YES
Defective engine throttle con- Replace
Is
resistan- be- _ troller
ween em7 m OT
Y . EOl (femaleB, or
1 between each pin
and chassis as
Is resistance be- shown in Table l? Defective wiring harness in
Repair or
tween each pin of system with defective resis-
NO tance replace
E05 (male), or be- - Turn starting
tw~en each pin and switch OFF.
chassis as shown in
Table l? I * Disconnect E01.
202CK06503
20-I 13
E-4 [E3:181 Abnormalitv (short circuit) in governor motor drive system is
displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the abnormality occurs during operation, because of the force of the spring,
1) the engine will run at low idling
2) the engine will not stop
* If the problem occurs when the engine is stopped,
1) the engine can be started, but it stays in low idling, or
2) it will not stop after it is started.
A Stop the engine (push the fuel control lever of the fuel injection pump to the NO INJECTION
before checking.
position)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
CaUSe Remedy
2 YES
Defective engine throttle con- Replace
Is resistance be-
tween each in of troller
ES EOl (female P, or _
between each pin
and chassis BS
shown in Table l? Defective wiring harness in
Repair or
system with defective resis-
* Turn starting NO replace
w
tance
tween each pin and switch OFF.
chassis as shown in
- Disconnect EOl.
* Turn starting L R
0
switch OFF. Defective governor motor Replace
NO
* Disconnect E05.
202CK06503
20-I 14
E-5 [E3:01] Abnormality in network reception system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned ON when there is a disconnection in the wiring harness between the
monitor panel and the controller, or the positive end (+) of the network wiring harness or the inside
of the controller are short circuited, the controller cannot carry out networking, so the monitor panel
does not display any abnormality.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
* Turn starting
Is connection of 4 YES
- pump controller - Defective pump controller Replace
switch OFF. NO displayed?
* Disconnect Is voltage between
connector, then ; co3 (7) - (15). _
connect connector (8) - (15) nor-
* Turn starting
again. ~ mal? Defective contact, or discon-
switch ON. Repair or
- Turn starting * Set to monitor- Does LED of
nection in network wiring
replace
switch ON. NC harness
ing code 08. - pump controller - . Turn starting
NO light up or flash? switch ON.
- 4-8V
Is there continuity
* Turn starting between PO2 (fe- _
switch OFF. male) (7). (8) and 3 YES
. Disconnect N& GND? Controller which has been 3eplac.e
connect connectors re- connected is defective
connector, then moved in Item 2 one at
connect connector - Turn starting _ B time. Is there conti- _
again. switch OFF. NO nuity between PO2 (fee-
. Turn starting * Disconnect P02, male) (7). (8) and
switch ON and GND?
C03. and EOl. Defective monitor panel
delete service - Shake wiring NO
* Turn starting
harness around switch OFF.
controller when . Shake wiring
checking for harness around
continuity. controller when
checking for
continuity.
* Connect PO2 last.
20-I 15
Monitoring display (Time display portion)
/-/ /-/ - 0 0 0
Lr 13 - 0 0 (1)
Pump controller
connected display
Engine throttle controller
connected display
Monitor
PO2(04016) EOl (MIC21)
Network circuit
202CK06504
202FO6392
20-116
E-6 [E3:05] Abnormality in model code is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
ES
Defective engine throttle con- Replace
troller
1
Is engine throttle
controller monitor-
2 YES1
Is resistance be-
- Turn starting tween EOl (female)
switch ON. ($$&9;b19 -
- Set to monitor- F Defective model selection con-
$g code 03 and shown in Table 2? nector, or short circuit, defec- Repair or
NO tive contact, or disconnection replace
. Turn starting in applicable wiring harness
switch OFF.
* Disconnect EOl.
___. :ON
_^ Table 1 Monitoring display (Time displayportion) .i-JFF Table 2 Resistance value
0Cd,_J cd
c-> c-_ c-w Between EOl
pNyle) (8) and Min. 1 MC2
PC100
36 0T~l c-v
l,_J
c-_
Ib-d
Max. 1 Q
Between EOI
--- Ld
0L-J 7 r-1
__d (female) (18)
and GND
Min. 1 MCI Min. 1 MD
PC120
36 0I:::1
r;1 Between EOI
(female) (9) and Min. 1 MR Min. 1 MR
GND
Between EOI
(female) (19) Min. 1 MR Min. 1 MD
and GND
E-6 Related electric circuit diagram
20-I 17
E-7 [E3:06] Abnormality in governor potentiometer system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
CatJSt! Remedy
2 YES
1 , Defective engine throttle con- Replace
Is resstancebetween
each pin of EOl (fee-
troller
YES _ male) (5) (16) (17). or
1 between each pin and
chassis as shown in
Is resistance be- Table l? Defective wiring harness in
system with defective resis- Repair or
tween E04 (male) replace
(1) - (2).(2) - - Turn starting NO tance
(3) as shown in switch OFF.
Table l? - Disconnect EOl.
- Turn starting
Defective governor motor
switch OFF. Replace
- Disconnect E04.
Note: If E3:08 also occurs at the same time, check the wiring harness be W.
l Wiring harness between EOI (female) (5) - X07 (6) - E06 (female) (I) short circuiting with
ground, or contact with other wiring harness
Table 1
Fllel
control dial
20-I 18
E-8 [E3:071 Abnormality in pump controller throttle system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
A Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position)
-
before checking.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Note: This only occurs when the engine is stopped and the starting switch is turned OFF.
Cause Remedy
YES
Defective engine throttle con- Replace
troller
2 YES
chassis normal? Defective battery relay Replace
Is resistant betwen
EOl (female) (13) and
* Approx. 1000 _ battery relay terminal _
. Turn starting ~0 BR, and between wir- 1) Contact between other
switch OFF. mg harness and chassis wiring harness and wiring
normal?
* Disconnect EOl. harness between EOl Repair or
. Between E01 NO (female) (13) - HO2 (9) -
(female) (13) and battery relay BR
battery relay 2) When light is connected
BR:Max. 10
. Between wiring
harness and
chassis:Min. 1M R
* Turn starting
switch OFF.
* Disconnect EOl
X07(MIC17)
Fuse
M D13
L t
202CK06505
20-I 19
E-10 [E3:16] Abnormality (step-out) in governor motor system is
displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If any other service code [E3:011 - [E3:181 has occurred at the same time, start troubleshooting from
that code.
* Check that fuse 2 is normal.
* Read the precautions given in TESTING AND ADJUSTING, Adjusting stroke of governor motor lever
before carrying out the troubleshooting.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
: Always connect any disconnected connectors before going on the next step.
Cause Remedy
ES -
Go to applicable failure mode
1 I YES I
Defective engine throttle con- Replace
troller
Are E3:06, E3:17, 3
and E3:16 dis-
played? operate fuel con-
trol dial MIN -
YES MAX andturn _
starting switch
- Turn starting ;:rQ,,l; operation
switch ON. 4 YES
1) Defective linkage Adjust or
_ 2- - Turn starting 2) Defective injection pump replace
Is there any twist-
switch ON. _ ing when spring _
* Turn auto decel- NO lod,is moved to in-
NO Is adjustment of _ eration OFF.
JeCtlOn pump end?
linkage normal?
Defective governor motor Replace
- Disconnect E05. NO
- Turn starting * Disconnect linkage
switch ON. at governor motor
- Turn auto- nor motor at end. Adjust (For
deceleration OFF. FULL.) $e;$sse&
Defective adjustment of link-
* Set to governor NO
motor adjustment age AND AD-
mode. JUSTING)
20-120
E-II Engine does not start
4 YES
Is voltage between
YES starting motor _
terminal B and
chassis normal?
3
* Turn starting NO
Y ES Is there sound of switch ON.
starting motor - * Approx. 24V
pinion engaging?
5 YES
* Turn starting Is voltage between
switch START. _ starting switch _
NO terminal C and
chassis normal?
* Turn starting NO
switch START.
* Approx. 24V
9 YES
switch is turned 1. lr
Is there contmulty
YES bEtWwn chassis
heard from bat- B - ground end bat- -
;;y relay termmal
Is resistance of
* Turn starting switch wiring harness be- ~ -
ON -OFF. YES tween starting NO
7- switch BR and
battery relay BR
normal?
Is there continuity -
1 YES between starting _ - Between starting NO
switch terminal B switch BR and battery relay BR:Max. 1 Q
and BR? . Between wiring harness and chassis:
Is voltage and 6
specific gravity of Min. 1MQ
battery normal? * Turn starting . Disconnect both starting switch and bat-
switch ON. tery relay ends.
starting switch
* Remove terminal
* Min. 24V B. NO
* Specific
gravity:Min. 1.26
-1
. Connect (-) end
of tester to bat-
tery terminal c-j. INo
.20-29v
NO
1
X07 (MIC17)
Q4
Startingmotor
Startingswitch
!z
B
Batteryrelay
D13
202CKO6506
20-122
CEUW Remedy
20-123
E-12 Engine speed is irregular
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
YES
2 4 YES
When linkage be-
tween governor
YES YES_ motor and pump is
- Is E3:Ol displayed? - adjusted, does con-
&&p? become nor-
Is voltage between
* Turn starting - ~01 (7) and (16) - *At low idling
switch ON.
ND normal and stable?
* Set to monitoring ,FN
code 03.
- At low idling:
4.0-4.7511
NO
Table 1
Engine throttle
controller model code
PC100
PC120
20-124
Remedy
see E-7
See E-2
See E-6
202CK06507
20-125
b) There is hunting
Y ES
Is E3:Ol displayed?
* See TESTING NO
- Turn starting AND ADJUST-
switch ON.
YES
Deceleration signal
I
YES Is voltage between
- E01 (4) and (12) -
* Turn starting Potentiometer 6( normal and stable?
switch ON.
- Turn fuel control Is voltage between ~
dial from MIN to yEs E01 (17) and (16) _ *At deceleration: _
MAX and stop as shown in Table Max. 1V NO
also at midway Fuel control dial 2 and is it stable? * When cancelled:
5
1
* Turn starting position. 8-12V
switch ON.
* Set to monitoring Is voltage between
code 03. EOl (7) and (16)
I
normal and stable? NO
I
* At low idling:
4.0-4.75v
-At MAX:
0.25v - 1.ov NO sf
St
NO
Table 1 Table 2 W)
Engine throttle Condition when measuring PC100 PC120
3
controller model code
At low idling 2.8 - 3.2 2.9 - 3.3
3 At high idling 0.5 - 0.9 0.5 - 0.9
PC100
20-126
I CEWe
I Remedy
Is voltage between
- EOl (6) and (12) -
normal and stable? Defective contact of wiring
harness between startin
1 Repair or
switch ACC - X07 (17 B -
replace
* During operation: ND EOl (female) (6). or defective
20-30V starting switch
See E-2 -
See E-6 -
Starting
switch X07(MICl?) Fuse
14
w
Engine throttle ContrOller
EOl(MIC21) X07(MIC17) E06(M3)
switch ON
Fuel control dial
H02(S16) E04(X3)
Throttle
power (-1
CO3(040-16)
I I I
Auto-
deceleration 8
G N 0 Q
20-I 27
E-13 Lack of output (engine high idling speed is too low)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
ES
Is E3:Ol displayed?
* Turn starting
switch ON.
YI
pump governor Potentiometer 6
I
FULL stopper?
Is voltage between
YES ~01 (17) and (16) _
. Start engine. as shown in Table
* Set fuel control Fuel control dial 5 2 and is it stable?
dial to MAX.
* l-l/O mode.
YES Is voltage between
Is engine throttle EOl (7) and (16) -
controller model normal and stable? r
code as shown in
1
* At low idling:
. Turn starting Is adjustment of 4.0-4.75v
switch ON. . At MAX:
0.25V - 1.OV NO
* Set to monitoring
code 03.
9 YES
- See TESTING NO
AND ADJUST-
ING.
Table 1 Table 2 W)
Engine throttle Condition when measuring PC100 PC1 20
controller model code At low idling 2.8 - 3.2 2.9 - 3.3
PC1 00 s 3 0 IUU
o
inn
At high idling 0.5 - 0.9 0.5 - 0.9
PC120
20-I 28
Remedy
:iseeEM5 -
* At deceleration: I SeeC-15 -
Max. 1V NO
- When cancelled:
8-12V
See E-7 -
See S mode -
see E-6 -
Starting
switch X07(MIC17) Fuse
i
Governor potentic
CO3(040-16)
Auto-
deceleration @.
GND Q
20-I 29
E-14 Engine does not stop
A Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position)
before checking.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
: Always connect any disconnected connectors before going on the next step.
* Read the precautions given in TESTING AND ADJUSTING, Adjusting stroke of governor motor lever
before carrying out the troubleshooting.
ES
YES
Does governor
YES; lever contact STOP I
NO
NO
Table 1
Engine throttle
controller model code
PC100
PC120
Table 2
When ON
1
To battery relay (BR)
OFF
(Note) Voltage output from controller when starting switch is OFF
----
I WhenON
Condition of actuation
~L(Approx. 24v) =,b4 To/ttery relay tBR1
of controller circuit
(EOl(13))
Drive time - Ma;. 7 sec. (when it is impossible to set to NO INJECTION
because of failure in motor)
Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is
always flowing from starting switch BR, so if the voltage is measured at EOI (13), there is a volt-
age of 20 - 30V.
20-130
Call.9 Remedy
See E-7 -
S%e E-6
Feedback signal
Throttle power
*ource (4
20-131
E-15 Defective operation of battery relay system (engine does not stop)
Note: This only occurs when the engine is stopped and the starting switch is turned OFF.
A Stop the engine (push the fuel control lever of the fuel injection pump to the NO INJECTION position)
before checking.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
CaWZ Remedy
YES
See E-9
YES
Is E3:15 displayed? - Defective engine throttle con-
Relay drive signal 2 troller
Is display of moni-
* Turn starting - toring code 35 as -
switch ON. NO shown in Table l?
3 YES
Defective battery relay Replace
.IS
- tween EOl (female)
(13) and battery
. Turn starting - relay Bq, and be- -
switch OFF. NO tween wiring ear- 1) Disconnection in wiring
.20-30V ness and chassis harness between E01
normal? Repair or
(female) (13) - HO2 (9) -
replace
. Between EOl NO battery relay BR
(female) (13) and 2) When light is connected
batterv relav BR:
Max. in I
- Between wiring harness and chassis:
Min. 1MO
*Turn starting switch OFF.
. Disconnect E01 and battery relay BR.
Table 1 When UN
Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 3OV is
always flowing from starting switch BR, so if the voltage is measured at EOI (131, there is a volt-
age of 20 - 30V.
X07 (MlC17)
Battery relay
202CK06505
20-132
TROUBLESHOOTING OF ENGINE THROTTLE l
PUMP CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
PCIOO-6 Serial No. : 41230 and up
PC120-6 Serial No. : 49821 and up 1
20-132-l
0
POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE THROlTLE
l PUMP CONTROLLER SYSTEM
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting
flow chart for the mechanical system or electrical system.
For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.
20-132-2
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
20-132-4
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. If during operation
1) Set to low idling
2) Engine does not stop
3) There are cases of hunting
2. When stopped
Sets motor drive current to 0 1) Engine starts, but stays at Ion
idling
2) Engine does not stop after start.
ing
3) There are cases of hunting
20-132-5
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
Abnormality (short cir- If excess current flows between CO3 (I) and battery relay
- E315 cuit) in battery relay out- * This occurs only when turning starting switch to OFF and
put system stopping engine
Abnormality (step-out)
- E316 2. Abnormality in engine throttle motor
in motor
20-132-6
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. Precision of engine speed control
may be reduced.
For example:
co3 E04 Resistance 1) Engine does not rise to high
(female) (male) value idling speed (a little too low)
2) Engine does not go down to
(7) - (14) (I) - (2) 0.25 - 7kQ low idling speed (a little too
Calculates position of motor
(7) - (17) (2) - (3) 0.25 - 7kQ high)
and carries out control from
(14) - (17) - 2 - 3kQ 3) Defective engine speed for auto-
value of voltage immediately
deceleration or automatic
(1) - (3) 4 - 6kQ before abnormality occurred warming-up
Between 4) Engine may not stop
each pin - Min. 1 MR Sr The governor motor moves
and chassis in the direction to stop the
engine, but the motor may
not move completely to the
position to stop the engine.
5) There are cases of hunting
2. Must move lightly when connector * Starts again trepeats Engine speed cannot be controlled
step-out)
is removed (particularly at high idling), so there
2. In some cases it may not
display when returning is hunting
from partial speed to low
3. Normal
idling
20-132-7
0
JUDGEMENT TABLE FOR ENGINE THROTTLE. PUMP CONTROLLER
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
Failure mode
20 Engine speed does not change even when working mode is switched
.roubleshooting code when service code is displayed E-l E-2 E-3 E-4 E-5 E-6 E-i
20-132-8
0
JUDGEMENT TABLE FOR ENGINE THROl-l-LE . PUMP CONTROLLER
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED PARTS
Machine
Checking monitoring, monitor
check items wck item
E
a
b
i;
E
r
m
lz
t
5
-
Monitoring code
-
_
-
-
-
E-9A), S-5
-
E-9A), S-5
-
E-10, S-6
-
E-3. E-4
-
E-II
-
E-3 E-4
-
s-7
-
S-8
-
s-9
-
-
-
-
-
0 s-14
-
s-15
-
+ - S-16
E-3 E-4
-
_
_
-
E-8
20-132-9
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
Fuel control
(M3)
L
C02(MIC21) ~
I-4
I i 1 I I I
I
n
I 7
I
x x 8
0
/ IO
1 I1
I--
I /
BKP00355
20-132-10
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR E MODE SYSTEM
L_----2
D13(KES
I 0 85 Gr
2 0:*5iR,:;
I i
3
8
n
x x
II s(-)
-LL II
Fuse box
BattervreIa,/ k! II H15(L2)
I 10A 2w
-
Battery
I
BKP00356
20-132-11
0
TROUBLESHOOTING E-l
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
Check that fuse 1 is not blown.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-8.)
Cause Remedy
04 O-
2
20-l 32-12
0
TROUBLESHOOTING E-2
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
* If E306 also occurs at the same time, check the wiring harness below.
. Wiring harness between CO3 (female) (7) - E04 (female) (I) short circuiting with ground, or
contact with other wiring harness
Table 1
co3 E04 I Resistance
(female) (male) value
(7) - (4) (1) - (2) 0.25 - 7kQ
(4) - (17) (2) - (3) 0.25 - 7kQ
(7) - (17) - 2 - 3kQ
(I) - (3) 4 - 6kQ
Between each
pin and - Min. 1 MQ
chassis
CO3(04020)
Fuel control
Throttle @ dial
command
Governor
potentiometer
Feedback
BKP00097
20-l 32-l 3
0
TROUBLESHOOTING E-3
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
During operation, if there is
1) a simultaneous disconnection in A phase and B phase:
1) the engine will run at low idling
2) the engine will not stop
2) a disconnection in either A phase or B phase, the engine speed will remain the same as before
the abnormality occurred
If the problem occurs when the engine is stopped,
I) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
Check with the engine stopped (push the fuel control lever of the fuel iniection oumo . . to the NO
INJECTION position).
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Remedy
Table 1
E05 co2 I Resistance I
(male) (female) value
(1) - (2) (2) - (3) 2.5 - 7.5kQ
(3) - (4) (4) - (5) 2.5 - 7.5kR
BKP00099
20-l 32-14
0
TROUBLESHOOTING E-4
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
* If the abnormality occurs during operation, because of the force of the spring,
I) the engine will run at low idling
2) the engine will not stop
* If the problem occurs when the engine is stopped,
I) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO
INJECTION position).
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
Table 1
I E05 co2 ) Resistance 1
(male) (female) value
(I) - (2) (2) - (3) 2.5 - 7.5kQ
(3) - (4) (4) - (5) 2.5 - 7.5kQ
(l)-(3) (2) - (4) Min. 1 MQ
(11 - (4) (2) - (5) Min. 1 MQ
Between chassis Between chassis
and pins and pins Min. 1 MCI
(l)(2)(3)(4) (2)(3)(4)(5)
BKP00098
20-l 32-l 5
0
TROUBLESHOOTING E-5
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
Ir If E308 also occurs at the same time, check the wiring harness below.
. Wiring harness between CO3 (female) (7) - X07 (6) - E06 (female) (I) short circuiting with
ground, or contact with other wiring harness
Table 1
co3 E04 I Resistance I
(female) (male) value
(7) - (4) (I) - (2) 0.25 - 7kQ
(14) - (17) (2) - (3) 0.25 - 7kQ
(7) - (17) - 2 - 3kQ
(I) - (3) 4 - 6kQ
Between each
pin and Min. 1 MR
chassis
CO3(04020)
3
Fuel control
Throttle @ 3 dial
command 3
E04(X3)
Throttle power 7 I
source (+I Governor
Feedback @ potentiometer
r I
Throttle power
source (-1
BKP00097
20-l 32-16
0
TROUBLESHOOTING E-6
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO
INJECTION position).
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
This only occurs when the engine is stopped and the starting switch is turned OFF.
Cause Remedy
I) Contact between
other wiring harness
and wiring harness
Replace
loon - Between CO1 NO between CO1 (female)
*Turn starting (female) (1) and (lkbattery relay BR.
switch OFF. battery relay BR: 2) When light is
- Disconnect COI. MaxlR connected
- Beetween wiring
harness and
chassis: Min. 1 MR.
-Turn starting switch
OFF.
- Disconnect CO1 and
battery relay BR.
Battery relay
Engine throttle - pump
controller
COl(MIC13)
I \ I
CO3(04020)
BKP00201
20-l 32-l 7
0
TROUBLESHOOTING E-7
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the service code E is not displayed, the problem has been removed.
If any other service code [E3061- IE3181 has occurred at the same time, start troubleshooting from
the code except code[E3161.
Check that the fuse is normal.
Read the precautions given in TESTING AND ADJUSTING, Adjusting travel of governor motor
lever before carrying out the troubleshooting.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
Go to applicable failure -
mode
1
tuu;~starting switch
4 YE: 1) Defective linkage Adjust or
Is operation 2) Defective injection
normal? Is there any replace
- Turn starting scuffing when pump
- Turn starting - spring rod is
switch ON. i switch ON. NO moved to injection
* Turn auto pump end? Defective governor
Is adjustment of deceleration OFF. * Disconnect E05 NC motor
* Disconnect
linkage at
- Turn starting governor motor
switch ON. end.
- Turn auto- Adjust (For
Defective governor details, see
deceleration OFf
linkage TESTING AND
- Set to governor hIO
motor ADJUSTING)
adjustment
mode.
- See TESTING
AND
ADJUSTING.
20-l 32-l 8
0
TROUBLESHOOTING E-8
II
Is
YE
terminal 6 and
chassis normal?
1
*Turn starting NO
there sound of switch ON.
YES
starting motor - Approx. 24V
pinion engaging?
Is voltage between
starting switch _
h terminal C and
chassis normal?
* Turn starting NO
1
switch to START.
2 I - Approx. 24V
When starting 9YES
switch is turned -I--
~OFF. is sound there continuity
Is
~;;$from battery YES between chassis
8 ground and battery
- Turn starting Is resistance of - relay terminal E?
switch ON+OFF wiring harness
YES_ between starting _ NO
switch BR and
7 battery relay BR
- normal?
YES Is there continuity * Between starting
- between starhng - switch BRand battery NO
switch terminal B relay BR:Max. 1 R
6 and BR?
specific gravity of *Between wiring harness and chassis:Min. 1MP
Is voltage of - Disconnect both starting switch and battery relay ends.
battery noromal? . Turn starting
starting switch
- switch ON.
NO terminal B NO
*Min. 24V * Remove
normal?
* Specific gravity: terminal B.
Min. 1.26 * Connect H end
of tester to
battery terminal NO
t-1.
*20-29v
NO
M2(X2) E08(SWP14)
I I
20-132-20
0
TROUBLESHOOTING E-8
Cause Remedy
20-132-21
0
TROUBLESHOOTING E-9
-Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
4 YES
2 when lmkaae II
1between a&ernor 11
YE
* See TESTING NO
* Turn starting AND
switch ON. ADJUSTING.
Starting motor signal YES
disconnected and Is voltage between
motor lever is
YES ~03 (8) and
placed at position
Potentiometer 6 chassis normal
1 engine low idling?
Is voltage and stable?
Is controller -Turn starting c
YE between CO3 (14) _ * During operation NO
model code as switch ON.
and (17) normal :20-30V
shown in Table Fuel control dial 5
and stable?
1I?
-Turn starting *At MIN: 2.9-3.3V
between CO3 (4)
switch ON. NO
and (17) normal
. Set to monitoring
code 03 or 02.
. At MIN
: 4.0 - 4.7511
IO
NO
Table 1
PC100 PC120
BKP00357 BKP00358
20- 132-22
0
TROUBLESHOOTING E-9
Cause Remedy
t--
See N mode
c
Defective injection pump See S mode
Defective governor
motor
Defective contact of
wiring harness between Repair or
starting switch ACC-X07 replace
(17)-CO3 (fernal) (8). or
defective starting switch
See E-5
See E-2 -
See C-14
Throttle command
I ! I
BKP00203
20-132-23
0
TROUBLESHOOTING E-9
b) There is hunting
YES
4 YES
2 When lhnkage
between governor
YE motor and pump is
YI Is E218 adjusted, does
displayed? condition become
normal?
NO
. Turn starting
switch ON.
I Starting motor signal 7 YES
L
I
1 I
motor lever is
matched with fuel
NO control dial, does
Potentiometer
Table 1
Controller model code
PC100 PC120
I BKP00357 I BKP00358 I
20-132-24
TROUBLESHOOTING E-9
I Cause Remedy
See N mode -
Defective contact of
wiring harness between
Repair or
starting switch ACC -
replace
X07 (17) - CO3 (female)
(8). or defective starting
switch
See E-5
See E-2 -
See C-14
Throttle command
Fuel control
dial
E04IX3)
L
BKP00203
20-132-25
0
TROUBLESHOOTING E-10
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Y ES
r
* Turn starting
YES
switch ON.
Potentiometer 6
Is voltage
* Start engine.
I Is voltage
* Set fuel control
dial to MAX.
* H/O mode.
model code as
shown in Table . *AtMIN
Is adjustment of
: 4.0 - 4.75V
linkage between NO
_ *AtMAX
NO governor motor
. Turn starting : 0.25 - 1.OV
switch ON. and pump
normal? 8 YES
- Set to monitoring
code 03 or 02. When linkage
between governor
_ motor and pump is _
NO adjusted, does
condition become
normal?
* See TESTING NO
AND
ADJUSTING.
Table 1
PC100 PC120
I
1 BKP00357 BKP00358
20- 132-26
0
TROUBLESHOOTING E-10
I=
Cause Remedy
See N mode -
Starting motor
signal 7 YES
Defective governor qeplace
Is voltage motor
between CO3 (8)
Defective contact of
and chassis
wiring harness between ?epair or
normal and
starting switch ACC - .eplace
stable?
- NO X07 (17) - CO3 (female)
. During
(8), or defective starting -
operation: 20 -
switch
3ov
See E-5 -
See E-2 -
Defective adjustment of
Adjust
governor motor linkage
See S mode
I
E-10 Related electric circuit diagram
zz:dig XO7(MICl7)
SeeC-14
H14(M6) FUSe
14
1
o)- 5
o)-""-
Engine throttle, pump controller
CO3(04020) X07( MIC17) E06(M3)
Throttle POW
Governor
Feedback potentio-
meter
I I I I I
EKP00203
20-132-27
0
TROUBLESHOOTING E-l 1
Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO
INJECTION position).
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* Read the precautions given in TESTING AND ADJUSTING, Adjusting travel of governor motor
lever before carrying out the troubleshooting.
YES
YES
3 Potentiometer 6YES
Trun starting
-Whenlinkage is When starting
switch ON+ OFF.
adjusted. does YES switch is OFF, is
condition become _ Relay drive signal 6 - Voltage bwfween -
NO normal? p CO3 (14) and (17)
* Does loose spring When starting
normal?
1 move freely? YES switch is OFF, does p -
_ Voltage bwtween _ * When engine is NO
Is controller - Starting motor
. See TESTING CO1 (1) and (6) (12) stopped
model code as signal 4
AND - change as shown in . 2.9-3.3v
shown in Table When statmg
ADJUSTING. Table2 ?
l? I switch is OFF, is
L voltage between - . 20 - 30V NO
. Turn starting NO Co3 (8) and
switch ON. chassis normal?
. Set to . Max. IV
monitoring code
03 or 02. NO
NO
Table 1
PC100 PC120
BKP00357 BKP00358
Table 2
OFF
See Note 1 Voltage output from controller when starting switch is OFF
Condition of actuation
of controller circuit
co1 (1)
Drive time Max. 7sec. (when it is impossible to set to
NO IINJECTION because of failure in motor)
BKP00206
Note 1: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is
always flowing from starting switch BR, so if the voltage is measured at CO1 (I), there is a
voltage of 20 - 30V.
20- 132-28
TROUBLESHOOTING E-II
I Cause Remedy
See E-5
Feedback
BKP00207
20-132-29
0
TROUBLESHOOTING E-12
Ir This only occurs when the engine is stopped and the starting switch is turned OFF.
Check with the engine stopped (push the fuel control lever of the fuel iniection .pump. to the NO
INJECTION position).
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
See E-6 -
I)Disconnection in wiring
harness between CO1
(female) (I) - battery Replace
relay BR
normal? !)When light is connectec
I
* Between CO1 (female) (1) and
battery relay BR: Max. 1 S2
* Between wiring harness and
chassis: Max. 1 MR
* Turn starting switch OFF.
* Disconnect CO1 and battery relay
BR.
Table 1
OFF
See Note 1 Voltage output from controller when starting switch is OFF
.________
When ON
(Approx. 24V)
Condition of actuation
of controller circuit OFF[ 1~ Mi. 4,0zcyw relay BR
co1 (I)
Drive time Max. 7sec. (when it is impossible to set to
NO IINJECTION because.of failure in motor)
BKP00206
Note 1:When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is
always flowing from starting switch BR, so if the voltage is measured at CO1 (I), there is a
voltage of 20 - 30V.
