parts manual - pc400

7/21/2019 Parts Manual - PC400

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SEBM033007

MACHINE MODEL SERIAL No.

PC400-7 50001 and up

PC400LC-7 50001 and up



GENERAL

CONTENTS

No. of page

01 GENERAL............................................................................................................................ 01-1

10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD............................................ 10-1

20 TESTING AND ADJUSTING ......................................................................... 20-1

30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1

90 OTHERS ................................................................................................................................ 90-1



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SAFETY SAFETY NOTICE

SAFETY

SAFETY NOTICE

IMPORTANT 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 symbolk is used to mark safety precautions in this manual.

The cautions accompanying these symbols should always be followed carefully. If any danger-

ous situation arises or may possibly arise, first consider safety, and take the necessary actions

to deal with the situation.

GENERAL PRECAUTIONS

Mistakes in operation are extremely dangerous.

Read the Operation and Maintenance Manual care-

fully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read

all the precautions given on the decals which are

fixed to the machine.

2. When carrying out any operation, always

wear safety shoes and helmet. Do not wear

loose work clothes, or clothes with buttons

missing.

• Always wear safety glasses when hitting

parts with a hammer.

• Always wear safety glasses when grinding

parts with a grinder, etc.

3. If welding repairs are needed, always have a

trained, experienced welder carry out the work.

When carrying out welding work, always wear

6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools

and parts in their correct places. Always keep

the work area clean and make sure that there is

no dirt or oil on the floor. Smoke only in the areas

provided for smoking. Never smoke while work-

ing.

PREPARATIONS FOR WORK

7. Before adding oil or making any repairs, park the

machine on hard, level ground, and block the

wheels or tracks to prevent the machine from

moving.

8. Before starting work, lower blade, ripper, bucket

or any other work equipment to the ground. If

this is not possible, insert the safety pin or use

blocks to prevent the work equipment from fall-

ing. In addition, be sure to lock all the control



SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK

11.When removing the oil filler cap, drain plug or

hydraulic pressure measuring plugs, loosen

them slowly to prevent the oil from spurting out.

Before disconnecting or removing components

of the oil, water or air circuits, first remove the

pressure completely from the circuit.

12.The water and oil in the circuits are hot when the

engine is stopped, so be careful not to getburned.

Wait for the oil and water to cool before carry-

ing out any work on the oil or water circuits.

13.Before starting work, remove the leads from the

battery. Always remove the lead from the nega-

tive (–) terminal first.

14.When raising heavy components, use a hoist or

crane.

Check that the wire rope, chains and hooks are

free from damage.

Always use lifting equipment which has ample

capacity.

Install the lifting equipment at the correct places.

Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.

Do not work with any part still raised by the hoist

or crane.

15.When removing covers which are under internal

pressure or under pressure from a spring,

always leave two bolts in position on opposite

sides. Slowly release the pressure, then slowly

loosen the bolts to remove.

16.When removing components, be careful not to

break or damage the wiring. Damaged wiring

may cause electrical fires.

17 When removing piping stop the fuel or oil from

19.Be sure to assemble all parts again in their origi-

nal places.

Replace any damaged parts with new parts.

• When installing hoses and wires, be sure

that they will not be damaged by contact

with other parts when the machine is being

operated.

20.When installing high pressure hoses, make sure

that they are not twisted. Damaged tubes are

dangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, check

that connecting parts are correctly installed.

21.When assembling or installing parts, always use

the specified tightening torques. When installing

protective parts such as guards, or parts which

vibrate violently or rotate at high speed, be par-

ticularly careful to check that they are installedcorrectly.

22.When aligning two holes, never insert your fin-

gers or hand. Be careful not to get your fingers

caught in a hole.

23.When measuring hydraulic pressure, check that

the measuring tool is correctly assembled before

taking any measurements.

24.Take care when removing or installing the tracks

of track-type machines.

When removing the track, the track separates

suddenly, so never let anyone stand at either

end of the track.



FOREWORD GENERAL

FOREWORD

GENERALThis 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 judge-

ments. 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 fur-ther divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-

standing of the structure, but also serves as reference material for troubleshooting.

In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-

nance standards.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to

be made at completion of the checks and repairs.

Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-

ponent, as well as precautions for them.

MAINTENANCE STANDARD

This section gives the judgment standards for inspection of disassembled parts.

The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS

This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.

In addition, this section may give the specifications of attachments and options together.



FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMESShop manuals are issued as a guide to carrying out

repairs. They are divided as follows:

Chassis volume: Issued for every machine model

Engine volume: Issued for each engine series

Electrical volume:

Attachments volume:

These various volumes are designed to avoid dupli-

cating the same information. Therefore, to deal with

all repairs for any model , it is necessary that chas-

sis, engine, electrical and attachment volumes be

available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will besent 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 page.

File the pages in correct order.

2. Following examples show how to read the page

number.

Example 1 (Chassis volume):

10 - 3

Item number (10. Structure and

Function)

Consecutive page number for each

item.

Example 2 (Engine volume):

12 - 5

Unit number (1 Engine)

REVISED EDITION MARK

When a manual is revised, an edit ion mark((1)(2)(3)....) is recorded on the bottom of the pages.

REVISIONS

Revised pages are shown in the LIST OF REVISED

PAGES next to the CONTENTS page.

SYMBOLS

So that the shop manual can be of ample practical

use, important safety and quality portions are

marked with the following symbols.

Symbol Item Remarks

k Safety

Special safety precautions

are necessary when per-

forming the work.

a Caution

Special technical precau-

tions or other precautions

for preserving standards

are necessary when per-forming the work.

4 Weight

Weight of parts of sys-

tems. Caution necessary

when selecting hoisting

wire, or when working pos-

ture is important, etc.

3Tighteningtorque

Places that require special

attention for the tighteningtorque during assembly.

2 Coat

Places to be coated with

adhesives and lubricants,

etc.

Pl h il t

}·

Each issued as one

volume to cover all

models



FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

k Heavy parts (25 kg or more) must be lifted

with a hoist, etc. In the DISASSEMBLY

AND ASSEMBLY section, every part

weighing 25 kg or more is indicated clearly

with the symbol

• If a part cannot be smoothly removed from the

machine by hoisting, the following checks

should be made:

1) Check for removal of all bolts fastening the

part to the relative parts.

2) Check for existence of another part causing

interference with the part to be removed.

WIRE ROPES

1) Use adequate ropes depending on the

weight of parts to be hoisted, referring to

the table below:

Wire ropes

(Standard "Z" or "S" twist ropes

without galvanizing)

Slinging near the edge of the hook may cause

the rope to slip off the hook during hoisting, and

a serious accident can result. Hooks have max-

imum strength at the middle portion.

3) Do not sling a heavy load with one rope alone,

but sling with two or more ropes symmetrically

wound onto the load.

k Slinging with one rope may cause turning

of the load during hoisting, untwisting of

the rope, or slipping of the rope from its

original winding position on the load, which

can result in a dangerous accident.

4) Do not sling a heavy load with ropes forming a

wide hanging angle from the hook.When hoisting a load with two or more ropes,

the force subjected to each rope will increase

with the hanging angles. The table below

shows the variation of allowable load kN {kg}

when hoisting is made with two ropes, each of

which is allowed to sling up to 9.8 kN {1000 kg}

vertically, at various hanging angles.

When two ropes sling a load vertically, up to

19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}

when two ropes make a 120° hanging angle.

On the other hand, two ropes are subjected to

an excessive force as large as 39.2 kN {4000

kg} if they sling a 19.6 kN {2000 kg} load at a

Rope diameter Allowable load

mm kN tons

10

11.5

12.5

14

16

18

20

22.4

30

40

50

60

9.8

13.7

15.7

21.6

27.5

35.3

43.1

54.9

98.1

176.5

274.6

392 2

1.0

1.4

1.6

2.2

2.8

3.6

4.4

5.6

10.0

18.0

28.0

40 0

4

SAD00479

41%71%79%88%100%



FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, releasethe residual pressure from the hydraulic tank.

For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic

tank.

k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out

when the hose is disconnected. Accordingly,

prepare an oil receiving container.

Disconnection

1) Release the residual pressure from the hydrau-

l ic tank. For details, see TESTING AND

ADJUSTING, Releasing residual pressure from

hydraulic tank.

2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1)

★ The adapter can be pushed in about 3.5

mm.

★ Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it

clicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)

★ Since some hydraulic oil flows out, prepare

an oil receiving container.

Connection

1) Hold hose adapter (1) or hose (5) and insert it in

mating adapter (3), aligning them with each

other. (See Fig. 4)★ Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting

condition. (See Fig. 5)

Type 1



FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 Type 3

D i s a s s e m b l y

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-

vention ring (1) contacts contact surface a of

the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn

lever (4) to the right (clockwise).

3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.

1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-

vention ring (1) contacts contact surface a of


2) Hold in the condition in Step 1), and push

until cover (3) contacts contact surface a of


3) Hold in the condition in Steps 1) and 2), and

pull out whole body (2) to disconnect it.

• Hold the mouthpiece of the tightening portion

and push body (2) in straight until sliding pre

• Hold the mouthpiece of the tightening portion

and push body (2) in straight until sliding pre



FOREWORD COATING MATERIALS

COATING MATERIALS

★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand 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

Adhesives

LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets, rubber

cushions, and cock plug from coming out.

LT-1B 790-129-9050 20 g(2 pcs.)

Polyethylenecontainer

• Used in places requiring an immediatelyeffective, strong adhesive.

Used for plastics (except polyethylene,polyprophylene, tetrafluoroethlene andvinyl chloride), rubber, metal and non-metal.

LT-2 09940-00030 50 gPolyethylene

container

• Features:Resistance to heat and chemicals

• Used for anti-loosening and sealantpurpose for bolts and plugs.

LT-3

790-129-9060(Set of adhesiveand hardening

agent)

Adhesive:1 kg

Hardeningagent:500 g

Can

• Used as adhesive or sealant for metal,glass and plastic.

LT-4 790-129-9040 250 gPolyethylene

container • Used as sealant for machined holes.

HoltzMH 705

790-126-9120 75 g Tube• Used as heat-resisting sealant for

repairing engine.

Three bond1735

790-129-9140 50 gPolyethylene

container

• Quick hardening type adhesive• Cure time: within 5 sec. to 3 min.• Used mainly for adhesion of metals,

rubbers, plastics and woods.

Aron-alpha201

790-129-9130 2 gPolyethylene

container

• Quick hardening type adhesive• Quick cure type

(max. strength after 30 minutes)• Used mainly for adhesion of rubbers,

plastics and metals.

Loctite648-50

79A-129-9110 50 ccPolyethylene

container

• Resistance to heat, chemicals• Used at joint portions subject to high

temperatures.

LG-1 790-129-9010 200 g Tube

• Used as adhesive or sealant for gaskets

and packing of power train case, etc.

LG-5 790-129-9080 1 kg Can

• Used as sealant for various threads, pipe joints, flanges.

• Used as sealant for tapered plugs,elbows, nipples of hydraulic piping.

• Features: Silicon based, resistance toheat, cold



FOREWORD COATING MATERIALS

Molybdenumdisulphidelubricant

LM-G 09940-00051 60 g Can • Used as lubricant for sliding portion (toprevent from squeaking).

LM-P 09940-00040 200 g Tube

• Used to prevent seizure or scuffling of thethread when press fitting or shrink fitting.

• Used as lubricant for linkage, bearings,etc.

Grease

G2-LI

SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LI

SYGA-160CNLI

Various Various

• General purpose type

G2-CA

SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA

Various Various

• Used for normal temperature, light loadbearing at places in contact with water orsteam.

MolybdenumdisulphidegreaseLM-G (G2-M)

SYG2-400MSYG2-400M-ASYGA-16CNM

400 g × 10400 g × 20

16 kg

Bellows typeBellows type

Can

• Used for heavy load portion

Hyper WhiteGrease G2-TG0-T (*)*: For use in

cold district

SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)

400 g16 kg

Bellows typeCan

• Seizure resistance and heat resistancehigher than molybdenum disulfide grease

• Since this grease is white, it does notstand out against machine body.

Biogrease G2BG2-BT (*)*: For high

temperatureand large load

SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)

400 g16 kg

Bellows typeCan

• Since this grease is decomposed bybacteria in short period, it has less effectson microorganisms, animals, and plants.

Primer

SUNSTARPAINT PRIMER580 SUPER

417-926-3910

20 ml Glasscontainer

c a b g l a s s

• Used as primer for cab side(Using limit: 4 months)

SUNSTARGLASS PRIMER580 SUPER

20 mlGlass

container

• Used as primer for glass side(Using limit: 4 months)

SUNSTARPAINT PRIMER435-95

22M-54-27230 20 mlGlass

container

• Used as primer for painted surface oncab side(Using limit: 4 months)

SUNSTARGLASS PRIMER435-41

22M-54-27240 150 ml Can

• Used as primer for black ceramic-

coated surface on glass side and forhard polycarbonate-coated surface(Using limit: 4 months)

SUNSTARSASH PRIMERGP-402

22M-54-27250 20 mlGlass

container

• Used as primer for sash (Alumite).(Using limit: 4 months)

SUNSTAR Ecocart • Used as adhesive for glass.

Category Komatsu code Part No. Q’ty Container Main applications, features



FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in

the table below.

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameterof bolt

Width acrossflats

Tightening torque

mm mm Nm kgm

6

8

10

12

14

10

13

17

19

22

11.8 – 14.7

27 – 34

59 – 74

98 – 123

153 – 190

1.2 – 1.5

2.8 – 3.5

6 – 7.5

10 – 12.5

15.5 – 19.5

16

18

20

2224

24

27

30

3236

235 – 285

320 – 400

455 – 565

610 – 765785 – 980

23.5 – 29.5

33 – 41

46.5 – 58

62.5 – 7880 – 100

27

30

33

36

39

41

46

50

55

60

1150 – 1440

1520 – 1910

1960 – 2450

2450 – 3040

2890 – 3630

118 – 147

155 – 195

200 – 250

250 – 310

295 – 370

Thread diameterof bolt

Width acrossflats

Tightening torque

mm mm Nm kgm

6

8

10

12

10

13

14

27

5.9 – 9.8

13.7 – 23.5

34.3 – 46.1

74.5 – 90.2

0.6 – 1.0

1.4 – 2.4

3.5 – 4.7

7.6 – 9.2

Sealing surface




TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the

table below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

10

12

16

14

17

22

59 – 74

98 – 123

235 – 285

6 – 7.5

10 – 12.5

23.5 – 29.5

Norminal No.

Thread diameter Width across flat Tightening torque (Nm {kgm})

mm mm Range Target

02

03, 04

05, 06

10, 12

14

14

20

24

33

42

Varies depending

on type of

connector.

35 – 63 {3.5 – 6.5}

84 – 132 {8.5 – 13.5}

128 – 186 {13.0 – 19.0}

363 – 480 {37.0 – 49.0}

746 – 1010 {76.0 – 103}

44 {4.5}

103 {10.5}

157 {16.0}

422 {43.0}

883 {90.0}

Norminal No.

Thread diameter Width across flat Tightening torque (Nm {kgm})

mm mm Range Target

08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}




TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES

1) BOLT AND NUTS

Use these torques for bolts and nuts (unit: mm) of Cummins Engine.

2) EYE JOINTSUse these torques for eye joints (unit: mm) of Cummins Engine.

3) TAPERED SCREWS

Use these torques for tapered screws (unit: inch) of Cummins Engine.

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)

★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.

★ Apply the following torque when the threads are coated (wet) with engine oil.

Thread diameter Tightening torque

mm Nm kgm

6

8

10

12

10 0 2

24 0 4

43 0 6

77 0 12

1.02 0 0.20

2.45 0 0.41

4.38 0 0.61

7.85 0 1.22


mm Nm kgm

6

8

10

12

14

8 0 2

10 0 2

12 0 2

24 0 4

36 0 5

0.81 0 0.20

1.02 0 0.20

1.22 0 0.20

2.45 0 0.41

3.67 0 0.51


inch Nm kgm

1 / 16

1 / 8

1 / 43 / 8

1 / 2

3 / 4

1

3 0 1

8 0 2

12 0 215 0 2

24 0 4

36 0 5

60 0 9

0.31 0 0.10

0.81 0 0.20

1.22 0 0.201.53 0 0.20

2.45 0 0.41

3.67 0 0.51

6.12 0 0.92

Nominal sizeof hose

Width acrossflats

Tightening torque (Nm {kgm})Taper seal

typeFace seal type

Range TargetThread size

(mm)

Nominal threadsize - Threads perinch, Thread series

Root diameter(mm) (Reference)

34 54 {3 5 5 5} 44 {4 5} 14 39



FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODEIn 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

CLASSIFICATION BY COLOR AND CODE

Norminalnumber

Copper wire

Cable O.D.(mm)

Currentrating

(A)

Applicable circuit

Number ofstrands

Dia. of

strands(mm2)

Cross

section(mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signaletc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

Priori-ty

Circuits

Classi-fication

Charging Ground Starting Lighting Instrument Signal Other

1Pri-

mary

Code W B B R Y G L

Color White Black Black Red Yellow Green Blue

2

Code WR — BW RW YR GW LW

Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White



FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the

method of using the Conversion Table, see the example given below.

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 (A), then draw a horizontal line

from (A).

(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down

from (B).

(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from

millimeters to inches. Therefore, 55 mm = 2.165 inches.

2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to theleft) to convert it to 55 mm.

(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.

(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point

one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

0.197

0.591

0.984

1.378

1.772

2.165

2.559

2.953

3.346

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

(A)

(B)

(C)




Millimeters to Inches

1 mm = 0.03937 in

Kilogram to Pound

1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

0.394

0.787

1.181

1.575

1.969

2.362

2.756

3.150

3.543

0.039

0.433

0.827

1.220

1.614

2.008

2.402

2.795

3.189

3.583

0.079

0.472

0.866

1.260

1.654

2.047

2.441

2.835

3.228

3.622

0.118

0.512

0.906

1.299

1.693

2.087

2.480

2.874

3.268

3.661

0.157

0.551

0.945

1.339

1.732

2.126

2.520

2.913

3.307

3.701

0.197

0.591

0.984

1.378

1.772

2.165

2.559

2.953

3.346

3.740

0.236

0.630

1.024

1.417

1.811

2.205

2.598

2.992

3.386

3.780

0.276

0.669

1.063

1.457

1.850

2.244

2.638

3.032

3.425

3.819

0.315

0.709

1.102

1.496

1.890

2.283

2.677

3.071

3.465

3.858

0.354

0.748

1.142

1.536

1.929

2.323

2.717

3.110

3.504

3.898

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

0

22.05

44.09

66.14

88.18

110.23

132.28

154.32

176 37

2.20

24.25

46.30

68.34

90.39

112.44

134.48

156.53

178 57

4.41

26.46

48.50

70.55

92.59

114.64

136.69

158.73

180 78

6.61

28.66

50.71

72.75

94.80

116.85

138.89

160.94

182 98

8.82

30.86

51.91

74.96

97.00

119.05

141.10

163.14

185 19

11.02

33.07

55.12

77.16

99.21

121.25

143.30

165.35

187 39

13.23

35.27

57.32

79.37

101.41

123.46

145.51

167.55

189 60

15.43

37.48

59.53

81.57

103.62

125.66

147.71

169.76

191 80

17.64

39.68

61.73

83.78

105.82

127.87

149.91

171.96

194 01

19.84

41.89

63.93

85.98

108.03

130.07

152.12

174.17

196 21




Liter to U.S. Gallon

1l = 0.2642 U.S. Gal

Liter to U.K. Gallon

1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

0

2.642

5.283

7.925

10.567

13.209

15.850

18.492

21.134

23.775

0.264

2.906

5.548

8.189

10.831

13.473

16.115

18.756

21.398

24.040

0.528

3.170

5.812

8.454

11.095

13.737

16.379

19.020

21.662

24.304

0.793

3.434

6.076

8.718

11.359

14.001

16.643

19.285

21.926

24.568

1.057

3.698

6.340

8.982

11.624

14.265

16.907

19.549

22.190

24.832

1.321

3.963

6.604

9.246

11.888

14.529

17.171

19.813

22.455

25.096

1.585

4.227

6.869

9.510

12.152

14.795

17.435

20.077

22.719

25.361

1.849

4.491

7.133

9.774

12.416

15.058

17.700

20.341

22.983

25.625

2.113

4.755

7.397

10.039

12.680

15.322

17.964

20.605

23.247

25.889

2.378

5.019

7.661

10.303

12.944

15.586

18.228

20.870

23.511

26.153

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

0

2.200

4.399

6.599

8.799

10.998

13.198

0.220

2.420

4.619

6.819

9.019

11.281

13.418

0.440

2.640

4.839

7.039

9.239

11.438

13.638

0.660

2.860

5.059

7.259

9.459

11.658

13.858

0.880

3.080

5.279

7.479

9.679

11.878

14.078

1.100

3.300

5.499

7.969

9.899

12.098

14.298

1.320

3.520

5.719

7.919

10.119

12.318

14.518

1.540

3.740

5.939

8.139

10.339

12.528

14.738

1.760

3.950

6.159

8.359

10.559

12.758

14.958

1.980

4.179

6.379

8.579

10.778

12.978

15.178




kg/cm2 to lb/in2

1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

230

0

142.2

284.5

426.7

568.9

711.2

853.4

995.6

1138

1280

1422

1565

1707

1849

1991

2134

2276

2418

2560

2702

2845

2987

3129

32 1

14.2

156.5

298.7

440.9

583.2

725.4

867.6

1010

1152

1294

1437

1579

1721

1863

2005

2148

2290

2432

2574

2717

2859

3001

3143

3286

28.4

170.7

312.9

455.1

597.4

739.6

881.8

1024

1166

1309

1451

1593

1735

1877

2020

2162

2304

2446

2589

2731

2873

3015

3158

3300

42.7

184.9

327.1

469.4

611.6

753.8

896.1

1038

1181

1323

1465

1607

1749

1892

2034

2176

2318

2460

2603

2745

2887

3030

3172

3314

56.9

199.1

341.4

483.6

625.8

768.1

910.3

1053

1195

1337

1479

1621

1764

1906

2048

2190

2333

2475

2617

2759

2901

3044

3186

3328

71.1

213.4

355.6

497.8

640.1

782.3

924.5

1067

1209

1351

1493

1636

1778

1920

2062

2205

2347

2489

2631

2773

2916

3058

3200

3343

85.3

227.6

369.8

512.0

654.3

796.5

938.7

1081

1223

1365

1508

1650

1792

1934

2077

2219

2361

2503

2646

2788

2930

3072

3214

33

99.6

241.8

384.0

526.3

668.5

810.7

953.0

1095

1237

1380

1522

1664

1806

1949

2091

2233

2375

2518

2660

2802

2944

3086

3229

33 1

113.8

256.0

398.3

540.5

682.7

825.0

967.2

1109

1252

1394

1536

1678

1821

1963

2105

2247

2389

2532

2674

2816

2958

3101

3243

338

128.0

270.2

412.5

554.7

696.9

839.2

981.4

1124

1266

1408

1550

1693

1835

1977

2119

2262

2404

2546

2688

2830

2973

3115

3257

3399




Temperature

Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-

tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn 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.

1°C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4

–37.2

–34.4

–31.7

–28.9

–28.3

–27.8

–27.2

–26.7

–26.1

–25.6

–25.0

–24.4

–23.9

–23.3

–22.8

–22.2

–21.7

–21.1

–20.6

–20.0

–19.4

–18.9

–18.3

–40

–35

–30

–25

–20

–19

–18

–17

–16

–15

–14

–13

–12

–11

–10

–9

–8

–7

–6

–5

–4

–3

–2

–1

–40.0

–31.0

–22.0

–13.0

–4.0

–2.2

–0.4

1.4

3.2

5.0

6.8

8.6

10.4

12.2

14.0

15.8

17.6

19.4

21.2

23.0

24.8

26.6

28.4

30.2

–11.7

–11.1

–10.6

–10.0

–9.4

–8.9

–8.3

–7.8

–7.2

–6.7

–6.1

–5.6

–5.0

–4.4

–3.9

–3.3

–2.8

–2.2

–1.7

–1.1

–0.6

0

0.6

1.1

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

51.8

53.6

55.4

57.2

59.0

60.8

62.6

64.4

66.2

68.0

69.8

71.6

73.4

75.2

77.0

78.8

80.6

82.4

84.2

86.0

87.8

89.6

91.4

93.2

7.8

8.3

8.9

9.4

10.0

10.6

11.1

11.7

12.2

12.8

13.3

13.9

14.4

15.0

15.6

16.1

16.7

17.2

17.8

18.3

18.9

19.4

20.0

20.6

46

47

48

49

50

51

52

53

54

55

56

57

58

59

0

61

62

63

64

65

66

67

68

69

114.8

116.6

118.4

120.2

122.0

123.8

125.6

127.4

129.2

131.0

132.8

134.6

136.4

138.2

140.0

141.8

143.6

145.4

147.2

149.0

150.8

152.6

154.4

156.2

27.2

27.8

28.3

28.9

29.4

30.0

30.6

31.1

31.7

32.2

32.8

33.3

33.9

34.4

35.0

35.6

36.1

36.7

37.2

37.8

40.6

43.3

46.1

48.9

81

82

83

84

85

86

87

88

89

90

91

92

93

94

95

96

97

98

99

100

105

110

115

120

117.8

179.6

181.4

183.2

185.0

186.8

188.6

190.4

192.2

194.0

195.8

197.6

199.4

201.2

203.0

204.8

206.6

208.4

210.2

212.0

221.0

230.0

239.0

248.0



FOREWORD UNITS

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).

As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:

N {kg}

Nm {kgm}

MPa {kg/cm2}

kPa {mmH2O}

kPa {mmHg}kW/rpm {HP/rpm}

g/kWh {g/HPh}



SPECIFICATION DRAWINGS......................................................................................................................01- 2

SPECIFICATIONS ........................................................................................................................................01- 4

WEIGHT TABLE............................................................................................................................................01- 8

FUEL, COOLANT AND LUBRICANTS .........................................................................................................01- 12

01 GENERAL

GENERAL SPECIFICATION DRAWINGS




SPECIFICATION DRAWINGS

DIMENSIONS

WORKING RANGES





DIMENSIONS

Fixed gauge specification

Variable gauge specification

Item Unit PC400-7 PC400LC-7 PC450-7 PC450LC-7

A Overall length mm 11,940 11,940 12,040 12,040

B Overall height mm 3,635 3,635 3,660 3,660

C Overall width mm 3,340 3,440 3,340 3,340

D Track shoe width mm 600 700 600 600

E Height of machine cab mm 3,265 3,265 3,265 3,265

F Tail swing radius mm 3,645 3,645 3,645 3,645

G Track overall length mm 5,055 5,355 5,055 5,355

H Length of track on ground mm 4,020 4,350 4,020 4,350

Min. ground clearance mm 555 550 555 550

Item Unit PC400-7 PC400LC-7 PC450-7 PC450LC-7

A Overall length mm 11,940 11,940 12,040 12,040

B Overall height mm 3,635 3,635 3,660 3,660

C Overall width mm 3,490 3,490 3,490 3,490

D Track shoe width mm 600 600 600 600

E Height of machine cab mm 3,265 3,265 3,265 3,265

F Tail swing radius mm 3,645 3,645 3,645 3,645

G Track overall length mm 5,055 5,355 5,055 5,355

H Length of track on ground mm 4,020 4,350 4,020 4,350

Min. ground clearance mm 685 685 685 685

GENERAL SPECIFICATIONS



G S C C O S

SPECIFICATIONS

PC400-7, PC400LC-7

Machine model

PC400-7 PC400LC-7

Fixed gauge

spec.

Variable

gauge spec.

Fixed gauge

spec.

Variable

gauge spec.

Serial Number 50001 and up

Bucket capacity m3 1.4 1.4

Weight of machine kg 41,200 42,400 42,200 43,500

P e r f o r m a n c e

W

o r k i n g r a n g e s

Max. digging depth

Max. vertical wall depth

Max. digging reach

Max. reach at ground level

Max. digging heightMax. dumping height

mm

mm

mm

mm

mmmm

7,820

6,870

12,025

11,820

10,9157,565

7,820

6,870

12,025

11,820

10,9157,565

Max. digging force

(using power max. function)

Swing speed

Swing max. slope angle

Travel speed

Gradeability

kN {kg}

kN {kg}

rpm

deg.

km/h

deg.

256.0 {26,100}

(274.6 {28,000})

9.1

20

Lo: 3.0, Mi: 4.4, Hi: 5.5

35

256.0 {26,100}

(274.6 {28,000})

9.1

20

Lo: 3.0, Mi: 4.4, Hi: 5.5

35

Ground pressure

[standard shoe width]

kPa {kg/cm2}

[mm]

77.7{0.79}

[600]

79.9 {0.82}

[600]

73.9 {0.75}

[700]

65.3 {0.67}

[700]

e n s i o n s

Overall length (for transport)

Overall width

Overall width of track

Overall width of track when extendedOverall height (for transport)

Overall height to top of machine

Ground clearance of upper structure

Min. ground clearance

mm

mm

mm

mmmm

mm

mm

mm

11,940

3,340

3,340

—3,635

3,265

1,320

555

11,940

3,490

2,990

3,4903,635

3,265

1,320

685

11,940

3,440

3,440

—3,635

3,265

1,320

555

11,940

3,490

2,990

3,4903,635

3,265

1,320

685




Machine model PC400-7 PC400LC-7


E n g i n e

Model

Type

No. of cylinders – bore × stroke

Piston displacement

mm

l {cc}

SAA6D125E-3

4-cycle, water-cooled, in-line, vertical, direct injection,

with turbocharger and aftercooler

6 – 125 × 150

11.045 {11,045}

P e r f o r m a n

c e Flywheel horsepower

Max. torqueMax. speed at no load

Min. speed at no load

Min. fuel consumption

kW/rpm {HP/rpm}

Nm/rpm {kgm/rpm}rpm

rpm

g/kWh {g/HPh}

246.4/1,850 {330/1,850}

1,334/1,400 {136/1,400}1,930

1,000

203 {151}

Starting motor

Alternator

Battery

24V, 7.5 kW

24V, 35A

12V, 110 Ah × 2

Radiator core type ALW-4

U n d e r c a r r i a g e Carrier roller 2 on each side

Track roller 7 on each side 8 on each side

Track shoe Assembly-type triple grouser,

45 on each side

Assembly-type triple grouser,

48 on each side

y d r a u l i c s y s t e m

H y d r a u

l i c p u m p Type × No.

Delivery

Set pressure

l /min

MPa {kg/cm2}

HPV190+190, variable displacement, piston type x2

345 × 2

37.8 {380}

C o n t r o l v a l v e Type × No.

Control method

6-spool type + 1-spool type × 1

Hydraulic

H y d r a u l i c m o t o r Travel motor

Swing motor

KMV200ADT-2, Variable displacement, piston type

(with brake valve, parking brake): × 2

KMF230ABE-5, Fixed displacement piston type(with safety valve, holding brake, reverse rotation preventive valve): × 1

Boom Arm Bucket




PC450-7, PC450LC-7

Machine model

PC450LC-7 PC450LC-7

Fixed gauge

spec.

Variable

gauge spec.

Fixed gauge

spec.

Variable

gauge spec.


Bucket capacity m3 1.4 1.4

Operating weight kg 42,700 44,000 43,700 44,600

P e r f o r m a n c e

W o r k i n g r a n g e s

Max. digging depth

Max. vertical wall depth

Max. digging reach

Max. reach at ground level

Max. digging height

Max. dumping height

mm

mm

mm

mm

mm

mm

7,790

6,600

12,005

11,800

10,925

7,625

7,790

6,600

12,005

11,800

10,925

7,625

Max. digging force

(using power max. function)

Swing speed

Swing max. slope angle

Travel speed

Gradeability

kN {kg}

rpm

deg.

km/h

deg.

258.9 {26,400}

(275.5 {28,300})

9.1

17

Lo: 3.0, Mi: 4.4, Hi: 5.5

35

258.9 {26,400}

(275.5 {28,300})

9.1

17

Lo: 3.0, Mi: 4.4, Hi: 5.5

35

Ground pressure[standard shoe width]

kPa {kg/cm2}[mm]

80.5 {0.82}[600]

82.9 {0.85}[600]

76.5 {0.78}[600]

78.1 {0.80}[600]

m e n s i o n s

Overall length (for transport)

Overall width

Overall width of track

Overall width of track when extended

Overall height (for transport)

Overall height to top of machine

Ground clearance of upper structure

Min. ground clearance

mm

mm

mm

mm

mm

mm

mm

12,040

3,340

3,340

—

3,660

3,265

1,320

555

12,040

3,490

2,990

3,490

3,660

3,265

1,320

685

12,040

3,340

3,340

—

3,660

3,265

1,320

555

12,040

3,490

2,990

3,490

3,660

3,265

1,320

685






E n g i n e

Model

Type

No. of cylinders – bore × stroke

Piston displacement

mm

l {cc}

SAA6D125E-3

4-cycle, water-cooled, in-line, vertical, direct injection,

with turbocharger and aftercooler

6 – 125 × 150

11.045 {11,045}

P e r f o r m a n c e Flywheel horsepower

Max. torque

Max. speed at no load

Min. speed at no load

Min. fuel consumption

kW/rpm {HP/rpm}

Nm/rpm {kgm/rpm}

rpm

rpm

g/kWh {g/HPh}

246.4/1,850 {330/1,850}

1,334/1,400 {136/1,400}

1,930

4,000

203 {151}

Starting motor

Alternator

Battery

24V, 7.5 kW

24 V, 35 A

12V, 110 Ah × 2

Radiator core type ALW-4

U n d e r c a r r i a g e Carrier roller 2 on each side

Track roller 7 on each side 8 on each side

Track shoe Assembly-type triple grouser,

45 on each side

Assembly-type triple grouser,

48 on each side

c s y s t e m

H y d r a u l i c p u m

p Type × No.

Delivery

Set pressure

l /min

MPa {kg/cm2}

HPV190+190, ariable displacement, piston type × 2

345 × 2

37.8 {380}

C o

n t r o l v a l v e Type × No.

Control method

6-spool type + 1-spool type × 1

Hydraulic

r a u l i c m o t o r Travel motor

Swing motor

KMV200ADT-2, Variable displacement, piston type

(with brake valve, parking brake): × 2

KMF230ABE-5, Fixed displacement piston type × 2

GENERAL WEIGHT TABLE



WEIGHT TABLE

PC400-7, PC400LC-7

k This weight table is for use when handling components or when transporting the machine.

Unit: kg



Engine assembly

• Engine

• Damper

• Hydraulic pump

1,500

1,150

14.7

210

1,500

1,150

14.7

210

Radiator, oil cooler assembly 195 195

Hydraulic tank, filter assembly (excluding hydraulic oil) 198 198

Fuel tank (excluding fuel) 251 251

Revolving frame 3,297 3,297

Operator's cab 279 279

Operator's seat 35 35

Counterweight 9,220 9,500

Swing machinery (including swing motor) 526 526

Control valve (with service valve) 257 257

Swing motor 105 105

Travel motor 208 × 2 208 × 2

Center swivel joint 40 40

• Track frame assembly

• Track frame

• • Center frame

• • Crawler frame

• Swing circle

Fixed gauge

specification

Variable gauge

specification

Fixed gauge

specification

Variable gauge

specification

10,173 11,367 10,965 11,934

5,506 6,766 6,077 7,096

— 3,229 — 3,229

— 1,754 × 2 — 1,921 × 2

605 × 2 605 × 2




Unit: kg



Track shoe assembly

• Standard triple grouser shoe (600 mm)


• Wide triple grouser shoe (800 mm)


4,470

4,890

5,320

—

4,760

5,210

5,670

6,130

Boom assembly 3,290 3,290

Arm assembly 1,374 1,374

Bucket assembly 1,366 1,366

Boom cylinder assembly 355 × 2 355 × 2

Arm cylinder assembly 510 510

Bucket cylinder assembly 280 280

Link assembly 258 258

Boom pin 92 + 20 × 2 + 73 + 27 + 54 92 + 20 × 2 + 73 + 27 + 54 Arm pin 17 + 23 17 + 23

Bucket pin 38 × 2 38 × 2

Link pin 34 × 2 34 × 2




PC450-7, PC450LC-7

Unit: kg



Engine assembly

• Engine

• Damper

• Hydraulic pump

1,500

1,150

14.7

210

1,500

1,150

14.7

210

Radiator oil cooler assembly 195 195

Hydraulic tank, filter assembly (excluding hydraulic oil) 198 198

Fuel tank (excluding fuel) 251 251

Revolving frame 3,402 3,402

Operator’s cab 279 279

Operator’s seat 35 35

Counterweight 9,220 9,220

Swing machinery 526 526

Control valve 257 257

Swing motor 105 105

Travel motor 208 × 2 208 × 2

Center swivel joint 40 40

• Track frame assembly

• Track frame

• • Center frame

• • Crawler frame• Swing circle

• Idler

• Idler cushion

• Carrier roller

Fixed gauge

specification

Variable gauge

specification

Fixed gauge

specification

Variable gauge

specification

10,462 11,697 11,269 12,244

5,506 6,766 6,077 7,096

— 3,229 — 3,229

— 1,754 × 2 — 1,921 × 2

605

230 × 2

338 × 2

32 × 4

605

230 × 2

338 × 2

32 × 4




Unit: kg



Track shoe assembly




4,470

4,890

—

4,760

5,210

—

Boom assembly 3,380 3,380

Arm assembly 1,622 1,622

Bucket assembly 1,941 1,941

Boom cylinder assembly 355 × 2 355 × 2

Arm cylinder assembly 580 580

Bucket cylinder assembly 280 280

Link assembly 258 258

Boom pin 92 + 20 × 2 + 73 + 27 + 54 92 + 20 × 2 + 73 + 27 + 54

Arm pin 17 + 23 17 + 23

Bucket pin 38 × 2 38 × 2

Link pin 34 × 2 34 × 2

GENERAL FUEL, COOLANT AND LUBRICANTS



FUEL, COOLANT AND LUBRICANTS



ENGINE RELATED PARTS..................... 10- 2

RADIATOR • OIL COOLER •

AFTERCOOLER ................................ 10- 3

POWER TRAIN ....................................... 10- 4

FINAL DRIVE .......................................... 10- 6

SPROCKET............................................. 10- 7-1

SWING MACHINERY.............................. 10- 8

SWING CIRCLE ...................................... 10- 10TRACK FRAME AND RECOIL SPRING. 10- 12

IDLER...................................................... 10- 14

CARRIER ROLLER ................................. 10- 16

TRACK ROLLER..................................... 10- 17

TRACK SHOE ......................................... 10- 18

HYDRAULIC PIPING DRAWING ............ 10- 22

HYDRAULIC TANK.................................. 10- 24

HYDRAULIC PUMP ................................ 10- 26

LS(PC)-EPC VALVE ................................ 10- 44VARIABLE VOLUME VALVE .................. 10- 47

CONTROL VALVE ................................... 10- 50

MAIN RELIEF VALVE.............................. 10- 64

CLSS ....................................................... 10- 66

SELF PRESSURE REDUCING VALVE... 10- 69

SWING MOTOR...................................... 10- 72

CENTER SWIVEL JOINT........................ 10- 80

TRAVEL MOTOR..................................... 10- 82

TRAVEL JUNCTION VALVE.................... 10- 93

VALVE CONTROL................................... 10- 95

TRAVEL PPC SHUTTLE VALVE ............. 10- 96

WORK EQUIPMENT • SWING PPC

VALVE ................................................ 10-100

TRAVEL PPC VALVE 10 104

AIR CONDITIONER .................................10-144

ENGINE CONTROL.................................10-145

ELECTRONIC CONTROL SYSTEM........10-151

MONITOR SYSTEM.................................10-178

7-SEGMENT MONITOR SYSTEM........ 10-197-1

SENSOR ..................................................10-198

10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE RELATED PARTS



ENGINE RELATED PARTS

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RADIATOR • OIL COOLER • AFTERCOOLER



RADIATOR • OIL COOLER • AFTERCOOLER

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN



POWER TRAIN



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE



FINAL DRIVE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE



Unit: mm

No. Check item Criteria Remedy

14 Backlash between No. 1 sungear and No. 1 planetary gear

Standard clearance Clearance limit

0.15 – 0.54 1.10

15Backlash between No. 1

planetary gear and ring gear 0.18 – 0.66 1.30

Backlash between No 2

Specification

Reduction ratio:

– × = –68.600

1. Level plug

2. Drain plug3. No. 1 planetary gear (No. of teeth: 43)

4. No. 1 sun gear (No. of teeth: 10)

5. No. 2 sun gear (No. of teeth: 18)

6. No. 1 planetary carrier

7. No. 2 planetary carrier

8. Cover

9. Ring gear (No. of teeth: 98)

10. Sprocket

11. Floating seal12. Travel motor

13. No. 2 planetary gear (No. of teeth: 38)

10 + 98

10

18 + 98

18

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET



SPROCKET

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET



SPROCKET TOOTH SHAPE OF REAL DIMENSION

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY



SWING MACHINERY

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY



Unit: mm


14Backlash between swing

motor shaft and No. 1 sun gear

Standard clearance Clearance limit

Replace

0.18 – 0.28 —

15

Backlash between No. 1 sun

gear and No. 1 planetary

gear

0.15 – 0.51 1.00

16

Backlash between No. 1

planetary gear and ring gear 0.17 – 0.60 1.10

17

Backlash between No. 1

planetary carrier and No. 2

sun gear

0.40 – 0.75 1.20

18Backlash between No. 2 sun

0 16 0 55 1 00

Specification

Reduction ratio:

× = 24.039

1. Swing pinion (No. of teeth: 13)

2. Cover 3. Case

4. No. 2 planetary gear

5. No. 2 sun gear

6. Ring gear

7. No. 1 sun gear

8. Swing motor

9. Oil level gauge

10. No. 1 planetary gear

11. No. 1 planetary carrier 12. No. 2 planetary carrier

13. Drain plug

19 + 6819 16 + 6816

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CIRCLE



SWING CIRCLE



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING

TRACK FRAME AND RECOIL SPRING



TRACK FRAME AND RECOIL SPRING

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING



Standard shoe

Unit: mm

Model

ItemPC400-7 PC400LC-7 PC450-7 PC450LC-7

Shoe width 600 mm 700 mm 600 mm 600 mm

Link pitch 228 mm 228 mm 228 mm 228 mm

No. on track (one side) 46 (Pieces) 46 (Pieces) 49 (Pieces) 49 (Pieces)


Standard

sizeTolerance Repair limit

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER

IDLER



IDLER

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD



Unit: mm


1Outside diameter of protrud-

ing

Standard sizeRepair limit

Rebuild or

704 —

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER

CARRIER ROLLER



CARRIER ROLLER

Unit: mm


1 Outside diameter of flangeStandard size Repair limit

175 —

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER

TRACK ROLLER



TRACK ROLLER

Unit: mm


1Outside diameter of outer

flange

Standard size Repair limit

Rebuild or

replace

240 —

2Outside diameter of inner flange

(double flange)237 —

3 Outside diameter of tread 200 188

4 Thickness of tread 56.2 50.2

5 Overall width 278 —

6 Width of treadSinge flange 54.6 —

Double flange 51.6 —

Width of outer Singe flange 32.6 —

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE

TRACK SHOE



C S OTRACK SHOE




Unit: mm


1 Link pitchStandard size Repair limit

Reverse orreplace

228.9 231.9

2 Bushing outside diameter Standard size When turned

71.5 66.5

3 Thickness of bushing metal 12 7 Adjust or

replace

4 Link heightStandard size Repair limit

Repair or

replace

129 119

5 Thickness of link metal(bushing press-fitting portion)

34.5 24.5

6

Shoe bolt pitch

184

Replace7 144

8 76.2

9

Link

Inside

width106

Repair or

replace10

Overall

width51.6

11Tread

width44.8




Unit: mm


20

Shoe bolt

a. Regular

link

Tightening torque

(Nm {kgm})

Additinal tightening

angle (deg.)

RetightenTriple shoe 393±39 {40±4} 120±10

b. Master

link

Tightening torque

(Nm {kgm})

Additinal tightening

angle (deg.)

Lower limit torque

(Nm {kgm})

— — —

No. of shoes (each side)PC400-7, PC450-7: 46

PC400LC-7, PC450LC-7: 49—

21 Interference betweenbushing and link

Standard sizeTolerance Standard

interference

Shaft Hole

71+0.494

+0.454

+0.074

00.380 – 0.494

22Interference between regular

pin and link47

+0.235

+0.085

–0.218

–0.2800.303 – 0.515




TRIPLE GROUSER SHOE

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING DRAWING

HYDRAULIC PIPING DRAWING



1. Bucket cylinder

2. Arm cylinder

3. Boom cylinder

4. Swing motor

5. Control valve

6. Oil cooler

7. Hydraulic filter

8. Hydraulic pump

9. L.H. travel motor

10. Hydraulic tank11. Multi-pattern selector valve

12. L.H. PPC valve

13. Safety lever (electric type)

14. Center swivel joint

15. R.H. PPC valve

16. Travel PPC valve

17. Attachment circuit selector valve

18. Holding valve

19. Accumulator 20. Solenoid valve assembly

20A. PPC lock solenoid

20B. Travel junction solenoid

20C. Pump merge/divider solenoid

20D. Travel speed solenoid

20E. Swing brake solenoid

20F. Machine push-up solenoid

20G. 2-stage relief solenoid

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING DRAWING



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK

HYDRAULIC TANK



1. Oil filler cap Specifications

Tank capacity: 335 l2 Breather



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP

HYDRAULIC PUMP



HPV190+190

1. Front main pump

2. Rear main pump

3 LS valve

IM : PC mode selector current

ISIG : LS set selector current

PAF : Front pump delivery

PENR : Rear pump control

pressure detection port

PLSF : Front load pressure input




Function

• The rotation and torque transmitted to the pump

shaft are converted into hydraulic energy, and

pressurized oil is discharged according to the

load.

• It is possible to change the discharge amount by

changing the swash plate angle.

Structure

• Cylinder block (7) is supported to shaft (1) by a

spline, and shaft (1) is supported by the front and

rear bearings.

• The tip of piston (6) is a concave ball, and shoe

(5) is caulked to it to form one unit. Piston (6) and

shoe (5) form a spherical bearing.

• Rocker cam (4) has flat surface A, and shoe (5) is

always pressed against this surface while sliding

in a circular movement.Rocker cam (4) brings high pressure oil at cylin-

der surface B with cradle (2), which is secured to

the case, and forms a static pressure bearing

when it slides.

Pi t (6) i t l ti t i th




Operation

1) Operation of pump

i Cylinder block (7) rotates together with shaft

(1), and shoe (5) slides on flat surface A.

When this happens, rocker cam (4) moves

along cylindrical surface B, so angle

between center line X of rocker cam (4) and

the axial direction of cylinder block (7)

changes. (Angle is called the swash plate

angle.)ii Center line X of rocker cam (4) maintains

swash plate angle in relation to the axial

direction of cylinder block (7), and flat surface

A moves as a cam in relation to shoe (5).

In this way, piston (6) slides on the inside of

cylinder block (7), so a difference between

volumes E and F is created inside cylinder

block (7). The suction and discharge is car-ried out by this difference F – E.

In other words, when cylinder block (7)

rotates and the volume of chamber E

becomes smaller, the oil is discharged during

that stroke. On the other hand, the volume of

chamber F becomes larger, and as the vol-

ume becomes bigger, the oil is sucked in.

iii If center line X of rocker cam (4) is in line with

the axial direction of cylinder block (7) (swashplate angle = 0), the difference between vol-

umes E and F inside cylinder block (7)

becomes 0, so the pump does not carry out

any suction or discharge of oil.

(In actual fact, the swash plate angle never

becomes 0.)


2) C t l f di h t



2) Control of discharge amount

• If the swash plate angle becomes larger,the difference between volumes E and F be-

comes larger and discharge amount Q in-

creases.

• Swash plate angle is changed by servo

piston (12).

• Servo piston (12) moves in a reciprocal

movement ( ) according to the signal pres-

sure from the PC and LS valves. This

straight l ine movement is transmittedthrough rod (13) to rocker cam (4), and rock-

er cam (4), which is supported by the cylin-

drical surface to cradle (2), slides in a

rotating movement in direction of arrow.

• With servo piston (12), the area receiving the

pressure is different on the left and the right,

so main pump discharge pressure (self pres-

sure) PP is always brought to the chamber

receiving the pressure at the small diameter

piston end.

• Output pressure Pen of the LS valve is

brought to the chamber receiving the pres-

sure at the large diameter end. The relation-

ship in the size of pressure PP at the small

diameter piston end and pressure Pen at the

large diameter end, and the ratio between

the area receiving the pressure of the smalldiameter piston and the large diameter pis-

ton controls the movement of servo piston

(12).


LS VALVE



PC VALVE

1. Plug PA : Pump port

2. Locknut PP : Pump port

3. Sleeve PDP : Drain port

4. Spring PLP : LS control pressure output port

5. Seat PLS : LS pressure input port6. Spool PPL : PC control pressure input port

7. Piston PSIG : LS mode selection pilot port

8. Sleeve


Function

(1) LS valve

The LS valve detects the load and controls the



The LS valve detects the load and controls the

discharge amount.This valve controls main pump discharge

amount Q according to differential pressure

PLS (=PP – PLS) [called the LS differential

pressure] (the difference between main pump

pressure PP and control valve outlet port pres-

sure PLS).

Main pump pressure PP, pressure PLS {called

the LS pressure} coming from the control valve

output, and pressure PSIG {called the LS selec-

tor pressure} from the proportional solenoid

valve enter this valve. The relationship between

discharge amount Q and differential pressure

PLS, (the difference between main pump

pressure PP and LS pressure PLS) (= PP –

PLS) changes as shown in the diagram at the

right according to LS pressure selector current

PSIG of the LS-EPC valve.When PSIG changes between 0 and 1A, the set

pressure of the spring changes according to this,

and the selector point for the pump discharge

amount changes at the rated central valve

between 1.2 2.6 MPa {12 27 kg/cm2}.

(2) PC valve

When the pump discharge pressure PP1 (self-

pressure) and PP2 (other pump pressure) arehigh, the PC valve controls the pump so that no

more oil than the constant flow (in accordance

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 horsepower.

In other words, If the load during the operationbecomes larger and the pump discharge pres-

sure rises, it reduces the discharge amount from

the pump; and if the pump discharge pressure

drops, it increases the discharge amount from

the pump The relationship between the average


OPERATION



(1) LS valve

1) When control valve is at neutral position

• The LS valve is a three-way selector valve, with

pressure PLS (LS pressure) from the inlet port of

the control valve brought to spring chamber B,

and main pump discharge pressure PP brought

to port H of sleeve (8). The size of this LS pres-sure PLS + force Z of spring (4) and the main

pump pressure (self pressure) PP determines

the position of spool (6). However, the size of the

output pressure PSIG (the LS selection pres-

) f th EPC l f th LS l t i

of the piston, so the swash plate is moved to the

minimum angle by the difference in the area of

the piston (12).




2) Operation in increase direction for pump

discharge amount




3) Operation in decrease direction for

pump discharge amount




(2) PC Valve

1) When pump controller is normal

a. When the load on the actuator is smalland pump pressures PP1 and PP2 are

low

i) Movement of PC-EPC solenoid (1)

• The command current from the pump con- • The size of command current X is deter-





• Port C of the PC valve is connected to port E

of the LS valve (see (1) LS valve). Self pres-

sure PP1 enters port B and the small diame



sure PP1 enters port B and the small diame-

ter end of servo piston (9), and other pump

pressure PP2 enters port A.

• When pump pressures PP1 and PP2 are

small, spool (3) is on the left. At this point,

port C and D are connected, and the pres-

sure entering the LS valve becomes drain

pressure PT. If port E and port G of the LS

valve are connected (see (1) LS valve), the

pressure entering the large diameter end of the piston from port J becomes drain pres-

sure PT, and servo piston (9) moves to the

left. In this way, the pump discharge amount

moves in the direction of increase.

• As servo piston (9) moves further, springs

(4) and (6) expand and the spring force be-

comes weaker. When the spring force be-

comes weaker, spool (3) moves to the right,

so the connection between port C and port Dis cut, and the pump discharge pressure

ports B and C are connected. As a result, the

pressure at port C rises, and the pressure at

the large diameter end of the piston also ris-

es, so the movement of piston (9) to the left

is stopped.

• In other words, the stop position for piston (9)

(= pump discharge amount) is decided at the

point where the force of springs (4) and (6)

and the pushing force from the PC-EPC

valve solenoid and the pushing force created

by the pressures PP1 and PP2 acting on the

spool (3) are in balance.




b. When load on actuator is large and pump

discharge pressure is high

• When the load is large and pump discharge • If pump discharge pressure PP and PP2 in-


• The relation of average pump pressure (PP1

+ PP2)/2 and the position of servo piston (9)

forms a bent line because of the double-

spring effect of springs (4) and (6). The rela-



tionship between average pump pressure(PP1 + PP2)/2 and pump discharge amount

Q is shown in the figure at the right.

• If command voltage X sent to PC-EPC valve

solenoid (1) increases further, the relation-

ship between average pump pressure (PP1

+ PP2)/2, and pump discharge amount Q is

proportional to the pushing force of the PC-

EPC valve solenoid and moves in parallel. In

other words, the pushing force of PC-EPC

solenoid (1) is added to the force pushing tothe left because of the pump pressure ap-

plied to the spool (3), so the relationship be-

tween the average pump pressure (PP1 +

PP2)/2 and Q moves from to in accord-

ance with the increase in X.




2) When pump controller is abnormal and

emergency pump drive switch is ON

a. When load on main pump is light

• If there is a failure in the pump controller turn

• At this point, port C is connected to the drain

pressure of port D, and the large diameter

end of the piston of servo piston (9) also be-

comes the drain pressure PT through the LS




b. When main pump load is heavy

• In the same way as in the previous item,

when the emergency pump drive switch is

ON, the command current sent to PC-EPC

valve solenoid (1) becomes constant. For

this reason, the force of piston (2) pushing

l (3) i t t

the diagram for the valve of the current sent

to the PC-EPC valve solenoid through the

resistor.

The curve when the emergency pump drive

switch is ON is curve , which is to the left

f f h th t ll i

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LS(PC)-EPC VALVE

LS(PC)-EPC VALVE



1. Body 5. Coil PSIG : To LS(PC) valve

2. Spool 6. Plunger PT : To tank


Function

• The EPC valve consists of the proportional sole-

noid portion and the hydraulic valve portion.

Wh it i i l t i f th



• When it receives signal current i from the pumpcontroller, it generates the EPC output pressure

in proportion to the size of the signal, and outputs

it to the LS valve.

Operation

1. When signal current is 0 (coil de-energized)

• When there is no signal current flowing from the

controller to coil (5), coil (5) is de-energized.• For this reason, spool (2) is pushed to the left in

the direction of the arrow by spring (3).

• As a result, port PEPC closes and the pressu-

rized oil from the main pump does not flow to the

LS valve.

At the same time, the pressurized oil from the LS

valve passes from port PSIG(PM) through port

PT and is drained to the tank.


2. When signal current is very small (coil ener-

gized)

• When a very small signal current flows to coil (5),

coil (5) is energized, and a propulsion force is

generated which pushes plunger (6) to the left



generated which pushes plunger (6) to the left.• Push pin (4) pushes spool (2) to the left, and

pressurized oil flows from port PEPC to port

PSIG(PM).

• When the pressure at port PSIG(PM) rises and

the load of spring (3) + the force acting on sur-

face a of spool (2) becomes greater than the pro-

pulsion force of plunger (6), spool (2) is pushed

to the right. The circuit between port PEPC and

port PSIG(PM) is shut off, and at the same time,

port PSIG(PM) and port PT are connected.

• As a result, spool (2) is moved up or down until

the propulsion force of plunger (6) is balanced

with the load of spring (3) + pressure of port

PSIG(PM).

• Therefore, the circuit pressure between the EPC

valve and the LS valve is controlled in proportion

to the size of the signal current.

3. When signal current is maximum (coil ener-

gized)

• When the signal current flows to coil (5), coil (5)

is energized.

• 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 (2) is completely pushed to

the left by push pin (4).

• As a result, the maximum flow of pressurized oil

from port PEPC flows to port PSIG(PM), and the

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VARIABLE VOLUME VALVE

VARIABLE VOLUME VALVE



1. Block PM : To PC valve

2. Plug PT : To tank

3. Spring PEPC:From self-reducing pressure valve

4. Piston

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VARIABLE VOLUME VALVE

Function

• This stabilizes the EPC output pressure.



Operation

• The output pressure from EPC flows to port PM,

and when the propulsion force of piston (4) be-

comes larger than the load of spring (3), piston

(4) is pushed to the left and the volume at port

PM increases.

When the propulsion force of piston (4) becomes

less than the load on spring (3), piston (4) ispushed to the right and the volume at port PM

goes down.



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE

CONTROL VALVE

1. 6-spool valve

2. Cover 1

3. Cover 2

Outline

• This control valve consists of a 7-spool valve (6

spool valve + boom • arm Hi valve). A merge-di-

vider valve, back-pressure valve, boom hydraulic



3 Co e

4. Pump merge-divider valve

5. Back pressure valve

6. Boom lock valve

7. Boom, arm Hi valve

8. Quick return valve

9. Boom Hi check valve

de a e, bac p essu e a e, boo yd au c

drift prevention valve, quick return valve, and Hi

valve check valve are installed to it.

• Since all the valves are assembled together with

connecting bolts and their passes are connected

to each other inside the assembly, the assembly

is small in size and easy to maintain.

• Since one spool of this control valve is used for

one work equipment unit, its structure is simple.

A1 : To bucket cylinder bottom P11 : From arm PPC valve

A2 : o left travel motor P12 : From arm PPC valve

A3 : To boom cylinder bottom BP1 : Boom RAISE PPC output pressure

A4 : To swing motor PB5 : From 2-stage safety valve solenoid valve

A5 : To right travel motor PLS1 : To rear pump control

A6 : To arm cylinder head PLS2 : To front pump control

A-1 : To boom cylinder bottom PP1 : To rear pump control

A-2 : To attachment PP2 : To front pump control

B1 : To bucket cylinder head PPS1 : From rear main pumpB3 : To bottom cylinder head PPS2 : From front main pump

B4 : To swing motor PR : To solenoid valve, PPC valve, EPC valve

B5 : To right travel motor PS : From pump merge-divider solenoid valve

B6 : To arm cylinder bottom PST : From travel junction valve

B-1 : To arm cylinder bottom PX1 : From 2-stage solenoid valve

P1 : From bucket PPC valve PX2 : From 2-stage solenoid valve

P2 : From bucket PPC valve SA : Pressure sensor fitting port

P3 : From left travel PPC valve SB : Pressure sensor fitting port

P4 : From left travel PPC valve T : To tank

P5 : From boom PPC valve T1 : To tank

P6 : From boom PPC valve TS : To tank

P7 : From swing PPC valve TSW : To swing motor


7-spool valve

(1/9)




(2/9)




(3/9)



1. Unload valve 9. Pressure compensation valve (Arm IN)

2. Pressure compensation valve (Arm OUT) 10. Pressure compensation valve (Bucket DUMP)

3. Pressure compensation valve (Right travel re-

verse)

11. Pressure compensation valve (Left travel forward)

12. Pressure compensation valve (Boom LOWER)

4. Pressure compensation valve (Left swing) 13. Pressure compensation valve (Right swing)

5. Pressure compensation valve (Boom RAISE) 14. Pressure compensation valve (Right travel for-




(5/9)



1. Safety-suction valve (Arm OUT) 9. Safety-suction valve (2-stage) (Boom LOWER)

2. Suction valve (Right travel reverse) 10. Suction valve (Right travel forward)

3. Suction valve (Boom RAISE) 11. Safety-suction valve (Arm IN)

4 S ti l (L ft t l ) 12 LS h ttl l (A i ht t l)


(6/9)



ARM CONTROL VALVE R. H. TRAVEL CONTROL VALVE

1. Unload valve 5. Safety-suction valve 12. Suction valve

2. Main relief valve 6. Spool 13. Spool

3. Safety valve (Boom RAISE) 7. Pressure compensation valve

(OUT)

14. Pressure compensation valve

(Reverse)4. Lift check valve

8. LS shuttle valve 15. LS shuttle valve

9. Pressure compensation valve 16. Pressure compensation valve


Unit: mm


Standard size Repair limitFree length Installed Installed Free Installed



18 Regeneration valve spring

If damaged or

deformed,

replace spring

Free length

× OD

Installed

length

Installed

load

Free

length

Installed

load

31.5 × 10.3 19.56.2 N

{0.6 kg}—

4.9 N

{0.5 kg}

19 Piston return spring 36.9 × 11.1 2829.4 N

{3 kg}—

23.5 N

{2.4 kg}


{3 kg} —23.5 N

{2.4 kg}


(7/9)



SWING CONTROL VALVE

1. Spool2. Pressure compensation valve

(Left)

3. LS select valve

ARM CONTROL VALVE

5. Suction valve6. Spool

7. Pressure compensation valve

(RAISE)

L. H. TRAVEL CONTROL VALVE

13. Pump merge-divider valve(Travel junction valve)

14. Return spring

15. Suction valve


Unit: mm


Standard size Repair limitFree length Installed Installed Free Installed



21 Regeneration valve spring

If damaged or

deformed,

replace spring

× OD length load length load

31.5 × 10.3 19.56.2 N

{0.6 kg}—

4.9 N

{0.5 kg}


{1.8 kg}—

14.0 N

{1.4 kg}

23 Piston return spring 36.9 × 11.1 28

29.4 N

{3 kg} —

23.5 N

{2.4 kg}

24 Spool return spring 30.7 × 20.5 2350.0 N

{5.1 kg}—

40.0 N

{4.1 kg}


(8/9)



BUCKET CONTROL VALVE

1. Safety-suction valve2. Spool

3. Pressure compensation valve (CURL)

4. LS shuttle valve

5 Pressure compensation valve (DUMP)

BOOM, ARM HI VALVE

7. Boom Hi spool8. Pressure compensation valve (Boom RAISE)

9. Boom Hi check valve

10. Quick-return valve

11 Pressure compensation valve (Arm IN)




(9/9)



1 Unload valve 9 LS bypass plug


Unit: mm


17 Check valve spring

Standard size Repair limit

Free length

× OD

Installed

length

Installed

load

Free

length

Installed

load



17 Check valve spring

If damaged or

deformed,

replace spring

× OD length load length load

11.5 × 4.6 8.51.5 N

{0.15 kg}—

1.2 N

{0.12 kg}

18 Spool return spring 46.6 × 21.8 3.3156.8 N

{16.0 kg}—

125.5 N

{12.8 kg}

19 Spool return spring 64.5 × 32.3 63

177.5 N

{18.1 kg} —

142.0 N

{14.5 kg}

20 Sequence valve spring 70.9 × 18.0 59199.8 N

{20.4 kg}—

160.0 N

{16.3 kg}

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN RELIEF VALVE

MAIN RELIEF VALVE



Function

• The relief valve set pressure is set to 2 stages.

When power is needed, pilot pressure P is turned

ON and the pressure is set to high pressure.

Operation

• The relief valve set pressure is determined by the

installed load of spring (1). (First stage)

• It is unnecessary to set the first and second

stage individually.

The second stage is set when the first stage is

set.

1. When pilot pressure P is OFF: Low-pressure

setting

The set pressure is determined by the installed

load of spring (1).

1. Spring

2. Poppet



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS

CLSS

OUTLINE OF CLSS



Features Structure


Basic principle

1) Control of pump swash plate

• The pump swash plate angle (pump dischargeamount) is controlled so that LS differential pres-

sure PLS (the difference between pump pres-



( p p p

sure PP and control valve outlet port LS pressure

PLS) (load pressure of actuator) is constant.

(LS pressure PLS = Pump discharge pressure

PP – LS pressure PLS)

• If LS differential pressure PLS becomes lower

than the set pressure of the LS valve (when the

actuator load pressure is high), the pump swashplate moves towards the maximum position; if it

becomes higher than the set pressure of the LS

valve (when the actuator load pressure is low),


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 P be-

In this way, the flow of oil from the pump is divid-

ed (compensated) in proportion to the area of

opening S1 and S2 of each valve.



tween the upstream (inlet port) and downstream

(outlet port) of the spool of each valve the same

regardless of the size of the load (pressure).

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE

SELF PRESSURE REDUCING VALVE

Function

• This value reduces the discharge pressure of themain pump and supplies it as control pressure for

the solenoid valves, PPC valves, etc.



Operation

1. When engine is stopped

• Poppet (11) is pressed by spring (12) against the

seat and port PR is not connected to TS.• Valve (14) is pressed by spring (13) against the

left side and port P2 is connected to PR.

• Valve (7) is pressed by spring (8) against the left

side and port P2 is not connected to A2.


2. When in neutral or load pressure P2 is low

(When the boom is lowered and arm is at the IN

position and they are moving down under their

own weight)Note: When load pressure A2 is lower than self-

pressure reducing valve output pressure

PR



PR.

• Valve (7) receives the force of spring (8) and PR

pressure (which is 0 MPa {0 kg/cm2} when the

engine is stopped) in the direction to close the

circuit between ports P2 and A2. If the hydraulic

oil flows in port P2, the fdx P2 pressure becomesequal to the total force of spring (8) and the value

of area of ød × PR pressure, then the area of the

pass between ports P2 and A2 is adjusted so the

P2 pressure will be kept constant above the PR

pressure.

• If the PR pressure rises above the set level, pup-

pet (11) opens and the hydraulic oil flows from

the PR port through orifice “a” in spool (14) and

open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated

between before and after orifice “a” in spool (14)

and then spool (14) moves to close the pass be-

tween port P2 and PR. The P2 pressure is con-

trolled constant (at the set pressure) by the area

of the oil pass at this time and supplied as the PR

pressure.

3. When load pressure P2 is high

• If load pressure A2 rises and the pump discharge

increases because of operation of the work

equipment, the fdx P2 pressure rises higher than

the total of the force of spring (8) and the value of

ød × PR pressure, and then valve (7) moves to

the right stroke end.

• As a result, the area of the pass between ports

P2 and A2 increases and the pass resistancelowers and the loss of the engine power is re-

duced.

• If the PR pressure rises above the set pressure,

t (11) d th h d li il fl


4. When abnormal high pressure is generated

• If the PR pressure on the self-pressure reducing

valve rises abnormally high, ball (16) separates

from the seat against the force of spring (15) andthe hydraulic oil flows from output port PR to TS.

Accordingly, the PR pressure lowers. By this op-

eration the hydraulic devices (PPC valves sole



eration, the hydraulic devices (PPC valves, sole-

noid valves, etc.) are protected from abnormal

pressure.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR

SWING MOTOR

KMF230ABE-5




RELIEF VALVE

1. OutlineThe relief portion consists of check valves (2)

and (3), shuttle valves (4) and (5), and relief

valve (1).



2. Function

When the swing is stopped, the outlet port circuit

of the motor from the control valve is closed, but

the motor continues to rotate under inertia, so

the pressure at the output side of the motor becomes abnormally high, and this may dam-

age the motor.

To prevent this, the abnormal high pressure oil is

relieved to port S from the outlet port of the

motor (high-pressure side) to prevent any dam-

age.

3. Operation

1) When starting swing

• When the swing control lever is operated to

swing right, the pressure oil from the pump pass-

es through the control valve and is supplied to

port MA. As a result, the pressure at port MA ris-

es, the starting torque is generated in the motor,

and the motor starts to rotate. The oil from the

outlet port of the motor passes from port MA

through the control valve and returns to the tank.(Fig. 1)

2) When stopping swing

• When the swing control lever is returned to neu-

tral, the supply of pressure oil from the pump to

port MA is stopped. With the oil from the outlet

port of the motor, the return circuit to the tank is

closed by the control valve, so the pressure at

port MB rises. As a result, rotation resistance isgenerated in the motor, so the braking effect

starts.

• If the pressure at port MB becomes higher than


Operation of swing lock

1. When swing lock solenoid valve is deactivat-

edWhen the swing lock solenoid valve is deacti-

vated, the pressurized oil from the main pump is

shut off and port B is connected to the tank cir-

it



cuit.

As a result, brake piston (7) is pushed down by

brake spring (1), discs (5) and plates (6) are

pushed together, and the brake is applied.

2. When swing lock solenoid valve is activated

When the swing lock solenoid valve is activated,the valve is switched and the pressure oil from

the main pump enters port B and flows to brake

chamber a.

The pressure oil entering chamber a overcomes

brake spring (1) and pushes brake piston (7) up.

As a result, discs (5) and plates (6) are sepa-

rated and the brake is released.


REVERSAL PREVENTION VALVE

Outline diagram



Explanation of effect

1. Valve body

2. Spool (MA side)

3. Spring (MA side)

4. Plug

5. Spool (MB side)

6. Spring (MB side)

7. Plug


Outline

This valve reduces the swing back generated in

the swing body by the inertia of the swing body,the backlash and rigidity of the machinery sys-

tem, and the compression of the hydraulic oil

when the swing is stopped. This is effective in

preventing spillage of the load and reducing the



preventing spillage of the load and reducing the

cycle time when stopping the swing (the posi-

tioning ability is good and it is possible to move

swiftly to the next job.

Operation

1. When brake pressure is being generated at

port MB

• Pressure MB passes through the notch and goes

to chamber d, spool (5) pushes spring (6) ac-

cording to the difference in area D1 > D2, moves

to the left, and MB is connected to e.

When this happens, pressure MA is below the

set pressure of spring (3), so spool (2) does not

move. For this reason, the pressure oil is closed

by spool (2), and the braking force is ensured.

2. After motor stops• The motor is reversed by the closing pressure

generated at port MB. (1st reversal)

When this happens, reversal pressure is gener-

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT

CENTER SWIVEL JOINT



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR

TRAVEL MOTOR

KMV280ADT




Operation of moter

1) At low speed (motor swash plate angle at

maximumu)




2) At high speed (motor swash plate angle at

minimum)




PARKING BRAKE

1. When starting to travel



Operation

• When the travel lever is operated, the pressu-

rized oil from the pump actuates counterbalance


2. When stopping travel



Operation

• When the travel lever is placed in neutral, coun-

terbalance valve spool (13) returns to the neutral

valve (7) when the brake piston returns, and this

ensures that the brake is applied after the ma-

chine stops


Operation of brake valve

• The brake valve consists of a check valve (1),

counterbalance valve (2), and safety valve (3) in

a circuit as shown in the diagram on the right.

• The function and operation of each component is

as given below.

1) Counterbalance valve, check valve



) ,

Function

• When traveling downhill, the weight of the ma-

chine makes it try to travel faster than the speedof the motor.

As a result, if the machine travels with the engine

at low speed, the motor will rotate without load

and the machine will run away, which is extreme-

ly dangerous.

To prevent this, these valves act to make the ma-

chine travel according to the engine speed

(pump discharge amount).

Operation when pressurized oil is supplied


rized oil from the control valve is supplied to port

PA. It pushes open check valve (12a) and flows

from motor inlet port MA to motor outlet port MB.

However, the motor outlet port is closed by check

valve (12b) and spool (13), so the pressure at the

supply side rises.


• The pressurized oil at the supply side flows from

orifice E1 in spool (13) and orifice E2 in the pis-

ton to chamber S1. When the pressure in cham-

ber S1 goes above the spool switching pressure,

spool (13) is pushed to the right.

As a result, port MB and port PB are connected,

the outlet port side of the motor is opened, and

the motor starts to rotate.



Operation of brake when traveling downhill

• If the machine tries to run away when travelingdownhill, the motor will turn under no load, so the

pressure at the motor inlet port will drop, and the

pressure in chamber S1 through orifices E1 and

E2 will also drop.

When the pressure in chamber S1 drops below

the spool switching pressure, spool (13) is re-

turned to the left by spring (14), and outlet port

MB is throttled.

As a result, the pressure at the outlet port siderises, resistance is generated to the rotation of

the motor, and this prevents the machine from

running away.

In other words, the spool moves to a position

where the pressure at outlet port MB balances

the pressure at the inlet port and the force gener-

ated by the weight of the machine. It throttles the

outlet port circuit and controls the travel speed

according to the amount of oil discharged from

the pump.

2) S f t l (2 di ti ti 2 t


Operation in both directions

1) When pressure in chamber MB has become

high (when rotating clockwise)

• When the travel is stopped (or when traveling

downhill), chamber MB in the outlet port circuit is

closed by the check valve of the counterbalance

valve, but the pressure at the outlet port rises be-

cause of inertia.



• If the pressure goes above the set pressure, the

force produced by the difference in area between

D1 and D2 [x/4 (D12 – D2) × pressure] overcomes

the force of the spring and moves the poppet tothe left, so the oil flows to chamber MA in the cir-

cuit on the opposite side.

2) When stopping travel (low-pressure setting)

• When the travel lever is placed at neutral, the

pressure in chamber PA drops and counterbal-

ance valve spool (13) returns to the neutral posi-

tion. While the counterbalance valve spool (13) is

returning to the neutral position, the pressurizedoil in chamber J passes through passage H, and

escapes to chamber PA from chamber G. The

piston moves to the left, and the set load be-


3) When pressure in chamber MA has become

high (when rotating counterclockwise)

• When the travel is stopped (or when traveling

downhill), chamber MA in the outlet port circuit is

closed by the check valve of the counterbalance

valve, but the pressure at the outlet port rises be-

cause of inertia.



• If the pressure goes above the set pressure, the

force produced by the difference in area between

D1 and D3 [x/4 (D32 – D12) × pressure] over-comes the force of the spring and moves the

poppet to the left, so the oil flows to chamber MB

in the circuit on the opposite side.

Operation of mechanism for varying set

pressure

1) When starting travel (high-pressure setting)


rized oil from the pump actuates counterbalance

valve spool (19), and opens the pilot circuit to the

safety valve. The oil passes from chamber G to

passage H and flows into chamber J, pushes thepiston to the right, and compresses the spring to

make the set load larger. Because of this, the set

pressure of the safety valve is switched to the

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL JUNCTION VALVE

TRAVEL JUNCTION VALVE

Function

• This valve connects both travel circuits to each

other so that the hydraulic oil will be supplied

evenly to both travel motors and the machine will

travel straight.

• When the machine is steered, outside pilot pres-

sure PST closes the travel junction valve to se-

cure high steering performance.

Operation

When pilot pressure is turned ON

• If the pilot pressure from the travel junction sole-

noid valve becomes higher than the force of

spring (14), travel junction spool (13) moves to

the left stroke end and the junction circuit be-

tween port PTL (Left travel circuit) and PTR

(Right travel circuit) is closed.



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL JUNCTION VALVE

When pilot pressure is turned OFF

• If pilot pressure PST from the solenoid valve is 0,

travel junction spool (13) is pressed by the force

of spring (14) against the right side and the pass

between ports PTL and PTR is open.

• If the oil flow rates in both travel motors become

different from each other, the oil flows through

the route between port PTL, travel junction spool

(13), and port PTR so that the oil flow rates will

be equalized again.



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL

VALVE CONTROL



Lever positions

1. Travel PPC valve 8. Solenoid valve (1) Hold (9) Swing “RIGHT”

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE

TRAVEL PPC SHUTTLE VALVE

Function

• If boom RAISE or arm IN are operated when the

machine is traveling, the stroke of the spools for the boom and arm is controlled by the travel PPC

pressure and this limits the flow of oil to the boom

and arm cylinders.

• When the boom and arm stroke is controlled, the

travel PPC pressure passes through the circuit



travel PPC pressure passes through the circuit

inside the control valve to actuate the system.

Operation

1. When travel is at neutral

• Stroke limit signal chambers a and b are con-

nected to the travel PPC valve through orifices

(5) and (6) in pistons (3) and (4) inside the travel

spring case, and the is drained.

• When arm IN is operated, spool (1) moves to the

right by stroke (st0) to a point where it contactsthe end face of spring case (2).

• When boom RAISE is operated, spool (9) moves

to the left by stroke (st3) to a point where it con-

tacts the end face of spring case (10).





2. When travel is operated

• When the travel lever is operated to right RE-

VERSE (or FORWARD), the right (REVESE (or

FORWARD) PPC pressure pushes spool (7) to

the left (or right).• Spool (7) pushes piston (3), orifice (5) closes,

and stroke limit signal chamber a is shut off from

the drain circuit of the travel PPC valve.

• At the same time, the right REVERSE (or FOR-

WARD) PPC pressure passes through orifice (6)



) p p g ( )

in piston (4), acts on the right end face of piston

(8), and pushes piston (8) to the left.

• If arm IN is operated, spool (1) moves to the right,

but the maximum stroke of the spool is limited by

the amount of movement st2 of piston (8) and

becomes st1.

• If boom RAISE is operated, spool (9) tries to

move to the left, but the travel PPC pressure en-

ters stroke control signal chamber b, so the spool

does not move.



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE

WORK EQUIPMENT • SWING PPC VALVE



P : From self pressure reducing valve P1 : Left PPC: Arm OUT / Right PPC: Boom LOWER




1. Spool 7. Joint

2. Metering spring 8. Plate

3. Centering spring 9. Retainer

4. Piston 10. Body

5. Disc 11. Filter

6. Nut (For connection of lever)


Operation

1) At neutral

Ports A and B of the control valve and ports P1

and P2 of the PPC valve are connected to drainchamber D through fine control hole f in spool

(1)



2) During fine control (neutral o oo o fine control)

When piston (4) starts to be pushed by disc (5),

retainer (9) is pushed; spool (1) is also pushed

by metering spring (2), and moves down.When this happens, fine control hole f is shut off

from drain chamber D, and at almost the same

time, it is connected to pump pressure chamber

PP, so pilot pressure oil from the main pump

passes through fine control hole f and goes from

port P1 to port A.

When the pressure at port P1 becomes higher,

spool (1) is pushed back and fine control hole f

is shut off from pump pressure chamber PP. Atalmost the same time, it is connected to drain

chamber D to release the pressure at port P1.

Wh thi h l (1) d


3) During fine control (when control lever is

returned)

• When disc (5) starts to be returned, spool (1) is

pushed up by the force of centering spring (3)and the pressure at port P1.

When this happens, fine control hole f is con-

nected to drain chamber D and the pressure oil

at port P1 is released.

If the pressure at port P1 drops too far, spool (1)

is pushed down by metering spring (2) and fine



is pushed down by metering spring (2), and fine

control hole f is shut off from drain chamber D.

At almost the same time, it is connected to

pump pressure chamber PP, and the pump

pressure is supplied until the pressure at port P1

recovers to a pressure that corresponds to the

lever position.

When the spool of the control valve returns, oil

in drain chamber D flows in from fine control

hole f’ in the valve on the side that is not work-

ing. The oil passes through port P2 and enters

chamber B to fill the chamber with oil.

4) At full stroke

When disc (5) pushes down piston (4), andretainer (9) pushes down spool (1), fine control

hole f is shut off from drain chamber D, and is

connected with pump pressure chamber PP.

Therefore, the pilot pressure oil from the main

pump passes through fine control hole f and

flows to chamber A from port P1, and pushes

the control valve spool.

The oil returning from chamber B passes from

port P2 through fine control hole f’ and flows todrain chamber D.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE

TRAVEL PPC VALVE




Travel signal/Steering function

• Travel signal

If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the

travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.• Steering signal

If the operation quantities of both levers are different from each other as in the steering operation, the higher

one of the PPC output pressures on both sides is output as the steering signal.

Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neu-

tral.

Accordingly, if the machine is being steered is judged by the signal of port P6.



Operation

1. While in NEUTRAL

The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not out-

put.


2. While travelling straight

(The following drawing shows the circuit for traveling straight forward.)

While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also

operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and

right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal valve is keptin neutral and the steering signal (Port P6) is not output.




3. When steered or pivot-turned

(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)

If the operation quantities of both levers are different from each other as in the steering operation (If the dif-

ference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output

as the steering signal.In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2.

The pressure in right spring chamber (l) is P4.

If (P4 – P2) × (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow

and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the

steering signal to port P6.




4. When pivot-turned

(The following drawing shows the circuit for left reverse and right forward operation.)

While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is

operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of

steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and outputs thesteering signal (port P6).



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SERVICE PPC VALVE

SERVICE PPC VALVE

a Refer to the section WORK EQUIPMENT •

SWING PPC VALVE for function of this valve.

1. Spool

2. Metering spring

3. Centering spring

4. Piston

5. Lever

6. Plate

7. Retainer



8. Body

T : To tank

P : From main pump

P1 : Port

P2 : Port

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE

SOLENOID VALVE

PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid

valves



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE

1. Connector

2. Moving core

3. Coil

4. Spool5. Block

6. Spring



Operation

WHEN SOLENOID IS TURNED OFF

• Since the signal current does not flow from the

controller, solenoid (3) is turned off.

Accordingly, spool (4) is pressed by spring (6)

against the left side.

By this operation, the pass from P to A is closed

and the hydraulic oil from the main pump does

not flow into the actuator.

At this t ime, the oil from the actuator is drained

through ports A and T into the tank.

WHEN SOLENOID IS TURNED ON

• The signal current flows from the controller to so-

lenoid (3), and the latter is turned on.

Accordingly, spool (4) is pressed against to the

right side.

By this operation, the hydraulic oil from the main

pump flows through port P and spool (4) to port

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC ACCUMULATOR

PPC ACCUMULATOR

1

2

3

1. Gas plug

2. Shell3. Poppet

4. Holder

5. Bladder

6. Oil port

Specifications



4

5

6

SBP00290

Gas capacity: 300 cc (for PPC)

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETURN OIL FILTER

RETURN OIL FILTER

FOR BREAKER



Specifications

1. Drain plug Rated pressure : 6.9 MPa {70 kg/cm2}

Fl 200 l/ i2 El t

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION

BOOM HYDRAULIC DRIFT PREVENTION VALVE

Function

• When the boom lever is not being operated,

these valves act to prevent the oil at the boombottom from leaking from spool (1) and prevent

the boom from moving down.

Operation

1. Boom RAISE



When the boom RAISE is operated, the main

pressure oil acts in the left direction on ring-shaped area A (= Area of ød1 – Area of ød2)

because of the difference in the outside diame-

ter d1 of poppet (5) and seat diameter d2. When

it overcomes the force of spring (4), poppet (5)

moves to the left.

In addition, the main pressure oil acts in the right

direction on seat diameter d3 of valve (6). When

it overcomes the force of spring (4), valve (6)

moves to the right.

As a result, the main pressure oil prom the con-

trol valve passes through the opening of poppet

(5) and flows to the bottom end of the boom cyl-

inder.





2. Boom at HOLD

• When the boom is raised and the control lever is

returned to the HOLD position, the oil that has

flowed into the inside of poppet (5) through ori-

fice a in poppet (5) is closed by pilot piston (2).The main pressure oil and hold pressure at the

bottom of the boom cylinder are shut off.

• At the same time, the hold pressure at the bottom

end of the boom cylinder acts in the right direc-

tion on ring-shaped area A (= Area of ød1 – Area

of ød2) because of the difference in the outside

diameter d1 of poppet (5) and seat diameter d2.

Poppet (5) is closed by the total of this force and




the force of spring (4), so the main pressure oiland hold pressure at the bottom of the boom cyl-

inder are shut off.

• In addition, the hold pressure at the bottom of the

boom cylinder acts in the left direction on outside

diameter d4 of valve (6).

• Valve (6) is closed by the total of this force and

the force of spring (4), so the main pressure oil

and hold pressure at the bottom of the boom cyl-

inder are shut off. As a result, the boom is held in

position.





3. Boom LOWER

• When boom LOWER is operated, the pilot pres-

sure from the PPC valve pushes pilot spool (2),

and the pressure oil chamber b inside the poppet

is drained through orifice c.The oil at the bottom end of the boom flows from

orifice a to chamber b to orifice c to drain, so the

oil pressure in chamber b drops.

When the pressure in chamber b drops below

the pressure at port b, poppet (4) opens, and

the pressure oil from port B goes to port A and

flows to the control valve.



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ARM HYDRAULIC DRIFT PREVENTION

ARM HYDRAULIC DRIFT PREVENTION VALVE(If equipped)

Function

• When the arm lever is not being operated, thesevalves act to prevent the oil at the arm head from

leaking from spool (1) and prevent the arm from

moving down.

Operation

1 Arm DUMP



1. Arm DUMP

When the arm DUMP is operated, the mainpressure oil acts in the left direction on ring-

shaped area A (= Area of ød1 – Area of ød2)

because of the difference in the outside diame-

ter d1 of poppet (5) and seat diameter d2. When

it overcomes the force of spring (4), poppet (5)

moves to the left.

As a result, the main pressure oil prom the con-

trol valve passes through the opening of poppet

(5) and flows to the bottom end of the boom cyl-

inder.


2. Arm at HOLD

• When the arm DUMP is operated and the control

lever is returned to the HOLD position, the oil that

has flowed into the inside of poppet (5) through

orifice a in poppet (5) is closed by pilot piston (2).The main pressure oil and hold pressure at the

head of the arm cylinder are shut off.

• At the same time, the hold pressure at the bottom

end of the boom cylinder acts in the right direc-

tion on ring-shaped area A (= Area of ød1 – Area

of ød2) because of the difference in the outside

diameter d1 of poppet (5) and seat diameter d2.




pp ( ) y

the force of spring (4), so the main pressure oiland hold pressure at the head of the arm cylinder

are shut off.

• In addition, the hold pressure at the bottom of the

boom cylinder acts in the left direction on outside

diameter d4 of valve (6).

As a result, the arm is held in position.


3. Arm IN

• When arm IN is operated, the pilot pressure from

the PPC valve pushes pilot spool (2), and the

pressure oil chamber b inside the poppet is

drained through orifice c.The oil at the head end of the arm flows from ori-

fice a to chamber b to orifice c to drain, so the oil

pressure in chamber b drops.

When the pressure in chamber b drops below

the pressure at port b, poppet (4) opens, and

the pressure oil from port B goes to port A and

flows to the control valve.




4. When abnormally high pressure is

generated

• If abnormally high pressure is generated in the

boom cylinder bottom circuit, the hydraulic oil in

port B pushes check valve (6) open, then safetyvalve (3) operates.

• If the hydraulic drift prevention valve for the arm

cylinder head circuit is installed (optional), the

hydraulic oil in the boom cylinder bottom circuitor that in the arm cylinder head circuit, having

higher pressure, pushes check valve (6) open,

then safety valve (3) operates.



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD QUICK RETURN VALVE

QUICK RETURN VALVE

Function

When arm OUT is operated, this valve reduces the

pressure loss of the large amount of oil returningfrom the cylinder bottom.

Operation

1. Arm at OUT

When arm OUT is operated, the pilot pressure

from the PPC valve pushes pilot spool (1), and



the pressure oil from chamber b inside the pop-pet is drained through orifice c.

The oil at the bottom end of the arm flows from

orifice a to chamber b to orifice c to drain, so the

oil pressure in chamber b drops.

When the pressure in chamber b drops below the

pressure at port A, the pressure at port A and

acts on ring -shaped area C (= Area of ød1 –

Area of ød2) because of the difference in the out-

side diameter d1 of valve (2) and seat diameter d2. Valve (2) moves to the left and the pressure

oil from port A goes to port B. From port B, the oil

is drained directly to the tank.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD QUICK RETURN VALVE

2. Arm at HOLD

The oil that has flowed through orifice a in valve

(2) is closed by pilot piston (1). At the same

time, the hold pressure at the bottom end of the

arm acts in the right direction on ring-shapedarea C (= Area of ød1 – Area of ød2) because

of the difference in the outside diameter d1 of

valve (2) and seat diameter d2 . Valve (2) is

closed by the total of this force and the force of

spring (3), so port A and port B are shut off.



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIFT CHECK VALVE

LIFT CHECK VALVE

Function

This valve applies back pressure to the drain circuit

to prevent generation of negative pressure on thehydraulic devices for the work equipment (motors,

cylinders, etc.)

Operation

1. While engine is stopped

Any oil is not supplied from the pump to the self-



pressure reducing valve and valve (1) is pressedby only the force of spring (2) toward the right

and drain circuit “a” of the control valve is con-

nected through orifice “b” of valve (1) to port T.

2. While engine is running

• Output pressure PR of the self-pressure reduc-ing valve is applied through the control valve to

spring chamber “c” of the back pressure valve.

• Output pressure PR applied to spring chamber

“c” is applied to the left end of valve (1) (area of

ød) to push valve (1) to the right.

• At this time, pressure PA of drain circuit “a” of the

control valve is applied to the right end of valve

(1) (area of ød1) to push valve (1) to the left.

• Valve (1) is balanced so that the back pressurePA will be as follows.

PA = {(Area of ød) × PR + Force of spring (2)} /

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE

ATTACHMENT CIRCUIT SELECTOR VALVE



1. Spool V : To control valve

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE

Function

When a breaker is installed, the return oil from the

breaker does not pass through the main valve, butreturns directly to the hydraulic tank. When other

attachments (crusher, etc.) are installed, the attach-

ment and the main valve are interconnected.

Operation

1. When attachment other than breaker is in-

t ll d



stalledSpool (1) is pushed fully to the left by the force

of spring (2), ATT port and port V are intercon-

nected, and ATT port and port T are shut off, so

the attachment and main valve are intercon-

nected.

2. When breaker is installed

When the pilot pressure from the attachment cir-

cuit selector solenoid valve overcomes the force

of spring (2), the spool (1) moves fully to the

right. ATT port and port V are shut off and ATT

port and port T are interconnected, so the oil

returning from the breaker does not pass

through the main valve, but passes through port

T and returns directly to the hydraulic tank.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOLDING VALVE

HOLDING VALVE

Downward movement prevention valve

(For boom and arm)



V : From control valve

T : To hydraulic tank

CY : To hydraulic cylinder

PI : From PPC valvePCY : Fror pressure pickup and equalizer circuits




Unit: mm

1. Pilot spool2. Spring (1st stage of spool)

3. Spring (2nd stage of spool)

4. Safety valve

5. Check valve

6. Spring


Function

If the piping between the main valve and a work

equipment cylinder bursts, this valve prevents the oil

from flowing back from the work equipment cylinder

to prevent sudden fall of the work equipment.

Operation

1. When the work equipment is in neutral

[When piping is normal]

• Check valve (5) is closed by the work equip-



• Check valve (5) is closed by the work equip-ment cylinder holding pressure applied

through port CY to chamber “b”.

• When the work equipment is in neutral, no pi-

lot pressure is applied from the PPC valve to

port Pi. Accordingly, pilot spool (1) is moved

to the left end by the force of springs (2) and

(3), then chambers “a” and “b” are shut of

from each other.

• By this operation, oil does not flow betweenthe main valve and the work equipment cyl-

inder, thus the work equipment cylinder held.

• If the pressure in the work equipment cylin-

der rises abnormally high, work equipment

cylinder holding pressure Pb operates safety

valve (4).

• In the downward movement prevention

valves for the boom, chambers “b” of both of

them are connected through ports PCY. Ac-

cordingly, even if the leakages are different

between both valves, the pressures in both

chambers “b” become the same.

[When piping bursts]

Even if piping A between the main valve and

work equipment cylinder bursts, chamber

“a” is shut off from chamber “b” as in thecase where the piping is normal. Accord-

ingly, the work equipment cylinder is held.


2. When oil is sent from main valve to cylinder


• If pressure Pa of the oil sent from the main

valve to chamber “a” is higher than the total

of pressure Pb in chamber “b” connected to

the work equipment cylinder and the force of

spring (6), check valve (5) opens and cham-

bers and the oil flows from the main valve to

the work equipment cylinder.


• If piping A between the main valve and the

work equipment cylinder bursts the oil inh b “ ” fl t th h th b t t



work equipment cylinder bursts, the oil inchamber “a” flows out through the burst part

and pressure Pa in chamber “a” lowers.

• If Pa lowers below the total of pressure Pb in

chamber “b” and the force of spring (6),

check valve (5) closes and chambers “a” and

“b” are shut off from each other. Accordingly,

pressure Pb in the cylinder is held and the

work equipment does not fall suddenly.


3. When oil is returned from work equipment

cylinder to main valve


• The work equipment cylinder holding pres-

sure is applied to chamber “b” and check

valve (5) closes.

• The pilot pressure from the PPC valve is ap-

plied to port Pi. If it is higher than the force of

spring (2) (area of ød), spool (1) moves to

the right standby position (1st-stage stroke).

• At this time, chambers “a” and “b” are not

connected to each other.

• If the pilot pressure rises higher than theforce of spring (3) (area of ød) spool (1)



If the pilot pressure rises higher than theforce of spring (3) (area of ød), spool (1)

moves further to the right and chambers “a”

and “b” connected to each other (2nd-stage

stroke).

• Accordingly, the oil is returned from the work

equipment cylinder to the main valve.


• If piping A between the main valve and work

equipment cylinder bursts, the oil in chamber “a” flows out through the burst part.Since the

oil supplied from chamber “b” to chamber “a”



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER

HYDRAULIC CYLINDER

BOOM CYLINDER



ARM CYLINDER

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER



Unit: mm


1

Clearance

between

piston rod and

bushing

Cylinder Standard

size

Tolerance Standard

clearance

Clearance

limit

Replace

bushing

Shaft Hole

Boom 110 –0.036

–0.090

+0.261

+0.047

0.083 –

0.3510.412

Arm 120 –0.036 –0.090

+0.263+0.048

0.084 –0.353

0.412

0 036 +0 257 0 083

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT

WORK EQUIPMENT



Unit: mm


1

Clearance between

connecting pin and bushing

of revolving frame and boom

Standard

size

Tolerance Standard

clearance

Clearance

limitShaft Hole

120 –0.036

–0.090

+0.173

+0.101

0.137 –

0.2631.0

2

Clearance between

connecting pin and bushing

of boom and arm

120 –0.036 –0.090

+0.180+0.112

0.148 –0.270

1.0


1. Dimension of arm




Unit: mm

Model

No.

PC400-7 PC450-7

1 ø110 / ø110 /

2 ø129.3 / 126 ± 1.2 ø129.3 / 126 ± 1.2

3 ø355 / 351 ø355 / 351

4 ø120 / ø120 /

+0.1+0

–0.036 –0.090

+0.1+0

–0.036 –0.090

+1.5+0

+1.5+0

+0.5+0

–0.3 –0.8

+0.5+0

–0.3 –0.8

+0.1

+0

–0.036

–0.090

+0.1

+0

–0.036

–0.090



5 514.8 570.6

6 195 208.2

7 1,038 1,132.2

8 3,375 3,375

9 2,977.5 2,975.1

10 502 506.8

11 720 720

12 719 719

13 537.1 537.1

14 1,850 1,817

15 ø100 / ø100 /

16 ø371 / 370 ± 0.5 ø371 / 370 ± 0.5

+0.1+0

–0.036 –0.090

+0.1+0

–0.036 –0.090

+1+0

+1+0


2. Dimension of bucket




Unit: mm

Model

No.

PC400-7 PC450-7

1 534.1 ± 0.5 534.1 ± 0.5

2 56.3 ± 0.5 56.3 ± 0.5

3 96° 1’ 94° 14’

4 537.1 537.1

5 1,839 1,806

6 190 198

7 — —

8 62° 1’ 46° 1’

A ø140 1 ø140 1+0.1+0

+0.1+0



9

A ø140.1 ø140.1

B ø130 ø130

C ø100 ø100

10 371 371

11 A 57 58

B 72 7212 144 144

13 562.5 562.5

14 ø26 ø26

15 A ø165 ø165

B — —

16 ø230 ø230

17 146.1 135.5

18 137.6 142.0

19 R115 R115

20 R85 R85

21 410 ± 1 410 ± 1

22 64 64

+0 +0

+0.063 –0

+0.063 –0

+0.1+0

+0.1+0

+1+0

+1+0

+0.5 –2.5

+0.5 –2.5

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER

AIR CONDITIONER

AIR CONDITIONER PIPING



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL

ENGINE CONTROL

1. Operation of system

Starting engine

• When the starting switch is turned to the START

position, the starting signal flows to the starting

motor, and the starting motor turns to start theengine.

When this happens, the engine controller

checks the signal from the fuel control dial and

sets the engine speed to the speed set by the

fuel control dial.



Engine speed control

• The fuel control dial sends signal voltages to the

engine controller according to its angle.

The engine controller sends drive signals to the

supply pump according to the signal voltages

received from the fuel control dial and controlsthe fuel injection pump to control the engine

speed.

Stopping engine

• When the engine controller detects that the start-ing switch is at the OFF position, it cuts the signal

to the supply pump drive solenoid to stop the en-

gine.


2. Components of system

Fuel control dial

1. Knob

2. Dial

3. Spring

4. Ball5. Potentiometer

6. Connector




3. Engine controller




CN1 [CN-E11] CN2 [CN-E12]

Pin No. Signal nameInput/

OutputPin No. Signal name

Input/

Output

CN1-1 POWER (+24V constant) CN2-1 GND

CN1-2 POWER (+24V constant) CN2-2 NC

CN1-3 Model selection 1 Input CN2-3 NC Input

CN1-4 GND CN2-4 RS232C_1RX Input

CN1-5 NC Input CN2-5 NC

CN1-6 NC Output CN2-6 NC

CN1-7 GND CN2-7 NC Input

CN1-8 GND CN2-8 NC Input

CN1-9 NC Input CN2-9 Sensor 5V power supply 2 Output

CN1-10 GND CN2-10 Fuel control dial Input

CN1-11 NC Input CN2-11 S_NET_SHIELD GNDCN1-12 NC Output CN2-12 CAN_SHIELD

CN1-13 Key switch (ACC) Input CN2-13 NC Output



CN1 13 Key switch (ACC) Input CN2 13 NC Output

CN1-14 NC Input CN2-14 RS232C_1TX Output

CN1-15Engine oil pressure switch (For high

pressure)Input

CN2-15 G_SHIELD (GND)

CN2-16 Ne_SHIELD (GND)

CN1-16 Memory clear Input CN2-17 Fuel temperature sensor Input

CN1-17 Model selection 3 Input CN2-18 NC Input

CN1-18 NC Output CN2-19 Sensor 5V power supply 1 OutputCN1-19 Key switch (ACC) Input CN2-20 Boost pressure sensor Input

CN1-20 Starting switch (C) InputCN2-21 S_NET (+)

Input/

OutputCN1-21

Engine oil pressure switch (For low

pressure)Input

CN2-22 CAN0_LInput/

OutputCN1-22 Auto deceleration signal Input

CN1-23 Model selection 2 Input CN2-23 NC

CN1-24 NC Output CN2-24 FWE_switch Input

CN2-25 G pulse (–) Input

CN2-26 Ne pulse (–) Input

CN2-27 Coolant temperature sensor (High) Input

CN2-28 NC Input

CN2-29 Analog GND

CN2-30 NC Input

CN2-31 S_NET (+)Input/

Output

CN2-32 CAN0_HInput/

Output


CN3 [CN-E13]


Output

CN3-1 Power supply for power


CN3-3 NC

CN3-4 NC

CN3-5 Injector #3 (+) Output


CN3-7 NC Input

CN3-8 Output mode selection 1 (Test mode) Input

CN3-9 Lever neutral flag (Test mode) Input

CN3-10 Engine rotation pulse output Output



CN3-11 Power GND Input

CN3-12 Supply pump 1 (+) Output

CN3-13 Supply pump 2 (+) Output


CN3-15 Injector #3 (–) Output

CN3-16 Injector #2 (–) OutputCN3-17 NC Input

CN3-18 Output mode selection 2 (Test mode) Input

CN3-19 NC Input

CN3-20 Q command output Output


CN3-22 Supply pump 1 (–) Output

CN3-23 Supply pump 2 (–) Output

CN3-24 Injector #1 (–) OutputCN3-25 Injector #6 (+) Output


CN3-27 NC Output

CN3-28 Auto deceleration flag (Test mode) Input

CN3-29 NC Input

CN3-30 GND

CN3-31 Power GND

CN3-32 Power GND

CN3-33 Injector #5 (–) Output



STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM

ELECTRONIC CONTROL SYSTEM

CONTROL FUNCTIONS




TOTAL SYSTEM DIAGRAM




1. Engine and Pump control function




Function

• The operator can set the work mode switch on

the monitor panel to mode A, E, or B (or L) and

select proper engine torque and pump absorp-

tion torque according to the type of work.

• The engine throttle and pump controller detectsthe speed of the engine governor set with the fuel

control dial and the actual engine speed and con-

trols them so that the pump will absorb all the

torque at each output point of the engine, accord-

ing to the pump absorption torque set in each

mode.

: The L mode is on the multi-monitor specification

machine only.




1) Control method in each mode

Mode A, Mode E

• Matching point in mode A: Rated speed

• If the pump load increases and the pressure ris-

es, the engine speed lowers.

At this time, the controller lowers the pump dis-

charge so that the engine speed will be near the

full output point. If the pressure lowers, the con-

troller increases the pump discharge so that theengine speed will be near the full output point.

By repeating these operations, the controller

constantly uses the engine near the full output

Mode A246.3 kW/1,850 rpm

{331 HP/1,850 rpm}

Mode E 213.3. kW/1,720 rpm{286 HP/1,720 rpm}



constantly uses the engine near the full output

point.


Mode B / (Mode L)

• At this time, the controller keeps the pump ab-

sorption torque along the constant horsepower

curve and lower the engine horsepower by thecomposite control of the engine and pump.

By this method, the engine is used in the low

fuel consumption area.

Mode Mode B Mode L

Partial output point 82% 61%

Mode B194.9 kW/1,730 rpm

{261 HP / 1,730 rpm}

Mode L150.8 kW/1,250 rpm

{202 HP / 1,250 rpm}



fuel consumption area.

: The L mode is on the multi-monitor specification

machine only.


2) Function to control pump during travel

• When the travel is operated in A operation, or E

or B working mode, the working mode stays as it

is, and the pump absorption torque and engine

speed rise to A travel mode.

• If the machine travels in mode L, the working

mode and engine speed do not change, but the

pump absorption torque is increased.: The L mode is on the multi-monitor specification

machine only.



3) Function to control when emergency pump

drive switch is turned ON

• Even if the controller or a sensor has a trouble,

the functions of the machine can be secured with

pump absorption torque almost equivalent to

mode E by turning on emergency pump drive

switch (10).

In this case, a constant current flows from the

battery to the EPC valve for PC and the oil pres-

sure is sensed by only the EPC valve for PC.


2. Pump/Valve control function




1) LS control function

• The change point (LS set differential pressure) of

the pump discharge in the LS valve is changed

by changing the output pressure from the LS-

EPC valve to the LS valve according to the oper-

ating condition of the actuator.

• By this operation, the start-up time of the pump

discharge is optimized and the composite opera-

tion and fine control performance is improved.

2) Cut-off function

• When the cut-off function is turned on, the PC-

EPC current is increased to near the maximum

value.

• By this operation, the flow rate in the relief state

is lowered to reduce fuel consumption.• Operating condition for turning on cut-off function

Condition



The cut-off function does not work, however, while

the machine is travelling in mode A or the arm crane

operation width swing lock switch is turned on.

1) 2-stage relief function

• The relief pressure in the normal work is 34.8

MPa {355 kg/cm2}. If the 2-stage relief function is

turned on, however, the relief pressure rises to

about 37.2 MPa {380 kg/cm2}.By this operation, the hydraulic force is increased

further.

• Operating condition for turning on 2-stage relief

function

• The average value of the front and rear pressure

sensors is above 27.9 MPa {285 kg/cm2} and the

one-touch power maximizing function is not turned

on

ConditionRelief pres-

sure

• Condition

• During travel 34.8 MPa


3. One-touch power maximizing/machine

push-up function



Function


1) One-touch power maximizing function

• When the operator needs more digging force to

dig up a large rock, etc., if the left knob switch is

pressed, the hydraulic force is increased about

7% to increase the digging force.

• If the left knob switch is turned on in working

mode “A” or “E”, each function is set automatical-

ly as shown below.

Working

modeEngine/Pump control 2-stage relief function Operation time

Software cut-off

function

A, E Matching at ratedoutput point

34.8 MPa {355 kg/cm2

}

37.2 MPa {380 kg/cm2}

Automatically reset at8.5 sec

Cancel



2) Machine push-up function

• Operate switch (1) to increase the boom pushing

force when digging ditches or holes on hard

ground.

Switch2-stage safety valve

function

OFF

Setting of safety valve at

boom cylinder

14.7 MPa

{150 kg/cm2}

ON

Setting of safety valve at

boom cylinder

28.4 MPa{290 kg/cm2}


4. Auto-deceleration function



Function

• If all the control levers are set in NEUTRAL while

waiting for a dump truck or work, the enginespeed is automatically lowered to the medium

level to reduce fuel consumption and noise.

• If any lever is operated, the engine speed rises

instantly to the set level.


Operation

WHEN CONTROL LEVERS ARE SET IN NEUTRAL

• If all the control levers are set in NEUTRAL while

the engine speed is above the decelerator oper-

ation level (about 1,300 rpm) for 4 seconds, the

engine speed lowers to the second deceleration

level (about 1,300 rpm) and keeps at that level

until any lever is operated again.

WHEN ANY CONTROL LEVER IS OPERATED

• If any control lever is operated while the engine

speed is kept at the second deceleration level,

the engine speed rises instantly to the level setwith the fuel control dial.




5. Auto-warm-up/Overheat prevention

function



Function

• After the engine is started, if the engine coolant

temperature is low, the engine speed is automat-

ically raised to warm the engine. If the coolant

temperature rises too high during work, the pump

load is reduced to prevent overheating.


1) Auto-warm-up function

• After the engine is started, if the engine coolant

temperature is low, the engine speed is automat-

ically raised to warm the engine.

Operating condition (All) Operated

Coolant temperature: Below 30°C.Engine speed: Max. 1,200 rpm

Engine speed: Max. 1,200 rpm

Resetting condition (Any one) Reset

AutoCoolant temperature: Above 30°C

Engine speed: Any level Auto-warm-up operation time: Min. 10 minutes

ManualFuel control dial: Kept at 70% of full level for

3 sec. or longer



2) Overheat prevention function

• If the engine coolant temperature rises too highduring work, the pump load and engine speed

are reduced to prevent overheating.

• This function is turned on when the coolant tem-perature rises above 95°C.

Operating condition Operation/Remedy Resetting condition

Coolant tempera-

ture: Above 105°C

Work mode: Any mode

Engine speed: Low idle

Monitor alarm lamp: Lights up Alarm buzzer: Sounds

Coolant temperature: Below 105°C

Fuel control dial: Return to low idle

position once.

• Under above condition, controller isset to condition before operation of

function. (Manual reset)

Operating condition Operation/Remedy Resetting condition

Coolant tempera-

ture: Above 102°C

Work mode: Mode A, E, OR B

Engine speed: Keep as is.

Monitor alarm lamp: Lights up.

Lower pump discharge.

Coolant temperature: Below 102°C

• Under above condition, controller is

set to condition before operation of

function. (Automatic reset)


6. Swing control function



Function

The swing lock and swing holding brake functions

are installed.


1) Swing lock and swing holding brake func-

tions

• The swing lock function (manual) is used to lock

machine from swinging at any position. The

swing holding brake function (automatic) is used

to prevent hydraulic drift after the machine stops

swinging.

• Swing lock switch and swing lock/holding brake

2) Quick hydraulic oil warm-up function when

swing lock switch is turned on

• If swing lock switch (4) is turned on, the pump-cut

function is cancelled and the relief pressure rises

from 34.8 MPa {355 kg/cm2} to 37.2 MPa {380

kg/cm2}. If the work equipment is relieved under

this condition, the hydraulic oil temperature rises

quickly and the warm-up time can be shortened.

Lock

switch

Lock

lampFunction Operation

OFF OFF

Swing

holding

brake

If swing lever is set in

neutral, swing brake

operates in about 7 sec. If

swing lever is operated,

brake is released andmachine can swing freely.

ON ONSwing

l k

Swing lock operates and

machine is locked from

swinging. Even if swing

l i t d i



: Operation of swing holding brake release switch

• If the controller, etc. has a problem, the swing

holding brake does not work normally, and the

machine cannot swing, the swing lock can be re-

set with the swing holding brake release switch.

a Even if the swing holding brake release switch is

lock lever is operated, swing

lock is not reset and

machine does not swing.

Swing hold-

ing brake

releaseswitch

ON

(When control has

trouble)

OFF

(When controller is

normal)

Swing lock

switchON OFF ON OFF

Swing

brake

Swing

lock is

turned on

Swing

lock is

canceled

Swing

lock is

turned on

Swing

holding

brake is

turned on


7. Travel control function



Function


1) Pump control function during travel

• If the machine travels in a work mode other than

mode A, the work mode and the engine speed

are kept as they are and the pump absorption

torque is increased.

a For details, see ENGINE/PUMP COMPOSITE

CONTROL FUNCTION.

1. Travel speed change function

i) Manual change with travel speed switch

If the travel speed switch is changed

between Lo, ( Mi), and Hi, the governor/

pump controller controls the pump capacity

and motor capacity at each gear speed as

shown at right to change the travel speed.

Travel speed

switch

Lo

(Low speed)

( Mi)

(Middle

Speed)

Hi

(High

speed)

Pump capacity

(%)90 82 100



ii) Automatic change according to engine speed

If the fuel control dial is used to set the

engine speed to less than 1,200 rpm:

• When traveling in Lo, it will not switch even

when set to Hi or Mi.

• When traveling in Hi or Mi, it will switch auto-

matically to Lo.

iii) Automatic changes according to pump dis-

charge pressure

When traveling with the travel speed switch

set to Hi or Mi, it the load increases, such as

when traveling uphill, and the travel pres-

sure goes above 3.23 MPa {330 kg/cm2} for

more than 0.5 sec, the travel motor capacity

will automatically change to low speed

(equivalent to Lo). (The travel speed switch

will stay at Hi or Mi.) After continuing to travel in Lo, if the load

i h h t li l l

(%)

Motor capacity Max. Max. Min.

Travel speed

(km/h)3.2 4.5 5.5


8. ATT flow control, circuit selector func-

tion (if equipment)



Function


9. System component parts1) Engine revolution sensor



Function

• The engine revolution sensor is installed to the

ring gear of the engine flywheel. It electrically cal-

culates the number of the gear teeth which passin front of it and transmits the result to the engine

throttle and pump controller.

• A magnet is used to sense the gear teeth. Each

time a gear tooth passes in front of the magnet,

a current is generated.

1. Sensor

2. Locknut

3. Wiring harness

4. Connector


2) PPC oil pressure switch



Specifications

Type of contacts: Normally open contacts

Operating (ON) pressure: 0.5 ± 0.1 MPa{5.0 ± 1.0 kg/cm2}

Resetting (OFF) Pressure: 0.3 ± 0.5 MPa

{3.0 ± 0.5 kg/cm2}

Function

• The junction block has 7 pressure switches, which

check the operating condition of each actuator bythe PPC pressure and transmit it to the engine

1. Plug

2. Switch

3. Connector


3) Pump pressure sensor



Function

• The pump pressure sensor is installed to the inlet

circuit of the control valve. It converts the pump

discharge pressure into a voltage and transmits

it to the engine throttle and pump controller.

Operation

• The oil pressure applied from the pressure intake

part presses the diaphragm of the oil pressure

sensor, the diaphragm is deformed.

• The gauge layer facing the diaphragm measures

the deformation of the diaphragm by the change

of its resistance, then converts the change of the

resistance into a voltage and transmits it to the

amplifier (voltage amplifier)

1. Sensor

2. Connector


Pump controller




Input and output signals

CN-1 CN-2


OutputPin No. Signal name

Input/

Output

1 NC 1 NC

2 R pump pressure sensor Input 2 Swing emergency switch Input

3 NC 3 NC Input

4 NC 4 232C_RxD Input

5 NC 5 NC

6 NC Input 6 NC

7 NC 7 Model selection 4 Input

8 F boom pressure sensor Input 8 Attachment circuit selector signal Output

9 NC 9 NC10 Signal GND 10 NC

11 Knob SW Input 11 NC

12 NC 12 CAN shield

13 Buchet CURL PPC pressure sensor Input 13 Model selection 5 Input



14 NC 14 232C_TxD Output

15 NC Input 15 NC

16 NC 16 Travel steering signal pressure SW Input

17 Starting switch (Terminal C) Input 17 Model selection 3 Input18 NC 18 NC

19 Arm IN PPC pressure sensor Input 19 Auto deceleration signal Output

20 NC 20 NC

21 NC21 S_NET

Input/

output22 POT_PWR Output

23 Starting switch (terminal ACC) Input22 CAN0_L

Input/

output

24 NC 23 NC

24 FWE_SW Input

25 NC

26 NC

27 Model selection 2 Input

28 NC

29 GND (pulse GND)

30 NC

31 GND (S_NET GND)


CN-3


Output

1 VB (controller power) Input

2 VIS (solenoid power) Input

3 SOL_COM (solenoid common gnd)

4 Battery relay drive Output 5 NC

6 LS-EPC Output

7 Travel junction SOL Output

8 NC

9 NC Input

10 Boom RAISE pressure SW Input

11 VB (controller power) Input

12 VIS (solenoid power) Input13 SOL_COM (solenoid common gnd) Input

14 KEY_SIG Input

15 NC

16 PC-EPC Output



17 Pump merge/divider solenoid Output

18 Heater relay drive Output

19 Bucket DUMP pressure switch Input

20 Boom LOWER pressure switch Input21 GND (controller GND) Input

22 NC

23 SOL_COM (solenoid common gnd) Input

24 KEY_SIG Input

25 NC

26 Service flow adjustment EPC (1) Output

27 Travel Hi/Lo selector solenoid Output

28 2-stage relief solenoid Output29 Swing pressure switch Input

30 Arm IN pressure switch

31 NC Input

32 GND (controller GND) Input

33 GND (controller GND) Input

34 NC

35 NC

36 NC37 Swing parking brake solenoid Output

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM

MONITOR SYSTEM



• The monitor system monitors the condition of the

machine with sensors installed on various parts

of the machine. It processes and immediately

displays the obtained information on the panel

notifying the operator of the condition of the ma-

chine.The panel is roughly divided as follows.

• The monitor panel also has various mode selec-

tor switches and functions to operate the ma-

chine control system.


1. Monitor panel



Outline

• The monitor panel has the functions to display

various items and the functions to select modes

and electric parts.

The monitor panel has a CPU (Central Process-

ing Unit) in it to process, display, and output the

information.

The monitor display unit consists of LCD (Liquid

Crystal Display). The switches are flat sheet

switches.


Input and output signals

CN-1 CN3

Pin

No.Signal name

Input/

output

Pin

No.Signal name

Input/

output

1 Key ON Input 1 NC Input

2 Key ON Input 2 NC Input

3 Washer motor output Output 3 NC Input4 Starting signal Input 4 NC Input

5 Limit switch (W) Input 5 NC Input

6 GND 6 NC Input

7 GND 7 RS230C CTS Input

8 VB + Input 8 RS230C RXD Input

9 Wiper motor (+) Output 9 RS230C RXD

Input/

Output10 Wiper motor (-) Output

11 Buzzer ON signal Input 10 RS230C RXD Input/Output12 Limit switch (P) Input

11 BOOTSW Input

12 NC Input

CN-2 13 GND

PinSi l

Input/14 CAN (SHIELD) I t



Pin

No.Signal name

Input/

output14 CAN (SHIELD) Input

1 Engine coolant temperature Input 15 CAN (+) Input

2 Fuel level Input 16 CAN (-) Input

3 Radiator coolant level Input

4 (Hydraulic oil level) Input

5 Air cleaner clogging Input

6 NC Input

7 Engine oil pressure Input

8 Engine oil level Input

9 N/W signalInput/

Output

10 N/W signalInput/

Output

11 Battery charge Input

12 Hydraulic oil temperature (analog) Input

13 GND (for analog signal)

14 Buzzer drive Input

15 Limit SW (window) Input

16 Buzzer cancel Input

17 Swing lock Input


MONITOR CONTROL, DISPLAY PORTION

MONITOR PORTION



1. Wiper motor 11. Fuel level monitor

2. Preheating monitor 12. Hydraulic oil temperature monitor

3. Swing lock monitor 13. Power max. monitor

4. Engine coolant temperature monitor 14. Auto-deceleration monitor

5. Hydraulic oil temperature gauge 15. Radiator coolant level caution

6. Engine coolant temperature gauge 16. Battery charge caution

7. Working mode monitor 17. Engine oil pressure caution8. Service monitor 18. Engine oil level caution


MONITOR ITEMS AND DISPLAY

Symbol Display item Display method

Swing lock

Swing lock switchSwing holding brake

release switchSwing lock monitor

OFF OFF OFF

ON OFF ON

OFF ON Flashes

ON ON ON

Preheating

Continuous set time Preheating monitor status

Up to 30 sec. ON

From 30 sec to 40 sec Flashes



From 30 sec. to 40 sec. Flashes

More than 40 sec. OFF

Power Max

Power Max. switch status Power Max. monitor status

Being pressedLights up but goes out after

approx. 9 sec when kept pressed

Not being pressed Flashes

Engine coolant

temperature

See gauge display on the next pageHydraulic oil

temperature

Fuel level




Gauge Range Temperature, volume Indicator Buzzer sound

Engine coolant

temperature (°C)

A1 105 Red

A2 102 Red

A3 100 Green

A4 80 Green

A5 60 Green

A6 30 White

B1 105 Red


Checks before starting (caution lamps all light up), when maintenance interval is exceeded.

If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil

temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are dis-

played.

Symbol Display itemCheck before starting

item

When engine is

stopped

When engine is

running

Engine oil pressure q —

When abnormal,

lights up and buzzer

sounds

Battery charge q —Lights up when

abnormal

Radiator coolant level qLights up when

abnormal

When abnormal,

lights up and buzzer

sounds



Th bl th t h d di l d i d f th l ft

Engine oil level qLights up when

abnormal—

Air cleaner clogging q —Lights up when

abnormal

Maintenance

Lights up when there is a warning. Lights up for

only 30 sec. after key is turned ON, then goes

out.


Display category Symbol Display item Display range Display method

Monitor

Wiper Displays set condition

Working mode Displays set mode

ON INT OFF



Travel speed Displays set speed

Auto-decelera-

tionON OFF

Displays actuation

status

Service meter Service meter

indicator When service meter is working

Lights up when service

meter is working


SWITCHES



1. Selector switch

2. Selector switch

3. Display brightness, contrast adjustment switch

4. Control switch5. Window washer switch

6. Wiper switch

7. Maintenance switch

8. Travel speed selector switch

9. Auto-deceleration switch


• Working mode selector switch

The condition of the machine changes accord-

ing to the switch that is pressed (A, E, L, B). It is

possible to check the condition on the working

mode monitor display. The relationship between

each working mode and the monitor display is

shown in the table on the right.

• Selector switch

This is used when making detailed settings in

each working mode. (For details, see ATTACH-

MENT FLOW CONTROL FUNCTION for modes

A and E.)

• Maintenance switch

Check the condition of the maintenance items.

(For details, see MAINTENANCE FUNCTION.)

• Auto-deceleration switch

Each time the auto-deceleration switch is

pressed, the auto-deceleration function is

switched ON/OFF.

Use the a to deceleration monitor displa to

Switch that is

pressedDisplay

Working mode status

after setting

[A] A A mode (default)

[E] E E mode

[L] L Heavy-lift mode[B] B Swing priority mode



Use the auto-deceleration monitor display to

check the present condition.

When the working mode switch is operated to

switch the working mode, it is automatically set

to ON.

• Travel speed selector switch

Each time the travel speed selector switch is

pressed, the travel speed changes.

Lo o Hi o Lo ……

Use the travel speed monitor display to check

the present condition.The relationship between the set speed and the

monitor display in the table on the right.

• Wiper switch

Each time the wiper switch is pressed, the wiper

setting changes OFF o INT o ON o OFF o

……

Use the wiper monitor display to check the

present condition.The relationship between the wiper setting and

Display Setting

Crawler symbol + Lo Low speed (default)

Crawler symbol + Mi Medium speed

Crawler symbol + Hi High speed

Display SettingWiper actuation

status

None OFFStowing stopped or

now stowing

Wiper symbol + INT INT Intermittent actuation

Wiper symbol + ON ON Continuous actuation


• Window washer switch

While the switch is being pressed, window

washer liquid is sprayed out. There is a time

delay before the wiper starts.

• Control switch

This is used for control when using the mainte-

nance function or select function.(For details, see each function.)

• Display brightness, contrast adjustment switch

Use this switch when adjusting the display

brightness and contrast.

(For details, see each function.)




SELECT MODE FUNCTION

• This is used when setting the flow in each work-

ing mode. It is possible to make the setting when

genuine attachment piping is installed and the in-

itial value setting function on the service menu

has been used to set to ATTACHMENT IN-

STALLED.• It is possible to check on the working mode mon-

itor if this function can be set.

MEHOD OF USE

a Carry out the setting on the normal screen

1. A mode, E mode

1) Press select switch (1) on the monitor to

Working mode Monitor display

A mode [A] + crusher symbol

E mode [E] + crusher symbol

B mode [B] + flow symbol




move to the adjustment screen.

2) Press control switch (2) to select the flow

level.

3) After completing the level selection, press

input confirmation switch (3).

The selection flow level is confirmed and the

screen moves to the normal screen.

From the moment that the flow level is

selected, the content of the selection is

Control switch Actuation

Flow level bar graph

extends to the right

Flow level bar graphretracts to the left


2. B mode


move to the screen for selecting the 3-stage

flow level.

2) Press control switch (2), or input [01] – [03]

with the numeral 10-key pad to choose one

on the three flow levels.


No. 10-key pad operation

01

02

03



) p g , p


The selected flow level is selected.

a Before the input confirmation switch is

pressed, the flow level is not confirmed,

so press return switch (4) to return to the

operator screen. This function can be

used to return to the previously set flow.

4) After the flow level is confirmed, the screen

changes to the screen shown in the diagram

on the right.

With this screen, it is possible to make fineadjustment to the flow.

5) Press control switch (2) and select the flow

level.




No. Flow level (L/min.) Remarks

01 230 Default

02 190

03 150




The selected flow level is confirmed and the

screen moves to the operator screen.

From the moment that the flow level is

selected, the content of the selection is

reflected for the attachment flow.

a Before the input confirmation switch ispressed, the flow level is not confirmed,

se press return switch (4) to return to the

normal screen. This function can be

used to return to the previously set flow.

The relationship between the set flow

level and the flow value is as shown in

the table on the right.

7) Check the set value with the working mode

monitor.The relationship between the display level

and the set value is as shown in the table on

the right, and it is possible to check the level

of the flow that can be set.

Flow

level

When

flow is

140 l/

min.

When

flow is

220 l/

min.

When

flow is

300 l/

min.

Remarks

7 200 280 360

6 180 260 3405 160 240 320

4 140 220 300 Default

3 120 200 280

2 100 180 260

1 80 160 240

Display level Set value (l/min.)

8 220 or 360

7 200 or 340

6 180 or 320



5 160 or 300

4 140 or 280

3 120 or 260

2 100 or 240

1 80


MAINTENANCE FUNCTION

When the maintenance time for replacement,

inspection, or filling has approached for the 10 main-

tenance items, press maintenance switch (1) and

the caution display (yellow or red) appears on the

monitor display for 30 seconds after the starting

switch is turned ON to remind the operator to per-form lubrication maintenance.

a Maintenance items

No. ItemReplacement interval

(hours)

01 Engine oil 500

02 Engine oil filter 500

03 Fuel filter 500

04 Hydraulic filter 1000

05 Hydraulic tank breather 500

06 Corrosion resistor 1000

07 Damper case oil 1000



a The above replacement intervals are set for

each item, and the time remaining to mainte-

nance is reduced as the machine is operated.

The content of the caution display differs

according to the ramaining time. The relation-ship is as shown in the table below.

07 Damper case oil 1000

08 Final case oil 2000

09 Machinery case oil 1000

10 Hydraulic oil 5000

Display Condition

None

Remaining time for mainte-

nance for all items is more

than 30 hours

Notice display (black sym-bol displayed on yellow

There is one or more items

with less than 30 hoursremaining time for mainte


METHOD OF CHECKING STATUS

MAINTENANCE ITEMS

a Operate as follows when on the operator

screen.

1. Press maintenance switch (1) and switch to the

maintenance list display screen.

a The maintenance items are displayed assymbols on the screen.

2. Press control switch (2), or use the 10-key pad

to input the number (01 – 10) of the mainte-

nance item to select the item.

a The cursor moves and the item is highlight-

ed.

a The display method is the same as de-

scribed on the previous page (relationship

between remaining time and caution dis-play). If the remaining time is less than 30

hours, the item is displayed in yellow, and if

it is less than 0 hours, it is displayed in red.

MAINTENANCE OPERATION



1. After completing the selection, press input con-firmation switch (3).

The screen will change to the maintenance

reset screen.

2. Use the maintenance reset screen to check the

content, and if there is any problem, press input

confirmation switch (3) to move to the check

screen.

If the wrong item is selected, press return switch

(4) to return to the maintenance list screen.3. Check the content on the check screen, and if

there is no problem, press input confirmation

switch (3) to reset the maintenance time.

After the reset is completed, the screen returns

to the maintenance list display screen. To check

the remaining time, or if the wrong item is

selected, press return switch (4) to return to the

maintenance list screen.

a The check screen shows the symbol for the


BRIGHTNESS, CONTRAST ADJUSTMENT

FUNCTION

This function is used to adjust the brightness and

contrast of the display.

ADJUSTMENT METHOD

a Operate as follows when on the operator

screen.

1. Press display brightness/contrast adjustment

switch (1) and switch to the adjustment screen.

a Relationship between menu symbol and con-

tent.

No. Symbol Content

01 Return mark Return

02 Contrast



2. Press control switch (2), or use the 10-key pad

to input the number (00 – 02) to select either

contrast or brightness.

After completing the selection, press input con-

firmation switch (3) and return to the adjustment

screen.

Then press return switch (4) or use the 10-keypas to set to [00] and press input confirmation

switch (3) to return to the normal screen.

3. Press control switch (2) and adjust the bright-

ness and contrast as desired.

03 Brightness





SERVICE METER CHECK FUNCTION

• When the starting switch is at the OFF position,

keep return switch (1) and control switch (2) of

the monitor pressed at the same time, and the

service meter is shown on the display.

• This display is shown only while the two switches

are being pressed. When the switches are re-leased, the display goes out.

Note that it takes 3 – 5 seconds after the

switches are pressed for the service meter dis-

play to appear.

DISPLAY LCD CHECK FUNCTION

• On the password input screen or on the normal

screen, if monitor return switch (1) and working

mode (A) switch are kept pressed at the same

time, all the LCD display will light up and the

whole screen will become white, so the display

can be checked.

• If any part of the display is black, the LCD is bro-



ken.


USER CODE DISPLAY FUNCTION

• If there is any problem in operating the machine,

the user code is displayed on the monitor to ad-

vise the operator of the steps to take.

This code display appears on the operator

screen.

• On the operator screen, the user code is dis-played on the portion for the hydraulic oil temper-

ature gauge.

• If more than one user code is generated at the

same time, the user codes are displayed in turn

for 2 seconds each to display all the user codes.




• While the user code is being displayed, if the in-

put confirmation switch is pressed, the service

code and failure code can be displayed.