20-132-30
0
TROUBLESHOOTING E-12
@ @
Starting
switch 02
QI @
BKPOOZOl
20-132-31
0
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
20-133
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the users level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under 0 in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of 0 that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20- 134
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-135
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-136
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Step 1
Step 2
Step 3
20-137
0
TROUBLESHOOTING S-l
_ .- _..___
-.. _
._.___.. . .._...s on fuel injection pump are out of alignment
Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
I) Little fuel comes out even when injection pump sleeve
20-l 38
0
TROUBLESHOOTING s-2
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
4 : Possible causes due to length of use (used for a long period)
0: Items to confirm the cause.
$ When starting switch is turned to START, pinion does not move out
.=
:: When starting switch is turned to ON, there is no clicking sound
al
6 Battery terminal is loose
terminal E
Found to be chipped
-
20- 139
0
TROUBLESHOOTING s-2
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
20-140
0
TROUBLESHOOTING s-2
Legena
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
20-141
0
TROUBLESHOOTING s-3
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
L 1: Possible causes due to length of use (used for a long period)
Items to confirm the cause.
r P
When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
I
0
I
a
0
1-1
I I.1
I I I I
I I I I I I
/ I
20- 142
0
TROUBLESHOOTING S-4
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Condition when
it is found to be abnormal
it is found to be abnormal
20-143
0
TROUBLESHOOTING s-5
Condition of hunting
to Operation Manual
improperly adjusted
F
._ When control rack is pushed, it is found to be heavy, or
ij
; does not return
4 When fuel cap is inspected directly, it is found to be clogged
Lo
z When feed pump strainer is inspected directly, it is found to
:
be clogged
found to be clogged
Remedy
20- 144
0
S-6
TROUBLESHOOTING
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
20-l 45
0
TROUBLESHOOTING s-7
20- 146
0
TROUBLESHOOTING S-8
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
0: Possible causes due to length of use (used for a long period)
items to confirm the cause.
T Confirm recent repair history
20-147
TROUBLESHOOTING s-9
Causes
Legend
0: Possible causes (judging from Questions and check items)
@: Most probable causes (judging from Questions and Check items)
a: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
be catching or broken
20-l 48
0
TROUBLESHOOTING S-IO
I Causes /
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
0: Possible causes due to length of use (used for a long period)
m : Items to confirm the cause.
Condition of fuel
20-l 49
0
TROUBLESHOOTING S-l 1
S-l 1 Oil is in cooling water, or water spurts back, or water level down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
20-150
0
TROUBLESHOOTING s-12
I Ambient temperature
Type of oil
-22
30 --A -A?l 32
0 50
10 68
20 30
86 104F
40C
--F T- Causes
Diesel fuel
I L
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items1
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Confirm recent repair history
2
.g Degree of use of machine Operated for long period n arm
5 When engine is first started, drops of water come from muffler 0
5
Exhaust smoke is white 0
There is oil in radiator cooling water 000
1 Leave radiator cap open. When engine is run at idling, an I I I-1 I I
abnormal number of bubbles appear, or water spurts back
20-152
0
TROUBLESHOOTING s-14
/-
tanks is excessive
tanks is slight
Remedy
20- 153
0
TROUBLESHOOTING s-15
Legend
0: Possible causes (judging from Questions and check items)
0: Most probable causes (judgingfrom Questions and Check items)
a: Possible causes due to length of use (used for a long period)
0: Items to confirm the cause.
20-154
0
TROUBLESHOOTING S-16
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
1 Confirm recentrepair history I I I I I I I I
Degree of use of machine Operated for long period nnn
Suddenly increased 0 0
Condition of vibration
Gradually increased 0.0 0
al
Vibration occurs at mid-range speed 00 11
I I
.Z
%
m
Vibration follows engine speed
Points to remember when carrying out troubleshooting of pump controller system ............................ 20 158
Action taken by controller when abnormality occurs and problems on machine .................................. 20-159
Judgement table for pump controller and hydraulic related parts .......................................................... 20-163
c-2 [E2:32] Short circuit in TVC solenoid system is displayed . .. . .. . .. ... . . .. .. . .. .. . .. . .. .. . .. . .. . .. .. .. . .. .. . . .. .. .. . 20-166
c-4 [E2:031 Short circuit in swing holding brake cancel solenoid system is displayed . . ... . .. . . .. .. . .. .. 20-170
c-5 [E2-131 Disconnection in swing holding brake cancel solenoid system is displayed .. . .. . . .. .. . .. . . 20-172
[E2:06] Short circuit in travel speed selector solenoid system is displayed . .. . .. . .. .. . .. .. . .. .._......_. 20-174
[E2:16] Disconnection in travel speed selector solenoid system is displayed . .. .._.._......._.._....... 20-176
c-9 [E2:18] Network response overtime error is displayed . . . ... . .. .. . .. . ..._............................................ 20-179
C-IO [E2:22] Short circuit in LS-EPC solenoid system is displayed ..................................................... 20-181
C-12 [E2:241 Abnormality in pump pressure sensor system is displayed .......................................... 20-183
C-13 [E2:26] Abnormality in pump pressure sensor power source is displayed.. .............................. 20-184
C-14 [E2:27] Abnormality in speed sensor power source system is displayed .................................. 20-185
20-157
0
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP
CONTROLLER SYSTEM
Points to remember if abnormality returns to normal by itself
In the following cases, there is a high probability that the same problem will occur again, so it is desir-
able to follow up this problem carefully.
1) If any abnormality returns to normal by itself,
2) If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and
the connector is returned to its original position when carrying out troubleshooting of the failure,
and the service code is no longer displayed, or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the service code from memory.
8
8
8
20-158
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
1. Defective TVC solenoid system. Resistance of solenoid: Makes current to solenoid 0 1. No current flows to the TVC
2. Defective TVC solenoid system or wiring harness IO-22 R Displays E:02 on monitor panel solenoid, therefore when the
between controller N-001 (16) and TVC solenoide Cl3 Resets power source to restore load is large, there is a big
E2 . 32 Short circuit in TVC (1) short circuitting with chassis ground. drop in the engine speed
solenoid system 3. Abnormality in pump controller which may result in the engine
stalling.
io2 1. Disconnection inside TVC solenoid or disconnection in Resistance of solenoid: 1. In the case of 1, the current stops flowing to the 1. In the case of 1, it is the same
wiring harness between controller CO1 (8), (16) and IO-22 R solenoid, so no particular action is taken. as E2:32.
TVC solenoid Cl3 (I), (2) Current: 1000 mA Therefore, if the abnormality is restored by the vibra- 2. In the case of 2, the current
2. Wiring harness between controller CO1 (8) and TVC (H/O mode, auto-deceleration tion of the machine, the condition will return to nor- continues to flow to the TVC
E2. 33 Disconnection in TVC solenoid Cl3 (2) short circuiting with ground ON, levers at neutral, fuel control mal. solenoid (approx. 1 A), so the
solenoid system 3. Abnormality in pump controller dial at MAX.) * However, the display does not go out. output pressure of the TVC
2. In the case of 2, the current (approx. 1 A) continues to valve increases and the overall
flow to the solenoid. speed becomes slower.
Displays E:02 on the monitor panel.
1. Short circuit inside solenoid or between solenoid (1) Resistance of solenoid: Makes current to solenoid 0 When the swing is operated, the
E2 . o3 Short circuit in swing and (2) (when internal resistance of solenoid is ex- 20 - 60 R Displays E:03 on monitor panel motor brake is not released, so
tremely low), and excess current is flowing. Resets power source to restore the upper structure does not
brake solenoid system
2. Abnormality in pump controller swing.
1. Short circuit inside solenoid (when internal resistance Resistance of solenoid: 1. In the case of 1 and 2, the current stops flowing to the 1. In the case of 1 and 2, it is the
of solenoid is extremely high) 20 - 60 R solenoid, so no particular action is taken. same as E2:03.
2. Disconnection in wiring harness between solenoid (2) Therefore, if the abnormality is restored by the vibra- 2. In the case of 3, the brake
and controller tion of the machine, the condition will return to nor- remains released, so even
3. Solenoid (2) short circuiting with ground mal. when the levers are returned
4. Abnormality in pump controller j, However, the display does not go out. to neutral, the brake does not
2. In the case of 3, the current stops flowing to the take effect (there is overrun of
solenoid, but the controller takes no particular action. the swing on slopes).
Therefore, if the abnormality is restored, the condition
IO3
will return to normal.
* However, the display does not go out.
E2. 13 Disconnection in swing * If the controller gives a signal to turn the solenoid
brake solenoid system current OFF, the voltage at portion (a) should be 20 -
30V. If there is a disconnection or short circuit with
the ground, the voltage at portion (a) is low (almost
OV), so it is judged that there is an abnormality.
Pump
controller
XL-
Solenoid
202FO6393
1. Short circuit inside solenoid or between solenoid (1) Resistance of solenoid: Makes current to solenoid 0 If swing or work equipment are
and (2) (when internal resistance of solenoid is ex- 20 - 60 R Resets power source to restore operated when traveling, there is
E2 . o1 Short circuit in LS tremely low), and excess current is flowing. a big drop in the travel speed.
bypass solenoid system 2. Abnormality in pump controller
I I
User Service Condition when normal Problem that appears on machine
Abnormal system Nature of abnormality Action by controller when abnormality is detected when there is abnormality
code code (voltage, current, resistance)
1. Short circuit inside solenoid or between solenoid (I) Resistance of solenoid: Makes current to solenoid 0 When traveling or using the
Short circuit in 2-stage and (2) (when internal resistance of solenoid is ex- 20 - 60 R Resets power source to restore power max. function, the relief
- E2 : 05 pressure is not raised, so there is
relief solenoid system tremely low), and excess current is flowing.
2. Abnormality in pump controller lack of power.
1. Short circuit inside solenoid or between solenoid (1) Resistance of solenoid: Makes current to solenoid 0 Travel speed does not change to
and (2) (when internal resistance of solenoid is ex- 20 - 60 R Resets power source to restore Hi
- Short circuit in travel
E2 : 06 tremely low), and excess current is flowing.
speed solenoid system
2. Abnormality in pump controller
1. Short circuit inside solenoid (when internal resistance Resistance of solenoid: 1. In the case of 1 and 2, the current stops flowing to the 1. In the case of 1 and 2, it is the
of solenoid is extremely high) 20 - 60 R solenoid, so no particular action is taken. same as E2:Ol.
2. Disconnection in wiring harness between solenoid (2) Therefore, if the abnormality is restored by the vibra- 2. In the case of 3, the current
and controller tion of the machine, the condition will return to nor- continues to flow to the LS
3. Solenoid (2) short circuiting with ground mal. bypass solenoid, so the LS
4. Abnormality in pump controller * However, the display does not go out. pressure drops and the overall
2. In the case of 3, the current continues to flow to the speed becomes slow.
solenoid, but the controller takes no particular action.
Therefore, if the abnormality is restored, the condition
will return to normal.
- E2 . 11 Disconnection in LS * However, the display does not go out.
bypass solenoid system * If the controller gives a command to turn the solenoid
current OFF, the voltage at portion (a) should be 20 -
30V. If there is a disconnection or short circuit with
the ground, the voltage at portion (a) is low (almost
OV), so it is judged that there is an abnormality.
Pump
controller
XL-
Solenoid
202FO6393
1. Short circuit inside solenoid (when internal resistance Resistance of solenoid: 1. In the case of 1 and 2, the current stops flowing to the 1. In the case of 1 and 2, it is the
of solenoid is extremely high) 20 - 60 R solenoid, so no particular action is taken. same as E2:05.
2. Disconnection in wiring harness between solenoid (2) Therefore, if the abnormality is restored by the vibra- 2. In the case of 3, it becomes the
and controller tion of the machine, the condition will return to nor- same condition as when the 2-
3. Solenoid (2) short circuiting with ground mal. stage relief is used, so the
4. Abnormality in pump controller * However, the display does not go out. relief pressure remains in-
2. In the case of 3, the current continues to flow to the creased (34.8 MPa (355 kg/
solenoid, but the controller takes no particular action. cm?). (The solenoid stays ON)
Therefore, if the abnormality is restored, the condition
will return to normal.
- E2 . 15 Disconnection in 2-stage * However, the display does not go out.
relief solenoid system j, If the controller gives a signal to turn the solenoid
current OFF, the voltage at portion (a) should be 20 -
30V. If there is a disconnection or short circuit with
the ground, the voltage at portion (a) is low (almost
OV), so it is judged that there is an abnormality.
Pump
controller
Solenoid
202FO6393
20-I 60
User Service Condition when normal Problem that appears on machine
Abnormal system Nature of abnormality Action by controller when abnormality is detected when there is abnormality
code code (voltage, current, resistance)
1. Short circuit inside solenoid (when internal resistance Resistance of solenoid: 1. In the case of 1 and 2, the current stops flowing to the 1. In the case of 1 and 2, it is the
of solenoid is extremely high) 20 - 60 S2 solenoid, so no particular action is taken. same as the E2:06 display.
2. Disconnection in wiring harness between solenoid (2) Therefore, if the abnormality is restored by the vibra- 2. In the case of 3, the solenoid
and controller tion of the machine, the condition will return to nor- remains actuated, so the Mi
3. Solenoid (2) short circuiting with ground mal. and Lo speeds are fast.
4. Abnormality in pump controller * However, the display does not go out.
2. In the case of 3, the current continues to flow to the
solenoid, but the controller takes no particular action.
Therefore, if the abnormality is restored, the condition
will return to normal.
- E2. 16 Disconnection in travel -k However, the display does not go out.
speed solenoid system * If the controller gives a signal to turn the solenoid
current OFF, the voltage at portion (a) should be 20 -
30V. If there is a disconnection or short circuit with
the ground, the voltage at portion (a) is low (almost
OV), so it is judged that there is an abnormality.
Pump
controller
XL-
Solenoid
202FO6393
1. Disconnection, short circuit in model selection wiring Detects abnormality in input 1. It selects the starting condition
harness I) Retains data when starting switch is ON for that model when it actu-
Model selection input 2. Abnormality in pump controller 2) Functions as PC100 when non-set conditions are input ates, so there is no particular
- change.
E2 I7 error
2. Functions as PC100
1. Disconnection, short circuit, short circuit with ground 1. PC100 1. When networking are impossible with the monitor and 1.
in network wiring harness Between CO2 (131, (141, (151, engine throttle controller (I) Even when travel is oper-
2: Abnormality in engine throttle controller (16) and chassis: Min. 1 MR (I) Working mode: G/O ated, the power does not
3. Abnormality in pump controller 2. PC120 (2) Travel speed: Lo increase
Between CO3 (13) and chassis: (3) Auto-deceleration: ON (2) The swift slow-down func-
Max. 1 R (4) Power max. : ON tion does not work
Between CO3 (141, (15), (16) 2. When networking are impossible with engine throttle (3) The auto-deceleration
E2. 18 Network response and chassis: Min. 1 MR controller cannot be canceled
-
overtime error Control is carried out by recognizing the throttle signal (4) The travel slow does not
as FULL (others are as usual) increase
2. The engine speed may drop
1. Short circuit inside solenoid or between solenoid (I) Resistance of solenoid: Makes current to solenoid 0 1. In F/O mode, the arm IN speed
and (2) (when internal resistance of solenoid is 7-149 Resets power source to restore is too fast.
extremely low), and excess current is flowing. 2. When the engine is running at
Short circuit in LS 2. Abnormality in pump controller low idling, the swing speed is
- E2 : 22 control EPC solenoid too fast.
system 3. The Mi and Lo travel speeds
are too fast.
20-161
cUser
code
Service
code Abnormal system Nature of abnormality
1. Abnormality in pump pressure sensor Takes pump pressure as 0 MPa (0 kg/cm21 when actuat- 1. The travel speed does not
2. Disconnection, short circuit in wiring harness between v ing. automatically shift (it does not
pressure sensor CO8 and controller CO3 If abnormality is restored, it actuates as normal. change from Hi or Mi to Lo).
3. Abnormality in pump controller j, However, the display does not go out. * If the button is operated
k manually, the panel display
P
205FO5350
is switched.
- Abnormality in pump
E2 : 24 1. Between CO3 (I 1and (9):
pressure sensor system
0.5 - 4.5 v
2. Resistance between CO3
(female) (I) and (9), (1) and
chassis: Min. 1 MR
(Disconnect connector CO8
and connector C3 end)
1. Defective pressure sensor 1. Voltage between CO3 (3) and Same as E2:24
2. Wiring harness between pressure sensor (2) and (9) and between CO3 (3) and Takes pump pressure as 0 MPa (0 kg/cm*) when actuat-
controller short circuiting with ground (IO): ing.
Abnormality in pump 18-28V When abnormality is detected, it switches the output
- E2 : 26 pressure sensor power OFF, and when all levers are returned to neutral, it
source system outputs again.
Sr This automatic resetting is repeated up to 3 times.
1. Disconnection, short circuit in engine speed sensor Resistance: 500 - 1000 Q It operates about the same as
2. Disconnection, short circuit in solenoid wiring harness Voltage (AC range) : 0.5 - 3.0 V 1. It functions as the equivalent of the G/O mode (the G/O mode (prolix) (the power is
between E7 and CO2 speed rises) slightly lower)
E2. 27 Abnormality in engine 3. Abnormality in pump controller 2. When the sensor is lost, such as when there is a
-
speed sensor system disconnection inside the engine speed sensor, moni-
toring code IO is not displayed.
1. Disconnection, short circuit in wiring harness of CO3 1. Voltage between CO3 (5) and It is controlled as usual (there
(5) and EOI (4) chassis When there is a short circuit, it stops the output, and may be a delay in response)
2. Abnormality in engine throttle controller At deceleration: 8 - 12 V restores by resetting the power.
Abnormality in auto- 3. Abnormality in pump controller When canceled: 0 - 1 V When there is a disconnection, it continues to move as it
- E2 : 28 deceleration output 2. Resistance between CO3 (5) is.
system and chassis: Min. 1 M R
20-162
JUDGEMENT TABLE FOR PUMP CONTROLLER AND HYDRAULIC RELATED PARTS Figure in 0 shows position of bit pattern
I I
D13CKESl 2)
H02tS16)
0.85ER
Prolix resistor
..
c--
I ,,,,-
Fuse box
Battery relay H06tL21 I
300 B_bW 5Wk 5w _ 1 1OA 2v
I.
I - FiJL2)
I I 1 Fusible I IIIIII I ! I I I I I ,I._LI__J Kero
I IIP4llll lwl I I
I
I
IIIIIII
IIIIIII
I I,,
1111IIIII
1, I,, , I
Monitor panel
er
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* Check that fuses 1 and 14 are not blown.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-l 1.)
Cause Remedy
YES
Defective pump controller Replace
1
Is voltage between
CO1 (lO)(ll) and - Defective contact, or discon-
(1) (2) normal?
2 YES section in wiring harness be- Repair or
tween fuse 1 and CO1 (fe- replace
male) (10) (11)
Is voltage between
. 20-30V - fuse 1 and GND -
- Turn starting ND normal? Defective contact, or discon-
switch ON. section in wiring harness be-
Repair or
tween fuse 1 - HO6 (2) -
replace
* 20-30V NO Ml4 (2)(l) - battery relay
* Turn starting terminal M
switch ON.
8
8
8
Ml4 (L2)
Pump controller
Controller power
Controller power
ZO2CK06509
20-I 65
C-2 [E2:32] Short circuit in TVC solenoid system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if E2:32 is displayed. (If it is not displayed, the problem has been removed.)
* Always turn the TVC prolix switch OFF.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
L-l
tween Cl3 (male) switch OFF. NO (male? (2) in contact with replace
NO $~~hh,s$Q~)
(1) and (2). (2) * Disconnect C05. oower source wiring harness
shown in Table l?
and chassis as
shown in Table l? - Turn starting Wring harness between Cl3
switch OFF. (female) (2) and CO5 (fe- Repair or
. Turn starting * Disconnect C05.
switch OFF. NO male) (4) in contact with replace
- Disconnect C13. power source wiring harness
Table 1
Measurement location
Resistance value
Troubleshooting 1 Troubleshooting 2 Troubleshooting 3
I I
Between Cl3 (male) (1) Between CO1 (female) Between CO5 (female)
IO-22 n
and (2) (16) and (8) (3) and (4)
Between Cl3 (male) (2) Between CO1 (female) K. Between CO5 (female)
Min. 1 R
and chassis (8) and chassis (4) and chassis
20-166
C-2 Related electric circuit diagram
Prolix resistor
mNC
valve
Cl3
(X2)
1
205CAO6503-1
20-167
C-3 [E2:33] Disconnection in TVC solenoid system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.
If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues
to flow to the solenoid.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if E2:33 is displayed. (If it is not displayed, the problem has been removed.)
* Always turn the NC prolix switch OFF.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* Check that fuse 1 is normal.
Cause Remedy
Y
Iefective pump controller qeplace
r
YE tween CO1 (female) YES :Ol (female) (8) and CO5 ?epair or
(16) and (8). (8) :fem&) ??j, 6; wring har- .eplaoe
and chassis as less between CO1 (female)
4
:8) and CO5 (female) (2)
short circuiting with ground
. Turn starting
switch OFF. tween CO5 (male)
defective TVC prolix switch,
. Disconnect COl. )r disconnection in wiring
and (4) as shown
larness between prolix switch
- co5 (1). (2). (3). (4). (5).
. Turn starting :9). or wlrlng harness be-
switch OFF. :ween TVC prolix switch (5)
Is resistance be- L Repair or
. Disconnect C05. NC snd CO5 (4). TVC prolix
tween CO5 (female) eeplace
Wtch (6) and CO5 (2). TVC
volix switch (11) and CO5
[9) short circuiting with
Jround
. Turn starting
* Turn starting Disconnection in wiring har-
switch OFF.
switch OFF. Tess between Cl3 (female)
- Disconnect C05.
* Disconnect C13. (1) and CO5 (female) (3). Repair or
:13 (female) (2) - CO5 (fe- replace
NO
male) (41, or wiring harness
Jetween Cl3 (female) (2)
snd CO5 (female) (4) short
:ircuiting with ground
20-168
Table 1
Measurement location I
Resistance value
Troubleshooting 1 Troubleshooting 2 Troubleshooting 3
Between Cl3 (male) (I) Between CO1 (female) Between CO5 (female)
IO-22 R
and (2) (16) and (8) (3) and (4)
Between Cl3 (male) (2) Between CO1 (female) Between CO5 (female)
Min. 1 Q
and chassis (8) and chassis (4) and chassis
Prolix resistor
n I I n
Cl3 (lJ@@@ QtJQ?J CO1
HO1
(MIC17)
(x2) (516) G T T T T
205CA06503.1
20-169
C-4 [E2:03] Short circuit in swing brake solenoid system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the swing,
and check if E2:03 is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
Cause Remedy
YES
3efective pump controller Replace
I
Is resistance be-
3,I
YES twsen CO1 (female)
- (lO)(ll) - (13). -
2 (13) - chassis as
shown in Table l?
Is resistance be-
YE2 tween V04 (male) _ . Turn starting
(1) and (2) as switch OFF. NO
> Go to A
~ shown in Table l? . Disconnect COl.
Interchange wiring ~ . Turn swing lock switch OFF.
with other sole- _ . Turn starting
noid. Is E2:03 dis- switch OFF.
played? * Disconnect V04.
Table 1
20-170
C-4 Related electric circuit diagram
Pump controller
l----w
Cl (iTJo
II
I
v4
Hl
H4
205CA06504
20-171
C-5 [E2:13] Disconnection in swing brake solenoid system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated.
If the No. 2 pin of the solenoid is short circuiting with the ground, the solenoid continues to be actu-
ated.
* If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the swing
lever slightly (not enough to move the swing), and check if E2:13 is displayed. (If it is not displayed,
the problem has been removed.)
* Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* Check that fuse 1 is normal.
Remedy
YES
Iefective pump controller ?eplaca
31
. Lever at neutral:
,Goto A
. Lever operated:
I
NO
switch OFF.
. Disconnect X05.
20-172
C-5 Related electric circuit diagram
Xl
Pump controller
Cl II
I
GND.
v4
I@.
Hl
Swing brake
solenoid I
205CA06504
20-173
C-6 [E2:01] Short circuit in LS bypass solenoid system is displayed
[E2:05] Short circuit in 2-stage relief solenoid system is displayed
[E2:06] Short circuit in travel speed solenoid system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if any service code is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause
Table 1
Measurement location
Service
code
Troubleshooting 2 Troubleshooting 3
;yr;y2y lmaie) 2. _ 60 C Between CO1 (female) (IO), (II) and (6) 20-6OR
E2 : 06
Between CO1 (female) (6) and chassis Min. 1 MC
20-174
C-6 Related electric circuit diagram
Pump controller
co1
(MIC17)
I I
VB*
-lY
- Z-stage relief
HO2
VI3 il (316)
2 -stage relief 1
1 DO6
t - Travelspeed
solenoid
5 2 - valve
-
HO4
VO6(X2)
(S16)
DO7
205CA06505.1
20-175
C-7 [E2:1 I] Disconnection in LS bypass solenoid system is displayed
[E2:15] Disconnection in 2-stage relief solenoid system is displayed
[E2:16] Disconnection in travel speed solenoid system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated.
If the No. 2 pin of the solenoid is short circuiting with the ground, the solenoid continues to be actu-
ated.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON, operate
according to Condition 2 in Table 1, and check if any service code is displayed. (If it is not displayed,
the problem has been removed.)
z* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Check that fuse 1 is normal.
Cause Remedy
A
I Table 1 normal? t-
Is resistance be- I I
YES tweeneach pin for _ * Turn starting switch ON.
1 troubleshooting 2 *When 0N:Max. 3V
~ in Table 1 normal? When OFF:ZO-30V
Interchange wiring . Operate according to
with other sole- Condition 1.
* Turn starting
noid. Is applicable -
switch OFF. NO
service code dis-
* Disconnect connec-
played?
tors Vol. V05, or
VO6,, whichever is lne of following solenoids is
* Interchange
apphcable. defective
wiring. V E2:11-..LS bypass solenoid Replace
* Turn starting
NO E2:15..2-stage relief solenoid
switch ON again.
EZ:lG...Travel speed solenoid
* Operate according
to Condition 2.
4 YES
Replace
II
Defective pump controller
H
YES Is applicable service
L
A code displayed?
* Turn starting N 0
YES switch ON.
A = * Operate according
to Condition 2.
Is resistance be-
Disconnection in applicable
_ tween each pin for . wiring harness between CO1
NO troubleshooting 4
(female) (lO),(ll) - CO1
m Table 1 normal?
(12). (14) or (6). or applica- Repair or
ble wirin harness between reolace
* Turn starting solenoid 9 2) - CO1 (female)
switch OFF. (12). (14) or (6) short cir-
- Disconnect COl. xiting with ground
20-176
Table 1
Measurement location 1
Service
code Troubleshooting 2
T Troubleshooting
t Lfoltage between
!ach pin
3
Condition 1
I-
1 T Condition 2
Between CO1
When ON:
(female) (IO) 20 - 60 R l Stan engine
Same as
Between Between (11) and (6) l Set travel speed switch to Hi
Condition 2
E2 : 16 V06 (male) 20-60 Q CO1 (female) (6)
When OFF:
l Turn fuel control dial to MAX.
(I) and (2) and chassis Between CO1 l Operate travel lever slightly
Travel levers (female) (6) Min. 1 MR (but do not move machine)
at neutral and chassis
Pump controller
co1
(MIC17)
III-
LS bypass
3 - LS bypass
solenoid
3 _ valve
VO2(X2)
ri t
VB
HO2
VB (S16) 5
I
2
I-
I DO6
L 8
FlEZ
-
HO4
VO6(X2)
(S16)
DO7
205CA06505-1
20-177
C-8 [E2:17] Model selection input error is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if E2:17 is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective pump controller RePlace
1 I 4
Between CO2
(female) (13) Min. 1 MD Max. 1 Q
and GND
Between CO2
(female) (14) Min. 1 MD Min. 1 MD
and GND
Between CO2
(female) (15) Min. 1 MD Min. 1 MD
and GND
Between CO2
C-8 Related electric circuit diagram (female) (16) Min. 1 MQ Min. 1 MD
and GND
-
Pump controller
PC120 PC100
202CK06516
20-178
C-9 [E2:18] Network response overtime error is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned ON when there is a disconnection in the wiring harness between the
monitor panel and the controller, or the positive end (+) of the network wiring harness or the inside of
the controller are short circuited, the controller cannot carry out networking, so the monitor panel
does not display any abnormality.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
: Always connect any disconnected connectors before going on the next step.
Cause Remedy
* Turn starting
. ._.
Defective engine throttle con- Replace
switch OFF. Is connection of
troller
. Disconnect con- engine throttle con- - Is voltage between
nector, then con- NO troller displayed? YES EOl (14) - (3). _
nect connector 3 (15) - (3) nor-
again. - mat? Defective contact, or discon-
Repair or
- Turn starting * Turn starting Does LED of en- nection in network wiring
replace
switch ON. switch ON. _ gine throttle con- _ . Turn starting N( harness
. Set to monitor- NO troller light up or switch ON.
ing code 08. flash? * 4-8V
- Turn starting
switch ON.
NOSeE-
When E2:18 and E3:Ol are displayed simultaneously
I Cause Remedy
goout?
- Is there continuity
* Turn starting _ between PO2 (fe- _
switch OFF. NO rm&(7). (8) and 3 YES
* Disconnect con-
Connect wnnecf0rs re-
Controller
connected
which has been
is defective
Replace
nector, then con- p moved in Item 2 one at
flect connector * Turn starting _ a time. Is there conti- _
again. switch OFF. NO nuity bef~Ben PO2 tfe-
* Turn starting * Disconnect P02, male) (7). (8) and
switch ON and GND?
C03, and EOl. Defective monitor panel
delete service * Shake wiring NO
. Turn starting
code. harness around switch OFF.
controller when . Shake wiring
checking for con- harness around
tlnuity. controller when
checking for con-
tinuity.