• If there is more than one service code or failure

code, the display switches every 2 seconds and

displays all the service codes/failure codes thatcaused the user code to be displayed.

Even i f service codes/fai lure codes have

occurred, if they did not cause the user code to

be displayed, this function does not display

them.



• If the telephone number has been set using the

telephone number input on the service menu, it

is possible to switch on the service code/failure

code and display the telephone symbol and tele-

phone number.

For details of inputting and setting the telephone

number, see SPECIAL FUNCTIONS OF MONI-

TOR PANEL in the TESTING AND ADJUSTING

section.

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM

7-SEGMENT MONITOR SYSTEM

SJP08775

OR

08931



• The monitor system monitors the condition of the

machine with sensors installed on various parts

of the machine. It processes and immediatelydi l th bt i d i f ti th l

• The monitor panel also has various mode selec-

tor switches and functions to operate the ma-

chine control system.


1. Monitor panel



OUTLINE

• The monitor panel has the functions to display

various items and the functions to select modes

and electric parts.

The monitor panel has a CPU (Central Process-

ing Unit) in it to process, display, and output the

information.

The monitor display unit consists of LCD (LiquidCrystal Display) and LED (Light Emitting Diode).

The switches are flat sheet switches.

INPUT AND OUTPUT SIGNALS

CN-P01 CN-P02

Pin

No.Signal name

Pin

No.Signal name

1 Key switch (Battery) 1 Engine water temperature

2 Key switch (Battery) 2 Fuel

3 Washer motor output 3 Radiator water level

4 Key switch (Terminal C) 4 NC

5 Wiper contact W 5 Air cleaner clogging sensor

6 GND 6 NC

7 GND 7 Engine oil pressure sensor

8 VB + (24 V) 8 Engine oil level sensor

9 Wiper motor (+) 9 Network signal

10 Wiper motor (–) 10 Network signal

11 (Buzzer ON signal input) 11 Charge level

12 Wiper contact P 12 NC


Display section of monitor



1. Service meter display

2. Coolant temperature gauge

3. Coolant temperature caution

4. Digital meter display (Service code and user code

are displayed when trouble occurs

5. Fuel level caution

6. Fuel level gauge

7. Engine oil level caution lamp

8. Preheating pilot lamp

9. Swing holding brake pilot lamp

10. Oil maintenance pilot lamp11 Battery charge caution lamp


Monitored items and display

Symbol Displayed item Display rangeWhen engine is

stoppedWhile engine is running

Engine oil pressure

Max. 1,500 rpm

Max. 0.05 MPa

{0.5 kg/cm²}

Min. 1,500 rpm

Max. 0.15 MPa

{1.5 kg/cm²}

Lights when normal.

(Goes off whenengine is started.)

Flashes and buzzer

sounds when abnormal.

Air cleaner clogging When clogged Goes off. Flashes when abnormal.

Charge level When charge isabnormal

Lights when normal.

(Goes off whenengine is started.)

Flashes when abnormal.

Engine oil level Below low levelFlashes when

abnormal.Goes off.



Packing (Swing lock) When swing islocked

Lights up when swing is locked. Flashes whenswing holding brake release switch is turned on.

Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.

Preheating When preheated

Lights up for 30 sec. when starting switch is set to

HEAT. Then, flashes for 10 sec. to indicated

completion of preheating.

C lFlashes at 102°C or higher Flashes and


Oil maintenance function

1. Function and operation

At a set t ime after the engine oil is replaced, the oil

maintenance function is turned on to notify the oper-

ator by the LED lamp on the monitor panel that it is

time to replace the oil. The function to indicate the

phone number of the place to make contact for ser-vice on the LCD unit is installed, too.

1) Check of elapsed time

Nothing is displayed normally until point B

shown in the figure at right after this function

is reset. If the key is turned on with the

buzzer cancel switch processed (for 2.5

seconds), however, the elapsed time is dis-

played on the service meter section.2) Display of replacement of oil

If time passes point B after this function is

reset, the elapsed time is displayed on the

service meter section and the LED flashes

when the key is turned on.

2. Setting of time interval



1) The time interval is set in the interval setting

mode. It can be set to "125h", "250h",

"500h", "Not set", or "Demo-mode". The

default is "Not set".

2) To enter the interval setting mode, press

and hold the clock switch for 2.5 seconds.

3) If the buzzer cancel switch is pressed in the

interval setting mode, the clock display sec-

tion changes to "—" o "125" o "250" o

"500" o

"d" in order. ("—" corresponds to"Not set" and "d" corresponds to "Demo-

mode".)

4) To save the time interval, set a desired time

(mode) on the monitor panel and press and

hold the clock switch for 2.5 seconds.


3. Timing and contents of display

1) When replacement of oil is displayed

2) The elapsed time is displayed for 10 sec-

onds after all segments are turned on.

Phone number is displayed for the next 10

seconds.

If the phone number has not been input,

however, the elapsed time is displayed for 20 seconds after all segments are turned

on.

3) When elapsed time is checked

The elapsed time is displayed for 10 sec-

onds after all segments are turned on.

4. Resetting elapsed time

1) When the replacement of oil and elapsed

time are displayed, press the buzzer cancelswitch 10 seconds after all segments are

turned on (while the elapsed time is dis-

p layed) and hold for 3 seconds. The

elapsed time is reset. After this operation,

"0h" is displayed for 1 second.

2) When the set time is changed, the elapsed

time is reset to "0h".



5. Demo-mode1) In the demo-mode, the time is set to 250h,

the elapsed time is set to 240h, and replace-

ment of oil is displayed when the key is

turned on. The elapsed time does not

increase, however. The time can be reset in

this mode. Turn on the key 3 times in this

mode, and the time interval is automatically

set to "Not set" at the 4th time and after. The

elapsed time is set to "0h" and counting of

elapsed time is started.


Mode selector switches1. Travel speed switch

2. Auto-deceleration switch

3. Wiper switch

4. Work mode selector switch

(Including setting switch)



• There are 4 sets of the mode selector switches

on the switch section. Each time one switch is

pressed, the machine condition changes. The

current condition is indicated by the lighting of

the LED above the switch.

• The initial setting of only the work mode after thestarting switch is turned on can be changed.

a For how to change the setting, see "Work mode

default setting mode" in TROUBLESHOOTING-

Display and special functions of monitor panel.

Operations table of switch section

a The bold letters are the positions of the switches

reset when the starting switch is turned on.

Item Operation

Work mode A↔ E↔ B

Auto-deceleration ON↔ OFF

Wiper OFF↔ Intermittent↔ ON

Travel speed Hi↔ Lo

STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR

SENSOR

• The signals from the sensors are input to the

panel directly. Either side of a sensor of contact

type is always connected to the chassis ground.

Name of sensor Type of sensor When normal When abnormal

Engine oil level Contact ON (closed) OFF (open)

Engine oil pressure Contact OFF (open) ON (closed)

Hydraulic oil temperature Resistance — —

Coolant temperature Resistance — —

Fuel level Resistance — —

Air cleaner clogging Contact type OFF (open) ON (closed)




Engine oil level sensor

Engine oil pressure sensor (For low pressure)

1. Connector

2. Bracket

3. Float

4. Switch

1. Plug

2. Contact ring

3. Contact

4. Diaphragm

5 Spring



Coolant temperature sensor

Hydraulic oil temperature sensor

5. Spring

6. Terminal


Fuel level sensor

1. Float

2. Connector

3. Cover

4. Variable resistor



Air cleaner clogging sensor

STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-2

STANDARD VALUE TABLE FOR CHASSIS .................................................................................................. 20-3

TESTING AND ADJUSTING ...................................................................................................................... 20-101

TROUBLESHOOTING................................................................................................................................ 20-201

20 TESTING AND ADJUSTING



a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-

bleshooting.

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE

STANDARD VALUE TABLE FOR ENGINE

Machine modelPC400, 400LC-7

PC450, 450LC-7

Engine SAA6D125E-3

Item Measurement condition Unit Standard value Permissible value

Engine speed

High idling

Low idling

Rated speed

rpm

1,930 ± 50

1,000 ± 25

1,850

1,930 ± 50

1,000 ± 25

1,850

Intake air pressure At rated outputkPa

{mmHg}Min 107 {Min. 800} 87 {650}

Exhaust gaspressure

All speed range(intake air temp: 20°C)

°C Max. 700 Max. 700

Exhaust gas color

At sudden acceleration

At high idling

Bosch

index

Max. 4.0

Max. 1.0

6.0

2.0

Valve clearance

(normal temperature)

Intake valve

Exhaust valve

mm

0.33

0.71

—

—



Compressionpressure

Oil temperature: 40 – 60°C(Engine speed)

MPa {kg/cm2}(rpm)

Min. 2.9 {Min. 30}(150 – 200)

2.0 {20}(150 – 200)

Blow-by pressure

(Coolant temperature:

within operating range)

At rated output

kPa

{mmH2O}Max. 1.18 {Max. 120} 1.96 {200}

Oil pressure

(Coolant temperature:

within operating range)

At high idling (SAE30)

At high idling (SAE10W)

At low idling (SAE30)

At low idling (SAE10W)

MPa

{kg/cm2}

0.39 – 0.69 {4.0 – 7.0}

0.34 – 0.64 {3.5 – 6.5}

Min. 0.15 {Min. 1.5}

Min. 0.1 {Min. 1.0}

0.21 {2.1}

0.18 {1.8}

0.08 {0.8}

0.07 {0.7}

Oil temperature All speed range (inside oil pan) °C 90 – 120 120

Fan, alternator belt

tension

Deflection when pressed with fin-

ger force of approx. 58.8 N {6 kg} mm Approx. 13 Approx. 13

TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS

STANDARD VALUE TABLE FOR CHASSIS

Applicable modelPC400, 400LC-7

PC450, 450LC-7

Cate-

goryItem Measurement conditions Unit Standard value Permissible value

E n g i n e s p e e d

2 pumps at relief

• Engine coolant temperature:Within operating range

• Hydraulic oil temperature:

Within operating range

• Engine at high idling

• Arm in relief condition

rpm

1,930 ± 100 1,930 ± 100

At 2-pump relief + one

touch power up

• Engine coolant temperature:



Within operating range• Engine at high idling

• Arm relief + One-touch power

max. switch in ON condition

1,830 ± 100 1,830 ± 100

Speed when auto-

deceleration is oper-

ated


• Auto-deceleration switch in ON

condition

• All control levers in NEUTRAL

condition

1,300 ± 100 1,300 ± 100



S p o o l s t r o k e

Boom control valve

mm 9.5 ± 0.5 9.5 ± 0.5

Arm control valve

Bucket control valve

Swing control valve

Travel control valve

T r a v e l o f c o n t r o l l e v

e r s Boom control lever

• Engine stopped

• At center of control lever grip

• Max. reading up to stroke end

(excepting lever play in NEU-

TRAL position)

mm

85 ± 10 85 ± 10

Arm control lever 85 ± 10 85 ± 10

Bucket control lever 85 ± 10 85 ± 10

Swing control lever 85 ± 10 85 ± 10

Travel control lever 115 ± 12 115 ± 12

Play of control levers Max. 10 Max. 15

er s

Boom control lever 15.7 ± 4.9

{1.6 ± 0.4}

Max. 24.5

{Max. 2.5}



PC450, 450LC-7

Cate-


Unload pressure


Within operation range

• Engine at high idling• Working mode: A mode

• Hydraulic pump output pressure

with all control levers in NEU-

TRAL position

4.2 ± 1.0

{42 ± 10}

4.2 ± 1.0

{42 ± 10}

Boom • Hydraulic oil

temperature:

Within opera-

tion range

• Engine at high

idling

RAISE

34.81

(37.27 )

{355 (380 )}

33.34 – 36.77

(35.79 – 39.23)

{340 – 375 (365 – 400)}

L O W E R

At low-pressure

setting

18.14 ± 0.98

{185 ± 10}

16.67 – 19.61

{170 – 200}

At high-

pressure

setting

31.38 ± 1.47

{320 ± 15}

29.2 – 33.34

{300 – 340}

Arm

• Working mode: A mode

• Hydraulic pump output pressure

34.81

(37.27 )

33.34 – 36.77

(35.79 – 39.23)

+1.47 –0.98+1.47

–0.98+15

–10+15

–10

+1.47 –0.98+1.47

–0.98



H y d r a u l i c p r e s s u r e

MPa

{kg/cm2}

with all measurement circuitsrelieved

• Values inside parenthesis:

Hydraulic oil pressure with one-

touch power max. switch in ON

mode (reference only)

{355 (380 )} {340 – 375 (365 – 400)}

Bucket

34.81

(37.27 )

{355 (380 )}

33.34 – 36.77

(35.79 – 39.23)

{340 – 375 (365 – 400)}

Swing30.89

{315 }

27.95 – 32.85

{285 – 335}

Travel 37.27{380 }

35.79 – 40.70{365 – 415}

Control circuit source

pressure




• Self-reducing pressure valve

output pressure with all control

levers in NEUTRAL position

3.24 ± 0.2

{33 ± 2}

2.84 – 3.43

{29 – 35}

• Hydraulic oil tem-perature: Within When allcontrol

+15 –10

+15 –10

+1.47 –0.98+1.47

–0.98+15

–10+15

–10

+1.47 –2.45+15

–25

+2.94

–0.98+30

–10



PC450, 450LC-7

Cate-


Swing brake angle • Hydraulic oil temperature:


• Bucket: Empty



• Swing circle misalignment amount

when stopping after one turn

deg.

(mm)

PC400: Max. 120

PC450: Max. 130

PC400: Max. 150

PC450: Max. 160

Time taken to start

swing



• Bucket: Empty

90°

sec.

3.7 ± 0.4 Max. 4.6



S w i n g


• Time required for passingpoints 90 and 180 degrees

from starting point

180° 5.4 ± 0.5 Max. 6.4

Time taken to swing • Hydraulic oil temperature:


• Bucket: Empty



• Time required for 5 more turns

after making initial one turn

sec. 33.0 ± 3.3 Max. 38


S w

i n g

Leakage from swing

motor

• Hydraulic oil temperature: Within

operation range


• Swing lock switch: ON• Leakage amount for one minute

during swing relief

l/min Max. 5.5 Max. 11

Travel speed(Idle travel) • Hydraulic oil temperature:



• Time required for track shoes

to make 5 turns after making

one initial idle turn

Lo

sec.

STD: 63.2 ± 12.6

LC: 67.3 ± 13.5

STD: 42.0 – 80.0

LC: 45.0 – 84.5

MiSTD: 45.1 ± 6.8

LC: 48.1 ± 7.2

STD: 31.5 – 55.0

LC: 34.0 – 58.0

HiSTD: 34.5 ± 35

LC: 36.7 ± 3.6

STD: 28.0 – 41.5

LC: 32.0 – 44.0


PC450, 450LC-7

Cate-




T r a v e l

Travel speed

(Actual travel)• Hydraulic oil temperature:



• Working mode: A mode• Flat ground

• Time required for traveling

20 m after 10 m trial run

Lo

sec.

24.0 ± 4.8 18.9 – 31.0

Mi 17.1 ± 2.6 14.4 – 21.0

Hi 13.1 – 1.3 11.7 – 15.1


T r a v e l

Hydraulic drift of travel • Hydraulic oil temperature:


• Engine stopped

• Parking machine on slope 12

degrees with sprocket facing ups-

lope

• Sliding distance for 5 minutes

mm 0 0

Leakage of travel

motor




• Travel: Lock sprocket.

• Oil leakage amount for one

minute with traveling in relief con-

dition

l/min Max. 20 Max. 40

Whole work

equipment(tooth PC400: Max 600 PC400: Max 900


PC450, 450LC-7

Cate-




W o r k

e q u i p m e n t

H y d r a u l i c d r i f t o f w o r k e q u i p m e n t

equipment (tooth

tip fall amount)

• Hydraulic oil temperature: Within

operation range

• Flat and level ground

• Work equipment in measure-

ment posture as illustratedabove

• Bucket load: 3,060 kg

• Engine stopped

• Work equipment control lever in

NEUTRAL position

• Fall amount for 15 minutes as

measured every 5 minutes start-

ing immediately after initial setting

mm

PC400: Max. 600PC450: Max. 700

PC400: Max. 900PC450: Max. 1,050

Boom cylinder

(cylinder retrac-

tion amount)

PC400: Max. 25

PC450: Max. 29

PC400: Max. 38

PC450: Max. 44

Arm cylinder (cyl-

inder extensionamount)

PC400: Max. 85

PC450: Max. 100

PC400: Max. 128

PC450: Max. 150

Bucket cylinder

(cylinder retrac-

tion amount)

PC400: Max. 30

PC450: Max. 35

PC400: Max. 45

PC450: Max. 53



PC450, 450LC-7

Cate-

goryItem Measurement conditions Unit

Standard value for

new machineService limit value

e q u i p m e n t

u i p m e n t s p e e d

Boom • Hydraulic oil temperature:




• Time required from raise

stroke end till bucket

touches ground

R A I S

E

sec.

PC400: 4.0 ± 0.4PC450: 4.2 ± 0.4

PC400: Max. 4.8PC450: Max. 5.0

L O W E R

PC400: 2.9 ± 0.3

PC450: 2.8 ± 0.3

PC400: Max. 3.4

PC450: Max. 3.3

Arm • Hydraulic oil temperature:



C U R L PC400: 4.3 ± 0.4

PC450: 4.7 ± 0.5

PC400: Max. 5.0

PC450: Max. 5.4



W o r k

W o r k e q • Engine at high idling


• Time required from dump-

ing stroke end to digging

stroke end

D U M P

3.6 ± 0.4 Max. 4.3

Bucket • Hydraulic oil temperature:




• Time required from dump-

ing stroke end to digging

stroke end

C U R L

3.6 ± 0.4 Max. 4.3

D U M P

2.9 ± 0.3 Max. 3.5



PC450, 450LC-7

Cate-

goryItem Measurement Condition Unit Standard value Permissible value

g

Boom• Hydraulic oil temperature:


• Engine at low idling


• Time required from raise stroke

end till bucket touches ground

and pushes up machine front

sec. Max. 3.0 Max. 3.6

• Hydraulic oil temperature: PC400: Max 3 0 PC400: Max 3 6



W o r k e q u i p m e n t

T i m e l a g

Arm• Hydraulic oil temperature:




• Time required from dumping

stroke end till bucket stops

momentarily after control lever

is tilted to digging and starts to

move again

sec.

PC400: Max. 3.0

PC450: Max. 4.0

PC400: Max. 3.6

PC450: Max. 4.6

Bucket• Hydraulic oil temperature:



Max. 3.0 Max. 5.0


P e r f o r m

a n c e i n c o m p o u n d o p e r a t i o n

Swerving amount in

simultaneous opera-

tion of work equip-

ment and travel





• Traveling speed: Lo

• Flat and level ground

• Swerving amount (X) when

traveling 20 m after initial trial

run of 10 m mm Max. 400 Max. 440

er

f o r m a n c e o f

yd

r a u l i c p u m p

Hydraulic pump

deliverySee next page l/min See next page


PC450, 450LC-7

Cate-

goryItem Measurement Condition Unit Standard value Permissible value



P e r h y d



PC450, 450LC-7

Cate-

goryItem Measurement Condition Unit Standard value

Permissible

value

mp

Discharge amount of hydraulic pump (A mode)



P e r f o

r m a n c e o f h y d r a u l i c p u m p

• Pump speed: At 1,950 rpm, PC current 280 mA

Check point

Test pump

discharge

Discharge

pressure of

Average

pressure

Standard value

for discharge

Judgement

standard lower



TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE...................................................... 20-102

MEASURING ENGINE SPEED .................................................................................................................. 20-104

MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................ 20-105

MEASURING EXHAUST TEMPERATURE ................................................................................................ 20-106

MEASURING EXHAUST GAS COLOR...................................................................................................... 20-107 ADJUSTING VALVE CLEARANCE ............................................................................................................ 20-108

MEASURING COMPRESSION PRESSURE.............................................................................................. 20-110

MEASURING BLOW-BY PRESSURE........................................................................................................ 20-112

MEASURING ENGINE OIL PRESSURE.................................................................................................... 20-113

HANDLING OF FUEL SYSTEM DEVICES................................................................................................. 20-114

RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM .................................................................. 20-114

MEASURING FUEL PRESSURE ............................................................................................................... 20-115

BLEEDING AIR FROM FUEL CIRCUIT ..................................................................................................... 20-116

INSPECTION OF FUEL CIRCUIT FOR LEAKAGE.................................................................................... 20-118




ADJUSTING ENGINE SPEED SENSOR ................................................................................................... 20-119

TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION........................................ 20-120

TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................ 20-121

MEASURING CLEARANCE OF SWING CIRCLE BEARING..................................................................... 20-122

TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................. 20-123

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,

SWING, AND TRAVEL CIRCUITS....................................................................................................... 20-124

MEASURING BASIC PRESSURE IN CONTROL CIRCUIT....................................................................... 20-128

TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ................................... 20-129

TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.................................... 20-132

MEASURING SOLENOID VALVE OUTPUT PRESSURE.......................................................................... 20-137

MEASURING PPC VALVE OUTPUT PRESSURE..................................................................................... 20-140

ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES................................................ 20-142

TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT ................................... 20-143

RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT.............................................................. 20-145

MEASURING OIL LEAKAGE...................................................................................................................... 20-146

BLEEDING AIR FROM EACH PART 20 149

TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE

TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE

Testing/Adjusting item

s y m b o l

Part No. Part name Q ’ t y

Remarks

Measuring intake air pres-

sure (boost pressure) A 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}

Measuring exhaust

temperatureB 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C

Measuring exhaust gas

color C

1 799-201-1502 Handy smoke meter 1Pollution level: 0 – 70 % (With standard

color)

(Pollution level × 1/10 Bosch index)2

Commercially

availableSmoke meter 1

Adjusting valve clearance DCommercially

availableFeeler gauge 1

Air intake side: 0.35 mm, Exhaust side:

0.57 mm

Measuring compression

pressureE

1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}

2795-471-1410 Adapter 1

For 125E-3 engine6217-71-6112 Gasket 1

3 795-799-1170 Puller 1

Measuring blow-by pres-sure

F 799-201-1504 Blow-by checker 1



surey

Measuring engine oil

pressureG

1799-101-5002 Hydraulic tester 1

(Pressure gauge): 2.5, 5.9, 39.2, 58.8 MPa

{25, 60, 400, 600 kg/cm2}

790-261-1203 Digital hydraulic tester 1 (Pressure gauge): 58.8 MPa {600 kg/cm2}

2 799-401-2320 Hydraulic tester 1 (Pressure gauge): 0.98MPa {10 kg/cm2}

Measuring fuel pressure H 1


Same as G790-261-1203 Digital hydraulic tester 1

2 799-401-2320 Hydraulic tester 1

Measuring clearance of

swing circle bearingJ

Commercially

availableDial gauge 1 with magnet

Measuring and adjusting oil

pressures in work equip-

ment, swing, and travel cir-

cuits

k



2 799 101 5220 Nipple 2 (Si ) 10 × 1 25

TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE

Testing and adjusting

pressure in pump LS

control circuit

N



2799-101-5220 Nipple 4

Same as M2

07002-11023 O-ring 4

3 799-401-2701Differential pressure

gauge1

Measuring solenoid valve

output pressureP



2799-401-3100 Adapter 1 (Size): 02

799-401-3200 Adapter 1 (Size): 03

Measuring PPC valve

output pressureQ



2 970-301-1740 Joint 1 (Size): PF1/4 + PT1/4

Measuring oil leakage RCommercially

availableMeasuring cylinder 1

Testing wear of sprocket — 799-627-1120 Wear gauge 1

Measuring coolant and oiltemperatures

— 799-101-1502 Digital thermometer 1 Same as B

Testing/Adjusting item

s y m b o l

Part No. Part name Q ’ t y

Remarks



a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor

panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connec-

tors and electric circuit diagram of each system.

temperatures

Measuring operating effort

and pressing force—

79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}

79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}

Measuring stroke and

hydraulic drift—

Commercially

availableScale 1

Measuring work equip-

ment speed

—Commercially

available

Stopwatch 1

Measuring voltage and

resistance—

Commercially

availableTester 1

TESTING AND ADJUSTING MEASURING ENGINE SPEED

MEASURING ENGINE SPEED

1. Turn the starting switch ON and set the monitor

panel to “Monitoring”.

a For the operating method, see “Special func-

tions of monitor panel”.

• Monitoring code: 01002 Engine Speed

01006 Engine Speed

a Code 01002 is information of the engine control-

ler and code 01006 is information of the pump

controller. The engine speed can be measured

with either of those codes.

a The engine speed is displayed in rpm.

4) Measuring 2-pump relief + one-touch power

maximizing speed (near rated speed):

i) Start the engine and set the fuel control

dial in the high idling position (MAX).

ii) Set the working mode switch in the A-

mode position.

iii) While relieving the arm circuit by moving

the arm in, keep pressing the one-touch

power maximizing switch.

a The one-touch power maximizing func-

tion is reset automatically in about 8.5

seconds even if the switch is kept held.

Accordingly, measure the engine speed

in that period.

5) Measuring auto-deceleration speed1) Start the engine and set the fuel control


2) Turn the auto-deceleration switch ON.

3) Set the work equipment control and

swing control levers in neutral.

a The engine speed lowers to a certain

level about 5 seconds after all the levers

are set in neutral. This level is the auto-

deceleration speed.



2. Run the engine and raise engine coolant and

hydraulic oil temperatures to operating range.

3. Measure the engine speed under each meas-

urement condition.

1) Measuring low idling speed:


dial in the low idling position (MIN).

ii) Set the work equipment control, swing

control, and travel levers in neutral and

measure the engine speed.

2) Measuring high idling speed:



ii) Set the working mode switch in the A-

mode position

TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

a Measuring instruments for intake air pressure

(boost pressure)

a When installing and removing the measuring

instruments, take care not to touch a hot part of

the engine.

1. Open the engine hood and remove intake air

pressure pick-up plug (1).



5. Set the working mode switch in the A-mode

position.

6. While running the engine at high idling, relieve

the boom circuit by raising the boom and meas-

ure the intake air pressure (boost pressure).

7. After finishing measurement, remove the meas-uring instruments and return the removed parts

Symbol Part No. Part Name

A 799-201-2202 Boost gauge kit



2. Install nipple [1] of boost gauge kit A and con-

nect gauge [2].

uring instruments and return the removed parts.

TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE

MEASURING EXHAUST TEMPERATURE

a Measuring instrument of exhaust gas tempera-

ture

k Install and remove the measuring instrument af-

ter the exhaust manifold is cooled.

1. Open the engine hood and remove exhaust

temperature pick-up plug (1).

5. Procedure for measuring exhaust temperature

periodically for preventive maintenance (Pm

Clinic), etc.

1) Set the working mode switch in the A-mode

position.

2) Run the engine at high idling, relieve the

arm circuit by moving the arm in, and meas-

ure the exhaust temperature.

a Measure the exhaust temperature after

it is stabilized.

6 After finishing measurement remove the meas-


B 799-101-1502 Digital thermometer



2. Install sensor [1] of digital thermometer B and

connect them to meter [2].

a Clamp the wiring harness of the digital ther-

mometer so that it will not touch a hot part.

6. After finishing measurement, remove the meas


TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR

MEASURING EXHAUST GAS COLOR

a Measuring instrument of exhaust gas color

k When installing and removing the measuring in-

struments, take care not to touch a hot part.

a If an air source and an electric power source are

not available in the field, use handy smoke

checker C1. When recording official data, use

smoke meter C2.

1. Measuring with handy smoke checker C1

1) Stick a sheet of filter paper to C1.

2) Insert the exhaust gas intake pipe in

exhaust pipe (1).

3) Run the engine and raise engine coolant

temperature to operating range.

4) Accelerate the engine suddenly or run it at

high idling and operate the handle of smoke

checker C1 so that the filter paper will

absorb the exhaust gas

2) Connect the probe hose, receptacle of the

accelerator switch, and air hose to smokemeter C2.

a Limit the supplied air pressure to 1.5

MPa {15 kg/cm2}.

3) Connect the power cable to a receptacle of

AC 100 V.

a Before connecting the cable, check that

the power switch of the smoke meter is

turned off.

4) Loosen the cap nut of the suction pump andfit the filter paper.


C

1 799-101-9000 Handy smoke checker

2

Commercially

available Smoke meter



absorb the exhaust gas.

5) Remove the filter paper and compare it with

the attached scale

p p

a Fit the filter paper securely so that the

exhaust gas will not leak.

5) Turn on the power switch of smoke meter

C2.

TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

ADJUSTING VALVE CLEARANCE

a Adjusting instrument for valve clearance

1. Open the engine hood and remove all cylinder

head covers (1).

a Remove all the intermediate clamps of the

fuel high-pressure tube and disconnect the

sleeve nuts on the common rail side and in-

jector side, and you can remove the cylinder

head covers.

aUse ring wrenches (on the market) for high-pressure pipes to disconnect and connect

the fuel high-pressure tubes.

a Remove the air intake connector, too, from

the top of the No. 1 cylinder head cover.

a After removing the head covers, tighten the

sleeve nuts temporarily so that the fuel high-

pressure tubes will not interfere with the

rocker arms.

the compression top dead center. In this

case, rotate the crankshaft one more turn.

5. Insert feeler gauge D in clearance “b” between

rocker arm (3) and crosshead (4) and adjust the

valve clearance with adjustment screw (5).

a With the feeler gauge inserted, turn the ad-

justment screw to a degree that you can

move the filler gauge lightly.

6. Fix adjustment screw (5) and tighten locknut (6).

3 Locknut:53.0 – 64.7 Nm {5.4 – 6.6 kgm}


DCommercially

availableFeeler gauge



2. Remove the belt protection covers (2 pieces)

and loosen the fan belt and alternator belt.

3 Remove the radiator undercover

{ g }

a After tightening the locknut, check the valve

clearance again.

TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE

8. After finishing adjustment, return the removed

parts.

3 Cylinder head cover mounting bolt:

9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}

a After tightening the sleeve nuts permanently,

tighten the clamp bolts of the fuel high-pres-

sure tubes permanently.

3 Fuel high-pressure tube sleeve nut:39.2 – 49.0 Nm {4 – 5 kgm}

3 Fuel high-pressure tube clamp bolt:

11.8 – 14.7 Nm {1.2 – 1.5 kgm}

3 Air intake connector clamp:

9.8 ± 0.5 Nm {100 ± 5 kgcm}

a Adjust the belt tension. For details, see

TESTING AND ADJUSTING FAN BELT

AND ALTERNATOR BELT TENSION.



TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pressure

k When measuring the compression pressure,

take care not to burn yourself on the exhaust

manifold, muffler, etc. or get caught in a rotating

part.

1. Run the engine and warm up the engine oil tem-

perature to 40 – 60°C.

2. Open the engine hood and remove cover (1) of

the cylinder head to be measured.

a Remove all the intermediate clamps of the

fuel high-pressure tube and disconnect the

sleeve nuts on the common rail side and in-

jector side, and you can remove the cylinder head cover.

4. Install adapter E2 and connect it to compressiongauge E1.

3 Holder mounting bolt:

58.8 – 73.5 Nm {6.0 – 7.5 kgm}


E

1 795-502-1590 Compression gauge

2

795-471-1410 Adapter

6217-71-6112 Gasket

3 795-799-1170 Puller



a Use ring wrenches (on the market) for high-

pressure pipes to disconnect and connect

the fuel high-pressure tubes.

a Remove the air intake connector, too, from

the top of the No. 1 cylinder head cover.

5. Adjust the valve clearance. For details, see

ADJUSTING VALVE CLEARANCE.

6. Remove the engine undercover and disconnect

engine intermediate connectors ER02 and

ER03.

k If the connectors are not disconnected, the

engine starts during measurement, and that

i d A di l b t di

TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE

8. Crank the engine with the starting motor and

measure the compression pressure.

a Measure the pressure when the pointer of

the gauge is stabilized.

a While measuring the compression pressure,

measure the engine speed, too, and check

that it is in the measurement condition range.

9. After finishing measurement, remove the meas-uring instruments and return the removed parts.

3 Injector holder mounting bolt:

58.8 – 73.5 Nm {6.0 – 7.5 kgm}

3 Cylinder head cover mounting bolt:

9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}

a After tightening the sleeve nuts permanently,

tighten the clamp bolts of the fuel high-pres-

sure tubes permanently.

3 Fuel high-pressure tube sleeve nut:39.2 – 49.0 Nm {4 – 5 kgm}

3 Fuel high-pressure tube clamp bolt:

11.8 – 14.7 Nm {1.2 – 1.5 kgm}

3 Air intake connector clamp:

9.8 ± 0.5 Nm {100 ± 5 kgcm}



TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE

MEASURING BLOW-BY PRESSURE

a Measuring instrument for blow-by pressure

1. Remove the engine undercover.

2. Install nozzle [1] of blow-by checker F to blow-by

hose (1) and connect it to gauge [2] by the hose.


hydraulic oil temperatures to operating range


F 799-201-1504 Blow-by checker




4. Run the engine at high idling and measure the

blow-by pressure under the following condition.

• Work equipment mode: A

• Swing lock switch: ON (High pressure relief)

• Work equipment, swing, and travel circuits:

Relieve by moving arm in.

a Read the blow-by checker when its

pointer is stabilized.

TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE

MEASURING ENGINE OIL PRESSURE

a Measuring instruments for engine oil pressure

1. Open the engine hood and remove oil pressure

pick-up plug (1) from the engine cylinder block.

2. Install nipple [1] of hydraulic tester G1 and con-

5. After finishing measurement, remove the meas-uring instruments and return the removed parts.


G1

799-101-5002 Hydraulic tester

790-261-1203 Digital hydraulic tester

2 799-401-2320 Hydraulic tester



2. Install nipple [1] of hydraulic tester G1 and con

nect it to hydraulic tester G2.


HANDLING OF FUEL SYSTEM DEVICES

RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM

HANDLING OF FUEL SYSTEMDEVICES

a Precautions for testing and adjusting fuel sys-

tem

The common rail fuel injection system (CRI)

consists of more precise parts than the conven-

tional fuel injection pump and nozzle. If foreignmatter enters this system, it can cause a trouble.

When testing and adjusting the fuel system,

take care more than the past. If dust, etc. sticks

to any part, wash that part thoroughly with clean

fuel.

a Precautions for replacing fuel filter cartridge

Always use a Komatsu genuine fuel filter car-

tridge.

Since the common rail fuel injection system(CRI) consists of more precise parts than the

conventional fuel injection pump and nozzle, it

employs a high-efficiency special filter to pre-

vent foreign matter from entering it.

If a filter other than a Komatsu genuine filter is

used, the fuel system may have trouble. So

never use any thing but a Komatsu genuine fil-

ter.

RELEASING RESIDUALPRESSURE FROM FUELSYSTEM

a Pressure is generated in the low-pressure circuit

and high-pressure circuit of the fuel system

while the engine is running.

Low-pressure circuit: Feed pump – Fuel filter –Fuel supply pump

High-pressure circuit: Fuel supply pump – Com-

mon rail – Fuel injector

a The pressure in both low-pressure circuit and

high-pressure circuit lowers to a safety level

automatically 30 seconds after the engine is

stopped.

a Before the fuel circuit is tested and its parts are

removed, the residual pressure in the fuel circuitmust be released completely. Accordingly,

observe the following.

k Before testing the fuel system or removing

its parts, wait at least 30 seconds after stop-

ping the engine until the residual pressure in

the fuel circuit is released. (Do not start the

work just after stopping the engine since

there is residual pressure.)



TESTING AND ADJUSTING MEASURING FUEL PRESSURE

MEASURING FUEL PRESSURE

a Measuring instruments for fuel pressure

a Measure only the fuel pressure in the low-pres-

sure circuit from the feed pump to the fuel filter

and fuel supply pump.

k Since the pressure in the high-pressure circuit

from the fuel supply pump to the common rail

and fuel injector is very high, it cannot be meas-ured.

1. Open the engine hood and remove fuel pres-

sure pick-up plug (1).

3. Run the engine at high idling and measure the

fuel pressure.

a If the fuel pressure is in the following range,

it is normal.

0.15 – 0.3 MPa {1.5 – 3 kg/cm2}

4. After finishing measurement, remove the meas-



H1






2. Install nipple [1] of hydraulic tester H1 and con-

nect them to hydraulic tester H2.

TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT

BLEEDING AIR FROM FUEL CIRCUIT



a If fuel is used up or if a fuel circuit device is

removed and installed, bleed air from the fuel

circuit according to the following procedure.

a Open the engine hood.

1. Remove fuel filter (1) and fill it with fuel and

install it again.

a Fill the fuel filter with clean fuel and take care

TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT

3. Remove air bleed plug (2b) of the fuel filter and

operate priming pump (3).

a Operate the priming pump until the fuel flows

out of the plug hole and install the plug.3 Air bleed plug:

7.8 – 9.8 Nm {0.8 – 1.0 kgm}

4. Loosen air bleeder (4) of the fuel supply pump

and operate priming pump (3) 90 – 100 times.

a Operate the priming pump until fuel flows

from air bleeder (2b) and tighten the air

bleeder. Then operate the priming pumpseveral more times, until it becomes heavy.

3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}



5. Start the engine with the starting motor.

a Air in the high-pressure circuit is automati-

cally bled when the engine is cranked.

a If the engine does not start, there may be still

air in the low-pressure circuit. In this case,

repeat the above procedure from step 2.

TESTING AND ADJUSTING INSPECTION OF FUEL CIRCUIT FOR LEAKAGE

INSPECTION OF FUEL CIRCUIT FOR LEAKAGE

k Very high pressure is generated in the high-

pressure circuit of the fuel system. If fuel leaks

while the engine is running, it is dangerous

since it can catch fire.

After testing the fuel system or removing its

parts, inspect it for fuel leakage according to the

following procedure.a Clean and degrease the engine and the parts

around it in advance so that you can inspect it

easily for fuel leakage.

1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and

joints of the high-pressure piping.

2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.

3. Inspect the fuel piping and devices for fuel leak-

age.

a Inspect around the high-pressure circuit

parts coated with the color checker for fuel

leakage.

a If any fuel leakage is detected, repair it andinspect again from step 2.

4 R th i t l idli


age.



leakage.

a If any fuel leakage is detected, repair it and

inspect again from step 2.a If any fuel leakage is not detected, inspection

is completed.



4. Run the engine at low idling.


age.



leakage.a If any fuel leakage is detected, repair it and

inspect again from step 2.

6. Run the engine at high idling.


age.


TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR

ADJUSTING ENGINE SPEED SENSOR

a Adjust the engine speed sensor for the pump

controller according to the following procedure.

a The engine G speed sensor and engine Ne

speed sensor for the engine controller cannot be

adjusted.

a Open the engine hood and remove engine

speed sensor (1) before adjusting it and checkthat its tip is free from steel chips and flaws, and

then install it again.

1. Screw in sensor (1) until its tip touches the toothtip of flywheel ring gear (2).

2 Threads: Hydraulic sealant



2. Return sensor (1) by 1/2 – 2/3 turns.

a Adjust clearance “a” between the sensor tip

and gear tooth tip to 0.75 – 1.00 mm.

3. Secure sensor (1) with nut (3).

3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}


TESTING AND ADJUSTING FAN BELT AND ALTERNA-

TOR BELT TENSION

TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELTTENSION

Testing

1. Open the engine hood and remove belt protec-

tion covers (2 pieces).

2. Press the intermediate point between alternator

pulley and fan pulley with a finger and measure

deflection “a” of the belt.

a Deflection “a” when pressing force is approx-

imately 58.8 N {approximately 6 kg}: 13 mm

Adjusting

a If the deflection is abnormal, adjust it according

to the following procedure.

1. Loosen bolts and nuts (1), (2), and (3).

2. Turn nut (4) to move alternator (5) and adjust

the belt tension.

a If nut (4) is

• Tightened clockwise, the belt tension is

decreased.

• Loosened counterclockwise, the belt

tension is increased.

a Check breakage of the pulleys, wear of theV-grooves and V-belts, and contact of the

belts and V-grooves.

a If a belt is lengthened to the adjustment limit,

cut, or cracked, replace it with a new belt.

3. Tighten nuts and bolts (3), (2), and (1).

a If a V-belt is replaced, readjust its tension af-

ter 1 operating hour.




TESTING AND ADJUSTING AIR CONDITIONER COM-

PRESSOR BELT TENSION

TESTING AND ADJUSTING AIR CONDITIONER COMPRESSORBELT TENSION

Testing

1. Open the engine hood and remove belt protec-

tion covers (2 pieces).

2. Press the intermediate point between air condi-

tioner compressor pulley and crank pulley with a

finger and measure deflection “a” of the belt.

a Deflection “a” when pressing force is approxi-mately 58.8 N {approximately 6 kg}:

14 mm – 16 mm

Adjusting

a If the deflection is abnormal, adjust it according


1. Loosen bolts (1) and (2).

2. Move compressor (3) to adjust the belt tension.

a Check breakage of the pulleys, wear of the

V-grooves and V-belts, and contact of the

belts and V-grooves.

a If a belt is lengthened to the adjustment l imit,

cut, or cracked, replace it with a new belt.

3. Tighten bolts (2) and (1).a If a V-belt is replaced, readjust its tension af-

ter 1 operating hour.



TESTING AND ADJUSTING MEASURING CLEARANCE OF SWING CIRCLE BEARING

MEASURING CLEARANCE OF SWING CIRCLE BEARING

a Measuring instrument for clearance of swing cir-

cle bearing

a When measuring the clearance of the swing cir-

cle bearing on the actual machine, observe the

following procedure.

k While measuring, do not put your hands or foot

under the undercarriage.

1. Fix dial gauge J to outer race (1) or inner race(2) of the swing circle and apply the probe to the

end face of inner race (2) or outer race (1) on

the opposite side.

a Set dial gauge J on the front or at rear side

of the machine.

4. Set the arm at almost right angle to the ground

and lower the boom until the track shoe at the

front end of the machine rises.

a At this time, the front end of the upper struc-

ture rises and the rear end lowers.

5. Under this condition, read dial gauge J.a Dial gauge J indicates the clearance of the

bearing.

6. Return the machine to the position of step 2 andcheck that dial gauge J indicates 0 again.

a If dial gauge J does not indicate 0, repeat

steps 3 – 5


JCommercially

availableDial gauge



2. Set the work equipment in the maximum reach

position and set the bucket tip at the height of

the revolving frame bottom.

a At this time, the front end of the upper struc-

ture lowers and the rear end rises.

steps 3 5.

TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING AND ADJUSTING TRACK SHOE TENSION

Testing

1. Run the engine at low idling and move the

machine forward by the length of track on

ground and stop slowly.

2. Place square bar [1] on the track shoe between

idler (1) and 1st carrier roller (2).a As the square bar [1], use angle iron which

has less deflection.

3. Measure maximum distance “a” between square

bar [1] and track shoe.

• Standard maximum distance “a” : 10 – 30 mm

Adjusting

a If the track shoe tension is abnormal, adjust it

according to the following procedure.

1. When tension is too high

Loosen valve (3) to discharge the grease.

k Since the valve may jump out because of

the high-pressure grease, do not loosen it

more than 1 turn.

2. When tension is low

Add grease through valve (3).

a If the track shoe is not tensed well, drive the

machine forward and in reverse slowly.




TESTING AND ADJUSTING OIL PRESSURE IN WORK

EQUIPMENT, SWING, AND TRAVEL CIRCUITS

TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,SWING, AND TRAVEL CIRCUITS

a Testing and adjusting instruments for oil pres-

sure in work equipment, swing, and travel cir-

cuits

a The oil pressure in work equipment, swing, and

travel circuits can be checked with the monitor-ing function of the monitor panel (For the operat-

ing method, see “Special functions of monitor

panel”).

• Monitoring code: 01100 F Pump Pressure

01101 R Pump Pressure

• The pump oil pressure is displayed in 1 MPa

{1 kg/cm2, 1 PSI).

2) Install nipple K2 and connect it to oil pres-

sure gauge [1] of hydraulic tester K1.

a Use the oil pressure gauges of 58.8 MPa

{600 kg/cm2}.


K



2799-101-5220 Nipple (10 × 1.25 mm)

07002-11023 O-ring



Measuring

1. Preparation work

k Lower the work equipment to the ground and

stop the engine. Operate the control levers sev-

3) Run the engine and raise the hydraulic oil

temperature to the operating range.




2. Combination of pump, actuator, and valve

a When the oil from the pumps is divided, the

front pump and rear pump act independently

on each actuator. Note that different actua-

tors relieve different valves.

a When the work equipment circuit or swing

circuit is relieved singly, the oils of the pumps

are merged. When the travel circuit is re-

lieved singly, the oils of the pumps are divid-ed.

a The actuators in the table are arranged in the

order when the control valve is seen from the

front of the machine (and an attachment is

installed to the service valve).

a If the one-touch power maximizing switch is

released, the valve is relieved at low pres-

sure. If the former is pressed, the lower is re-

lieved at high pressure.

a If the swing lock switch is turned ON, the 2-

stage relief valve is kept turned ON and the

valve is relieved at high pressure. Accord-

ingly, keep the swing lock switch turned

OFF.

5. Measuring swing circuit relief pressure

1) Start the engine and turn the swing lock

switch ON.

2) Run the engine at high idling and relieve the

swing circuit and measure the oil pressure.

a The pressure measured when the swing mo-

tor safety valve is relieved is indicated.

a The swing motor relief pressure is lower thanthe main relief valve.

6. Measuring travel circuit relief pressure

1) Start the engine and lock the travel mecha-

nism.

k Set pin [2] between the sprocket and

track frame to lock the travel mecha-

nism securely.

Pump Actuator Valve relieved

Front

(F unload valve) (F main relief valve)

Service Safety valve for service

Boom Hi

Arm HiF main relief valve

Bucket F main relief valve

Left

travelF main relief valve

BoomRAISE: F main relief valveLOWER: Safety-suction

valve

(Pump merge-divider valve) (Travel junction valve)



3. Measuring unload pressure

1) Start the engine.

2) Run the engine at high idling and set all the


travel circuit and measure the oil pressure.

( p g ) ( j )

Rear

(Self-pressure reducing valve)

Swing Swing motor safety valve

Right

travelR main relief valve

Arm Lo R main relief valve

(R unload valve) (R main relief valve)

(Centralized safety valve) (Back pressure valve)




Adjusting

a The unload valve cannot be adjusted.

1. Adjusting main relief pressure

a If the relief pressure of the work equipment

circuit and/or travel circuit is abnormal, ad-

just main relief valves (3) and (4) according

to the following procedure.• (3): Front main relief valve

• (4): Rear main relief valve

a When adjusting the main relief valve on the

front pump side, remove the control valve

top cover.

a When adjusting the main relief valve on the

rear pump side, remove the control valve un-

dercover (if the covers are installed).

a Adjust only the low relief pressure of themain relief valve. (If the low relief pressure is

adjusted, the high relief pressure is adjusted

automatically.)

a The low relief pressure is the pressure ap-

plied when the 2-stage relief solenoid valve

is turned OFF and the pilot pressure is not

applied to the selector port.

5) Connect pilot hose (5).

6) After finishing adjustment, check again that

the pressure is normal according to the pro-cedure for measurement described above.

2. Adjustment of boom LOWER relief pressure

(High-pressure setting side)

a If the high relief pressure of the boom LOW-

ER circuit is abnormal, adjust the high pres-

sure setting side of boom LOWER safety-

suction valve (8) according to the following

procedure.

a The high relief pressure is the pressure ap-

plied when the machine push-up switch is

turned ON and the pilot pressure is not ap



1) Disconnect pilot hose (5).

2) Fixing holder (6), loosen locknut (7).

3) Turn holder (6) to adjust the pressure.

a If the holder is

turned ON and the pilot pressure is not ap-

plied to the selector port.




5) Connect pilot hose (9).

6) After finishing adjustment, check again that

the pressure is normal according to the pro-

cedure for measurement described above.a If the high pressure setting side is adjust-

ed, the low pressure setting side chang-

es. Accordingly, adjust the low pressure

setting side.

3. Adjustment of boom LOWER relief pressure

(Low-pressure setting side)

a If the low relief pressure of the boom LOW-

ER circuit is abnormal or the high pressure

setting side was adjusted, adjust the low

pressure setting side of boom LOWER safe-

ty-suction valve according to the following

4. Adjusting swing relief pressure

a If the relief pressure of the swing circuit is ab-

normal, adjust swing motor safety valve (14)


1) Fixing adjustment screw (15), loosen lock-

nut (16).

2) Turn adjustment screw (15) to adjust the

pressure.

a If the adjustment screw is

• Turned to the right, pressure rises.

• Turned to the left, pressure lowers.

a Quantity of adjustment per turn of adjust-

ment screw:

4.70 MPa {47.9 kg/cm2}

3) Fixing adjustment screw (15), tighten lock-

nut (16)



ty suction valve according to the following

procedure.

a The low relief pressure is the pressure ap-

plied when the machine push-up switch is

turned OFF and the pilot pressure is applied

to the selector port.1) Disconnect pilot hose (9).

2) Fixing holder (12), loosen locknut (13).

3) Turn holder (12) to adjust the pressure.

a If the holder is

• Turned to the right, pressure rises.• Turned to the left, pressure lowers.

a Quantity of adjustment per turn of holder:

Approx. 25.3 MPa {Approx. 258 kg/cm2}

nut (16).

3 Locknut:

147 – 196 Nm {15 – 20 kgm}

TESTING AND ADJUSTING MEASURING BASIC PRESSURE IN CONTROL CIRCUIT

MEASURING BASIC PRESSURE IN CONTROL CIRCUIT

a Measuring instruments for basic pressure in

control circuit



eral times to release residual pressure in the

piping, then slowly loosen the hydraulic tank oil

filler cap to release the internal pressure.

1. Remove the control valve top cover and remove

control circuit basic pressure pick-up plug (1).

a The figure shows the control valve seen from

inside of the pump room.

3. Run the engine and raise the hydraulic oil tem-

perature to the operating range.

4. Run the engine at high idling and set all the con-

trol levers in neutral and measure the oil pres-

sure.



a The relief valve for the control circuit basic

pressure is not adjustable.


L



2799-101-5220 Nipple (10 × 1.25 mm)

07002-11023 O-ring



2. Install nipple L2 and connect it to oil pressure

gauge [1] of hydraulic tester L1.

a Use the oil pressure gauges of 5.9 MPa {60

kg/cm2}.


TESTING AND ADJUSTING OIL PRESSURE IN PUMP

PC CONTROL CIRCUIT

TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL

CIRCUIT


sure in pump PC control circuit

Measuring

a Before measuring the oil pressure in the pump

PC control circuit, check that the oil pressure inthe work equipment, swing, and travel circuits

and the basic pressure in the control circuit are

normal.






1. Measuring PC valve output pressure (servo

piston inlet pressure)

a Measure the PC valve output pressure (ser-

2) Install nipple M2 and connect it to oil pres-

sure gauge [1] of hydraulic tester M1.


{600 kg/cm2}.

• The figure shows the pump discharge

pressure side.

• The figure shows the PC valve output

pressure side.


M



2799-101-5220 Nipple (10 × 1.25 mm)

07002-11023 O-ring



a Measure the PC valve output pressure (ser-

vo piston inlet pressure) and pump dis-

charge pressure at the same time and

compare them.

1) Open the pump room cover and remove oil

pressure pick-up plugs (1), (2), (3), and (4).• (1): Front pump discharge pressure pick-

up plug

• (2): Rear pump discharge pressure pick-

up plug

• (3): Front PC valve output pressure pick-

up plug

• (4): Rear PC valve output pressure pick-

up plug





PC CONTROL CIRCUIT

4) Run the engine at high idling and measurethe pump discharge pressure and PC valve

output pressure (servo piston inlet pressure)

at the same time under the following condi-

tion.

• Working mode: A

• Swing lock switch: ON

(2-stage relief solenoid valve is turned

ON and oil is relieved at high pressure)• Work equipment, swing, and travel cir-

cuits: Relieve by moving arm IN.

a Judging method:

If the pump discharge pressure and PC

valve output pressure (servo piston out-

put pressure) are as follows, they are

normal.

a If the PC valve or servo piston is abnor-

mal, the PC valve output pressure (servo

piston output pressure) becomes “the

same as the pump discharge pressure”or “almost 0”.

5) After finishing measurement, remove the

measuring instruments and return the

d t

2. Measuring PC-EPC valve output pressure1) Open the pump room cover and remove

PC-EPC valve output pressure pick-up plug

(5).

2) Install nipple M2 and connect it to oil pres-

sure gauge [1] of hydraulic tester M1.


{60 kg/cm2}.

Measured pressure Pressure ratio

Pump discharge

pressure1

PC valve output

pressure

Approx. 0.6

(Approx. 3/5)



removed parts.





PC CONTROL CIRCUIT

4) Set all the control levers in neutral andmeasure the oil pressure while running the

engine at low idling and high idling.

a If the PC-EPC valve output pressure

changes as shown below, it is normal.



removed parts.

Adjusting

aIf any of the following phenomena occurs andthe PC valve seems to be defective, adjust PC

valves (6) and (7) according to the procedure

shown below.

• When the working load is increased, the en-

gine speed is drastically reduced.

• The engine speed is normal but the work

equipment speed is low.

• (6): Front pump PC valve

• (7): Rear pump PC valvea The width across flats of the PC valve lock-

nut is 13 mm, and the adjustment screw (in-

side width) is 4 mm. Do not turn any other

locknuts or adjustment screws since they ef

2. Turn adjustment screw (9) to the right or left toadjust.

a Turn the adjustment screw in the following

directions.

• If the work equipment speed is low, turn

the adjustment screw to the right (to in-

crease the pump absorption torque).

• If the engine speed lowers, turn the ad-

justment screw to the left (to decreasethe pump absorption torque).

a The adjustable range of the adjustment

screw is as follows.

• Counterclockwise: Max. 1 turn

• Clockwise: Max. 1 turn

3. Tighten locknut (8).

3 Locknut:

27.5 – 34.3 Nm {2.8 – 3.5 kgm}

Engine Control lever Oil pressure

Low idling

Neutral

2.94 MPa

{30 kg/cm2}

High idling0 MPa

{0 kg/cm2}



locknuts or adjustment screws since they ef-

fect the hydraulic pumps.

4. After finishing adjustment, check that the PC

valve output pressure (servo piston inlet pres-

sure) is normal according to the procedure for measurement described above.



LS CONTROL CIRCUIT

TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL

CIRCUIT


sure in pump LS control circuit

Measuring

a Before measuring the oil pressure in the pump LScontrol circuit, check that the oil pressure in the

work equipment, swing, and travel circuits and the

basic pressure in the control circuit are normal.






1. Measuring LS valve output pressure (servo

piston inlet pressure)

a Measure the LS valve output pressure (ser-

2) Install nipple N2 and connect it to oil pres-

sure gauge [1] of hydraulic tester N1.


{600 kg/cm2}.


pressure side.

• The figure shows the LS valve output

pressure side.


N



2799-101-5220 Nipple (10 × 1.25 mm)

07002-11023 O-ring

3 799-401-2701 Differential pressure gauge



p p (

vo piston inlet pressure) and pump dis-

charge pressure at the same time and

compare them.


pressure pick-up plugs (1), (2), (3), and (4).• (1): Front pump discharge pressure pick-

up plug


up plug

• (3): Front LS valve output pressure pick-

up plug

• (4): Rear LS valve output pressure pick-

up plug


temperature to the operating range and

push up the track shoe on the side to be


TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS

CONTROL CIRCUIT

4) Run the engine at high idling and measure

the pump discharge pressure and LS valve

output pressure (servo piston inlet pressure)

at the same time under the following condi-tion.

• Working mode: A

• Work equipment, swing, and travel con-

trol levers: Measure with all the levers in

neutral and measure with only the travel

lever operated halfway (with the track

shoe on one side driven idle).

a Check the safety around the machine,

drive the track shoe pushed up idle.a Judging method:

If the pump discharge pressure and LS

valve output pressure (servo piston out-

put pressure) are as follows they are

2. Measuring LS differential pressurea Measure the pump discharge pressure and

LS pressure (actuator load pressure) at the

same time and calculate the difference be-

tween them.


pressure pick-up plugs (1), (2), (5), and (6).

• (1): Front pump discharge pressure pick-up plug


up plug

• (5): Front LS valve output pressure pick-

up plug• (6): Rear LS valve output pressure pick-

up plug



put pressure) are as follows, they are

normal.


Measured

pressure

Pressure ratio

All leversin neutral

Travel lever

operatedhalfway

Pump discharge

pressure Almost

same

1

LS valve output

pressure

Approx. 0.6

(Approx. 3/5)



LS CONTROL CIRCUIT

a When using oil pressure gauge:Use the oil pressure gauge of 58.8 MPa

{600 kg/cm2}.

Since the differential pressure is about

2.9 MPa {30 kg/cm2} at maximum, meas-

ure it by installing the same gauge to the

pick-up plugs alternately.


pressure side.

• The figure shows the LS valve output

pressure side.

4) Run the engine at high idling and measure

the pump discharge pressure and LS pres-

sure (actuator load pressure) at the same

time under the following condition.• Working mode: A

• Travel speed: Hi

• Work equipment, swing, and travel con-

trol levers: Measure with all the levers in

neutral and measure with only the travel

lever operated halfway (with the track

shoe on one side driven idle).

a Check the safety around the machine,

drive the track shoe pushed up idle.a Calculation of LS differential pressure

(When oil pressure gauge is used):

LS differential pressure = Pump dis-

charge pressure LS pressure




temperature to the operating range and

push up the track shoe on the side to be

measured with the work equipment.

charge pressure – LS pressure

a If the LS differential pressure is as fol-

lows, it is normal.

Operation of lever LS differential

pressure

Set all levers in

neutral

Unload pressure

(See standard valuestable)

Operate travel lever

halfway

(Run track shoe idle)

Specified LS differen-

tial pressure

(See standard values

table)


TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS

CONTROL CIRCUIT

3. Measuring LS-EPC valve output pressure1) Open the pump room cover and remove LS-

EPC valve output pressure pick-up plug (7).

2) Install nipple N2 and connect it to oil pres-sure gauge [1] of hydraulic tester N1.


{60 kg/cm2}.

4) Operate the travel speed switch and travellever and measure the oil pressure while

running the engine at high idling.

a If the LS-EPC valve output pressure

changes as shown below, it is normal.

Note: Operate the travel lever to a

degree that the PPC oil pressure

switch is turned ON (Stop before

the machine starts traveling).



removed parts.

Adjusting

a If the LS differential pressure is abnormal, adjust

LS valves (8) and (9) according to the following

procedure.

• (8): Front pump LS valve• (9): Rear pump LS valve

Travel speed Travel lever Oil pressure

Lo Netral2.94 MPa

{30 kg/cm2}

Hi Fine opera-tion (Note)

0 MPa{0 kg/cm2}





1. Fixing adjustment screw (10), loosen locknut

(11)



LS CONTROL CIRCUIT

3. After finishing adjustment, check that the LS

pressure is normal according to the procedure

for measurement described above.



TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE

MEASURING SOLENOID VALVE OUTPUT PRESSURE

a Measuring instruments for solenoid valve output

pressure

a Before measuring the solenoid valve output

pressure, check that the basic pressure in the

control circuit is normal.


stop the engine. Operate the control levers sev-eral times to release residual pressure in the



1. Remove the control valve top cover and discon-

nect outlet hoses (1) – (7) of the solenoid valve

to be removed.

a Since the outlet hoses of the PPC lock sole-

noid valves have quick couplers on the sole-

noid valve side, measure the pressure on the

PPC valve side (on the back side of the op-

erator’s cab).

2. Install adapter P2 and reconnect the hose.

3. Install nipple [1] of hydraulic tester P1 and con-

nect it to hydraulic gauge [2].


kg/cm2}.

a The figure shows the measuring instrumentsconnected to the outlet hose of the 2-stage

relief solenoid valve.

4. Run the engine and raise the engine oil temper-

ature to the operating range.


P



2799-401-3100 Adapter (Size 02)

799-401-3200 Adapter (Size 03)



5. Run the engine at high idling, operate the con-

trol levers and switches to turn the solenoid

No. Solenoid valve to be measured

1 2-stage relief solenoid valve

2 Machine push-up solenoid valve

3 Swing holding brake solenoid valve

4 Travel speed selector solenoid valve

5 Merge-divider solenoid valve

6 Travel junction solenoid valve

7 PPC lock solenoid valve


a If the output pressure is as follows, the sole-noid valve is normal.



Operation table of 2nd-stage relief solenoid valve

Solenoid valve Output pressure

OFF (Deenergized) 0 MPa {0 kg/cm2}

ON (Energized)

Almost same as control

basic pressure


table)

Operating condition Operation

When overheating No. 1 setting is turned ON OFFWhen all of work equipment, swing, and travel signals are turned OFF

When swing lock switch is turned ON

ON

When travel signal is turned ON

When in L-mode

When boom LOWER signal is turned ON

When in A/E-mode When left knob switchis turned ON

When signal other than swing sin-

gle operation signal is turned ONWhen swing single operation sig-

nal is turned ON OFF

When not under above condition



Operation table of machine push-up solenoid valve

Operation table of swing holding brake solenoid valve


Machine push-upswitch

OFF ON

ON OFF


Work equipment,

When all are

turned OFFOFF


Operation table of merge-divider solenoid valve

Operation table of travel junction solenoid valve

Operation table of PPC lock solenoid valve


When in B-mode When service signal is turned ON

ON

When travel signal is

turned ON

When travel operation is performed singly

When work equipment,

switch, and service sig-nals are turned ON

When not in L-mode

When F or R pump pressure is

above 19.6 MPa {200 kg/cm2}


below 14.7 MPa {150 kg/cm2}OFF

When in L-mode


above 16.7 MPa {170 kg/cm2}ON


below 11.8 MPa {120 kg/cm2}OFF

When travel signal is

turned OFF

When swing signal is

turned OFF

When arm IN and

bucket CURL PPC

pressures are above

1.9 MPa {19.5 kg/cm2}


above 24.5 MPa {250 kg/cm2}ON


below 19.6 MPa {200 kg/cm2} OFF

When not under above condition


When travel steering signal is turned ON

ON

When travel steering signal is turned OFF

When travel system is

operated singly


above 34.3 MPa {350 kg/cm2}

When not under above condition OFF

Operating condition



Operating condition

Safety lock lever Lock OFF

Free ON

TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE

MEASURING PPC VALVE OUTPUT PRESSURE

a Measuring instruments for PPC valve output

pressure






1. Remove the control valve top cover and opera-tor’s cab undercover.

2. Disconnect PPC oil pressure switch or PPC

pressure sensors (1) – (10) of the solenoid valve

to be removed.

a If the starting switch is turned ON while the

arm IN or bucket CURL PPC pressure sen-

sor is disconnected, an electrical equipment

system error is detected. Accordingly, if the

pressure sensor is removed, reconnect it to

the connector and clamp it to the nearest

bracket.

3. Install joint Q2 and nipple [1] of hydraulic tester

Q1 and connect them to oil pressure gauge [2].a Use joint Q2 only when measuring the pres-

sure at the pressure sensor mounting part.


kg/cm2}.

a The figure shows the measuring instruments

installed to the mounting part of the arm IN

PPC pressure sensor.


Q1



2 790-301-1740 Joint (PF 1/4 + PT 1/8)



4. Run the engine and raise the engine oil temper-

ature to the operating range.

No.Circuit to be

measuredNo.

Circuit to be

measured

1 Boom RAISE (S06) 7 Swing LEFT (S07)

2 Boom LOWER (S02) 8 Swing RIGHT (S03)

3 Arm IN (S04) 9 Travel (S30)

4 Arm OUT (S08) 10 Steering (S31)

5 Bucket CURL (S01)

6 Bucket DUMP (S05)

TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE

5. Run the engine at high idling and measure theoil pressure while the control lever of the meas-

ured circuit is in neutral and while it is operated

to the stroke end.

a If the PPC valve output pressure is as fol-

lows, the solenoid valve is normal.



Operation of lever Output pressure

In neutral 0 MPa {0 kg/cm2}

Operated to

stroke end

Almost same as control

basic pressure


table)



TESTING AND ADJUSTING ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES

ADJUSTING PLAY OF WORKEQUIPMENT AND SWING PPCVALVES

a If the work equipment and swing levers have

excessive play, adjust them according to the fol-

lowing procedure.

1. Remove the work equipment and swing PPC

valve assembly.

2. Remove bellows (1).

3. Loosen locknut (2) and tighten disc (3) until it

touches the heads of 4 pistons (4).

a Do not move the piston at this time.

4. Fix disc (3) and tighten locknut (2) to the speci-

fied torque.

3 Locknut: 98 – 127 Nm {10 – 13 kgm}

5. Install bellows (1).

6. Install the work equipment and swing PPC valve

assembly.




TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF

WORK EQUIPMENT

TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORKEQUIPMENT

a If the work equipment (cylinder) drifts hydrauli-

cally, check to see if the cause is on the cylinder

packing side or control valve side according to

the following procedure.

1. Testing boom cylinder and bucket cylinder 1) Set the machine in the position of measur-

ing hydraulic drift and stop the engine.

a Fill the bucket with a rated load or with

dirt and sand.

2) When testing the boom cylinder, set the

boom control lever in the RAISE position.

When testing the bucket cylinder, set the

bucket control lever in the CURL position.

2. Testing arm cylinder

1) Stop the arm cylinder about 100 mm before

the IN stroke end and stop the engine.

2) Operate the arm control lever in the IN posi-

tion.

• If the lowering speed is increased at this

time, the cylinder packing is defective.

• If the lowering speed does not change at

this time, the control valve is defective.a Operate the control lever while the start-

ing switch is in the ON position.

a If the pressure in the accumulator is lost,

run the engine for about 10 seconds to

heighten the pressure in the accumula-



• If the lowering speed is increased at this

time, the cylinder packing is defective.

• If the lowering speed does not change at

this time, the control valve is defective.a Operate the control lever while the start-

ing switch is in the ON position.

a If the pressure in the accumulator is lost,

run the engine for about 10 seconds to

heighten the pressure in the accumula-

tor.

tor.

[Reference] Reason why the lowering speed is

increased by the above operationwhen the cylinder packing is the

cause of the hydraulic drift:

1) If the machine is set in the above position

(where the holding pressure is applied to the

bottom side), the oil leaks from the bottom

side to the head side. Since the volume on

the head side is less than that on the bottom

side by the volume of the rod the pressure


TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT

OF WORK EQUIPMENT

3. Testing PPC valveWhile the pressure in the accumulator is high,

set the safety lock lever in the LOCK/FREE

position and measure the lowering distance.

a Operate the control lever while the starting

switch is in the ON position.

a If the pressure in the accumulator is lost, run

the engine for about 10 seconds to heighten

the pressure in the accumulator.

a If there is a difference in the lowering dis-tance between the LOCK position and FREE

position, the PPC valve is defective (it has an

internal defect).



TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT

RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT

1. Releasing residual pressure in hydraulic tank

k Since the hydraulic tank is enclosed and

pressurized, release the residual pressure

in it when removing a hose or a plug con-

nected to it.

1) Lower the work equipment to the ground in

a stable position and stop the engine.2) Loosen oil filler cap (1) of the hydraulic tank

gradually to release the air in the tank.

2. Releasing residual pressure in hydraulic cyl-inder circuit

k When disconnecting a pipe between a hy-

draulic cylinder and the control valve, re-

lease the residual pressure in the piping

according to the following procedure

3. Releasing residual pressure in swing motor

circuit

a The residual pressure in the swing motor cir-

cuit can be released by performing the oper-

a t i on f o r RELEASING RESIDUAL

PRESSURE IN HYDRAULIC CYLINDER

CIRCUIT. (Operate the control lever in theswing direction only.)

4. Releasing residual pressure in travel motor

circuit

a Since the control valve spool of the travel mo-

tor circuit is open, the pressure in this circuit

can be released by performing RELEASING

RESIDUAL PRESSURE IN HYDRAULICTANK.




1) Release the residual pressure in the hydrau-

lic tank. For details, see RELEASING

RESIDUAL PRESSURE IN HYDRAULICTANK.

a Keep the oil filler cap of the hydraulic

tank removed.

2) Turn the starting switch ON and set the

safety lock lever in the FREE position, then

operate the work equipment control levers

on both sides forward, backward, to the

right, and to the left.

TESTING AND ADJUSTING MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE

a Measuring device for oil leakage

1. Measuring oil leakage from boom cylinder 1) Run the engine and raise the engine oil tem-


2) Move the boom cylinder to the RAISE stroke

end and stop the engine.

k Release the residual pressure in the

piping on the boom cylinder head side.

For details, see RELEASING RESIDU-

AL PRESSURE IN HYDRAULIC CIR-CUIT. (Operate the control lever in the

boom RAISE direction only.)

3) Disconnect hose (1) on the cylinder head

side and block the hose side with a plate.

k Take care not to disconnect the hose on

the cylinder bottom side.

a Use the following part to block the hose

side.

07379-01044 (Flange #10)

2. Measuring oil leakage from arm cylinder

1) Run the engine and raise the engine oil tem-


2) Move the arm cylinder to the IN stroke end

and stop the engine.


piping on the arm cylinder head side.For details, see RELEASING RESIDU-

AL PRESSURE IN HYDRAULIC CIR-

CUIT. (Operate the control lever in the

arm IN direction only.)




the cylinder bottom side.a Use the following part to block the hose

side.

07379-01044 (Flange #10)


RCommercially

availableMeasuring cylinder




boom circuit by raising the boom.


arm circuit by moving the arm IN.

k Take care not to “move the arm OUT”.

5) Measure the oil leakage for 1 minute after

30 seconds since relieving is started.

6) After finishing measurement, return the

removed parts.


3. Measuring oil leakage from bucket cylinder 1) Run the engine and raise the engine oil tem-


2) Move the bucket cylinder to the CURL

stroke end and stop the engine.


piping on the bucket cylinder head side.

For details, see RELEASING RESIDU-

AL PRESSURE IN HYDRAULIC CIR-CUIT. (Operate the control lever in the

arm CURL direction only.)




the cylinder bottom side.


side.

07379-01044 (Flange #10)

4. Measuring oil leakage from swing motor 1) Run the engine and raise the engine oil tem-


2) Disconnect drain hose (4) and block the

hose side with a plug.


side.

07376-70522 (Plug #05)

3) Turn the swing lock switch ON.


swing circuit by swinging.

a Measure the oil leakage for 1 minute af-

ter 30 seconds since relieving is started.a After measuring 1 time, swing 180°, and

then measure again.


removed parts.




bucket circuit by curling the bucket.

k Take care not to “dump the bucket”.

5) Measure the oil leakage for 1 minute after

30 seconds since relieving is started.


removed parts.


5. Measuring oil leakage from travel motor 1) Remove the travel motor cover.

2) Run the engine and raise the engine oil tem-

perature to the operating range, and then

lock the travel system and stop the engine.

k Put pin [1] between the sprocket and

track frame to lock the travel system se-

curely.

3) Disconnect drain hose (5) of the travel

motor and block the hose side with a plug.


side.07376-70522 (Plug #05)




TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART

BLEEDING AIR FROM EACH PART

Air bleeding procedure

1 2 3 4 5 6

Bleeding

air from

hydraulic

pump

Starting

engine

Bleeding

air from

cylinder

Bleeding

air from

swing

motor

Bleeding

air from

travel

motor

Check oil

level and

starting

work

• Replacing hydraulic oil

• Cleaning strainer q q q

q

(See note)

q

(See note) q

• Replacing return filter element q q

• Replacing and repairing hydrau-

lic pump

• Removing suction piping

q q q q

• Replacing and repairing control

valve

• Removing control valve piping

q q q

• Replacing and repairing cylinder

• Removing cylinder piping q q q

• Replacing and repairing swing

motor

• Removing swing motor piping

q q q

• Replacing and repairing travel

motor • Removing travel motor piping

q q q

• Replacing and repairing swivel

joint

• Removing swivel joint piping

q q

Work

Air bleeding item



Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.

1. Bleeding air from hydraulic pump

1) Loosen bleeder (1) and check that oil flowsout.

2) If the oil does not flow out, disconnect drain

hose (2) and fill the pump case with oil

through the drain port.

a Fix the drain hose adapter to a place

higher than the oil level in the hydraulic

tank.

a Fill the pump case with oil until oil con


3. Bleeding air from cylinder a If a cylinder was replaced, bleed air from it

before connecting the work equipment. In

particular, the boom cylinder does not move

to the lowering stroke end, if it is installed to

the work equipment.

1) Run the engine at low idling for about 5 min-

utes.

2) Running the engine at low idling, raise and

lower the boom 4 – 5 times.a Stop the piston rod about 100 mm before

each stroke end. Do not relieve the oil.

3) Running the engine at high idling, perform

step 2).

4) Running the engine at low idling, move the

piston rod to the stroke end and relieve the

oil.

5) Bleed air from the arm cylinder and bucket

cylinder according to steps 2) – 4).

4. Bleeding air from swing motor

1) Run the engine at low idling.

2) Loosen hose (3) of port S slowly and check

that oil flows out.

k At this t ime, do not perform the swing-

ing operation.

3) If the oil does not flow out, stop the engineand disconnect the hose of port S and fill the

pump case with oil.

a After filling the pump case with oil, con-

nect the hose of port S, and then repeat

steps 1) and 2).

5. Bleeding air from travel motor 1) Remove the travel motor cover.

2) Run the engine at low idling.

3) Loosen bleeder (4) and check that oil flows

out.

4) After oil containing no bubbles flows out,

tighten bleeder (4).

3 Bleeder:

9.8 – 12.74 Nm {1.0 – 1.3 kgm}

5) Using the work equipment, raise the track

shoe on either side.

6) Drive the raised track shoe idle slowly for

about 2 minutes.a Drive the track shoe on the opposite side

idle similarly.



4) After oil containing no bubbles flows out,

tighten the hose of port S.

5) Slowly swing 2 turns or more in each direc-

tion.


6. Check oil level and starting work1) Run the engine, retract the arm cylinder and

bucket cylinder to the stroke ends, lower the

work equipment to the ground, and stop the

engine.

2) Check the oil level by sight gauge (5) of the

hydraulic tank.

a If the oil level is between lines H and L,

it is normal.

a If the oil level is below line L, add new oil.



TESTING AND ADJUSTING TESTING PROCEDURE OF DIODE

TESTING PROCEDURE OF DIODEa Test an assembled-type diode or a diode unit


a The conductive direction of an assembled-type

diode is marked as shown in the figure.

a The conductive direction of each diode is

marked on its surface.

2. When using an analog tester

1) Set the tester in the resistance range.2) Apply the test pins as shown and check

movement of the pointer.

i) Apply the red (+) test pin to the anode

(P) side of the diode and the black (–)

test pin to the cathode (N) side.

ii) Apply the red (+) test pin to the cathode

(N) side of the diode and the black (–)

test pin to the anode (P) side.

3) Judge the condition of the diode from move-ment of the pointer.

• The pointer does not move in step i)

above but moves in step ii): Normal

(Moving angle (resistance) depends on

the type and measurement range of the

tester)



1. When using a digital tester

1) Set the tester in the diode range and check

the indicated value.

a If an ordinary tester is used, the voltage

of the battery in itself is indicated.

2) Apply the red (+) test pin to the anode (P)

side of the diode and the black (–) test pin to

the cathode (N) side and read the indicated

tester)

• The pointer moves in both step i) and

step ii): Defective (Internal short circuit)

• The pointer does not move in either step

i) or step ii): Defective (Internal discon-

nection)

TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL

SPECIAL FUNCTIONS OF MONITOR PANEL




Ordinary functions and special functions of monitor panelThe monitor panel has the ordinary functions and special functions and displays various pieces of information

on the multi-display unit.

Some items are displayed automatically according to the internal setting of the monitor panel and the others are

displayed by operating switches.

1. Ordinary functions: Operator menu

The items in this menu are displayed normally. The operator can display and set them by operating

switches.

2. Special functions: Service menu

The items in this menu are not displayed normally. Each serviceman can display them by operating specialswitches.

Operator’s Menu Service Menu

1 Function of inputting and setting password 16 Function of monitoring [01]

2 Screen to display KOMATSU logo

17

Function of

abnormality

record [02]

Electrical system

3 Function of check before starting Mechanical system

4 Function of displaying maintenance items 18 Function of maintenance record [03]

5 Function of displaying caution items 19 Function of maintenance mode change [04]

6Function of checking working mode and

travel speed20 Function of phone No. entry [05]

7 Function of displaying ordinary screen

21Function ofinitial setting

and default [06]

Mode in which key is ON

8Function of adjusting brightness and contrast

of display

Language

9Function of adjusting flow rate for breaker

and attachmentsUnit

10Function of checking maintenance informa-

tionWith/Without service circuit

11 Function of displaying service meter Pump absorption torque



22Function of

adjustment [07]12 Function of checking display LCD

Adjustment of flow for

attachment during com-

pound operation

13 Function of displaying cautions 23Function of cylinder cut out mode operation

[09]

14 Function of displaying user code

15Function of displaying error code and failure

code


Operation and display of Operator’sMenu (Outline)a Only outline of the operating method is

described in this section. For details of contents

and operation of each menu, see OPERATION

MANUAL or the volume of STRUCTURE AND

FUNCTION.

1. Function of inputting and setting password

When the starting switch is turned ON, the

screen to input a password is displayed.

a This screen is displayed only when the pass-

word function is set.

2. Screen to display KOMATSU logo

When a password is input (if it is set) or when

the starting switch is turned ON, the KOMATSU

logo is displayed for 2 seconds.

3. Function of check before starting

Aft er the KOMATSU logo is di sp layed, the

screen for check before starting is displayed for

2 seconds.



4 F ti f di l i i t it


5. Function of displaying caution items After the screen for check before starting is dis-

played, if any check item is abnormal, the corre-

sponding symbol mark is displayed.

6. Function of checking working mode and trav-

el speed

After the screen for check before starting is dis-

played, the symbol marks of the working modeand travel speed are displayed in large size for 2

seconds to urge the operator to check the set-

ting.

7. Function of displaying ordinary screen

After the screen for checking the working mode

and travel speed is displayed, the ordinary

screen is displayed.

a When the ordinary screen is displayed if the



a When the ordinary screen is displayed, if the

working mode or travel speed is changed or

if the auto deceleration or windshield wiper isset effective, the corresponding symbol mark

is displayed in large size for 2 seconds.

a The preheating monitor is displayed only

when the preheater is turned ON.

8. Function of adjusting brightness and con-


9. Function of adjusting flow rate for breaker and attachments

(for machine with breaker or attachment)

The operator can adjust the pump flow rate for

the breaker or an attachment with the selector

switch.

a The symbol marks and description of the

breaker and attachment shown on the

screen are partly different.

10. Function of checking maintenance informa-

tion

The operator can check the detailed information

about the maintenance items (set time andelapsed time) and reset them after checking

with the maintenance switches.

a The maintenance function is set and reset

and the maintenance time is set with the

service menu.

11. Function of displaying service meter

When the starting switch is turned OFF, the

operator can display only the service meter by

operating the following switches.

• Operation of switches: [ ] + [ ] (Operate



p [ ] [ ] ( p

these switches simultaneously)

12 Function of checking display LCD


13. Function of displaying cautionsIf there is any abnormal item in the calculation

items, the corresponding symbol mark is dis-

played in large size for 2 seconds, then it is dis-

played in small size until the abnormal item is

repaired.

14. Function of displaying user code

If the machine has any failure, the correspond-

ing user code is displayed to urge the operator

to take a proper remedy, depending on the

degree of the failure.a If any switch is operated while the user code

is displayed, the service code and failure

code screen appears (See 15).

a User codes and instructions given to operator

User

codeFailure mode Instructions given to operator

E02 Error in pump control system

If the emergency pump drive switch is set in the upper (emergency) position,

the machine can operate normally Have the machine inspected immediately



E02 Error in pump control system the machine can operate normally. Have the machine inspected immediately,

however.

E03 Error in swing brake system

Set the swing holding brake release switch in the upper (release) position torelease the brake. Apply the swing brake manually with the swing lock

switch, if necessary. The brake may not be released, depending on the

cause of the failure. In any case, have the machine inspected immediately.

E10

Error in engine controller power

supply or abnormality in engine

controller drive system circuit

(Engine stops)

Have the machine inspected immediately.


15. Function of displaying error code and failurecode

While a user code is displayed, if the following

switches are operated, the phone mark (if regis-

tered), phone No. (if registered), error code, and

failure code are displayed in order.

• Operation of switch: [ ]

a The following are displayed in order repeat-

edly as the switch is operated.

(1) Phone mark

(2) Phone No.

(3) Error code and failure code

a The phone mark and phone No. are dis-

played only when the phone No. is regis-

tered in the monitor panel. The phone No. is

registered, changed, or deleted with theservice menu.

a For details of the displayed error code and

failure code, see the error codes and failure

codes table.




Table for Error and Failure Code Nos.

U s e r

c o d e Error code Failure code

H i s t o r y

d i v i s i o n

Code Contents Code Component Trouble

— E112 Wiper Drive (For) S/C DY2DKB Wiper motor (Forward) Short Circuit

E l e c t r i c a l s y s t e m

— E113 Wiper Drive (Rev) S/C DYDEKB Wiper Motor (Reverse) Short Circuit

— E114 Washer Drive S/C DY2CKBWindshield Washer

Motor Short Circuit

— E115 Wiper Working Abnormality DY20KA Wiper Motor Disconnection

— E116 Wiper Parking Abnormality DY20MA Wiper Motor Malfunction

— E117 Eng. Controller S-NET Comm Err. DAC0KR Engine Controller

Defective communica-

tion (Abnormality in

related component)

— E118 Pump Controller S-NET Comm Err. DAB0KR Pump Controller

Defective communica-

tion (Abnormality in

related component)

E0E E128 Monitor Comm. Abnormality DAFRMC Monitor CAN Communi-cation

Defective Operation

— E201 Travel Junction Sol. S/C DW91KBTravel Neutral Solenoid

ValveShort Circuit

E03 E203 Swing Brake Sol. S/C DW45KBSwing Holding Brake

Solenoid ValveShort Circuit

— E204 Merge-divider Sol. S/C DWJ0KBPump Merge-divider

Solenoid ValveShort Circuit

— E205 2-stage Relief Sol. S/C DWK0KB2-stage Relief Solenoid

Valve Short Circuit

— E206 Travel Speed Sol. S/C DW43KBTravel Speed Hi/Lo

Selector Solenoid ValveShort Circuit

— E211 Travel Junction Sol. Disc. DW91KATravel Neutral Solenoid

ValveDisconnection

E03 E213 Swing Brake Sol. Disc. DW45KASwing Holding Brake

Solenoid ValveDisconnection



ESolenoid Valve

— E214 Merge-divider Sol. Disc. DWJ0KA

Pump Merge-divider

Solenoid Valve Disconnection

— E215 2-stage Relief Sol. Disc. DWK0KA2-stage Relief Solenoid

ValveDisconnection

— E216 Travel Speed Sol. Disc. DW43KATravel Speed Hi/Lo

Selector Solenoid ValveDisconnection

— E217 Model Selection Abnormality DA2SKQ

Pump Controller Model

Selection Wiring Har-

ness

Disagreement of Model

Selection Signals


E02 E233 PC-EPC Sol. Disc. DXA0KA TVC Solenoid Valve Disconnection

l e c t r i c a l s y s t e m

— E238 Service Return Relay Disc. D196KA ATT Selector Relay Disconnection

— E245 Service Current EPC S/C DXE4KB ATT Flow Throttle EPC

ValveShort Circuit

— E246 Service Current EPC Disc. DXE4KA ATT Flow Throttle EPC

ValveDisconnection

— E247 Arm Curl PPC Sen. Abnormality DHS3MA Arm IN PPC Pressure

Sensor Malfunction

— E248 Bucket Curl PPC Sen. Abnormality DHS4MABucket CURL PPC

Pressure Sensor Malfunction

— E251 Overload Sensor Abnormality DHX1MA Malfunction

E0E E257 Pump Comm. Abnormality DA2RMCPump Controller CAN

CommunicationDefective Operation

— E315 Battery Relay Drive S/C D110KB Battery Relay Short Circuit

E11 E91B Engine Ne Sensor Problem DLE3LC NE Speed Sensor Disagreement of Speed

Signal

E11 E91C Engine G Sensor Problem DLH1LC G Speed Sensor Disagreement of Speed

Signal

E11 E920 Engine Type Selection Error DB29KQ

Engine Controller Model

Selection Wiring Har-

ness

Disagreement of Model

Selection Signals

E11 E921 Engine Type Mismatch DB20KQ Engine Controller Disagreement of Model

Selection SignalsE14 E931 Fuel Dial sys. error DK10KX Throttle Angle Sensor Out of input signal range

E15 E934 Engine Coolant Sensor Hi Error DGE2KXEngine Coolant Temper-

ature Sensor Out of input signal range

E15 E936 Engine Oil Press. Sw. Error DDE2L6Engine Oil Pressure

Switch

Disagreement of signal

with operation of engine

E11 E93C Engine Boost Sensor Error DH30KX Boost Pressure Sensor Out of input signal range

U s e r


H i s t o r y

d i v i s i o n




E

E15 E93D Engine Fuel Temp. Sensor Error DGE4KXFuel Temperature Sen-

sor

Out of input signal range

E0E E953 Engine Comm. Abnormality DB2RMCEngine Controller CAN

CommunicationDefective Operation

— E954 Short Engine Starter SW. DD11KB Starter SW Short Circuit

E0E E955 Engine S-NET error DB2SMCEngine Controller S-

NET CommunicationDefective Operation

E10 E956 Engine Power Failure (1) DB22KKEngine Controller Load

Power Supply Line

Lowering of source volt-

age (Input)


a Th it i thi t bl d i th d f th d

E11 E979 Rail Press. High 1 AD00L2 Common Rail Abnormally High Fuel

Pressure

E l e c t r i c a l s y s t e m

E11 E97A Rail Press. High 2 AD00MA Common Rail Malfunction

E15 E97B Rail press. low AD10L3 Supply Pump Out of control

E11 E97C Rail press. too low AD10MB Supply Pump Lowering of Function

E11 E97D Rail Press. Out of Control AD10MA Supply Pump MalfunctionE11 E980 Eng. Controller Abnormality DB20KT Engine Controller Abnormality in Controller

E11 E981 Fuel Injector 1 Disc. ADA1KA Injector 1 Solenoid Valve Disconnection

E11 E982 Fuel Injector 2 Disc. ADB1KA Injector 2 Solenoid Valve Disconnection

E11 E983 Fuel Injector 3 Disc. ADC1KA Injector 3 Solenoid Valve Disconnection

E11 E984 Fuel Injector 4 Disc. ADD1KA Injector 4 Solenoid Valve Disconnection

E11 E985 Fuel Injector 5 Disc. ADE1KA Injector 5 Solenoid Valve Disconnection

E11 E986 Fuel Injector 6 Disc. ADF1KA Injector 6 Solenoid Valve Disconnection

E11 E98A Fuel Injector 1 – 3 S/C ADAZKBInjector 1, 2, 3 Solenoid

ValveShort Circuit

E11 E98B Fuel Injector 4 – 6 S/C ADDZKBInjector 4, 5, 6 Solenoid

ValveShort Circuit

E22 E922 Eng. Hi Out of Std A000N1 Engine Overrun

M e c h a n i c a l

s y s t e m

— Eng. Lo Out of Std A000N2 Engine Out of input signal range

— Aircleaner Clogging AA10NX Air Cleaner Element Clogging

— Charge Voltage Low AB00KE Alternator Defective Charge

— Eng. Oil Press. Low B@BAZG Engine Oil Lowering of Oil Pressure

— Eng. Oil LvI. Low B@BAZK Engine Oil Lowering of level

— Eng. Coolant Overheat B@BCNS Coolant Overheating

— Eng. Coolant Lvl Low B@BCZK Coolant Lowering of level

— Hydr. Oil Overheat B@HANS Hydraulic Oil Overheating

U s e r


H i s t o r y

d i v i s i o n




a The items in this table are arranged in the order of the error codes.

aThe error codes having no numbers in the user code column and the failure codes having no numbers inthe user code column and error code column are not displayed on the normal screen, even if abnormality

related to them occurs. They are simply recorded in the failure history of the service menu (Electrical equip-

ment system or mechanical equipment system).

a The history division column shows in which division each failure is classified, the electrical equipment sys-

tem or mechanical equipment system, when it is recorded in the failure history.

a Letter “E” at the head of each error code indicates the following condition.

• With E: The failure has not been repaired yet.

• Without E: The failure has been repaired


Operation and display of Service MenuHow to select service menu

a When using the service menu, perform the fol-

lowing special operation to change the screen.

1) Checking display

Check that the ordinary screen is displayed.

a The service menu can be selected only while

the ordinary screen is displayed.

2) Operating switches

Operate the following switches.

• Operation of switches: [ ] o [1] o [2] o [3]

(While pressing [ ], press the numeralkeys)

3) Displaying menu screen

The initial screen of the service menu is dis-

played. Select a menu which you will use.

No. Service menu

00 Return (Finish service menu)

01 Monitoring

02 Abnormality record

03 Maintenance record

04 Maintenance mode change

05 Phone number entry

06 Initial setting/Default

07 Adjust



4) Finishing menu and function

To finish the service menu screen or each menu

screen, perform one of the following operations.

(1) Press the [ ] switch (This operation is

effective on all screens).

(2) When the “Return” switch is displayed, press

it

j

09 Cylinder cut out mode operation


16. Function of monitoring [01]

The monitor panel monitors the signals from various

switches, sensors, and actuators installed to various

parts of the machine. The operator can display and

check the monitoring information in real time by the

following operation.

1) Selecting menu

On the initial screen of the service menu, select

“01 Monitoring” and press the [ ] switch.

2) Setting monitoring items

Select and register monitoring items with the fol-

lowing switches.

• [ ] switch: Select• [ ] switch: Select

• [ ] switch: Register

a You can set up to 4 monitoring items (You

cannot set up to 4 monitoring items, howev-

er, depending on the selected items).

a When monitoring up to 3 items, go to the

monitoring information screen by either of

the following operations after registering

those items.• Hold the [ ] switch (for about 3 sec-

onds).

• Select menu “99999” and press the [ ]

switch.

a If all of the settable items are registered, the

monitoring information screen appears auto-

matically after registering those items.



y g g

a For the detail, display units, etc. of the moni-

toring items, see the monitoring items table.

3) Operating for monitoring


4) Function of holding monitoring information

If the [ ] switch is pressed during the monitor-

ing operation, all the monitoring information is

held. If the [ ] switch is pressed while the mon-

itoring information is held, the monitoring infor-

mation is released.

5) Function of selecting machine setting mode

To change settings of the working mode, travel

speed, or auto deceleration during the monitor-

ing operation, press the switches for thoseitems, and the mode checking screen appears.

a After checking the settings, press the [ ]

switch, and the monitoring screen appears

again.

a If the settings are changed during the moni-

toring operation, the new settings are held

even after monitoring is finished and the

service menu disappears and the operator

menu appears again.




Monitoring items list

Code

No.Monitoring item

Unit (Default: ISO)Remarks

SI meter inch

00000 Return (Not displayed) Finish Menu

99999 To Display Screen (Not displayed) Display and Execution Menu

00200 Controller Model Select Numerals

00201 Controller Model Select Numerals

01002 Engine Speed r/min rpm rpm

01601 2nd Eng. Speed Command r/min rpm rpm

01100 F Pump Pressure MPa kg/cm2 psi

01101 R Pump Pressure MPa kg/cm2 psi

07200 Arm Curl PPC Pressure MPa kg/cm2 psi

07300 Bucket Curl PPC Pressure MPa kg/cm2 psi

04102 Engine Coolant Temp. Hi °C °C °F

14200 Fuel Temperature °C °C °F

04401 Hydr. Oil Temperature °C °C °F

01300 PC-EPC Sol. Curr. mA mA mA

01500 LS-EPC Sol. Curr. mA mA mA

01700 Service Sol. Curr. mA mA mA

03200 Battery Voltage V V V

03500 Battery Relay O/P Vol. V V V

04300 Battery Charge Vol. V V V





04107 Engine Coolant Temp. Low °C °C °F

36400 Rail Pressure MPa kg/cm2 psi

36500 Boost Pressure kPa kg/cm2 psi

36700 Torque Ratio % % %

03000 Fuel Dial Vol. V V V

04200 Fuel Level Sensor Vol. V V V


01900 Pressure Switch 1

Swing ON/OFF

Travel ON/OFF

Boom Lower ON/OFF

Boom Raise ON/OFF

Arm Curl ON/OFF Arm Dump ON/OFF

01901 Pressure Switch 2

Bucket Curl ON/OFF

Bucket Dump ON/OFF

Service ON/OFF

Travel Steering ON/OFF

02300 Solenoid 1

Travel Junction ON/OFF

Swing Brake ON/OFF

Merge-divider ON/OFF

2-stage Relief ON/OFF

Travel Speed ON/OFF

02301 Solenoid 2 Service Return ON/OFF

02200 Switch Input 1

Lever Sw. ON/OFF

Swing Release Sw. ON/OFF

Swing Brake Sw. ON/OFF

02201 Switch Input 2

Model Select 1 ON/OFF




CodeNo.

Monitoring item Unit (Default: ISO) RemarksSI meter inch





02202 Switch Input 3 Key Switch (ACC) ON/OFF

03700 Controller Output 1 Batt. Relay Dr. ON/OFF

04500 Monitor Input 1

Key Switch ON/OFF

Start ON/OFF

Preheat ON/OFF


a As the unit of display, one of “SI unit system”, “Metric unit system”, and “Inch unit system” can be selected.

The unit of display can be changed with “Selecting unit” in the “Setting initial values” function of the service

menu.

a “CA” of the unit of display denotes the crankshaft angle.

17400Eng. Controller

Input

Key SW (C) ON/OFF

Eng. Oil Press. Lo ON/OFF

Eng. Oil Press. Hi ON/OFF

Machine Sel. 1 ON/OFF

Machine Sel. 2 ON/OFFMachine Sel. 3 ON/OFF

36800 Q Adjust Switch R (ROT-SW1) Alphanumerals

36801 Q Adjust Switch L (ROT-SW2) Alphanumerals

05100 S-NET ConnectionPump Controller ON/OFF

Eng. Controller ON/OFF

20200 Monitor Prog. Version Numerals

20212 Pump Con. Prog. Version Numerals

20209 Eng. Con. Prog. Version Numerals

CodeNo.

Monitoring item Unit (Default: ISO) RemarksSI meter inch




17. Function of abnormality record [02]

The monitor panel classifies and records the

past failures into the electrical system group and

mechanical system group. The operator can

display and check those failures by the following

operation.

1) Selecting menu

On the initial screen of the service menu,

select “02 Abnormality Record” and pressthe [ ] switch.

2) Selecting sub-menu

On the abnormality record menu screen,

select a sub-menu and press the [ }

switch.

3) Contents of electrical system abnormality

record screen

[1]: Reverse sequential order/Total number

of records

[2]: Error code

[3]: Failure code (Component: 4 characters,

Trouble: 2 characters)

No. Sub-menu of abnormality record

00 Return (Finish sub-menu)

01 Electrical systems

02 Mechanical systems



Trouble: 2 characters)

[4]: Advance of service meter after 1stoccurrence

[5]: Contents of failure

a See “Error codes and failure codes ta-

ble” in the operator menu.

4) Contents of mechanical system abnormality


5) Resetting electrical system abnormality recorda Only the abnormality record of the elec-

trical system can be reset (deleted). The

abnormality record of the mechanical

system cannot be reset.

a If necessary, reset each item or all items

of the abnormality record of the electrical

system according to the following proce-

dure.

i) While the electrical system abnormality

record screen is displayed, operate the

following switches to display the reset

screen.

• Operation of switches: [ ] + [1]

[2] [3]

a This operation is the same as that

for selecting the service menu.

ii) Operate the switches according to thedirection shown on the reset screen.

a When resetting only 1 item, be sure

display it with the [ ] switch or [ ]

switch, and then perform the reset

procedure.

a When resetting all the items, you

can perform the reset procedure, re-

gardless of the item displayed on the

screen.




18. Function of maintenance record [03]

The monitor panel records the maintenance

information about the filters and oils. The opera-

tor can display and check that information by the

following operation.

1) Selecting menu


select “03 Maintenance Record” and press

the [ ] switch.

2) Displayed information

(1) Names of oils and filters

(2) Number of replacement times up to now

(3) Service meter reading at previousreplacement




19. Function of maintenance mode change [04]

The condition for setting the operation of the

maintenance display function can be changed


• Set the function effective or ineffective.

• Change the set replacement interval.

1) Selecting menu


select “04 Maintenance Mode Change” andpress the [ ] switch.

2) Selecting item to be changed

On the screen of maintenance mode chang-

ing menu, select an item to be changed.

No. Item of maintenance mode change

00 Return

01 Use/Disuse maintenance mode

02 Replacement interval of engine oil

03 Replacement interval of engine oil filter

04 Replacement interval of fuel filter

05 Replacement interval of hydraulic oil filter

06 Replacement interval of hydraulic tankbreather

07Replacement interval of corrosion resistor

(if equipped)

08 Check and refill interval of damper case oil

09 Replacement interval of final drive case oil

10 Replacement interval of machinery case oil

11 Replacement interval of hydraulic oil



a Menus “01” and “12” are used to set the

whole maintenance mode and menus

“02” – “11” are used to set the items one

by one.

3) Contents of setting of “maintenance mode

O /Off”

12 Return all items to initial values


4) Contents of setting of each item

(1) Default: Maintenance time set in monitor.(Value recommended by manufacturer.Constant value.)

(2) Set value: Maintenance time which oper-ation can set freely. Monitor panel oper-a tes acco rd ing t o t h i s va lue i nmaintenance mode. (This value can be

changed by 50 hours with [ ] and [ ]

switches.)(3) Off: Function of displaying this mainte-

nance item becomes ineffective.(4) On: Function of displaying this mainte-

nance item becomes effective.

a The lower limit of the set time is 50 h.

5) Contents of setting “Return all items to initial

values”

If this menu is selected and the [ ] switchis pressed, all the information items are

changed to the initial values.




20. Function of phone number entry [05]

The operator can input a phone No. and change

it according to the following procedure. Once

the phone No. is input, it and service code are

displayed alternately when the user code is dis-

played.

a If a phone No. is not input, the phone No.

screen is not displayed.

1) Selecting menuOn the initial screen of the service menu,

select “05 Phone Number Entry” and press

the [ ] switch.

2) Selecting input screen

Select “Entry” to display the phone No. input

screen.

a Even if a phone No. has been registered,

if the phone No. input screen is dis-played, the registered phone No. is

cleared.

3) Inputting and setting phone No.

On the phone No. input screen, input a

phone No. according to the following proce-

dure (The phone No. is input from the cursor

at the left end automatically).

i) Input a No. with the numeral keys from

the cursor at the left end.



ii) After finishing inputting the No., press the

[ ] switch.

a Up to 12 digits can be input. You do not

need to input a digit to an unnecessary

place, however.

a If you input a wrong No., press the [B]

switch, and the cursor returns 1 place by

1


21. Function of initial setting and default [06]

The operator can change the following items

related to the monitor panel and machine, if nec-

essary.

• Working mode when starting switch is turned

ON

• Language displayed on service menu

• Unit displayed in monitoring function mode

• With/Without attachment

1) Selecting menu


select “06 Function of initial setting and

default” and press the [ ] switch.

2) Selecting sub-menu

Select a sub-menu to change its setting and

press the [ ] switch.

3) Function of selecting mode when key is ON

When the starting switch is turned ON, a

working mode is displayed on the monitor

panel. The operator can change this work-

ing mode.

• A-mode, E-mode, L-mode, B-mode: If

any of these modes are set, the machine

is started in the selected mode when the

No. Sub-menu of initial value/default

00 Return (Finish initial value/default)

01 Key-on mode

02 Language

03 Unit

04 With/Without service circuit



is started in the selected mode when the

starting switch is turned ON.

• Mode when key was turned off last: If

this mode is set, the machine is started

in the mode used last when the starting

switch is turned ON.

• Initial value: If this mode is set, the ma-

chine is started in the default mode set in

the factory when the starting switch is


4) Function of setting language

The operator can select Japanese or English as the language displayed on the

service menu.

a The default language of the monitor pan-

el is English.

a When using a spare monitor panel in the

Japanese language area, select Japa-

nese with this function.

5) Function of selecting unit

The operator can select 1 of the 3 unit sys-

tems as the unit system used for the data

displayed by the monitoring function of the

service menu.

a The default unit system of the monitor

panel is the SI unit system.

6) Function of selecting “with/without service

circuit”

The operator can set “with/without service

circuit”.

• With service circuit: When attachment is

installed

• Without service circuit: When attach-



ment is not installed.a When an service circuit is installed, if

“With service circuit” is not set on this

screen, the operator cannot use the se-

lect function (adjustment of oil flow for

the attachment) in the operator mode.


22. Function of adjustment [07]

The operator can adjust various items of themachine on the monitor panel.

1) Selecting menu


select “07 Adjustment” and press the [ ]

switch.

2) Selecting sub-menuSelect a sub-menu to change its setting and

press the [ ] switch.

3) Function of pump absorption torque

The operator can adjust the pump absorp-

tion torque within the ranges shown in the

following table.

No. Sub-menu of adjustment

00 Return (Finish adjustment)

01 Pump absorption torque

02 Adjustment of oil flow for attachment in

compound operation

Adjustment

value

Adjustment

torque

Adjustment

value

Adjustment

torque



4) Function of adjustment of oil flow for attach-

220 +8.0 kgm 225 –2.0 kgm221 +6.0 kgm 226 –4.0 kgm

222 +4.0 kgm 227 –6.0 kgm

223 +2.0 kgm 228 –8.0 kgm

224 0.0 kgm


23. Function of cylinder cut out mode operation

[09]The operator can operate the machine in the

cylinder cut out mode with the monitor panel.

Cylinder cut out mode operation means to run

the engine with 1 or more fuel injectors disabled

electrically to reduce the number of effective cyl-

inders. This operation is used to find out a cylin-

der which does not output power normally (or,

combustion in it is abnormal).

1) Selecting menu


select “09 Cylinder cut out mode operation”

and press the [ ] switch.

2) Setting cylinders to be disabled

Press switches [1] – [6] on the monitor panel

corresponding to the cylinder Nos. to be dis-abled.

a After a switch is pressed, if the cylinder

No. corresponding to it on the monitor

panel is displayed white in a white frame,

the cylinder is disabled (If setting is

wrong, press the same switch again).

a Only one or more cylinders can be disa-

bled for the reduced cylinder mode oper-

ation.

3) Cancellation of disabled cylinders

Press switches [1] – [6] on the monitor panel

corresponding to the disabled cylinder Nos.

to cancel disabling of those cylinders.

a After a switch is pressed, if the cylinder

No. corresponding to it on the monitor

panel is displayed black in a black frame,



disabling of the cylinder is cancelled.


4) Function of holding engine speed

I f the [ ] swi tch is p ressed wh ile the

reduced cylinder mode operation screen is

used, the engine speed is held and dis-

played on the lower line.

If the [ ] switch is pressed while the engine

speed is held, holding of the engine speed is

cancelled and the engine speed displayed

on the lower line goes off.

a If the holding function is used, the heldengine speed is displayed in ( ) on the

lower line and the current engine speed

is displayed on the upper line.

a The holding function can be used both in

and out of the cylinder cut out mode.

[Reference]: How to use holding function effec-

tively

The engine speed displayed by the holding

function is held on the screen until the holding

function is cancelled, regardless of setting and

cancellation of the cylinder cut out mode.

Accordingly, a defective cylinder can be found

out effectively according to the following proce-dure.

(1) Run the engine normally (without disabling

any cylinder) and hold the engine speed.

(2) Disable a cylinder to be checked.

(3) Run the engine under the same condition as

the normal operation in step (1) and com-

pare the engine speed at this time with the

held engine speed.

(4) Cancel the c linder c t o t mode regard



(4) Cancel the cylinder cut out mode, regard-less of the change of the engine speed.

(5) Repeat steps (2) – (4) to check the other

cylinders.

a If the engine speed does not lower at all or

lowers less when a cylinder is selected for

the cylinder cut out mode operation, com-

bustion in that cylinder must be abnormal



TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL

SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL




Ordinary functions and special functions of monitor panel

The monitor panel has the ordinary functions and special functions and displays various pieces of informationon display section (1) and service meter section (2).

Some items are displayed automatically according to the internal setting of the monitor panel and the others are

displayed by operating switches.

1. Ordinary functions: Operator menu

The items in this menu are displayed normally or displayed automatically when a trouble occurs.

2. Special functions: Service menu

The items in this menu are not displayed normally. Each serviceman can display them by operating special

switches. These functions are used for special setting, testing, adjusting, or troubleshooting.

Flow of each function

a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.

Ordinary functions (Operator menu) Special functions (Service menu)

1 Function of displaying service meter

< O p e r a t i o n o f s w i t

c h > O 3 Function of displaying service code [01]

O <Automatic> 4 Monitoring function [02]

2 Function of displaying user code 5 Function of selecting maintenance period [04]

6 Function of selecting default working mode [05]

7 Function of setting installation of attachment [16]

8Special function of monitoring replacement

of engine oil



Display of operator menu

a Only outline of the operator menu is described in

this section. For details of each menu, see OP-

ERATION MANUAL or the volume of STRUC-


2. Function of displaying user code

If the machine has any trouble, the correspond-ing user code is displayed automatically in dis-

play section (1) and the caution buzzer is turned

ON to urge the operator to take a proper rem-

edy, depending on the degree of the trouble.

a Service meter section (2) continues display-

ing the service meter.

a For displayed user codes and the remedies

shown to the operator, see "User codes and

remedies shown to operator".

a Each user code simply shows occurrence of

a trouble to the operator. To find out the

cause of the trouble, a serviceman must

check the service code with the "Function of

displaying service code [01]" in the service

menu.

<Reference> A user code is displayed only when a serious

trouble occurs.

Even if a user code is not displayed, a trouble

may have occurred. If you feel any abnormality,

be sure to check for a service code with the

"Function of displaying service code [01]" in the

service menu.

a User codes and remedies shown to operator

User

codeError mode Remedy (shown to operator)

Caution

buzzer

E02Error in pump

control system

If the emergency pump drive switch is set in the upper position,

the machine can operate normally. Have the machine inspected

immediately, however.

q

E03 Error in swingb k t

Set the swing holding brake release switch in the upper position

to release the brake. When applying the swing brake, operate

the swing lock switch manually. The brake may not be released, q



E03 Error in swingbrake system

the swing lock switch manually. The brake may not be released,

depending on the cause of the failure. In this case, have the

machine inspected immediately.

q

E10

Error in engine controller

power supply

Abnormality in engine con-

troller drive system circuit

Have the machine inspected immediately. q


Operation and display of service menu

How to select service menu

a When using the general functions in the service

menu, perform the following switch operation to

change the screen of the monitor panel.

3. Function of displaying service code [01]

4. Monitoring function [02]

5. Function of selecting maintenance period

[04]6. Function of selecting default working

mode [05]

7. Function of setting installation of attach-

ment [16]

1) Operating switches

While holding caution buzzer stop switch (3),

hold auto decelerator switch (4) for 2.5 seconds.

2) Displaying display section and service meter

section

If the switches are operated as shown above,

the first menu No. [01] (Monitoring function) is

displayed in service meter section (2).

a Nothing is displayed in display section (1).

3) Selecting menu

While holding caution buzzer stop switch (3),operate working mode selector switches (7) and

(8) to select a menu you will use.

• UP switch (7): Increase Menu No.

• DOWN switch (8): Decrease Menu No.

Menu

No.

Service menu

(Excluding special functions)

01 Function of displaying error code

02 Monitoring function



4) Executing menu

Select a menu you will use and press set switch

02 Monitoring function

04 Function of selecting maintenance period

05 Function of selecting default working mode

16 Function of setting installation of attachment


a To use the following special function, you must

operate the switches differently from the above.See details of this function "8. Special function

of monitoring replacement of engine oil".

3. Function of displaying service code [01]

With this function, you can check the service

code of a trouble which is occurring at present

or has occurred in the past.

1) Selecting and executing function

i) Select menu No. [01] in the menu selec-

tion mode.

ii) Press set switch (5) to execute this

function.

2) Information displayed in display section and

service meter section 1 (When service codeis recorded)

If a service code is recorded, the following

information is displayed in display section

(1) and service meter section (2).

(a): Service code

(b): Service meter reading increased after

trouble occurred

(c): Mark [E] to indicate that trouble is occur-

ring at presenta Mark [E] to indicate that a trouble is oc-

curring at present indicates that the serv-

ice code is being detected now. It is not

displayed if the trouble has been re-

paired or the service code is not detect-

ed.

a For the service codes which the monitor

panel and engine throttle and pump con-

troller can detect, see the "Service



codes table".


service meter section 2 (When service code

is not recorded)

If a service code is not recorded, display

section (1) and service meter section (2)


5) Change of displayed service codes

While holding caution buzzer stop switch(3), operate working mode selector switches

(7) and (8) to change the displayed service

codes.

• UP switch (7):

Next service code appears.

• DOWN switch (8):

Previous service code appears.

6) How to delete service code

i) While holding caution buzzer stop

switch (3), turn the starting switch OFF

and keep holding caution buzzer stop

switch (3).

ii) Under the above condition, turn the

starting switch ON again and hold cau-

tion buzzer stop switch (3) for 5 sec-

onds.a A service code having the mark [E] is not

deleted.




Service codes table

User code Service code Trouble

— E112 Short circuit in wiper motor drive forward system

— E113 Short circuit in wiper motor drive reverse system

— E114 Short circuit in windshield washer drive system

— E115 Trouble in operation of windshield wiper

— E116 Trouble in storage of windshield wiper

— E117 Abnormality in engine controller S-NET

— E118 Abnormality in pump controller S-NET

E0E E128 Abnormality in communication (monitor)

— E201 Short circuit in travel junction solenoid

E03 E203 Short circuit in swing holding brake solenoid

— E204 Short circuit in merge-divider solenoid

— E205 Short circuit in 2-stage relief solenoid

— E206 Short circuit in travel speed shifting solenoid

— E211 Disconnection in travel junction solenoid

E03 E213 Disconnection in swing holding brake solenoid

— E214 Disconnection in merge-divider solenoid

— E215 Disconnection in 2-stage relief solenoid

— E216 Disconnection in travel speed shifting solenoid

— E217 Abnormality in input model code

— E218 Disconnection in S-NET signal line— E222 Short circuit in LS-EPC solenoid

— E223 Disconnection in LS-EPC solenoid

— E224 Abnormality in F pump pressure sensor

— E225 Abnormality in R pump pressure sensor

— E226 Abnormality in pressure sensor power supply

— E227 Abnormality in engine speed sensor

— E228 Short circuit in ATT return selector relayE02 E232 Short circuit in PC EPC solenoid



E02 E232 Short circuit in PC-EPC solenoid

E02 E233 Disconnection in PC-EPC solenoid

— E238 Disconnection in ATT return selector relay

— E245 Short circuit in ATT flow adjustment EPC

— E246 Disconnection in ATT flow adjustment EPC

E247 Ab lit i IN PPC


E11 E93C Abnormality in boost pressure sensor system

E15 E93D Abnormality in fuel temperature sensor system

E0E E953 Abnormality in communication (engine)

— E954 Short circuit in starting switch C terminal system

E0E E955 Abnormality in network system

E10 E956 Abnormality in power supply system 1

E15 E957 Abnormality in power supply system 2

— E95A Abnormality in Q-adjustment switch signal

E15 E96A Abnormality in coolant low temperature sensor system

E11 E970 Overcurrent in fuel supply pump PCV1 system

E11 E971 Overcurrent in fuel supply pump PCV2 system

E11 E974 Disconnection in fuel supply pump PCV1 system

E11 E975 Disconnection in fuel supply pump PCV2 system

E11 E977 Abnormality in common rail fuel pressure sensor systemE11 E979 Abnormality in common rail fuel high pressure 1

E11 E97A Abnormality in common rail fuel high pressure 2

E15 E97B No-pressure feed by supply pump 1

E11 E97C No-pressure feed by supply pump 2

E11 E97D Abnormality in common rail fuel pressure

E11 E980 Abnormality in controller

E11 E981 Disconnection in fuel injector 1 systemE11 E982 Disconnection in fuel injector 2 system

E11 E983 Disconnection in fuel injector 3 system




E11 E98A Short circuit in fuel injector 1 – 3 systems

E11 E98B Short circuit in fuel injector 4 – 6 systemsE22 E922 Out of engine high idle standard

User code Service code Trouble



a "E" at the head of each service code indicates the following condition.

• With E: The trouble has not been repaired.

• Without E: The trouble has been repaired.

E22 E922 Out of engine high idle standard


4. Monitoring function [02]

With this function, you can monitor the revolu-tion speed, oil pressure, current, voltage, input

condition, output condition, etc. in real time by

the signals from the sensors, switches, and

solenoids installed to various parts of the

machine.



tion mode.ii) Press set switch (5) to execute this

function.

2) Selecting and executing monitoring code

While holding caution buzzer stop switch

(3), operate working mode selector switches

(7) and (8) to select a monitoring code dis-played in service meter section (1).

• UP switch (7): Increase code No.

• DOWN switch (8): Decrease code No.

a This function displays monitoring code

[00200] and its information first.

a For the items and code Nos. which you

can monitor, see the "Monitoring codes

table".


service meter section 1 (When numeral

code is displayed)

If a numeral monitoring code is selected, the

following information is displayed in display

section (1) and service meter section (2).

(a): Monitoring code

(b): Monitoring information (Value is dis-

l d)



played)


service meter section 2 (When 6 bit code is


Monitoring codes table

Code Monitoring item Unit Remarks

00200 Controller model code Numeral

00201 Controller model code Numeral

01002 Engine speed rpm

01601 2nd throttle command rpm

01100 F pump pressure kg/cm2

01101 R pump pressure kg/cm2

07200 Arm IN PPC pressure kg/cm2

07300 Bucket curl PPC pressure kg/cm2

04102 Engine coolant temperature (high) °C

14200 Fuel temperature °C

04401 Hydraulic oil temperature °C

01300 PC-EPC solenoid current mA

01500 LS-EPC solenoid current mA

01700 Service solenoid current mA

03200 Power supply voltage V

03500 Battery relay output voltage V

04300 Charge voltage V

01006 Engine speed rpm

04107 Engine coolant temperature (low) °C

36400 Common rail fuel pressure kg/cm2

36500 Boost pressure kg/cm2

36700 Converted torque %03000 Fuel control dial voltage V



03000 Fuel control dial voltage V

04200 Fuel sensor voltage V

04106 Engine coolant temperature sensor voltage high V

04105 Engine coolant temperature sensor voltage low V

14201 Fuel temperature sensor voltage V


01900 Pressure switch 1

a Swing (6 bit)

b Travel (6 bit)

c Boom LOWER (6 bit)

d Boom RAISE (6 bit)

e Arm IN (6 bit)

f Arm OUT (6 bit)

01901 Pressure switch 2

a Bucket CURL (6 bit)

b Bucket DUMP (6 bit)

c Service (6 bit)

d Travel differential pressure (6 bit)

02300 Solenoid 1

a Travel junction (6 bit)

b Swing holding brake (6 bit)

c Pump merge-divider (6 bit)

d 2-stage relief (6 bit)

e Travel speed shifting (6 bit)

02301 Solenoid 2 ATT return selection (6 bit)

02200 Switch input 1a Knob switch (6 bit)b Swing brake release switch (6 bit)

c Swing holding brake switch (6 bit)

02201 Switch input 2

a Model selection 1 (6 bit)

b Model selection 2 (6 bit)

c Model selection 3 (6 bit)

d Model selection 4 (6 bit)

e Model selection 5 (6 bit)





02202 Switch input 3 Key switch (ACC) (6 bit)

03700 Controller output 1 Battery relay drive (6 bit)

a Key switch (6 bit)


a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or

(d) and (e) light up.

Display of numeral code Display of 6-bit code

04502 Monitor input 3

a Swing holding brake switch (6 bit)

b Buzzer cancel switch (6 bit)

c Window limit switch (6 bit)

d W limit switch (6 bit)

e P limit switch (6 bit)

17400 Engine controller input state

a Key switch (C) (6 bit)

b Engine oil pressure low (6 bit)

c Engine oil pressure high (6 bit)

d Model selection 1 (6 bit)


f Model selection 3 (6 bit)

36800 Right Q-adjustment switch (ROT-SW1)Numeral and

alphabet

36801 Left Q-adjustment switch (ROT-SW2)Numeral and

alphabet

05100 S-NET connection statea Pump controller (6 bit)

b Engine controller (6 bit)

20200 Program version (monitor) Numeral

20212 Program version (pump controller) Numeral

20209 Program version (engine controller) Numeral





5. Function of selecting maintenance period [04]

With this function, you can adjust the mainte-nance period of the engine oil for the function of

the engine oil replacement monitor.



tion mode.


function.

2) Selecting maintenance period

The current display mode or maintenance

period is displayed in service meter section

(2). Press set switch (5) to select a mainte-

nance period.

a Nothing is displayed in display section

(1).

a Each time the set switch is pressed, the

display mode or maintenance period

changes in the following order.

3) Settling maintenance period

The d i sp lay o r ma in tenance pe r i od

becomes effective when it is selected

DisplayDisplay mode/

Maintenance period

0 Maintenance function is reset.

125 125-hour interval



d Demonstration mode



becomes effective when it is selected.

Accordingly, perform the ordinary finishing

operation.

<Special functions of engine oil replacement

monitor>


6. Function of selecting default working mode [05]

With this function, you can freely select theworking mode which is set automatically when

the starting switch is turned ON (When the

machine is delivered, mode A is set).



tion mode.


function.

2) Selecting default working mode

The currently set working mode is displayed

in service meter section (2). Press working

mode selector switches (7) and (8) to select

a working mode.

• UP switch (7): Next mode is displayed.

• DOWN switch (8): Previous mode is dis-

played.

a Nothing is displayed in display section

(1).

a The working mode changes in the fol-

lowing order: A o E o B

3) Settling default working mode

Press set switch (5) to settle the selected

working mode.




7. Function of setting installation of attachment [16]

With this function, you can set installation of attachment.

a When an attachment is installed, if IN-

STALLED is not set with this function, the B-

mode function (automatic single/double op-

eration selecting function) cannot be used.



tion mode.ii) Press set switch (5) to execute this

function.

a While this function is executed, [16SET]

is displayed in the service meter section

(2) and [0] or [1] is displayed in display

section (1).

2) Selecting installation of attachment

i) The current setting is displayed in serv-

ice meter section (1). Check the actual

installation of attachment and setting.

• [0]: Attachment is not installed.

• [1]: Attachment is installed.

ii) While holding caution buzzer stop

switch (3), operate working mode selec-

tor switches (7) and (8) to select [0] or

[1].• UP switch (7): [1] is selected.

• DOWN switch (8): [0] is selected.

3) Settling installation of attachment

Press set switch (5) to settle the selected

setting of installation of attachment.




8. Special functions of engine oil replacement monitor

1) Ordinary display of engine oil replacementmonitor

If the rest of time before the set engine oil

replacement time is 10 hours or shorter,

engine oil replacement monitor (10) lights

up and display the elapsed time in service

meter section (2) for 20 seconds each time

the starting switch is turned ON.

2) Checking elapsed timeTo check the elapsed time while engine oil

replacement monitor (10) is OFF, turn the

starting switch OFF and press set switch (5)

and then turn the starting switch ON and

keep holding set switch (5).

3) Clearing elapsed time

To clear the elapsed time after replacing the

engine oil, hold set switch (5) for 3 seconds

while the elapsed time is displayed in serv-

ice meter section (2).

a If the above operation is performed, the

elapsed time in the monitor panel is set

to 0 hours.

4) Function of demonstration mode

If the demonstration mode is selected, youcan perform demonstration of the oil mainte-

nance function when teaching the operation

to a customer.

The functions and display of the demonstra-

tion mode are as follows.

i) The internally set interval is recognized

as 250 hours and the elapsed time is

recognized as 240 hours.

ii) When the starting switch is turned ONafter the demonstration mode is set, the

ordinary display is repeated up to 3



ordinary display is repeated up to 3

times (number of the times of turning

the starting switch ON).

iii) After the demonstration is finished,

resetting of maintenance setting [0] is

recognized



TESTING AND ADJUSTING HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER

HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER

k The engine controller has a high-voltage circuit

(110 – 130 V) to drive the fuel injector. This cir-

cuit is connected to the wiring harness and con-nectors between the engine controller and fuel

injector.

a Normally, the engine controller outputs the high

voltage to the fuel injector only while the engine

is running and stops outputting if the engine

stops.

k If you touch the high-voltage circuit directly, you

may get an electric shock. To avoid this, ob-serve the following precautions.

1. The following connectors are used in the high-

voltage circuit.

• Engine controller connector: CB3

• Junction connector: ER03

• Injector connectors:

CN1, CN2, CN3, CN4, CN5, CN6

• Injector head terminal (in head cover)

2. When disconnecting or connecting a connector



2. When disconnecting or connecting a connector

related to the high-voltage circuit, be sure to turn

the starting switch OFF.

3. If a T-adapter is inserted in or connected to a

connector related to the high voltage circuit for


PREPARATION WORK FOR TROUBLESHOOTING FOR

ELECTRICAL EQUIPMENT SYSTEM

PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL

EQUIPMENT SYSTEM

a When carrying out troubleshooting for an elec-

tric circuit related to the monitor panel, engine

controller, or pump controller, expose the related

connectors according to the following proce-

dure.

1. Monitor panel1) Remove cover (1).

a The cover is fixed with the upper and

lower 2 clips. You can remove the cover

by pulling it up.

a If the sunlight sensor for the air condi-

tioner is installed, disconnect connector

P15 on the back side of the cover.

2) Remove the 3 mounting screws and discon-

nect monitor panel (2) from the mount.

a Take care not to drop the mounting

screws in the console.

3) Insert or connect T-adapters in or to con-nectors P01, P02, P70 of the monitor panel.

2. Engine controller

1) Open the right side cover and remove radia-

tor sub tank (3) and bracket together.

2) Remove the 4 mounting bolts and pull out

engine controller (4).

3) Insert or connect T-adapters in or to con-

nectors CB1, CB2, and CB3 of the engine

controller.

a Since the connectors are secured with

screws, loosen those screws before dis-

connecting.

a When connecting the connectors again,

tighten their screws to the specified

torque.

3 Screw: 2.82 Nm {0.288 kgm}




PREPARATION WORK FOR TROUBLESHOOTING FOR

ELECTRICAL EQUIPMENT SYSTEM

3. Pump controller

a The pump controller is installed inside the cover at the rear of the operator’s seat.

1) Remove the 3 mounting bolts and cover (5).

2) Insert or connect T-adapters in or to connectors

C01, C02, and C03 of the pump controller.

a Since the connectors are secured with

screws, loosen those screws before discon-

necting.

a When connecting the connectors again,

tighten their screws to the specified torque.

3 Screw: 2.82 Nm {0.288 kgm}



PM-CLINIC SERVICE



MEASURING PROCEDURES

Positions to install measuring devices (Related to engine)



MEASURING PROCEDURES

Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)



Pm-CLINIC SERVICE PC400 (LC), 450 (LC)-7

Visual check of welded structures

a If any crack is found, draw its shape below.



UNDERCARRIAGE INSPECTION(Program form No.: SELA195001)

Y Komatsu

Undercarriage Inspectio n Customer name:

T20606 Address:

Model Serial# Equip# Work Order No

Location SMR Wet,AR,HD or Dry

Soi l condit ion Dealer Shoe width (mm)

Working condit ion nspector Shoe type

Insp.Date(yyyy/mm/dd) (yyyy/m/d) Wear type

New 100% Measured Wear SMR Hours o Comments/Observation

Wear mm % New Rebuil t Parts:

LH 915.6 927.6

R

RH 915.6 927.6

LH 228.90 231.90

M

RH 228.90 231.90

LH 129.0 119.0

RH 129.0 119.0

New TurnedLH 71 .5 6 6. 5

New Turned

RH 71 .5 6 6. 5

LH 37 .0 2 2. 0

RH 37 .0 2 2. 0

LH 148.0 134.0

Front

RH 148.0 134.0

LH 148.0 134.0

Rear

RH 148.0 134.0

LH 22 .0 2 8. 0

Front

RH 22 .0 2 8. 0

LH 22 .0 2 8. 0

Rear

RH 22 .0 2 8. 0

1 LH 200.0 188.0

2 LH 200.0 188.03 LH 200.0 188.0

4 LH 200.0 188.0

5 LH 200.0 188.0

6 LH 200 0 188 0

PC400/450-7

DRY

TRIPLE

NORMAL



6 LH 200.0 188.0

7 LH 200.0 188.0

8 LH 200.0 188.0

9 LH 200.0 188.0

10 LH 200.0 188.0



POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203

POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204

CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF

EACH SYSTEM.................................................................................................................................... 20-217

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-234

T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-256

TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM”

AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED .................................................. 20-301

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ................................................................. 20-501

TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) ................................. 20-601

TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................... 20-701

TROUBLESHOOTING



TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.

k 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.

k 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.

k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.

k 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 properly.

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 func-

tion.

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 hurry

to disassemble the components.

If components are disassembled immediately

any failure occurs:

• Parts that have no connection with the failure

or other unnecessary parts will be disassem-

bled.

• It will become impossible to find the cause of

the failure.

It will also cause a waste of manhours, parts, or

oil or grease, and at the same time, will also lose

the confidence of the user or operator.

For this reason, when carrying out troubleshoot-

ing, it is necessary to carry out thorough prior

investigation and to carry out troubleshooting in

accordance with the fixed procedure.

2. Points to ask user or operator

1) Have any other problems occurred apart

5) Other maintenance items can be checked

externally, so check any item that is consid-

ered to be necessary.

4. Confirming failure

• Confirm the extent of the failure yourself, and

judge whether to handle it as a real failure or

as a problem with the method of operation,

etc.

a When operating the machine to reenact

the troubleshooting symptoms, do not

carry out any investigation or measure-

ment that may make the problem worse.

5. Troubleshooting

• Use the results of the investigation and in-spection in Items 2 – 4 to narrow down the

causes of failure, then use the troubleshoot-

ing flowchart to locate the position of the fail-



from the problem that has been reported?

2) Was there anything strange about the

machine before the failure occurred?

3) Did the failure occur suddenly or were there

ure exactly.

a The basic procedure for troubleshooting

is as follows.

1) Start from the simple points

TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING



TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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 repairs 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).

1. Points to remember when handling electric

equipment

1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting

one component to another component, connec-

tors used for connecting and disconnecting one

wire from another wire, and protectors or tubes

used for protecting the wiring.

Compared with other electrical components fit-

ted in boxes or cases, wiring harnesses are

more likely to be affected by the direct effects of

rain, water, heat, or vibration. Furthermore, dur-

ing inspection and repair operations, they are

frequently removed and installed again, so they

are likely to suffer deformation or damage. For

this reason, it is necessary to be extremely care-

ful when handling wiring harnesses.

Main failures occurring in wiring harness1) Defective contact of connectors (defective

contact between male and female)

Problems with defective contact are likely to

occur because the male connector is not

properly inserted into the female connector,

or because one or both of the connectors is

deformed or the position is not correctly

aligned, or because there is corrosion or

oxidization of the contact surfaces.