- Connect PO2 last.
20-179
Monitoring code display (Time display portion)
4 ,,;;s~~mtroller connected
Monitor
PO2 (04016) EOl (MIC21)
Network circuit
202CK06504
* Check for the LED display for the engine Engine throttle controller
.A-
throttle controller and pump controller from
the direction of the arrow as shown in the
diagram on the right.
202FO6392
20-180
C-IO [E2:221 Short circuit in LS control EPC solenoid system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if E2:22 is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
CfdEe Remedy
. Turn starting
switch OFF. Defective LS control EPC so- Replace
NO lenoid
. Disconnect ClO.
Table 1
COl(MIC21) HO1
LS control
EPC valve
202CK06510
20-181
C-II [E2:23] Disconnection in LS control EPC solenoid system is dis-
played
-k This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if E2:23 is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
CaW3 Remedy
2 YES
Defective pump controller Replace
Is resistance be-
YES tween CO1 (female)
- (15) - (7). (7) - - Disconnection in wiring har-
1 chassis as shown in ness between CO1 (female)
Table l? (15) and (7), or wiring har- Repair or
Is resistance be-
NO ness between CO1 (female) replace
tween Cl0 (male) _ . Turn starting
(7) and Cl0 (female) (2)
(1) - (2) as switch OFF. short circuiting with ground
shown in Table l? . Disconnect COl.
Table 1
Pump controller
CO1 (MIC21) HO1
LS control
EPC valve
202CK06510
20-182
C-12 [E2:24] Abnormality in pump pressure sensor system is displayed
* This troubleshooting, is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON, start the
engine, and check if E2:24 is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause
Table 1
I Measurement location 1
Troubleshooting 1 Troubleshooting 2 Troubleshooting 3 Troubleshooting 4 I
I---
Between CO3 Between CO3
(female) (I) and (9)
CO8 (3) 0.5-4.5v Min. IMQ CO8 (2) 18-28V Min. IMR
Between CO3 and (1) Between CO3
and (I)
(female) (I), (9) and (female) (3), (9) and
chassis chassis
Pump controller
CO3 (040- 16) HO1 (S16)
Pump
pressure
*ensIr
202CK06517
20-183
C-13 [E2:26] Abnormality in pump pressure sensor power source system
is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if E2:26 is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
j, Always connect any disconnected connectors before going on the next step.
CEN.9 Remedy
YES
Defective pump pressure sen- Replace
;or
Pump Controller
co3 (040-16) HO1 (S16)
Pump
senscr
202CK06517
20-184
C-14 [E2:27] Abnormality in engine speed sensor system is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if E2:27 is displayed. (If it is not displayed, the problem has been removed.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
: Always connect any disconnected connectors before going on the next step.
Cause Remedy
2 YES
Defective pump controller Replace
Is resistance be-
YES _ tween CO3 (female) _
1 (6) - (14) nor-
mal? Disconnection in wiring har-
ness between CO3 (female) Repair or
Is resistance be- NO (6).(14) - E07 (1). (2) or replace
tween E07 (male) * 500-1000 Q
* Turn starting short circuit with ground
(1) - (2) normal?
switch OFF.
. Disconnect C03.
. 500-1000 R
--I Defective engine speed sensor Replace
* Turn starting h
switch OFF.
* Disconnect E07.
Monitor
PumpController
co3 104016) HO3 (Sl6) E08 (SWPl4) E07 (X2)
_ Engine
speed
sen*or
202CK06511
20-185
C-15 [E2:28] Abnormality in auto-deceleration output system is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the service code is not displayed, the problem has been removed.
When the auto-deceleration switch is ON.
If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the control
lever (neutral - operated) with the auto-deceleration ON, and check if E2:28 is displayed.
(If it is not displayed, the problem has been removed.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause
YES
Defective pump controller Replace
1 I
Is voltage between
CO3 (5) and chassis _
as shown in Table 2
l?
When CO3 is dis-
connected, is volt-
- Turn starting - age between EOl -
switch ON. ND (44,;nd (12) nor- 3 YES
Defective engine throttle con- Replace
Is resistenm between troller
- CO3 (female) (5) and
- 8-12V _ EOl (female) (4). and _
* Turn starting NO betwean CO3 (female)
switch ON. (5) and chassis es Disconnection in wiring har-
shown in Table 2? ness between CO3 (female) Repair or
(5) and E01 (female) (4). or
. Turn starting short circuit with ground
switch OFF.
* Disconnect CO3
and EOl.
Table 1
Operation Voltage between CO3(female) (5) and chassis
Table 2
202CK06512
20-186
TROUBLESHOOTING OF ENGINE THROTTLE PUMP l
20-186-l
0
POINTS TO REMEMBER WHEN TROUBLESHOOTING
TROUBLESHOOTING PUMP CONTROLLER SYSTEM
20-186-2
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
E02
1. Disconnection, defective contact inside pump TVC solenoid
2. Disconnection, defective contact in wiring harness between
Disconnection in controller CO2 (8) and TVC solenoid Cl3 (1) ((+) side)
E233 pump TVC solenoid 3. Disconnection, defective contact, short circuit with ground
system in wiring harness between controller CO2 (18) and TVC
solenoid Cl3 (2) ((-1 side)
4. Defective engine throttle.pump controller
E03
1. Disconnection, defective contact inside swing holding brake
solenoid
2. Disconnection, defective contact, short cicuit with power
Disconnection in source in wiring harness between controller CO1 (3) and
E213 swing holding brake solenoid V04 (I) ((+I side)
solenoid system 3. Disconnection, defective contact in wiring harness between
solenoid V04 (2) and chassis ground ((-) side)
4. Defective engine throttle*pump controller
20- 186-4
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
20-186-5
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
20-186-7
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
- Network response
E218
overtime error
20-186-8
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
voltage, current, resistance) abnormality is detected when there is abnormality
Between Cl7 (61, (13) and Detects abnormality in input. 1. Engine stalls, or
chassis: Max. 1 !J 1. Maintains data when starting 2. All work equipment, swing,
Between Cl7 (51, (71, (14) switch is ON travel speeds are slow, or lack
and chassis: Min. IMR 2. Functions as PC100 if non-set power
conditions are input
20-186-9
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
20-186-10
0
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
[voltage, current, resistance) abnormality is detected when there is abnormality
Between CO3 (3) and (16): 1. Takes front pump pressure as 0 1. The travel speed does not
0.5 - 4.5 V MPa (0 kg/cm*) when actuating. automatically shift (it does not
Between CO3 (6) and (16): * If the abnormality is restored by change from Hi to Lo).
18-28V the vibration of the machine, it * If the button is operated
Between CO3 (female) (3) resets the power source to restore manually, the panel display
and (16), (3) and chassis to the proper condition. (However, is switched.
t Resistance: Min. IM the service code display does not
(Disconnect connectors go out.)
CO3 and CO8.1
1 Resistance: 500 - 1000 R 1. If functions in the equivalent of the It operates about the same as G/C
1 Voltage (AC range): G/O mode (the speed rises) mode (prolix) (the power is
0.5 - 3.0 V (engine slightly lower)
started)
20-186-11
0
JUDGEMENT TABLE FOR ENGINE THROTTLE . PUMP CONTROLLER
TROUBLESHOOTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
I
Excessive abnormal noise when stopping swing
-
Excessive hydraulic When holding brake is released
-
drift of swing When holding brake is applied
Swina soeed is faster than soecified swina soeed +-
7
Troubleshootina code when service code is disolaved 1 :-2 c-: :-4 C-E
I
Troubleshooting code when there is abnormalitv in monitorino check - +
--
-
6 : This shows item that needs only checking with monitoring
1 : This shows item to check with monitoring or machine monitor
20-l 86-12
0
JUDGEMENT TABLE FOR ENGINE THROlTLE . PUMP CONTROLLER
TROUBLESHOOTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
L
$ ;;i
_c t
d E 0 z
8 s 3
2 i
E ,-E
L f
E
z z I
Lu
Si :rn ii G
32 lo ii i
7x 7x 7
x 7
x
- t
-% -x - - t
- - - t - i-3 t
- f-4 t
=_
- -x - _ i-5 t
- i-6 t
L
- i-7 t
.=
x
- - _ i-8 t
.=
x
- - - - i-9 t
- - - -
- - - _ i-10 t
- - _
- - - - i-11 t
- - - i-12 t
g-
_ I-i-13
- - - - t i-14
- - - - t i-15
- t i-16
- - t i-17
- - - t i-18
- - t i-19
- - - - t l-20
- - - _ -t l-21
-
- - - l-l-22
- - K
- _ I-l-23
- - I-l-24
- l-l-25
- - %
- _ -l- l-26
- - -
- ir - -I- l-27
-
- - - _ -l- l-28
- - - -
- - - _ l-i-29
- - - - bl-30
- - - _ -b l-31
- -
-
-
-
-
-
-
-
-- --
-_ --
- 5 5% - Hl-32
_
_
-
20-186-13
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
TVC
Starting switch Swing prolix switch resistor
C06(M2)
x07
(MIC17)
18
HWS16) 1%
Monitor panel
HI3
(S16)
20-186-14
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR C MODE
PC100
LS-EPC Pump Pump
PC120
solenoid TVC valve pressure switch Model selection connector BKP00360
valve sensor
20-186-15
0
TROUBLESHOOTING C-l
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the
connector to its original position, if an E service code is not displayed, the problem has been
removed.
Check that fuse 1 is not blown.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
When the starting motor rotates normally. (If the starting motor also does not rotate, go to E-8.)
Remedy
C02(MIC21)
BKP00186
20-l 86-16
0
TROUBLESHOOTING c-2
Cause Remedy
Table 1
Troubleshooting No. 1 Troubleshooting No. 2 Troubleshooting No. 3 Resistance value
Between Cl3 (male) (1) - (2) Between CO2 (female) (8) - (18) Between CO5 !female) (3) - (4) IO--22fl
Between Cl3 (male) (1) -chassis Between Co2 (female) (8) - chassis Between CO5 (female) (3) -chassis Min. 1MR
Table 2
1 Troubleshooting No. 4 / Resistance value
Between CO5 (male) (1) - (3), (2) - (4) 1 Max. 1 R I
Between CO5 (male) (1)12)(3)(4) -chassis ) Min. IMfl
20-l 86-17
0
TROUBLESHOOTING c-2
C13(X2)
BKP00361
20-186-18
0
TROUBLESHOOTING c-3
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
* If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.
If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. IA) continues to
flow to the solenoid.
* Always turn the NC prolix switch OFF.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
: Always connect any disconnected connectors before going on the next step.
I Cause Remedy
Y ES Defective engine
throttle. pump controller
Table 1
Troubleshooting No. 1 Troubleshooting No. 2 Troubleshooting No. 3 Resistance value
Between Cl3 (male) (I) - (2) Between CO2 (female) (8) - (18) Between CO5 (female) (3) - (4) IO-22n
Between Cl3 (male) (I) -chassis Between CO2 (female) (181 -chassis Between CO5 (female) (4) - chassis Min. IMR
Table 2
Troubleshooting No. 4 Resistance value
Between CO5 (male) (I) - (3). (2) - (4) Max. 1 C
Between CO5 (male) (lKW3)(4) -chassis Min. IMfl
20-186-19
0
TROUBLESHOOTING c-3
COZ(MIC21) HI21
I \ I T
PalI Pralixl
20-186-20
0
TROUBLESHOOTING c-4
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the service code E is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the switch ON again and check if
the service code E is displayed. (If it is not displayed, the problem has been removed.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
: Always connect any disconnected connectors before going on the next step.
Cause Remedy
Table 1
Between VOI (male) (I) and (2) 20-6Ofl
Between VOI (male) (1) and chassis Min. IMfl
LS bypass
solenoid valve
DO2
-1
2
BKP00362
20-186-21
0
TROUBLESHOOTING c-5
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the service code E is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the switch ON again and check if
the service code E is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
Defective contact or
YEE disconnection in wiring
4
harness between VOI lepair or
(female) (2) and chassis eplace
ground
chassis as shown
Short circuit with power lepair or
source, defective contact eplace
l Turn starting NC
or disconnection in
YES tween CO1 (male) switch ON.
wiring harness between
2 Jz?I l Disconnect Vol.
CO1 (female) (2) and VOI
Ishown in Table I?
Is resistance (female) (I)
YES between VOI *Turn starting
1 - (male) (1) and (2) - switch ON. Defective engine throttle,
- normal? l Disconnect COl. NO pump controller
Interchange con- p
nectar with other _ *Turn starting
solenoid. Is switch OFF.
NO
[E211 I displayed? . Disconnect Vol.
* 20 -6OR
. Turn starting Defective LS bypass
solenoid
switch OFF. I \y ieplace
-InterchangeVOl NO (internal short circuit or
with other short circuit with ground)
solenoid.
l Turn starting
switch ON.
Table 1
Troubleshooting No. 3 Troubleshooting No. 4 Voltage Measurement conditions
0- 3V All levers at neutral
Between CO1 (male) Between VOl (female) Compound operation of
(2) and chassis (1) and chassis 20-30V travel + work equipment
or swina
BKP00362
20-186-22
TROUBLESHOOTING C-6
j, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.
* Always connect any disconnected connectors before going on the next step.
* Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
Cause Remedy
Table 1
1Between V04 (male) (1) - (2) 1 20-6Ofl 1
Between V04 (male) (I) -chassis 1 Min. 1MR
20-186-23
0
TROUBLESHOOTING C-6
VO4(X2)
DO5
Swing holding
L
2
brake solenoid
1 valve
m
BKP00363
20-186-24
0
TROUBLESHOOTING c-7
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
* Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
3 YES
GotoA
2 chassis as shown
Is resistance in Table I? Defective engine throttle,
Replace
YES between V04 NO pump controller
* Turn starting
- (male) (I) and (2) - switch ON.
_ 1 normal? , - Disconnect COI.
Interchange
connector with -Turn starting
other solenoid. Is - switch OFF. NO
IE2131 displayed? * Disconnect V04.
- .20-60R Defective swing holding
z *Turn starting switch brake solenoid (internal
0 \ Reolace
OFF. disconnection or short
NO
* Interchange V04 circuit with power source)
with other Defective contact or
connector. disconnection in wiring
*Turn starting switch Repair or
harness between V04
ON. (female) (2) and chassis replace
ground
Short circuit with power
source, defective contact, or Repair or
disconnection in wiring
replace
harness between X05
(male) (4) -X01 (6) - HI3 (7)
-VO4 (female) (1)
Table 1
Troubleshooting No. 3 Troubleshooting No. 4 Troubleshooting No. 6 Voaltage Measurement condition
Between CO1 (male) Between X05 (male) Between V04 (female) 0-3V 5 seconds after all levers are returned to neutral
(3) -chassis (3) -chassis (I) - chassis 20 - 30V Swing lever operated
20- 186-25
0
TROUBLESHOOTING c-7
Fuse
I I
y(qq&
VO4(X2)
DO5
Swing holding
brake solenoid
valve
m
BKP00363
20- 186-26
0
TROUBLESHOOTING C-8
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the service code E is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the switch ON again and check if
the service code E is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
Is resistance be-
2
IC 1 (female) (IO) and
chassis normal? I
I Short circuit with ground
in wiring harness
between CO1 (female)
qepair or
.eplace
NO
(IO) and V05 (female) (1)
/$jjs;;~d?, . S^Wi:;nOeFc:.;O5. 1
Table 1
Between V05 (male) (1) and (2) 1 20-6OC
Between V05 (male) (1) and chassis Min. IMR
2 2-stage relief
solenoid valve
1
BKP00364
20-186-27
0
TROUBLESHOOTING c-9
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the service code E is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the switch ON again and check if
the service code E is displayed. (If it is not displayed, the problem has been removed.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
: Always connect any disconnected connectors before going on the next step.
Cause Remedy
Defective contact or
disconnection in wiring
harness between V05 Repair or
(female) (2) and chassis replace
ground
male) (10) and H
I+1 ;;as_s&a,s;hown 11
Short circuit with power Repair or
3
1
source, defective contact replace
-Turn starting NC
YES
_ I...
Is voltage be-
tween CO1 (male)
l
switch ON.
Disconnect V05.
or disconnection in
wiring harness between
CO1 (female) (2) and V05
Is resistance (female) (I)
YES between V05
(male) (1) and (2) Defective engine throttle,
Replace
normal? l Disconnect COI. h pump controller
Table 1
Troubleshooting No. 3 Troubleshooting No. 4 Voltage Measurement conditions
I 10- 3V 1 All
I
levers at neutral 1
Between CO1 (male) Between V05 (female)
Operation of work
(IO) and chassis (I) and chassis
26-30V equipment + power
I 1 max. I
2-stage relief
2-stage relief solenoid valve
solenoid
BKP00364
20-186-28
0
TROUBLESHOOTING C-IO
C-IO [E206] Short circuit in travel speed selector solenoid system is dis-
played
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
: Always connect any disconnected connectors before going on the next step.
Cause Remedy
Table 1
Between V06 (male) (I) and (2) 20-6OD
Between V06 (male) (1) and chassis Min. 1Mn
Travel speed
solenoid valve
20-186-29
0
TROUBLESHOOTING C-II
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
Defective contact or
disconnection in wiring Repair or
harness between V06
redlace
(female) (2) and chassis
ground
-Turn starting
connector with
switch OFF.
otehr solenoid. Is
* Disconnect V06. No
*20-60Q
* Turn starting
switch OFF. Defective travel speed
Replace
- Interchange V06 NO solenoid (internal
with other disconnection or short
circuit with power source)
connector.
. Turn starting
switch ON.
Table 1
Troubleshooting No. 3 Troubleshooting No. 4 Voltage Measurement conditions
0- 3V Travel speed switch at Lo
Between CO1 (male) Between V06 (female) Travel speed switch at
(9) -chassis (1) -chassis 20-30V operate the lever slightly not
enough to move the machine
BKP00365
20- 186-30
0
TROUBLESHOOTING c-12
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the service code E is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the switch ON again and check if
the service code E is displayed. (If it is not displayed, the problem has been removed.)
2 Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
r 1
2 (female) (8) and
Short circuit with ground
Isresistance be- 1 chassis normal? 1 in wiring harness tepair or
l Turn starting between CO1 (female) (8) eplace
switch OFF. and V07 (female) (1)
l Disconnect COl.
. 20-6OC
1
I
I
solenoid. Is switch OFF.- k.
fE2071 displayed? * Disconnect V07.
I I
l Turn starting Defective active mode
g
l
switch OFF.
Interchange V07
I v solenoid
(internal short circuit or
z NO
with other short circuit with ground)
z solenoid.
l Run engine at high idling.
l Turn active mode ON.
Table 1
Between V07 (male) (1) and (2) 20-6OD
Between V07 (male) (1) and chassis Min. IMC
Active mode
solenoid valve
20-186-31
0
TROUBLESHOOTING c-13
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the service code E is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the switch ON again and check if
the service code E is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
.II
Defective contact or
YEI disconnection in wiring
4 Repair or
harness between V07
Is voltage be- (female) (2) and chassis replace
YE S tween V07 (fe- ground
male) (1) and
chassis as shown
in Table I? Short circuit with power Repair or
H source, defective contact replace
,Turn starting NC
or disconnection in
switch ON.
wiring harness between
(2) and chassis as *Disconnect V07. CO1 (female) (8) and V07
shown in Table I?
L
Is resistance (female) (1)
between V07
(male) (1) and (2) Defective engine throttle,
Replace
. Disconnect COI. ND pump controller
Table 1
Troubleshooting No. 3 Troubleshooting No. 4 Voltage Measurement conditions
0- 3V Active mode switch OFF
Between CO1 (male) Between V07 (female) Engine at high idling
(8) and chassis (2) and chassis 20-30V + active mode switch
ON
BKP00366
20-186-32
0
TROUBLESHOOTING c-14
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
mode display as
shown in Table 2 YES
Is voltage be-
- tween Cl7 (5) (6) Defective model selection
l Turn starting
- (7) (13) (14) and -
switch ON. connector, or disconnec-
ND chassis as shown
. Set to monitor- tion, short circuit with tepair or
in Table 2?
ing codes [02, ground, or short circuit in eplace
*Turn starting NO
031 and L21.221. wiring harness where
switch ON. voltage is defective
PC1 20
n?
--
BKP00368 BKP00194 BKP00370
Cl7 Detween (5) _ chassis Between (6) -chassis Between (7) -chassis Between (13) -chassis Between (14) -chassis
20-186-33
0
TROUBLESHOOTING c-14
PC100
BKP00371
PC120
BKP00372
20-186-34
0
TROUBLESHOOTING c-15
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
2 Always connect any disconnected connectors before going on the next step.
Cause Remedy
lk
pump controller Replace
1Is resistance
_..
Short circuit with ground or short
circuit with power source in
wiring harness between CO2 Repair or
(female) (7) - Cl0 (female) (l), or replace
NO short circuit with power source in
wiring harness betweenCO2
(female)(171- Cl0 (female)(2)
-Turn starting I Replace
Defective LS-EPC solenoid
switch OFF: NO (internal short circuit with
* Disconnect CIO.
ground or short circuit
with power source)
$
8
x Table 1
Troubleshooting No. 1 Troubleshooting No. 2 Resistance value
Between Cl0 (male) (1) - (2) Between CO2 (female) (7) - (17) 7--14n
Between Cl0 (male) (1) -chassis Between CO2 (female) (7) -chassis Min. 1MC
20-186-35
0
TROUBLESHOOTING C-16
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
j, Always connect any disconnected connectors before going on the next step.
Cause Remedy
Table 1
Troubleshootina No. 1 I Troubleshootina No. 2 I Resistance value I
Between Cl0 (male) (1) - (2) 1Between CO2 (female) (7) - (17) / 7-14.C
Between Cl0 (male) (2) -chassis 1Between CO2 (female) (17) -chassis 1 Min. 1MB
BKP00251
20-186-36
0
TROUBLESHOOTING c-17
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the service code E is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the switch ON again and check if
the service code E is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Remedy
YES
F
Defective engine throttle,
pump controller
Replace
h
Is voltage YES between CO8 (3) or disconnection)
I
I
l
between CO3 (3)
and (16) normal?
Engine at high
I Is resistance
3
and chassis
II
normal?
lTurn starting
I
b
Short circuit with power
~source or ground, defective
contactor disconnection in
~wiring harness between
Repair or
replace
YES between CO8 (1) switch OFF.
idling. - lDisconnect C03, CO3 (female) (3) and CO8
2- and chassis (female) (3)
. Operate lever arm C08.
Is voltage normal?
IN relief -- -Min. 1 MR Short circuit with ground, Repair or
neutral. between CO8 (2) _ *Turn starting NO defective contact or
replace
l 0.5 - 4.5 v NO and chassis switch OFF. disconnection in wiring
normal? l Disconnect C08. harness between CO3
(female) (16) and CO8
Disconnect C08. . Max. 1 G
l (female) (1)
. Turn starting
Short circuit with ground,
switch ON. Repair or
defective contact or
l 18-28V disconnection in wiring replace
NO
harness between CO3
(female) (6) and CO8
(female) (2)
BKP00373
20-186-37
0
TROUBLESHOOTING C-18
j, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if the service code E is not displayed, the problem has been removed.
* If the starting switch is turned OFF after an abnormality occurs, turn the switch ON again and check if
the service code E is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause 1 Remedy
BKP00373
ZO-186-38
0
TROUBLESHOOTING c-19
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its
original position, if an E service code is not displayed, the problem has been removed.
jr If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if
an E service code is displayed. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
BKP00374
20- 186-39
0
TROUBLESHOOTING OF PUMP CONTROLLER
INPUT SIGNAL SYSTEM (F MODE)
* When the monitoring mode is checked, if the following input signals are not displayed or do not light up,
carry out troubleshooting for that item.
F-l Bit pattern 20-(l) Swing oil pressure switch does not light up ................................................... 20-188
F-2 Bit pattern 20-(2) Travel oil pressure switch does not light up ................................................... 20-189
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up.. .................................... 20-190
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up ........................................ 20-191
F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up ................................................. 20-192
F-6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up ............................................. 20-193
F-7 Bit pattern 21-(l) Bucket CURL oil pressure switch does not light up ........................................ 20-194
F-8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up ...................................... 20-195
8 F-9 Bit pattern 21-(3) Swing lock switch does not light up ................................................................ 20-196
z
8 F-IO Engine speed is not displayed in Monitor code 10 (abnormality in speed sensor system) ...... 20-197
F-II Bit pattern 22-(5) Kerosene mode connection does not light up ................................................ 20-198
F-12 Bit pattern 22-(6) Knob switch does not light up ......................................................................... 20-199
20-187
0
F-l Bit pattern 20-(I) Swing oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
A Turn the swing lock switch ON before operating the swing lever.
* If there is no display when the lever is operated on one side, the PPC shuttle valve is defective.
Cause Remedy
Pump controller
205CA06509
20-188
F-2 Bit pattern 2042) Travel oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
A Before operating the travel lever, check that the surrounding area is safe.
* If there is no display when the travel lever is operated on one side, the PPC shuttle valve is defective.
YES
Defective pump controller qeplace
f Lever at neutral:
2 male) (3) normal,
and is circuit insu-
Defective contact, short cir-
~ cuit with ground, or discon-
20-30V Is resistance be- lated from chassis? qepair or
nection in wiring harness be-
. Travel lever tween SO1 (male) ,eplace
_ * Between SO1 and NO tween SO2 (female) (3) -
operated:Max. IV _ (1) and (2) nor-
NO pal, and is circuit HO4 (11) - SO1 (female) (2)
* Start engine. CO2:Max. 1D
Insulated from
chassis? * Between wiring harness and chassis:Min. 1M C
- Disconnect SO1 and C02.
Defective travel oil pressure qeplace
switch
* Travel lever at * If the condition does not
neutral:Min. 1M D return to normal even
. Start engine. when the switch is
* Disconnect Sol. replaced, go to H-5.
Sr It is also possible to fit a short connector and judge the condition.
In this case, check the voltage between CO2 (3) and the chassis in
Item 1 on the flow chart.
. If it is 20-30V:Go to YES
* If it is less than 1V:Go to NO
205CA06510
20-189
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
A When measuring with the engine running, make sure that the work equipment
the lever is operated.
does not move when
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
j, Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective pump controller Replace
* Lever at neutral: p
2 male) (2) normal,
and is circuit insu-
Defective contact, short cir-
:uit with ground, or discon-
20-30V Is resistance be- lated from chassis? Repair or
section in wiring harness be-
* Boom LOWER tween SO4 (male) replace
_ * Between SO4 and NC tween SO4 (female) (2) -
o&w$;$ _ (1) and (2) nor-
NO +, and is circuit HO4 (9) - CO2 (female) (2)
CO2:Max. 10
Insulated from - Between wiring harness and chassis:Min. 1M f~
. Start engine. chassis?
. Disconnect SO4 and C02.
. Boom LOWER Defective boom LOWER oil Replace
operated:Max. 1R NO wessure switch
- si;,; ytral: f If the condition does not
return to normal even
* Start engine. when the switch is
. Disconnect S04. replaced, go to H-5.
* It is also possible to fit a short connector and judge the condition.
In this case, check the voltage between CO2 (2) and the chassis in
Item 1 on the flow chart.
* If it is 20-30V:Go to YES
. If it is less than 1V:Go to NO
Pump controller
205CA06511
20-I 90
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up
* This troubleshooting. is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
A When measuring with the engine running, make sure that the work equipment does not move when
the lever is operated.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
1 I
Defective contact, or discon-
3 YES nection in wiring harness be- qepair or
ya,v;p02 (female) (1) and .eplaw
Pump controller
205CA06512
20-191
F-5 Bit pattern 2045) Arm IN oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
A When measuring with the engine running, make sure that the work equipment
the lever is operated.
does not move when
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective pump controller ?eplace
- Lever
-
20-3ov
Arm
Max. 1V
at neutral:
IN operated:
. Start engine.
Nail * Between wiring harness and chassis:Min. 1MC
Defective contact,
:uit with ground,
nection in wiring
tween SO5 (female)
short cir-
or discon-
harness be-
Pump controller
205CA06513
20-192
F-6 Bit pattern 2046) Arm OUT oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
When measuring with the engine running, make sure that the work equipment does not move when
a
the lever is operated.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Remedy
YES
3efective pump controller Replace
Pump controller
CO2(04020) H04(S16) SO3(X2) Arm OUT oil
pressure switch
205CA06514
20-193
F-7 Bit pattern 21-(I) Bucket CURL oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
A When measuring with the engine running, make sure that the work equipment
the lever is operated.
does not move when
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
1 I
Defective contact, or discon-
Is voltage between 3 YES nection in wiring harness be- Repair or
CO2 (7) and chassis - tween SO6 (female) (1) and replace
Is resistant be-
normal? chassis
tween SO6 (female)
-5 (2) and coz (fe- _
* Lever at neutral: p
2 male) (7) normal,
and is circuit ~nsu-
Defective contact, short cir-
cuit with ground, or discon-
20-30V Is resistance be- lated from chassis? Repair or
nection in wiring harness be-
* Bucket CURL tween SO6 (male) replace
operated:Max. IV _ (1) and (2) nor- _ * Between CO2 and ND tween SO6 (female) (2) -
NO pal, and is circuit HO4 (14) - CO2 (female) (7)
- Start engine. insulated from
SO6:Max. 10
chassis? - Between wiring harness and chassis:Min. 1M Q
- * Disconnect CO2 and S06.
. Bucket CURL Defective bucket CURL oil Replace
ooerated:Max. 10 NO pressure switch
+ If the condition does not
return to normal even
* Start engine. when the switch is
* Disconnect S06. replaced, go to H-5
k It is also possible to fit a short connector and judge the condition.
In this case, check the voltage between CO2 (7) and the chassis in
Item 1 on the flow chart.
. If it is 20-30V:Go to YES
* If it is less than 1V:Go to NO
Pump controller
205CA06515
20-194
TROUBLESHOOTING F-8
F-8 Bit pattern 2142) Bucket DUMP oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to
its original position, if the monitoring code display returns to normal, the problem has been removed.