2) Defective crimping or soldering of connec-

tors


3) 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.

4) High-pressure water entering connector

The connector is designed to make it diffi-

cult for water to enter (drip-proof structure),

but if high-pressure water is sprayed directly

on the connector, water may enter the con-

nector, depending on the direction of the

water jet.

As already said, the connector is designed

to prevent water from entering, but at the

same time, if water does enter, it is difficult

for it to be drained. Therefore, if water

should get into the connector, the pins willbe short-circuited by the water, so if any

water gets in, immediately dry the connector

or take other appropriate action before

passing electricity through it.

5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector

and an oil film is formed on the mating sur-

face between the male and female pins, theoil will not let the electricity pass, so there

will be defective contact.

If there is oil or grease stuck to the connec-

t i it ff ith d l th bl it d



tor, wipe it off with a dry cloth or blow it dry

with compressed air and spray it with a con-

tact restorer.


2) Removing, installing, and drying connectors

and wiring harnesses

• Disconnecting connectors

1) Hold the connectors when disconnecting.

When disconnecting the connectors, hold

the connectors and not the wires. For con-

nectors held by a screw, loosen the screw

fully, then hold the male and female connec-

tors in each hand and pull apart. For con-

nectors which have a lock stopper, pressdown the stopper with your thumb and pull

the connectors apart.

a Never pull with one hand.

2) When removing from clips

When removing a connector from a clip, pull

the connector in a parallel direction to the

clip.

a If the connector is twisted up and downor to the left or right, the housing may

break.



3) Action to take after removing connectors

After removing any connector, cover it with a

vinyl bag to prevent any dust dirt oil or


• Connecting connectors

1) 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,

defective contact, corrosion, or damage

to the connector pins.

3) Check that there is no damage or break-

age to the outside of the connector.

a If there is any oil, water, or dirt stuck tothe 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.

a If there is any damage or breakage, re-

place the connector.

2) Fix the connector securely. Align the position of the connector correctly,

then insert it securely.

For connectors with lock stopper, push in

the connector until the stopper clicks into

position.

3) Correct any protrusion of the boot and any

misalignment of the wiring harness

For connectors fitted with boots, correct any

protrusion of the boot. In addition, if the wir-

ing harness is misaligned, or the clamp is

out of position, adjust it to its correct posi-

tion.

a If the connector cannot be corrected

easily, remove the clamp and adjust the

position.

4) If the connector clamp has been removed,

be sure to return it to its original position.

Check also that there are no loose clamps.



• Connecting connectors (DT type connector)

Since the DT 8 pole and 12 pole DT type con


• Drying wiring harness

If there is any oil or dirt on the wiring harness,

wipe it off with a dry cloth. Avoid washing it in

water or using steam. If the connector must be

washed in water, do not use high-pressure

water or steam directly on the wiring harness.

If water gets directly on the connector, do as fol-

lows.

1) Disconnect the connector and wipe off the

water with a dry cloth.a If the connector is blown dry with com-

pressed air, there is the risk that oil in the

air may cause defective contact, so re-

move all oil and water from the com-

pressed air before blowing with air.

2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a

dryer to dry the connector.a Hot air from the dryer can be used, but

regulate the time that the hot air is used

in order not to make the connector or re-

lated parts too hot, as this will cause de-

formation or damage to the connector.

3) Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-

connected and carry out a continuity test to

check for any short circuits between pins

caused by water.

a After completely drying the connector,blow it with contact restorer and reas-

semble.




3) Handling control box

1) The control box contains a microcomputer

and electronic control circuits. These control

all of the electronic circuits on the machine,

so be extremely careful when handling the

control box.

2) Do not open the cover of the control box

unless necessary.

3) Do not place objects on top of the control

box.

4) Cover the control connectors with tape or a

vinyl bag.

Never touch the connector contacts withyour hand.

5) During rainy weather, do not leave the con-

trol box in a place where it is exposed to

rain.

6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short

time.

(Place it on a suitable dry stand).

7) Precautions when carrying out arc welding

When carrying out arc welding on the body,

disconnect all wiring harness connectors

connected to the control box. Fit an arcwelding ground close to the welding point.



2. Points to remember when troubleshooting electric circuits


3. Points to remember when handling hydraulic

equipment

With the increase in pressure and precision of

hydraulic equipment, the most common cause of

failure is dirt (foreign material) in the hydraulic cir-

cuit. When adding hydraulic oil, or when disassem-

bling or assembling hydraulic equipment, it is

necessary to be particularly careful.

1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or

repairing the machine in rain or high winds, or

places where there is a lot of dust.

2) Disassembly and maintenance work in the

field

If disassembly or maintenance work is carried

out on hydraulic equipment in the field, there is

danger of dust entering the equipment. It is alsodifficult to confirm the performance after repairs,

so it is desirable to use unit exchange. Disas-

sembly and main-tenance of hydraulic equip-

ment should be carried out in a specially

prepared dustproof workshop, and the perfor-

mance should be confirmed with special test

equipment.

3) Sealing openings After any piping or equipment is removed, the

openings should be sealed with caps, tapes, or

vinyl bags to prevent any dirt or dust from enter-

ing. If the opening is left open or is blocked with

a rag, there is danger of dirt entering or of the

surrounding area being made dirty by leaking oil

so never do this.

Do not simply drain oil out on to the ground, col-

lect it and ask the customer to dispose of it, or

take it back with you for disposal.



4) Do not let any dirt or dust get in during refill-

ing operations


5) Change hydraulic oil when the temperature

is high.

When hydraulic oil or other oil is warm, it flows

easily. In addition, the sludge can also be

drained out easily from the circuit together with

the oil, so it is best to change the oil when it is

still warm. When changing the oil, as much as

possible of the old hydraulic oil must be drained

out. (Drain the oil from the hydraulic tank; also

drain the oil from the filter and from the drain

plug in the circuit.) If any old oil is left, the con-taminants and sludge in it will mix with the new

oil and will shorten the life of the hydraulic oil.

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: primaryflushing is carried out with flushing oil, and sec-

ondary flushing is carried out with the specified

hydraulic oil.

7) Cleaning operations

After repairing the hydraulic equipment (pump,contro l va lve, etc . ) or when running the

machine, carry out oil cleaning to remove the

sludge or contaminants in the hydraulic oil cir-

cuit.

The oil cleaning equipment is used to remove

the ultrafine (about 3µ) particles that the filter

built into the hydraulic equipment cannot

remove, so it is an extremely effective device.



TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING

ItemJudgement

value Action

L u b r i c a t i n g o i l ,

c o o l a n t

1. Check fuel level, type of fuel

2. Check for impurities in fuel

3. Check hydraulic oil level

4. Check hydraulic oil strainer

5. Check swing machinery oil level

6. Check engine oil level (oil pan oil level)

7. Check coolant level8. Check dust indicator for clogging

9. Check hydraulic filter

10. Check final drive oil level

—

—

—

—

—

—

——

—

—

Add fuel

Clean, drain

Add oil

Clean, drain

Add oil

Add oil

Add water Clean or replace

Replace

Add oil

E l e c t r i c a l

e q u i p m e n t

1. Check for looseness, corrosion of battery terminal, wiring

2. Check for looseness, corrosion of alternator terminal, wiring

3. Check for looseness, corrosion of starting motor terminal, wiring

—

—

—

Tighten or replace

Tighten or replace

Tighten or replace

H y d r a

u l i c ,

m e c h a

n i c a l

e q u i p m e n t

1. Check for abnormal noise, smell

2. Check for oil leakage3. Carry out air bleeding

—

——

Repair

Repair Bleed air

E l e c t r i c s , e l e c t

r i c a l e q u i p m e n t

1. Check battery voltage (engine stopped)

2. Check battery electrolyte level

3. Check for discolored, burnt, exposed wiring

4. Check for missing wiring clamps, hanging wiring

5. Check for water leaking on wiring (be particularly careful attention to

water leaking on connectors or terminals)

6. Check for blown, corroded fuses

7. Check alternator voltage (engine running at 1/2 throttle or above)

8. Check operating sound of battery relay

(when switch is turned ON/OFF)

20 – 30V

—

—

—

—

—

Afterrunning for

several

minutes :

27.5 – 29.5V

—

Replace

Add or replace

Replace

Repair

Disconnect

connector and dry

Replace

Replace

Replace



TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

CLASSIFICATION AND STEPS FOR TROUBLESHOOTING

Classification of troubleshooting

Steps for troubleshootingIf some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting

No. and proceed to the explanations for diagnosis.

1. Troubleshooting steps when calling User Code display in the monitor panel

In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error

Code for the electrical system, carry out the troubleshooting along the corresponding code display.

2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is

recorded in the failure history:

If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system

Failure Code, using the failure history function of the monitor panel.

a If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the

display again to check if the same abnormality still persists.

a Failure Code in the mechanical system cannot be deleted.

3. Troubleshooting steps without User Code display and no failure history is available

If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that

the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-

ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from

among “Failure like Phenomena and Troubleshooting No.” and carry out E mode or H mode troubleshooting

related to the phenomenon in question.

Mode Content

Code displayTroubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are

displayed.

E mode Troubleshooting of electrical system

H mode Troubleshooting of hydraulic and mechanical systems

S mode Troubleshooting of engine




Phenomena considered to be failures and troubleshooting Nos.

No. Phenomena considered to be failures

Troubleshooting

Display of

codeE-mode H-mode S-mode

Possible faults related to user code, error code, or failure code

1 User code is displayed on monitor panel

Accord-

ing to

displayed

code

2When failure history is checked, error code is displayed in electrical

system

3When failure history is checked, error code is displayed in mechani-

cal system

Possible faults related to engine

4 Engine does not start easily (It always takes time to start) S-1

5

Engine does not start

Engine does not crank E-1 S-2 a)

6

Engine cranks but exhaust smoke

does not come out S-2 b)

7Exhaust smoke comes out but engine

does not startS-2 c)

8 Engine speed does not rise sharply (Follow-up performance is low) S-3

9 Engine stops during operation S-4

10 Engine rotation is abnormal (Engine hunts) S-5

11 Output is insufficient (Power is low) S-6

12 Exhaust gas color is bad (Incomplete combustion) S-7

13 Oil is consumed much or exhaust gas color is bad S-8

14 Oil becomes dirty quickly S-9

15 Fuel is consumed much S-10

16 Coolant contains oil (or it blows back or reduces) S-11

17 Engine oil pressure caution lamp lights up (Oil pressure lowers) S-12

18 Oil level rises (Water or fuel is mixed in oil) S-13

19 Water temperature rises too high (Overheating) S-14

20 Abnormal sound comes out S-15

S



21 Vibration is excessive S-16

22 Engine is not preheated normally E-2


Possible faults related to work equipment

30 Speed or power of boom is low H-7

31 Speed or power of arm is low H-8

32 Speed or power of bucket is low H-9

33 Work equipment does not move singly H-10

34 Hydraulic drift of work equipment is large H-11

35 Time lag of work equipment is large H-12

36When a work equipment device is relieved singly, other work equip-

ment device movesH-13

37 One-touch power maximizing function does not work E-6 H-14

38 Machine push-up function does not work normally E-7 H-15

39 Attachment circuit is not selected (when attachment is installed) E-8 H-30

40Oil flow in attachment circuit cannot be adjusted (when attachment is

installed)H-31

Possible faults related to compound operation

41In compound operation of work equipment, speed of part loaded

more is lowH-16

42When machine swings and raises boom simultaneously, boom rising

speed is low

H-17

43When machine swings and travels simultaneously, travel speed low-

ers largelyH-18

Possible faults related to travel

44 Machine deviates during travel H-19

45 Travel speed is low H-20

46 Machine is not steered well or steering power is low H-21

47 Travel speed does not change or it is lower or higher than set speed H-22

48 Travel motor does not work (only 1 side) H-23

49 Travel alarm does not sound or does not stop sounding E-31

Possible faults related to swing


Troubleshooting

Display ofcode

E-mode H-mode S-mode



Possible faults related to swing

47 Machine does not swing H-24


58 Engine coolant temperature gauge does not indicate normally E-13

59 Hydraulic oil temperature gauge does not indicate normally E-14

60 Fuel level gauge does not indicate normally E-15

61 Swing lock monitor does not indicate normally E-16

62 When monitor switches are operated, no items are displayed E-17

63 Windshield wiper or windshield washer does not operate E-18

64 Alarm buzzer cannot be cancelled E-19

Possible faults related to monitor panel (Service menu: Special function screen)

65 Monitoring function does not indicate “Boom RAISE” normally. E-20

66 Monitoring function does not indicate “Boom LOWER” normally. E-21

67 Monitoring function does not indicate “Arm IN” normally. E-22

68 Monitoring function does not indicate “Arm OUT” normally. E-23

69 Monitoring function does not indicate “Bucket CURL” normally. E-24

70 Monitoring function does not indicate “Bucket DUMP” normally. E-25

71 Monitoring function does not indicate “Swing” normally. E-26

72 Monitoring function does not indicate “Travel” normally. E-27

73Monitoring function does not indicate “Travel differential pressure”

normally.

E-28

74 Monitoring function does not indicate “Service” normally. E-29

Other failure

75 Air conditioner does not operate

(Troubleshooting for air conditioner system)E-31


Troubleshooting

Display ofcode

E-mode H-mode S-mode



TROUBLESHOOTING

CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC

CIRCUIT DIAGRAM OF EACH SYSTEM


CIRCUIT DIAGRAM OF EACH SYSTEMConnectors list

a The address of each connector roughly shows the place of the connector in the connectors stereogram and

the circuit diagram of each system.

Connector

No.Type

No. of

pinsName of device

Address

Stereo-

gram

M

circuit

E

circuit

P

circuit

A01 X 4 Intermediate connector T-1 H-6 D-7 G-7 A02 X 4 Intermediate connector T-1 H-6 G-7

A03 DT 12 Intermediate connector N-2 H-6 D-7 G-7

A04 SWP 6 Intermediate connector O-1 G-6

A05 SWP 14 Intermediate connector T-1 H-5 G-6

A06 SWP 14 Intermediate connector O-1 H-5 G-5

A07 SWP 16 Intermediate connector S-1 A-4 D-7 G-5

A09 SWP 8 Intermediate connector N-2 G-5

A10 Terminal 1 Revolving frame grounding H-2 I-1 F-1 J-8 A11 Terminal 1 Revolving frame grounding I-2 F-1

A12 Terminal 1 Revolving frame grounding I-2 I-1

A13 Terminal 1 Revolving frame grounding I-2 I-1 J-8

A14 Terminal 1 Revolving frame grounding F-1 I-1 J-8

A15 Terminal 1 Revolving frame grounding J-3 I-1 J-8

A16 Terminal 1 Revolving frame grounding J-3 I-1 K-8

A20 Terminal 1 Battery relay (Terminal E) D-1 L-5 K-9

A21 Terminal 1 Battery relay (Terminal BR) D-2 J-6 K-9 A22 Terminal 1 Battery relay (Terminal N) F-2 J-5 D-8 K-9

A23 Terminal 1 Battery relay (Terminal B) F-2 J-6 K-9

A31 D 2 Air cleaner clogging sensor H-9 K-4

A33 X 2 Radiator water level sensor H-9 K-5

A34 L 2 Fusible link (65 A) D-2 K-6 K-9

A35 M 2 Fusible link (30 A) G-9 K-6 D-9 K-9

A40 Terminal 1 Horn (Low tone) G-9

A41 Terminal 1 Horn (High tone) G-9 A42 M 1 Intermediate connector H-9 J-7

A43 D 2 Travel alarm J-3 K-5

A44 M 1 Right headlamp D-5 K-7

A50 KES0 2 Windshield washer motor (Tank) L-5 K-5

A51 D 3 F il L 8 L 5



A51 D 3 F pump oil pressure sensor L-8 L-5

A52 D 3 R pump oil pressure sensor L-7 L-5

TROUBLESHOOTING



CB2 DRC 40 Pump controller I-9 K-1 A-5 L-8

CB3 DRC 40 Pump controller J-9 A-3

CB5 DT 8 Model selection connector (Engine controller) J-9 A-7

CN1 DT 2 No. 1 fuel injector AI-2 K-3

CN2 DT 2 No. 2 fuel injector AI-3 K-2

CN3 DT 2 No. 3 fuel injector AJ-3 K-2




D01 SWP 8 Concentrated diode W-7 A-9 A-4

D02 SWP 8 Concentrated diode W-5 A-8 A-4

E06 M 3 Fuel control dial P-7 K-7

ENE DT 2 Engine speed sensor AJ-5

ER02 HD30 31 Intermediate connector AF-8 J-3 I-5 K-6

ER03 HD30 31 Intermediate connector AF-8 I-3

F02 M 2 Rotary lamp AA-9

FB1 — — Fuse box V-2 I-9 E-7 G-8

G YAZAKI 2 Engine G sensor AH-2 K-3

GND DT 2 Joint connector (with diode) AJ-6

GND2 Terminal 1 Engine grounding AJ-5

GND3 Terminal 1 Engine grounding AE-7

H08 M 8 Intermediate connector W-6 J-8

H09 S 8 Intermediate connector W-6 J-8

H10 S 16 Intermediate connector T-9 D-6 I-7 E-2

H11 S 16 Intermediate connector S-9 D-6 E-2

H12 S 12 Intermediate connector S-9 D-5 I-6 E-2

H15 S090 20 Intermediate connector O-7 C-2 I-7 A-2

HT/B Terminal 1 Heater relay B terminal AH-9

HT/S Terminal 1 Heater relay S terminal AJ-7

J01 J 20 Junction connector (Black) T-9 C-9 H-9 B-9

J02 J 20 Junction connector (Black) T-9 D-9 C-1

J03 J 20 Junction connector (Green) U-9 D-9 H-9 C-9

J04 J 20 Junction connector (Green) V-3 E-9 H-9 C-9

J05 J 20 Junction connector (Pink) V-3 E-9 D-9

J06 J 20 Junction connector (Orange) W-3 F-9 I-9 D-9

J07 J 20 Junction connector (Orange) W-5 F-9 I-9 D-9

Connector

No.Type

No. of

pinsName of device

Address

Stereo-

gram

M

circuit

E

circuit

P

circuit



J08 J 20 Junction connector (Pink) W-5 I-9 E-9

TROUBLESHOOTING



M31 M 2 Optional power supply (2) W-7

M32 M 2 Optional power supply (1) W-6

M33 M 2 Optional power supply (3) V-9

M33 SUMITOMO 4 Air conditioner unit W-4

M34 X 1 Air conditioner compressor electromagnetic clutch I-9

M37 Terminal 1 Horn switch (High tone) H-1

M38 Terminal 1 Horn switch (Low tone) G-1

M38 M 2 Machine push-up switch Q-8 A-1

M40 M 2 Working lamp Z-8 K-8

M41 M 2 Working lamp (Additional) Y-7 K-8

M42 M 1 Intermediate connector H-9 J-7, K-7

M43 M 1 Working lamp (Rear) J-9 K-7

M45 D 12 Intermediate connector W-7

M46 X 4 RS232C junction connector V-9 A-4

M71 M 2 Room lamp AA-8

M72 M 4 DC/DC converter U-2

M73 M 2 Speaker (Left) AD-8

M79 M 2 12-V accessory outlet V-9

NE YAZAKI 2 Engine Ne sensor AJ-5 K-4

OL DT 2 Engine oil level sensor AJ-3 K-2

P01 070 12 Monitor panel N-6 A-7 K-7 E-1


P03 M 2 Buzzer cancel switch Q-8 D-1

P05 M 2 Rotary lamp switch U-2

P15 Y050 2 Air conditioner daylight sensor N-5


PCV1 SUMITOMO 2 Fuel supply pump PCV1 AH-2 K-1

PCV2 SUMITOMO 2 Fuel supply pump PCV2 AI-2 K-1

PSH Terminal 1 Engine oil pressure switch (High pressure) AH-2 L-5

PSL Terminal 1 Engine oil pressure switch (Low pressure) AG-1 L-5

PFUEL AMP 3 Common rail pressure sensor AJ-4 K-5

PIM SUMITOMO 3 Boost pressure sensor AJ-8 K-5

R10 R 5 Light relay P-7 E-1

R11 R 5 Starting motor cutout relay (PPC lock) P-8 E-1

R13 R 5 Starting motor cutout relay (Personal code) Q-8 F-1

R20 R 5 ATT circuit selector relay W-7 E-9

Connector

No.

TypeNo. of

pins

Name of device

Address

Stereo-

gram

M

circuit

E

circuit

P

circuit



R22 R 5 Power supply relay for engine controller W-6 G-9

TROUBLESHOOTING



S21 Terminal 6 Emergency pump drive switch R-9 C-1

S22 Terminal 6 Swing holding brake release switch R-8 D-1

S25 S090 16 Intermediate connector R-9 C-2

S30 X 2 Travel oil pressure switch P-1 A-9

S31 X 2 Travel steering oil pressure switch P-1 A-9

ST DT 2 Starting motor AF-7 K-3 K-6

ST/B Terminal 1 Starting motor B terminal AF-7

T05 Terminal 1 Floor frame grounding V-3 J-8

T06 Terminal 1 Radio body grounding S-9

T06A M 1 Intermediate connector T-2

T11 Terminal 1 Cab grounding K-8

THL DT 3 Spill fuel temperature sensor AJ-4 K-3

TWH DT 2Engine water temperature sensor (High tempera-

ture) AE-7 K-5

TWL DT 3Engine water temperature sensor (Low tempera-

ture) AG-8 K-5

V01 DT 2 PPC oil pressure lock solenoid valve J-3 K-5

V02 DT 2 Travel junction solenoid valve J-2 K-5

V03 D 2 Merge-divider solenoid valve J-2 K-4

V04 D 2 Travel speed solenoid valve J-2 K-4

V05 D 2 Swing holding brake solenoid valve J-2 K-4

V06 D 2 Machine push-up solenoid valve J-2 K-4

V08 D 2 2nd-stage relief solenoid valve J-1 K-4

V12 D 2 ATT return selector solenoid valve J-1 K-4V21 D 2 PC-EPC solenoid valve L-6 L-7

V22 D 2 LS-EPC solenoid valve L-6 L-7

V30 X 2 ATT flow adjustment EPC solenoid valve P-1 F-1

W03 M 2 Rear limit switch (Window) AB-9 K-8

W04 M 6 Wiper motor Y-5 B-9

X05 M 4 Swing lock switch Q-8 D-2 A-1

Connector

No.

TypeNo. of

pins

Name of device

Address

Stereo-

gram

M

circuit

E

circuit

P

circuit



TROUBLESHOOTING



Connector type Detailed informationD or DT Japanese and German makes DT type connector (08192-XXXXX)

L Product of Yazaki Corporation L type connector (08056-2XXXX)

J Product of Sumitomo Wiring Systems 090 type splice

M Product of Yazaki M type connector (08056-0XXXX)

R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector

S Product of Yazaki S type connector (08056-1XXXX)

X Product of Yazaki X type connector (08055-0XXXX)

PA Product of Yazaki PA type connector

SWP Product of Yazaki SWP type connector (08055-1XXXX)

DRC Japanese and German makes DRC type connector

040 Product of Japan AMP 040 type connector

070 Product of Japan AMP 070 type connector

Y050 Product of Yazaki 050 type connector S090 Product of Sumitomo 090 type connector

Y090 Product of Yazaki 090 type connector

YAZAKI Yazaki-made connector

SUMITOMO Product of Sumitomo Wiring Systems 6098 type connector

KES0 KESO type connector (08027-0XXXX)

Terminal Round pin type single terminal connector

Terminal Round terminal



TROUBLESHOOTING



Connector Location Stereogram



TROUBLESHOOTING





TROUBLESHOOTING



Monitor Panel System Circuit Diagram (M Circuit)



TROUBLESHOOTING



a This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging

system, light system, and communication network system from the general electric circuit diagram.



TROUBLESHOOTING



Engine Control System Circuit Diagram (E Ciruit)



TROUBLESHOOTING



a This circuit diagram is made by extracting the engine controller system from the general electric circuit dia-

gram.



TROUBLESHOOTING



Pump Controller System Circuit Diagram (P Circuit)



TROUBLESHOOTING



a This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine

push-up solenoid system, and boom shockless solenoid system from the general electric circuit diagram.



TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

a The terms male and female refer to the pins, while the terms male housing and female housing refer to themating portion of the housing.

No.of

pins

X type connector

Male (female housing) Female (male housing)T-adapter

Part No.

1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010

2 799-601-7020

Part No.: 08055-00282 Part No.: 08055-00292

3 799-601-7030

Part No.: 08055-00381 Part No.: 08055-00391

4 799-601-7040

Part No.: 08055-00481 Part No.: 08055-00491

—

Terminal part No.: 79A-222-3370

• Electric wire size: 0.85

• Grommet: Black

• Q’ty: 20



• Grommet: Black

• Q’ty : 20

—




No.of

pins

SWP type connector


Part No.

6 799-601-7050

Part No.: 08055-10681 Part No.: 08055-10691

8 799-601-7060

Part No.: 08055-10881 Part No.: 08055-10891

12 799-601-7310

Part No.: 08055-11281 Part No.: 08055-11291

14 799-601-7070

Part No.: 08055-11481 Part No.: 08055-11491




No. of

pins

SWP type connector


Part No.

16 799-601-7320

Part No.: 08055-11681 Part No.: 08055-11691

—

Terminal part No.:


• Grommet: Black

• Q’ty: 20

Terminal part No.:


• Grommet: Black

• Q’ty: 20

—

—

Terminal part No.:


• Grommet: Red

• Q’ty: 20

Terminal part No.:


• Grommet: Red

• Q’ty: 20

—




No.of

pins

M type connector

Male (female housing) Female (male housing)T-adapter Part

No.

1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080

2 799-601-7090

Part No.: 08056-00271 Part No.: 08056-00281

3 799-601-7110

Part No.: 08056-00371 Part No.: 08056-00381

4 799-601-7120

Part No.: 08056-00471 Part No.: 08056-00481

6 799-601-7130




No.of

pins

S type connector


Part No.

8 799-601-7140

Part No.: 08056-10871 Part No.: 08056-10881

10

(White)799-601-7150

Part No.: 08056-11071 Part No.: 08056-11081

12(White)

799-601-7350

Part No.: 08056-11271 Part No.: 08056-11281

16

(White)799-601-7330

Part No.: 08056-11671 Part No.: 08056-11681




No.of

pins

S type connector


Part No.

10

(Blue)—

— —

12

(Blue)799-601-7160

Part No.: 08056-11272 Part No.: 08056-11282

16(Blue)

799-601-7170

Part No.: 08056-11672 Part No.: 08056-11682




No.of

pins

MIC type connector


No.

7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —

11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —

5 799-601-2710

Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)

9 799-601-2950


13 799-601-2720





No.of

pins

MIC type connector


No.

17 799-601-2730


21 799-601-2740



(Q’ty: 50)


(Q’ty: 50)—




No.of

pins

AMP040 type connector


No.

8 799-601-7180

— Housing part No.: 79A-222-3430 (Q’ty: 5)

12 799-601-7190


16 799-601-7210


20 799-601-7220





No.of

pins

AMP070 type connector


No.

10 799-601-7510

— Part No.: 08195-10210

12 799-601-7520

— Part No.: 08195-12210

14 799-601-7530

— Part No.: 08195-14210

18 799-601-7540

— Part No.: 08195-18210




No.of

pins

L type connector


No.

2 —

— —

No.of

pins

Connector for PA


No.

9 —

— —

No.of

pins

Bendix MS connector


No.

10 799-601-3460




No.ofpins

KES 1 (Automobile) connector


No.

2 —

Part No.: 08027-10210 (Natural color)

08027-10220 (Black)


08027-10270 (Black)

3 —

Part No.:08027-10310 Part No.:08027-10360

4 —


08027-10420 (Black)


08027-10470 (Black)

6 —




No.ofpins

KES 1 (Automobile) connector


No.

8 —


08027-10820 (Black)


08027-10870 (Black)

No.of

pins

Connector for relay (Socket type)

Male (female housing) Female (male housing) T-adapter PartNo.

5 799-601-7360

— —

6 799-601-7370

— —




No.ofpins

F type connector


Part No.

4 —

— —




[The pin No. is also marked on the connector (electric wire insertion end)]

Type

(shell

size

code)

HD30 Series connector

Body (plug) Body (receptacle)T-adapter

Part No.

18-8

(1)

Pin (male terminal) Pin (female termial)

799-601-9210

Part No.: 08191-11201, 08191-11202,

08191-11205, 08191-11206

Part No.: 08191-14101, 08191-14102,

08191-14105, 08191-14106

Pin (female terminal) Pin (male termial)

799-601-9210

Part No.: 08191-12201, 08191-12202,08191-12205, 08191-12206

Part No.: 08191-13101, 08191-13102,08191-13105, 08191-13106

18-14

(2)


799-601-9220

Part No.: 08191-21201, 08191-12202,

08191-21205, 08191-12206

Part No.: 08191-24101, 08191-24102,

08191-24105, 08191-24106






Type

(shell

size

code)



Part No.

18-20

(3)


799-601-9230

Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102


799-601-9230

Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102

18-21

(4)


799-601-9240

Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102






Type

(shell

size

code)



Part No.

24-9

(5)


799-601-9250

Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102


799-601-9250

Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102

24-16

(6)


799-601-9260

Part No.: 08191-61201, 08191-62202,

08191-61205, 08191-62206

Part No.: 08191-64101, 08191-64102,

08191-64105, 08191-64106






Type

(shell

size

code)



Part No.

24-21

(7)


799-601-9270

Part No.: 08191-71201, 08191-71202,

08191-71205, 08191-71206

Part No.: 08191-74101, 08191-74102,

08191-74105, 08191-74106


799-601-9270

Part No.: 08191-72201, 08191-72202,08191-72205, 08191-72206

Part No.: 08191-73101, 08191-73102,08191-73105, 08191-73106

24-22


799-601-9280

Part No.: 08191-81201, 08191-81202

08191-81203, 08191-81204

08191-81205, 08191-80206

Part No.: 08191-84101, 08191-84102

08191-84103, 08191-84104

08191-84105, 08191-84106





Type

(shell

size

code)



Part No.

24-31

(9)

Pin (male termial) Pin (female terminal)

799-601-9290

Part No.: 08191-91203, 08191-91204,

08191-91205, 08191-91206

Part No.: 08191-94103, 08191-94104,

08191-94105, 08191-94106


799-601-9290

Part No.: 08191-92203, 08191-92204,08191-92205, 08191-92206

Part No.: 08191-93103, 08191-93104,08191-93105, 08191-93106





No.of

pins

DT Series connector

Body (plug)Body (receptacle) T-adapter

Part No.

2 799-601-9020

Part No.: 08192-12200 (normal type)

08192-22200 (fine wire type)



3 799-601-9030





4 799-601-9040





6 799 601 9050





No.of

pins

DT Series connector

Body (plug) Body (receptacle) T-adapter Part No.

8

8GR: 799-601-9060

8B: 799-601-90708G: 799-601-9080

8BR: 799-601-9090





12

12GR: 799-601-9110

12B: 799-601-9120

12G: 799-601-9130

12BR: 799-601-9140











No.of

pins

DTM Series connector

Body (plug) Body (receptacle)T-adapter Part

No.

2799-601-9010

Part No.: 08192-02200 Part No.: 08192-02100

No.of

pins

DTHD Series connector

Body (plug) Body (receptacle)T-adapter Part

No.

2 —

Part No.: 08192-31200 (Contact size#12)

08192-41200 (Contact size #8)

08192-51200 (Contact size #4)

Part No.: 08192-31100 (Contact size#12)

08192-41100 (Contact size #8)

08192-51100 (Contact size #4)

TROUBLESHOOTING T BRANCH BOX AND T BRANCH TABLE



TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE

T-BRANCH BOX AND T-BRANCH TABLE

aThe vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows partnumber of Harness Checker Ass'y.

Part No.Connector type or

part nameNo. of pins

7 9 9 - 6 0 1 - 2 5 0 0

7 9 9 - 6 0 1 - 2 7 0 0

7 9 9 - 6 0 1 - 2 8 0 0

7 9 9 - 6 0 1 - 2 9 0 0

7 9 9 - 6 0 1 - 3 0 0 0

7 9 9 - 6 0 1 - 5 5 0 0

7 9 9 - 6 0 1 - 6 0 0 0

7 9 9 - 6 0 1 - 6 5 0 0

7 9 9 - 6 0 1 - 7 0 0 0

7 9 9 - 6 0 1 - 7 1 0 0

7 9 9 - 6 0 1 - 7 4 0 0

7 9 9 - 6 0 1 - 7 5 0 0

7 9 9 - 6 0 1 - 8 0 0 0

7 9 9 - 6 0 1 - 9 0 0 0

7 9 9 - 6 0 1 - 9 1 0 0

7 9 9 - 6 0 1 - 9 2 0 0

7 9 9 - 6 0 1 - 9 3 0 0

—

799-601-2600 Measurement box Econo-21P

799-601-3100 Measurement box MS-37P799-601-3200 Measurement box MS-37P799-601-3300 Measurement box Econo-24P799-601-3360 Plate For MS box799-601-3370 Plate For MS box799-601-3380 Plate For MS box799-601-3410 BENDIX (MS) 24P799-601-3420 BENDIX (MS) 24P799-601-3430 BENDIX (MS) 17P

799-601-3440 BENDIX (MS) 17P799-601-3450 BENDIX (MS) 5P799-601-3460 BENDIX (MS) 10P799-601-3510 BENDIX (MS) 5P799-601-3520 BENDIX (MS) 14P799-601-3530 BENDIX (MS) 19P799-601-2910 BENDIX (MS) 14P799-601-3470 Case799-601-2710 MIC 5P

799-601-2720 MIC 13P799-601-2730 MIC 17P799-601-2740 MIC 21P799-601-2950 MIC 9P799-601-2750 ECONO 2P799-601-2760 ECONO 3P799-601-2770 ECONO 4P799-601-2780 ECONO 8P799-601-2790 ECONO 12P799-601-2810 DLI 8P799-601-2820 DLI 12P799-601-2830 DLI 16P799-601-2840 Additional cable799-601-2850 Case799-601-7010 X 1P799-601-7020 X 2P





Part No.Connector type or part name

No. of pins

7 9 9 - 6 0 1 - 2

5 0 0

7 9 9 - 6 0 1 - 2

7 0 0

7 9 9 - 6 0 1 - 2

8 0 0

7 9 9 - 6 0 1 - 2

9 0 0

7 9 9 - 6 0 1 - 3

0 0 0

7 9 9 - 6 0 1 - 5

5 0 0

7 9 9 - 6 0 1 - 6

0 0 0

7 9 9 - 6 0 1 - 6

5 0 0

7 9 9 - 6 0 1 - 7

0 0 0

7 9 9 - 6 0 1 - 7

1 0 0

7 9 9 - 6 0 1 - 7

4 0 0

7 9 9 - 6 0 1 - 7

5 0 0

7 9 9 - 6 0 1 - 8

0 0 0

7 9 9 - 6 0 1 - 9

0 0 0

7 9 9 - 6 0 1 - 9

1 0 0

7 9 9 - 6 0 1 - 9

2 0 0

7 9 9 - 6 0 1 - 9

3 0 0

—

799-601-7140 S 8P799-601-7150 S 10P-White799-601-7160 S 12P-Blue799-601-7170 S 16P-Blue799-601-7330 S 16P-White

799-601-7350 S 12P-White799-601-7180 AMP040 8P799-601-7190 AMP040 12P799-601-7210 AMP040 16P799-601-7220 AMP040 20P799-601-7230 Short connector X-2799-601-7240 Case799-601-7270 Case799-601-7510 070 10P

799-601-7520 070 12P799-601-7530 070 14P799-601-7540 070 18P799-601-7550 070 20P799-601-7360 Relay connector 5P799-601-7370 Relay connector 6P799-601-7380 JFC connector 2P799-601-9010 DTM 2P799-601-9020 DT 2P

799-601-9030 DT 3P799-601-9040 DT 4P799-601-9050 DT 6P799-601-9060 DT 8P-Gray799-601-9070 DT 8P-Black799-601-9080 DT 8P-Green799-601-9090 DT 8P-Brown799-601-9110 DT 12P-Gray799-601-9120 DT 12P-Black

799-601-9130 DT 12P-Green799-601-9140 DT 12P-Brown799-601-9210 HD30 18-8799-601-9220 HD30 18-14799-601-9230 HD30 18-20799-601-9240 HD30 18-21799 601 9250 HD24 24 9




TROUBLESHOOTING T BRANCH BOX AND T BRANCH TABLE

Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power (A

switch power supply is a device which supplies power while the starting switch is at the ON position and a

constant power supply is a device which supplies power while the starting switch is at the OFF position).

a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fus-

ible link to see if the power is supplied normally.

Type of

power supplyFuse No. Fuse capacity Destination of powerDestination of power

Switch power supply

(Fusible link: A34)

1 10 A

Pump controller (Controller power supply)

Swing holding brake solenoid

(When emergency brake is released)

PC-EPC solenoid (When emergency pump is driven)

2 20 A

Pump controller (Solenoid power supply)

Machine push-up solenoid

ATT return selector relay & solenoid

3 10 AStarting motor cutout relay (For PPC lock)

PPC lock solenoid

4 10 ACigarette lighter

Windshield washer motor

5 10 A Horn

Switch power supply

(Fusible link: A34)

6 10 A (Spare)

7 10 A Rotary lamp

8 10 A Right front working lamp & boom working lamp

9 10 A

One-touch power maximizing switch

(Input to pump controller input)

Radio

10 10 A (Spare)

Switch power supply

(Fusible link: A34)

11 20 A Air conditioner unit

12 20 AMonitor panel

Starting motor cutout relay (For personal code)

13 20 ALight relay (For right front working lamp & boom working lamp)

Headlamp & additional headlamp

14 10 A Service power supply 1 (M32 connector)

15 10 ATravel alarm

Service power supply 2 (DC/DC converter)

Constant

power supply

(Fusible link: A35)

16 10 A Radio (For backing up)

17 10 A Monitor panel (For backing up)

18 10 A Starting switch

19 10 A Room lamp

20 10 A (Spare)



INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304

Error Code in Electrical System [E112]

(Short-circuiting in normal rotation system of windshield wiper motor drive)........................................ 20-306


(Short-circuiting in reverse rotation system of windshield wiper motor drive)....................................... 20-308

Error Code in Electrical System [E114] (Short-circuiting in window washer drive system)......................... 20-310

Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion) ........................................... 20-312

Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper) ................................. 20-314Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)............................................. 20-316

Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)........................................... 20-318

Error Code in Electrical System [E128] (Monitor Comm. Abnormality)....................................................... 20-320

Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid) ............................ 20-322

Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid) ........................ 20-324

Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid).................................... 20-326

Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid) ................................... 20-327

Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid) ........................ 20-328Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid).............................. 20-329

Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid).......................... 20-330

Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)..................................... 20-332

Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)..................................... 20-333

Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid).......................... 20-334

Error Code in Electrical System [E217] (Abnormal input model code)........................................................ 20-336

Error Code in Electrical System [E218] (S-Net Comm. Disc.)..................................................................... 20-338

Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid) ........................................... 20-340

Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system) ................................ 20-341Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality) .................................................. 20-342

Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality) .................................................. 20-344

Error Code in Electrical System [E226] (Press. Sensor Power Abnormality).............................................. 20-346

Error Code in Electrical System [E227] (Abnormality in engine rotation sensor) ........................................ 20-348

Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay).................. 20-349

TROUBLESHOOTING WHEN ERROR CODE

“ELECTRICAL SYSTEM” AND FAILURE CODE

“MECHANICAL SYSTEM” ARE DISPLAYED

TROUBLESHOOTING



Error Code in Electrical System [E936] (Engine oil press. sw. error) .......................................................... 20-376

Error Code in Electrical System [E93C] (Engine boost sensor error) ......................................................... 20-378

Error Code in Electrical System [E93D] (Engine fuel temp. sensor error) .................................................. 20-380

Error Code in Electrical System [E953] (Engine Comm. Abnormality)........................................................ 20-382Error Code in Electrical System [E954] (Short engine starter sw.).............................................................. 20-384

Error Code in Electrical System [E955] (Engine S-NET error) .................................................................... 20-386

Error Code in Electrical System [E956] (Engine power failure (1)) ............................................................. 20-388

Error Code in Electrical System [E957] (Engine power failure (2)) ............................................................. 20-390

Error Code in Electrical System [E95A] (Engine Q-adj. sw. signal error).................................................... 20-392

Error Code in Electrical System [E96A] (Engine coolant sensor Lo error).................................................. 20-394

Error Code in Electrical System [E970] (PCV1 over current)...................................................................... 20-396

Error Code in Electrical System [E971] (PCV2 over current)...................................................................... 20-397

Error Code in Electrical System [E974] (PCV1 line cut).............................................................................. 20-398

Error Code in Electrical System [E975] (PCV2 line cut).............................................................................. 20-399

Error Code in Electrical System [E977] (Rail press. sensor error) .............................................................. 20-400

Error Code in Electrical System [E979] (Rail press. high)........................................................................... 20-402

Error Code in Electrical System [E97A] (Rail press. abnormal) .................................................................. 20-402

Error Code in Electrical System [E97B] (Rail press. low)............................................................................ 20-403

Error Code in Electrical System [E97C] (Rail press. too low) ..................................................................... 20-405

Error Code in Electrical System [E97D] (Rail press. out of control)............................................................ 20-405

Error Code in Electrical System [E980] (Eng. Controller Abnormality) ....................................................... 20-406Error Code in Electrical System [E981] (Fuel Injector 1 Disc.).................................................................... 20-408

Error Code in Electrical System [E982] (Fuel Injector 2 Disc.).................................................................... 20-409





Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C) ............................................................... 20-414

Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C) ............................................................... 20-416

Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)........................... 20-418Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard) ............................ 20-418

Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging) ........................................................ 20-420

Failure Code in Mechanical System [AB00KE] (Charge Voltage Low) ....................................................... 20-422

Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)...................................................... 20-424

Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)........................................................ 20-426

Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat).................................................... 20-427

Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)....................................................... 20-428

Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)........................................................ 20-429



TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE



INFORMATION CONTAINED IN TROUBLESHOOTING TABLE

aThe troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-tents fully before proceeding to actual troubleshooting work.

User Code Error Code Failure CodeFailure

phenomenonTitle of failure phenomenon shown in failure historyDisplay in

monitor panel

Display in

monitor panel

Display in

monitor panel

Failure content Failure status as detected by monitor panel or controller

Response from

monitor panel

or controller

Action taken by the monitor panel or controller to protect an affected system or equipment, when they

detect some failure.

Phenomenon

occurring on

machine

Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or

controller

Relative

informationInformation on the failure occurred as well as the troubleshooting

P r e s u m e d c a u s e a n d

s t a n d a r d v a l u e i n n o r m a l c y

Cause Standard value in normalcy and references for troubleshooting

1

Cause that presumably

triggered failure in

question (The assigned

No. is for filing purpose

only. It does not stand for

any priority)

<Content Included>• Standard value in normalcy by which to pass “Good” or “No Good” judgement

over the presumed cause

• Reference for passing the above “Good” or “No Good” judgement

<Phenomenon of Wiring Harness Failure>

• Disconnection

There is a faulty contact at the connector or disconnection of wiring harness

occurred.

• Defective grounding

A wiring harness that is not connected with a grounding circuit has a contact withthe grounding circuit.

• Short-circuiting

A wiring harness that is not connected with a 24 V electric circuit has a contact

with the electric circuit.

<Precaution for Troubleshooting>

1) Connector No. display method and handling of T-adapter

Insert or connect T-adapters in the following manner before starting

troubleshooting unless otherwise instructed.• If there is no indication of “male” or “female” in a specific connector No.,

disconnect the connector and insert the T-adapter into both male and female

sides.

• If there is an indication of “male” or “female” in a specific connector No.,

disconnect the connector and connect the T-adepter with only one side of either

“male” or “female”

2

3

4




Relative Electrical Circuit Diagram

This is part of the electrical circuit diagram which shows the portion where the failure occurred.

• Connector No.: Indicates (Type - numbers of a pin) (color)

• Arrow: Roughly indicates the location in the machine where it is installed.

TROUBLESHOOTING E112



Error Code in Electrical System [E112](Short-circuiting in normal rotation system of windshield wiper motor drive)

User Code Error Code Failure Code Failure

phenomenon

Short-circuiting in normal rotation system of wind-

shield wiper motor drive (in monitor panel system)— E112 DY2DKB

Failure content • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.

Response from

Monitor Panel• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.

Phenomenon

occurring on

machine

• The windshield wiper stops moving.

Relative

information


s

t a n d a r d v a l u e i n n o r m a l c y


1

Windshield wiper motor

defective

(Internal short-circuitingor grounding fault)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF

position for the troubleshooting.

W04 (female) Continuity and resistance value

Between (3) and (1) Continued

Between (3) and grounding Above 1 Mz

2

Grounding fault of wiring

harness

(Contact with grounding

circuit)



Between wiring harness between P01 (female) (9) and

W04 (male) (3) and grounding

Resistance

value

Above

1 Mz

3 Monitor panel defective

aTurn the engine starting switch OFF for the preparations, and hold it in the ON


P01 Windshield wiper switch Voltage

Between (9) and ground-

ing

OFF Below 3 V

ONBelow 3 V 20 – 30 V

(at constant cycle)




Electric Circuit Diagram for Windshield Wiper Motor




Error Code in Electrical System [E113](Short-circuiting in reverse rotation system of windshield wiper motor drive)


phenomenon

Short-circuiting in reverse rotation system of wind-

shield wiper motor drive (in Monitor Panel system)— E113 DY2EKB

Failure content• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the

windshield wiper was set in motion.

Response from

Monitor Panel• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.

Phenomenon

occurring on

machine

• The windshield wiper stopped moving.

Relative

information




1


defective

(Internal short-circuiting

or grounding fault)



W04 (female) Continuity and resistance value

Between (1) and (3) Continued


2


harness


circuit)




W04 (male) (1) and grounding

Resistance

value

Above

1 Mz




P01 Windshield wiper switch Voltage

Between (10) and

grounding

OFF Below 3 V

ONBelow 3 V 20 – 30 V

(at constant cycle)




Electric Circuit Diagram for Windshield Wiper Motor




Error Code in Electrical System [E114](Short-circuiting in window washer drive system)


phenomenon

Short-circuiting in window washer drive system

(in Monitor Panel system)— E114 DY2CKB

Failure content• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power

was switched ON.

Response from

Monitor Panel• Power supply to the grounding in the window washer motor circuit was switched OFF.

Phenomenon

occurring on

machine

• The window washer stopped moving.

Relative

information


s t a n d a r d v a l u e i n n o r m a l c

y


1

Window washer drive

motor defective

(Internal short-circuiting)



A50 (male) Resistance value

Between (1) and (2) 5 – 20 z

2

Short-circuiting of wiring

harness

(Contact with 24 V

circuit)



Between wiring harness from P01 (female) (3) to J04 to

A50 (female) (2) and grounding, or between wiring

harness between P01 (female) (3) and D02 (female) (8)

and grounding

Voltage Below 1 V



position for the troubleshooting.P01 Window washer switch Voltage

Between (3) and

grounding

OFF 20 – 30 V

ON Below 1 V




Electrical Circuit Diagram for Window Washer Motor




Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion)


phenomenon

Abnormal operation of windshield wiper

(in Monitor Panel system)— E115 DY20KA

Failure content • A W signal is not inputted at both ends of movement, when it is in motion.

Response from

Monitor Panel• Power to the windshield wiper motor is turned OFF.

Phenomenon

occurring on

machine

• The windshield wiper motor does not work.

Relative

information

• Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.

(Code No.: 04502 Monitor input 3)


s



1


defective

(Internal disconnection)



W04 (female) Windshield wiper blade Resistance value

Between (6) and (5)

At upper end of operation

rangeBelow 1 z

Outside upper end ofoperation range

Above 1 Mz

2

Disconnection of wiring

harness

(Disconnection or faulty

contact with connector)



Wiring harness between P01 (female) (5) and W04

(male) (6)

Resistance

valueBelow 1 z

Wiring harness between W04 (male) (5) and groundingResistance

valueBelow 1 z


aTurn the engine starting switch OFF for the preparations, and hold it in the ONposition for the troubleshooting.

P01 Windshield wiper blade Voltage

Between (5) and

grounding

At upper end of operation

rangeBelow 1 V

Outside upper end of

operation range2 0 – 3 0 V




Windshield Wiper Motor Electrical Circuit Diagram




Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper)


phenomenon

Abnormal in retracting windshield wiper

(in Monitor Panel system)— E116 DY20MA

Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.

Response from

Monitor Panel

• Power supply to the windshield wiper motor is switched OFF, when the wiper is

retracted.

Phenomenon

occurring on

machine

• The windshield wiper cannot be retracted completely.

Relative

information

• It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation

range is inputted or not. (Code No.: 04502 Monitor Input 3)




1


defective




W04 (female) Windshield wiper blade Resistance value

Between (4) and (5)Retraction range Below 1 z

Operation range Above 1 Mz

2


harness

(Disconnection or

defective contact with

connector)


position during the troubleshooting.


(male) (4)

Resistance

valueBelow 1 z

Between wiring harness W04 (male) (5) and groundingResistance

valueBelow 1 z




P01 Windshield wiper blade Voltage

Between (12) and

grounding

Retraction range Below 1V

Operation range 20 – 30 V




Windshield Wiper Motor Electrical Circuit Diagram




Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)


phenomenon

Eng. Controller S-NET Comm. Err.

(Monitor panel system)— E117 DAC0KR

Failure content• The monitor panel detected communication failure in the S-NET communication circuit to the engine

controller.

Response from

monitor panel

• The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.

• When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon

occurring on

machine

• The output lowers (The pump absorption torque is reduced).

• If the working load increases, the engine may stall.

Relative

information

• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.

(Code No. 05100: Connection of S-NET)




1


harness

(Disconnection or defec-

tive contact with connec-

tor)



Wiring harness between P02 (female) (9), (10) and CB2

(female) (21), (31) or between P02 (female) (9), (10)

and C02 (female) (21)

Resistance

valueBelow 1 z

2


harness


circuit)



Between wiring harness between P02 (female) (9), (10)

and CB2 (female) (21), (31) or between P02 (female)

(9), (10) and C02 (female) (21) and related circuits and

grounding

Resistance

value Above 1 Mz

3Short-circuiting of wiringharness

(Contact with 24 V circuit)






grounding

Voltage Below 1 V

4Engine controller

defective



CB2 Voltage

Between (21), (31) and (11) 6 – 9 V




P02 Voltage

Between (9), (10) and (20) 6 – 9 V




Electrical circuit diagram related to S-NET communication




Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)


phenomenon

Pump Controller S-NET Comm. Err.

(Monitor panel system)— E118 DAB0KR

Failure content• The monitor panel detected communication failure in the S-NET communication circuit to the pump

controller.

Response from

monitor panel



Phenomenon

occurring on

machine



Relativeinformation

• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.(Code No. 05100: Connection of S-NET)




1


harness



tor)






Resistance

valueBelow 1 z

2


harness


circuit)






grounding

Resistance

value Above 1 Mz








grounding

Voltage Below 1 V

4Pump controller

defective



C02 Voltage

Between (21) and (31) 6 – 9 V




P02 Voltage

Between (9), (10) and (20) 6 – 9 V




Error Code in Electrical System [E128] (Monitor Comm. Abnormality)


phenomenon

Monitor Comm. Abnormality

(Monitor panel system)E0E E128 DAF0MC

Failure content• The monitor panel detected communication failure in the CAN communication circuit to the engine con-

troller or pump controller.

Response from

monitor panel



Phenomenon

occurring on

machine



Relativeinformation




1


harness


tive contact with connec-tor)



Wiring harness between P70 (female) (16) and CB2

(female) (22) or between P70 (female) (16) and C02

(female) (22)

Resistance

valueBelow 1 z



(female) (32)

Resistance

valueBelow 1 z

2


harness


circuit)




CB2 (female) (22) or between P70 (female) (16) and

C02 (female) (22) or between P70 (female) (16) and

related circuits and grounding

Resistance

value Above 1 Mz





Resistance

value Above 1 Mz

3


harness





CB2 (female) (22) or between P70 (female) (16) andC02 (female) (22) or between P70 (female) (16) and


Voltage Below 1 V



C02 (female) (32) or between P70 (female) (15) andVoltage Below 1 V




Electrical circuit diagram related to CAN communication


E C d i El t i l S t [E201]



Error Code in Electrical System [E201](Short-circuiting in travel interlocking solenoid)

Electrical Circuit for Travel Interlocking Solenoid


phenomenon

Short-circuiting in travel interlocking solenoid

(Pump controller system)— E201 DW91KB

Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.

Response from

controller

• Power supply to the travel interlocking circuit is switched OFF.

• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the

engine starting switch is once turned OFF.

Phenomenon

occurring on

machine

• It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits connot be disconnected)

Relative

information

• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.

(Code No.: 02300 Solenoid 1)



y


1

Travel interlocking sole-

noid defective


or grounding fault)



V02 (male) Resistance value

Between (1) and (2) 20 – 60 zBetween (2) and grounding Above 1 Mz

2


harness


circuit)



Between wiring harness from C03 (female) (7) to V02

(female) (2) and grounding

Resistance

value

Above

1 Mz

3Pump controller

defective

aTurn the engine starting switch OFF for the preparations, and hold it running during

the troubleshooting.

C03 R.H. & L.H. travel controllever

Voltage

Between (7) and

grounding

Neutral Below 1 V

Steering 20 – 30 V



Error Code in Electrical System [E203](Short-circuiting in swing holding brake solenoid)

User Code Error Code Failure Code Failurephenomenon

Short-circuiting in swing holding brake solenoid(Pump controller system)E03 E203 DW45KB

Failure content• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the

circuit.

Response from

controller

• Power supply to the swing holding brake solenoid circuit is switched OFF.

• Even after the failure cause disappears of itself, the swing and steering brake does not return to

normalcy, unless the engine starting switch is once turned OFF.

Phenomenon

occurring onmachine

• The upper structure cannot swing. (The swing holding brake cannot be released.)

Relative

information

• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.


• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning

the swing holding brake releasing switch to the RELEASE position.

(In this case, however, the holding brake does not work, when stopping the machine)

P r e s u m e

d c a u s e a n d

s t a n d a r d v a

l u e i n n o r m a l c y


1

Swing holding brake

solenoid defective


or grounding fault)

aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.


Between (1) and (2) 20 – 60 z


2


harness

(Contact with groundingcircuit)



Wiring harness from C03 (female) (37) to D01 to J02 to

X05 to V05 (female) (2), or C03 (female) (37) and S25


Resistancevalue

Above1 Mz

3Pump controller

defective



C03L.H. work equipment

control lever Voltage

Between (37) and

grounding

NEUTRAL Below 1 V

Swing operated 20 – 30 V


Electrical Circuit Diagram for Swing Holding Brake Solenoid



Electrical Circuit Diagram for Swing Holding Brake Solenoid


Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid)



Error Code in Electrical System [E204] (Short circuiting in merge/divide solenoid)

Electrical Circuit Diagram for Merge/Divide Solenoid


phenomenon

Short-circuiting in merge/divide solenoid

(Pump controller system)— E204 DWJ0KB

Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.

Response from

controller

• Power supply to the merge/divide solenoid circuit is switched OFF.

• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,

unless the engine starting switch is once turned OFF.

Phenomenon

occurring on

machine

• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.

(F•R pumps cannot be disconnected.)

Relativeinformation

• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.(Code No.: 02300 Solenoid 1)




1

Merge/divide solenoid

defective


or grounding fault)




Between (1) and (2) 20 – 60 z


2


harness


circuit)



Wiring harness from C03 (female) (17) to V03 (female)

(2) and grounding

Resistance

value

Above

1 Mz

3Pump controller

defective



C03L.H. and R.H. travel

control levers

Voltage

Between (17) and

grounding

NEUTRAL Below 1 V

When operating one side

only2 0 – 3 0 V


Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid)



Error Code in Electrical System [E205] (Short circuiting in 2 stage relief solenoid)

Electric Circuit Diagram for 2-stage Relief Solenoid


phenomenon

Short-circuiting in 2-stage relief solenoid

(Pump controller system)— E205 DWK0KB

Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.

Response from

controller

• Power supply to the 2-stage relief solenoid circuit is switched OFF.



Phenomenon

occurring on

machine

• The one-touch power max. switch does not work.

(The main relief valve cannot be set to high-pressure set.)

Relativeinformation

• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.(Code No.: 02300 Solenoid 1)

P r e s u m e d c a u s e

a n d

s t a n d a r d v a l u e i n n o

r m a l c y


1

2-stage relief solenoid

defective


or grounding fault)




Between (1) and (2) 20 – 60 z


2


harness


circuit)




(2) and grounding

Resistance

value

Above

1 Mz

3Pump controller

defective



C03 Working mode Voltage

Between (28) and

grounding

Other than L mode Below 1 V

L mode 20 – 30 V





y [ ](Short-circuiting in travel speed shifting solenoid)

Electrical Circuit Diagram for Travel Speed Shifting Solenoid


Short-circuiting in travel speed shifting solenoid(Pump controller system)— E206 DW43KB

Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.

Response from

controller

• Power supply to the travel speed shifting solenoid circuit is switched OFF.



Phenomenon

occurring on

machine

• The travel speed does not turn to Hi.

(The travel motor swash plate angle does not turn to minimum.)

Relative

information

• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.



s t a n d a r d v a l u e i n n o r m a

l c y


1

Travel speed shifting

solenoid defective


or grounding fault)




Between (1) and (2) 20 – 60 zBetween (2) and grounding Above 1 Mz

2


harness


circuit)




(2) and grounding

Resistance

value

Above

1 Mz

3 Pump controllerdefective



C03 Travel speed + travel lever Voltage

Between (27) and

grounding

Lo + Neutral Below 1 V

Hi + Travel operation 20 – 30 V


Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid)



Electrical Circuit Diagram for Travel Interlocking Solenoid


phenomenon

Disconnection in travel interlocking solenoid

(Pump controller system)— E211 DW91KA

Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.

Response from

controller

• None in particular (The solenoid does not function as there is current flowing to it)


Phenomenon

occurring on

machine

• It is difficult to steer the machine while traveling. (L.H. and R.H. travel circuits cannot be disconnected.)

Relative

information

• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.

(Code No.: 02300 Solenoid 1)• The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power

ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code

[E201].)


s t a n d

a r d v a l u e i n n o r m a l c y


1

Travel interlocking

solenoid defective





Between (1) and (2) 20 – 60 z

2


harness

(Disconnection or


connector)




(2)

Resistance

valueBelow 1 z

Wiring harness between C03 (female) (3), (13), (23)

and V02 (female) (1)

Resistance

valueBelow 1 z


(Contact with 24 V cir-

cuit)




(2) and groundingVoltage Below 1 V

4Pump controller

defective



C03 (female) Resistance value

Between (7) and (3), (13), (23) 20 – 60 z





(Disconnection in swing holding brake solenoid)


Disconnection in swing holding brake solenoid(Pump controller system)E03 E213 DW45KA

Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.

Response from

controller

• None in particular (The solenoid does not function as there is no current flowing to it)


Phenomenon

occurring on

machine

• The machine's upper structure does not swing. (The swing holding brake cannot be released.)

Relative

information

• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.(Code No.: 02300 Solenoid 1)

• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can

swing by moving the swing holding brake release switch to the RELEASE position. (In this case,

however, the holding brake does not work, when stopping the machine)

• While in troubleshooting, hold both the swing lock switch and the swing holding brake release switch in

the OFF position.

• The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power


[E203].)

e s u m e d c a u s e

a n d

d a r d v a l u e i n n o

r m a l c y


1

Swing holding brake

solenoid defective





Between (1) and (2) 20 – 60 z

2Swing lock switchdefective




X05 (female) Swing lock switch Resistance value

Between (3) and (4)OFF Below 1 z

ON Above 1 Mz

3

Assembled-type diode

D01 defective




D01 (male) Digital type circuit tester Continuity

Between (7) and (3) Diode mode Continued

Disconnection of

wiring harness



Wiring harness between C03 (female) (37) and D01

(female) (7)

Resistance

valueBelow 1 z

Wiring harness from D01 (female) (3) to J02 to X05 Resistance




Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)



Electrical Circuit Diagram for Merge/Divide Solenoid


phenomenon

Disconnection in merge/divide solenoid

(Pump controller system)— E214 DWJ0KA

Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.

Response from

controller



Phenomenon

occurring on

machine

• In L mode, speeds of the work equipment and swing in its single operation are too fast.

(F•R pumps cannot be disconnected.)

Relative

information

• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.



[E204].)


s t a n d



1

Merge/divide solenoid

defective





Between (1) and (2) 20 – 60 z

2


harness

(Disconnection or


connector)




(2)

Resistance

valueBelow 1 z



Resistance

valueBelow 1 z

3


harness

(Contact with 24 V

circuit)





4Pump controller

defective




Between (17) and (3), (13), (23) 20 – 60 z


Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)



Electrical Circuit Diagram for 2-stage Relief Solenoid


phenomenon

Disconnection in 2-stage relief solenoid

(Pump controller system)— E215 DWK0KA

Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.

Response from

controller



Phenomenon

occurring on

machine

• The one-touch power max. switch does not work.

(The main relief valve cannot be set to high-pressure set.)

Relative

information

• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.



[E205].)


s t a n d



1

2-stage relief solenoid

defective





Between (1) and (2) 20 – 60 z

2


harness

(Disconnection or


connector)




(2)

Resistance

valueBelow 1 z



Resistance

valueBelow 1 z

3


harness

(Contact with 24 V

circuit)





4Pump controller

defective




Between (28) and (3), (13), (23) 20 – 60 z


Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid)



Electrical Circuit Diagram for Travel Speed Shifting Solenoid


phenomenon

Disconnection in travel speed shifting solenoid

(Pump controller system)— E216 DW43KAFailure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.

Response from

controller



Phenomenon

occurring on

machine

• The travel speed does not shift to Hi.

(The travel motor swash plate angle does not turn to minimum.)

Relative

information

• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.



[E206].)


s t a n d



1

Travel speed shifting

solenoid defective





Between (1) and (2) 20 – 60 z

2


harness

(Disconnection or


connector)




(2)

Resistance

valueBelow 1 z



Resistance

valueBelow 1 z

3


harness

(Contact with 24 V

circuit)





4Pump controller

defective




Between (27) and grounding (3), (13), (23) 20 – 60 z




Error Code in Electrical System [E217] (Abnormal input model code)




phenomenon

Abnormality in inputting model code

(Pump controller system)— E217 DA2SKQFailure content • A model code signal for a model which is not registered in the controller is inputted.

Response from

controller

• The controller controls the machine as a default model (PC750).



Phenomenon

occurring on

machine

• Since the controller controls the machine as PC750/800, the working speed changes and operation

becomes difficult.

Relative

information

• The model name (number) recognized by the controller can be checked in the monitoring function.(Code No. 00200: Controller model code)

• Input of the model selection signal (ON or OFF) can be checked in the monitoring function.

(Code No. 02201: Switch input 2)

P r e s u m e d c a u s

e a n d



1

Model selection connec-

tor defective

(Internal disconnection orshort-circuit)




Between (4), (5), (6) and (8) Min. 1 Mz

Between (1), (2), (3), (7) and (8) Max. 1 z

2


harness

(Disconnection or defec-tive contact with connec-

tor)



Wiring harness between C02 (female) (37) and C09

(male) (1)

Resistance

valueMax, 1 z


(male) (2)

Resistance

valueMax, 1 z


(male) (3)

Resistance

valueMax, 1 z


(male) (7)

Resistance

valueMax, 1 z

Wiring harness between C09 (male) (8), J05, and

grounding

Resistance

valueMax, 1 z

3


harness


circuit)



Between wiring harness between C02 (female) (7) and

C09 (male) (4) and grounding

Resistance

valueMin. 1 Mz



C02 V lt


Electrical circuit diagram related to model selection connector (for pump controller)




Error Code in Electrical System [E218] (S-Net Comm. Disc.)




phenomenon

S-Net Comm. Disc.

(Pump controller system)E0E E218 DA2SKA

Failure content• The pump controller detected communication failure in the S-NET communication circuit to the monitor

panel or engine controller.

Response from

controller



Phenomenon

occurring on

machine



Relativeinformation

• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.(Code No. 05100: Connection of S-NET)


s t a n d a r d v a l u e i n

n o r m a l c y


1


harness

(Disconnection or


connector)






Resistance

valueMax. 1 z

2


harness


circuit)





(9), (10) and C02 (female) (21) or between P02 (female)

(9), (10) and related circuits and grounding

Resistance

valueMin. 1 Mz

3 Short-circuiting of wiringharness




Between wiring harness between P02 (female) (9), (10)and CB2 (female) (21), (31) or between P02 (female)



Voltage Max. 1 V




P02 Voltage

Between (9), (10) and (20) 6 – 9 V

5Engine controller

defective

aTurn the engine starting switch OFF for the preparations, and hold it in the ONposition during the troubleshooting.

CB2 Voltage

Between (21), (31) and (11) 6 – 9 V

a O f O


Electrical Circuit Diagram for S-NET Communication




Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid)

User Code Error Code Failure Code F il Di i i LS EPC l id



Electrical Circuit Diagram for LS-EPC Solenoid


phenomenon

Disconnection in LS-EPC solenoid

(Pump controller system)— E222 DXE0KBFailure content • Abnormal current flew to the LS-EPC solenoid circuit.

Response from

controller

• The controller reduces the output to the LS-EPC solenoid circuit to 0.

• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting

switch is once turned OFF.

Phenomenon

occurring on

machine

• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too

fast. (The LS valve set pressure cannot be controlled.)

Relativeinformation

• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.(Code No.: 01500 LS-EPC solenoid current)


a n d



1

LS-EPC solenoid

defective


or grounding fault)




Between (1) and (2) 7 – 14 z


2


harness


circuit)




V22 (female) (1) and grounding

Resistance

value

Above

1 Mz

3Pump controller

defective




Between (6) and (3) (13) (23) 7 – 14 zBetween (6) and grounding Above 1 Mz


Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system)

User Code Error Code Failure Code F il Di ti i LS EPC l id



Electrical Circuit Diagram for LS-EPC Solenoid


phenomenon

Disconnection in LS-EPC solenoid

(Pump controller system)— E223 DXE0KAFailure content • No current flows to the LS-EPC solenoid circuit.

Response from

controller



Phenomenon

occurring on

machine

• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too

fast. (The LS valve set pressure cannot be controlled.)

Relative

information

• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.

(Code No.: 01500 LS-EPC solenoid current)

P r e s u m e d c a u s e a n

d

s t a n d a r d v a l u e i n n o r m

a l c y


1

LS-EPC solenoid

defective





Between (1) and (2) 7 – 14 z

2


harness

(Disconnection or


connector)





Resistance

valueBelow 1 z

Wiring harness between C03 (female) (3) (13) (23) and

V22 (female) (2)

Resistance

valueBelow 1 z

3


harness

(Contact with 24 V

circuit)




V22 (female) (1) and groundingVoltage Below 1 V

4 Pump controller defective




Between (6) and (3) (13) (23) 7 – 14 z


Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality)

User Code Error Code Failure Code Failure F Pump P Sensor Abnormality




phenomenon

F Pump P. Sensor Abnormality

(Pump controller system)— E224 DHPAMAFailure content • Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V.

Response from

controller

• The controller sets the F pump pressure to 0 MP {0 kg/cm2} for control.


Phenomenon

occurring on

machine

• The travel speed does not shift automatically (The travel load pressure cannot be detected).

Relativeinformation

a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure

sensor will be broken. Accordingly, take extreme care when checking.• Input from the front pump pressure sensor (pressure) can be checked in the monitoring function.

(Code No. 01100: Front pump pressure)




1Sensor power supply

system defectiveIf error code [226] is displayed, carry out troubleshooting for it first.

2

Front pump pressure

sensor defective

(Internal defect)

aTurn the engine starting switch OFF for the preparations, and turn to ON or keep

the engine running during the troubleshooting.

A51 Voltage

Between (B) and (A) Power supply 4.5 – 5.5 V

Between (C) and (A) Signal 0.5 – 4.5 V

The pressure sensor voltage is measured with the wiring harness connected.

Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,

for another cause of the trouble, and then judge.

3


harness

(Disconnection or


connector)



Wiring harness between C01 (female) (22) and A51

(female) (B)

Resistance

valueMax. 1 z


(female) (A)

Resistance

valueMax. 1 z

Wiring harness between C01 (female) (8) and P30

(female) (C)

Resistance

valueMax. 1 z

4


harness(Contact with grounding

circuit)




A51 (female) (C) and grounding

Resistance

valueMin. 1 Mz

Sh t i iti f i i




Electrical circuit diagram related to front pump pressure sensor




Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality)

User Code Error Code Failure Code Failure R Pump P. Sensor Abnormality



Failure

phenomenon

R Pump P. Sensor Abnormality

(Pump controller system)— E225 DHPBMA

Failure content • Signal voltage from the rear pump pressure sensor is below 0.3 V or above 4.42 V.

Response from

controller

• The controller sets the R pump pressure to 0 MP {0 kg/cm2} for control.


Phenomenon

occurring on

machine

• The travel speed does not shift automatically (The travel load pressure cannot be detected).

Relativeinformation

a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure

sensor will be broken. Accordingly, take extreme care when checking.• Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function.

(Code No. 01101: Rear pump pressure)






2

Rear pump pressure

sensor defective

(Internal defect)



A52 Voltage

Between (B) and (A) Power supply 4.5 – 5.5 V

Between (C) and (A) Signal 0.5 – 4.5 V




3


harness



tor)




(female) (B)

Resistance

valueMax. 1 z


(female) (A)

Resistance

valueMax. 1 z


(female) (C)

Resistance

valueMax. 1 z

4



circuit)




A52 (female) (C) and grounding

Resistance

valueMin. 1 Mz

Sh t i iti f i i




Electrical circuit diagram related to rear pump pressure sensor




Error Code in Electrical System [E226] (Press. Sensor Power Abnormality)

User Code Error Code Failure Code Failure Press. Sensor Power Abnormality



phenomenon (Pump controller system)— E226 DA25KP

Failure content • Abnormal current flowed in the pressure sensor power supply (5 V) circuit.

Response from

controller

• Power to the power supply (5 V) circuit is switched OFF.



Phenomenon

occurring on

machine

• The pressure sensor signal is not input normally.

• The error code of abnormality in the pressure sensor is displayed, too.

Relativeinformation

P r e s u m e d c

a u s e a n d

s t a n d a r d v a l u e

i n n o r m a l c y


1

Pressure sensor

defective(Internal short-circuiting)

aDisconnect the connector when the engine starting switch is in OFF, and hold it in

the ON position during the troubleshooting.

Disconnect the parts

shown at right in order.If the error code goes off

when one of those parts is

disconnected, that part is

defective.

Front pump

pressure sensor Connector A51

Rear pump

pressure sensor Connector A52

Arm IN PPC

pressure sensor Connector S04

Bucket CURL PPC

pressure sensor Connector S01

2


harness


circuit)



Between wiring harness between C01 (female) (22),

A51 (female) (B) and grounding

[Front pump pressure sensor system]

Resistancevalue

Min. 1 Mz


A51 (female) (B) and grounding

[Rear pump pressure sensor system]

Resistance

valueMin. 1 Mz


S04 (female) (A) and grounding

[Arm IN PPC pressure sensor system]

Resistance

valueMin. 1 Mz

Between wiring harness between C01 (female) (22),S01 (female) (A) and grounding

[Bucket CURL PPC pressure sensor system]

Resistance

valueMin. 1 Mz






Error Code in Electrical System [E227] (Abnormality in engine rotation sensor)


h

Abnormality in engine rotation sensor

(P t ll t )



Electrical Circuit Diagram for Engine Rotation Sensor

phenomenon (Pump controller system)— E227 DLE2MA

Failure content • A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.

Response from

controller

• The controller exercises a control equivalent to E mode.

• If the failure cause disappears of itself, the signal input returns to normalcy.

Phenomenon

occurring on

machine

• The machine lacks power a bit. (The engine rotation sensing does not work.)

• The engine speed (in the pump controller system) is not monitored on the monitor panel.

Relative

information

• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.

(Code No.: 01006 Engine RPM)


s t a

n d a r d v a l u e i n n o r m a l c y


1

Engine rotation sensor

fault


or disconnection)



ENE (male) Resistance value

Between (1) and (2) 500 – 1,000 z


2 Engine rotation sensoradjustment improper For the inspection and adjustment, refer to the section of “Adjusting Engine RotationSensor” in this manual.

3


harness

(Disconnection or


connector)



Wiring harness between C02 (female) (40) and ENE

(female) (1)

Resistance

valueBelow 1 z

Wiring harness between C02 (female) (29) (39) and

ENE (female) (2)

Resistance

valueBelow 1 z

4

Short-circuiting of wiringharness

(Contact with 24 V

circuit)



ENE (female) (1) and groundingVoltage Below 1 V

5Pump controller

defective




Between (40) and (29) (39) 500 – 1,000 z



Error Code in Electrical System [E228](Short-circuiting in attachment return switching relay)

U C d E C d F il C d



Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid

User Code Error Code Failure CodeFailurephenomenon Short-circuiting in attachment return switching relay(Pump controller system)— E228 D196KB

Failure content• Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power

ON).

Response from

controller

• The controller turned OFF power to the attachment return switching relay circuit.

• Even when the failure cause disappears of itself, the current does not return to normalcy.

Phenomenon

occurring on

machine

• The hydraulic circuit for attachments is not switched to the single operation circuit.

(The switching valve is not switched to the tank circuit.)

Relative

information

• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON

or OFF). (Code No.: 02301 Solenoid 2)

• This error code detects abnormality on the primary side (coil side) of the attachment return selector

relay and cannot detect abnormality on the secondary side (contact side).




1

Attachment return

switching relay defective




R20 (male) Resistance valueBetween (1) and (2) 100 – 500 z

2


harness

(Contact with 24 V

circuit)




R20 (female) (2) and groundingVoltage Below 1 V




C02 Working mode Voltage

Between (8) and

grounding

Other than B mode 20 – 30 V

B mode Below 1 V


Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid)


phenomenon

Disconnection in PC-EPC solenoid

(Pump controller system)



phenomenon (Pump controller system)E02 E232 DXA0KB

Failure content • Abnormal current flew to the PC-EPC solenoid circuit.

Response from

controller

• The controller reduces the output to the PC-EPC solenoid circuit to OFF.

• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting

switch is once turned OFF.

Phenomenon

occurring on

machine

• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.

(The pump absorption torque cannot be controlled.)

Relative

information

• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.

(Code No.: 01300 PC-EPC solenoid current)

• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be

operated in a working mode equivalent to E mode by turning the emergency pump drive switch to the

emergency position. (At that time the monitor panel continues to display Error Code No. [E233], but this

is not abnormal)

• Turn the emergency driving switch normal position during the troubleshooting.

P r e s u m e d c a u s e a

n d



1

PC-EPC solenoiddefective


or grounding fault)




Between (1) and (2) 7 – 14 z


2

Emergency pump driving

switch defective




S25 (male)Emergency pump drive

switchResistance value

Between (3) and (4)

Normal

Above 1 Mz

Between (3) and

grounding Above 1 Mz

3


harness


circuit)



Between wiring harness from C03 (female) (16) to S25


Resistance

value

Above

1 Mz

Between wiring harness from S25 (female) (2) to V21(female) (1) and grounding

Resistancevalue

Above1 Mz

4Pump controller





Electrical Circuit Diagram for PC-EPC Solenoid




Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)


phenomenon

Disconnection in PC-EPC solenoid

(Pump controller system)E02 E233 DXA0KA



p ( p y )E02 E233 DXA0KA

Failure content • No current flows to the PC-EPC solenoid circuit.

Response from

controller


• When the failure cause disappears of itself, the current returns to normalcy.

Phenomenon

occurring on

machine

• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.

(The pump absorption torque cannot be controlled.)

Relativeinformation

• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.

(Code No.: 01300 PC-EPC solenoid current)

• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be

operated in a working mode equivalent to E mode by turning the emergency pump driving switch to the

emergency position.




1

PC-EPC solenoid

defective





Between (1) and (2) 7 – 14 z

2

Emergency pump driving

switch defective




S25 (male)Emergency pump driving

switchResistance value

Between (2) and (3)Normal Below 1 z

Emergency Above 1 Mz

Between (5) and (6)

Normal Below 1 z

Emergency Above 1 Mz

3


harness

(Disconnection or


connector)



Wiring harness between C03 (female) (16) and S25

(female) (3)

Resistance

valueBelow 1 z

Wiring harness between S25 (female) (2) and V21

(female) (1)

Resistance

valueBelow 1 z

Wiring harness between C03 (female) (3) (13) (23) and

S25 (female) (6)

Resistance

value Below 1 z

Wiring harness between S25 (female) (5) and V21

(female) (2)

Resistance

valueBelow 1 z



Electrical Circuit Diagram for PC-EPC Solenoid




Error Code in Electrical System [E238] (Disconnection in attachment return switching relay)


phenomenon

Disconnection in attachment return switching relay

(Pump controller system)— E238 D196KA



Failure content• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24 V

voltage is not generated.

Response from

controller

• None in particular

• If the failure cause disappears, the governor returns to normalcy.

Phenomenon

occurring on

machine

• The hydraulic circuit for attachments cannot be switched to the single operation.

(The switching valve cannot be switched to the tank circuit.)

Relative

information

• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON

or OFF). (Code No.: 02301 Solenoid 2)

• This error code detects abnormality on the primary side (coil side) of the attachment return selector

relay and cannot detect abnormality on the secondary side (contact side).




1 Fuse No. 2 faultIf fuse No.2 has been blown, there is a big possibility that grounding fault occurred in

the relay circuit. (See Cause 4.)

2

Attachment return

switching relay defective




R20 (male) Resistance value

Between (1) and (2) 100 – 500 z

3

Disconnection in wiring

harness (Disconnection

in wiring or defective

contact in connector)



Wiring harness between C02 (female) (8) and R20

(female) (2)

Resistance

valueBelow 1 z

Wiring harness from R20 (female) (1) to J03 to FB1-2

outlet

Resistance

value

Below 1 z

4


harness


circuit)




R20 (female) (2) and grounding

Resistance

value

Above

1 Mz

Between wiring harness from R20 (female) (1) to J03 to

FB1-2 outlet and grounding

Resistance

value

Above

1 Mz

5Pump controller

defective


position during the troubleshooting.C02 Working mode Voltage

Between (8) and

grounding

Other than B mode 20 – 30 V

B mode Below 1 V


Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid




Error Code in Electrical System [E245](Short-circuiting in attachment oil flow rate adjusting EPC)

User Code Error Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting



Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid

phenomenon EPC (Pump controller system)— E245 DXE4KB

Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.

Response from

controller

• The controller reduces the output to the attachment oil flow rate adjusting EPC solenoid circuit to OFF.

• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless

the engine starting switch is once turned OFF.

Phenomenon

occurring on

machine

• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)

Relative

information

• It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow

rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)



a l c y


1

Attachment oil flow rate

adjusting EPC defective


or grounding fault)




Between (1) and (2) 7 – 14 z


2


harness


circuit)





Resistance

value

Above

1 Mz

3

Pump controller

defective




Between (26) and (3) (13) (23) 7 – 14 z



Error Code in Electrical System [E246](Disconnection in attachment oil flow rate adjusting EPC)


h

Disconnection in attachment oil flow rate adjusting

EPC (P t ll t )



Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid

phenomenon EPC (Pump controller system)— E246 DXE4KA

Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.

Response from

controller

• None in particular (The solenoid does not work, as there is no current flowing to it)

• If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.

Phenomenon

occurring on

machine

• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)

Relativeinformation • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flowrate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)




1

Attachment oil flow rate

adjusting EPC defective


or grounding fault)




Between (1) and (2) 7 – 14 z

2

Disconnection of wiringharness

(Disconnection or


connector)




V30 (male) (1) and grounding

Resistance

valueBelow 1 z

Between wiring harness between C03 (female) (3) (13)

(23) and V30 (male) (2) and grounding

Resistance

valueBelow 1 z

3


harness

(Contact with 24 V

circuit)




V30 (female) (1) and grounding Voltage Below 1 V

4Pump controller

defective




Between (26) and (3) (13) (23) 7 – 14 z


Error Code in Electrical System [E247](Arm IN PPC pressure sensor abnormality)


phenomenon

Arm IN PPC pressure sensor abnormality

(Pump controller system)E247 DHS3MA



phenomenon (Pump controller system)— E247 DHS3MA

Failure content • Signal voltage from the arm IN PPC pressure sensor is below 0.3 V or above 4.42 V.

Response from

controller

• The controller sets the arm IN PPC pressure to 0 MP {0 kg/cm2} for control.


Phenomenon

occurring on

machine

• If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The

arm IN PPC circuit pressure cannot be detected).

Relative

information

aIf the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressuresensor will be broken. Accordingly, take extreme care when checking.

• Input from the arm IN PPC pressure sensor (pressure) can be checked in the monitoring function.

(Code No. 07200: Arm IN PPC pressure)

P

r e s u m e d c a u s e a n d

s t a n

d a r d v a l u e i n n o r m a l c y




2

Arm IN PPC pressure

sensor defective

(Internal defect)



S04 Voltage

Between (A) and (C) Power supply 4.5 – 5.5 V

Between (B) and (C) Signal 0.5 – 4.5 V

The pressure voltage is measured with the wiring harness connected. Accordingly, if

the voltage is abnormal, check the wiring harness and controller, too, for another

cause of the trouble, and then judge.

3


harness


tive contact with connector)




(female) (A)

Resistance

valueMax. 1 z


(female) (C)

Resistance

valueMax. 1 z


(female) (E)

Resistance

valueMax. 1 z

4Grounding fault of wiringharness


circuit)




S04 (female) (E) and grounding

Resistance

valueMin. 1 M z



Circuit diagram related to arm IN PPC pressure sensor




Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)


phenomenon

Bucket CURL PPC pressure sensor abnormality

(Pump controller system)— E248 DHS4MA

Failure content Signal voltage from the bucket CURL PPC pressure sensor is below 0 3 V or above 4 42 V



Failure content • Signal voltage from the bucket CURL PPC pressure sensor is below 0.3 V or above 4.42 V.

Response from

controller

• The controller sets the bucket CURL PPC pressure to 0 MP {0 kg/cm2} for control.


Phenomenon

occurring on

machine

• If auto deceleration is operated, when auto deceleration cannot be released when moving the bucket

CURL (The bucket CURL PPC circuit pressure cannot be detected).

Relative

information

a If the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure

sensor will be broken. Accordingly, take extreme care when checking.

• Input from the bucket CURL PPC pressure sensor (pressure) can be checked in the monitoring function.(Code No. 07300: Bucket CURL PPC pressure)






2

Bucket CURL PPC pres-

sure sensor defective

(Internal defect)



S04 Voltage

Between (1) and (3) Power supply 4.5 – 5.5 V

Between (2) and (3) Signal 0.5 – 4.5 V




3


harness


tive contact with connector)




(female) (1)

Resistance

valueMax. 1 z


(female) (3)

Resistance

valueMax. 1 z


(female) (2)

Resistance

valueMax. 1 z

4


harness





S04 (female) (2) and grounding

Resistance

valueMin. 1 Mz

Sh t i iti f i i




Circuit diagram related to bucket CURL PPC pressure sensor




Error Code in Electrical System [E257] (Pump Abnormality)


phenomenon

Pump Abnormality

(Pump controller system)E0E E257 DA2RMC

• The pump controller detected communication failure in the CAN communication circuit to the monitor



Failure contentThe pump controller detected communication failure in the CAN communication circuit to the monitor

panel or engine controller.

Response from

controller



Phenomenon

occurring on

machine



Relative

information




1


harness



tor)





(female) (22)

Resistance

valueBelow 1 z

Wiring harness between P70 (female) (15) and CB2(female) (32) or between P70 (female) (15) and C02

(female) (32)

Resistance

valueBelow 1 z

2


harness


circuit)







Resistance

value Above 1 Mz





Resistance

value Above 1 Mz

3


harness






C02 (female) (22) or between P70 (female) (16) andrelated circuits and grounding

Voltage Below 1 V









Error Code in Electrical System [E315] (Battery Relay Drive S/C)


phenomenon

Battery Relay Drive S/C

(Pump controller system)— E315 D110KB

Failure content • When a signal is output to the battery relay drive circuit, abnormal current flowed.



g p y y

Response from

controller

• The controller turns OFF the output to the battery relay drive circuit.


Phenomenon

occurring on

machine

• There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.

Relative

information

• Operation of the battery relay (ON or OFF) can be checked in the monitoring function.

(Code No. 03700: Controller output 1)




1

Battery relay defective


or grounding fault)



Battery relay (Unit) Resistance value

Between BR and E Approx. 100 z

Between BR and grounding Min. 1 Mz

2


harness


circuit)


Between wiring harness between C03 (female) (4), D01,

J01, battery relay terminal BR or between C03 (female)

(4) and starting switch terminal B or between C03

(female) (4) and D01 (female) (2) and grounding

Resistance

valueMin. 1 Mz

3Pump controller

defective



C03 (female) Starting switch Voltage

Between (4) and grounding ON o OFF2 0 – 3 0 V

(For 0.5 sec)


Electrical circuit diagram related to battery relay drive



TROUBLESHOOTING E91C

Error Code in Electrical System [E91C] (Engine G sensor problem)


phenomenon

Engine G sensor problem

(Engine controller system)E11 E91C DLH1LC

Failure content • Cylinder cannot be judged from the engine G speed sensor signal.



Electrical circuit diagram related to engine G speed sensor

Response from

controller

• The machine is driven with limited output.

• Control is carried out with the Ne speed sensor signal.


Phenomenon

occurring on

machine

• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).

• The output lowers (Only the pump absorption torque is reduced).

• The engine speed does not rise above low idling.

Relative

information • Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.

P r e

s u m e d c a u s e a n d

s t a n d



1

Engine G speed sensor

defective

(Internal disconnection or

short-circuiting)



G (male) Resistance value

Between (1) and (2) 1.4 k – 3.5 kz

Between (1), (2) and grounding Above 1 Mz

2


harness

(Disconnection or


connector)



Wiring harness between CB2 (female) (35) and G

(female) (2)

Resistance

valueBelow 1 z

Wiring harness between CB2 (female) (25) and G

(female) (1)

Resistance

valueBelow 1 z

3Grounding fault of wiringharness


circuit)



Between wiring harness between CB2 (female) (35) and

G (female) (2) and grounding

Resistance

value Above 1 Mz


G (female) (1) and grounding

Resistance

value Above 1 Mz

4Engine controller

defective



E12 (female) Resistance value

Between (35) and (25) 1.4 k – 3.5 kz



Error Code in Electrical System [E920] (Engine type selection error)


phenomenon

Engine type selection error

(Engine controller system)E11 E920 DB29KQ

Failure content• The model selection signal directly taken by the engine controller does not conform to the model in the

controller or it is not confirmed



controller or it is not confirmed.

Response from

controller

• Control is carried out with the default model (PC400).



Phenomenon

occurring on

machine




Relative

information

• The model name (figure) recognized by the controller can be checked in the monitoring function.(Code No. 00201: Controller model code)

• Input of the model selection signal (ON or OFF) can be checked in the monitoring function.

(Code No. 17400: Engine controller input state)



i n n o r m a l c y


1

Model selection

connector defective(Internal disconnection or

short-circuiting)



CB5 (female) Resistance valueBetween (2), (3) (4), (5), (6), (7), and

(8) Above 1 Mz

Between (1) and (8) Below 1 z

2


harness

(Disconnection or


connector)



Wiring harness between CB1 (female) (3) and CB5

(male) (1)

Resistance

valueBelow 1 z

Wiring harness between CB2 (female) (1) and CB5(male) (8)

Resistancevalue

Below 1 z

3


harness


circuit)




CB5 (male) (2) and grounding

Resistance

value Above 1 Mz


CB5 (male) (3) and grounding

Resistance

value Above 1 Mz

4Engine controller

defective


CB1, CB2 Voltage

Between CB1 (23), (17) and CB2 (1) 20 – 30 V


Electrical circuit diagram related to model selection connector (for engine controller)




Error Code in Electrical System [E921] (Engine type mismatch)


phenomenon

Engine type mismatch

(Engine controller system)E11 E921 DB20KQ

Failure content• The model information taken by the engine controller through the model selection connector does not

conform to the model information taken from the pump controller by communication.



conform to the model information taken from the pump controller by communication.

Response from

controller

• The normal operation is continued.



Phenomenon

occurring on

machine




Relative

information

• The model name (figure) recognized by the engine controller can be checked in the monitoring func-tion. (Code No. 00201: Controller model code)

• The model name (figure) recognized by the pump controller can be checked in the monitoring function.

(Code No. 00200: Controller model code)

P r e s u m e d c a

u s e a n d


i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting

1Model selection connec-

tor system defectiveIf error code [E920] is displayed, carry out troubleshooting for it.

2Engine controller

defective

Engine controller may be defective. (Since trouble is in the controller, troubleshoot-

ing cannot be carried out.)

3 Pump controller defectivePump controller may be defective. (Since trouble is in the controller, troubleshooting

cannot be carried out.)




Error Code in Electrical System [E931] (Fuel dial sys. error)


phenomenon

Fuel dial sys. error

(Engine controller system)E14 E931 DK10KX

Failure content • The signal voltage from the fuel control dial is below 0.3 V or above 4.5 V.

• If the abnormality is detected before the engine is started the fuel control dial signal is kept at 0% or



Response from

controller

If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or

100% after the engine is started.

• If the abnormality is detected while the engine is running, the fuel control dial signal just before the

abnormality is detected is kept.


Phenomenon

occurring on

machine

• The engine speed cannot be controlled.

Relative

information

• Input from the fuel control dial (voltage) can be checked in the monitoring function.

(Code No. 03000: Fuel control dial voltage)



y


1

Fuel control dial defective


short-circuiting)



E06 (male) Resistance value

Between (1) and (3) 4.0 – 6.0 kzBetween (1) and (2) 0.25 – 7.0 kz

Between (3) and (2) 0.25 – 7.0 kz

2


harness

(Disconnection or


connector)



Wiring harness between CB2 (female) (19) and E06

(female) (1)

Resistance

valueBelow 1 z

Wiring harness between CB2 (female) (10) and E06

(female) (2)

Resistance

value Below 1z

Wiring harness between CB2 (female) (29), (39), and

E06 (female) (3)

Resistance

valueBelow 1 z

3


harness


circuit)




E06 (female) (1) and grounding

Resistance

value Above 1 Mz


E06 (female) (2) and grounding

Resistance

value Above 1 Mz

4


h



Between wiring harness between CB2 (female) (19) andV lt B l 1 V


Electrical circuit diagram related to fuel control dial




Error Code in Electrical System [E934] (Engine coolant sensor Hi error)


phenomenon

Engine coolant sensor Hi error

(Engine controller system)E15 E934 DGE2KX

Failure content • The signal voltage from the engine water high temperature sensor is below 0.5 V or above 4.5 V.

Response from • The signal of the engine water high temperature sensor is kept at 90°C.



p

controller

g g g p p


Phenomenon

occurring on

machine

• The engine does not start easily when temperature is low.

• The overheat protection function does not operate.

• If the controller is also defective, the engine does not stop.

Relative

information

• Input from the engine water high temperature sensor (voltage and water temperature) can be checked

in the monitoring function.

(Code No. 04106: Engine water temperature sensor Hi, 04102: Engine water temperature (High tem-perature))




1

Engine water high

temperature sensor

defective


short circuit)



TWH (male) Resistance value

Between (1) and (2) 3.5 k – 90 kz


2


harness

(Disconnection or


connector)



Wiring harness between CB2 (female) (27) and TWH

(female) (1)

Resistance

valueBelow 1 z


TWH (female) (2)

Resistance

valueBelow 1 z

3


harness


circuit)



Between wiring harness between E12 (female) (27) and

TWH (female) (1) and grounding

Resistance

value Above 1 Mz

4Engine controller

defective



CB2 Resistance value

Between (27), (29) and (39) 3.5 k – 90 kz

Between (27), (29), (39) and grounding Above 1 Mz


Electrical circuit diagram related to engine water temperature sensor (for low temperature and high

temperature)




Error Code in Electrical System [E936] (Engine oil press. sw. error)


phenomenon

Engine oil press. sw. error

(Engine controller system)E15 E936 DDE2L6

• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit ofthe high-pressure switch is opened (disconnected from grounding) while the engine is running.

• The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine



Failure content• The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine

is stopped (the starting signal is OFF).

• The signal circuit of the high-pressure switch is opened (disconnected from grounding) while the

engine is stopped (the starting signal is OFF).

Response from

controller

• None in particular.


Phenomenon

occurring on

machine




Relative

information

• Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring func-

tion. (Code No. 17400: Engine controller input)

P r e s u m

e d c a u s e a n d

s t a n d a r d

v a l u e i n n o r m a l c y


1

Engine low-oil pressure

switch defective(Internal disconnection or

short-circuiting)


position and start the engine during the troubleshooting.

PSL Engine Resistance value

Between terminal

and grounding

Stopped Below 1 z

Low idling Above 1 Mz

2

Engine high-oil pressure

switch defective


short-circuiting)


position and start the engine during the troubleshooting.

PSH Engine Resistance value

Between terminal

and grounding

Stopped Below 1 z

Running at 1,300 rpmor higher

Above 1 Mz

3


harness

(Disconnection or


connector)



Wiring harness between CB1 (female) (21) and PSLResistance

valueBelow 1 z

Wiring harness between CB1 (female) (15) and PSHResistance

valueBelow 1 z

4


harness


)



PSL and grounding

Resistance

value Above 1 Mz


Electrical circuit diagram related to engine oil press switch (for low pressure and high pressure)



TROUBLESHOOTING E93D

Error Code in Electrical System [E93D] (Engine fuel temp. sensor error)


phenomenon

Engine fuel temp. sensor error

(Engine controller system)E15 E93D DGE4KX

Failure content • The signal voltage from the fuel temperature sensor is above 4.5 V.

Response from

controller





controller When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon

occurring on

machine




Relative

information

• Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.

(Code No. 14201: Fuel temperature sensor voltage)




1

Fuel temperature sensor

defective


short-circuiting)



THL (male) Resistance value

Between (1) and (2) 0.3 k – 9 kz


2


(Disconnection or


connector)



Wiring harness between E12 (female) (17) and THL

(female) (1)

Resistance

valueBelow 1 z

Wiring harness between E12 (female) (29), (39) and

THL (female) (2)

Resistance

valueBelow 1 z

3


harness


circuit)



Between wiring harness between E12 (female) (17) and

THL (female) (A) and grounding

Resistance

value Above 1 Mz

4Engine controller

defective



CB2 Resistance value

Between (17), (29) and (39) 0.3 k – 9 kz

Between (17) and (29), (39) and


TROUBLESHOOTING E93D

Electrical circuit diagram related to fuel temperature sensor




Error Code in Electrical System [E953] (Engine Comm. Abnormality)


phenomenon

Engine Comm. Abnormality

(Engine controller system)E0E E953 DB2RMC

Failure content • The engine controller detected communication failure in the CAN communication circuit to the monitorpanel or pump controller.

Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.



controller • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon

occurring on

machine



Relative

information



a l c y


1


harness

(Disconnection or


connector)





(female) (22)

Resistance

valueBelow 1 z

Wiring harness between P70 (female) (15) and CB2(female) (32) or between P70 (female) (15) and C02

(female) (32)

Resistancevalue

Below 1 z

2


harness


circuit)







Resistance

value Above 1 Mz

Between wiring harness between P70 (female) (15) andCB2 (female) (32) or between P70 (female) (15) and



Resistance

value Above 1 Mz

3


harness(Contact with 24 V circuit)







Voltage Below 1 V









Error Code in Electrical System [E954] (Short engine starter sw.)


phenomenon

Short engine starter sw.

(Engine controller system)— E954 DD11KB

Failure content • Starting switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).

Response from

controller

• Starting switch signal is recognized to be OFF.




Phenomenon

occurring on

machine

• The machine operates normally.

Relative

information

• Input of starting switch signal C (ON or OFF) can be checked in the monitoring function.

(Code No. 17400: Engine controller input)


n d



1Starting switch defective


aTurn the engine starting switch OFF for the preparations, and hold it in the OFF and

ON positions during the troubleshooting.

Starting switch Resistance value

Between terminal B

and terminal C

OFF Above 1 Mz

START Below 1 z

2


harness




Between wiring harness between starting switch termi-

nal C, J01, and CB1 (female) (20) or between starting

switch terminal C and C01 (female) (17) or between

starting switch terminal C and P01 (female) (4) or

between starting switch terminal C and R11 (female) (5),

or between starting switch terminal C or related circuits

and grounding

Voltage Below 1 V

4Engine controller

defective

aTurn the engine starting switch OFF for the preparations, and keep the engine

running during the troubleshooting.

CB1 Starting switch Voltage

Between (20) and

grounding

ON

(Engine is running)Below 1 V


Electrical circuit diagram related to engine preheating, starting, charging




Error Code in Electrical System [E955] (Engine S-NET error)


phenomenon

Engine S-NET error

(Engine controller system)E0E E955 DB2SMC

Failure content • The engine controller detected communication failure in the S-NET communication circuit to the moni-tor panel or pump controller.

Response from

controller


• When the failure cause disappears of itself the machine operation returns to normalcy



controller • When the failure cause disappears of itself, the machine operation returns to normalcy.

Phenomenon

occurring on

machine



Relative

information

• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.

(Code No. 05100: Connection of S-NET)

P r e s u m e d c

a u s e a n d


i n n o r m a l c y


1


harness

(Disconnection or


connector)






Resistance

valueBelow 1 z

2


harness


circuit)







Resistance

value Above 1 Mz

3


harness





and CB2 (female) (21), (31) or between P02 (female)(9), (10) and C02 (female) (21) or between P02 (female)


Voltage Below 1 V




P02 Voltage

Between (9), (10) and (20) 6 – 9 V

5Engine controller

defective



CB2 Voltage

Between (21), (31) and (11) 6 – 9 V

O f O






Error Code in Electrical System [E956] (Engine power failure (1))


phenomenon

Engine power failure (1)

(Engine controller system)E10 E956 DB22KK

Failure content • When the starting switch is turned ON, the source voltage of the controller is below 10 V.

Response from

controller



Phenomenon



Phenomenon

occurring on

machine

• The engine stalls.

• The engine cannot be started.

Relative

information

P r e s u m e d c a u

s e a n d


n o r m a l c y


1Circuit breaker 7

defective

If circuit breaker is turned OFF, the circuit probably has grounding fault, etc.

(See cause 4.)

2

Engine controller power

supply relay defective


short-circuiting)



Replace the power supply relay with another one. If the condition

becomes normal, the relay is defective.R22

3


harness

(Disconnection or


connector)


Wiring harness between CB3 (female) (1), (2), (21) and

R22 (female) (5)

Resistance

valueBelow 1 z

Wiring harness between R22 (female) (3) and B27Resistance

valueBelow 1 z

Wiring harness between B17 and battery relay B terminalResistance

valueBelow 1 z

Wiring harness between R22 (female) (1) and J02(male) (1)

Resistancevalue

Below 1 z

Wiring harness between R22 (female) (2) and groundingResistance

valueBelow 1 z

4


harness




Between wiring harness between CB3 (female) (1), (2),

(21) and R22 (female) (5) and grounding

Resistance

value Above 1 Mz

Between wiring harness between R22 (female) (3) andB27

Resistancevalue

Above 1 Mz

Between wiring harness between R22 (female) (1) and

J02 (male) (1) or between R22 (female) (1) and relatedResistance

value Above 1 Mz


Electrical circuit diagram related to engine controller power supply




Error Code in Electrical System [E957] (Engine power failure (2))


phenomenon

Engine power failure (2)

(Engine controller system)E15 E957 D1D0KB

Failure content • When the starting switch is turned OFF, the source voltage of the controller is above 10 V.

Response from

controller



Phenomenon • The engine does not start easily when temperature is low.



Phenomenon

occurring on

machine

The engine does not start easily when temperature is low.



Relative

information

P r e s u m e d c a

u s e a n d


i n n o r m a l c y


1

Engine controller power

supply relay defective




Replace the power supply relay with another one. If the condition

becomes normal, the relay is defective.R22

2





Between wiring harness between E13 (female) (1), (2),(21) and R22 (female) (3) and grounding

Voltage Below 1 V

Between wiring harness between R22 (female) (1) and

J03, J06 (male) (2), or related circuits and groundingVoltage Below 1 V

3Engine controller

defective

aTurn the engine starting switch OFF for the preparations, and hold it in the OFF and

ON positions during the troubleshooting.

CB3 Starting switch Voltage

Between (1), (2), (21)

and (11), (31), (32)

OFF Below 1 V

ON 20 – 30 V





TROUBLESHOOTING E96A

Error Code in Electrical System [E96A] (Engine coolant sensor Lo error)


phenomenon

Engine coolant sensor Lo error

(Engine controller system)E15 E96A DGE3L6

Failure content • The signal voltage from the engine water low temperature sensor is above 4.5 V.

Response from

controller

• The signal of the engine water low temperature sensor is kept at 20°C (If the signal of the high temper-

ature sensor is effective, it is used as a substitute).


Ph Th i d t t t il h t t i l



Phenomenon

occurring on

machine




Relative

information

• Input from the engine water low temperature sensor (voltage and water temperature) can be checked

in the monitoring function. (Code No. 04105: Engine water temperature sensor voltage Lo, 04107:

Engine water temperature (Low temperature))

P




1

Engine water low

temperature sensor

defective


short circuiting)



TWL (male) Resistance value

Between (1) and (2) 0.3 k – 9 kz


2


harness



tor)



Wiring harness between CB2 (female) (37) and TWL

(female) (1)

Resistance

valueBelow 1 z


TWL (female) (2)

Resistance

valueBelow 1 z

3



circuit)


position during the troubleshooting.Between wiring harness between E12 (female) (37) and

TWL (female) (1) and grounding

Resistance

value Above 1 Mz

4Engine controller

defective



E12 Resistance value

Between (29), (37) and (39) 0.3 k – 9 kz




temperature)




Error Code in Electrical System [E970] (PCV1 over current)


phenomenon

PCV1 over current

(Engine controller system)E11 E970 AD11KB

Failure content • Abnormal current flowed in the fuel supply pump PCV1 circuit.

Response from

controller

• Power to the fuel supply pump PCV1 circuit is switched OFF.



• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced)



Electrical circuit diagram related to fuel supply pump PCV1

Phenomenon

occurring on

machine




• The engine stops and it cannot be started (when user code [E10] is displayed).

Relative

information • Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.


s t a



1

Fuel supply pump PCV1

defective


or grounding fault)



PCV1 (male) Resistance value

Between (1) and (2) 2.3 – 5.3 z


2


harness


circuit)




PCV1 (female) (1)

Resistance

value Above 1 Mz

3


harness





PCV1 (female) (1)

Voltage Below 1 V


PCV1 (female) (2)Voltage Below 1 V

4Engine controller

defective



CB3 (female) Resistance value

Between (12) and (22) 2.3 – 5.3 z



Error Code in Electrical System [E971] (PCV2 over current)


phenomenon

PCV2 over current

(Engine controller system)E11 E971 AD51KB

Failure content • Abnormal current flowed in the fuel supply pump PCV2 circuit.

Response from

controller




Ph• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).




Phenomenon

occurring on

machine

The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).




Relative



s t a



1


defective


or grounding fault)




Between (1) and (2) 2.3 – 5.3 z


2


harness


circuit)




PCV2 (female) (1)

Resistance

value Above 1 Mz

3


harness





PCV2 (female) (1)

Voltage Below 1 V


PCV2 (female) (2)Voltage Below 1 V

4Engine controller

defective




Between (13) and (23) 2.3 – 5.3 z



Error Code in Electrical System [E974] (PCV1 line cut)


phenomenon

PCV1 line cut

(Engine controller system)E11 E974 AD11KA

Failure content • Fuel supply pump PCV1 circuit is disconnected.

Response from

controller




Phenomenon• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).




Phenomenon

occurring on

machine

p ( g p p p p q )




Relative



s t a



1


defective





Between (1) and (2) 2.3 – 5.3 z


2


harness

(Disconnection or


connector)




PCV1 (female) (1)

Resistance

valueBelow 1 z


PCV1 (female) (2)

Resistance

valueBelow 1 z

3



circuit)




PCV1 (female) (2)

Resistance

value Above 1 Mz

4Engine controller

defective




Between (12) and (22) 2.3 – 5.3 z



Error Code in Electrical System [E975] (PCV2 line cut)


phenomenon

PCV2 line cut

(Engine controller system)E11 E975 AD51KA

Failure content • Fuel supply pump PCV2 circuit is disconnected.

Response from

controller




Phenomenon• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).




Phenomenon

occurring on

machine




Relative



s t a



1


defective





Between (1) and (2) 2.3 – 5.3 z


2


harness

(Disconnection or


connector)




PCV2 (female) (1)

Resistance

valueBelow 1 z


PCV2 (female) (2)

Resistance

valueBelow 1 z

3



circuit)




PCV2 (female) (2)

Resistance

value Above 1 Mz

4Engine controller

defective




Between (13) and (23) 2.3 – 5.3 z



Error Code in Electrical System [E977] (Rail press. sensor error)


phenomenon

Rail press. sensor error

(Engine controller system)E11 E977 DH40KX

Failure content • The signal voltage from the common rail fuel pressure sensor is below 0.7 V or above 4.5 V.Response from

controller



Phenomenon

occurring on





machine • The engine speed does not rise above low idling.

Relative

information

• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring

function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)

• Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor.



l c y


1

Common rail fuel

pressure sensor

defective

(Internal defect)



PFUEL Voltage

Between (3) and (1) Power supply 4.6 – 5.4 V

Between (2) and (1) Signal 0.7 – 4.5 V

The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,


2


harness

(Disconnection or


connector)



Wiring harness between CB2 (female) (9) and PFUEL

(female) (3)

Resistance

valueBelow 1 z


(female) (1)

Resistance

valueBelow 1 z


(female) (2)

Resistance

valueBelow 1 z

3


harness


circuit)




PFUEL (female) (3), or between CB2 (female) (9) and

related ciricuits and grounding

Resistance

value Above 1 Mz


PFUEL (female) (2) and grounding

Resistance

value Above 1 Mz




Electrical circuit diagram related to common rail fuel pressure sensor



TROUBLESHOOTING E979, E97A

Error Code in Electrical System [E979] (Rail press. high)


phenomenon

Rail press. high

(Engine controller system)E11 E979 AD00L2

Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1).Response from

controller



Phenomenon

occurring on

machine



• The engine speed does not rise above low idling



Error Code in Electrical System [E97A] (Rail press. abnormal)

machine • The engine speed does not rise above low idling.

Relative

information






1Related systems

defective

If any other error code or failure code is displayed, carry out troubleshooting for it

first.

2 Fuel used improper Fuel used may be improper. Check it directly.

3

Electric system of

common rail fuel

pressure sensor defective

Carry out troubleshooting for error code [E977].

4

Mechanical system of

common rail fuel

pressure sensor defective

The common rail fuel pressure sensor may have a mechanical defect. Check itdirectly.

5 Overflow valve defectiveThe overflow valve may have trouble of breakage of spring, wear of seat, or fixing of

ball. Check it directly.

6 Overflow piping clogged The overflow piping may be clogged. Check it directly.

7 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.


phenomenon

Rail press. abnormal

(Engine controller system)E11 E97A AD00MA

Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2).

Response from

controller

• The machine is driven with limited output.• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,


Phenomenon The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced)

TROUBLESHOOTING E97B

Error Code in Electrical System [E97B] (Rail press. low)


phenomenon

Rail press. low

(Engine controller system)E15 E97B AD10L3

Failure content • No-pressure feed by fuel supply pump (level 1) occurred.

Response from

controller




Phenomenon

occurring on


• The overheat protection function does not operate



Note 1: Check the low-pressure circuit devices for the following points.

1) Insufficiency of fuel

2) Fixing and wear of feed pump and clogging of filter

3) Leakage from and clogging of low-pressure fuel piping

4) Malfunction of bypass valve and installation of wrong part (See Fig. 1)5) Clogging of fuel filter

6) Entry of fuel in oil pan (Fuel leakage in head cover)

• Fuel low pressure circuit pressure: 0 15 0 3 MPa {1 5 3 0 kg/cm2}

occurring on

machine



Relative

information




a n d


r m a l c y


1Related systems

defective

If any other error code or failure code is displayed, carry out troubleshooting for it

first.

2 Fuel used improper Fuel used may be improper. Check it directly.

3Fuel low-pressure circuit

device defective

A low-pressure circuit device may be defective. Referring to Note 1, carry out

troubleshooting.

4Fuel filter/strainer

clogged

The fuel filter/strainer may be clogged. Referring to Note 2, carry out

troubleshooting.

5

Electrical system of fuel

supply pump PCV1

defective

Carry out troubleshooting for error codes [E970], [E971], [E974], and [E975].

6Fuel supply pump

defectiveThe fuel supply pump may be defective. Check it directly.

7

Common rail fuel

pressure sensor

defective

The common rail fuel pressure sensor may be defective. Check it directly.

8 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.

9 Fuel injector defective The fuel injector may be defective. Referring to Note 3, check it directly.


Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)

• Overflow valve (1): Spring is seen through both holes.

• Bypass valve (2): Spring is seen through hole on nut side.

• Fuel inlet joint (3): Gauze filter is seen through both holes.



Note 2: Check, clean, and replace the filters and strainers according to the following procedure.

1) Gauze filter: Disassemble and check the gauze filter. If it is clogged, clean it.

2) Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too.

3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.

Note 3: Judge the condition of the fuel injector by

measuring the fuel spill rate.

kWhen performing the follow work, take carenot to scald yourself with the fuel which be-

comes hot (up to 90°C).

1) Disconnect the hose connected to the cen-

3) Run the engine and stall at each speed

(relieve the arm circuit by moving the arm

in). Measure the quantity of the fuel spillingin 1 minute under this condition.

a Limit of spill of fuel (Total of spill from 6

cylinders)

TROUBLESHOOTING E97C, E97D

Error Code in Electrical System [E97C] (Rail press. too low)


phenomenon

Rail press. too low

(Engine controller system)E11 E97C AD10MB

Failure content • No-pressure feed by fuel supply pump (level 2) occurred.

Response from

controller

• The machine is driven with limited output and speed.



Phenomenon

occurring on





Error Code in Electrical System [E97D] (Rail press. out of control)

g

machine

p ( y p p p q )


Relative

information



Presumed

cause and

standard value

in normalcy


1Common rail-related

device defectiveCarry out troubleshooting for error code [E97B].


phenomenon

Rail press. out of control

(Engine controller system)E11 E97D AD10MA

Failure content • Abnormal fuel pressure was generated in the common rail.

Response from

controller

• The machine is driven under the normal control.



Phenomenon

occurring on

machine




Relative

information



Presumed

cause and standard value

in normalcy


1Common rail-relateddevice defective

Carry out troubleshooting for error code [E97B].


Error Code in Electrical System [E980] (Eng. Controller Abnormality)


phenomenon

Eng. Controller Abnormality

(Engine controller system)E10 or E11 E980 DB20KT

Failure content • The controller has abnormality in it.

Response from

controller

• The machine is driven with limited output or all output is turned OFF.



Phenomenon

occurring on





occurring on

machine

p ( y p p p q )


• The engine stop and it cannot be started (when user code [E10] is displayed).

Relative

information

P r e s

u m e d c a u s e a n d

s t a n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting

1


harness

(Disconnection or


connector)



Wiring harness between CB3 (female) (11), (31), (32)

and grounding

Resistance

valueBelow 1 z

2Engine controller

defective

If cause 1 is not detected, the engine controller may be defective.

(Since trouble is in the engine controller, troubleshooting cannot be carried out.)






Error Code in Electrical System [E981] (Fuel Injector 1 Disc.)


phenomenon

Fuel Injector 1 Disc.

(Engine controller system)E11 E981 ADA1KA

Failure content • Fuel injector 1 circuit is disconnected.

Response from

controller

• Power to the fuel injector 1 circuit is switched OFF.



Phenomenon

occurring on



Th i d d t i b l idli



Electrical circuit diagram related to fuel injector 1

occurring on

machine• The engine speed does not rise above low idling.


Relative

information


e a n d



1Fuel injector 1 defective




CN1 (male) Resistance value

Between (1) and (2) 0.4 – 1.1 z

2


(Disconnection or


connector)



Wiring harness between CB3 (female) (14) and CN1

(female) (1)

Resistance

valueBelow 1 z


(female) (2)

Resistance

valueBelow 1 z

3Engine controller

defective




Between (14) and (24) 0.4 – 1.1 z




phenomenon


(Engine controller system)E11 E982 ADB1KA


Response from

controller




Phenomenon

occurring on



The engine speed does not rise above low idling




g



Relative

information


e a n d








Between (1) and (2) 0.4 – 1.1 z

2


(Disconnection or


connector)




(female) (1)

Resistance

valueBelow 1 z


(female) (2)

Resistance

valueBelow 1 z

3Engine controller

defective




Between (6) and (16) 0.4 – 1.1 z




phenomenon


(Engine controller system)E11 E983 ADC1KA


Response from

controller




Phenomenon

occurring on









Relative

information


e a n d








Between (1) and (2) 0.4 – 1.1 z

2




tor)




(female) (1)

Resistance

valueBelow 1 z


(female) (2)

Resistance

valueBelow 1 z

3Engine controller

defective




Between (5) and (15) 0.4 – 1.1 z




phenomenon


(Engine controller system)E11 E984 ADD1KA


Response from

controller




Phenomenon

occurring on







machineThe engine speed does not rise above low idling.


Relative

information


e a n d








Between (1) and (2) 0.4 – 1.1 z

2


(Disconnection or


connector)




(female) (1)

Resistance

valueBelow 1 z


(female) (2)

Resistance

valueBelow 1 z

3Engine controller

defective




Between (26) and (36) 0.4 – 1.1 z




phenomenon


(Engine controller system)E11 E985 ADF1KA


Response from

controller




Phenomenon

occurring on

hi







machineThe engine speed does not rise above low idling.


Relative

information


e a n d








Between (1) and (2) 0.4 – 1.1 z

2


(Disconnection or


connector)




(female) (1)

Resistance

valueBelow 1 z


(female) (2)

Resistance

valueBelow 1 z

3Engine controller

defective




Between (34) and (33) 0.4 – 1.1 z




phenomenon


(Engine controller system)E11 E986 ADF1KA


Response from

controller




Phenomenon

occurring on

machine







machineg p g


Relative

information


e a n d








Between (1) and (2) 0.4 – 1.1 z

2


(Disconnection or


connector)




(female) (1)

Resistance

valueBelow 1 z


(female) (2)

Resistance

valueBelow 1 z

3Engine controller

defective




Between (25) and (35) 0.4 – 1.1 z


Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C)


phenomenon

Fuel Injector 1 – 3 S/C

(Engine controller system)E11 E98A ADAZKB

Failure content • Abnormal current flowed in the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit.

Response from

controller

• Power to the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit is switched OFF.



Phenomenon

occurring on

machine






machine• The engine stops and it cannot be started (when user code [E10] is displayed).

Relative

information



n o r m a l c y


1

Fuel injector 1 defective


or grounding fault)




Between (1) and (2) 0.4 – 1.1 z


2



or grounding fault)




Between (1) and (2) 0.4 – 1.1 z


3





CN3 (male) Resistance valueBetween (1) and (2) 0.4 – 1.1 z


4


harness





CN1 (female) (1) and grounding

Resistance

value Above 1 Mz



Resistance

value Above 1 Mz



Resistance

value Above 1 Mz


u s e a n d

n n o r m a l c y


5


harness





CN1 (female) (1) and groundingVoltage Below 1 V









Electrical circuit diagram related to fuel injectors 1, 2, and 3

P r e s u m

e d c a u

s t a n d a r d v a l u e i n ( ) ( ) g g





6Engine controller

defective




Between (14) and (24) 0.4 – 1.1 z

Between (6) and (16) 0.4 – 1.1 z

Between (5) and (15) 0.4 – 1.1 z

Between (5), (6), (14), (15), (16), (24)

and grounding Above 1 Mz


Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C)


phenomenon

Fuel Injector 4 – 6 S/C

(Engine controller system)E11 E98B ADDZKB

Failure content • Abnormal current flowed in the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit.

Response from

controller

• Power to the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit is switched OFF.



Phenomenon

occurring on

machine




Th i t d it t b t t d ( h d [E10] i di l d)




Relative

information



n o r m a l c y


1



or grounding fault)




Between (1) and (2) 0.4 – 1.1 z


2



or grounding fault)




Between (1) and (2) 0.4 – 1.1 z


3





CN6 (male) Resistance valueBetween (1) and (2) 0.4 – 1.1 z


4


harness






Resistance

value Above 1 Mz



Resistance

value Above 1 Mz



Resistance

value Above 1 Mz


u s e a n d

n n o r m a l c y


5


harness














Electrical circuit diagram related to fuel injectors 4, 5, and 6

P r e s u m

e d c a u

s t a n d a r d v a l u e i





6Engine controller

defective




Between (26) and (36) 0.4 – 1.1 z

Between (34) and (33) 0.4 – 1.1 z

Between (25) and (35) 0.4 – 1.1 z

Between (25), (26), (33), (34), (35), (36)

and grounding Above 1 Mz

TROUBLESHOOTING A000N1, A000N2

Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)


phenomenon

Engine high-idling speed out of standard

(Mechanical system)E22 E922 A000N1

Failure content • While the engine is running, its speed above 2,350 rpm is detected.

Response from

controller • None in particular.

Phenomenon

occurring on

machine

• If the machine is used as it is, the engine may be damaged.

Relative

i f ti

• Input from the engine speed sensor (rpm) can be checked in the monitoring function.

(C d N 01006 E i d)



Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard)

information (Code No. 01006: Engine speed)




1Overrun of engine

(While system is normal)

Check for an external or an internal factor which heightens the engine high-idling

speed, and then check the mechanical system of the engine.

2Engine speed sensor

system abnormalIf error code [E227] is displayed, carry out troubleshooting for it first.

3Engine controller defec-

tive

aTurn the engine starting switch ON for the preparations, and keep the engine


Monitoring Engine Engine speed

01006

Engine speedHigh idling 1,880 – 1,980 rpm


phenomenon

Engine low-idling speed out of standard

(Mechanical system)— — A000N2

Failure content • While the engine is running, its speed below 500 rpm is detected.

Response from

controller



Phenomenon

occurring on

machine


Relative

information

• Input from the engine speed sensor (rpm) can be checked in the monitoring function.

(Code No. 01006: Engine speed)



TROUBLESHOOTING AA10NX

Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging)


phenomenon

Aircleaner Clogging

(Mechanical system)— — AA10NX

Failure content

• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine

is running.

Response from


Phenomenon

occurring on

machine


• If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running this



Relative

information

• If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this

failure code is recorded.

• Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function.(Code No. 04501: Monitor input 1)


s



1 Air cleaner clogged

(While system is normal)Check the air cleaner. If it is clogged, clean or replace it.

2

Air cleaner clogging

switch defective(Internal disconnection)


position or keep the engine running during the troubleshooting.

A31 (male) Air cleaner Resistance value

Between (1) and (2)Normal Below 1 z

Clogged Above 1 Mz

3


harness

(Disconnection or


connector)



Wiring harness between P02 (female) (5) and A31

(female) (1)

Resistance

valueBelow 1 z

Wiring harness between A31 (female) (2) and groundingResistance

valueBelow 1 z



position or keep the engine running during the troubleshooting.

P02 Air cleaner Voltage

Between (5) and groundingNormal Below 1 V

Clogged 20 – 30 V

TROUBLESHOOTING AA10NX

Electrical circuit diagram related to air cleaner clogging switch



TROUBLESHOOTING AB00KE

Electrical circuit diagram related to engine preheating, starting, charging



TROUBLESHOOTING B@BAZG

Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)


phenomenon

Eng. Oil Press. Low

(Mechanical system)E11 E924 B@BAZG

Failure content

• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of

the high-pressure switch is closed (connected to grounding) while the engine speed is above 600 rpm.• The signal circuit of the low-pressure switch is opened (disconnected from grounding) and the signal

circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above

1,300 rpm.

Response from


Phenomenon

occurring on • If the machine is used as it is the engine may be damaged



occurring on

machine


Relative

information

• When this failure occurs, the error code is displayed only when the user code is turned ON and the fail-

ure code is recorded in only the mechanical system of the failure history.

• If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this

failure code is recorded.

• Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function.

(Code No. 17400: Engine controller input)


s t a n d a r

d v a l u e i n n o r m a l c y


1Engine oil pressurelowered


Check the engine oil pressure. If it is abnormal, find out the cause and check the

engine for damage, then repair.

2Engine oil pressure

switch system defectiveCarry out troubleshooting for error code [E936].

3Engine controller

defective


position or start the engine during the troubleshooting.

CB1 Engine Voltage

Between (21) and grounding(Low-pressure switch signal)

Stopped Below 1 VLow idling 20 – 30 V

Between (15) and grounding

(High-pressure switch signal)

Stopped Below 1 V

Above 1,300 rpm 20 – 30 V

When carrying out troubleshooting while the engine is running, wait for 15 seconds

after the engine is started.

TROUBLESHOOTING B@BAZG

Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)



TROUBLESHOOTING B@BAZK

Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)


phenomenon

Eng. Oil Level Low

(Mechanical system)— — B@BAZK

Failure content

• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the

engine is stopped.

Response from


Phenomenon

occurring on

machine


R l ti

• If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this fail-

d i d d



Electrical circuit diagram related to engine oil level switch

Relative

information

ure code is recorded.

• Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.(Code No. 04501: Monitor input 2)




1Engine oil level low


Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced fre-

quently, find out the cause.)

2

Engine oil level switch

defective(Internal disconnection)



OL (male) Engine oil level Resistance value

Between (1) and groundingNormal level Below 1 z

Below normal level Above 1 Mz

3


harness

(Disconnection or


connector)



Wiring harness between P02 (female) (8) and OL

(female) (1)

Resistance

valueBelow 1 z




P02 Engine oil level Voltage

Between (8) and groundingNormal level Below 1 V

Below normal level 20 – 30 V

TROUBLESHOOTING B@BCNS

Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat)


phenomenon

Eng. Water Overheat

(Mechanical system)— — B@BCNS

Failure content • The signal circuit of the engine water high temperature sensor detected temperature above 105°C.

Response from


Phenomenon

occurring on

machine


Relative

• If the engine water temperature monitor on the monitor panel lights up in red while the engine is run-

ning, this failure code is recorded.

• Input from the engine water high temperature sensor (water temperature and voltage) can be checked




temperature)

information• Input from the engine water high temperature sensor (water temperature and voltage) can be checked

in the monitoring function. (Code No. 04102: Engine water temperature (High), 04106: Engine watertemperature sensor voltage Hi)




1Engine overheated


Check the engine for overheating. If it has been overheated, find out the cause and

check the engine for damage, then repair.

2

Engine water high

temperature sensor

system defective

Carry out troubleshooting for “Display of engine water temperature gauge on monitor

panel is abnormal” in E mode.

3Engine controller

defective



CB2 (female) Engine water temperature Resistance value

Between (27) and (29), (39) 105°C 3.28 kz

TROUBLESHOOTING B@BCZK

Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)


phenomenon

Eng. Water Lvl Low

(Mechanical system)— — B@BCZK

Failure content• The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the

engine is running.

Response from


Phenomenon

occurring on

machine

• If the machine is used as it is, the engine will overheat.

Relative

• If the radiator water level monitor on the monitor panel lights up in red while the engine is stopped (the

starting switch is at the ON position) this failure code is recorded



Electrical circuit diagram related to radiator water level switch

Relative

information

starting switch is at the ON position), this failure code is recorded.

• Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function.(Code No. 04500: Monitor input 1)




1Sub-tank water level low


Check the radiator sub-tank water level. If it is low, add water. (If it is reduced fre-

quently, find out the cause.)

2

Radiator water level

switch defective(Internal disconnection)



A33 (male) Sub-tank water level Resistance value

Between (1) and (2)Within normal level Below 1 z

Below LOW level Above 1 Mz

3


harness

(Disconnection or


connector)




(female) (1)

Resistance

valueBelow 1 z

Wiring harness between A33 (female) (2), J08, J12 and

grounding

Resistance

value

Below 1 z




P02 Sub-tank water level Voltage

Between (3) and groundingWithin normal level Below 1 V

Below LOW level 20 – 30 V

TROUBLESHOOTING B@HANS

Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)


phenomenon

Hydr. Oil Overheat

(Mechanical system)— — B@HANS

Failure content • The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.

Response from


Phenomenon

occurring on

machine

• If the machine is used as it is, the hydraulic equipment may be damaged.

Relative

information

• If the hydraulic oil temperature monitor on the monitor panel lights up in red while the engine is running,

this failure code is recorded.

• Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring func-



Electrical circuit diagram related to hydraulic oil temperature sensor

information Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring func

tion. (Code No. 04401: Hydraulic oil temperature)



a l c y


1Hydraulic oil overheated


Check the hydraulic oil for overheating. If it has been overheated, find out the cause

and check the hydraulic equipment for damage, then repair.

2

Hydraulic oil temperature

sensor defective




A61 (male) Hydraulic oil temperature Resistance value

Between (1) and (2) 10 – 100°C 90 – 3.5 kzBetween (2) and grounding Above 1 Mz

3


harness


circuit)




A61 (female) (2) and grounding

Resistance

value Above 1 Mz




P02 Hydraulic oil temperature Resistance value

Between (12) and (13)

10 – 100°C

90 – 3.5 kz

Between (12) and




INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-503

E-1 The engine does not start (The engine does not rotate) ...................................................................... 20-504

E-2 Preheater does not operate.................................................................................................................. 20-508

TROUBLESHOOTING OF

ELECTRICAL SYSTEM (E MODE)



E-3 Auto engine warm-up device does not work ........................................................................................ 20-510E-4 Auto-decelerator does not operate ....................................................................................................... 20-511

E-5 All work equipment, swing and travel do not move .............................................................................. 20-512

E-6 One-touch power max. function does not operate ............................................................................... 20-514

E-7 Machine push-up function does not operate normally.......................................................................... 20-515

E-8 Attachment circuit does not change ..................................................................................................... 20-517

E-9 No display in monitor panel at all ......................................................................................................... 20-519

E-10 Part of display on monitor panel is missing ........................................................................................ 20-520

E-11 Monitor panel displays contents irrelevant to the model..................................................................... 20-520

E-12 Fuel level monitor red lamp lights up while engine is running ............................................................ 20-521E-13 Engine water temperature gauge does not display correctly ............................................................. 20-522

E-14 Hydraulic oil temperature gauge does not display correctly ............................................................... 20-524

E-15 Fuel gauge does not display correctly ................................................................................................ 20-525

E-16 Swing lock monitor does not display correctly.................................................................................... 20-526

E-17 When monitor switch is operated, nothing is displayed...................................................................... 20-528

E-18 Windshield wiper and window washer do not work ............................................................................ 20-530

E-19 Alarm buzzer cannot be cancelled ..................................................................................................... 20-534

E-20 “Boom RAISE” is not correctly displayed in monitor function ............................................................. 20-535

E-21 “Boom LOWER” is not correctly displayed in monitor function........................................................... 20-536E-22 “Arm IN” is not displayed normally in monitoring function .................................................................. 20-537

E-23 “Arm DUMPING” is not correctly displayed in monitor function.......................................................... 20-538

E-24 “Bucket CURL” is not displayed normally in monitoring function........................................................ 20-539

E-25 “Bucket DUMPING” is not correctly displayed in monitor function ..................................................... 20-540

E-26 “Swing” is not displayed normally in monitoring function.................................................................... 20-542

E-27 “TRAVEL” is not correctly displayed in monitor function..................................................................... 20-544

E-28 “Travel Differential Pressure” is not correctly displayed in monitor function ....................................... 20-546

E-29 “Service” is not correctly displayed in monitor function ...................................................................... 20-548

E-30 Travel alarm does not sound or does not stop sounding.................................................................... 20-550

E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM.............................................................. 20-552

TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)

Before carrying out troubleshooting for electrical system (E-mode)

Connection table of fuse box

a This connection table shows the devices to which each power supply of the fuse box supplies power (A

switch power supply is a device which supplies power while the starting switch is at the ON position and a

constant power supply is a device which supplies power while the starting switch is at the OFF position).a When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if

the power is supplied normally.