When measuring with the engine running, make sure that the work equipment does not move when
a
the lever is operated.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
Pump controller
TDP00302
20- 195
0
F-9 Bit pattern 2143) Swing lock switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and insetting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
* If the panel display is normal, go to M-18 When swing lock lamp on monitor panel does not light up.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause
YES
Defective pump controller Replace
II
HOl(S
PO2(04016)
pip-p
Monitor panel
205CA06517
20-I 96
TROUBLESHOOTING F-IO
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
2 Defective adjustment of Replace
engine speed sensor
Does condition be-
YES come norrna~ when
engine speed sensor 4 YES
is adjusted? Defective pump controller Replace
I-
,
j, See TESTING
_ \...,..,,
Defective engine speed sensor
4). (6) - Ll . Measure in AC NO
Pump controller
CO3 (040 161 HO3 (S16) E07 (X2)
20-197
0
TROUBLESHOOTING F-II
F-l 1 Bit pattern 2245) Kerosene mode connection does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the con-
nector and inserting the T-adapter, or when removing the T-adapter and returning the connector to
its original position, if the monitoring code display returns to normal, the problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective pump controller Replace
1
Is voltage between
CO2 (17) and chas- - Defective contact, or discon-
sis normal? 2 YES nection in wiring harness be- Repair or
tween M36 (male) (1) and replace
- Is resistance be- CO1 (female) (1) (2)
- M36 connector _ tween CO2 (female) _
Connected: ND (17) and M36 (fe- Defective contact, short cir-
Max. 1V male) (1) normal? cuit with ground, or discon-
Disconnected: nectlon in wiring harness be- Repair or
20-30V . Between ~02 and ND tween CO2 (female) (17) and replace
* Turn starting M36:Mex. 1Q M36 (female) (1)
switch ON. * Turn starting
switch OFF.
* Disconnect CO2
and M36.
GND a
@ I cm-
GND
Kerosene mode (connected)
Normal mode (disconnected)
CO2 (04020)
Kerosene
mode
20- 198
0
F-12 Bit pattern 2246) L.H. knob switch does not light up
* This troubleshooting. is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connector
to its original position, if the monitoring code display returns to normal, the problem has been re-
moved.
* Set the working mode to G/O or H/O and the power max./ swift slow-down switch to the power max.
position.
* When fuse 5 is not blown.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
1
I3efective contact, or discon-
Is voltage between 3 YES ,section in wiring harness be-
Repair or
CO2 (18) and chas- - 1:ween knob switch - M23
replace
kt2 <fe;i;e:e)(2;,& HO1 (16) -
Is resistance be-
YES tween terminals of _
I
- Knob switch
2 L.H. knob s.witch
- normal?
ON:20-30V
0FF:Max. 1V IDefective L.H. knob switch Replace
Is voltage of L.H.
. Turn starting * L.H. knob switch NO
knob switch inlet -
switch ON. r 0N:Max. 1 fl
terminal normal?
0FF:Min. lM0
_ * Turn starting switch OFF. IDefective contact, or discon-
* Disconnect switch connector Isection in wiring harness be-
* Starting switch - 1tween L.H. knob switch -
ON:20-30V NO IM23 (1) - M22 (1) - HO4
* Turn starting (16) - fuse 5
switch ON.
Pump controller
205CA06520
20-199
TROUBLESHOOTING OF ENGINE THROTTLE,
PUMP CONTROLLER (INPUT SIGNAL SYSTEM)
(F MODE)
1
PCIOO-6 Serial No. : 41230 and up
PC120-6 Serial No. : 49821 and up
20-200-l
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE
TYC
Starti n! 3 switch Swing prolix switch resistor
-
l!Ej
COUMZ)
:
Battery I
x07
(MIC17)
Batten, relay
D13
(KESl)
IIt
1
H12lS161 1g
+-I 211
Monitor panel
Network bus
1 1
LS bypass Active mode
Solenoid valves
20-200-2
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR F MODE
r--I---Ii-Ii-i-I---i- M36CMl) /
L =i
LS-EPC Pump Pump PC120
solenoid TVC valve ~~n~o~ switch Model selection connector BKPOO360
valve
20-200-3
0
TROUBLESHOOTING F-l
F-l Bit pattern 20-(l) Swing oil pressure switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
Turn the swing lock switch ON before operating the swing lever.
If there is no display when the lever is operated on one side, the PPC shuttle valve is defective.
(See H-5)
(When measuring with the engine stopped, charge the accumulator first.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause
Defective contact, or
disconnection in wiring Repair or
harness between SO8 replace
between Cl6 (5)
(female) (1) and chassis
YE ~ ground
Defective contact, short
. Start engine circuit with ground, or Repair or
* Swing lever at istance between disconnection in wiring replace
neutral male) (I) and 12) . Turn startina switch harness between Cl6
:20-3ov
al, and is circuit OFF. - (female) (5) and SO8
sted from * Disconnect Cl6 and SOS. (female) (2)
* Swing lever
1chassis? * Between Cl6 and SOS:Max. 1 R
opereated
: Max. 1V * Disconnect SOS. * Between wiring harness and Defective swing oil
. Start enaine. chassis: Min. 1 MR pressure switch
(If the condition does Replace
* Swing lever at UO
neutral not return to normal
: Min. 1 MC? even when the switch
- Swing lever operated: Max. 1 Q is replaced, go to H-5.
* See Note 1.
BKP00257
20-200-4
0
TROUBLESHOOTING F-2
F-2 Bit pattern 2042) Travel oil pressure switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
Before operating the travel lever, check that the surrounding area is safe.
If there is no display when the travel lever is operated on one side, the PPC shuttle valve is
defective. (See H-5)
(When measuring with the engine stopped, charge the accumulator first.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
1
3 Defective contact, or
Is voltage disconnection in wiring harness Repair or
IIs resistance betwa YES
between Cl6 (13) between SO1 (female) (I) and replace
Cl6 (female) (13) and
and chassis YES SO1 (female) (2) chassis ground
normal? normal, and is circuit
insulated from Defective contact, short circuit
* Start engine. 2 with ground, or disconnection in Repair or
- chassis?
*Travel lever at is resistance between NO wiring harness between Cl6 replace
SO1 (male) (1) and (2) *Turnstarting switch (female) (13) and SO1 (female) (21
neutral
normal, and is circuit - oFF,
:20-30V I\ insulated from
. Travel lever chassis?
*Disconnect ClGand Sol.
Defective travel oil
operated - Between Cl6 and Sol: Max. 1 Q
* Disconnect SO1 pressure switch
: Max. 1 V *Between wiring harness and chassis: Min. 1 MR
* Start engine. (If the condition does
Replace
* Travel lever at not returen to normal
NO
neutral even when the switch
: Min. 1Mfi is replaced, go to H-5.)
*Travel lever operated
: Max: 1 .Q
* See Note 1.
Travel oil
pressure switch
BKP00258
20-200-5
0
TROUBLESHOOTING F-3
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
When measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
(When measuring with the engine stopped, charge the accumulator first.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
--
__,._..._ Defective contact, or
disconnection in wiring harness
between SO4 (female) (1) and
Repair or
replace
il
chassis ground
+ fl normal, a~
?_%d
Defective contact, short circuit with
ground, or disconnection in wiring
harness between Cl7 (female) (101
Repair or
replace
neutral: 20 - 30V -Turnstarting switch - H13 (11) - SO4(female) (2)
* Boom lever
* Disconnect Cl7 and S04.
* Between Cl7 and 504: Max. IQ Defective boom LOWER
LOWER:Max. IV
* Disconnect S04. * Between wiring harness and oil pressure switch
* Start engine. (If the condition does
Replace
* Boom lever at NO not return to normal
neutral even when the switch
: Min. 1 MQ is replaced, go to H-5.)
* Boom lever operated to LOWER: Max. 1 Q
* See Note 1.
BKP00259
20-200-6
0
TROUBLESHOOTING F-4
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
When measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
(When measuring with the engine stopped, charge the accumulator first.)
k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
1 Defective contact, or
disconnection in wiring Repair or
Is voltage harness between SO2
between Cl7 (2) replace
(female) (I) and chassis
and chassis Yt ~ ground
normal?
Defective contact, short circuit
* Start engine. 2 Repair or
with ground, or disconnection
* Boom lever at Is resistancebetween in wiring harness between Cl7 replace
neutral: 20 - 30V SO2(male)(1) and (2) . + Turn startina switch (female) (2) - HI3 (9) - SO2
OFF. -
- Boom lever NC normal,and is circuit (female) (2)
operated to RAISE insulatedfrom chassis?
* Disconnect Cl7 and 502.
* Between Cl7 and SO2 : Max. 1 Q Defective boom RAISE oil
: Max. 1 V * Between wiring harness and chassis
* Disconnect S02. pressure switch
- Start engine. : Min. 1 MD (If the condition does Replace
* Boom lever at NIO not return to normal
neutral: Min. 1 MC1 even when the switch
* Boom lever operated to RAISE is replaced, go to H-5.)
: Max. 1 R.
. See Note 1.
BKP00260
20-200-7
0
TROUBLESHOOTING F-5
F-5 Bit pattern 2045) Arm IN oil pressure switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
When measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
(When measuring with the engine stopped, charge the accumulator first.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
1 Defective contact, or
3
Is voltage - YES disconnection in wiring harnes Repair or
Is resistance between -
between Cl7 (3) _ Cl7 (female) (3) and between SO5 (female) (I) and replace
and chassis YES SO5(female) (2) chassis ground
normal? normal, and is circuit
insulated from Defective contact, short circuit
* Start engine. 2 with ground, or disconnection Repair or
chassis?
. Arm lever at Is,_ in wiring harness between Cl7 replace
NO
neutral: 20 - 30V SO5(male) (1) and (2) * Turn starting (female) (3) - HI3 (IO) - SO5
- normal, and is circuit - switch OFF.
. Arm lever (female) (2)
NO insulated from * Disconnect Cl7 and S05.
operated to IN chassis? - Between Cl7 and S05: Max. 1 D
: Max. 1 V * Between wiring harness and chassis
Defective arm IN oil
* Disconnect S05. pressure switch
* Start engine. : Min. 1 MO (If the condition does Replace
* Arm lever at NO not return to normal
neutral even when the switch
: Min. 1 MQ is replaced, go to H-5.)
-Arm lever operated to IN: Max. 1 Q
* See Note 1.
@ Arm IN oil
pressure switch
a
EKP00261
20-200-8
0
TROUBLESHOOTING F-6
F-6 Bit pattern 2046) Arm OUT oil pressure switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
When measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
(When measuring with the engine stopped, charge the accumulator first.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
1 Defective contact, or
3 disconnection in wiring
Is voltage 1-1 YES Repair or
I Is resistance betweenI harness between SO3
between Cl7 (11) Cl7 (female) (11) and (female) (I) and chassis
and chassis YES SO3(female) (2) ground
normal? normal, and is circuit Defective contact, short
insulated from circuit with ground, or
* Start engine. 2 Repair or
Is chassis7 disconnection in wiring replace
* Arm lever at NO
SO3(male) (1) and (2) * Turn starting harness between Cl7
neutral: 20 - 30V (female) (11) - HI3 (12) -
- normal, and is circuit - switch OFF.
*Arm lever SO3 (female) (2)
operated to
NO insulated from * Disconnect Cl7 and S03.
chassis? * Between Cl7 and S03: Max. 1 L2
OUT: Max. 1 V Defective arm OUT oil
* Disconnect S03. * Between wiring harness and chassis pressure switch
* Start engine. 1 : Min. 1 MC? (If the condition does Replace
* Arm lever at NO not return to normal
neutral even when the switch
: Min. 1 MQ is replaced, go to H-5.)
* Arm lever operated to OUT: Max. 1 Q
* See Note 1.
BKP00262
20-200-9
0
TROUBLESHOOTING F-7
F-7 Bit pattern 2141) Bucket CURL oil pressure switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
When measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
(When measuring with the engine stopped, charge the accumulator first.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Remedy
Defective contact; or
1
3 disconnection in wiring
Is voltage - YES harness between SO6 Repair or
Is resistance between P
between Cl6 (11) (female) (I) and chassis replace
Cl6 (female) (11) and
and chassis YES SO6(female) (2) ground
normal? normal, and is circuit
insulated from Defective contact, short
* Start engine. 2 Repair or
- chassis? circuit with ground, or
. Bucket lever at Is resistance between - NO replace
disconnection in wiring
neutral: 20 - 30V SO6(male) (1) and (2) -Turn starting
- nOrtTtal, and is circuit - switch OFF. harness between Cl6
. Bucket lever (female) (11) and SO6
NO insulated from * Disconnect Cl6 and S06.
operated to chassis? (female) (2)
* Between Cl6 and S06: Max. 1 R
CURL: Max. 1 V
* Disconnect S06. * Between wiring harness and chassis
Defective bucket CURL
* Start engine. : Min. 1 MD oil pressure switch Replace
* Bucket lever at NO (If the condition does
neutral: Min. 1 ._- not return to normal
MQ even when the switch
* Bucket lever operated to CURL: Max. 1 R is replaced, go to H-5.)
* See Note 1.
20-200- 10
0
TROUBLESHOOTING F-8
F-8 Bit pattern 2142) Bucket DUMP oil pressure switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
When measuring with the engine running, operate the lever slightly and make sure that the work
equipment does not move.
(When measuring with the engine stopped, charge the accumulator first.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
1
3 Defective contact or
Is voltage 1 YES
Is resistance between , disconnection in wiring harness Repair or
between Cl6 (12) _ between SO7(female) 12)and replace
Cl6 (female) WI and
and chassis YES SO7(female) (2) chassis ground
normal? - normal, and is circuit
insulated from Defective contact, short
* Start engine. 2 circuit with around. or Repair or
- chassis?
* Bucket lever at Is resistance between ~ disconnection in wiring replace
NO
SO7 (male) (1) and (2) *Turn starting switch harness between Cl6
neutral: 20 - 30V
- normal, and is circuit - OFF. (female) (12) and SO7
* Bucket lever
operated to
NO insulated from - Disconnect Cl6 and S07. (female) (2)
chassis? * Between Cl6 and S07: Max. 1 Q
DUMP: Max. 1 V
* Disconnect S07. - Between wiring harness and chassis: Defective bucket DUMP
* Start engine. Min. 1 MQ oil pressure switch
Replace
* Bucket lever at NO (If the condition does
neutral not return to normal
: Min. 1 ML? even when the switch
- Bucket lever operated to DUMP: Max. 1 ~2 is replaced, go to H-5.)
* See Note 1.
ExPOrm4
20-200-11
0
TROUBLESHOOTING F-9
F-9 Bit pattern 2143) Swing lock switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
+ If the panel display is normal. (If the swing lock lamp does not light up, go to M-21.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
w+
Monitor panel
PO1(04020)
BKPOO265
20-200- 12
0
TROUBLESHOOTING F-IO
F-IO Bit pattern 2245) Kerosene mode connection does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
Defective contact, or
YES disconnection in wiring Repair or
harnessbetween M36 replace
(male) (I) and chassis
ground
Defective contact or
Repair or
disconnection in wiring
Connected NO replace
. Turn starting harness between Cl7
: Max. IV switch OFF. (female) (15) and M36
Open: 20 - 30V * Disconnect Cl7 (female) (1)
and M36.
* Max. 1 Q
@+---JJ
lKerosene mode
(connected)
lDiesel oil mode (open)
BKP00266
20-200- 13
0
TROUBLESHOOTING F-II
F-II Bit pattern 22-(6) L.H. knob switch does not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting the T-adapter, or when removing the T-adapter and returning the connec-
tor to its original position, if the monitor code display returns to normal, the problem has been
removed.
* When fuse No. 5 is not blown.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
Defective contact, or
3 YES disconnection in wiring Repair wiring
between CO3 (9) harness between knob harness
switch outlet - M23 (2) -
I
IES
M22 (2) - CO3 (female) (91
EHP
. Turn starting
i
Defective L.H. knob Replace
switch ON.
I
Is voltage between . Turn starting NO switch
* Knob switch knob switch inlet switch OFF.
ON:20-30V h ) terminal and chassis . Disconnect switch terminal.
normal? . Knob switch Defective contact, or
OFF: Max. 1 V
ON: Max. 1 Q disconnection in wiring
* Turn starting OFF: Min. 1 MQ harness between fuse Repair wiring
switch ON. No.5-H12(16)-M22(11 harness
.20-30V NO
- H23 (1) -knob switch
inlet
H12(S16) Fuse
Engine throttle,
r:rE , L.,H. knob switch
pump controller
CO3(040)
L I
BKP00267
20-200- 14
0
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (H MODE)
Table of failure modes and causes for hydraulic and mechanical system.. .............................................. 20-203
Troubleshooting flow charts for each failure mode
All work equipment, travel, swing
H-l Speeds of all work equipment, swing, travel are slow or lack power .............................................. 20-204
H-2 There is excessive drop in engine speed, or engine stalls ................................................................ 20-206
H-3 No work equipment, travel, swing move ........................................................................................... 20-207
H-4 Abnormal noise generated (around pump) ........................................................................................ 20-207
H-5 Auto-deceleration does not work (when PPC shuttle valve is cause) ............................................... 20-208
H-6 Fine control ability is poor or response is poor ................................................................................. 20-208
Work equipment
H-7 Boom is slow or lacks power .............................................................................................................. 20-210
H-8 Arm is slow or lacks power. ................................................................................................................ 20-212
H-9 Bucket is slow or lacks power. ............................................................................................................ 20-214
H-10 Work equipment (boom, arm, bucket) does not move.. .................................................................... 20-215
H-l 1 Excessive hydraulic drift (boom, arm, bucket) ................................................................................... 20-215
H-12 Excessive time lag (engine at low idling) ........................................................................................... 20-216
H-13 Lack of power when pressure rises .................................................................................................... 20-216
H-14 Other equipment moves when single circuit is relieved ................................................................... 20-216
H-15 Work equipment speed is slow when active mode is ON or is fast when active mode is OFF.. ..... 20-217
H-16 In F/O mode, work equipment speed is faster than set speed .......................................................... 20-218
Compound operations
H-17 In compound operations, work equipment with larger load is slow ................................................ 20-218
H-18 In swing + boom RAISE, boom RAISE is slow ................................................................................... 20-219
H-19 In swing + travel, travel speed drops excessively.. ............................................................................ 20-219
H-20 In work equipment + travel, travel speed drops excessively.. ........................................................... 20-219
Travel system
H-21 Travel deviation .................................................................................................................................... 20-220
H-22 Travel speed is slow ............................................................................................................................ 20-222
H-23 Steering does not turn easily or lacks power ..................................................................................... 20-224
H-24 Travel speed does not switch or is faster than specified speed ........................................................ 20-226
H-25 Travel does not move (one side only) ................................................................................................. 20-226
Swing system
H-26 Does not swing .................................................................................................................................... 20-227
H-27 Swing acceleration is poor .................................................................................................................. 20-228
H-28 Excessive overrun when stopping swing ........................................................................................... 20-230
H-29 Excessive shock when stopping swing (one direction only) ............................................................. 20-231
H-30 Excessive abnormal noise when stopping swing .............................................................................. 20-231
H-31 Excessive hydraulic drift of swing ...................................................................................................... 20-232
H-32 Swing speed is faster than specified speed .................................................................................... 20-232-I
20-201
0
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM
TABLE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM
2
P P 8
5 5x
I
E
8 z
0 F m 4
8 5 El 8
iim :
E ii : s
e c s s F
!! Ej
(3,
.g
kl 3L 1 5
e 5 5 2
u P P
B D : D
.r iz t;
8 2
8 a, ? z : 3 9 I k IF! fz 6 8
: h 5
F s 5 5
zJ0F=
m
: b
D
cc 5 fj
5 :: & : ii
_c
:
z> iii 2 8 E b
5 a, D 5 2 z Y I s E E
E rs, 2
5
I$ 5
2
Failure mode z
z
E!
5
:
2
E
z c E
s1
2 3
L
3
5 D e
r z
1
z
:
5
2
2 3 m
8
t : z ;
7
5
2 -I 2
-
-
-
- -- - -I
- -
- - -
-
-
-
-
-
-
-
- -
-
-
- -
- 3 H-2
H-l
-
-
5 2
2-
-
-
-
-
-
-
-
- - -
- -
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
H-3
H-4
- - - - - - 2 - - - - - - - - - - - - H-5
- - - - - - - - - - - - - - - - - - H-6
Boom is slow or lacks power - - - - - - - - - - - - - - - - G - H-7
$ Travel deviation
Deviation is excessive
- - - - - - - - - - - - - - - - - - -
t:
Deviation is excessive when starting - - - - - - - - - - - - - - - - - - -
6 Travel speed is slow
- - - - - - - - - - - - - - - - - - -
5 Steering does not turn easily or lacks power
- - - - - - - - - - - - - - - - - - -
5 Travel speed does not switch or is faster than set speed
- - - - - - - - - - - - - - - - - - -
F Does not move (one side only) - - - - - - - - - - - _ - - - - - - -
Does not swing
Both left and right
- - - - - - - - - - - - - - - - - - -
One direction only - - - - - - - - - - - - - - - - - - -
Swing acceleration is poor or Both left and right - - - - - - - - - - - - - - - - - - -
E
a,
swing speed is slow One direction only - - - - - - - - - - - - - - - - - - -
s Excessive overrun when stop- Both left and right - - - - - - - - - - - - - - - - - - -
2 ping swing One direction only - - - - - - - - - - - - - - - - - - -
.-? Excessive shock when stopping swing (one direction only) - - - - - - - - - - - - - - - - - - -
5 Excessive abnormal noise when stopping swing - - - - - - - - - - - - - - - - - - -
Excessive hydraulic drift of swing
When brake is ON - - - - - - - - - - - - - - - - - - -
When brake is OFF - - - - - - - - - - - - - - - - - - -
1 Swing speed is faster than specified swine soeed - -
In the failure modes, modes for compound operations are used 1 er ,penc ni lpera ms are non achmes eqi bped wit1 3C
:tiLre mode IO-6 trial No. : 41230 and up PC120-6 Serial No. : 49821 and up
20-203
0
TROUBLESHOOTING H-l
Remedy
Defective adjustment of
Adjust
TVC valve
Repair or
Defective servo assembly
replace
Repair or
Defective piston pump
replace
Repair or
Defective servo assembly rep,ace
Defective operation of LS
Replace
control EPC solenoid valve
Replace
Replace
Adjust or
replace
20-205
0
H-2 There is excessive drop in engine speed, or engine stalls
FIES
Clogged throttle inside servo Clean
or clogged filter inside servo
I
1
Replace (pis-
. See below.
Defective servo piston ton pump as-
NO sembly)
* Replace the servo assembly on the defective side with a new part, and if the engine speed is lower
than the value in Table 1, carry out troubleshooting for S mode.
If it is higher, it can be judged that the TVC valve (servo assembly) is defective, so replace it.
Table 1
Engine speed
Model Conditions
at arm relief
20-206
H-3 No work equipment, travel, swing move
Cause Remedy
2 I
trol relief valve, or defective ?epair or
control circuit .eplace
YE:
i I
Is safety
working
lock valve
properly?
H Defective PTO spline Repair
.eplace
or
Cause Remedy
3 YES
, 7 Go to 4
YES Do bubbles disap-
- pear when engine is -
stopped?
2
Defective hydraulic oil Replace hy-
NO draulic oil
1 Is suction strainer
5
clogged by external -
NO object? Defect inside pump Repair or
Is suction strainer
Is hydraulic tank replace
clogged with metal
oil level normal?
* External object: _ Particles or aTa
Cloth, etc. NO metal particles
stuck to drain Inspect again
Operate for a short time and
plug? (depending on
watch for any change in
changes in
symptoms
symptoms)
20-207
H-5 Auto-deceleration does not work (when PPC shuttle valve is cause)
* The control pressure for the travel and swing passes through the PPC shuttle valve and is supplied to
the oil pressure switch.
1 YES
Defective oil pressure switch Replace
Does condition be-
come normal when _
oil pressure switch
is replaced? Defective operation of PPC
shuttle valve in applicable Repair or
NO system (swing or travel) replace
Is throttle in LS
1
_
YES
t-=--r=
Clogged throttle in LS circuit Clean
circuit clogged?
Defective servo assembly (LS
valve), or defective servo pis- Replace
NO ton
20-208
TROUBLESHOOTING H-7
YES
sr
H
YEI Does LS shuttle
valve move
5 smoothly?
YE l Check LS shuttle
for arm and NO
RAISE circuit is
$
bucket
l 31.9+2.45MPa
(325t25 kg/cm*)
l Engine at high
4 idling
Is pressure com-
il
pensation valve
YES normal, or does
pressure compen- [High] -
sation valve pis-
pressure normal
ton move
smoothly?
3 * It is also possible
- to interchange [Low1 -
with other com- l 4.9+2.9MPa NO
yts_ Does control
valve spool _ pensation valve. (50&30 kg/cm?
* Note: After inspec- l Engine at high
move smoothly?
tion, do not forget idling
2 - -1 to return to the
original position. NO
Is output
YES_ pressure of PPC -
valve normal?
1 NO
- l 2.9?0.5MPa
Is oil pressure (30+5 kg/cm*)
switch for boom _ l Engine at high
RAISE. LOWER idling
Inormal? 1 NO
l See Judgement
Table.
l Note: If auto-
deceleration is
canceled when
boom RAISE or
boom LOWER is
operated, system
is normal.
20-210
0
TROUBLESHOOTING H-7
-
Cause Remedy
f
7 YES Defective boom cylinder Tepair or
piston packing .eplace
Is leakage from
- boom cylinder -
normal?
Defective operation of 3epair or
. Max. 15 cc/min NO boom holding valve ,eplace
. Engine at high
idling
Defective operation of LS ?epair or
shuttle valve (LS shuttle for eeplace
arm or bucket)
Defective operation of
boom holding valve or Repair or
suction valve of control replace
valve
Defective operation of
pressure compensation Repair or
valve or pressure compen- replace
sation valve piston
20-211
0
TROUBLESHOOTING
YES
Y Does LS shuttle
. Check LS shuttle L
for bucket NO
4 I I
* 31.9?1.OMPa
(325?10kg/c$ IO
* Engine at high
sure compensation
valvepiston move idling
. It is also possible
to interchange
with other com-
pensation valve.
* Note:After Inspection, do not forget to return
to the original position.
YES Is output pressure
- ;fa;?PC valve nor- -
1
*2.9+0.5MP.a
Is oil pressure (30+5kg/c$ NO
SWItCh for arm IN, - * Engine athigh
OUT normal? idling
*Operate lever
20-2 12
0
TROUBLESHOOTING H-8
F==
Remedy
Replace
20-213
0
TROUBLESHOOTING H-9
Ca!Xe Remedy
3 YES
I 7 Go to A
YES Does control valve
- spool move
2 smoothly?
Is oil pressure
switch for bucket _ . 2.gfO.5Mpa
Defective PPC valve Replace
CURL, DUMP (30f5kg/c$ NO
normal? * Engine at high
idling
-See JUDGEMENT l Operate lever
TABLE. Defective bucket CURL or
* Note: bucket DUMP oil pressure Replace
NO switch
If auto-decelera-
tlon is canceled
when bucket
CURL or bucket
DUMP IS oper-
ated, system is
normal.
5 YE! 3
Defective operation of Replace
safetv-suction valve
l Engine at high
valve piston move
idling
Defective operation of pres-
I sure compensation valve or sepalr or
. It is also possible NO pressure compensation valve .eplace
to interchange piston
with other com-
pensation valve.
* Note:
After inspection,
do not forget to
return to the
original position.
20-214
0
TROUBLESHOOTING H-10
1 YES
Defective control valve spool
I replace
Is output pressure
of PPC valve nor- -
mal?
Defective PPC valve Replace
* 2.9+0.5MPa NO
(30i5kg/cd)
- $giie at high
Cause Remedy
YES ieplace
Defective hydraulic cylinder
I piston packing
1
Does speed of
downward move- YES
ment become faster Defective operation of
when lever is oper-
2 safety-suction valve
ated? Does condition be-
come normal when
. See TESTING safety-suction 3
pNNNGqADJUST- F YES
valve is inter- Is slipper seal of Go to A
changed? pressure compensa-
* It is also possible
tion valve free of
to measure leak-
- damage? Or does -
age of cylinder. Damaged slipper seal of pres-
NO pressure compensa-
l Max. 15 cdmin sure compensation valve. or
tion valve piston
* At relief defective operation of pres-
move smoothly? 7
* Engine at high sure compensation valve pis-
idling . It is also possible ton
to interchange
with other com-
pensation valve.
* Note:
After inspection,
do not forget to
return to the
orlginal position.
---II
trol valve spool
20-215
0
H-12 Excessive time lag (engine at low idling)
Remedy
Replace
2 YES
Defective main relief valve
Is output pressure
1
Y ES of Z-stage relief so.
lenoid valve nor-
mal?
1 Defective operation of Z- Repair or
- 2.9&0.5MPa NO stage relief solenoid valve replace
(30+5kg/cm)
Is oil pressure * H/O or G/O mode
switch normal? - Power max. mode
* L.H. knob switch
ON
- Arm IN relief
* Operate each con-
trol lever, and if
auto-deceleration
Defective oil pressure switch
is canceled, condi- N 0
tion is normal.
Cause Remedy
* The slipper seal in the pressure compensation valve of the circuit that moved is defective.
20-216
TROUBLESHOOTING H-15
Cause
Defective operation of
2 YES lepair or
variable throttle valve
aplace
inside servo
YES Is strokeof
- control valve -
normal?
Defective operation of lepair or
1
control valve spool eplace
Active mode switch NO
l
Is output pres-
ON: 9.520.5 mm
sure of active _
mode solenoid OFF: 8eO.5 mm
valve normal? . Push spool from opposite end to check.
Defective active mode
leplace
l Active mode NO solenoid valve
switch
ON : 0.2kO.2 MPa
(2+2 kg/cm2)
OFF : 2.9eO.5 MPa
(30+5 kg/cm*)
b) Boom RAISE, arm OUT, bucket CURL, DUMP speeds are slow or fast
Cause Remedy
Defective operation of
, YES iepair or
variable throttle valve
eplace
Is output pres- inside servo
sure of active _
mode solenoid
valve normal?
Defective active mode
l Active mode NO solenoid valve
switch
ON : 0.2kO.2 MPa
(2+2 kg/cm?
OFF : 2.9kO.5 MPa
(30*5 kg/cm21
20-217
0
TROUBLESHOOTING H-16, H-17
H-16 In F/O mode, work equipment speed is faster than specified speed
CalSe Remedy
1 YES
Defective LS valve Repair or
Is output pressure replace
of LS control EPC _
solenoid valve nor-
mal?
Table 1
1 Cause Remedy
20-218
0
TROUBLESHOOTING H-18, H-19, H-20
1 YES
Defective operation of LS se- Repair or
lect valve replace
Is output pressure
of LS select valve -
normal?
Defective operation of PPC
shuttle valve (PPC shuttle Repair or
. 2.9+0.5MPa NO for LS select) replace
i30$5kg!qd)
- tngane81 nlgn
idling
. Operate boom
RAISE (operate
lever slightly).
3 YES
Defective operation of LS se. Repair or
lect valve replace
FH_
1 YES
Defective operation of LS qepair or
bypass valve .eplace
Is pressure of LS
bypass solenoid _
valve circuit nor-
mal?
Defectwe operation of LS Repair or
. 0.2?0.2MPa NO bypass solenoid valve
(2+2kg/c$)
. Engine at high
idling
. Operate boom
RAISE and travel
simultaneously.
TROUBLESHOOTING H-21
YE
S Defective travel motor as-
qepair or
sembly (counterbalance valve
2 eplace
or check valve)
I
Y ES
IL Defective operation of con- ?epair or
I I
N 0 trol valve spool eplace
* Check as an
individual part
1
Defective operation of travel qepair or
Is difference in unction valve eplace
outputpressure
be-
tween left and
right travel PPC
valves normal? I 6 YES
Defective PPC shuttle (3 qepair or
- Difference in out- places, for travel) eplace
put pressure be-
tween FORWARD
and REVERSE:
Min. 0.2MPa
(Min. Zkg/cm)
Defective travel PPC valve ?eplace
* Engine at high
idling
* Travel relief Is lever of travel
PPC valve contact- * Remove PPC shuttle block inlet
hose,fit adapter,and block tip(fit
blind plug).(Note).
Note: If the adapter for blocking the circuit is not available, interchange swing with one of arm (IN), boom
(LOWER), OR BUCKET (CURL, DUMP).
Table 1
Cause Remedy
Defective operation of travel counterbalance valve Repair or replace
20-220
0
TROUBLESHOOTING H-22
5 YES
1
* See Table 1.
Slow in both Is traveloil pres-
NO
FORWARD and sure switch nor-
REVERSE mal?
Is speed slow in i , t1
both FORWARD
and REVERSE, or
Note:
If auto-deceleration
IS it slow in one dl- is canceled when IO
rection only? travel is operated,
system is normal.
(When travel PPC
shuttle is normal)
1
Slow in one
direction only
~1
l Travel lever at fine control position (auto-deceleration canceled)
20-222
0
TROUBLESHOOTING H-22
Cause Remedy
Defective operation of LS
shuttle valve (for boom, arm, Repair or
bucket) replace
Go to H-20 -
20-223
0
TROUBLESHOOTING H-23
31.9+1MPa
(325+ lOkg/cm) I
I YES
Is output pressure
_ Max. 31.9MPa
of LS bypass sole-
(Max. 325kg/un)
I noid valve normal?
2 YES
L--l
Is travel oil pres-
8
sure switch nor-
1
mal? Difficult to turn
- in one direction YES
only
*See JUDGEMENT 91
TABLE. II
. Note: Is problem reversed
If auto-decelera- when suction valve
tion is canceled
when travel is
operated, system
is normal. (When come normal when
(Lo, Mi, and Hi) check valves of
travel PPC shuttle
is normal) travel motor are
NO
NO
20-224
0
TROUBLESHOOTING H-23
CElUSe Remedy
Go to H-13 _
7 YES
Defective travel motor servo Repair or
piston or center swivel joint replace
Is output pressure
_ of travel speed so- _
lenoid valve nor-
mal?
Defective operation of travel Repair or
NO speed solenoid valve replace
20-225
0
TROUBLESHOOTING H-24, H25
H-24 Travel speed does not switch or is faster than specified speed
Remedy
3 YES
Defective operation of travel qeplace
speed selector servo piston
*set
travel
level
UN.
speed solenoid valve
sure H
Is
mal?
travel oil pres-
switch nor-
* See Table 1.
NO
Defective
control
operation
EPC solenoid
of LS
valve
3epair
,eplace
or
1
;gFMEN~ Defective
switch
travel oil pressure 3eplace
If auto-decelera- No
tion is canceled
when travel is
operated, system is
normal. (When
travel PPC shuttle
is normal)
Lo Mi Hi
Remedy
-1Max.
l 10 Umin Defective travel motor Replace
l Engine at high NO
idling
. At travel relief
20-226
0
TROUBLESHOOTING H-26
Cause Remedy
3 YES
Defective swing machinery Repair or
II replace
YES Is any dirt found
- in swing machinery -
2 drain?
Cause Remedy
2 YES
Defective swng motor safety Replace
I II
H
valve
YES Does control valve
spool move
1 smoothly?
I s-l
I I Defective operation of con- Repair or
Is PPC valve out- NO trol valve spool replace
put pressure nor-
20-227
0
TROUBLESHOOTING H-27
4 YES
II
r
. Travel operated 1
Independently. NO
* 2.9*0.5MPa
(30i5kg/cd)
* LS shuttle for
boom, arm, bucket,
1
R.H. travel, L.H. NO
travel
r
YES
Is swing accelera-
tion poor in both a
directions or in one
dlrectlon only? $
1 z
sure compensation
valve piston rnOB s:
* It is also possible
Yt Does control valve to interchange
with other com- L
pensation valve. NO
* Note:
After inspection,
do not foroet to
NO
t
. Same conditions as
Is output pressure for Item 5
_ One direc- 1
- of PPC valve nor- - . ~~~~~~ ppC
tion only
1 mal? N0
shuttle block inlet
hose, fit adapter,
and block tip.
- 2.9*0.5MPa (Note).
(30+5kg/cd)
* Engine at high
NO
ldlino
* Turn-swing lock
switch ON (lock)
Note: If the adapter for blocking the circuit is not available, interchange PPC hose of swing with one of
bucket (CURL, DUMP), boom (LOWER), or arm (IN).
20-228
0
TROUBLESHOOTING H-27
c
Defective
sembly
swing motor as- Repair
replace
or
9 YES
Defective swing motor safety Replace
Does condition be- valve
come normal when
_ left and right
safety valves of
motor are inter-
changed?
Defective swing motor suc- Replace
* lt is also possible ND tion valve
to measure relief
pressure of motor.
l Relief pressure:
25.0 - 30.4MPa
(255 - 310 kg/cm?
Defective operation of pres-
sure compensation valve or Repair or
compensation valve piston replace
20-229
0
TROUBLESHOOTING H-28
Remedy
2 YES
Defective PPC valve Replace
Is problem reversed
when left and right
output hoses of -
PPC valve are in-
terchanged?
Defective swing motor safety Replace
Does controlvalve NO WlVe
spool move
smoothly?
b) Both directions
Table 1
Cause Remedy
Defective swing motor Repair or replace
20-230
0
TROUBLESHOOTING H-29, H-30
Cause Remedy
1 YES
Defective PPC valve Replace
II
Does control valve
spool move
smoothly?
ES
;;;;tIve swing motor safety Replace
I I I
Defective lift check valve Repair or
NO reolace
20-231
0
TROUBLESHOOTING H-31
Cause Remedy
YES
- [ %Zions
1
I!Idreinam.ynl/
tr;; motor nor- 1
Defective oil tightness
trol valve spool
of con- Replace
Cause Remedy
20-232
0
TROUBLESHOOTING H-32
Remedy
1 YES
Defective operation of LS Replace servo
Is LS control EPC valve assembly
solenoid valve out- _
put pressure nor-
mal?
I I
Defective LS control EPC SCJ- Repair or
- See Table 1. NO lenoid valve replace
0.2 + 0.2 MPa 0.2 f 0.2 MPa 1.2 & 0.2 MPa 0.9 & 0.2 MPa
(20 312.0 kg/cm*) (20 f 2.0 kg/cm? (12 3~ 2.0 kg/cm? (9.0 f 2.0 kg/cm*)
20-232-l
0
TROUBLESHOOTING OF MACHINE MONITOR
SYSTEM (M MODE)
PCIOO-6 Serial No : 40001-41229
PC120-6 Serial No : 45001-49820 I
Action taken by monitor panel and condition of a) Engine oil pressure flashes.. ......... 20-247
machine when abnormality occurs .. .. . ... . .. .._. 20-235 b) Coolant level flashes ..................... 20-248
Machine monitor system circuit diagram .. . . 20-236 c) Coolant temperature flashes ....... .20-248
Troubleshooting flow charts for each failure d) Battery charge flashes .................. 20-249
mode e) Fuel level flashes ........................... 20-249
M-l [El:011 Abnormality in error data is M-12 a) When starting switch is turned ON
displayed . .. . ... . . .. .. . .. . .. .. . .. .. . ... . . 20-237 (engine stopped), buzzer does not
M-2 [El:021 Error in clock data is sound for 1 second.. ...................... 20-250
displayed . . .. . ... . .. . .. .. .. . .. . .. . .. .. . .. 20-237 Caution items are flashing but buzzer
M-3 [El:031 Short circuit in buzzer output or does not sound. ............................. 20-250
contact of 24V wiring harness b) No abnormality is displayed on
with buzzer drive harness is monitor but buzzer sounds.. ........ .20-250
displayed . .. . .. . .. . .. . .. .. . .. .. . ... . .. . .. 20-237 M-13 Liquid crystal night lighting on monitor
M-4 When starting switch is turned ON, panel does not light up.. .................... 20-251
none of lamps on monitor panel light M-14 Coolant temperature gauge does not
up for 3 seconds . .. . ... . . ... . .. . .. .. . .. .. . .. . .. . 20-238 rise ...................................................... 20-252
a) None of lamps on monitor panel M-15 Coolant temperature gauge does not
light up . .. .. . .. . .. .. . .. .. . . .. .. .. . .. .. .. . .. . .. . .. . 20-238 give any display ................................ .20-253
b) Some of lamps on monitor panel M-16 Fuel level gauge always displays
do not light up ..._.............._............ 20-238 FULL ................................................... 20-254
g
M-5 When starting switch is turned ON, M-17 Fuel level gauge does not give any
8
8 monitor panel lamps all stay lighted up display ................................................ 20-254
and do not go out ._............................ 20-239 M-18 Swing lock switch is turned ON (LOCK)
M-6 When starting switch is turned ON, items but monitor panel parking display does
lighted up on monitor panel are different not light up . . .. . .. .. . .. . ... . .. .. . .. .. . .. . .. . .. . ... . . 20-255
from actual machine (model) .. . ..._..... 20-239 M-19 Swing prolix switch is ON (prolix),
M-7 When starting switch is turned ON but monitor panel parking display
(engine stopped), CHECK items does not flash . . .. ... .. ... . .. . .. . ... .. ... . .. .. . .. . 20-255
flash . . .. .. . .. . .. . ... . . .. .. .. .. . .. . .. . ... . .. .. .. . .. . .. .. . 20-240 M-20 Defective fuel level sensor system .. . 20-256
a) Coolant level flashes . . .. .. .._............ 20-240 M-21 Defective coolant temperature sensor
b) Engine oil level flashes ...._.........._. 20-241 system . . .. .._......................................... 20-257
M-8 Preheating is not being used but M-22 Defective engine oil level sensor
preheating display lights up ._._....._.... 20-242 system .._.._.._..~. . .. . .. .. .~. .. . .. . .. .. .. .. . .. . .. .. . . 20-258
M-9 When starting switch is turned ON and M-23 Defective coolant level sensor
engine is started, CHECK items system .._........._................................... 20-259
flash .. .._............................................... 20-243 M-24 Working lamp, panel lighting do not
a) Alternator system .. .. .._.......__.......... 20-243 light up, or switch is not being used
b) Engine oil pressure system .. . .. . .. .. 20-244 but lamps light up .. .. .. . ... . .. . .. . .. . ... . . ... . . 20-260
M-10 When starting switch is turned ON a) Working lamp does not light up . .. 20-260
(engine stopped), CAUTION items b) Panel lighting does not light up . ..20-260
flash . . .. .. ..._......._.................................. 20-245 c) Light switch is not being used but
a) Alternator system . .. .. .. .. .. . .. . .. .. . .. .. . 20-245 working lamp lights up .. . .. . .. .. . .. .. . . 20-261
b) Engine oil pressure sensor M-25 Wiper does not work or switch is not
system .. . .. .. . .. .. .._........................_... 20-245 being used but wiper is actuated . .. . .. 20-262
M-l 1 When starting switch is turned ON and a) Wiper does not work . .. ... . .. . .. .. . .. . .. . 20-262
engine is started, CAUTION items b) Wiper switch is not being used but
flash .._._......_........................................ 20-247 wiper is actuated . ... . .. .. . .. . .. .. . .. . .. .. . . 20-264
20-233
0
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE
User Service Condition when normal Action by controller when abnormality. Problem that appears on machine when
code code Abnormal system Nature of abnormality
(voltage, current, resistance) is detected there is abnormality
1. Short circuit inside buzzer Voltage between PO1 (13) - (II) (12)
2. Power line in contact with wiring harness Buzzer ON: Max. IV
between monitor panel PO1 (13) - buzzer Buzzer OFF: 20 - 30V
- Short circuit in buzzer 3. Abnormality in monitor panel Buzzer does not sound
El :03 *When there is disconnection, El:03 is not -
output system
displayed and buzzer does not sound
MACHINE MONITOR SYSTEM CIRCUIT DIAGRAM
Starting switch Service meter Light switch Swing lock switch Wiper, washer switch Swing lock prolix switch
6OW
R.H. head
light
H02(S16)
7ow
Working
light
(boom)
W04(M6)
Light relay
D13(KESl 2)
Window washer
(KESO 2) M2El(X2)
c-_3 IVY
IO. 85WL 1
nh H05(M6)
I II IIIII I
I II II!! I
I II I I I
L---I
mground m AEXSW
I I Enaine throttle controller
I III L- --
$?2
1_1 Enaine oil .^
m*
20-236 sensor
M-l [El:011 Abnormality in error data is displayed
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check
if El:03 is displayed. (If it is not displayed, the system has been reset.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Remedy
2 YES
Defective monitor panel qeplaca
205CA06522
20-237
M-4 When starting switch is turned ON, none of lamps on monitor
panel light up for 3 seconds
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Iefective monitor panel qeplace
Monitor panel
POl(O4020)
I Fuse 13
W
6 H05CM6)
I_
777
205CA06523
20-238
M-5 When starting switch is turned ON, monitor panel lamps all stay
lighted up and do not go out
CalSe Remedy
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
8
8
Cause Remedy
8
r
\rES
Defective monitor panel 3eplace
1
Is display of moni-
toring code 01 as 1
shown in Table l?
* Turn starting
switch ON. No
:ON
Table 1 (:::I : OFF Table 2
20-239
M-7 When starting switch is turned ON (engine stopped), CHECK items
flash
(Fluid levels for CHECK items are at specified level)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* Check that the coolant is at the specified level before carrying out troubleshooting
a)
sl 8 (coolant level) flashes
Cause
3 YES
Defective monitor panel
connBxor IS con- Is continuit be- Replace
netted to PO8 (fe- YES tween PO1 rfemale)
male) ? - (17) and (3) as -
~
2 shown in the ta- Defective contact, or discon-
* Turn starting ble? nection in wiring harness be-
switch ON. Is there continuity p p Repair or
tween PO8 (female) (1) - replace
_ between PO8 (fe- _ . Connect - NO
HO3 (11) - PO1 (female)
NO male) (2) and disconnect short
chassis ground? (10)
connector to PO8
(female).
* Turn starting * Turn starting switch ON.
switch OFF. * Disconnect POl. Defective contact, or discon- Clean (defec-
* Disconnect POE. nection in wiring harness be- tive contact)
NO tween PO8 (female) (2) - or replace
chassis ground
Table
205CA06524
20-240
(engine oil level) flashes
* Use the level gauge to check that the engine oil level is correct before carrying out troubleshooting.
cause Remedy
PO1
Monitor
pXld
20-241
M-8 Preheating is not being used but preheating display lights up
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
Starting HO3
switch Ml(M4) Ell(X2) t24v
Monitor panel
Electrical
POl(O4020) intake
air heater
H05CM6)
I
205CA06545
20-242
M-9 When starting switch is turned ON and engine is started, CHECK
items flash
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* Check both the alternator system and the engine oil pressure system.
a) Alternator system
2 YES
I Defective monitor panel Reolace
20-243
bl Engine oil pressure system
YES
Defective oil pressure sensor Replace
1 I (for low pressure)
When engine IS run-
ning at low idling
and wiring harness _
Contact of chassis ground
of oil pressure sensor 2 YES with wiring harness between Replace or
is removed, does dis- p -
play go out? PO1 (female) (17) - HO3 replace
~ Is there continuity (13) - oil pressure sensor
. Engine at low _ between PO1 (fe- _
idling ~0 male) (17) and
chassis ground?
Defective monitor panel Replace
* Turn starting NO
switch OFF.
* Disconnect wiring
harness PO1 of oil
pressure sensor.
PO2(04016) Alternator
Monitor
panel
205CA06546
20-244
TROUBLESHOOTING M-10
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
a) Alternator system
Cause Remedy
2 YES
Defective monitor panel Replace
Is voltage between
YES POZ (female) (13) _
1 and chassis ground
1 normal? Contact of 24V wiring har-
ness with wiring harness be- Repair or
Is voltage between p -
tween alternator terminal R - replace
alternator terminal _ . When engine is NO
HO3 (7) - PO2 (female) (13)
R and chassis stopped:Max. 3V
ground normal? - Turn starting
p switch ON.
* When engine is - Disconnect P02.
Defective alternator Replace
stopped:Max. 3V ND
* Turn starting
switch ON.
- Remove wiring
harness from
terminal R.
2 YES
Defective monitor panel Replace
Is there continuity
between wiring
yE? harness or PO1 (fa- _
1 male) (17) and ter-
Defective contact, or discon-
- minal of oil pres-
nection In wiring harness be- Repair or
Is there continuity sure seosor ?
between oil pres- tween oil pressure sensor ter- replace
NO minal - HO3 (13) - PO1
sure sensor termi- - * Turn starting
switch OFF. (female) (17)
nal and chassis
ground? - Disconnect POl.
* Turn starting
Defective oil pressure sensor Replace
switch OFF. NO
. Remove wiring
harness from oil
pressure sensor
20-245
0
2) High pressuresensor
Remedy
2 YES
Seplace
Defective monitor panel
Is there continuity
between wiring
YES harness of PO1 tfe- _
, r male) (16) and ter- Defective contact, or discon-
nliFll of Oil nres- nection in wiring harness be-
tween oil pressure sensor ter-
* Turn starting NO minal - HO3 (12) - PO1
switch OFF. (female) (16)
6 Disconnect POl.
ground?
PO2(04016) Alternator
H03CS16) terminal R
Monitor
Dawl
205CA06566
20-246
M-II When starting switch is turned ON and engine is started, CAUTION
items flash
(but when there is no abnormality in engine or CHECK items)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
YES
Defective engine oil pressure Replace
1 sensor
When wiring har-
ness at terminal of
oil pressure sensor - Contact of chassis ground
is removed, does 2 YES with wiring harness between Repair or
display go out? HO3 (13) - PO1 (female) replace
- Is there continuity (17)
. Engine at low _ between PO1 (fe- _
idling. ND male) (17) -
(11)(12)?
Defective monitor panel Replace
- Turn starting NO
switch OFF.
* Disconnect POl.
Engine oil
c pressure sesoI
(IOWpressure)
Monitor
p.Slel H05CM6)
Remedy
205CA06548A
2) High pressure sensor
YES
Defective engine oil pressure
1 sensor
When wiring har-
ness at terminal of
oil pressure sensor - Contact of chassis ground
is removed, does 2 YES with wiring harness between Repair or
display go out? HO3 (12) - PO1 (female) replace
- Is there continuity (16)
* Engine at high _ between PO1 (fe- _
idling. NC male) (16) -
(11)(12)?
Defective monitor panel Replace
- Turn starting NO
switch OFF.
. Disconnect POl.
POl(O4020) H03CS16)
Engine
oil
pressure
sensor
(high pressure)
Monitor
panel
20-247
(coolant level) flashes
Cause Remedy
cl
El (coolant temperature) flashes
Cause
2 YES
I II Defective coolant temperature -
When short connec- iensor system (see M-21)
YES tar is connected to _
1 PO7 (female) does
display go out?
PO2 HO3
(04016) (S16) P7(X2) Cootant
femperature*e"*Or
Monitor
pall4
205CA06549
20-248
d) I_ (battery charge) flashes
cl
2 YES
Defective monitor panel Replace
Is voltage between
YES POZ (female) (13) _
I r wdhl,sis ground
Defective contact, or discon-
nection in wiring harness be- Repair or
NO tween alternator
and PO2 (female)
terminal
(13)
R
PO2 HO3
(04016) (S16)
Monitor
panel
PO2 HO3
(04016 (S16) PO6(Xl)
Monitor Fuel
DaneI level *ensor
779 205CA06534
20-249
M-12 (a) When starting switch is turned ON (engine stopped), buzzer
does not sound for 1 second
CAUTION items are flashing but buzzer does not sound
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
: Of the CAUTION items, the buzzer will not sound even if there is an abmormality in the battery charge
or fuel level.
Cause
1 YES
Defective monitor panel Replace
I Remedy
t24v
I calmon
PO1 P04(M2)
(04020)
Monitor
panel
I I 011
205CA06535
20-250
M-13 Liquid crystal night lighting on monitor panel does not light up
(Liquid crystal display is normal)
Remedy
YES
Blown bulb or defective con- Repair or
1 tact of bulb replace
Isbulb blown, or is
there defectlve cdn- -
tact? 2 YES
Defective monitor panel Replace
Does bit (2) of
* Remove bulb. - monitoring code 46 -
. Check bulb No light up?
visually. Defective contact, or discon-
nection in wiring harness be-
NO tween MO7 (male) (1) - X01
(1) - PO1 (female) (7)
Monitor panel
POl(O4020)
1) M07(M2)
Light switch
i
205CAO6536
20-251
M-14 Coolant temperature gauge does not rise
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
* If the coolant temperature actually does not rise, check the engine system.
Cause Remedy
YES
Defective monitor panel Replace
PO2 HO3
(04016) (S16) P7(X21 COOlent
>d
;,,i,,r Pcll
(04020)
205CAO6551
20-252
M-15 Coolant temperature gauge does not give any display
(none of gauge lamps light up during operation)
-
Remedy
__
YFS
-
Defective coolant temperature
sensor system (see M-21)
PO2 HO3
(04016) (S16) P7CX2) COolant
temperature sesor
>@I
Monitor P 0 1
panel (04020)
205CAO6551
20-253
M-16 Fuel level gauge always displays FULL
Remedy
YES
Defective fuel level Sensor -
1 system (see M-20)
* The fuel level may vary, so the display is given a time delay.
YES
Defective fuel level sensor
1 system (see M-20)
Does display ap-
pear when PO6
(female)(r) and - 2
YES
chassis ground are Is there continuity Defective monitor panel qeplace
connected? between PO2 (fe-
male) (11) and
* Turn starting _ chassis round
switch ON. NO when P 8 6
(female) (1) and Defective contact, or discon-
* Disconnect P06.
chassis ground are nection in wiring harness be-
connected? tween PO6 (female) (1) -
- NO
. Turn starting HO3 (5) - PO2 (female) (11)
switch OFF.
. ;$onnect P02,
PO2 HO3
(04016) (S16) PO6(Xl)
Fuel level sensor
Moltor
panel
20-254
M-18 Swing lock switch is turned ON (LOCK) but monitor panel parking
display does not light up
* Carry out this troubleshooting only if the swing lock is actually being actuated.
Callse
T Remedy
205CA06540
* Carry out this troubleshooting only if the swing prolix is actually being actuated.
Cause
Table 1
205CA06541
20-255
M-20 Defective fuel level sensor system
Remedy
Table 1
F20205053
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so
be careful when installing.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate
action.
20-256
M-21 Defective coolant temperature sensor system
Cause Remedy
Table 1
Normal temperature (25C) 1 Approx. 37 - 50 KQ
Eo 100C 1 Approx. 3.5 - 4.0 KQ
z
%
Connector Sensor
--
F20205054
Note 1: If the problem occurs again, the connector (female) at the chassis ecd is probably defective, so
check the connector and wiring harness at the chassis end.
Note 2: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate
action.
20-257
M-22 Defective engine oil level sensor system
CaW3
down, IS resistance
between connector
YES
1
~
YES
NO
1 Defective movement
due to dirt
Resonance
IDefective
1tor (Note
of mount
contact
2)
of float
of connec-
Replace sensor
(Note 4)
Clean connec-
tor or replace
(1) and flange as
shown in Table l?
IDisconnection in wiring har-
4 YES Iless (Note 3) (defective
,:lam ) (external force ap- Replace sensor
I
Izlied P
Check wiring har-
i ness visually. Is it -
NO broken?
Table 1
Float UP Max. 1 Q
Float DOWN 1 Min.lMQ
UP
F20205055
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so
check the connector and wiring harness at the chassis end.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate
action.
Note 4:Defective installation is a possible cause, so be careful when installing. If the problem occurs
again, check for any vibration of the mount, and if there is excessive vibration, take the appropri-
ate action.
20-258
M-23 Defective coolant level sensor system
Cause Remedy
YES
- I Iefective movement of float :lean
2 clue to dirt
ES Is anydirt stuck to
moving part of -
float?
3 YES
qeplace sensor
- fTesonance of mount
(:Note 2) [Note 4)
- Is there any large
- crack, chip, or
NO damage to float?
12
Replace sensor
<;;e! 1 (external force ap-
Table 1
Float UP 1 Max. 1 Q
Float DOWN 1 Min. 1 MD
F20205056
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so
check the connector and wiring harness at the chassis end.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate
action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs
again, check for any vibration of the mount, and if there is excessive vibration, take the appropri-
ate action.
20-259
M-24 Working lamp, panel lighting do not light up, or switch is not
being used but lamps light up
H
tion in lamp replace
Is there any dis-
Y j connection or de- Defective contact, or discon-
/a%;; contact in nection in wiring harness be-
tween MO7 (male) (2) - X01
2 i (3) - fuse (4). MO7 (male) Repair or
NO (1) - X01 (1) - R04 (1). replace
Is resistance be- * Check visually. R04 (2) - HO6 (1) - chassis
YI tween R04 (male) ground, between R04 (3) and
(3) and (5) nor- Fuse (4). between R04 (5) -
mal? HO2 (10) - MO8 (female)
1 I
(1) or R04 (5) - HO2 (10) -
Ml0 (1) - MO9 (female) (1)
Is resistance be-
tween MO7 (fe- Defective light relay
male) (1) and (2) ground. NO
*Max. 10
- Disconnect R04.
. Turn light switch
_...
ON
- Max. 1Q Defective light switch Replace
. Disconnect M07. NO
I Cause I Remedy
-Max. 10
20-260
cl Light switch is not being used but working lamp lights up
Remedy
. Turn starting
switch ON.
8
8 M-24 Related electric circuit diagram
8
Light switch
Light relay
, q
M08(Ml f
Flight
MlO(M1) M09(Ml)
Working light
H02(S16)
XOl(MIC21) H06( L2 1
Floor ground
POl(O4020)
Monitor
pa4
205CAO6542
20-261
TROUBLESHOOTING M-25
M-25 Wiper does not work or switch is not being used but wiper is
actuated
Cause Remedy
4 YE!
+GotoA
Is resrstance
YES between Ml8
- (female) (1) - (2), -
- 3 (I)-(4)asshown
in Table l? Defective wiper washer
YES Is voltage Reolace
NC switch
- between M46 (2) - -Turn starting
and (I) normal? switch OFF.
2
* Disconnect M18. Defective contact, or discon
Is resistance nection in wirin harness
*20-30V Repair or
YES between WI0 between fuse (73 - W08 (fe-
- (male) (3) (4) - - * Turn starting male) (5). W08 (female) (1). replace
NO
W08 (4) (18) switch ON. (8) - HO6 (1) - GND
~ 1 normal?
Is resistance Defective contact, or discon
* Max. 1 R
between WI0 nection in wiring harness
- *Turn starting between Ml0 (male) (3) (4).
(female) (3) and NO
switch OFF. W08 (female) (4) (18)
(4) normal? * Disconnect WlO,
* Front window W08.
Defective rear limit switch Replace
closed position:
NO * Front window is open I Setwindow in
Min. 1 MD
position cor-
* Turn starting
rectly
switch OFF.
* Disconnect WIO. 7 YE! Defective wiper motor
Replace
controller
between Ml8
(female) (1) (2) (4) Defective wiper motor Replace
A-
- W08 (female)
(12) (14) (15) as
shown in Table I?