Type of

power supplyFuse No. Fuse capacity Destination of power

1 10 A

Pump controller (Controller power supply)

Swing holding brake solenoid (When emergency brake is released)

PC-EPC solenoid (When emergency pump is driven)



Switch power supply

(Fusible link: A34)

2 20 APump controller (Solenoid power supply)Machine push-up solenoid

ATT return selector relay & solenoid

3 10 AStarting motor cutout relay (For PPC lock)

PPC lock solenoid

4 10 ACigarette lighter

Windshield washer motor

5 10 A Horn

Switch power supply

(Fusible link: A34)

6 10 A (Spare)7 10 A Rotary lamp

8 10 A Right front working lamp & boom working lamp

9 10 AOne-touch power maximizing switch (Input to pump controller input)

Radio

10 10 A (Spare)

Switch power supply

(Fusible link: A34)

11 20 A Air conditioner unit

12 20 AMonitor panel

Starting motor cutout relay (For personal code)

13 20 ALight relay (For right front working lamp & boom working lamp)

Headlamp & additional headlamp

14 10 A Service power supply 1 (M32 connector)

15 10 ATravel alarm

Service power supply 2 (DC/DC converter)

Constant power

supply(Fusible link: A35)

16 10 A Radio (For backing up)

17 10 A Monitor panel (For backing up)

18 10 A Starting switch19 10 A Room lamp

20 10 A (Spare)



a The following information are edited and contained in the “Information Contained in Troubleshooting Table”.

You are required to proceed with troubleshooting after fully grasping the contents.

Failureinformation Phenomena occurring on machine

Relative

informationInformation on occurred failures and troubleshooting


1

<Contents>

• The standard values in normalcy by which to judge “good” or “no good” about

presumed causes



Relative Electrical Circuit Diagram

P r e s u m e d c a

u s e a n d


Cause for presumed

failure(The attached No. for

filing and reference

purpose only. It does not

stand for any priority)

presumed causes.

• References for making judgement of “good” or “no good”

<Phenomena of wiring harness fault>

• Failure due to disconnection

Defective contact with connector or disconnection of wiring harness has occurred.

• Grounding fault

A wiring harness that is not originally connected with a grounding circuit is in

contact with it.

• Failure due to short-circuiting

A wiring harness that is not originally connected with a power source circuit (24 V)is in contact with it.

<Points to remember in troubleshooting>

1) Connector denotation method and handling of T-adapters

Insert or connect T-adapters in the following manner, unless specifically otherwise

instructed.

• If there is no indication of (male) or (female) in the connector No., pull off a

connector and insert a T-adapter into both sides of male and female.

• If there is an indication of (male9 and (female) in the connection No., pull off a

connector and insert a T-adapter into only one side of (male) or (female).

2) Description sequence of pin No. and handling of circuit tester leads

Connect the positive lead (+) and negative lead (–) for troubleshooting in the

following manner unless specifically otherwise instructed.

• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.

• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.

2

3

4

5

TROUBLESHOOTING E-1

E-1 The engine does not start (The engine does not rotate)

Failure

information• The engine does not start.

Relative

information• The engine starting circuit has the start lock mechanism of the safety lock lever type


1Insufficient battery

capacity

aPrepare with starting switch OFF, then carry out troubleshooting without turning

starting switch ON.

Battery voltage Electrolyte specific gravity

Min. 24 V Min. 1.26

2Defective fusible link A35

or fuse No 3 or 17

If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has a

grounding fault (See cause 9)





or fuse No. 3 or 17 grounding fault (See cause 9).

3Defective starting switch


aPrepare with starting switch OFF, then keep starting switch OFF or turn it START

and carry out troubleshooting.

H15 (male) Starting switch Resistance

Between (1) and (4)OFF Min. 1 Mz

START Max. 1 z

4

Defective safety lock

switch(Internal short circuit)


starting switch ON.

S14 (female) Safety lock lever Resistance

Between (1) and (3)FREE Min. 1 Mz

LOCK Max. 1 z

5

Defective starting motor

cut-out relay

(Internal defect)



R11 (female), R13 (female) Resistance

Between (1) and (2) 100 – 500 z

Between (3) and (5) Min. 1 Mz

Between (3) and (6) Max. 1 z

6Defective starting motor

(Internal defect)

aPrepare with starting switch OFF (with wiring harness connected), then turn

starting switch to START and carry out troubleshooting.

Starting motor Voltage

Between terminal B and

chassis ground

B (Power

supply)2 0 – 3 0 V

Between ST (1) and chas-

sis groundS (Start) 20 – 30 V

Between ST (2) and chas-

sis groundR (Charge) Max. 1 V

TROUBLESHOOTING E-1


8



in wiring harness or

defective contact in con-

nector)


starting switch ON.

Wiring harness between battery relay B terminal and

A35 (male) (1) Resistance Max. 1 z

Wiring harness between A35 (male) (2) and H15

(female) (1)Resistance Max. 1 z

Wiring harness between H15 (female) (4), J01, and

R11 (female) (5)Resistance Max. 1 z

Wiring harness between R11 (female) (3) and ST


Wiring harness between FB1-3 and S14 (male) (1) Resistance Max. 1 z





i n n o r m a l c y

g ( ) ( )

Wiring harness between S14 (male) (3) and R11


Wiring harness between R11 (female) (2) and R13


Wiring harness between R13 (female) (3), J04, and

chassis groundResistance Max. 1 z

9

Short circuit with chas-

sis ground in wiring har-

ness (Contact with

ground circuit)


starting switch ON.

Between wiring harness between A35 (male) (2) and

H15 (female) (1) and chassis groundResistance Min. 1 Mz

Wiring harness between H15 (female) (4), J01, and

R11 (female) (5), and other related circuits and chassis

ground

Resistance Min. 1 Mz

Wiring harness between R11 (female) (3) and ST

(female) (1) and chassis groundResistance Min. 1 Mz

Wiring harness between FB1-3 and S14 (male) (1) and

chassis ground Resistance Min. 1 Mz

Wiring harness between A14 (male) (3) and R11


Wiring harness between R11 (female) (2) and R13


Wiring harness between R13 (female) (2), J05, P02

(female) (14), and other related circuits and chassis

ground


10

Short circuit with power

source in wiring harness

(Contact with 24 V cir

aPrepare with starting switch OFF, then turn starting switch ON and carry outtroubleshooting.

Between wiring harness between ST (female) (2),

TROUBLESHOOTING E-1

Electrical circuit diagram for engine preheating, starting, charging



TROUBLESHOOTING E-1

E-2 Preheater does not operate

Failure

information• The preheater does not operate.

(1) When the starting switch is turned to the HEAT posi-

tion, the preheating monitor does not light up.

Relative

information

• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about

30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).

• Input of the preheating signal (ON or OFF) can be checked in the monitoring function.

(Code No. 04500: Monitor input 1)

s e a n d

n o r m a l c y


1Starting switch system

defective

If the preheater does not operate (the heater unit is not warmed), carry out trouble-

shooting (2).


harness






s t a n d a r d v a l u e i n 2 (Disconnection or


connector)

Wiring harness between P02 (female) (18) and J02

(male) (7)

Resistance

valueBelow 1 z


aTurn the engine starting switch OFF for the preparations , and hold it in the OFF or

HEAT position during troubleshooting.

P02 Starting switch Voltage

Between (18) and

grounding

OFF Below 1 V

HEAT 20 – 30 V

Failure

information• The preheater does not operate.

(2) When the starting switch is turned to the HEAT

position, the heater unit is not warmed.

Relative

information

• Check that the starting motor rotates normally.

• (If the starting motor does not rotate, carry out troubleshooting in “Engine does not start”.)

s e a n d

n o r m a l c y


1Starting switch defective


aTurn the engine starting switch OFF for the preparations, and hold it in the OFF or HEAT position during troubleshooting.

H15 (male) Starting switch Resistance value

Between (1) and (3)OFF Above 1 Mz

HEAT Below 1 z

2Heater relay defective(Internal disconnection)

aTurn the engine starting switch OFF for the preparations (with the wiring harness

connected), and hold it in the OFF or HEAT position during troubleshooting.

Heater relay Starting switchContinuity and

resistance value

Between coil terminalOFF Continued

TROUBLESHOOTING E-2

Electrical circuit diagram for engine preheating, starting, charging



TROUBLESHOOTING E-3

E-3 Auto engine warm-up device does not work

Failure

information• The auto engine warm-up device does not work.

Relative

information

• The auto engine warm-up device is activated, when the engine cooling water temperature is below

30°C, and raise the engine rotation up to 1,200 rpm.

• The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more

than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.

• If the engine water temperature is below 10°C, the turbocharger protection function operates to keep

the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.

a n d

o r m a l c y


aTurn the starting switch ON for the troubleshooting (monitoring).

Monitoring code Item Normal display

C th it




s t a n d a r d v a l u e i n n

1Engine cooling water

temperature signal fault 04107

Engine cooling water

temperature

(low temperature)

Compare the monitorindication with the actual

engine cooling water

temperature.

If the display on the monitor panel is abnormal, carry out troubleshooting in “Engine

water thermometer does not display normally”.

2Engine controller

defective

If cause 1 is not detected, the engine controller may be defective. (Since trouble is in

the engine controller, troubleshooting cannot be carried out.)

TROUBLESHOOTING E-4

E-4 Auto-decelerator does not operate

Failure

information• The auto-decelerator does not operate.

Relativeinformation

• Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above

this level.

• Check the display on the monitor panel while the engine is running.

• If the display on the monitor panel is abnormal, carry out troubleshooting in “ is not displayed

normally in monitoring function”.


1Boom RAISE signal

defective


01900

Pressure switch 1Boom RAISE

Lever operated: ON

Lever in neutral: OFF





s


2Boom LOWER signal

defective


01900

Pressure switch 1Boom LOWER

Lever operated: ON


3 Arm IN signal defective


01900

Pressure switch 1 Arm IN

Lever operated: ON


4 Arm OUT signal defective


01900Pressure switch 1 Arm OUT Lever operated: ONLever in neutral: OFF

5Bucket CURL signal

defective


01901

Pressure switch 2Bucket CURL

Lever operated: ON


6Bucket DUMP signal

defective


01901

Pressure switch 2Bucket DUMP

Lever operated: ON


7 Swing signal defectiveMonitoring code Item Normal display

01900

Pressure switch 1Swing

Lever operated: ON


8 Travel signal defective


01900

Pressure switch 1Travel

Lever operated: ON


9 Service signal defective


01901

Pressure switch 2 Service

Lever operated: ON


10 Pump controller defectiveIf causes 1 – 9 are not detected, the pump controller may be defective.

(Since trouble is in the pump controller troubleshooting cannot be carried out )

TROUBLESHOOTING E-5

E-5 All work equipment, swing and travel do not move

Failure

information• All the work equipment, swing and travel do not move.

Relative

information—


1 Fuse No. 3 faultIf the fuse is blown, there is a big possibility that grounding fault occurred in the

circuit. (See cause 6.)

2

Safety lock switch

defective




S14 (female) Safety lock lever Resistance value

Between (1) and (2) Free Below 1z





o r m a l c y

Between (1) and (2) Free Below 1Lock Above 1 Mz

3

PPC lock solenoid

defective

(Internal disconnection,

short-circuiting, or

grounding fault)




Between (1) and (2) 20 – 60 z


4 Assembled-type diodeD01 defective




D01 (male) Resistance value (Continuitiy)

Between (4) and (8) Above 1 Mz (No continuitiy)

5


harness

(Disconnection or

defective contact withconnector)



Wiring harness between FB1-3 outlet and S14 (male)

(1)

Resistance

valueBelow 1 z

Wiring harness from S14 (male) (2) and J02 – V01(female) (2) Resistancevalue Below 1 z

Wiring harness between V08 (female) (1) to J13 and

grounding

Resistance

valueBelow 1 z

6


harness


circuit)



Between wiring harness between FB1-3 outlet and S14

(male) (1) and grounding

Resistance

value Above 1 Mz

Wiring harness from S14 (male) (2) to J02 – V01

(female) (2), or between wiring harness between S14

(male) (2) and D01 (female) (4) and grounding

Resistancevalue

Above 1 Mz

TROUBLESHOOTING E-5

Electrical circuit diagram for PPC lock solenoid



TROUBLESHOOTING E-6

E-6 One-touch power max. function does not operate

Failure

information• One-touch power max. function does not operate

Relative

information

• If the one-touch power max. switch is pressed while the engine is running, the one-touch power max.

monitor is displayed on the monitor panel.

• Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in

the monitoring function. (Code No. 02200: Switch input 1)


1 Fuse No. 9 defectiveIf the fuse is broken, there is a big possibility that grounding fault occurred in the cir-

cuit. (See cause 4.)

2One-touch power max.

i h d f i (I l



M23 (male) One-touch power Resistance value



Electrical circuit diagram related to one-touch power max. switch

P r e s u m e d

c a u s e a n d

s t a n d a r d v a l u

e i n n o r m a l c y

2One touch power max.switch defective (Internal

disconnection)

M23 (male) One touch powermax. switch

Resistance value

Between (1) and (2)Released Min. 1 Mz

Pressed Max. 1 z

3



or defective contact with

connector)



Wiring harness between FB1-9 outlet and M23 (female)

(1)

Resistance

valueMax. 1 z

4


harness (Contact with

grounding circuit)



Between wiring harness between FB1-9 outlet and M23

(female) (1), or between wiring harness between FB1-9

outlet and other related circuit and grounding

Resistance

valueMin. 1 Mz

Between wiring harness between M23 (female) (2) and

C01 (female) (11) and grounding

Resistance

valueMin. 1 Mz




C01One-touch power

max. switchVoltage

Between (11) and

grounding

Released Max. 1 V

Pressed 20 – 30 V

TROUBLESHOOTING E-7

E-7 Machine push-up function does not operate normally

Failure

information

• Machine push-up function does not operate

normally.(1) The machine push-up function does not operate.

Relative

information• When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.

su m e d c a u s e a n d

ard

v a l u e i n n o r m a l c y


1

Machine push-up switch

defective




M38 (female) Machine push-up switch Resistance value

Between (1) and (2)Low pressure position Below 1 z

High pressure position Above 1 Mz

aTurn the engine starting switch OFF for the preparations, and hold it in the ONiti d i t bl h ti



Electrical circuit diagram related to machine push-up solenoid

P r e s u

s t a n d a r d

2


harness


g g p p ,position during troubleshooting.

Between wiring harness between M38 (female) (2), J07

and V06 (female) (2) or between M38 (female) (2) and

D02 (female) (3) and grounding

Voltage Below 1 V

TROUBLESHOOTING E-7

Failure

information

• Machine push-up function does not operate

normally.(2) The machine push-up function is not turned OFF.

Relative

information• When the machine push-up function is set in the low pressure position, the solenoid is turned ON.


1 Fuse No. 2 defective If the fuse is broken, the circuit probably has grounding fault (See cause 6).

2

Machine push-up switch

defective




M38 (female) Machine push-up switch Resistance value

Between (1) and (2)Low pressure position Below 1 z

High pressure position Above 1 Mz




e a n d


g

3

Machine push-up

solenoid defective


short-circuiting or

grounding fault)




Between (1) and (2) 20 – 60 z


4

Assembled-type diode

D04 defective(Internal short-circuiting)


position during troubleshooting.

D02 (male) Resistance value (Continuitiy)

Between (3) and (7) Above 1 Mz (No continuitiy)

5


harness

(Disconnection or


connector)



Wiring harness between FB1-2 outlet and M38 (male)

(1)

Resistance

valueBelow 1 z

Wiring harness between M38 (male) (2), J07 and V06

(female) (2)

Resistance

valueBelow 1 z

Wiring harness between V06 (female) (1) and groundingResistance

valueBelow 1 z

6


harness


circuit)



Between wiring harness between FB1-2 outlet and M38

(male) (1) or between FB1-2 outlet and related circuits

and grounding

Resistance

value Above 1 Mz

Between wiring harness between M38 (male) (2), J07

and V06 (female) (2) or between M38 (male) (2) and

D02 (female) (3) and grounding

Resistancevalue

Above 1 Mz

TROUBLESHOOTING E-8

E-8 Attachment circuit does not changeWhen attachment is installed

Failure

information

• Attachment circuit does not

change.

(1) When working mode A or E is selected, attachment circuit is not

switched to crusher circuit (reciprocation circuit).

(2) When working mode B is selected, attachment circuit is not

switched to breaker circuit (one-way circuit).

Relative

information

• If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or discon-

nection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected,

however.


1

Attachment return selec-

tor solenoid defective

(Internal disconnectionor short circ it)




Between (1) and (2) 20 – 60 z



P r e s u m e d

c a u s e a n d



or short-circuit) Between (1) and (2) 20 60 z


2

Attachment return selec-

tor relay defective

(Internal disconnection

or short-circuit)



R20 (male) Resistance value

Between (3) and (5) Below 1 z

Between (3) and (6) Above 1 Mz

3


harness

(Disconnection or


connector)



Wiring harness between J03 (male) (8) and R20

(female) (3)

Resistance

valueBelow 1 z

Wiring harness between R20 (female) (5) and V12

(female) (2)

Resistance

valueBelow 1 z



Resistance

valueBelow 1 z

4

Short-circuit of wiring

harness

(Contact with 24 V

circuit)



Between wiring harness and R20 (female) (5) and V12

(female) (2) and groundingVoltage Below 1 V

TROUBLESHOOTING E-8

Electric Circuit Diagram for Attachment Return Selector Relay and Solenoid



TROUBLESHOOTING E-9

E-9 No display in monitor panel at all

Failure

information

• No display in monitor panel at all.

When the engine starting switch is turned ON, there appears no display at all in the monitor panel.

Relative

information—

a n d r m a l c y


1 Fuse No. 12 faultIf the fuse No. 12 is blown, there is a big possibility that grounding fault occurred in

the circuit. (See Cause 3.)

2


harness

(Disconnection or defect




Wiring harness from P01 (female) (1) (2) to J07 to FB1-

12

Resistance

valueBelow 1 z

Wiring harness from P01 (female) (6) (7) to J04 andgrounding

Resistancevalue

Below 1 z



Electrical Circuit Diagram for Power Source in Monitor Panel


s t a n d a r d v a l u e i n n o r grounding value

3


harness


(GND)

circuit)



Between wiring harness from P01 (female) (1) (2) to

J07 to FB1-12 outlet or related circuits and grounding

Resistance

value

Above

1 Mz

4Monitor panel

controller defective



P01 Starting switchVoltage and resistance

value

Between (1) (2) and

groundingON Voltage: 20 – 30 V

Between (6) (7) and

groundingOFF

Resistance value: Below

1 z

TROUBLESHOOTING E-10, E-11

E-10 Part of display on monitor panel is missing

Failure

information• Part of display on monitor panel is missing

Part of the display in the monitor panel is missing during

starting switch in ON.

Relative

information—



1 Monitor panel LCD fault

aTurn the starting switch ON during the troubleshooting.

If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen

becomes totally white) by the following switching operation, then the monitor panel is

normal.

• Switching operation: [ ] + [ A ] (push swiches simultaneously.)

2 Monitor paneldefective

If cause 1 is not detected, the monitor panel may be defective. (Since trouble is inthe monitor panel troubleshooting cannot be carried out )



E-11 Monitor panel displays contents irrelevant to the model

s defective the monitor panel, troubleshooting cannot be carried out.)

Failure

information• The monitor panels displays contents that have nothing to do with the model on which it is installed.

Relative

information—



1Model code signal fault

(Internal failure)

aTurn the starting switch in ON during the troubleshooting (monitoring).


00200 Controller model code PC400-a

If the display on the monitor panel is normal, troubleshoot Error Code [E217].

2Monitor panel

defective

If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in

the monitor panel, troubleshooting cannot be carried out.)

TROUBLESHOOTING E-10, E-11

E-12 Fuel level monitor red lamp lights up while engine is running

Failure

information• The fuel level monitor red lamp lights up while the engine was running.

Relative

information

• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.

• (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.

(Code No.: 04200 Fuel level sensor)

s e a n d

n o r m

a l c y


1Fuel level lowered (sys-

tem in normal condition) aCheck fuel level in fuel tank. If insufficient, refill fuel.

2

Fuel level sensor fault

(Internal

disconnection)



A60 (male) Fuel level Resistance value

Between (1) and ground-ing

FULL (Upper limit) Approx. 12 zEMPTY (Lower limit) 85 – 110 z



Electrical Circuit Diagram for Fuel Level Sensor



ing EMPTY (Lower limit) 85 – 110 z

3


harness


(GND)

circuit)




(female) (1)

Resistance

valueBelow 1 z

4Monitor panal

defective



P02 (female) Fuel level Resistance value

Between (2) and

grounding

FULL (Upper limit) Approx. 12 z

EMPTY (Lower limit) 85 – 110 z

TROUBLESHOOTING E-13

E-13 Engine water temperature gauge does not display correctly

Failure

information

• Engine water temperature gauge does not

display correctly

(1) While the engine water temperature rises normally,

the temperature gauge does not rise above the white

range (C).

(2) While the engine water temperature is stabilized

normally, the temperature gauge rises up to the redrange (H).

Relative

information

• The signal of the engine water high temperature sensor for the water temperature gauge is received

from the engine controller through the communication line.

• If the engine water high temperature sensor system becomes defective, error code [E934] may be dis-

played.

• Input from the engine water high temperature sensor (voltage and temperature) can be checked in the

monitoring function. (Code No. 04106: Engine water sensor voltage Hi, 04102: Engine water tempera-

ture (High temperature))




P r e s u

m e d c a u s e a n d


1

Engine water high

temperature sensor

defective


short-circuiting or

grounding fault)



TWH (male) Resistance value

Between (1) and (2) 3.5 k – 90 kz


2


(Disconnection or


connector)



Wiring harness between CB2 (female) (27) and TWH

(female) (1)

Resistance

valueBelow 1 z

Wiring harness between CB2 (female) (29), (39) and

TWH (female) (2)

Resistance

valueBelow 1 z

3


harness


circuit)




TWH (female) (1) and grounding

Resistance

value Above 1 Mz

4


harness





TWH (female) (1) and groundingVoltage Below 1 V

5Engine controller

defective




Between (27), (29) and (39) 3.5 k – 90 kz



Electrical circuit diagram related to engine water high temperature sensor




E-14 Hydraulic oil temperature gauge does not display correctly

Failure

information

• Hydraulic oil temperature gauge does not display correctly

(1) Hydraulic oil temperature rises normally, but the display does not rise from the white range (C).

(2) Hydraulic oil temperature remains stable, but the display rises up the red range (H).

Relative

information

• Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.

(Code No.: 04401 Hydraulic oil temperature)


1

Hydraulic oil temperature

sensor fault


or short-circuiting)



A61Engine cooling water

temperatureResistance value

Between (1) and (2)

10 – 100 °C

90 – 3.5 kz


Above 1 Mz



Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor

P r e s u m e d

c a u s e a n d



2


harness

(Disconnection or


connector)




(female) (2)

Resistance

valueBelow 1 z


(female) (1)

Resistance

valueBelow 1 z

3

Grounding fault of wiringharness


(GND) circuit)




Resistance

value

Above

1 Mz

4


harness

(Contact with 24 V

circuit)




A61 (female) (2) and groundingVoltage Below 1 V

5Monitor panal

defective


P02Engine cooling water

temperatureResistance value

Between (12) and (13)

10 – 100 °C

90 – 3.5 kz

Between (12) and

grounding90 – 3.5 kz


E-15 Fuel gauge does not display correctly

Failure

information

• Fuel gauge does not display correctly

(1) Though fuel was refilled, the display does not exceed the red range (E).

(2) Though the remaining fuel level is low, the display does not drop below the green range (F).

Relative

information

• Input from the fuel level sensor (voltage) can be confirmed in the monitor function.

(Code No.: 04200 Fuel sensor voltage)

y


1

Fuel level sensor fault





A60 (male) Fuel level Resistance value

Between (1) and

grounding

FULL (Upper limit) Approx. 12 z

EMPTY (Lower limit) 85 – 110 z





Electrical Circuit Diagram for Fuel Level Sensor


s t a n d

a r d v a l u e i n n o r m a l c

2 (Disconnection or


connector)


(female) (1)

Resistance

valueBelow 1 z

3


harness


(GND) circuit)





Resistance

value

Above

1 Mz

4


harness

(Contact with 24 V

circuit)




A60 (female) (1) and groundingVoltage Below 1 V

5Monitor panal

defective



P01 Fuel level Resistance value


FULL (Upper limit) Approx. 12 zEMPTY (Lower limit) 85 – 110 z


E-16 Swing lock monitor does not display correctly

Failure

information• Swing lock monitor does not display correctly

(1) Though the swing lock switch was turned ON, the

swing lock monitor does not light up.

(2) Though the swing lock switch was turned OFF, the

swing lock monitor lights up.

Relativeinformation

• Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.(Code No.: 04502 Monitor input 3)


1

Swing lock switch

defective


short-circuiting)



X05 (female) Swing lock switch Resistance value

Between (1) and (2)

OFF Above 1 Mz

ON Below 1 z






i n n o r m a l c y 2


harness

(Disconnection or


connector)

a g g p p ,


Wiring harness from P02 (female) (17) to J02 and X05

(male) (1)

Resistance

valueBelow 1 z

Wiring harness from X05 (male) (2) to J05 and

grounding

Resistance

valueBelow 1 z

3



(GND) circuit)



Between wiring harness from P02 (female) (17) to J02

and X05 (male) (1), or between P02 (female) (17) to


Resistance

value Above 1 Mz

4


harness




Between wiring harness from P02 (female) (17) to J02

and X05 (male) (1), or between P02 (female) (17) to


Voltage Below 1 V




P02 Swing lock switch Voltage

Between (17) and

grounding

OFF 20 – 30 V

ON Below 1 V


Electrical circuit diagram related to swing holding brake solenoid




E-17 When monitor switch is operated, nothing is displayed

Failure

information

• When monitor switch is operated, nothing is dis-

played.

(1) When mode selector switch is operated, working

mode monitor is not displayed.

Relative

information—

Presumed

cause and

standard value

in normalcy


1Monitor panel

defective As this is an internal failure, troubleshooting cannot be conducted.

Failure

information

• When monitor switch is operated, nothing is

displayed.

(2) When LCD monitor adjustment switch is oper-

ated, mode selection screen is not displayed.Relative

information—



information

Presumed

cause and

standard value

in normalcy


1Monitor panel


Failure

information


displayed.

(3) When selector switch is operated, flow rate

adjustment screen or flow rate selection screen

is not displayed.

Relative

information—

Presumed

cause and

standard valuein normalcy


1 Monitor paneldefective

As this is an internal failure, troubleshooting cannot be conducted.

Failure

information


displayed.

(4) When maintenance switch is operated, item

selection screen is not displayed.

Relative

information—

Presumed

cause and



Failure

information


displayed.

(6) When travel speed selector switch is operated,

travel speed monitor is not displayed.

Relative

information• When the travel speed does not change either, conduct the troubleshooting for H-22.

Presumedcause and

standard value

in normalcy


1Monitor panel


Failure

information


displayed.

(7) When wiper switch is operated, wiper monitor is

not displayed.

Relativeinformation

• When the wiper does not operate either, conduct the troubleshooting for E-18.



Presumed

cause and

standard value

in normalcy


1Monitor panel



E-18 Windshield wiper and window washer do not work

Failure

information

• Windshield wiper and window washer do not

work.(1) The windshield wiper does not work.

Relative

information

• Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.



1

Window rear limit switch

fault





W03 (female) Front window Resistance value

Between (1) and (2)When installed at front Above 1 Mz

When retracted at rear Below 1 z

2Windshield wiper motorfault




W04 (male) Continuity and resistance value





( )Between (3) and (1) Continued

3


harness

(Disconnection or


connector)




(female) (3)

Resistance

valueBelow 1 z


(female) (1)

Resistance

value Below 1 z

4


harness


(GND) circuit)




W03 (2)

Resistance

value

Above

1 Mz

5

Monitor panel fault

(Window rear limit switch

system)



P02 Front window Voltage


ing

When installed at front 20 – 30 V

When retracted at rear Below 1 V

Monitor panel fault

(Windshield wiper motor

system)



P01 Windshield wiper switch Resistance value

Between (9) and

grounding

Between (10) andgrounding

OFF Below 3 V

ON

Below 3 V 20 – 30 V

(Constant cycle)


Electrical Circuit Diagram for Windshield Wiper Motor and Window Rear Limit Switch




Failure

information

• Windshield wiper and window washer do not

work.(2) Windshield washer does not operate.

Relative

information—

d a l c y


1 Fuse No. 4 defective If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 4.)

2

Washer motor defective


or grounding fault)



A50 (male) Resistance value

Between (1) and (2) 5 – 20 z



harness


Wiring harness from FB1 4 to J03 to J06 and A50 Resistance




s t a n d

a r d v a l u e i n n o r m a

3 (Disconnection or


connector)

Wiring harness from FB1-4 to J03 to J06 and A50

(female) (1)

Resistance

valueBelow 1 z

Wiring harness from A50 (female) (2) to J04 and P01

(female) (3)

Resistance

valueBelow 1 z

4



circuit)



Between wiring harness from FB1-4 to J03 to J06 and A50 (female) (1), or FB1-4 to D02 (female) (4), and to

other relative circuits and grounding

Resistance

value

Above

1 Mz

Between wiring harness from A50 (female) (2) to J04

and P01 (female) (3), or A50 (female) (2) to D02


Resistance

value

Above

1 Mz

5Monitor panel

defective



P01 Windshield washer switch VoltageBetween (3) and

grounding

OFF 20 – 30 V

ON Below 1 V


Electrical Circuit Diagram for Window Washer Motor




E-19 Alarm buzzer cannot be cancelled

Failure

information• The alarm buzzer cannot be cancelled.

Relative

information

• Input from the alarm buzzer stop switch (ON or OFF) can be confirmed in the monitor function.


s e a n d

n o r m a l c y


1

Alarm buzzer stop switch

defective




P03 (female) Alarm buzzer

stop switchResistance value

Between (1) and (2)Release Above 1 Mz

Depress Below 1 z


harness



Wiring harness between P02 (female) (16) and P03 Resistance



Electrical circuit diagram related to alarm buzzer stop switch



2 (Disconnection or


connector)

Wiring harness between P02 (female) (16) and P03

(male) (1)

Resistance

valueBelow 1 z

Wiring harness from P03 (male) (2) to J05 to groundingResistance

valueBelow 1 z

3






P03 (male) (1) and groundingVoltage Below 1 V




P02 Alarm buzzer stop switch Voltage

Between (16) and

grounding

Release 20 – 30 V

Depress Below 1 V


E-20 “Boom RAISE” is not correctly displayed in monitor function

Failure

information

• “Boom RAISE” is not correctly displayed in monitor function

“Boom RAISE” is not correctly displayed in the monitor function on the monitor panel.

Relative

information—

c y


1

Boom RAISE PPC

hydraulic switch fault





S06 (male)R.H. work equipment

control lever Resistance value

Between (1) and (2)NEUTRAL Above 1 Mz

Boom RAISE Below 1 z

2


harness

(Disconnection or


Wiring harness between C03 (female) (10) and S06 ResistanceBelow 1 z



Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch


s t a n d a r d v a l u e i n n o r m a l c 2 (Disconnection or


connector)

(female) (2) valueBelow 1 z

Wiring harness between S06 (female) (1) and

grounding

Resistance

valueBelow 1 z

3


harness


(GND)

circuit)



Between wiring harness between C03 (female) (10) andS06 (female) (2) and grounding

Resistancevalue

Above1 Mz

4


harness

(Contact with 24 V

circuit)




S06 (female) (2) and groundingVoltage Below 1 V

5Pump controller

defective

aTurn the engine starting switch OFF for the preparations, and start the engine

during the troubleshooting.

C03R.H. work equipment


Between (10) and

grounding

NEUTRAL 20 – 30 V

Boom RAISE Below 1 V


E-21 “Boom LOWER” is not correctly displayed in monitor function

Failure

information

• “Boom LOWER” is not correctly displayed in monitor function

“Boom LOWER” is not correctly displayed in the monitor function on the monitor panel.

Relative

information—

a l c y


1

Boom LOWER PPC









Boom LOWER Below 1 z

2


harness

(Disconnection or



(f l ) (2)

Resistance

lBelow 1 z



Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch


s t a n d a r d v a l u e i n n o r m a 2 (Disconnection or


connector)


Wiring harness between S02 (female) (1) and ground-

ing

Resistance

valueBelow 1 z

3


harness

(Contact with grounding(GND) circuit)



Between wiring harness between C03 (female) (20) andS02 (female) (2) and grounding

Resistancevalue

Above1 Mz

4


harness

(Contact with 24 V cir-

cuit)








C03 R.H. work equipmentcontrol lever

Voltage


ing

NEUTRAL 20 – 30 V

Boom LOWER Below 1 V


E-22 “Arm IN” is not displayed normally in monitoring function

Failure

information

• “Arm IN” is not displayed normally in monitoring

function.

“Arm IN” is not displayed normally in monitoring

function (special function) of monitor panel.

Relative

information


s t a

n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting

1 Arm IN PPC pressure

sensor defective

The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for

error code [E247].

2Pump controller

defective

If cause 1 is not the cause of the trouble, the pump controller may be defective

(Troubleshooting cannot be carried out since the defect is in the pump controller).




E-23 “Arm DUMPING” is not correctly displayed in monitor function

Failure

information

• “Arm DUMPING” is not correctly displayed in monitor function

“Arm DUMPING” is not correctly displayed in the monitor function (special function) on the monitor

panel.

Relative

information

—

y


1

Arm DUMPING PPC

hydraulic switch defect


and short-circuiting)



S08 (male)L.H. work equipment



Arm DUMPING Below 1 z


harness



Wiring harness between C03 (female) (40) and S08 Resistance



Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch

P r e s u m

e d c a u s e a n d


2 (Disconnection or


connector)


(female) (2)

Resistance

valueBelow 1 z


grounding

Resistance

valueBelow 1 z

3



(GND) circuit)





Resistance

value

Above

1 Mz

4


harness

(Contact with 24 V

circuit)





5Pump controller

defective



C03L.H. work equipment



ing

NEUTRAL 20 – 30 V

Arm DUMPING Below 1 V


E-24 “Bucket CURL” is not displayed normally in monitoring function

Failure

information

• “Bucket CURL” is not displayed normally in

monitoring function.

“Bucket CURL” is not displayed normally in

monitoring function (special function) of monitor

panel.

Relative

information



1Bucket CURL PPC pres-

sure sensor defective

The bucket CURL PPC pressure sensor may be defective. Carry out troubleshoot-

ing for error code [E248].

2Pump controller

defective

If cause 1 is not the cause of the trouble, the pump controller may be defective

(Troubleshooting cannot be carried out since the defect is in the pump controller).




E-25 “Bucket DUMPING” is not correctly displayed in monitor function

Failure

information

• “Bucket DUMPING” is not correctly displayed in monitor function

“Bucket DUMPING” is not correctly displayed in the monitor function (special function) on the monitor

panel.

Relative

information

—

c y


1

Bucket DUMPING PPC



and short-circuiting)






Bucket DUMPING Below 1 z

2


harness

(Di ti



Wiring harness between C03 (female) (19) and S05 ResistanceB l 1 z



Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch


s t a n d a r d

v a l u e i n n o r m a l c 2 (Disconnection or


connector)

g ( ) ( )



grounding

Resistance

valueBelow 1 z

3



(GND) circuit)





Resistance

value

Above

1 Mz

4


harness

(Contact with 24 V

circuit)





5Pump controller

defective



C03R.H. work equipment


Between (19) and

grounding

NEUTRAL 20 – 30 V

Bucket DUMPING Below 1 V




E-26 “Swing” is not displayed normally in monitoring function

Failure

information

• “Swing” is not displayed normally in monitor-

ing function.

“Swing” is not displayed normally in monitoring

function (special function) of monitor panel.

Relative

information


1

Swing left PPC pressure

switch defective


short-circuit)



S07 (male)Left work equipment


Between (1) and (2)Neutral Min. 1 Mz

Left swing position Max. 1 z

2

Swing right PPC pres-

sure switch defective

(I t l di ti



S03 (male)Left work equipment

control leverResistance value





2(Internal disconnection or

short-circuit)

( )control lever

Between (1) and (2)Neutral Min. 1 Mz

Right swing position Max. 1 z

3


harness

(Disconnection or defective





(female) (2) or S03 (female) (2)

Resistance

valueMax. 1 z

Wiring harness between S07 (female) (1) and groundingResistance

valueMax. 1 z

Wiring harness between S03 (female) (1) and groundingResistance

valueMax. 1 z

4


harness


circuit)




S07 (female) (2) or S03 (female) (2) and grounding

Resistance

valueMin. 1 Mz

5


harness





S07 (female) (2) or S03 (female) (2) and groundingVoltage Max. 1 V




C03Left work equipment

control leverVoltage


Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches




E-27 “TRAVEL” is not correctly displayed in monitor function

Failure

information

• “TRAVEL” is not correctly displayed in monitor function

“TRAVEL” is not correctly displayed in the monitor function (special function) on the monitor panel.

Relative

information—

a n d

rm a l c y


1

Travel PPC hydraulic

switch fault





S30 (male) Travel control lever Resistance value


Forward or reverse Below 1 z

2


(Disconnection or


connector)


position during the troubleshooting.Wiring harness from C03 (female) (39) to J01 to S30

(female) (2)

Resistance

valueBelow 1 z

Wiring harness from S30 (female) (1) to J05 to ground- ResistanceBelow 1 z



P r e

s u m e d c a u s e a

s t a n d a

r d v a l u e i n n o r )

ing valueBelow 1 z

3


harness


(GND) circuit)



Wiring harness from C03 (female) (39) to J01 to S30

(female) (2), or between wiring harness between C03(female) (39) and A43 (female) (2) and grounding

Resistance

value

Above

1 Mz

4


harness

(Contact with 24 V

circuit)



Wiring harness from C03 (female) (39) to J01 to S30

(female) (2), or between wiring harness between C03

(female) (39) and A43 (female) (2) and grounding

Voltage Below 1 V

5Pump controller

defective



C03 Travel control lever Voltage

Between (39) and

grounding

NEUTRAL 20 – 30 V

Forward or backward Below 1 V


Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm




E-28 “Travel Differential Pressure” is not correctly displayed in monitor function

Failure

information

• “Travel Differential Pressure” is not correctly displayed in monitor function

“Travel Differential Pressure” is not correctly displayed in the monitor function (special function) on the

monitor panel.

Relative

information

• When pressure difference is created between the right and left travel PPC circuits (in steering), the

travel differential mechanism is turned ON.

d a l c y


1

Travel steering PPC






S31 (male) Travel control lever Resistance value

Between (1) and (2)

NEUTRAL Above 1 Mz

One side of right or left

onlyBelow 1 z

2


harness

(Disconnection or




(female) (2)

Resistance

valueBelow 1 z




s t a n d a r d

v a l u e i n n o r m a


connector)

(female) (2) value

Wiring harness from S31 (female) (1) to J05 to

grounding

Resistance

valueBelow 1 z

3


harness


(GND) circuit)





Resistance

value

Above

1 Mz

4


harness

(Contact with 24 V

circuit)





5Pump controller

defective



C02 Travel control lever Voltage


ing

NEUTRAL 20 – 30 V

One side of right or left

onlyBelow 1 V


Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch




E-29 “Service” is not correctly displayed in monitor function

Failure

information

• “Service” is not correctly displayed in monitor function

“Service” is not correctly displayed in the monitor function (special function) on the monitor panel.

Relative

information—


1

Service (front) PPC






S10 (male) Service pedal Resistance value


Operated to front Below 1 z

2Service (rear) PPChydraulic switch fault




running during the troubleshooting.S11 (male) Service pedal Resistance value


Operated to rear Below 1 z





3


harness

(Disconnection or

defective contact withconnector)




(female) (2), or wiring harness between C02 (female)

(35) and S11 (female) (2)

Resistance

valueBelow 1 z

Wiring harness between S10 (female) (1) and ground-

ing

Resistance

valueBelow 1 z

4


harness


(GND)

circuit)





(female) (35) and S11 (female) (2) and grounding

Resistance

value

Above

1 Mz

5


harness

(Contact with 24 V

circuit)




(female) (35) and S11 (female) (2) and grounding

Voltage Below 1 V




C02 Service pedal Voltage


NEUTRAL 20 – 30 VOperated to front or rear Below 1 V


Electrical Circuit Diagram for Service PPC hydraulic Switch




E-30 Travel alarm does not sound or does not stop sounding

Failure

information

• Travel alarm does not sound or does not stop sounding.

(1) The travel alarm does not sound while the machine is traveling.

(2) The alarm begins to sound when the machine is at a standstill.

Relative

information—

u s e a n d

n n o r m a l c y


1 Fuse No. 15 faultWhen fuse No.15 is blown, there is a big possibility that grounding fault occurred in

the circuit. (See Cause 4.)

2 Travel signal fault

aStart the engine during the troubleshooting (monitoring).


01900 Travel

Control lever operated:

ON

Control lever NEUTRAL:OFF

If the monitor display is not correct, proceed to No. E-29 Troubleshooting.

Di ti f i iaTurn the engine starting switch OFF for the preparations, and hold it in the OFF



P

r e s u m e d c a u

s t a n

d a r d v a l u e i n

3


harness

(Disconnection or


connector)


Wiring harness between FB1-15 outlet to J03 and A43

(female) (1)

Resistance

valueBelow 1 z

Wiring harness between A43 (female) (2) and J01 (19)

Resistance

value Below 1z

4


harness


(GND) circuit)



Between wiring harness between FB1-15 outlet to J03

and A43 (female) (1), or between wiring harness

between FB1-15 outlet and other related circuit and

grounding

Resistance

value

Above

1 Mz

5 Travel alarm fault

As this is an internal failure, troubleshooting cannot be conducted. (If none of the

causes listed in Item 1 through 4 above is found, the travel alarm is judged asdefective)


Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm




E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM

Troubleshooting procedure for air conditioner system

a The control panel of the air conditioner constantly monitors the sensors and other devices in the system .

When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially.

a If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to

the procedure for “Troubleshooting by self-diagnosis notice”, and then;

• If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”.

• If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.

Troubleshooting by self-diagnosis notice

a Check the “Self-diagnosis notice” on the control

panel according to the following procedure.

• How to display “Self-diagnosis notice”

1) Turn the starting switch ON.

2) Press OFF switch (1) and check that any-

thing is not displayed on display monitor (2).



3) Hold the UP switch ( ) and DOWN switch

( ) of temperature setting switch (3) simul-

taneously for 3 seconds or more.

4) Check the “Self-diagnosis notice” displayed

on display monitor (2).

• How to select “Self-diagnosis notice”

If multiple “Self-diagnosis notices” are recorded,

press the UP switch ( ) or DOWN switch ( )

of temperature setting switch (3) to select

another notice.

• How to delete “Self-diagnosis notice”When reproducing the “Self-diagnosis notices”

or after removing the cause of a failure, press

the switches on both sides of recirc/fresh air

selector switch (4) simultaneously for 3 seconds

or more, and all the “Self-diagnosis notices” are

deleted.

• Finishing display of “Self-diagnosis notice”

To finish display of the “Self-diagnosis notice”,press OFF switch (1) or turn the starting switch

Self-diagnosis

noticeFailure mode

E-- No failures

E11Disconnection in recirculated air

sensor

E12 Short-circuit in recirculated air sensor

E15 Disconnection in water temperaturesensor

E16Short-circuit in water temperature

sensor

E18 Short-circuit in daylight sensor

E43 Abnormality in air outlet damper

E44 Abnormality in air mix damper

E45 Abnormality in recirculated and fresh

air damper


Self-diagnosis

notice Trouble Disconnection in recirculated air sensor

E11

Contents of

trouble• Disconnection in the recirculated air sensor system is detected.

Action of

control panel

• Fixes the recirculated air temperature for control.

• When the following condition is satisfied, the operation returns to normalcy.

<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF

and ON> + <Starting air conditioner>

Related

information

s e s a n d

n o r m a l s t a t e

Cause Standard value in normal state/Remarks on troubleshooting

1

Defective recirculated

air sensor


aPrepare with starting switch OFF, then carry out troubleshooting without turningstarting switch ON.

THI (male) Resistance

Between (1) and (2) 300 z – 430 kz

aPrepare with starting switch OFF then carry out troubleshooting without turning



P

o s s i b l e c a u s


2




connector)


starting switch ON.

Wiring harness between M30 (female) (12) and TH I

(female) (2)Resistance Max. 1z

Wiring harness between M29 (female) (11) and TH I (female) (1)

Resistance Max. 1z

3Defective air conditioner

system

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system

may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

Self-diagnosis

notice Trouble Short circuit in recirculated air sensor

E12Contents of

trouble• Short circuit in the recirculated air sensor system is detected.

Action of

control panel

• Fixes the recirculated air temperature for control.




Related

information



Self-diagnosis

notice Trouble Disconnection in water temperature sensor

E15

Contents of

trouble• Disconnection in the water temperature sensor system is detected.

Action of

control panel

• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.




Related

information

s e s a n d

n o r m a l s t a t e


1

Defective water tempera-

ture sensor (Internal dis-

connection)

aPrepare with starting switch OFF, then carry out troubleshooting without turningstarting switch ON.

THW (male) Resistance

Between (1) and (2) 95 z – 455 kz

aPrepare with starting switch OFF then carry out troubleshooting without turning



P

o s s i b l e c a u


2




connector)


starting switch ON.

Wiring harness between M30 (female) (14) and THW


Wiring harness between M29 (female) (11) and THW (female) (1)

Resistance Max. 1z


system



Self-diagnosis

notice Trouble Short circuit in water temperature sensor

E16Contents of

trouble• Short circuit in the water temperature sensor system is detected.

Action of

control panel

• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.




Related

information



Self-diagnosis

notice Trouble Short circuit in daylight sensor

E18

Contents of

trouble• Short circuit in the daylight sensor system is detected.

Action of

control panel

• Assumes that the daylight sensor is not installed for control.




Related

information

c a u s e s a n d

u e i n n o r m a l s t a

t eCause Standard value in normal state/Remarks on troubleshooting

1 Defective daylight sen-sor (Internal short circuit)

The daylight sensor may be defective. Check it directly.

2




starting switch ON.

Wiring harness between M30 (female) (16) and P15Resistance Max 1z



P o s s i b l e

s t a n d a r d v a l u 2


connector)


Wiring harness between M30 (female) (3) and P15


3 Defective air conditionersystem

If neither of causes 1 and 2 is the cause of the trouble, the air conditioner systemmay be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.

Self-diagnosis

notice Trouble Abnormality in air outlet damper

E43

Contents of

trouble• Abnormality in air outlet servomotor system is detected.

Action of

control panel

• Stops the air outlet servomotor.


• <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF


Related

information

aDo not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage

the motor output shaft and break the motor coils.


1 Defective air outlet servo-motor (Internal defect)

The air outlet servomotor may be defective. Check it directly.


Self-diagnosis

notice Trouble Abnormality in air mix damper

E44

Contents of

trouble• Abnormality in air mix servomotor system is detected.

Action of

control panel

• Stops the air mix servomotor.




Related

information



a n d

m a l s t a t e


1 Defective air mix servo-motor (Internal defect)

The air mix servomotor may be defective. Check it directly.


starting switch ON.

Wiring harness between M AM (female) (1) and M29Resistance Max 1z



P o s s i b l e c a u s e s a

s t a n d a r d v a

l u e i n n o r m

2




defective contact in con-nector)


Wiring harness between M AM (female) (3) and M30


Wiring harness between M AM (female) (5) and M30(female) (2)

Resistance Max. 1z






system




Self-diagnosis

notice Trouble Abnormality in recirculated and fresh air damper

E45

Contents of

trouble• Abnormality in recirculated and fresh air servomotor system is detected.

Action of

control panel

• Stops the recirculated and fresh air servomotor.




Related

information



s a n d

r m a l s t a t e


1Defective recirculatedand fresh air servomotor

(Internal defect)

The recirculated and fresh air servomotor may be defective. Check it directly.

2 Defective fuse (in unit)If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.

Check the related circuits.

aP ith t ti it h OFF th t t bl h ti ith t t i



P o s s

i b l e c a u s e s


3



in wiring harness ordefective contact in con-

nector)


starting switch ON.

Wiring harness between MRF (female) (1) and M29


Wiring harness between MRF (female) (3) and M29


Wiring harness between MRF (female) (7), fuse in unit,

and M33 (female) (3)Resistance Max. 1z


system

If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be

defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.


Electrical Circuit Diagram for Air Conditioner




Troubleshooting by failure phenomenon

Trouble • The air conditioner does not operate. (1) The air conditioner does not operate at all.

Related

information

s a n d

r m a l s t a t e


1 Defective fuse No. 11 If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.)

2





nector)


starting switch ON.

Wiring harness between fuse 11 outlet and M33 (male)

(3)Resistance Max. 1z

Wiring harness between M27 (female) (14) and M30


Wiring harness between M33 (male) (2) and chassisground

Resistance Max. 1z

Wiring harness between M29 (female) (12) and chassis

groundResistance Max. 1z

Sh t i it ith h i


starting switch ON



P o s s i b l e c a u s e s

s t a n d a r d v

a l u e i n n o r

3

Short circuit with chassis

ground in wiring harness

(Contact with ground cir-

cuit)

starting switch ON.

Between wiring harness between circuit breaker fuse 11

outlet and M33 (male) (3) and chassis groundResistance Min. 1 Mz

Between wiring harness between M27 (female) (14) andM30 (female) (6) and chassis ground



unit

aPrepare with starting switch OFF, then turn starting switch ON and carry out

troubleshooting.

M33 Voltage

Between (2) and (3) 20 V – 30 V

If the above voltage is normal and the air conditioner does not operate, the air condi-

tioner is defective.

5 Defective control panel


M30, M29 Voltage

Between M30 (6) and M29 (12) 20 V – 30 V

If the above voltage is normal and the air conditioner does not operate, the control

panel is defective.


Trouble • The air conditioner does not operate. (2)A ir does not come out (Air flow is insufficient).

Related

information


1 Defective fuse (in unit) If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.Check the related circuits.

2Defective blower relay

(on coil side)


starting switch ON.

R30 (male) Resistance

Between (1) and (3) 140 – 340 z

3 Defective blower relay(on contact side)


troubleshooting.

R30 Fan switch Voltage

Between (4) and

chassis groundON (Operated) 20 – 30 V

Defective power transis-


troubleshooting.



P o s s i b l e c a u s e s a n d

s t a

n d a r d v a l u e i n n o r m a l s t a t e

4Defective power transis

tor (Internal defect) Fan switch If air flow can be changed with fan switch,

power transistor is normal.Operate in range of Low, Medium, and High

5Defective blower motor

(Internal defect)


MB (female) Fan switch Voltage

Between (1) and (2) ON (Operated) 20 – 30 V

If the above voltage is normal and the blower motor does not rotate, the blower motor

is defective.

6





nector)


starting switch ON.

Wiring harness between fuse 11 outlet, fuse in unit, R30(3), R31 (female) (1), and M30 (female) (6)

Resistance Max. 1z

Wiring harness between M29 (female) (3) and R30


Wiring harness between M29 (female) (12) and chassis

groundResistance Max. 1z

Wiring harness between MB (female) (1) and R30


Wiring harness between MB (female) (2) and PTR (female) (3)

Resistance Max. 1z


Trouble • The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).

Related

information


1 Defective fuse (in unit) If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.Check the related circuits.

2Defective compressor

relay (on coil side)


starting switch ON.

R31 (male) Resistance

Between (1) and (2) 140 – 340 z

3 Defective compressorrelay (on contact side)


troubleshooting (Setting of temperature: Highest cooling position).

R31 Fan switch Voltage

Between (4) and chassis

groundON (Operated) 20 – 30 V

4Defective thermostat

(Internal defect)The thermostat may be defective. Check it directly.



P o s s i b l e c a u s e s a n d

s t a n d a r d v a l u e i n n o r m a l

s t a t e

5

Defective high/low pres-

sure switch (Internal dis-

connection)


starting switch ON.

P17 (male) Resistance

Between (1) and (2) Max. 1 z


clutch (Internal defect)The compressor clutch may be defective. Check it directly.


(Internal defect)The compressor may be defective. Check it directly.

8





nector)


starting switch ON.

Wiring harness between M30 (female) (4) and P17(female) (1)

Resistance Max. 1 z

Wiring harness between P17 (female) (2) and chassis

groundResistance Max. 1 z

Wiring harness between fuse 11 outlet, R31 (female)

(2), fuse in unit, R31 (female) (1), and M30 (female) (6)Resistance Max. 1 z

Wiring harness between ST1 (female) (1) and R31


Wiring harness between M29 (female) (2) and ST1 (female) (2)

Resistance Max. 1 z


Electrical Circuit Diagram for Air Conditioner



System chart for hydraulic and mechanical system .................................................................................... 20-602

H-1 All work equipment lack power, or travel and swing speeds are slow.................................................. 20-605

H-2 Engine speed sharply drops or engine stalls ....................................................................................... 20-606

H-3 No work equipment, travel or swing move ........................................................................................... 20-607

H-4 Abnormal noise is heard from around hydraulic pump......................................................................... 20-607

H-5 Auto-decelerator does not work ........................................................................................................... 20-608H-6 Fine control mode does not function.................................................................................................... 20-608

H-7 Boom moves slowly or lacks power ..................................................................................................... 20-609

H-8 Arm moves slowly or lacks power ........................................................................................................ 20-610

H-9 Bucket moves slowly or lacks power.................................................................................................... 20-611

H-10 Work equipment does not move in its single operation...................................................................... 20-611

TROUBLESHOOTING OF HYDRAULIC

AND MECHANICAL SYSTEM (H MODE)



q p g p

H-11 Work equipment has a bit too fast hydraulic drift................................................................................ 20-612

H-12 Work equipment has big time lag....................................................................................................... 20-613

H-13 Other work equipment moves when relieving single circuit................................................................ 20-613

H-14 One-touch power max. function does not work.................................................................................. 20-613

H-15 Machine push-up function does not work........................................................................................... 20-614

H-16 In compound operation, work equipment with larger load moves slowly ........................................... 20-615

H-17 In swing + boom RAISE operation, boom moves slowly.................................................................... 20-615

H-18 In swing + travel, travel speed drops sharply ..................................................................................... 20-615

H-19 Machine swerves in travel.................................................................................................................. 20-616

H-20 Machine travels slowly ....................................................................................................................... 20-617

H-21 Machine cannot be easily steered or lacks power ............................................................................. 20-618

H-22 Travel speed does not shift, or it is slower or faster than preset speed. ............................................ 20-619H-23 Track shoe does not turn (on one side only) ...................................................................................... 20-620

H-24 Machine does not swing..................................................................................................................... 20-621

H-25 Swing acceleration is poor, or swing speed is slow ........................................................................... 20-622

H-26 Excessive overrun when stopping swing ........................................................................................... 20-623

H-27 There is big shock when stopping swing............................................................................................ 20-624

H-28 There is big abnormal noise caused when stopping swing................................................................ 20-624

H-29 Swing natural drift is too big ............................................................................................................... 20-625

H-30 Attachment circuit does not change ................................................................................................... 20-626

H-31 Flow rate in attachment circuit cannot be adjusted ............................................................................ 20-626

TROUBLESHOOTING

BEFORE TROUBLESHOOTING FOR HYDRAULIC

AND MECHANICAL SYSTEMS (H MODE)

SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM



TROUBLESHOOTING

BEFORE TROUBLESHOOTING FOR HYDRAULIC

AND MECHANICAL SYSTEMS (H MODE)

a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a

reference material when troubleshooting the hydraulic and mechanical systems.





a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out

troubleshooting work after fully grasping their contents.

Failure information Phenomena occurring on machine

Relative information Information on occurred failures and troubleshooting



i n n o r m a l c y


1

Cause for presumed

failure

(The attached No. for

filing and reference

purpose only. It does not

stand for any priority)

<Contents>

• The standard values in normalcy by which to judge “good” or “no good” about pre-

sumed causes.

• References for making judgement of “good” or “no good”

2

3

4



5

TROUBLESHOOTING H-1

H-1 All work equipment lack power, or travel and swing speeds are slow

Failure information • All the work equipment lack power, or their travel and swing speeds are slow.

Relative information • Set the working mode at A mode for troubleshooting.


1Malfunctioning of unload

valve

aStop engine for preparations. Start troubleshooting at engine high idling.

Control lever Unload pressure

All control levers in NEUTRAL4.12 ± 1.0 MPa

{42 ± 10kg/cm2}

2

Improper adjustment or

malfunctioning of main

relief valve


Control lever Main relief pressure

Arm, DIGGING33.34 – 36.77 MPa

{340 – 375kg/cm2}

If the pressure does not return to normalcy even after the adjustment, malfunctioningof main relief valve or its internal failure is suspected. In that case, check the valve

itself.

3

Malfunctioning of

self pressure

decompression valve


Control lever Control circuit source pressure

All control levers in NEUTRAL2.84 – 3.43 MPa



P


s t a n


p All control levers in NEUTRAL{29 – 35kg/cm2}

4


malfunctioning of PC

valve


Oil pressure to be mea-sured

Measurement condition Oil pressure ratio

Pump delivery pressureSwing lock: ON

Arm: Digging relief

1

PC valve output pressure Approx. 0.6

(Approx. 3/5)

If the oil pressure does not return to normalcy even after the adjustment,

malfunctioning of PC valve or its internal failure is suspected. In that case, check the

valve itself.

5Malfunctioning of

LS-EPC valve


Travel speed Travel control lever LS-EPC output pressure

Lo NEUTRAL Approx. 1.37 MPa

{Approx. 14 kg/cm2}

Hi OPERATED 0 MPa {0 kg/cm2}


Oil pressure to be mea-sured

Oil pressure ratio

All control levers in

NEUTRAL

Travel without load (con-trol lever held at half

TROUBLESHOOTING H-2

H-2 Engine speed sharply drops or engine stalls

Failure information • The engine speed sharply drops or the engine stalls.

Relative information • Relative Information

c a u s e a n d



1


malfunctioning of main

relief valve


Control lever Main relief pressure

Arm, DIGGING33.34 – 36.77 MPa

{340 – 375kg/cm2}


malfunctioning of the main relief valve or its internal failure is suspected. In that

case, check the valve itself.

2


malfunctioning of PC

valve


Oil pressure to be

measured Measurement condition Oil pressure ratio

Pump delivery pressureSwing lock: ON

Arm: Digging relief

1

PC valve output pressure Approx. 0.6

(Approx. 3/5)


malfunctioning of the PC valve or its internal failure is suspected In that case check



P r e s

u m e d c

s t a n d a r d v a l u e malfunctioning of the PC valve or its internal failure is suspected. In that case, check

the valve itself.

3


malfunctioning of LS

valve


Oil pressure to be

measured

Oil pressure ratio


NEUTRAL

Travel without load

(control lever held at half

stroke)

Pump delivery pressure

Nearly equal pressure

1

LS valve output pressure Approx. 0.6

(Approx. 3/5)

If the oil pressure does not return to normalcy even after the adjustment,malfunctioning of the LS valve or its internal failure is suspected. In that case, check

the valve itself.

4Orifice or filter in servo

equipment clogged

The orifice or filter in the pump servo equipment is suspected of clogging. Check the

equipment itself.

5Malfunction of servo

pistonThe servo piston is suspected of malfunction. Check the piston itself.

TROUBLESHOOTING H-3, H-4

H-3 No work equipment, travel or swing move

Failure information • No work equipment nor travel and swing functions can be set in motion.

Relative information • Set the working mode at A mode for the troubleshooting.

P r e s

u m e d c a u s e a n d



1Malfunctioning of PPC

lock solenoid valve


Safety lock lever Solenoid output pressure

Locked 0 MPa {0 kg/cm2}

Released2.84 – 3.43 MPa

{29 – 35kg/cm2}

2

Malfunctioning of

self pressure

decompression valve



All control levers in NEUTRAL position2.84 – 3.43 MPa

{29 – 35kg/cm2

}

3 Piston pump defective

The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in

the following manner.

• Remove the main oil pressure measurement plug and crank the engine. If oil flows

out, it is in normal condition.

4 Damper defectiveIt is presumed that the pump shaft does not rotate due to some internal failure of the

damper Check the damper itself



H-4 Abnormal noise is heard from around hydraulic pump

damper. Check the damper itself.

Failure information • An abnormal noise is heard from around the hydraulic pump.

Relative information —

s u m e d c a u s e a n d

r d v a l u e i n n o r m a l c y


1Hydraulic oil level

loweredMake a visual check.

2Quality of hydraulic oil

bad Air may have get mixed with the oil. Make a visual check.

3Hydraulic tank cap

breather clogged

It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby

causing negative pressure inside the tank. Make a visual check.


H-5 Auto-decelerator does not work

H 6 Fi t l d d t f ti

Failure information • The auto-decelerator does not work.

Relative information

• This troubleshooting mode is applied when the auto-decelerator does not work, while operating

the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch

only in the travel circuit -actually located inside PPC valve)

• Set the working mode at A mode for the troubleshooting.


s t a

n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting

1Malfunctioning of travel

PPC valve (shuttle valve)


Travel control lever PPC valve output pressure

NEUTRAL 0 MPa {0 kg/cm2}

Operation Above 2.75 MPa

{Above 28 kg/cm2}



H-6 Fine control mode does not function

Failure information • The fine control mode poorly functions or its response is slow.



a n d



1Malfunctioning of LS-

EPC valve


Travel speed Travel control lever LS-EPC valve output

pressure


{Approx. 14 kg/cm2

}Hi OPERATED 0 MPa {0 kg/cm2}

2Orifice in LS circuit

cloggedThe orifice in the LS circuit is presumed to be clogged. Check the orifice itself.

3Improper adjustment ormalfunctioning of LS


Oil pressure to be

measured

Oil pressure ratio


NEUTRAL

Travel without load


stroke)

TROUBLESHOOTING H-7

H-7 Boom moves slowly or lacks power

Failure information • The boom moves slowly or lacks power



1

Malfunctioning of right

PPC valve

(in boom circuit)


R.H. work equipment control lever PPC valve output pressure


Boom RAISE

Boom LOWER

Above 2.75 MPa

{Above 28 kg/cm2}

2Malfunction of merge/

divide solenoid valve


Travel lever Solenoid output pressure

Neutral 0 MPa {0 kg/cm2}

Operated (Note) 2.84 – 3.43 MPa{29 – 35 kg/cm2}

3

Malfunctioning of merge/

divide valve (main and

LS valves)

The merge/divide valve of control valve (main and LS valves) is presumed to

malfunction. Check the valve itself.