Contact of wiring harness
*Turn starting I between Ml8 (male) (I) (2 Repair or
switch OFF. NO (4)-X01 (21) (11) (20)- replace
- Disconnect M18. W08 (female) (12) (14) (151
Table 1 Table 2
I
Actuation Resistance Between W04 (female) (I) -
Ml8 (female) W08 (female)
mode (R) W08 (female) (7)
/ Between(lk(4) 1Between(12k(15) 1 Max.1 D Between W04 (female) (3) -
INT mode Between (l)-(2) Between (12)~(14) Min 1 MD W08 (female) (6)
Between (2)-(4) Between (14)~(15) . Between W04 (female) (4) -
W08 (female) (II) Max. 1 R
Between (l)-_(2) Between (12)~(14)
OFF mode Between (l)-_(4) Between (12)-(15) Min. 1 MD Between W04 (female) (5) -
Between (2k(4) Between (14)~(15) W08 (female) (9)
Between (l)-(2) Between (12)~(14) Max. 1 R Between W04 (female) (6) -
W08 (female) (IO)
ON mode Between (l)-_(4) Between (12)~(15)
Between (2)~(4) Between (14)-(15) Min MR Between W04(female) (I),
Min 1 MD
(3). (4L (5). (6)-GND
20-262
0
Table 3
W04CM6)
Wmdow washer
M46lM3j
- HO4
FUW
iS16)
5
-
7
w
HO2
(S16)
I
I
I I I I
(M4
M18CM4)
205CA06543
20-263
b) Wiper switch is not being used but wiper is actuated
Cause Remedy
3 YES
C$$jj$q TGotoA
YES
Table 1 !
Defective wiper washer Replace
witch
shown in Table 3? 6 YE
3efective wiper motor con- qeplace
I I Is resistance be- :roller
4 . Turn starting tween each pin of
switch ON. r LVi4? (male) nor-
Contact between wiring har-
lesses of system with defec- 3epair or
- Max. 1 MD NI :ive resistance .eplace
* Turn starting
switch OFF.
- ;;cpnnect W04,
:ontact of wiring harness be-
ween Ml8 (male) (1) (2) (4) - qepair or
0 CO1 (21)(11)(20) - W08 replace
:fernale) (12) (14) (15)
Table 1
Actuation Resistance
Ml8 (female) W08 (female)
mode 10,
Between (l)-_(4) Between (12)-(15) Max. 1 R
INT mode Between (l)-_(2) Between (12)-(14) Min 1 Mn
Between (2)-(4) Between (14k(15)
Between (l)--_(2) Between (12)~(14)
OFF mode Between (l)-_(4) Between (12)-(15) Min. 1 MR
Between (2)-(4) Between (14)~(15)
Between (l)-_(2) Between (12)-(14) Max. 1 R
ON mode Between (l)-_(4) Between (12)~(15)
Between (2)-_(4) Between (14)-(15) Min. MR
20-264
Table 3
20-265
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM
(M MODE)
PCIOO-6 Serial No. : 41230 and up
PC120-6 Serial No. : 49821 and up I
Action taken by monitor panel when abnormality occurs and problems on machine ................. 20-270
M-6 When starting switch is turned ON, none of lamps on monitor panel
light up for 3 seconds ......................................................................................................... 20-280
M-7 When starting switch is turned ON, monitor panel lamps all stay lighted up
and do not go out ............................................................................................................... 20-282
M-8 When starting switch is turned ON, items lighted up on monitor panel are different from
actual machine (model). ...................................................................................................... 20-282
2i M-9 When starting switch is turned ON (engine stopped), basic check items flashes.. ....... .20-283
g
g M-10 Preheating is not being used but (preheating monitor) lights up.. .................................. 20-285
M-l 1 When starting switch is turned ON and engine is started, basic check items flash.. .... .20-286
M-12 When starting switch is turned ON (engine stopped), caution items,
emergency items flash ........................................................................................................ 20-288
M-13 When starting switch is turned ON and engine is started, caution items,
emergency items flash ........................................................................................................ 20-290
M-14 When starting switch is turned ON (engine stopped), buzzer does not sound for 1 second
Caution item flashes but buzzer does not sound .............................................................. 20-293
M-16 Night lighting on monitor panel does not light up (liquid crystal display is normal) ... .20-294
M-18 Coolant temperature gauge does not give any display .................................................... 20-295
M-20 Fuel level gauge does not give any display ...................................................................... 20-296
M-21 Swing lock switch is turned ON (LOCK) but (swing lock monitor) does not light up.. . .20-297
M-22 Swing prolix switch is turned ON (prolix), but (swing lock monitor) does not flash .... .20-297
M-23 Service meter does not advance while engine is running ............................................... 20-298
20-267
0
M-27 Defective engine oil level sensor system ........................................................................... 20-301
M-29 Wiper does not work or switch is not being used but wiper is actuated.. ................... .20-304
M-30 Washer motor does not work, or switch is not being used but washer
motor is actuated ................................................................................................................ 20-310
20-268
0
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
- Air cleaner clogging 1. Air cleaner clogging sensor has detected clogging
El04
detected is displayed
Engine water
1. Coolant temperature gauge has detected water temperature of
- El08 temperature 105C
105C
detected is displayed
20-270
0
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
voltage, current, resistance) abnormality is detected when there is abnormality
20-271
0
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
User Service
Abnormal system Nature of abnormality
code code
20-272
0
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
Voltage between W04 (3) and (5): Max. 3 V Sets output to relay box Operation of wiper stops
to 0
1
20 - 30 v
* Repeats in regular cycle
Voltage between W04 (1) and (5): Max. 3 V Same as El12 SameasE
T
20-30V
* Repeats in regular cycle
20-273
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
Startino switch
Right front
lamp
Boom work-
ing lamp H12(S16)
(MIC17) jm]
Window washer
H14(M6)
I I I
I I
I
I
I I
I I I I I
I II I I I I I
Network
path
Alarm
BKP00378
20-274
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR M MODE SYSTEM
M18IM4)
W04IM6)
Buzzer cancel
C17(04016)
Ikf;;;\
PO7(X2)
Engine water temperature sensor
20-275
0
TROUBLESHOOTING M-l
2,__(E
Remedy
,. . Replace
Is voltage
YES_ between PO2 Disconnection, defective
1 (8)(14) and contact, short circuit with
Does service code chassis normal? ground in wiring harness Repair or
display appear NO between battery - Ml 1 replace
_ * Turn starting
again after system (l)(2) - HI4 (1) -fuse No.
switch OFF.
13 - PO2 (female) (8)(14)
has been reset? *20-30V
* After resetting Normal
system, carry out NO
normal
operations for a
short time and
watch the
condition. (See
Note 1.)
Monitor Panel
PO2 (0 116)
Ml 1 IL21
GND
Power source
(+24v)
GND
Powersource
k24V) Fusible link
&-mHm@ w Battery
relay
TDP00305
20-276
0
TROUBLESHOOTING M-2
2 YES
I II Defective monitor panel Replace
Is voltage
YES_ between ~04 (2) _ Short circuit with power
1 and chassis source in wiring harness
between PO1 (femaleH7) Repair or
Is resistancebetween _normal? and PO4 (female)(Z) or replace
PO4(male)(1) - (21, _ l Turn starting NO short circuit in wiring
(2) -chassis as shown switch ON. harness between PO4 (I)
in the table? * Buzzer ON: Max. 1 V and (2)
*Turn starting * Buzzer OFF: 20 - 30 V
Defective buzzer Replace
switch OFF. NO
* Disconnect P04.
Table
P04(M2)
Buzzer
Fuse
BKP00273
20-277
0
TROUBLESHOOTING M-3, M-4
F
Cause Remedy
See M-13 0 -
Is E service
code displayed?
Failure in engine system
(See Note I)
-
*Turn starting NO
switch ON.
Note 1: The monitor panel display has returned to normal, but the air cleaner clogging sensor has
detected symptoms of clogging in the past, so carry out troubleshooting of the engine to $
remove the problem.
z
z
YES
1 I See M-13 a)
I Is engine oil I I
pressure caution
lamp on monitor 2 YES
flashing? Defective monitor panel Replace
Is E service
NO code displayed?
Note 1: The monitor panel display has returned to normal, but the engine oil pressure Hi sensor has
detected symptoms of a drop in the oil pressure in the past, so carry out troubleshooting of
the engine to remove the problem.
20-278
0
TROUBLESHOOTING M-5
Cause Remedy
Y -
1 See M-13 d)
temperaturegaugeon
monitor paneldisplay
* Turn starting
switch ON.
2 YES
NO
Defective monitor panel
Note 1: The monitor panel display has returned to normal, but the coolant temperature sensor has
detected symptoms of the coolant temperature reaching 105C in the past, so carry out
troubleshooting of the engine to remove the problem.
20-279
0
TROUBLESHOOTING M-6
Cause Remedy
YES
J I Defective monitor panel Replace
H
Disconnection, defective
contact, short circuit with
S YES ground in wiring harness Repair or
normal? between PO1 (female) (9) replace
and fuse No. 10
* Turn starting between fuse No.
switch ON. Disconnection,defective
Is voltage contact,short circuitwith
*20-30V Repair or
between PO2 ground in wiring harness
* Turn starting NO replace
(8)(14) - (l)(9) between fuse No. 10 - H15 (2)
normal? switch ON. - Ml4 (2)(l) - battery relay M
*20-30V
. Turn starting Disconnection, defective
4 YES Repair or
switch ON. contact, short circuit with
Is voltage ground in wiring harness replace
*20-30V
between fuse No. between PO2 (female)
NO 13 and chassis (8)(14) and fuse No. 13
normal? Disconnection, defective Repair or
-Turn starting NO contact, short circuit with replace
switch ON. ground in wiring harness
*20-30V between fuse No. 13 - H14
(I) - Ml1 (2)(l)-battery
Cause Remedy1
20-280
0
TROUBLESHOOTING M-6
Monitor Panel
PO 1 (04020) Ml4 (L2)
Starting switch ON
ble
GND
Power source 1+24v1
GND
Power source (+24V)
Battery relay
TDP00306
20-281
0
TROUBLESHOOTING M-7, M-8
M-7 When starting switch is turned ON, monitor panel lamps all stay
lighted up and do not go out
Cause
Cause Remedy
1 YES
Defective monitor panel Replace
Is display of II
monitoring code
01 as shown in
table? Go to troubleshooting for
-
NO C mode (See C-74)
- Turn starting
switch ON.
- Set to monitoring
code 01.
Table
PC100 PC120
BKP00380 BKPO0381
20-282
TROUBLESHOOTING M-9
* Check that the coolant is at the specified level before carrying out troubleshooting.
Cause Remedy
4
disconnection in wiring
Is there continuity code 24. Repair or
* Turn startina harness between Cl6
between PO8 switch OFF.- NO replace
(female) (8) - PO8
N(-J (female) (2) and
. Disconnect C16, P08. (female) (I)
chassis?
. Connect c) disconnect short
. Turn starting connector to PO8 (female). Defective contact, or
disconnection in wiring Repair or
switch OFF.
L replace
* Disconnect P08. I\10 harness between PO8
(female) (2) -chassis
ground
Table
1Short connector 1 Continuity 1
Connected Yes
Disconnected No
Coolsnt
level sensor
BKPO0277
20-283
0
TROUBLESHOOTING M-9
b) level) flashes
SAP00523
* Check that the engine oil is at the specified level before carrying out troubleshooting.
chassisground?
* Disconnect PO5.
* Turn starting Defective monitor panel
C16(femak) (16) and * Turn starting NO
switch ON.
switch ON.
* Set to monitoring code 24. Defective contact, or
disconnection in wiring Repair or
* Turn starting
harness between Cl6 replace
switch OFF. NO
(female) (16) - PO5
* Disconnect C16,
(female) (I)
PO5.
* Connect- disconnect short connector to
PO5 (female) (I).
Table
Chassis ground Continuity
Connected Yes
1 Disconnected / No 1
dIetwork
20-284
0
TROUBLESHOOTING M-10
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
r Cause Remedy
Starting switch
24V
Monitor panel I I
Heater relay
PO1 (04020) Electrical intake
H13(S16) - air heater
d-0 R
@
El1 <
C
20-285
0
TROUBLESHOOTING M-II
a) Alternator system
*20-30V
BKP00384
20-286
0
TROUBLESHOOTING M-II
2) High-pressure sensor
Cause Remedy
BKP00385
20-287
TROUBLESHOOTING M-12
a) Alternator system
I Cause I Remedy
et-work 2 BeEen/
charge
BKP00384
20-288
0
TROUBLESHOOTING M-12
2) High-pressure sensor
Cause Remedy
w
%
3 YES Defective engine throttle
Iqeplace
pump controller
YES ISbit (2) Of
- monitoring code -
2
- 24 lighted up?
Is there continutiy Defective monitor panel Iqeplace
YES between Cl6 (femle) _ *Engine at high NO
(7) and sensor wiring ilding
1 Defective contact, or
harness? * Set to monitoring code 24.
Is there continuity disconnection in wiring
-Turn starting harness between Cl6 Flepair or
between sensor
- switch OFF. NO (female) (7) - S16 rseplace
terminal S16 and
* Disconnect Cl6
chassis?
P andS16.
*Turn starting
switch OFF. Defective oil pressure Fieplace
*Removesensor NO sensor (high pressure)
wiring harness.
BKP00385
20-289
0
TROUBLESHOOTING M-13
0 6
SAP00520
(engine oil pressure) flashes
See M-II b)
See M-9 a) -
cl I-+
SAP00522
(battery charge) flashes
See M-l 1 a)
20-290
0
TROUBLESHOOTING M-13
YI is disconnected,
does only level 1 - 3 YES Defective engine throttle,
(left end) of gauge Replace
Is resistance pump controller
1 display light up?
between CO3
- (female) (1) - (16). - Short circuit of wiring
* Start engine. NO (I) (16) -chassis harness between CO3
normal? (female) (1) - PO7 Repair or
(female) (1) and wiring replace
* Turn starting NO
harness between CO3
switch OFF. (female) (16) - PO7
* Start engine and * Disconnect CO3 and P07. (female) (2)
run at mid-range l Max. 1 MR
or above. Defective monitor panel Replace
IO
BKP00386
YE
Defective engine throttle,
~~ pump controller
Defective contact or
disconnection in wiring Repair or
(The fuel level harness between CO3 replace
- ConnectPO6(female) NO
(female) (2) and PO6
may vary, so the (1) to chassisground.
* Start engine. (female) (I)
display is given a *TurnstartingswitchON.
time delay.) - Max. 0.3 V Defective monitor panel Replace
NO
BKP00285
20-291
0
TROUBLESHOOTING M-13
*
f1 c__~
r3 (air cleaner clogging) flashes
SAP00521
j, Check that the air cleaner is not clogged before carrying out troubleshooting.
Remedy
BKP00286
20-292
0
TROUBLESHOOTING M-14, M-15
YES
Defective monitor panel Replace
When PO1(female)
. ,_^ Defective contact or
YES (7) and chassis are disconnection in wiring
connected, does 3 YES harness between PO1 Repair or
, buzzer sound? Is voltage (female) (7) and PO4 replace
(female) (2)
~ *Disconnect POI. _ between PO4
Is resistance * Turn starting NO (female) (1) and Disconnection, defective
between PO4 _ switch ON. chassis normal? contact, short circuit with Repair or
(male) (1) and (2) ground in wiring harness replace
* Disconnect ~04. NO
normal? between PO4 (female) (I)
. Turn starting
* Turn starting and fuse No. 13
switch ON.
switch OFF. *20-30V
* Disconnect P04. Defective buzzer Replace
*200-300 Q NO
23
g M-15 No abnormality is displayed on monitor but buzzer sounds
8
* When the buzzer sounds continuously.
If the buzzer sounds intermittently, carry out troubleshoot-
ing M-14.)
* Before carrying out troubleshooting, check that all the
related connectors are properly inserted. Remedy
* Always connect any disconnected connectors before going
on the next step.
Contact of chassis
ground with wiring
1 YES harness between PO1 Repair or
(female) (7) and PO4 replace
(female) (2). or defective
buzzer
gf-rfl Buzzer
Buzzer a. I 1 I
20-293
0
TROUBLESHOOTING M-16
M-16 Night lighting on monitor panel does not light up (liquid crystal
display is normal)
* When the front lamp and working lamp light up normally.
Cause Remedy
YES
Defective monitor panel Replace
Monitor panel
PO1 (04020) Light switch
XOl(MIC21) M07(M2)
OFF ON
Light @ a 3 1
@ 3 2
Fuse
BKP00287
20-294
0
TROUBLESHOOTING M-17, M-18
1
When short
connector is 3 YES
Defective monitor panel Replace
connected to PO7
(female), do level - Does monitoring
lamps on gauge cc YES_ code 41 show a _
up in turn and then value of less than
all lamps cc out? 2 Defective engine throttle,
50?
* Disconnect P07. Istherecontinuity . Connect short connector ~0 pump controller
-Turn starting betweenCO3(female) tc PO7lfemalel.
_ (1) and (1s)when _ *Turn starting switch ON. Defective contact, or
switch ON.
NO short connector is *Set to monitoring code 41. disconnection in wiring
connected to PO7 4 YES harness between CO3 Repair or
Is there continuity (female) (16) - PO7 replace
-Turn starting
switch OFF. between CO3 (female) (2)
- Disconnect CO3 NO (female) (1) and Defective contact or
and P07. PO7 (female) (l)? Repair or
disconnection in wiring
replace
*Turn starting switch NO harness between CO3
OFF. (female) (1) - PO7
- Disconnect CO3 and (female) (I)
PO7.
BKP00386
20-295
0
TROUBLESHOOTING M-19, M-20
BKP00285
20-296
0
TROUBLESHOOTING M-21, M-22
Carry out this troubleshooting only if the swing lock is actually being actuated.
: Before carrying out troubleshooting, check that all the
related connectors are properly inserted.
* Always connect any disconnected connectors before go-
ing on the next step.
Table
$
E
0 M-22 Swing prolix switch is turned ON (prolix), but
monitor) does not flash SAT00098
switch
SKP00289
20-297
0
TROUBLESHOOTING M-23. M-24
Cause Remedy
YES
See M-13 d) -
1 A
Does battery
charge caution _
2
lamp flash? Defective monitor panel Replace
Does monitoring
* Start engine and _ code 43 show a
run at mid- NO value of greater
range or above. than IOO? Defective engine throttle,
Replace
pump controller
* Start engine and
run at mid-range
or above.
* Set to monitoring code 43.
M-24 When starting switch is at OFF and time switch is pressed, time
and service meter are not displayed
I Cause Remedy
IYES
Defective monitor panel Replace
When starting
switch is ON, is _
panel display
normal?
See M-6 -
-Turn starting NO
switch ON.
20-298
0
TROUBLESHOOTING M-25
Cause Remedy
Clean
Defective contact of
connector or
connector replace
Table
TOP (FULL)
Bottom (EMPTY)
BLP00290
20-299
0
TROUBLESHOOTING
I Cause I Remedy
Clean
ES Defective contact of
connector or
connector (See Note I)
replace sensor
Table
BKP00291
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective,
so check the connector and wiring harness at the chassis end.
Note 2: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate
action.
20-300
0
TROUBLESHOOTING M-27
Cause Remedy
YE
Resonance of mount Replace sensor
(See Note 2) (See Note 4)
Clean
anddown,is resistance II Defective contact of
connector or
betweenconnector (1) NO connector (See Note 2)
replace
andflangeasshownin
Disconnection in wiring
A YES
harness (See Note 3) Replace sensor
(defective clamp)
II (external force applied)
,,I harness visually. H
[\lUl Is it broken? 11
Defective sensor Replace
NO
UP
BLPOO292
20-30 1
0
TROUBLESHOOTING M-28
Remedy
Clean
Defective contact of
connector or
resistsnce
between NO connector (See Note 2)
replace
connector(1)and12)as
shown inTablel?
Disconnection in wiring
4 YES Replace
harness (See Note 3)
I II (defective clamp)
sensor
Check wiring
I- harness visually. - (external force applied)
NO IS it broken?
Defective sensor Replace
NO
Table
KZZIZGl
BLPO0293
20-302
0
TROUBLESHOOTING M-29
M-29 Wiper does not work or switch is not being used but wiper is
actuated
Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.
: Always connect any disconnected connectors before going on to the next step.
YES
4
ES
code 1481go out
,rned%$kaIfH
l Set to service
code display *Turn startina Nfl
l Turn starting
mode. switch ON. - .-
switch ON.
Turn wiper switch OFF.
l
l Turn wiper
Setto monitoring code [4Cl
l
switch to ON or
9 YES
INT.
l Set to monitor-
ing code 1481.
monitoring code
. Front window
closed position switch OFF. NO
. Turn starting l Disconnect MIS.
switch ON.
l Set to monitoring
code [481. 11 YES
Isresrstance be-
tween WlO (male)
YES (3) - ~02 (female)
l Turn starting
switch OFF. NO
l Disconnect WIO.
20-304
0
TROUBLESHOOTING M-29
Defective contact or
disconnection in wiring Repair or
harness with defective replace
resistance
Short circuit with power
source in wiring harness
between PO2 (female) (3) Repair or
and W08 (female) (3). or replace
between PO2 (female) (I I)
and W08 (female) (2)
Defective contact or Repair or
disconnection in above replace
wiring harness
Defective contact or
disconnection in wiring Repair or
harness with defective replace
resistance
Repair or
replace
20-305
0
TROUBLESHOOTING M-29
Table 1
Timing chart when wiper switch is at ON
Length of pause
when stowing wiper TIP 1.5 set
blade I I
Safety circuit during
operation of wiper Tsp 10 set
Voltage: Max. 3V: OFF Isafetv function (2)l I I
ZC-30V: ON BLPOO387
Table 2 Table 3
1Resistance valu
20-306
0
TROUBLESHOOTING M-29
Cause Remedy
4YE!
lefective monitor oanel leplace
1s reststance oe-
tween pins of PO2
YES (female), WO4
- (male), WO8 (fe- -
3 male) as shown in lefective contact or
Is resistance J&Je 2) fisconnection in wiring lepair or
YE between pins of : Turn starting N( iarness with defective eplace
Ml8 (female) (l), -
switch OFF. .esistance
(21, (4) as shown
Disconnect P02,
l
in Table l?
W04, W08.
l Turn starting
Defective wiper, washer
Do bits (I) or (2) switch OFF. NO leplace
rwitch
YE l Disconnect M18.
1
l Turn starting
switch ON.
1
. Set to monitor-
ing code [#II.
Does bit (4) of
monitoring code
$ [461 light up?
f: Turn starting
SI l
NO,
$i?%;;:t t
6
02 (female) (3) and WO8
female) (3). or between
lepair or
aplace
II
02 (female) (11) - W08
l Turn starting Do bits (2) or (3) female) (2)
switch ON. of monitoring
l Set to monitor- NO code [4Cl light
UD? Defective relay box leplace
ing code 1471. L
l Turn starting short circuit with power
switch ON. source in wiring harness
l Set to monitor- )etween WO8 (female) (6) :epair or
ing code f4Cl. rnd W04 (male) (l), or
l Disconnect WO6. Nr splace
l Turn starting letween W08 (female) (7)
switch ON. md W04 (male) (3)
l Max. 1 V
20-307
0
TROUBLESHOOTING M-29
Table 1 Table 2
1Resistance value
Fi
Between W04 (female) (3) and W08
20-308
0
TROUBLESHOOTING M-29
Connector for
troubleshooting
H14(M6)
M46
(M3)
1W04(M6)
Monitor panel PO2(04016) _
GND
Washer output
Motor reverse rotation
Wiper switch ON
Wiper switch WASHER
Limit switch W
NC
Power source (+24V)
GND
Washer output
Motor normal rotation
Wiper switch INT
Window limit switch
Power source (+24V)
Limit switch P
GND
DO1 M28
Rear H15(L2) (KESI (X2)
limit switch
(KESO)
X01 (MIC21)
MlB(M4)
Wiper, washer
switch
I
Relay box
BKP00389
20-309
0
TROUBLESHOOTING M-30
M-30 Washer motor does not work, or switch is not being used but
washer motor is actuated
Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Sr Always connect any disconnected connectors before going on to the next step.
a) Washer motor does not work
* Check that fuse 5 is normal.
al-1 When El 14 is displayed Remedy
2 YES
Defective monitor panel Replace
YES Is resistance of
- washer motor -
1
~ normal?
Is voltage between Defective washer motor
PO2 (female) (2). Replace
* Turn starting NO (internal short circuit)
(IO), M28 (female) -
switch OFF.
(1) and chassis
* Disconnect W28.
normal?- Short circuit in wiring
* Check as nindividual part.
*Turn starting l5-20R harness between PO2
switch OFF. NO (female) (2). (9) and M28
* Disconnect P02, (female) (1)
M28.
* Connect T-adapter to PO2 (female) or
M28 (female).
* Turn starting switch to ON or OFF
. Max. 1 V
Cause Remedy
al-2 When El 14 is not displayed
YES
3
--c Iefective monitor panel teplace
Is voltage
between PO2
(female) (5) and 4To A
(9) normal?
Is resistance
. Turn starting _ between Ml8 _
switch OFF. NO (female) (1) and
. Insert T-adapter (3) normal? CDefective wiper washer
in P02. Ieplace
. Turn starting switch s;witch
* Turn starting
switch ON. OFF.
Is voltage * Disconnect M18.
* Wiper washer
(ES between PO2 . Check as individual
switch at [WASH
(female) (2). (10) II or [WASH Ill: part.
1and (9) normal? Max. 1 V *Wiper washer switch I
*Wiper washer at [WASH II or
-Turn starting [WASH Ill: Max. 1 R
switch at [OFF]:
switch OFF.
20-30V -Wiper washer switch I
- Insert T-adapter at [OFF]: Min. 1 M R
in P02. : short circuit with ground
Is resistance * Turn starting C )r disconnection in
6 YES Iepair or
between relay switch ON. - viring harness between
* Wiper washer 02 (female) (2). (IO) and
box W08 ( 16)
switch at IWASH ! ~428 (1)
and (17) normal?
II or [WASH III: EH_
Max. 1 V I ;hort circuit with ground
* Turn starting xepair or
* Wiper washer _C jr disconnection in wiring
switch OFF. t larness between fuse 5 eplace
switch at [OFF]: * Disconnect M28. NO
* Disconnect W08. i md M28 (16)
20-30V * Connect T-adapter
* Max. 1 R * Turn starting switch ON.
*20-30V
_t Defective relay box
xeplace
NO ( internal disconnection)
20-310
0
TROUBLESHOOTING
M28
Rear H15(L2) (X2)
limit swit
(KESO)
I la-1 I
II
U
X01 (MIC21)
6aO@@
MlB(M4)
Wiper, washer
switch
Relay box
BKP00389
20-311
0
30 DISASSEMBLY AND ASSEMBLY
30-2
8
METHOD OF USING MANUAL
(I) When removing or installing a unit assembly, the order of work and techniques used are given for
the removal opration; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked m, and the
same mark is placed after the relevant step in the removal procedure to indicate which step in the
installation procedure it applies to.
(Example)
REMOVAL OF 0 0 0 ASSEMBLY . . .. .. . . .. . .. . . .. Title of operation
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are
given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these pre-
cautions when carrying out the operation.
(I) For details of the description, part number, and quantity of any tools (AI, etc.) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
PRECAUTIONS WHEN CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the gen-
eral precautions given below when carrying out the operation.1
3) If the part is not under hydraulic pressure, the following corks can be used.
Normal Dimensions
Partnumber
number D / d 1 L
202F2001
24 07049-02430 24 / 20 / 30
27 1 07049-02734 1 27 1 22.5 1 34
30-4
2. Precautions for installation operations
l Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
l lnstalla the hoses without twisting or interference.
l Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
l Bend the cotter pin or lock plate securely.
l When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 - 3 drops of adhesive.
l When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
l Clean all parts, and correct any damage, dents, burrs, or rust.
l Coat rotating parts and sliding parts with engine oil.
l When press fitting parts, coat the surface with antifriction comopound (LM-P).
l After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
l When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
l When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align
the direction of the hook.
l When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
* When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping
100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
8 * When using the machine for the first time after repair or long storage, follow the same proce-
dure.
. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the
engine to circulate the water through the system. Then check the water level again.
l If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
l If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been re-
moved for repair, always bleed the air from the system after reassembling the parts.
* For details, see TESTING AND ADJUSTING, Bleeding air.
l Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related
parts.
30-5
SPECIAL TOOL LIST
*Engine l hydraulic
pump assembly
*Radiator l hydraulic
oil cooler assembly
l Control pump assem
bjy B 796-740-I 300 Oil stopper 1
l Hydraulic pump
assembly
l Removal, installation
of n/C l LS valve
assembly
Disassembly of center
swivel joint assembly C
791-635-3160 Extension
1
Removal, installation
of recoil spring assem. D
bjy
790-101-1102 Pump II
Socket (width
790-302-1310 across flats: 65mm) 1 PC100 Bucket
Disassembly, asse- -
bly of hydraulic Socket (width PC100 Boom
790-102-1320 1 PC120 Bucket Removal, instal-
cylinder across flats: 70mm)
lation of piston
Socket (width nut
790-302- 1340 across flats: 80mm) PC120 Boom
30-6
Nature of work Part No. Part Name Clty Remarks
-
790-720-1000 Expander 1 Expansion of piston ring
PC100 Bucket
796-720-1650 Ring 1
PC100 Boom
07281-01029 Clamp 1
PC120 Bucket
Installation of
piston ring
PC1 00 Arm
796-720-1660 Ring 1 PC1 00 Arm
07281-01159 Clamp 1 PC120 Boom
-
790-201-1702 Push tool kit
l790-201-1781 *Push tool 1 PC100 Bucket
l790-101-5021 l Grip 1
lOlOlO-50816 l Bolt 1
30-7
Nature of work Symbol Part No. Part Name CWy Remarks
I
Disassembly,
assembly of travel I
motor
Disassembly,
assembly of hydraulic
pump
30-7-I
8
REMOVAL OF STARTING MOTOR ASSEMBLY
INSTALLATION OF STARTING
MOTOR ASSEMBLY
202FO6402
30-8
REMOVAL OF ALTERNATOR ASSEMBLY
INSTALLATION OF
ALTERNATOR ASSEMBLY
30-9
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
m
* When installing the hoses, check that the O-
ring is not damaged or deteriorated, then
connect the hoses.
1
* Adjust the belt tension.
For details, see TESTING AND ADJUSTING,
Testing and adjusting belt tension for air
conditioner compressor.
30-10
REMOVAL OF CONDENSER ASSEMBLY
INSTALLATION OF
CONDENSER ASSEMBLY
m
j, Check that the O-ring is not damaged or de-
teriorated, then connect the hoses.
30-I 1
REMOVAL OF ENGINE OIL COOLER CORE ASSEMBLY
I 202FO6605
30-12
REMOVAL OF FUEL INJECTION PUMP
202FO6606
m
. Install the fuel injection pump as follows.
1) Set No. 1 cylinder at compression top dead
center.
* Rotate the crankshaft in the normal di- mark C
rection and align the pointer with the l-4
TOP line on the crankshaft pulley. If no
match mark can be seen on the idler
gear, rotate the crankshaft one more
turn.
2) Replace the normal bolt with bolt 0, and
lock drive gear (9) in position.
(Seen from flywheel)
3) Fuel injection pump assembly
* Insert pin @ (44.0-4.5 mm, length =
approx. 100 mm) through cover mount-
ing bolt hole a, and check that the pin en-
ters the casting hole in the drive gear
smoothly.
4) Remove bolt 0 and tighten the normal bolt
again.
9
VJ 20UF01204-K
.o-fl
20UF01206-E
30-14
Drain engine coolant.,
8 INSTALLATION OF WATER
z PUMP ASSEMBLY
z
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
30-16
REMOVAL OF TURBOCHARGER ASSEMBLY
3
205FO6650
INSTALLATION OF
TURBOCHARGER ASSEMBLY
25
I
l Carry out installation in the reverse order to re-
moval.
1. Remove cover (I 1.
It Do not disconnect the hose.
INSTALLATION OF
THERMOSTAT ASSEMBLY
30-18
REMOVAL OF ENGINE FRONT OIL SEAL
2. Remove fan (I ).
INSTALLATION OF ENGINE
FRONT OIL SEAL
0 ,
205F05403A-K
REMOVAL OF ENGINE REAR OIL SEAL
INSTALLATION OF ENGINE
REAR OIL SEAL
202FO5414A
&Thread of coupling mounting bolt:
Thread tightener (LT-2)
(I
0
* Order for tightening mounting bolts 3
CD;0
a Mounting bolt : Lubricating oil (E030)
0 5
w Mounting bolt : C3;0
2
1st pass 88.2+29.4Nm(9f3 kgm) 1
m
* When assembling again, check the wear
groove at the contact of the crankshaft and
oil seal lip. If necessary, move the oil seal
towards the flywheel up to the end face of
the housing when assembling.
30-20
A Disconnect the cable from the negative (-) ter-
minal of the battery.
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY
8 m
202FOfi434
30-2 1
a Disconnect the cable from the negative (-1 ter-
minal of the battery.
I
202FO6607 \\ 202FO6437
30-22
7. Remove fuel filter assembly (13) together with
mounting bracket, and move towards radiator
end.
I 202FO6441
202FO644:
INSTALLATION OF CYLINDER HEAD
30-24
1
Order for tightening head bolts
* If any rust of more than 5 mm square is
found on the shaft or the thread of the bolt, Exhaust side
replace the head bolt with a new bolt.
*
*
Be careful to check that there is no dirt or
dust on the mounting surface of the cylinder
head or inside the cylinder.
When installing the gasket, check that the
Front hi Rear
a Mounting bolt :
Anti-friction compound (LM-P)
2nd pass:
Tighten to 107.8k4.9 Nm(llf0.5 kgm)
21 WF02229
30-25
REMOVAL OF ENGINE l HYDRAULIC PUMP ASSEMBLY
30-26
DISASSEMBLY AND ASSEMBLY ENGINE . HYDRAULIC PUMP
202FO6448
23
202FO6451
31. Remove mount bolt, then lift off engine and hy-
draulic pump assembly (33) slowly. m
* When removing the engine and hydraulic
pump assembly, check that all wiring and
piping has been disconnected, and be careful
not to hit any part when removing.
202FO6454
30-28
INSTALLATION OF ENGINE l HYDRAULIC PUMP ASSEMBLY
l Bleeding air
Sr Bleed the air from the hydraulic pump.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-29
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
202FO6456
INSTALLATION OF HYDRAULIC
OIL COOLER ASSEMBLY
PC1 00-6
PC1 20-6
30-30
0
REMOVAL OF RADIATOR l HYDRAULIC OIL COOLER ASSEMBLY
:
u Hydraulic tank : Approx. 100 Q
202FO6609
202FO6465
30-32
8. Disconnect aeration hose (8).
INSTALLATION OF
RADIATOR l HYDRAULIC OIL
COOLER ASSEMBLY
30-33
REMOVAL OF FUEL TANK ASSEMBLY
1. Drain fuel.
30-34
REMOVAL OF CENTER SWIVEL JOINT ASSEMBLY
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
. Bleeding air
* Bleed the air from the travel motor.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-36
Remove cover (1).
Using tool C, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
ASSEMBLY OF CENTER
SWIVEL JOINT ASSEMBLY
m Mounting bolt :
31.4k2.9 Nm(3.2k0.3 kgm)
205F05421A
30-37
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
INSTALLATION OF SPROCKET
30-38
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
INSTALLATION OF TRAVEL
MOTOR ASSEMBLY
30-39
0
DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR
INSTALLATION OF TRAVEL
MOTOR ASSEMBLY
-202F05437A
PClOO-6 Serial No. : 42157 and up J
30-39- 1
0
DISASSEMBLY AND ASSEMBLY OF TRAVEL MOTOR
GM18VL-MSRV
CONTENTS
SAFETY
TYPES AND MEANING OF WARNING TERMS
The four warning terms shown in the following table are used in the maintenance manual according
to the degree of expected danger (or the scale of an expected accident).
Understand the meaning of these warning terms and observe the instructions given together with
these terms.
This term means that there is an imminent danger and is used when
DANGER neglecting the given procedure or instruction can cause death or seri-
ous injury.
This term means that there is a latent danger and is used when neglect-
WARNING ing the given procedure or instruction can cause death or serious in-
jury.
This term means that there is a latent danger and is used when neglect-
CAUTION ing the given procedure or instruction can cause injury of medium or
light degree or damage of equipment or devices.
The terms of Danger and Warning do not appear in this maintenance manual, however.
PARTS LIST
PARTS LIST
FINAL DRIVE
1 HUB 1 128 Spring 2
Spindle kit 1 130 Spring 2
Spindle assembly 1 136 O-ring 2
2 Spindle 1 137 O-ring 2
3 Hold flange 1 140 O-ring 2
19 Reamer bolt 3 163 Valve 1
RV gear assembly 1 164 Stopper 1
RV gear kit 1 165 Ring 1
4 RV gear kit A 1 166 Spring 1
5 RV gear kit B 1 168 Steel ball 2
9 Crankshaft 3 192 Plug 2
22 Tapered roller bearing 6 193 O-ring 2
23 Needle roller bearing 6 194 Steel ball 2
6 Input gear 1 102 Shaft 1
Spur gear kit 1 103 Swash plate 1
7 Spur gear 3 104 Cylinder block 1
8 Cover 1 Piston kit 1
14 Distance piece 3 Piston assembly 9
15 Coupling 1 105 Piston 1
17 Pin 24 106 Shoe 1
20 Snap ring 3 107 Retainer plate 1
t: Above 2.20 up to 2.25 108 Thrust ball 1
<At interval of 0.05> 109 Timing plate 1
t: Above 2.75 up to 2.80 110 Washer 2
111 Washer 1
21 Ball bearing 2 112 Piston 1
25 C-type snap for shaft 3 113 Spring 8
27 O-ring 2 114 Spring 1
29 O-ring 1 115 Friction plate 2
30 O-ring 1 116 Mating plate 2
Floating seal kit 1 117 Mating plate 1
31 Floating seal 2 121 Plug 1
33 Hexagon socket head plug 2 132 Oil seal 1
35 Hexagon socket head bolt 10 135 O-ring 1
36 Steel ball 1 138 O-ring 2
36 Steel ball 139 O-ring 1
141 Parallel pin 1
HYDRAULIC MOTOR 142 Parallel pin 2
Rear flange assembly kit 1 143 Hexagon socket head 8
Rear flange kit 1 145 THS Snap ring 1
101 Rear flange 1 149 Bearing 1
123 Spool 1 150 Bearing 1
146 Hexagon socket head plug 3 151 Roller 3
154 Hexagon socket head plug 7 Piston assembly 1
179 Filter 1 161 Piston 1
190 Orifice 1 162 Shoe 1
199 Nameplate 1 167 Pivot 2
124 Plug 2 169 Coller 1
125 Spling retainer 2 170 Hexagon socket head bolt 4
126 Plug 2 171 Parallel pin 2
127 Valve 2 173 O-ring 1
MSRV2
Valve kit 2
201 Valve 1
202 Sleeve 1
203 Spring retaner 1
204 Plug 1
205 Shim 1
206 Spring 1
208 O-ring 1
209 O-ring 1
210 O-ring 1
211 Backup ring 2
Body kit 1
Body piston kit 1
212 Valve body 1
213 Piston 1
209 O-ring 2
214 Plug 1
215 Plug 2
216 Steel ball 2
217 Backup ring 4
219 Orifice 2
220 O-ring 1
222 Hexagon socket head plug 6
224 O-ring 2
1. TOOLS
1-1. Standard tools
GM18VL Disassembly and assembly
No. Name Type/Standard Qty
7 Retainer (IV) 1
9 Holding rod 1
5 Retainer (III) 1
No. Name and type Qty No. Name and type Qty
2. DISASSEMBLY
2-1. General precautions
1) Before disassembling, fully understand the inspection items and the nature of abnormality, if
there is any, and determine the disassembly order.
5) Arrange the removed parts properly so that they will not be damaged or lost.
6) Replace every seal once it is removed, even if it is free of damage. Before disassembling, pre-
pare the necessary parts.
1. Removal of spools
1) Remove plug [124] from rear flange [101].
Take O-ring [136] out of plug [124].
Precautions:
Plug [124] is loosened easily if the rear flange
is installed to the turnover work stand.
Do not reuse removed O-ring [136].
Tools: Socket wrench
Adapter 36 socket for wrench
Precaution:
Since the clearance between body [212] and
piston [213] is adjusted for the combination
of them, keep them as a set.
Caution
If any part other than O-ring [210] in sleeve [202]
needs to be replaced, the relief pressure must be
set again. Accordingly, do not replace it alone
but replace the valve kit.
Precaution:
Place a container under the GM motor to re-
ceive the oil flowing out when the GM motor
is set on its side.
1) Set the GM motor on its side.
2) Drain the oil from the GM motor.
Before removing cylinder block [104], hold it
the hands and turn it in both directions by 2 -
3 turns to separate shoe [106] from swash
plate [103]. If cylinder block [104] is removed
without performing this operation, the shoe
will be left on the swash plate and the parts
(piston, shoe, etc.) sticking to the cylinder
block will separate from the cylinder block
and fall in the spindle.
3) Hold cylinder block [104] with both hands and
take it out of spindle [2].
Tool: Container
4) Remove 2 mating plates [116] and 2 friction
plates [115] from the periphery of removed
cylinder block [104].
5) Remove mating plate [117] from spindle [2].
CAUTION
When removing a C-ring, it may jump out from
the plier tips. Take care.
1) Remove shaft C-rings [25] (3 pieces) from
crankshafts [9].
2) Remove 3 spur gears [7] and 3 distance pieces
[14] from crankshafts [9].
Tool: Snap ring pliers
3. MAINTENANCE STANDARD
When disassembling and inspecting the GM motor, observe the following standard. Handle each part
carefully. In particular, take care not to damage the moving parts and sliding surfaces.
3-1. Seals
Once seals (O-rings, oil seals, floating seals, etc.) are removed, replace all of them with new
ones, even if they are free from damage.
RV gear assembly
(4) RV gear (A) RV gear tooth surface is worn
(5) RV gear (B) unevenly.
(9) Crankshaft Each part does not move
(22) Tapered roller bearing smoothly when crankshaft
(23) Needle roller bearing with [9] is turned.
retainer
Seizure.
Piston assembly
(105) Piston There is clearance on piston
(106) Shoe [105] and shoe [106] in axial Clearance:
Clearance:
direction. 0.05 mm 0.15 mm
Shoe is worn abnormally.
Shoe is worn unevenly.
4. ASSEMBLY
4-1. General precautions
1) Work in a clean place.
2) When assembling, do not use cloth gloves (to prevent fibers from entering the assembly).
3) Repair parts damaged when disassembled and replace the all seals such as oil seals with new
ones without fail.
4) Be sure to replace removed reamer bolt [19] with new one.
5) Clean each part in cleaning oil thoroughly, then dry it with compressed air. Never use cloths (to
prevent fibers from entering the assembly).
6) When assembling the moving parts and sliding parts of the hydraulic motor valve, be sure to
apply clean hydraulic oil (NAS Grade 9 or equivalent).
7) Tighten the mounting bolts and plugs to the specified torque with torque wrenches.
TIGHTENING TORQUE
Tigtening torque
Part No. Name Nominal size Q'ty
Nm {kgm}
35 Hexagon socket head bolt M12 (P1.75) 10 102.0 15.7 {10.4 1.6 kgm}
19 Reamer bolt M24 (P2.0) 3 686.5 49.0 {70 5 kgm}
33 Hexagon socket head plug PT 1/2 2 98.1 19.6 {10 2 kgm}
121 Plug M20 (P1.5) 1 78.5 9.8 { 8 1 kgm}
124 Plug M30 (P1.5) 2 353.0 39.2 {36 4 kgm}
126 Plug M24 (P1.5) 2 127.4 14.7 {13 1.5 kgm}
143 Hexagon socket head bolt M10 (P1.5) 8 57.9 9.8 { 5.9 1 kgm}
146, 218 Hexagon socket head plug PT 1/8 8 12.3 2.5 { 1.25 0.25 kgm}
192 Hexagon socket head screw plug PF 5/8 2 29.4 4.9 { 3 0.5 kgm}
154, 222 Hexagon socket head plug NPTF 1/16 8 5.9 2.5 { 0.6 0.25 kgm}
170 Hexagon socket head bolt M8 (P1.25) 4 29.4 4.9 { 3 0.5 kgm}
202 Sleeve PF 5/8 2 127.5 19.6 {13 2 kgm}
240 Plug M18 (P1.5) 2 78.5 19.6 { 8 2 kgm}
214 Plug PF 1/2 1 98.0 19.6 {10 2 kgm}
215 Plug PF 1/4 2 29.4 4.9 { 3 0.5 kgm}
2. Installation of spool
CAUTION
When inserting the spool, align it with the hole
of the flange.
If the hole of the flange or the outside of the spool
is damaged by contact, oil leaks internally after
assembly and the performance of the GM motor
lowers. Take care.
Precaution:
Apply hydraulic oil to spool [123] and insert
it in rear flange [101].
1) Insert spool [123] in rear flange [101].
Tools: Torque wrench
Adapter 36 socket for wrench
2) Fit O-ring [136] to plug [124].
Precaution:
Apply grease to O-ring [136].
3. Assembly of SRV
Precaution:
Apply grease to O-rings [208] [209].
1) Fit O-ring [209] and backup ring [217] (2
pieces) to body [212].
2) Fit O-rings [208] and [209] and backup ring
[211] (2 pieces) to sleeve [202].
Precaution:
Apply grease to O-ring [210].
3) Fit O-ring [210] to plug [204].
4) Insert shim [205] in plug [204].
Precaution:
Since the relief pressure is set with the shim,
reuse the removed shim.
Tightening torque:
58.8 98.0 Nm {6 10 kgm}
Tools: Torque wrench
Adapter 10 rod for wrench
Precautions:
When installing plug [204] and shim [205], fix
the shim with hydraulic oil or grease.
Tightening107.9
torque:
147.1 Nm {11 15 kgm}
Precautions:
Sleeve is installed easily if the body is gripped
in a vise.
Tools: Torque wrench
Adapter 27 socket for wrench
When reassembling the final drive unit and hydraulic motor after replacing any part, perform the
procedure for adjusting the thickness of hold flange [3] and the procedure for determining the thick-
ness of snap ring [20]. Before starting the assembly work, check to see if any of the following parts
was replaced.
CAUTION
When reassembling after replacing the above parts, be sure to adjust each of those parts. If the
parts are assembled without adjusting them, the GM motor will malfunction and will be broken in
an early period.
A. Assembly
CAUTION
C-ring [25] may jump out from the pliers. Fit it to
the pliers securely.
CAUTION
THS snap ring [145] may jump out from the pli-
ers. Fit it to the pliers securely.
16. Sling the motor assembly with sling (I) and in-
stall it to spindle [2].
Precautions:
When installing the motor assembly, match the
pivot holes of swash plate [103] to pivots [167]
and take care not to damage the assembly by
hitting it against spindle [2], etc.
After installing the motor assembly, turn the
cylinder block by hand to make sure that there
is not play. If there is play, inspect to find out
the cause. When inspecting, do not pull out
the cylinder block. If it is pulled out, washer
[111] and thrust ball [108] will come off and
the motor will not rotate normally.
CAUTION
Take care not to mistake the installation order of
the friction plates and mating plates. If they are
install in a wrong order, the braking force of the
parking brake may lower.
1) Fit mating plate [117] into spindle [2].
Precaution:
Before installing the friction plates, soak them
in hydraulic oil.
2) Fit mating plate [117] to peripheral groove of
cylinder block [104] first, then fit friction plates
[115] and mating plates [116] (2 pieces each)
alternately.
CAUTION
Since steel balls [193] fall easily, install them
relief valve body [201] carefully.
If the steel balls are not installed, the machine
may slip down on a sharp slope.
1) Fit O-rings [138] (2 pieces) and [140] (2 pieces)
to rear flange [101].
2) Put 1 steel ball [193] each (2 pieces in total) in
the holes of rear flange [101] to which O-rings
[140] are installed.
5. PREFORMANCE TEST
After maintaining the GM motor, perform the performance test according to the following proce-
dure.
2) Test procedure
1 Installation and ........... Install the GM motor to the machine body, then pipe it.
piping of GM motor Do not install the tracks, however.
[For performance test (no-load operation) of GM motor]
Notes) 1. Connect the piping so that the pressure gauge (main cir-
cuit) can be installed and the draining rate from the hy-
draulic motor can be measured.
2. When installing the GM motor, do not hit it with a ham-
mer, etc. but use the bolt holes to install slowly.
3 Performance test
of GM motor
Preparatory operation for test ..... Operate the GM motor until the temperature rises to
the following levels.
1 Hydraulic oil temperature: 45 55 C
Outside temperature of reduction gear unit hub:
40 80 C
Performance test .......................... Measure and check the following items.
Criteria GM motor drive pressure ...............Max. 1.57 MPa {16
2 kg/cm2} at 10 r.p.m.
Draining rate from hydraulic motor ... Max. 1.2 liters/min
at 10 r.p.m.
Acceptable Rejected
INSTALLATION OF SWING
MACHINERY SWING MOTOR
ASSEMBLY
PC100-6 Serial No . : 41401 42156
PC120-6 Serial No . : 50201 52400
Carry out installation in the reverse order to re-
moval.
k1
Mating surface of swing machinery case
: Gasket sealant (LG-4 or LG-6)
Bleeding air
Bleed the air from the swing motor.
For details, see TESTING AND ADJUSTING,
Bleeding air.
INSTALLATION OF SWING
MACHINERY SWING MOTOR l
ASSEMBLY
PClOO-6 Serial No. : 42157 and up
PC120-6 Serial No. : 52401 and up
. Carry out installation in the reverse order to re-
moval.
. Bleeding air
* Bleed the air from the swing motor.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-40
0
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
:
W Swing machinery case : 2.5 Q
202FO6461
CLPOl547
202FOEd82
I 21WF02266-1K
4. Ring gear
Remove ring gear (14).
._
202FO6483 202FO6484
22
21 WF02274A-K
6. Retainer, collar
I) Remove retainer (24).
2) Set shaft and case assembly in press, push
split collar (25) with push tool 0, and press
fit bearing (26).
* Operate the press slowly, and press fit
the bearing to a position where it is pos-
sible to remove the split collar.
3) Remove split collar (25).
202FO6486
7. Shaft assembly
1) Set block @ to shaft and case assembly (271,
then using push tool 0, remove shaft as-
sembly (28) with press.
202FO6487 11 202FO6488
30-42
3) Set shaft assembly to press, then using push
tool @I, remove bearing (29) and collar (30)
from shaft (31).
21 WF02266A-K
202FO6489
21 WF02267A.
30-43
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
3j
21 WF02269A-K
2. Shaft assembly
1) Fit O-ring to inside of collar (30), and install
to shaft (31).
21 WF02270A-K
28
202FO6490 202FO6491
i5
202FO6492 202FO6493
30-44
0
3. Oil seal
Using push tool @, press fit oil seal (32).
Sr Replace the oil seal with a new part.
21WF02273A-K
4. Retainer
Install retainer (24).
202FO6494
21 WFO2274-1
21WFO2274-2
30-45
2) Install No. 2 carrier assembly (16) to shaft
and case assembly.
16
6. Ring gear
Assemble O-ring to shaft and case assembly,
and install ring gear (14).
ZlWF02276A-K
I
I 21 WF02258A-K
30-46
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
202FO6482
202FO6481
30-47
0
DISASSEMBLY AND ASSEMBLY SWING MOTOR
.I
Sling swing motor assembly (51, then use forcing
screws @to remove. m
. Bleeding air
* Bleed the air from the swing motor.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-48
@
DISASSEMBLY AND ASSEMBLY SWING MOTOR
l Preparatory work
Set swing motor assembly (1) in position at a 25
angle using a block.
DWPO1536
2. Brake piston
Set brake case assemblyto unit repair stand Yl,
then remove brake piston (3).
3. Discs, plates
Remove discs (4) and plates (5).
DWPO1539
30-48-I
@
DISASSEMBLY AND ASSEMBLY SWING MOTOR
Piston assembly
1) Using tools Y2, Y2-1, and Y2-2 remove screw,
then remove retainer (6).
2) Remove piston assembly (7) together with
holder.
1 I DWPO1540
Drive shaft
Turn over unit repair stand Yl, and using tool Y3,
remove nut (8), then remove drive shaft.
Bearing
1) Remove snap ring (IO), then remove spacer
(11) and ring (12).
2) Remove oil seal (13) and bearing (14).
Cylinder block
Remove spring (16) from housing (15), then re-
move center shaft (17) and cylinder block (18).
DWPO1543
30-48-2
@
DISASSEMBLY AND ASSEMBLY SWING MOTOR
8. Valve plate
Remove valve plate (19).
it-l-A DWPO1544
9. Safety valves
Remove safety valves (20).
30-48-3
@
DISASSEMBLY AND ASSEMBLY SWING MOTOR
1. Check valve
Assemble valve (23) and spring (22), then fit O-
ring and install plug (21).
OWPO1546
2. Safety valves
Fit O-ring and install safety valves (20).
DWP01545
3. Valve plate
Turn over housing, then align valve plate with
dowel pin and install.
4. Cylinder block
1) Coat with engine oil, install cylinder block (18),
assemble center shaft (17), and secure using
tool Y4.
2) Install spring (16) to housing (15).
DWPOl550
30-48-4
@
DISASSEMBLY AND ASSEMBLY SWING MOTOR
5. Bearing
1) Press fit bearing (28) to drive shaft (9).
.20
DWPOl561
DWP01553
m Rotation torque :
1.5 - 2.5 Nm (0.15 - 0.25 kgm}
30-48-5
@
DISASSEMBLY AND ASSEMBLY SWING MOTOR
7. Piston assembly
33 32
Fit holder (31) to piston assembly (7), and as-
semble to retainer (6).
Install holder (33) and ball (32) of center shaft
to torque shaft end.
QIC Screw:
1st step : Max. 0.98 Nm (0.1 kgm)
2nd step : 4.90+0.98 Nm (0.5+0.1 kgm)
DWPO1556
3rd step : 9X1+0.98 Nm {I .O+O.l kgm)
DWP01557
8. Discs, plates
Install plates (5) and discs (4).
Ir Align the notched portion of the spline teeth
when installing the discs and plates.
rlWPO1539
30-48-6
@
DISASSEMBLY AND ASSEMBLY SWING MOTOR
9. Brake piston
Fit O-ring and install brake piston (3).
DWP01538
DWPO1637
30-48-7
@
DISASSEMBLY AND ASSEMBLY SWING MOTOR
. Bleeding air
Ir Bleed the air from the swing motor.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-48-8
8
REMOVAL OF REVOLVING FRAME ASSEMBLY
30-50
INSTALLATION OF REVOLVING FRAME ASSEMBLY
. Bleeding air
* Bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-5 1
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
202FO6500
Serial No.
30-52
0
REMOVAL OF IDLER l RECOIL SPRING ASSEMBLY
INSTALLATION OF IDLER l
RECOIL SPRING ASSEMBLY
I 202FO5463
30-53
202FO6615
30-54
ASSEMBLY OF RECOIL SPRING ASSEMBLY
a Inside of cylinder :
Grease (G2-LI) (Min. 120 cc)
30-55
1. Remove dowel pin (I), then remove support (2).
3. Pull out idler (4) from shaft (5) and support (7)
assembly.
* It is filled with 90 cc. of oil, so drain the oil at
this point or lay a cloth to prevent the area
from becoming dirty.
202FO6616
5
0
6K
7
202FO6617
202FO6618 21WFO2291
30-56
ASSEMBLY OF IDLER ASSEMBLY
21 WF02293
202FO6619
Fl
F19M02639B
I 202FO6620
30-57
5. Add oil between shaft (5) and idler (4).
21 WF02295
202FO6621
Fl
I \
F19M02639C
2 202FO6616
30-58
REMOVAL OF TRACK ROLLER ASSEMBLY
INSTALLATION OF TRACK
ROLLER ASSEMBLY
m
* Adjust the track tension. F20505321
For details, see TESTING AND ADJUSTING,
Testing and adjusting track tension.
30-59
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
8 5
CLP00790 209FO5708
209FO5709-1 K 11 209F05711A-K
209F05713A-K
CLPOO791 209F05714A-K
30-60
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
CLPOO793
202FO6505
CLPOO866
202FO6508
30-61
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
10. Using tool F2, fill track roller assembly with oil,
then tighten plug (11).
To oil pump
f
To vacuum tank
202FO6624
202FO6510
30-62
0
REMOVAL OF CARRIER ROLLER ASSEMBLY
A The adjustment
high pressure.
cylinder is under extremely
Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine backwards and
forwards.
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
30-63
REMOVAL OF TRACK SHOE ASSEMBLY
A The adjustment
high pressure.
cylinder is under extremely
Never loosen the lubricator
more than one turn. If the grease does not
come out, move the machine backwards and
forwards.
m
* Adjust the track tension.
For details, see TESTING AND ADJUSTING,
Testing and adjusting track tension.
)
* Use tool E and press fit so that the protru-
sion of the master pin is dimension a.
Protrusion a of master pin : 5.5f2 mm
1
* When assembling the dust seal, coat the
bushing contact surface with grease (GZ-LI).
30-64
REMOVAL OF HYDRAULIC TANK ASSEMBLY
202FO6513
202FO6515
II I II IYe. 202FO6516 1
30-66
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
l Bleeding air
* Bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-67
0
DISASSEMBLY AND ASSEMBLY CONTROL PUMP
30-68
0
DISASSEMBLY AND ASSEMBLY CONTROL PUMP
30-68-1
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP
I PI _,,A
B, stop the oil. t 202FO660:
l When not using tool B, remove the drain plug,
and drain the oil from the hydraulic tank and
inside the system.
lir I 7 202FO6523
DISASSEMBLY AND ASSEMBLY MAIN PUMP
18
l Bleeding air
Ir Bleed the air from main pump.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-70
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP
I
10. Disconnect main pump drain hose (11).
L
DISASSEMBLY AND ASSEMBLY MAIN PUMP
l Bleeding air
* Bleed the air from main pump.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-70-2
0
DISASSEMBLY AND ASSEMBLY MAIN PUMP
Pump assembly
Set pump assembly (1) to tool 21. I
DWP0149
DWPOl492
wDWPO1493
30-70-3
@
DISASSEMBLY AND ASSEMBLY MAIN PUMP
OWPO
42 DWP01495
DWP01496
DWPOl497
30-70-4
8
DISASSEMBLY AND ASSEMBLY MAIN PUMP
DWPOi498
DWPO1500
DWPOl501
DISASSEMBLY AND ASSEMBLY MAIN PUMP
DWPO1502
DWP01603
DWP01504
- DWPOl505
30-70-6
@
DISASSEMBLY AND ASSEMBLY MAIN PUMP
I
0wP01506
DWPO
30-70-7
@
DISASSEMBLY AND ASSEMBLY MAIN PUMP
+I
$;;;, 70%ZE-12160708-2E-12170708-2E-12180708-2E-12190
DWPO1510
DWPOISII
30-70-8
@
DISASSEMBLY AND ASSEMBLY MAIN PUMP
2. Rocker cam
Assemble rocker cam (62) to shaft and cradle as-
sembly (63).
DWPO1603
3. Piston
1) Assemble spherical surface of rod (60) to
rocker cam.
* When assembling the rod, set the spring
seat surface facing the left.
2) Fit piston (61 j, set tool 23 to top of rod (oppo-
site from when loosening), set spacer @ on
left side of rod (60), then tighten piston (61).
* Before tightening piston (61), slide to side
so that width across flats of rocker cam
and width across flats of cradle are sepa-
rated. DWPO 1514
(This is to prevent damage to the rocker
cam and cradle when tightening the pis-
ton.)
a
hesive (Loctite 648) near area \
w Piston :
330225 Nm (32.522.5 kgm}
J
DWPOl516
30-70-g
@
DISASSEMBLY AND ASSEMBLY MAIN PUMP
m Screw:
12.3k2.5 Nm (1.2520.25 kgm}
mount ina
3) Tighten locknut (70). surfase
DWPO1581
& Between case and screw :
Gasket sealant (LG-7 or LG-
5 (Loctite 5721575))
DWPOISOI
30-70-10
8
DISASSEMBLY AND ASSEMBLY MAIN PUMP
DWP01497
DWP01496
DWPO1521
30-70-11
8
DISASSEMBLY AND ASSEMBLY MAIN PUMP
8. Spring, plug
1) Assemble spring (58), then fit O-ring and in-
stall plug (57).
m Plug (56) :
126 240 Nm (12.8524.05 kgm}
DWPOl500
30-70-12
8
DISASSEMBLY AND ASSEMBLY MAIN PUMP
DWPOl525
m Mounting bolt :
66.227.4 Nm (6.752 0.75 kgm}
30-70-13
8
DISASSEMBLY AND ASSEMBLY MAIN PUMP
w Plug (26) :
110~12Nm{11.25~1.25kgm}
Ir Check that the relative movement of
the body and spool (2), and of sleeve
(27) and piston (28) is smooth.
ii) Assemble seat (25), spring (24), and seat
(23), then fit backup ring and O-ring, and
install plug (22).
iii) Install locknut (21).