4Malfunctioning of boom

control valve (spool)

The spool in the boom control valve (Lo • Hi) is presumed to malfunction. Check the

valve itself





l c y

control valve (spool) valve itself.

5

Malfunctioning of boom

control valve (pressurecompensation valve)

The pressure compensation valve in the boom control valve (Lo • Hi) is presumed to


6


control valve

(regeneration valve)

The regeneration valve in the boom control valve (Lo) or the seal is presumed to


7Malfunctioning of boom

control valve (lock valve)

The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the

valve itself.

8Malfunction of boom con-

trol valve (check valve)

The check valve in the boom control valve (Hi) is presumed to malfunction. Check

the valve itself.

9

Malfunctioning of safety

valve for lock valve or

seal defective

The safety valve for the lock valve is presumed to malfunction, or the seal is

suspected to be defective. Check the valve itself.

10


control valve (suction

valve) or seal defective

The suction valve (bottom side) in the boom control valve (Lo) is presumed to

malfunction, or the seal is suspected to be defective.

11


control valve (safety and

suction valves) or sealdefective

The safety and suction valves (head side) in the boom control valve (Lo) are

presumed to malfunction, or the seal is suspected to be defective. Check those

valves themselves.

TROUBLESHOOTING H-8

H-8 Arm moves slowly or lacks power

Failure information • The arm moves slowly, or lacks power.


s e a n d

n o r m a l c y


1Malfunctioning of left

PPC valve (arm circuit)


L.H. work equipment control lever PPC valve output pressure


Arm DIGGING

Arm DUMPING

Above 2.75 MPa

{Above 28 kg/cm2}

2Malfunctioning of merge/



Travel lever Solenoid output pressure

Neutral 0 MPa {0 kg/cm2}

Operated (Note) 2.84 – 3.43 MPa{29 – 35 kg/cm2}

3

Malfunctioning of merge/

divide valve (main and

LS valves)

The merge/divide valve of control valve (main and LS valves) is presumed to


4Malfunctioning of arm


The spool in the arm control valve (Lo • Hi) is presumed to malfunction. Check the

valve itself.



P r e s u m e

d c a u s

s t a n d a r d v a

l u e i n

control valve (spool) valve itself.

5

Malfunctioning of arm

control valve (pressurecompensation valve)

The pressure compensation valve in the arm control valve (Lo • Hi) is presumed to


6


control valve

(regeneration valve)

The generation valve in the arm control valve (Lo) is presumed to malfunction, or the

seal is suspected to be defective. Check the valve itself.

7



suction valves) or seal

defective

The safety and suction valves in the arm control valve (Lo • Hi) are presumed to

malfunction, or the seal is suspected of defect. Check those valves themselves.

8Malfunction of arm control

valve (quick return valve)

The quick return valve in the arm control valve (Hi) is presumed to malfunction.

Check the valve itself.

9

Malfunctioning of LS

shuttle valve (right travel,

boom, left travel, bucket

and service valves)

LS shuttle valves in the right travel control valve, boom control valve, left travel

control valve, bucket control valve and service valve are presumed to malfunction.

Check those valves themselves.

10 Arm cylinder defective


Arm cylinder Amount oil leakage from cylinder

Digging relief 20 cc/min


H-9 Bucket moves slowly or lacks power

Failure information • The bucket moves slowly, or lacks power.


P r e s u m e d

c a u s e a n d




1

Malfunctioning of right

PPC valve

(bucket circuit)


R.H. work equipment control lever PPC valve output pressure


Bucket DIGGING

Bucket DUMPING

Above 2.75 MPa

{Above 28 kg/cm2}

2Malfunctioning of bucket


The spool in the bucket control valve is presumed to malfunction. Check the valve

itself.

3

Malfunctioning of bucket

control valve (pressure

compensation valve)

The pressure compensation valve in the bucket control valve is presumed to


4

Malfunctioning of bucket


suction valves) or seal

defective

The safety and suction valves in the bucket control valve are presumed to

malfunction, or the seal is suspected to be defective. Check those valves

themselves.

5Malfunction of LS shut-

tle valve (service valve)

The LS shuttle valve in the service control valve is presumed to malfunction. Check

the valve itself



H-10 Work equipment does not move in its single operation

tle valve (service valve) the valve itself.

6 Bucket cylinder defective


Bucket cylinder Amount oil leakage from cylinder

Digging relief 20 cc/min

Failure information

• Work equipment does not move in its single operation

(1) The boom does not move when operated independently.

(2) The arm does not move when operated independently.

(3) The bucket does not move when operated independently.


e a n d

n o r m

a l c y Cause Standard value in normalcy and references for troubleshooting

M lf ti i f PPC


Work equipment control lever PPC valve output pressure

TROUBLESHOOTING H-11

H-11 Work equipment has a bit too fast hydraulic drift

Failure information• Work equipment has a bit too fast hydraulic drift

(1) Hydraulic drift of the boom is a bit too fast.




1 Boom cylinder defective


Boom cylinder Amount oil leakage from cylinder

Raise relief 20 cc/min

2Boom control lever (lock

valve) seal defective

The seal at lock valve in the boom control lever is suspected to be defective. Check

the valve itself.

3Seal at safety valve for

lock valve defective

The seal at the safety valve in the lock valve (Lo) is suspected to be defective.

Check the valve itself.


(2) Hydraulic drift of the arm is a bit too fast.







y1 Arm cylinder defective


Arm cylinder Amount oil leakage from cylinder Digging relief 20 cc/min

2

Arm control valve (safety

and suction valves) seal

defective

The seal for safety and suction valves (bottom side) in the arm control valve (Lo • Hi)

is suspected to be defective. Check the valve itself.

(Whether the seal is defective or not may well be determined by changing for other

safety and suction valves.)

3 Arm control valve (spool)

seal defective

The seal for spool in the arm control valve (Lo • Hi) is suspected to be defective.

Check the seal itself.

4 Arm control valve(pressure compensation


The seal for pressure compensation valve (bottom side) in the arm control valve(Lo • Hi) is suspected to be defective. Check the seal itself.


(3) Hydraulic drift of the bucket is a bit too fast.



TROUBLESHOOTING H-12, H-13, H-14

H-12 Work equipment has big time lag

Failure information • The work equipment has a big time lag.


P r e s u m

e d c a u s e a n d



1Malfunctioning of

LS-EPC valve



pressure


{approx. 14 kg/cm2}

Hi Operation 0 MPa {0 kg/cm2}

2

Malfunctioning of control

valve (regeneration

valve) - with boom and

arm only

The regeneration valve in the control valve is presumed to malfunction. Check the

valve itself.

3


valves (safety & suction

valve)

The safety and suction valves (boom : head side, arm and bucket : bottom side) of

the control valve are presumed to malfunction. Check those valves themselves

directly.

(Whether they are defective or not may well be determined by changing them for

other safety and suction valves.)

4


l (The pressure compensation valve of the control valve is presumed to malfunction.



H-13 Other work equipment moves when relieving single circuit

4 valve (pressure

compensation valve)

The pressure compensation valve of the control valve is presumed to malfunction.

Check the valve itself directly.

Failure information • Other work equipment moves when relieving the single circuit of specific work equipment.




l c y Cause Standard value in normalcy and references for troubleshooting

1

Control valve (pressure

compensation valve)

seal defective

The seal for pressure compression valve in the control valve is suspected to be

defective. Check the seal itself.


H-15 Machine push-up function does not work

Failure information • The machine push-up function does not work

Relative information • When carrying out troubleshooting, set the working mode in A-mode.


n d


1Malfunction of machine

push-up solenoid valve

aPrepare with starting switch OFF, then run engine at high idling and carry out

troubleshooting.

Machine push-up switch Solenoid outlet pressure

OFF Min. 2.75 MPa {Min. 28 kg/cm3}

ON 0 MPa {0 kg/cm2}

2

Malfunction of boom

control valve

(safety-suction valve)

The safety-suction valve of the boom control valve (Lo) (on the high-pressure setting

side on the head side) may be malfunctioning. Check it directly.



TROUBLESHOOTING H-16, H-17, H-18

H-16 In compound operation, work equipment with larger load moves slowly

Failure information • In a compound operation, work equipment with larger load tends to move slowly.

Relative information —

P


s t a n



1

Malfunctioning of

pressure compensation

valve for work equipment

with larger load

The pressure compensation valve for the work equipment with larger load is

presumed to malfunction. Check the valve itself.

Combination of compound

operation

Work equipment with

larger load

Work equipment with

smaller load

Boom RAISE +

arm DIGGINGBoom Arm

Boom RAISE +

arm DUMPING Arm Boom

Boom RAISE +

bucket DIGGINGBoom Bucket

Arm DUMPING +

bucket DIGGING Arm Bucket

Boom LOWER +

arm DUMPING Arm Boom



H-17 In swing + boom RAISE operation, boom moves slowly

H-18 In swing + travel, travel speed drops sharply

Failure information • In a compound operation of swing + boom RAISE, the boom tends to move slowly.

Relative information • If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.

P r e s u m e d

c a u s e a n d


e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting

1

Malfunctioning of LS

select valve or sealdefective

The LS select valve of control valve is presumed to malfunction, or the seal issuspected to be defective. Check the valve and seal themselves.

Failure information • In a compound operation of swing + travel, the travel speed drops sharply.


H-19 Machine swerves in travel

Failure information • The machine tends to swerve while traveling.


s e a n d

n o r m a l c y



PPC valve



Operated to Forward

Operated to Reverse

Above 2.75 MPa

{Above 28 kg/cm2}

Differential output between right

and left sides0.4 MPa {4 kg/cm2}

2

Malfunctioning of

self-pressure

decompression valve



All control levers in NEUTRAL 2.84 – 3.43 MPa{29 – 35 kg/cm2}

3


malfunctioning of LS

valve


Oil pressure to be

measured

Oil Pressure ratio


NEUTRAL

Travel without load


stroke)



P r e s u m e d

c a u


e i n Pump delivery pressure

Nearly equal pressure

1

LS valve output pressure Approx. 0.6(Approx. 3/5)

4

Malfunctioning of travel

interlocking solenoid

valve




Operating one side only2.84 – 3.43 MPa

{29 – 35 kg/cm2}

5


interlocking valve

The travel interlocking valve of control valve is presumed to malfunction. Check the

valve itself.



The spool in the travel interlocking valve is presumed to malfunction. Check the

spool itself.

7Malfunction of travel

motor


Travel control lever Amount of oil leakage from travel motor

Travel relief 40 l/min

8 Final drive defective

The final drive is suspected of an internal failure. Check the inside of the final drive

directly.(An internal failure in the final drive may well be determined by an abnormal noise


H-20 Machine travels slowly

Failure information aThe machine's travel speed is slow.

Relative information aSet the working mode at A mode for the troubleshooting.

c a u s e a n d




PPC valve



Operated to Forward

Operated to Reverse

Above 2.75 MPa

{Above 28 kg/cm2}

Output differential between right and left

or front and rear

Below 0.4 MPa

{Below 4 kg/cm2}

2

Malfunctioning of

self-pressure

decompression valve



All control levers in NEUTRAL 2.84 – 3.43 MPa{29 – 35kg/cm2}

3Malfunctioning of

LS-EPC valve



pressure


{approx. 14 kg/cm2}

Hi O t d 0 MP {0 k / 2}



P r e s u m

e d c

s t a n d a r d v

a l u e Hi Operated 0 MPa {0 kg/cm2}

4 Malfunction of travelcontrol valve (spool)

The spool in the travel control valve is presumed to malfunction. Check the spoolitself.

5



compensation valve)

The pressure compensation valve in the travel control valve is presumed to


6


control valve (suction

valve)

The suction valve in the travel control valve is presumed to malfunction. Check the

valve itself.

7Malfunctioning of LS

shuttle valve (bucket)

The LS shuttle valve in the bucket control valve is presumed to malfunction. Check

the valve itself.


motor






directly.

(An internal failure in the final drive may well be determined by an abnormal noise

from within, abnormal heat or metal chip or dust contained in the drained oil.)


H-21 Machine cannot be easily steered or lacks power

Failure information • The machine cannot be easily steered.


l c y


1


PPC valve (steering

spool)


Travel control lever PPC valve output pressure (steering)

NEUTRAL on both sides 0 MPa {0 kg/cm2}

Operating one side only Above 2.75 MPa

{Above 28 kg/cm2}

2


interlocking solenoid

valve


Travel control lever Solenoid valve output pressure


Operating one side only 2.84 – 3.43 MPa{29 – 35 kg/cm2}


interlocking valve

The travel interlocking valve of control valve is presumed to malfunction. Check the

valve itself.




Travel control lever Solenoid valve output pressure





s t a n d a r d v a l u e i n n o r m a divide solenoid valve

OPERATED

2.84 – 3.43 MPa

{29 – 35 kg/cm2}


divide valve

The merge/divide valve of control valve is presumed to malfunction. Check the valve

itself.



The spool in the travel control valve is presumed to malfunction. Check the spool

itself.

7



compensation valve)

The pressure compensation valve in the travel control valve is presumed to


8Malfunctioning of travelcontrol valve (suction

valve)

The suction valve in the travel control valve is presumed to malfunction. Check the

valve itself.

9Malfunctioning of LS

shuttle valve (bucket)

The LS shuttle valve in the bucket control valve is presumed to malfunction. Check

the valve itself.

10

Check valve seal

defective at LS oil

pressure pick-up port

The seal in the check valve of LS oil pressure pick-up port is suspected to be

defective. Check the seal itself.

Malfunctioning of travelThe seal in the check valve of the travel motor is suspected to be defective. Checkthe seal itself


H-22 Travel speed does not shift, or it is slower or faster than preset speed.

Failure information • Travel speed does not shift, or it is slower or faster than preset speed.


P r e s u m e d c

a u s e a n d


i n n o r m a l c y


1Malfunctioning of

LS-EPC valve


Travel speed Travel control lever Monitoring [01500]

Lo Fine control

(to the extent that the

decelerator is released)

690 mA

Mi 740 mA

Hi 0 mA



pressure

Lo NEUTRAL Approx. 1.37 MPa{approx. 14 kg/cm2}

Hi Operation 0 MPa {0 kg/cm2}


speed solenoid valve


Travel speed Travel control lever Solenoid output

pressure

Lo NEUTRAL 0 MPa {0 kg/cm2}



Hi Operation

2.84 – 3.43 MPa

{29 – 35 kg/cm2}


motor (speed shifting)

The travel motor is presumed to malfunction when shifting speed. Check the speed

shifting portion directly.


H-23 Track shoe does not turn (on one side only)

Failure information • A track shoe does not turn (only on one side).



s t a



1Travel control valve (suc-

tion valve) seat defective

The suction valve seat in the travel control valve is suspected of defect. Check the

seat itself.

2Travel motor (safety

valve) seat defectiveThe safety valve seat in the travel motor is suspected of defect. Check the seat itself.

3Travel motor (check

valve) seat defectiveThe check valve seat in the travel motor is suspected of defect. Check the seat itself.

4 Travel Motor speed






directly.

(A failure inside the final drive may well be determined by an abnormal noise from

within, abnormal heat generated or metal dust or chips contained in the drained oil.)




H-24 Machine does not swing

Failure information• Machine does not swing

(1) The machine swings neither to the right nor to the left.





1

Malfunctioning of swing

holding brake solenoid

valve

aStop engine for preparations. Start troubleshooting at engine high idling.R.H. work equipment control lever Solenoid valve output pressure


Swing operated 2.84 – 3.43 MPa {29 – 35 kg/cm2}

2Malfunctioning of swing

motor (holding brake)

The parking brake portion of the swing motor is presumed to malfunction.

Check it directly.

3


malfunctioning of swing

motor (safety valve)


Swing lock switchL.H. work equipment

control lever Swing relief pressure

ON Swing relief 27.95 – 32.85 MPa

{285 – 335 kg/cm2}

If the oil pressure does not return to normalcy even after the adjustment, the safety

valve is presumed to malfunction, or suspected of an internal failure. Check the

valve itself.




4 Swing motor defective L.H. work equipment control lever Amount of oil leakage from swing motor

Swing relief Below 11 l/min

5Swing machinery

defective

The swing machinery is suspected of an internal failure. Check the inside of the

swing machinery directly.

(A failure inside the swing machinery may well be determined by an abnormal noise

from within, abnormal heat generated or metal dust or chips contained in the drained

oil.)

Failure information• Machine does not swing

(2) The machine does not swing in one direction.


and ma

l c y



PPC valve




Swing operated Above 2 75 MPa {Above 28 kg/cm2}


H-25 Swing acceleration is poor, or swing speed is slow

Failure information• Swing acceleration is poor, or swing speed is slow

(1) Swing acceleration is poor, or swing speed is slow.




i n n o r m a l c y


1Malfunctioning of LSshuttle valve

(all LS shuttles)

The LS shuttle valves for all the control valves are presumed to malfunction. Check

them directly.


motor (holding brake)

The swing holding brake portion of the swing motor is presumed to malfunction.

Check it directly.

3


malfunctioning of swingmotor (safety valve)




ON Swing relief 27.95 – 32.85 MPa{285 – 335 kg/cm2}



valve itself.

4 Swing motor defective


L.H. work equipment control lever Amount of oil leakage from swing motor





5Swing machinery

defective

Inside of the swing machinery is presumed to malfunction. Check itself.(Whether it is defective or not may well be determined by abnormal noise, abnormal

generation of heat and the mixture of the metal particles in drain oil.)

Failure information• Swing acceleration is poor, or swing speed is slow

(2) Swing acceleration is poor only on one side, or swing speed is slow.


cau

s e a n d

ein

n o r m a l c y



PPC valve




Swing operated Above 2.75 MPa {Above 28 kg/cm2}



The spool in the swing control valve is presumed to malfunction. Check the valve

itself.

Malfunctioning of swingThe pressure compensation valve in the swing motor is presumed to malfunction


H-26 Excessive overrun when stopping swing

Failure information• Excessive overrun when stopping swing

(1) The work equipment overruns excessively when stopping swing.





1


malfunctioning of swing





ON Swing relief 27.95 – 32.85 MPa

{285 – 335 kg/cm2}



valve itself.

2 Swing motor defectiveaStop engine for preparations. Start troubleshooting at engine high idling.

L.H. work equipment control lever Amount of oil leakage from swing motor


Failure information• Excessive overrun when stopping swing

(2) Swing acceleration is poor only on one side, or swing speed is slow.

R l ti i f ti S t th ki d t A d f th t bl h ti





e a n d




PPC valve





2Swing PPC slow return

valve clogged

The PPC slow return valve is suspected of clogging. Check the valve itself.

(Whether the valve is clogged or not may well be determined by swapping the right

and left valves and watching the result.)



The spool in the swing control valve is resumed to malfunction. Check the valve

itself.

4Swing motor (suction


The seal in the suction valve of the swing motor is suspected of defect. Check the

seal itself.

(Whether the seal is defective or not may well be determined by swapping the right

and left suction valves and watching the result.)

5 Swing motor (checkl ) l d f ti

The seal in the check valve of the swing motor is suspected of defect. Check the

seal itself.(Wh th th l i d f ti t ll b d t i d b i th i ht


H-27 There is big shock when stopping swing

H-28 There is big abnormal noise caused when stopping swing

Failure information • There is a big shock caused when stopping a swing motion.


P r e s u m e d c a u s e a n

d


a l c y



PPC valve






PPC slow return valve

The swing PPC slow return valve is presumed to malfunction. Check the valve itself.

(Whether the valve malfunctions or not may well be determined by swapping the

right and left valves and watching the result.)


motor (shockless valve)The swing motor shockless valve is presumed to malfunction. Check the valve itself.

Failure information • There is a big abnormal noise caused when stopping a swing motion.




P r e s u m e d

c a u s e a n d



1Malfunctioning of

backpressure valveThe backpressure valve is presumed to malfunction. Check the valve itself.

2Malfunction of swing


The safety valve in the swing motor is presumed to malfunction. Check the valve

itself.

3Malfunction of swing

motor (suction valve)

The seal in suction valve of the swing motor is suspected of defect. Check the seal

itself.

(Whether the seal is defective or not may well be determined by swapping the right

and left valves and watching the result.)

4Swing machinery

defective

The swing machinery is suspected of an internal failure. Check the inside of the

machinery itself.

(A failure inside the swing machinery may well be determined by monitoring

abnormal noise, abnormal heat generated or metal dust or chips contained in the

drained oil.)


H-29 Swing natural drift is too big

Failure information• Swing natural drift is too big.

(1) When the swing holding brake is activated.


• When the swing lock switch is ON position, or the swing holding brake release switch is in the

normal position, the swing brake is activated and the swing is fixed with a disc brake.

• Set the working mode in A mode for troubleshooting.



1

Swing and holding brake

solenoid valve

malfunctioned


R.H. work equipment control lever Solenoid valve output pressure


Swing operated 2.84 – 3.43 MPa {29 – 35 kg/cm2}

2

Swing motor (parking

brake portion)

malfunctioned

The parking portion of the swing motor is suspected of malfunctioning and interior

failure. Check that portion directly.

Failure information• Swing natural drift is too big.

(2) When the swing holding brake is released.


• When the swing holding brake release switch is in the emergency condition, the swing brake is

released and the swing is retained only hydraulically.

• Set the working mode in A mode for troubleshooting.






1Swing control valve

(spool) malfunctioned

The seal in the spool of the swing control valve is suspected of defect. Check the

spool itself directly.

2

Swing control valve

(pressure compensation

valve) malfunctioned

The pressure compensation valve seal in the swing control valve is suspected of

defect. Check the valve itself directly.

3Swing motor (safety

valve) defective

The safety valve seal in the swing motor is suspected of defect. Check the valve

itself directly.

4Swing motor (suction

valve) defective

The suction valve seal in the swing motor is suspected of defect. Check the valve

itself directly.

5Swing motor (check

valve) defective

The check valve seal in the swing motor is suspected of defect. Check the valve

itself directly.

6

Swing motor (shockless

valve) malfunctioned or

seal defective

The shockless valve in the swing motor is suspected of malfunction or the seal is

suspected of defect. Check the valve or seal itself directly.


H-30 Attachment circuit does not change

When attachment is installed

Failure information • The return circuit of the attachment circuit does not change.


• If an attachment is installed, the service circuit changes according to the selected working mode

as shown below.

1) In mode A or E: The double acting circuit is selected and the safety valve is set to the lowpressure.

2) In mode B: The single acting circuit is selected and the safety valve is set to the high

pressure.

* Setting of the safety valve on only port B side is changed. Port A is always set to the low

pressure.



y


1

Malfunction of

attachment return

selector solenoid valve

aKeep the engine stopped for the preparations, and keep it running at high idling


Working mode Solenoid valve output pressure

Mode E or A 0 MPa {0 kg/cm2}

Mode B2.84 – 3.43 MPa

{29 – 35 kg/cm2}

2

Malfunction of

attachment return

selector valve

The attachment return selector valve may have a malfunction. Check it directly.



H-31 Flow rate in attachment circuit cannot be adjusted

When attachment is installed

s

3 Malfunction of servicecontrol valve (safety

valve)

The safety valve of the service control valve (on port B side) may have amalfunction. Check it directly.

Failure information • Flow rate in attachment circuit cannot be adjusted.


• If an attachment is installed, the flow rate in the service circuit changes according to the

selected working mode.

• How to adjust the flow rate in modes A and E is different from that in mode B. For details, see

OPERATION MANUAL.

an

d

rm

a l c y


1

Malfunction of

attachment flow rate

adjustment EPC valve

The attachment flow rate adjustment EPC valve may have a malfunction. Check it

directly.

POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-702

METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-703

S-1 Starting performance is poor (starting always takes time).................................................................... 20-706

S-2 Engine does not start ........................................................................................................................... 20-707

S-3 Engine does not pick up smoothly (follow-up is poor) .......................................................................... 20-710

S-4 Engine stops during operations ............................................................................................................ 20-711S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-712

S-6 Engine lacks output (or lacks power) ................................................................................................... 20-713

S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 20-714

S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-715

S-9 Oil becomes contaminated quickly ....................................................................................................... 20-716

S-10 Fuel consumption is excessive........................................................................................................... 20-717

S-11 Oil is in cooling water (or water spurts back, or water level goes down) ............................................ 20-718

S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-719

TROUBLESHOOTING OF ENGINE

(S MODE)



S-13 Oil level rises (water, fuel in oil) .......................................................................................................... 20-720S-14 Water temperature becomes too high (overheating) .......................................................................... 20-721

S-15 Abnormal noise is made..................................................................................................................... 20-722

S-16 Vibration is excessive ......................................................................................................................... 20-723



TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS

METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-

tions: questions, check items, and troubleshoot-

ing. The questions and check items are used to

pinpoint high probability causes that can be located

from the failure symptoms or simple inspeciton with-

out using troubleshooting tools.Next, troubleshooting tools or direct inspection are

used to check the high probability causes to make

final confirmation.

[Questions]Sections + in the chart on the right corre-

sponds to the items where answers can be

obtained from the user. The items in are

items that can be obtained from the user,depending on the user 's level.

[Check items]The serviceman carries out simple inspection to

narrow down the causes. The items under 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 that he has obtained



user and the results of 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].

The basic method of using the troubleshooting chartis as follows.

Items listed for [Questions] and [Check items] that

have a relationship with the Cause items are marked

with , and of these, causes that have a high prob-

ability are marked with .

Check each of the [Questions] and [Check items]

in turn, and marked the or in the chart for items

where the problem appeared. The vertical column

(Causes) that has the highest number of points is


<Example of troubleshooting> Exhaust smoke is black

S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black

• Insufficient intake of air

• There is excessive fuel.

• Abnormal fuel injection condition• Improper selection of fuel

• Engine overheating

a See troubleshooting for [Overheat].

• Controller controlled by delayed mode

(The injection amount (output) is limited because

an error has occurred in the electrical system.)



TROUBLESHOOTING S-1

S-1 Starting performance is poor (starting always takes time)

General causes why starting performance is poor

• Defective electrical system

• Insufficient supply of fuel


• Improper selection of fuel

a With the common rail fuel injection system, the

fuel injection timing is recognized electrically, so

even when the starting operation is carried out,

the engine may not start until the crankshaft has

completed two rotations. However, this does

not indicate any abnormality.



TROUBLESHOOTING S-2

S-2 Engine does not start

a) Engine does not turn

General causes why engine does not turn

• Internal parts of engine seized

a See “Engine stops during operations”.

• Defective electrical system

• Failure on chassis side



TROUBLESHOOTING S-2

b) Engine turns but no exhaust smoke comes out

General causes why engine turns but no exhaust

smoke comes out

• Fuel is not being supplied

• Supply of fuel is extremely small

• Improper selection of fuel (particularly in winter)



TROUBLESHOOTING S-2

c) Exhaust smoke comes out but engine does not

start (Fuel is being injected)

General causes why exhaust smoke comes out

but engine does not start

• Lack of rotating force due to defective electrical

system






TROUBLESHOOTING S-3

S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly



• Abnormal fuel injection condition







TROUBLESHOOTING S-4

S-4 Engine stops during operations

General causes why engine stops

• Internal part of engine seized




• Failure on chassis side



TROUBLESHOOTING S-5

S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate smoothly

• Air in fuel system

• Speed sensor is not normal

(abnormality not big enough to generate error display)



TROUBLESHOOTING S-6

S-6 Engine lacks output (or lacks power)

General causes why engine lacks output












TROUBLESHOOTING S-7

S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black


• There is excessive fuel.










TROUBLESHOOTING S-8

S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive

• Abnormal combustion of oil

• The engine has been run at low or high idling for a

long time continuously (more than 20 minutes con-

tinuous operation is not allowed).

• External leakage of oil

• Wear of lubrication system



TROUBLESHOOTING S-9

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly

• Entry of exhaust gas into oil due to internal wear

• Clogging of lubrication passage

• Improper fuel used

• Improper oil used

• Operation under excessive load



TROUBLESHOOTING S-10

S-10 Fuel consumption is excessive

General causes why fuel consumption is excessive

• Leakage of fuel

• Improper condition of fuel injection (injection pressure,

injection timing)

• Excessive injection of fuel




S-11 Oil is in cooling water (or water spurts back, or water level goes down)

General causes why oil is in cooling water

• Internal leakage in lubrication system

• Internal leakage in cooling system




S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure drops

• Leakage, clogging, wear of lubricating system

• Defective oil pressure control

• Improper oil used (improper viscosity)

• Deterioration of oil due to overheating




S-13 Oil level rises (water, fuel in oil)

General causes why oil level rises

• Water in oil (cloudy white)

• Fuel in oil (diluted, smells of diesel fuel)

a If there is oil in the cooling water, carry out troubleshooting

for “Oil is in cooling water”.




S-14 Water temperature becomes too high (overheating)

General causes why water temperature becomes too high

• Lack of cooling air (deformation, damage of fan)

• Drop in heat dissipation efficiency

• Defective cooling circulation system

• Rise of hydraulic oil temperature on chassis side




S-15 Abnormal noise is made

General causes why abnormal noise is made

• Abnormality due to defective parts

• Abnormal combustion

• Air sucked in from intake system

a Judge if the noise is an internal noise or an external noise.

a If the engine is not thoroughly warmed up, the enginesound becomes slightly louder because it is operated in the

low temperature mode, but this is not an abnormality.

a When the engine is accelerated, it enters the acceleration

mode and the engine noise is higher for 3 seconds, but this

is not an abnormality.




S-16 Vibration is excessive

General causes why vibration is excessive

• Defective parts (abnormal wear, breakage)

• Improper alignment with machine

• Abnormal combustion

a If there is abnormal noise together with the vibration, carry

out troubleshooting also for “Abnormal noise is made”.



HOW TO READ THIS MANUAL....................30- 2

PRECAUTIONS WHEN PERFORMING

OPERATION............................................30- 4

SPECIAL TOOL LIST....................................30- 6

REMOVAL AND INSTALLATION OF

CYLINDER HEAD ASSEMBLY................30- 13

REMOVAL AND INSTALLATION OF ENGINE

REAR SEAL.............................................30- 20


FRONT SEAL...........................................30- 24

REMOVAL AND INSTALLATION OF FUEL

SUPPLY PUMP ASSEMBLY....................30- 27REMOVAL AND INSTALLATION OF FUEL

INJECTOR ASSEMBLY 30- 30

DISASSEMBLY AND ASSEMBLY OF

RECOIL SPRING ASSEMBLY................. 30- 69

EXPANSION AND INSTALLATION OF TRACK

SHOE ASSEMBLY................................... 30- 71

REMOVAL AND INSTALLATION OF AIR

CONDITIONER UNIT ASSEMBLY .......... 30- 73


OPERATOR’S CAB ................................. 30- 75


MONITOR ASSEMBLY............................ 30- 78

REMOVAL AND INSTALLATION OF PUMP

CONTROLLER ........................................ 30- 79REMOVAL AND INSTALLATION OF ENGINE

CONTROLLER 30- 80

30 DISASSEMBLY AND

ASSEMBLY



INJECTOR ASSEMBLY ...........................30 30


NOZZLE TIP ............................................30- 33


STARTING MOTOR ASSEMBLY.............30- 35


RADIATOR ASSEMBLY...........................30- 36

REMOVAL AND INSTALLATION OFHYDRAULIC OIL COOLER ASSEMBLY .30- 38


AND HYDRAULIC PUMP ASSEMBLY ....30- 40

REMOVAL AND INSTALLATION OF SWING

CIRCLE ASSEMBLY................................30- 45

REMOVAL AND INSTALLATION OF SWING

MOTOR AND SWING MACHINERY

ASSEMBLY.............................................. 30- 46

DISASSEMBLY AND ASSEMBLY OF SWING

CONTROLLER ........................................ 30 80


REVOLVING FRAME ASSEMBLY .......... 30- 81


COUNTERWEIGHT ASSEMBLY............. 30- 84


HYDRAULIC TANK ASSEMBLY.............. 30- 85

REMOVAL AND INSTALLATION OFHYDRAULIC PUMP ASSEMBLY............. 30- 87

REMOVAL AND INSTALLATION OF OIL SEAL

IN HYDRAULIC PUMP INPUT SHAFT ... 30- 90


CONTROL VALVE ASSEMBLY ............... 30- 91

DISASSEMBLY AND ASSEMBLY OF

CONTROL VALVE ASSEMBLY ............... 30- 94


CENTER SWIVEL JOINT ASSEMBLY 30 98

DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

HOW TO READ THIS MANUAL

REMOVAL AND INSTALLATION OF ASSEMBLIES

SPECIAL TOOLS

• Special tools that are deemed necessary for

removal or installation of parts are listed.

• List of the special tools contains the followingkind of information.

1) Necessity

t: Special tools which cannot be substi-

tuted, should always be used.

q:Special tools which are very useful if

available, can be substituted with com-

mercially available tools.

2) Distinction of new and existing special toolsN: Tools with new part numbers, newly

developed for this model.

R: Tools with upgraded part numbers,

remodeled from already available tools

for other models.

Blank: Tools already available for other mod-

els, used without any modification.

3) Circle mark (Q) in sketch column:

A circle mark means that a ske tch of thespecial tool is presented in the section of

Sk t h f S i l T l

INSTALLATION OF PARTS

• Except where otherwise instructed, install parts

is the reverse order of removal.

• Instructions and precautions for installing partsare shown with [*1] mark in the INSTALLATION

Section, identifying which step the instructions

are intended for.

• Marks shown in the INSTALLATION Section

stand for the following.

k This mark indicates safety-related pre-

cautions which must be followed when

doing the work.a This mark gives guidance or precau-

tions when doing the procedure.

2 This mark stands for a specific coating

agent to be used.

3 This mark indicates the specified

torque.

5 This mark indicates an amount of oil or

water to be added.

SKETCHES OF SPECIAL TOOLS



Sketches for Special Tools.

a Part No. of special tools starting with 79*T means

that they are locally made parts and as such not

interchangeable with those made by Komatsu in

Japan e.g. 79*T--- xxx --- xxxx.

REMOVAL OF PARTS

• The REMOVAL Section contains procedures,

precautions and the amount of oil or water to be

drained.

• Various symbols used in the REMOVAL Section

are explained and listed below.



d i th k


• Various special tools are illustrated for the con-

venience of local manufacture.

DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL

DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES

SPECIAL TOOLS

• Special tools which are deemed necessary for

disassembly and assembly are listed in this sec-

tion. • List of the special tools contains the following

kind of information.

1) Necessity

t: Special tools which cannot be substi-

tuted, should always be used.

q: Special tools which are very useful if

available, can be substituted with com-

mercially available tools.

2) Distinction of new and existing special tools

N: Tools with new part numbers, newly

developed for this model.

R: Tools with upgraded part numbers,

remodeled from already available tools

for other models.

Blank: Tools already available for other mod-

els, used without any modification.

3) Circle mark (Q) in sketch column: A circle mark means that a sketch of the

special tool is presented in the section of

ASSEMBLY

• Section titled ASSEMBLY contain procedures,

precautions and the know-how for the work, as

well as the amount of oil or water to be added. • Various symbols used in the ASSEMBLY Sec-

tion are explained and listed below.



doing the work.

a This mark gives guidance or precau-

tions when doing the procedure.

2 This mark stands for a specific coatingagent to be used.

3 This mark indicates the specified

torque.

5 This mark indicates an amount of oil or

water to be added.


• Various special tools are illustrated for the con-venience of local manufacture.



special tool is presented in the section of

Sketches for Special Tools.

4) Part No. of special tools starting with 79*T

means that they are locally made parts and

as such not interchangeable with those

made by Komatsu in Japan e.g. 79*T--- xxx

--- xxxx.

DISASSEMBLY

• The DISASSEMBLY Section contains proce-

dures, precautions and the amount of oil or

water to be drained.

• Various symbols used in the DISASSEMBLY

Section are explained and listed below.

Thi k i di t f t l t d

DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION

PRECAUTIONS WHEN PERFORMING OPERATION

Be sure to follow the general precautions given below when performing removal or installation (disassembly or

assembly) of units.

1. Precautions when performing removal work

• If the engine coolant water contains antifreeze, dispose of it properly.

• After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.

• When draining oil, prepare a container of adequate size to catch the oil.

• Confirm the match marks showing the installation position, and make match marks in the necessary placesbefore removal to prevent any mistake during assembly.

• To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wir-

ing, hold onto the connectors when disconnecting them.

• Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent any

mistakes when re-installing.

• Count and check the number and thickness of the shims, and keep them in a safe place.

• When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.

• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.

• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from

entering after removal.

a Precautions when handling piping during disassembly

Install the following blind plugs into the piping after disconnecting it during disassembly operations.

A. Face seal type hoses and tubes

Nominal number Plug (nut end) Nut (elbow end)

02 07376-70210 02789-0021003 07376-70315 02789-00315

04 07376 70422 02789 00422



B. Split flange type hoses and tubes

C. If the part is not under hydraulic pressure, the following corks can be used.

04 07376-70422 02789-00422

05 07376-70522 02789-00522

06 07376-70628 02789-00628

Nominal number Flange (hose end) Sleeve head (tube end) Split flange04 07379-00400 07378-10400 07371-30400

05 07379-00500 07378-10500 07371-30500

Nominal number Part Number Dimensions

D d L

06 0 049 00608 6 8

DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION

2. Precautions when carrying out installation work

• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.

• Install the hoses without twisting or interference.

• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.

• Bend the cotter pin or lock plate securely.

• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion

with two or three drops of adhesive.

• 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. • Clean all parts, and correct any damage, dents, burrs, or rust.

• Coat rotating parts and sliding parts with engine oil.

• When press-fitting parts, coat the surface with anti-friction compound (LM-P).

• After installing snap rings, check that the snap ring is installed securely in the ring groove.

• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect it

securely.

• When using eye bolts, check that there is no deformation or deterioration. Screw them in fully, and align the

direction of the hook.

• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.

a When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other

hydraulic equipment removed for repair, bleed the air as follows:

1) Start the engine and run it at low idle.

2) Operate the work equipment control lever to operate the hydraulic cylinders, 4 – 5 times, stopping the

cylinders 100 mm from the end of their 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.

a When using the machine for the first time after repair or long storage, follow the same procedure.

3 Precautions when completing the operations



3. Precautions when completing the operations

• If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified

level. Run the engine to circulate the coolant water through the system. Then check the coolant water level

again.

• 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.

• If the piping or hydraulic equipment have been removed for repair, bleed the air from the system after reas-sembling the parts.

a For details, see TESTING AND ADJUSTING, Bleeding air.

• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.

DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

SPECIAL TOOL LIST

a Tools with part number 79 T- - cannot be supplied (they are items to be locally manufac-

tured).

a Necessity: t............Cannot be substituted, must always be installed (used)

q............Extremely useful if available or can be substituted with commercially available part

a New/Remodel: N............Tools with new part numbers, newly developed for this model

R:...........Tools with upgraded part numbers, remodeled from items already available for oth-er models

Blank: ....Tools already available for other models, can be used without any modification

a Tools markedQ in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-

ES OF SPECIAL TOOLS).

Component

S y m b o l

Part No. Part Name

N e c e s s i t

y

Q ' t y

N e w / r e m o d e l

S k e t c h

Nature of work, remarks

1 795-799-1170 Puller t 1Removal, installation of noz-

zle holder assembly

2 790-331-1110 Wrench q 1Tightening of cylinder head

bolt

3 795-931-1100 Seal puller t 1 Removal of engine seal

795-931-1210 Push tool t 1



Engine assembly A

4Press fitting of engine rear

seal

• 01050-31625 • Bolt t 3

• 01050-31645 • Bolt t 3

5795-931-1220 Push tool t 1

• 01050-31645 • Bolt t 3

6

795T-521-1140 Push tool t

1 Q

Press fitting of engine front

seal

• 790-101-5221 • Grip t 1

• 01010-81225 • Bolt t 1

• 01050-31640 • Bolt t 3

795-471-1800 Remover t 1 N

• 795-471-1810 • Plate t 1

• 795-471-1820 • Bolt t 1


Swing motor and

swing machinery

assembly

D

1 796T-627-1630 Push tool q 1 Q Removal of shaft

2 790-201-2350 Push tool t 1 Removal of bearing

3 790-201-2510 Push tool t 1 Press fitting of bearing

4

790-101-5401 Push tool kit t 1

Press fitting of oil seal• 790-101-5531 • Plate 1

• 790-101-5421 • Grip 1

• 01010-51240 • Bolt 1

5 790-201-2870 Push tool t 1Press fitting of bearing inner

race

6 790-201-2770 Push tool t 1Press fitting of bearing inner

race

7 796T-626-1110 Push tool t 1 Q Press fitting of bearing

1

796-627-1210 Wrench assembly t 1

Removal, installation of

round nut

• 796-627-1220 • Wrench 1

• 796-427-1140 • Pin 3

• 01314-20612 • Screw 3

796T-627-1230 Push tool t 1 Q

790-101-2510 Block q 1

Component

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ' t y


S k e t c h




Final drive assem-

blyE

2Pressing of bearing inner

race

791-122-1130 Plate q 1

790-101-2550 Leg q 2

790-101-2740 Adapter q 2

790-101-2570 Plate q 4

790-101-2560 Nut q 2

790-101-2102 Puller (294 kN {30 t}) t 1

790-101-1102 Pump t 1

3 796-627-1020 Installer t 1 Installation of floating seal

Carrier roller

assemblyF

791-430-3230 Installer t 1

791-601-1000 Oil pump t 1

Track roller 791-630-1780 Installer t 1


Track shoe

assembly K

791-650-3000Remover and

installer t 1

Pulling out of master pin790-101-1300 Cylinder(980 kN {100 t})

t 1

790-101-1102 Pump t 1

Control valveassembly L

1

796-946-1310 Guide 21.81

Replacement of pressurecompensation valve seal

(For 723-46-40100, 723-46-40601)

796-946-2110 Guide 20.91

(For 723-46-44100)

796-946-2210 Guide 20.61

(For 723-46-45100, 723-46-45500)

2

796-946-1320 Guide1

(For 723-46-40100, 723-46-40601)

796-946-1420 Guide 21.61

(For 723-46-42800)

796-946-2120 Guide1

(For 723-46-44100)

796-946-2220 Guide1

Component

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ' t y


S k e t c h




1(For 723-46-45100, 723-46-45500)

3

796-946-1330 Sleeve1

(For 723-46-40100, 723-46-40601)

796-946-1430 Sleeve1

(For 723-46-42800)

796-946-2130 Sleeve1

(For 723-46-44100)

796-946-2230 Sleeve1

(For 723-46-45100, 723-46-45500)

790-101-2501 Push puller t 1

• 790-101-2510 • Block 1


Hydraulic cylinder

assemblyN

1 790-502-1003 Cylinder repair stand t 1Disassembly, assembly of

hydraulic cylinder assembly

2 790-102-4300 Wrench assembly t 1 Removal, installation of pis-ton assembly790-102-4310 Pin t 2

3 790-720-1000 Expander q 1

Installation of piston ring4

796-720-1680Ring (For boom and

bucket) q 1

07281-01589Clamp (For boom

and bucket) q 1

796-720-1690 Ring (For arm) q

107281-01919 Clamp (For arm) q 1

5


Press fitting of bushing

• 790-201-1851• Push tool

(For bucket)1

• 790-201-1861• Push tool

(For boom)1

• 790-201-1871 • Push tool (For arm)120 1

• 790-101-5021 • Grip 1

Component

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ' t y


S k e t c h




• 01010-50816 • Bolt 1

6


Press fitting of dust seal

• 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1

• 790-201-1660 • Plate(For bucket)

1

• 790-201-1670 • Plate (For boom) 1

• 790-201-1680 • Plate (For arm) 1

796-670-1100 Remover q 1

• 796-670-1110 • Sleeve 1

• 796-670-1120 • Plate 1


Air conditioner

unit assemblyQ

799-703-1200 Service tool kit t 1

Filling with air conditioner

refrigerant (gas)

799-703-1100Vacuum pump

(100V)

t 1


(220V) t 1


(240V) t 1

799-703-1401 Gas leak detector t 1

Operator’s cab

glassY

1 793-498-1210Lifter

(Suction cup) t 2 Removal and Installation of

operator’s cab glass2 20Y-54-13180 Adapter t 2

Component

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ' t y


S k e t c h






NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.

A6. Push tool



A8. Wrench


B. Stopper

D1. Push tool




D7. Push tool

E2. Push tool



DISASSEMBLY AND ASSEMBLY CYLINDER HEAD

REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY

SPECIAL TOOLS

REMOVALk Disconnect the cable from the negative (–) ter-

minal of the battery.

1. Remove 2 engine undercovers (1).

7. Remove fuel filter (8) and bracket (9).

8. Remove clamp (10), 2 tubes (11), and filter (12).

9. Remove cap (13) and disconnect wire (15).

10. Disconnect heater switch (14).

11. Remove the 2 clips on the back side and

remove bracket (16).

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y

N e w / R e m o d e l

S k e t c h

A1 795-799-1170 Puller t 1

2 790-331-1110 Wrench q 1



2. Drain the coolant.

6 Coolant: Approx. 35

3. Open the engine hood.

4. Remove tube (2). [*1]

a Remove the tube and bracket together.

5. Remove clamp (4) and disconnect the bracket

12. Disconnect fuel supply pump wiring connectors

PCV1 (17) and PCV2 (18) and remove 2 clips

(19).

13. Disconnect bracket (20) and connector PIM (21)


14. Disconnect clip (23) and bracket (24), and then

disconnect 6 fuel injector connectors (25).

a Place disconnected wiring harness assem-

bly (26) so that it will not be an obstacle. [*4]

a To disconnect fuel injector connector "c", in-sert flat-head screwdriver [1] in stepped part

"a" and move it in direction "X", pressing

stopper "b".

17. Remove 3 high-pressure pipe clamps (31) and 3

brackets (32). [*6]

18. Remove lubrication tube clamp (33).

19. Sling air intake manifold assembly (34) tempo-rarily and remove the air intake manifold mount-

ing bolts. [*7]

a Do not remove XX.

20. Lift off air intake manifold assembly (34).

4 Air intake manifold assembly: 45 kg



15. Remove common rail-side high-pressure pipeclamp (28), cover (27), and gate-type bracket

(29). [*5]

16. Remove each high-pressure pipe cover (30).

[*5]

21. Remove mounting bolts (35) and disconnect

lower lubrication tube (36).

22. Remove heat insulation cover (37) and cover

(38).


23. Remove clip (39) and lubrication tubes (40) and

(36). [*8]

a Take care of the spacer.

24. Remove clamp (41). [*9]

25. Remove cover (44).

26. Remove clamp (42) and disconnect hose (43).[*10]

27. Sling turbocharger assembly (45) temporarily

and remove the mounting bolts of exhaust mani-

fold (46). [*11]

29. Remove coolant tube (48). [*13]

30. Remove each high-pressure pipe cover (49).

[*14]

31. Remove 6 high-pressure pipe sleeve nuts (50)on the common rail side. [*15]

32. Loosen 6 high-pressure pipe sleeve nuts (51) on

the head side and remove 6 high-pressure pipes

(52). [*16]

33. Remove spill tube (55). [*17]

34. Remove return tube (53). [*18]

35. Remove 6 head covers (54). [*19]



28. Lift off turbocharger and exhaust manifold

assembly (47).

4 Turbocharger and exhaust manifold


36. Remove capture nut (56) and disconnect the

wiring harness from the injector. [*20]

37. Remove rocker shaft mounting bolts (57) and

rocker arm and rocker shaft assembly (58). [*21]

38. Remove injector mounting bolts (59) and injec-

tor assembly (60). [*22]

aIf the injector assembly is not removed easi-ly, use tool A1.

a Do not hold the solenoid valve on the top of

the injector with pliers, etc.

39. Remove cross head (61). [*23]

40. Remove 2 push rods (62).

INSTALLATION • Carry out installation of all the parts, except the

high-pressure pipe, in the reverse order to

removal.

[*1]

3 Hose clamp:

9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}

[*2]

3 Air aftercooler pipe clamp:

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3]

3 Fuel tube (7):

24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*4]Install wiring harness assembly (26) and other

wiring harnesses at least 10 mm apart from the

high-pressure pipe.

[*7]

The tightening torque and tightening order of the

air intake manifold assembly mounting bolts are

not specified.

[*8]

3 Joint bolt on engine block side of lubri-

cation tube:



41. Remove 6 mounting bolts (63) and rocker hous-

ing (64). [*24]

ca o ube

24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*9]

3 Clamp (41):

68.6 – 98 Nm {7 – 10 kgm}

[*10]

3 Hose clamp:

10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*11]

Tighten the following 3 exhaust manifold assem-

bly mounting bolts first in the given order, and

then tighten the other bolts.


[*12]2 All periphery of inserting part of

exhaust pipe: Thermosetting sealant

(FIREGUM manufactured by HOLTS

or equivalent)

[*13]

3 Coolant tube (48):

9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*14]

a For the installation procedure for high-pressure

pipe cover (49), see REMOVAL AND INSTALLA-

TION OF FUEL INJECTOR ASSEMBLY.

[*5] [*6] [*15] [*16]

Installation procedure for high-pressure pipe

a Do not correct the high-pressure pipe by bendingbefore installing it.

1) Tighten high-pressure pipe (52) perma-

nently.

3 Sleeve nuts (50) and (51):

39.2 – 49.0 Nm {4.0 – 5.0 kgm}

2) Tighten high-pressure pipe clamps (28) and

(31) and bracket (32) with your fingers.


(31) permanently.3 Clamp bolt:

11.8 – 14.7 Nm {1.2 – 1.5 kgm}

4) Tighten bracket (32) permanently.

[*17]

3 Spill tube (55):

24.5 – 34.3 Nm {2.5 – 3.5 kgm}

[*18]

3 Return tube:

9.8 – 12.7 Nm {1.0 – 1.3 kgm}

[*19]

3 Head cover mounting bolt:

9.8 ± 1 Nm {1.0 ± 0.1 kgm}

[*20]

3 Capture nut:

2.0 – 2.4 Nm {0.2 – 0.24 kgm}



5) Install cover (30).

a Set the slit on the cylinder head side.

6) Install gate-type bracket (29) and cover

(which is used as the clamp, too) (27) tem-

porarily.

7) Tighten cover (27) permanently.

3 Cover mounting bolt:

11.8 – 14.7 kgm {1.2 – 1.5 kgm}

8) Tighten the gate-type bracket permanently.

[*21]

1) Loosen the locknut and install the rocker arm

and rocker shaft assembly.

3 Rocker shaft mounting bolt:

58.8 – 73.5 Nm {6 – 7.5 kgm}2) Remove covers (70) and (71) and adjust the

valve clearance. The pointer is under cover (70).

• Valve clearance

Intake: 0.33 mm

Exhaust: 0.71 mm

a For the adjustment procedure for the valve clear-

ance, see TESTING AND ADJUSTING, Adjust-

ing valve clearance.


[*22]a For the installation procedure for the injector and

holder, see REMOVAL AND INSTALLATION OF

FUEL INJECTOR ASSEMBLY.

[*23]

a Apply engine oil (EO30-CD) to the cross head

guide and cross head top sufficiently.

a Adjust the cross head according to the followingprocedure.

1) Loosen locknut (73) and return the adjust-

ment screw.

2) Press the cross head top lightly to put it to

valve stem (74) and tighten the adjustment

screw.

3) After the adjustment screw touches the

valve stem, tighten it further by 20°.4) Tighten the locknut at this position.

3 Locknut: 58.8 – 73.5 Nm {6 – 7.5 kgm}

[*25]a Clean the underside of the head, top of the block,

and liner with dry cloths or cloths soaked with

solvent.

a If a bolt has 5 punch marks on its head, replace it.

a Tighten the bolts with your fingers into the block

at least 2 turns.

2 Bolt threads and underside of bolt

head: LM-P or engine oil (EO30-CD)a Tighten the cylinder head mounting bolts in the

following order.

3 Cylinder head mounting bolts 1 – 6:

1st time: 88.3 – 108 Nm {9 – 11 kgm}

2nd time: 157 – 167 Nm {16 – 17 kgm}

3rd time:

1) When using tool A2



[*24]

3 Rocker housing mounting bolt:58.8 – 73.5 Nm {6 – 7.5 kgm}

Using tool A2 , retighten the bolts in the

order of 1 – 6 by 90° .+30° 0


2) When not using tool A2Make marks on the bolt heads with a marker

pen and retighten the bolts in the order of 1

– 6 by 90° .

a After tightening bolts 1 – 6, tighten auxil-

iary bolt 7.

3 Cylinder head auxiliary mounting

bolt 7:

66.2 ± 7.4 Nm {6.8 ± 0.8 kgm}a After tightening the bolts, make a punch

mark on each bolt head to show the

number of tightening time.

• Refilling with coolant

Add coolant through the coolant filler of the radi-

ator to the specified level. Run the engine to cir-

culate the coolant through the piping. Then,

check the coolant level again.

+30° 0




DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL

REMOVAL AND INSTALLATION OF ENGINE REAR SEAL

SPECIAL TOOLS

REMOVAL1. Remove they hydraulic pump assembly. For

details, see REMOVAL AND INSTALLATION OF

HYDRAULIC PUMP ASSEMBLY.

2. Using guide bolt [1], remove damper assembly(1). [*1]

4. Leave 1 mounting bolt (5) and sling flywheel (4)

temporarily. [*3]

a Sling [2] becomes diagonal because of the

muffler.

5. Lift off flywheel assembly (4). [*3]

4 Flywheel assembly: 50 kg

k When the flywheel is hung temporarily, sling

[2] becomes diagonal. Accordingly, when

flywheel assembly (4) (which has been fit-

ted firmly) is removed, it swings. Take care.

6. Rear seal

Remove rear seal (6) according to the following

procedure. [*4]

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y

N

e w / R e m o d e l

S k e t c h

A

3 795-931-1100 Seal puller t 1

4

795-931-1210 Push tool t 1

• 01050-31625 • Bolt t 3

• 01050-31645 • Bolt t 3

5

795-931-1220 Push tool t 1

• 01050-31645 • Bolt t 3



3. Disconnect engine speed sensor connector

EREV (2), loosen speed sensor locknut (3), and

procedure. [ 4]


• Removal of original rear seal

Set the drill-type tip to tool A3, make a hole

on the seal, and pull out the seal with the

impact force of the slide hammer (SH).

a Remove all the chips.

• Removal of spare rear seal

1) Set the hook-type tip to tool A3, hook it to

the metallic ring of seal (6), and pull out the

seal with the impact force of the slide ham-

mer (SH).

a Drive in the seal a little before pulling itout to separate it from the housing, and

you can put it out easily.

2) If sleeve (9) is installed, cut and remove it

with a chisel and a hammer.

INSTALLATION • Carry out installation in the reverse order to

removal.

[*1]

2 Mounting bolt: Adhesive (LT-2)

[*2]

Installation procedure for sensor

1)

2 Threads of sensor: Hydraulic

sealant manufactured by LOC-

TITE

2) Screw the sensor into the flywheel housing

to touch it to the ring gear.

3) Return the sensor by 1/2 – 2/3 turns. (Clear-ance between the sensor and ring gear:

0.75 – 1 mm)

4)

3 Sensor locknut:

69 – 74 Nm {7 – 7.5 kgm}

[*3]

a Apply sufficient amount of clean lubricating

oil (EO30-CD) to the threads of the bolt, seat,

and washer.

a Tighten the 6 flywheel assembly mounting

bolts in the order of 1 – 6 shown in the follow-



a When cutting sleeve (9), take care ex-

tremely not to damage crankshaft (8).

a If chips are made, remove all of them.

ing figure.

a Tighten the flywheel assembly mounting

bolts 2 times.

3 Mounting bolt:1st tightening torque:

147 ± 19.6 Nm {15 ± 2.0 kgm}

2nd tightening torque:

289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}


[*4] • Installation procedure for engine rear seal (6)

a Rear seal 6151-21-4161: Check the shaft for

wear and install "standard seal A" or

"sleeved seal B" according to the check re-

sult.

The part No. of the spare rear seal is 6151-

29-4160 (same as one installed to PC400-6)

and its shape is different from that of the

seal installed when shipped.

a If the shaft is still glossy (If the wear depth felt

with a finger cushion is 10 m or less) and

it does not have a flaw, install "standard seal

A". In other cases, install "sleeved seal B".

a Part (7) is the internal plastic cylinder which

is also used as a installation guide.

a Part (9) is the sleeve.

a Wipe off oil from the crankshaft and installthe seal while the crankshaft is dry (Do no

apply lubricating oil to the lip).

1) Put large inside diameter side "b" of internalplastic cylinder (7) to the end of crankshaft

(8).

a Take care not to mistake the direction of

the plastic internal cylinder.

2) Evenly push in the metallic ring of seal (6)

with both hands, getting over the large

diameter side of the internal plastic cylinder.

3) After pushing in seal (6), remove internal

plastic cylinder (7).

a When removing, take care not to dam-

age the seal lip.



• Installation procedure for standard seal A

aBefore installing the seal, check the rims of the crankshaft end, sliding surfaces of the

lip, and housing for flaw, burr, rust, etc.

a When installing the seal, do not apply oil,

grease, etc. to the shaft. Wipe oil thoroughly

from the shaft.

a Never remove internal plastic cylinder (7) of

the spare seal before installing the seal.

4) Tighten the bolt of tool A4 evenly until the

end of tool A4 touches the end of crankshaft

(8) to press fit seal (6).

a When press fitting the seal, take care not

to damage the lip on the damper side


• Installation procedure for sleeved seal Ba Before installing the seal, check the rims of

the crankshaft end, sliding faces of the lip,

and housing for flaw, burr, sharp fin, rust, etc.

a When installing the seal, do not apply oil,

grease, etc. to the shaft. Wipe oil thoroughly

from the shaft.

a Handle the seal and sleeve as an assembly.

Never separate them from each other.

1) Set sleeved seal (6) to tool A5.


the seal.

2 Internal cylinder (C) of sleeve:

Gasket sealant (LG-7)

2) Put the sleeve of the seal to the end of the

crankshaft and tighten the bolt of tool A5

evenly until the end of tool A5 touches the

end of crankshaft (8) to press fit sleeved

3) Remove tool A5 and install tool A4.4) Tighten the bolt of tool A4 evenly until the

end of tool A4 touches the end of crankshaft

(8) to press fit sleeved seal (6).

a After press fitting the seal, remove the

red sealant layer on its periphery.



end of crankshaft (8) to press fit sleeved

seal (6).

DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL

REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL

SPECIAL TOOLS

REMOVAL1. Remove the radiator and hydraulic oil cooler.

For details, see REMOVAL AND INSTALLA-

TION OF RADIATOR and REMOVAL AND

INSTALLATION OF HYDRAULIC OIL COOLER.

2. Open the right side cover.

3. Remove reservoir tank bracket (1) and discon-

nect air aftercooler hoses (2) and (3). [*1]

5. Remove covers (5) and (6).

6. Loosen the air conditioner compressor assem-

bly mounting bolt and adjustment screw (7). [*2]

7. Loosen alternator assembly mounting bolt (11),

adjustment bolt nuts (8) and (9), and adjustment

bolt guide bolt (10). [*3]

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y

N

e w / R e m o d e l

S k e t c h

A3 795-931-1100Seal puller

assembly t 1

A6

795T-521-1140 Push tool t 1 Q

• 790-101-5221 • Grip t 1

• 01010-81225 • Bolt t 1

• 01050-31640 • Bolt t 3



4. Remove the 4 mounting bolts and air aftercooler

(4).

8. Remove fan (12).


9. Remove alternator belt (13) and air conditioner

compressor belt (14).

10. Remove 6 pulley mounting bolts (15) and (16) in

total, and then remove pulley and damper

assembly (17).

a One mounting bolt (16) is small in diameter.[*4]

11. Using the seal pulley assembly and tool A3,

remove the front seal. [*5]

aRemove all the chips.


removal.

[*1]

3 Air aftercooler hose clamp:

10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*2]

a Belt tension: 14 – 16 mm

(When pressed with finger to about 58.8 N

{6 kg})

3 Mounting bolt:

24.5 – 29.4 Nm {2.5 – 3.0 kgm}

[*3]• Tense the belt according to the following pro-

cedure.

1) Loosen mounting bolt (11), nut (9), and bolt

(10).

2) Tense the belt with nut (8).

3) Tighten mounting bolt (11), nut (9), and bolt

(10).

a Tension of belt: 13 mm

(When pressed with finger to about 58.8

N {6 kg})

3 Bolt:

107.8 – 147 Nm {11 – 15 kgm}



[*4]

3 Pulley mounting bolt:

(M14): 156.8 – 196 Nm {16 – 20 kgm}

(M16): 245 – 308.7 Nm {25 – 31 kgm}


[*5]

4) Installation procedure for front seal (18)

a Before installing the seal, check the rims

of the crankshaft end, sliding surfaces of

the lip, and housing for flaw, burr, rust,

etc.a When installing the seal, do not apply oil,

grease, etc. to the shaft. Wipe oil thor-

oughly from the shaft.

a Never remove internal plastic cylinder of

the spare seal before installing the seal.

i) Put large inside diameter side "b" of

internal plastic cylinder (19) to the end

of crankshaft (20).

a T k i k h di i f

ii) Evenly push in the metallic ring of seal

(18) with both hands, getting over the

large diameter side of the internal plas-

tic cylinder.

iii) After pushing in seal (18), remove inter-

nal plastic cylinder (19).a When removing, take care not to dam-

age the seal lip.

iv) Tighten the bolt of tool A5 evenly until

the end of tool A6 touches the end of crankshaft (20) to press fit seal (18).

a When press fitting the seal, take care not

to damage the lip on the pulley side with

the tool, etc.

a Af fi i h l h




the plastic internal cylinder.

2 Lip: Lithium grease (G2-LI)

a After press fitting the seal, remove the

red sealant layer on its periphery.

a Seal driving dimension "a": 16 mm+1 0

DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP

REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMPASSEMBLY

SPECIAL TOOLS



1. Release the residual pressure from the fuel sys-

tem. For details, see TESTING AND ADJUST-

ING, Releasing residual pressure from fuel

system.


5. Remove air cleaner tube (2) and bracket

together. [*1]

6. Fix hose (3) with cords apart from the engine.


8. Remove clamp (5).

9. Disconnect fuel supply pump wiring connectors

PCV1 (6), PCV2 (7), and G (8).

10. Remove fuel hoses (9) and (10). [*2]

S

y m b o l

Part No. Part Name

N e

c e s s i t y

Q ’ t y


S

k e t c h

A7

795-471-1800 Remover t 1 N

• 795-471-1810 • Plate 1

• 795-471-1820 • Bolt 1

• 795-471-1830 • Bracket 1

• 01435-01035 • Bolt 3

• 01435-01025 • Bolt 1



2. Close the fuel supply valve of the fuel tank.

3. Remove two engine undercovers (1).

11. Remove cover (11). [*3]


12. Remove 4 high-pressure pipe clamps (12). [*4]

13. Remove 2 clamps (13) and fuel tubes (14) and

(15). [*5]

14. Remove 2 covers (16). [*3]

15. Remove 2 high-pressure pipes (17). [*6]

16. Remove lubrication tube (18). [*7]

17. Setting tool to remove fuel supply pump

drive gear

1) Remove 2 mounting bolts (19) and cover

(20). [*8]

4) Install plate (23) of tool A7 to installationhole B and install bracket (24) of tool A7 to

C.

5) Set bolt (25) of tool A7.

a Keep tool A7 installed until the pump is in-

stalled so that meshing point of the fuel sup-

ply pump drive gear and camshaft will

change.

18. Remove bracket (26) and mounting bolts of fuel

supply pump assembly (27) and install guide

bolt [1]. [*10]

a The proper length of the guide bolt is a half

of the length shown in the photo.

19. Remove the remaining 3 mounting bolts.



2) Remove mounting nut (22) and the