30-70-14
8
DISASSEMBLY AND ASSEMBLY MAIN PUMP
w Locknut (11) :
29&5 Nm (320.5 kgm} Position d-0 when mark
is temporarily assembled
Ir Check that the movement of plug (12) owpol62a
and plug (20) and lever (18) is smooth.
v) Assemble piston (IO), then fit O-ring and
install plug (9).
w Plug (10) :
11.321.5 Nm {1.15&0.15 kgm}
vi) Assemble spool (5) to sleeve (4), then in-
stall to body together with seat (6) and
springs (7) and (8).
* Check that the relative movement of
sleeve (5) and spool (4) is smooth.
vii) Fit O-ring and install solenoid assembly
(3).
m Solenoid assembly mounting bolt :
13.2k1.5 Nm (1.3520.15 kgm}
m Orifice (32) :
1723 Nm {I .7*0.3 kgm}
30-70-15
@
DISASSEMBLY AND ASSEMBLY MAIN PUMP
B Mounting bolt :
66.227.4 Nm (6.75 20.75 kgm}
tlWPOl525
30-70-16
8
DISASSEMBLY AND ASSEMBLY MAIN PUMP
1) Make centering tool for cylinder block and Chnder block Centering tool
valve plate.
* The tool can be made from plastic, bakelite
or any other soft material. L
2) Remove all oil and grease from parts to be
checked.
Ir Do not wipe with a cloth.
3) Set tool in position, then paint cylinder block
with inspection paint.
* Coat thinly with paint.
g 4) Push valve plate with a force of 39 - 49 N (4 -
z 5 kg} against cylinder block, turn valve plate DWPOl533
2 90, then turn it back to original position. Re-
peat this process 2 or 3 times.
5) Remove valve plate, transfer contact surface
to a tape, and check contact surface.
Ir The contact for the spherical surface of the
cylinder block and valve plate must fulfill
the following conditions and there must
be no break around the whole circumfer-
ence.
i) Seal portion (range of 090.5 mm from
bottom): Contact of more than 80%
ii) Land portion (range of 090.5 mm o 112
mm) : Contact of more than 60%
30-70-17
@
DISASSEMBLY AND ASSEMBLY MAIN PUMP
30-70-18
@
DISASSEMBLY AND ASSEMBLY MAIN PUMP
30-70-19
@
REMOVAL OF MAIN PUMP INPUT SHAFT OIL SEAL
202F0652E
30-7 1
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-72
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
INSTALLATION OF CONTROL
VALVE ASSEMBLY
PClOO-6 Serial No. : 40001- 41229
PC120-6 Serial No. : 45001- 49820
=m /iv
system. Then check the oil level again.
30-73- 1
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
00800
Ii
9. Remove connector (27) from clip, then disconnect
it.
* Disconnect the wiring harness from the har-
ness clamps (3 places).
~2Yszi #V 202F06537A-K
30-73-2
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
INSTALLATION OF CONTROL
VALVE ASSEMBLY
PCIOO-6 Serial No. : 41230 and up
PC120-6 Serial No. : 49821 and up
l Bleeding air
* Bleed the air from the circuit between the
valve and the hydraulic cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-73-3
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-74
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
4
7 5
8 6
10 9
202FO6535
CLP02167
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
spool, then fit O-ring to case (31) and install. m Unload valve : 166.7zb19.7 Nm(17&2 kgm)
* Check spring (32) when installing.
9. LS bypass valve, main relief valve
m Mounting bolt :
1) Fit O-ring and install LS bypass valve (2).
11.3f1.5 Nm(1.2f0.2 kgm)
m LS bypass valve :
3) Assemble retainer (29) and spring (28) to
166.7k19.7 Nm(17+2 kgm)
spool, then fit O-ring to case (27) and install.
2) Fit O-ring and install main relief valve (1).
m Mounting bolt :
11.3k1.5 Nm(1.2f0.2 kgm) m Main relief valve :
98.1f9.8 Nm(lOf1 kgm)
30-76
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
4
7 5
6 6
9
10
25b i6 i7
202FO6539
2d2F06541
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
2. LS bypass valve
Remove LS bypass valve (27).
5. LS select valve
1) Remove sleeve (29).
2) Remove valve (86) and spring (87).
30-77- 1
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-77-2
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
(l/3)
IL--
C
l--A
B I
27
tLD\
Z 16
\ 2
CKP01562
30-77-3
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
I 35 36 34 37 31 33 32
M-M L-L
Bucket valve
IO Bucket
II Arm
12 Boom
Right travel
I3
Left travel
I4
Swing
I5
A-A B-0
03 02 84 85 81 80 79 78 74 75 76 77 73 72 71
E-E F-F
Swina valve
DDPOOl63
30-77-4
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
(3/3)
58 53 52
K-K J-J
Arm valve Boom valve
89
88
20 17
30
21 18
24 I!
25 22
26 23
c-c D-D
67 68 69 70 65 64
H-H. G-G
Travel valve
DDP00164
30-77-5
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
CKP00820
30-77-6
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-77-7
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
(II31
tr A
F---
l--A
B
C
d------f
I!----+ -24
22-
CKPOl562
30-77-8
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
35 36 34 * 37 31 33 32
L-L
Bucket valve
IO Bucket
II Arm
Boom
12
Right travel
-13
Left travel
I4
Swing
I5
A-A B-0
6; 62
, 04 05 61 60 79 76 74 75 76 77 73 72 71
E-E F-F
Swing valve
DDPOOl63
30-77-9
0
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
58 59 63. 62 61 53 52
K-K J-J
Arm valve Boom valve
68 69 70 66 65 64
H-H. G-G
Travel valve
DDP00164
30-77-10
0
DISASSEMBLY OF LS SELECT VALVE
202FO6542
30-78
DISASSEMBLY AND ASSEMBLY LS SHUTTLE VALVE
$
8
8
1. Remove seat (2) from plug (I), then remove O-
ring (3) and ring (4).
InStall ring (8) and O-rings (7) and (6) to plug (1).
Fit ring (4) and O-ring (3) to seat (21, then as-
semble ball (5) to plug (I), and install seat (2).
30-80
0
DISASSEMBLY AND ASSEMBLY LS SHUTTLE VALVE
DEP00161
1. Install ring (8) and O-rings (7) and (6) to plug (I).
2. Fit ring (4) and O-ring (3) to seat (2), then as-
semble ball (5) to plug (I), and install seat (2).
30-81
0
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
30-81-l
0
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
202FO6644
30-81-2
0
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
l
Disassembly of pressure compensation valves l Disassembly of pressure compensation valve
A. B. C, D. F, G, I-I E
. The structure of the parts for pressure
compensation valves A, B, C, D, F, G and 1. Remove piston (13) and spring (14) from
H is the same, but the part number for the sleeve (12).
assembly marked is different, so be
careful when assembling. 2. Remove seals (15) and (16) from piston (131,
then remove O-ring (17), seals (18) and (19),
1. Remove piston (2) and spring (3) from sleeve and O-ring (20) from sleeve (12).
(I).
* After disassembling, if theie is any abnormal-
2. Remove plug (4) and ball (5) from piston (2). ity in sleeve (121, piston (13), or seals (15) and
(16), replace the whole pressure compensa-
3. Remove seals (6) and (7) from piston (2). tion valve assembly.
30-81-3
0
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
30-8 l-4
0
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY
202F0654E
30-82
ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY
202FO6545
8 l Before assembling coat the sliding surface * After installing to the control valve assembly,
z with engine oil. adjust the pressure.
For details, see TESTING AND ADJUSTING,
1. Install O-ring (17) and ring (16) to seat (151, Testing and adjusting oil pressure of work
and assemble sleeve (II). equipment, swing, travel circuits.
30-83
REMOVAL OF TVC l LS VALVE ASSEMBLY
INSTALLATION OF TVC l LS
VALVE ASSEMBLY
m
* Be careful not to let the O-ring or filter fall
out when installing.
* Tighten the mounting bolts gradually on op-
posite sides in turn.
w 202FO6627
30-84
DISASSEMBLY AND ASSEMBLY LS CONTROL EPC VALVE
-;
PCIOO-6 Serial No. : 40001- 41229
PC120-6 Serial No. : 45001 - 49820
1. Remove cover.
6
'2FO6551
INSTALLATION OF LS CONTROL
EPC VALVE ASSEMBLY
PCIOO-6 Serial No. : 40001 - 41229
PC120-6 Serial No. : 45001- 49820
30-85
0
DISASSEMBLY AND ASSEMBLY LS CONTROL EPC VALVE
INSTALLATION OF LS CONTROL
EPC VALVE ASSEMBLY
PCIOO-6 Serial No. : 41230 and up
PC120-6 Serial No. : 49821 and up
30-85 1
0
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
INSTALLATION OF SOLENOID
702F06fi28
30-85-2
0
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
INSTALLATION OF SOLENOID
VALVE ASSEMBLY
PCIOO-6 Serial No. : 41230 and up
PC120-6 Serial No. : 49821 and up
202FO6628
30-86
0
REMOVAL OF WORK EQUIPMENT l SWING PPC VALVE ASSEMBLY
INSTALLATION OF WORK
EQUIPMENT l SWING PPC VALVE
ASSEMBLY
30-87
DISASSEMBLY OF WORK EQUIPMENT l SWING PPC VALVE
ASSEMBLY
1. Remove nut (I), then remove disc (2) and boot
(3).
U
21WFO2349
30-88
ASSEMBLY OF WORK EQUIPMENT l SWING PPC VALVE ASSEMBLY
m Mounting bolt :
13.21!~1.5 Nm(1.35+0.15 kgm)
30-89
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
202FO6561
INSTALLATION OF TRAVEL PPC
VALVE ASSEMBLY
PCIOO-6 Serial No. : 40001 - 41400
PC120-6 Serial No. : 45001- 50200
. Carry out installation in the reverse order to re-
moval.
202FO6562
l/I CEFU0426
3. Remove pedals (I) and levers (2).
CEPO0427
CEP00429
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
30-92
0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
m Mounting bolt:
30.9 + 3.4 Nm (3.15 2 0.35 kgm)
m Mounting bolt:
27.9 + 3.4 Nm (2.85 f 0.35 kgm)
13
Cm0863
30-92- 1
0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
CEFQ0533
CLPO1455
30-92-2
0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
30-92-3
0
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
CLPO1455
30-92-4
0
REMOVAL OF BOOM HOLDING VALVE
INSTALLATION OF BOOM
HOLDING VALVE ASSEMBLY
30-93
REMOVAL OF BOOM CYLINDER ASSEMBLY
202FO6566
30-94
l Carry out installation in the reverse order to re-
moval.
. Bleeding air
j, Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
30-95
a Extend the
mm, lower
arm cylinder piston rod approx. 200
the work equipment completely to
the ground, then set the remaining safety lock
lever to the LOCK position.
3. Start engine, and retract piston rod, then tie pis- 202FO6630
ton rod with wire to prevent it from coming out.
30-96
INSTALLATION OF ARM CYLINDER ASSEMBLY
m
-Inside surface of bushing when assem-
bling pin : Anti-friction compound (LM-P)
m
-Inside surface of bushing when assem-
bling pin : Anti-friction compound (LM-PI
l Bleeding air
* Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air f.rom hydraulic cylinder.
30-97
REMOVAL OF BUCKET CYLINDER ASSEMBLY
30-98
l Carry out installation in the reverse order to re-
moval.
l Bleeding air
* Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
30-99
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
202FO5481
PC100 I 70 I 85 I 65
PC120 I 85 I 85 I 70
202FO5483
202F05501-K
30-I 00
2. Disassembly of piston assembly
30-101
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
18
18'
202FO5466
202FO5467C 1) 202FO54688/
202FO5485
30-I 02
3. Piston rod assembly
w Nut:
Unit: kNm(kam)
202FO5489
30-103
IO) Tighten head assembly (1) with mounting
bolts.
w Mounting bolt :
30-I 04
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
202FO6579
30-106
0
INSTALLATION OF WORK EQUIPMENT ASSEMBLY
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
l Bleeding air
* Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
30-I 07
REMOVAL OF BUCKET ASSEMBLY
Bucket assembly :
PCIOO-6 : 370 kg
PC120-6 : 400 kg
21WF02372A
30-108
INSTALLATION OF BUCKET ASSEMBLY
m
-1 nsrd e surface of bushing when assem- 41
0.5-1.5mm
bling pin :
Anti- friction compound (LM-P)
/ I
7 8
202FO658L
&Inside surface of bushing when assem-
bling pin, inside surface, end face of col-
lar (IO) : Anti-friction compound (LM-P)
A
compound (LM-P)
When aligning the position of the pin hole,
never insert your fingers in the pin hole.
30-I 09
REMOVAL OF ARM ASSEMBLY
30-I 10
l Carry out installation in the reverse order to re-
moval.
l Bleeding air .
* Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
30-111
REMOVAL OF BUCKET l ARM ASSEMBLY
30-I 12
INSTALLATION OF BUCKET l ARM ASSEMBLY
. Bleeding air
* Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
30-I 13
DISASSEMBLY AND ASSEMBLY BOOM
202FO5492-1
&Ik Boom assembly :
PCIOO-6 :
Serial No. 40001- 42156: 900kg
Serial No. 42157 and up : 860kg
PC120-6 : 950 kg
F20106129A
30-l 14
0
INSTALLATION OF BOOM ASSEMBLY
level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
l Bleeding air
* Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
30-I 15
REMOVAL OF OPERATORS CAB ASSEMBLY
I 202FO6634
30-I 16
8. Disconnect air conditioner hose (11) and speaker
wiring connector, then remove cover (12).
* When removing the cover, the speaker wir-
ing connector cannot be seen, so lift up the
cover to disconnect the wiring.
202FO6636
202FO663i
Front
205FO6662
INSTALLATION OF OPERATORS
CAB ASSEMBLY
30-I 18
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
PC1 20-6
IV
1 52401 and up 1 2,305 kg
-2
202FO6592
INSTALLATION OF COUNTER-
WEIGHT ASSEMBLY
30-l 19
0
DISASSEMBLY AND ASSEMBLY ENGINE THROlTLE CONTROLLER
202FO6598
INSTALLATION OF ENGINE
THROTTLE CONTROLLER
ASSEMBLY
PCIOO-6 Serial No. : 40001 - 41229
PC120-6 Serial No. : 45001- 49820
30- 120
0
DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
202FO6598
INSTALLATION OF PUMP
CONTROLLER ASSEMBLY
PCIOO-6 Serial No. : 40001- 41229
PC120-6 Serial No. : 45001- 49820
30-l 21
0
DtSASSEMBLY AND ASSEMBLY ENGtNE THROlTLE, PUMP CONTROLLER
INSTALLATION OF ENGINE
THROTTLE, PUMP CONTROLLER
ASSEMBLY
PCIOO-6 Serial No. : 41230 and up
PC120-6 Serial No. : 49821 and up
m
l Check the performance of the work equipment,
travel, and swing.
For details, see TESTING AND ADJUSTING.
30- 122
0
DISASSEMBLY AND ASSEMBLY
MONITOR
I / 202FO6603
$
g
s1 INSTALLATION OF MONITOR
ASSEMBLY
30- 123
0
40 MAINTENANCE STANDARD
40-l
@I
SWING MACHINERY
2 m 11025*1225Nm
(1125*125k~m)
202CD06023
40-2
Unit: mm
40-3
MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
PCIOO-6 Serial No. : 40001 - 42156
PC120-6 Serial No. : 45001 - 52400
I
.._
j__-__ ---7
c-c ---~
----
Unit: mm
40-4
0
MAINTENANCE STANDARD SWING CIRCLE
m B-0
Unit: mm
40-4-l
0
TRACK FRAME
m 277132Nm
(28.25 * 3.25h)
k
1
Unit: mm
82 77 Rebuild or
Idler
I I I replace
Free length Installed length Installed load Free length Installed load Replace
3 Recoil spring.
78.4 kN 494 69.8 kN
505 390
(8,000 kg) (7,120 kg)
40-5
IDLER
IF05181
Unit: mm
Width of protrution. 52 42
Replace
I
40-6
CARRIER ROLLER
FO20203314
Unit: mm
40-7
MAINTENANCE STANDARD TRACK ROLER
TRACK ROLLER
FO20203311
Unit: mm
40-8
0
SPROCKET
44
\
0 O 0
0 0
0 0
\L/
0 0 /
0 0
Q-L
202FO6285
Unit: mm
Wear in width of 27 - 22
3
sprocket tooth top.
T
40-9
TRACK SHOE
I
I \
6 7
I- 1
202CD06025
40-10
Unit: mm
I
No. Check item Criteria Remedy
Outside diameter of
8 2
bushing. I
Z -
Z
Triple 25 15
I I
I I
Swamp 75 63
Height of I
3 grouser Lug welding,
Flat rebuild or
replace
Rubber pat 1
5 Interference between
bushing and link.
Replace
40-11
A--A
F20205502
Unit: mm
Wear of meshing
3 portion of sprocket. 3 -2
40-12
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
PCIOO-6 Serial No : 40001- 41229
PC120-6 Serial No : 45001- 49820
m 66.2 + 7.4Nm
(6.75;0.75kp )
40-12-2
0
MAINTENANCE STANDARD HYDRAULIC PUMP
SKP01200
40-13
0
CONTROL PUMP
-53.9+4.9Nm
(5.5+0.5kgm)
w66.2F 7.4Nm
.--(6.75i0.75kqm
202FO6289
Unit: mm
40-14
MAINTENANCE STANDARD
CONTROL VALVE
CONTROL VALVE
PCIOO-6 Serial No : 40001- 41229
PC120-6 Serial No : 45001- 49820
166.6k9.8Nm
(17klkp)
w 11.311.4Nm
(1.15f0.15kgm)
/
& 30.9i3.4Nm
(3.15+0.35kp)
-m 276.9+31.9Nm
(28.25i3.25kqm)
30.9+3.4Nm
(3.15F0.35~~m )
w 30.9z 3.4Nm
(3.15iO.l5kp)---
202FO6290
40-l 5
0
-23.5k3.9Nm
(2.4io.dv 1
/
225.4+19.6Nm
(23?2kv)
A-A
202FO6291
Unit: mm
Pressure compensation
1 valve spring Replace spring if
(work equipment, swing) any damages or
deformations are
found.
40-16
I 166.6& 19.6Nm
(17f2kgm)
3.9Nm /=
B-B
202FO6292
Unit: mm
Spool return spring FreiELTth Installed length Installed load Free length Installed load
1 Replace spring if
(work equipment, swing)
any damages or
230.3k14.7 N _ 208.7 N deformations are
45.6X28 43
(23.5k1.5 kg) (21.3 kg) found.
221.5-1-13.7 N _ 179.3 N
2 Spool return spring (travel) 45.7X28 43
(22.6k1.4 kg) (18.3 kg)
40-17
$2%3 147+9.8Nm
/ (15+lkqm)
m147+9.8Nm
(lwlkqm)
202FO6293
40-18
202FO6294
40-19
m 166.6+ 19.6Nm
(17*2kw>
E-E
17.2+2.5Nm
(1.75+0.25b )
F-F
m 17.2+2.5Nm
(1.75+0.25kqm)
G-G 202FO6295
Unit: mm
135.2k4.9 N _ 112.7 N
2 Cooler bypass valve spring. 72.7X20.6 42.5
(13.8t0.5 kg) (11.5 kg)
40-20
17.2+2.5Nm
(1.75zto.25kqm )
17.2+2.5Nm
(1.75*0.25kqm)
J-J
17.2+2.5Nm
(1.75iO.25k9m)
K-K
202FO6296
40-21
m 9.812Nm
(1+0.&m)
8
8
8
M-M
202FO6297
40-22
MAINTENANCE STANDARD CONTROL VALVE
277.0*31.9Nm
(28.25~3.25kPm)
SKP01201
40-22-l
0
MAINTENANCE STANDARD CONTROL VALVE
SKP01202
Unit: mm
40-22-2
@I
MAINTENANCE STANDARD CONTROL VALVE
I
I
I
3
4
I
3
I
2
2
2 2
I
I
B-0 SKP01203
Unit: mm
Free length
1 Spool return spring Installed length Installed load Free length Installed load
x O.D.
230.5*14.7N 184.4 N Replace spring if
45.6 x 28 43 (23.5i1.5 kg) - (18.8 kg) any damages or
deformations are
221.6i13.7N 177.5 N found.
2 Spool return spring 45.7 x 28 43 (22.6k1.4 kg) - (18.1 kg)
I I I I I
I
221.6+13.7N 177.5 N
3 Spool return spring 42.4 x 28 39 (22.6k1.4 kg) - (18.1 kg)
.x When installing
xl00.0~5.9N 80.4 N to valve, spring
4 Stroke selector spring 36 x 9.6 %30 (10.2kO.6 kg) (8.2 kg) is free, so judge
from test height.
40-22-3
0
MAINTENANCE STANDARD CONTROL VALVE
SKP01204
40-22-4
0
MAINTENANCE STANDARD CONTROL VALVE
66.7
7*2
0
r
I::
D-D
SKP01205
40-22-5
0
MAINTENANCE STANDARD CONTROL VALVE
166.7+ 1%6Nm
E-E
17.2 * 2.5Nm
(1.75* 0.25kPm)
17.2+2.5Nm
(1.75*0.25kpm)
G-G SKP01'206
Unit: mm
-
No Check item Creiteria Remedy
40-22-6
0
MAINTENANCE STANDARD CONTROL VALVE
H-H
m 17.2+2.5Nm
.75+0.25!am)
K-K
SKP01207
40-22-7
0
MAINTENANCE STANDARD CONTROL VALVE
M-M
SKP01208
40-22-8
0
MAINTENANCE STANDARD CONTROL VALVE
SKP01209
Unit: mm
I I I
NO.1 Check item Creiteria I Remedy
74.5 N 59.8 N
2 Relief valve spring 17.1 x 9 15.5 (7.6 kg) - (6.1 kg)
40-22-9
0
MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
2.06 N 1.57 N
2 Main valve spring 20X7 14 IO.16 kg)
IO.21 kg} -
40-22-10
0
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF40AB-2
PCIOO-6 Serial No. : 40001 - 42156
PCWO-6 Serial No. : 45001 - 52400
\ \
$
8
8
\ /
w 83.4+39.2Nm w 166.7f19.6Nm
(8.5 +4kgm ) (17.0+2.0kqm)
202FO6299
Unit: mm
40-23
MAINTENANCE STANDARD SWING MOTOR
KMF40AB-3
PClOO-6 Serial No. : 42157 and up
PC120-6 Serial No. : 52401 and up
I
m, 125* 17.2Nm
(13.0* 1.5ko.l
A-A
SAD01391
Unit: mm
40-24
@
CENTER SWIVEL JOINT
@Z 142.2534.3Nm m 31.4+2.9Nm
(14.5~ Wgm 1 (xio.3kp)
\ /
&ii3 19.6+4.9Nm
(2+o.skp)
202FO6300
Unit: mm
40-25
MAINTENANCE STANDARD WORK EQUIPMENT. SWING PPC VALVE
112.8~14.7Nm
(11.5&1.5kgm)
m 13.2k1.5Nm
(1.35*0.15kgm)
4.4.1+4.9Nm
(4.5+0.5kgm)
39.2=4.9Nm
(4k0.5kgm)
8.5-c2.5Nm
(0.85?0.25kgm)
Unit: mm
16.7 N 13.7 N
3 Metering spring 26.5X8.2 24.9 {I.7 kg} - t1.4 kg}
40-26
MAINTENANCE STANDARD TRAVEL PPC VALVE
SBPOO435
Unit: mm
40-27
0
MAINTENANCE STANDARD TRAVEL PPC VALVE
SAP01255
Unit: mm
40-28
MAINTENANCE STANDARD SERVICE PPC VALVE
78.5Nm
(8.0kgm)
2.9Nm
(0.3kgm)
Unit: mm
Free length Installed length Installed load Free length Installed load
1 Centering spring X0.D. Replace spring if
54.4X21.2 40.5 308.9 N any damages or
277.3 N
53.1 $zz;matlons are
{31.5 kg} i28.3 kg)
40-29
0
MAINTENANCE STANDARD SERVICE PPC VALVE
13.23*lA7Nm
1.35*0.15hl
SAP01393
Unit: mm
Metering spring
I25.9x11.0 25.0 24.5 N
(2.5 kg1
25.8 21.6 N
12.2 kg) I
40-29-l
0
PPC SHUTTLE l TRAVEL JUNCTION VALVE
m
34.3f4.9Nm
(3.5+0.5kOm)
m 107.8i 14.7Nm
m l&8+ 14.7Nm &i3 66.2+7.4Nm
(11.0+1.5kp) (6.75+0.75C ) (ll.oilskqm)
202FO6306
40-30
F-F A-A AA
G-G
N-N
BB-BB
J-J
(ZPLACES)
1 -.I
K-K
(EPLACES)
M-M
L-L E-E
AA-AA
202FO6307
Unit: mm
No.
I Check item
I Criteria Remedy
FrF g.\fh Installed length Installed load Free length Installed load Replace
1 Spool return spring.
I
14.7 N 11.8 N
23.6X13.3 20 (1.5 kg) - (1.2 kg) I
40-3 1
EPC l SOLENOID VALVE
w 11.3+1.5Nm
(1.15fO.15kp)
\
\
m 9.8i2.ONm
(l+2+)
202FO6308
Unit: mm
I
No. Check item Criteria Remedy
I
Standard size Repair limit
Replace EPC
Frez &!fth Installed length Installed load Free length Installed load valve assy if
1 Return spring. any damages or
40-32
BOOM HOLDING VALVE
* For machine equipped with arm holding valve, the Maintenance Standard of arm holding valve
is the same as this valve.
-4.OF0.5kgm \
202FO5939
Unit: mm
40-33
HYDRAULIC CYLINDER
: 171.5k24.5 Nm (17.5k2.5 kgm) m Boom : 3332f333.2 Nm (34Ok34 kgm) (Width across flats : 70)
: 269.5k39.2 Nm (27.5k4.0 kgm) Arm : 7056f705.6 Nm (720+72 kgm) (Width across flats : 85)
Bucket : 171.5&24.5 Nm (17.5k2.5 kgm) Bucket : 2646f264.6 Nm (2701!~27 kgm) (Width across flats : 65)
202FO6302
22
Unit: mm 2
No.
r Check item Criteria Remedy
2
Cylinder r
Clearance Boom
Replace
between piston bushing
rod and bushing.
Arm
Bucket
Boom
Clearance
between piston
2 rod support pin Arm
and bushing.
Bucket
Replace pin
or bushing
Boom
Clearance
between cylinder
3 Arm
bottom support
pin and bushing.
Bucket
40-34
PC1 20-6 * Figure shows boom cylinder.
m Boom : 171.51b24.5 Nm (17.5k2.5 kgm) w Boom : 5096+509.6 Nm (520+52 kgm) (Width across flats : 80)
Arm : 269.5zb39.2 Nm (27.5k4.0 kgm) Arm : 7056k705.6 Nm (720+72 kgm) (Width across flats : 85)
Bucket : 171.5k24.5 Nm (17.5k2.5 kgm) Bucket : 3332k333.2 Nm (3401b34 kgm) (Width across flats : 70)
\ I
202FO6303
Unit: mm
No.
T Criteria
T Remedy
Bucket 65 0.426
Boom
L
Clearance
between piston
2 rod support pin Arm
and bushing.
Bucket 65
Replace pin
or bushing
Boom
Clearance
between cylinder
3 Arm
bottom support
pin and bushing.
-0.030 0.130-
Bucket 65 -0.080 0.254 1.0
40-35
WORK EQUIPMENT
L
J
202FO6309
D-D
H-H
A-A
J-J
E-E
B-B
K-K
F-F
G-G L-L
202FO6310
40-36
Unit: mm
Standard
Clearance between con- size Shaft
necting pin and bushing of
revolving frame and boom. -0.030
70 -0.100
40-37
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
-4-k
A-A
B-B
c-c
SEP01359
40-38
0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
Unit: mm
1 $70 $70
2 80 80
I I
3 226 226
4 470 $70
5 247 275.7
6 188.9 199.7
I I
7 550 635
8 2,352 2,492.2
9 I 2,099.8 I 2,100
10
I 290
I 290
11 487 487
12 415 415
13 374.9 374.9
I I
14 1,168.7 1,241.3
15 460 $60
16 261 261
17 260 $60
I I
Arm as individual part 275 275
18
When press fitting bushing - -
40-39
0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
2. BUCKET PORTION
A-A SEP01487
40-40
0
MAINTENANCE STANDARD DIMENSION OF WORK EQUIPMENT
Unit:mm
1 371.3 371.3
2 51.6 51.6
3 97.9" 97.9"
4 374.9 374.9
5 1,153.l 1,226.6
6 190.5 190.2
7 I - I -
9
I 660
I
$60
10
I
I
261
I
261
I I
51 51
11
I I
12 87 87
13 380 380
14 618 418
15 $110 $110
16 6132 $132
17 105 105
18 80 80
19 74 74
21 275 275
40-41
0
DataKom Publishing Corporation
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications PROPOSAL FOR MANUAL OR CSS REVISION
Fax No. (847) 970-4186
) STATE OR PROVINCE::
DEPARTMENT: COUNTRY:
SOOK DESCRIPTION
IACHINE MODEL 8 S/N:
ROBLEM:
:ORRECTIVE ACTION:
m
PROPFREV.WPD 071: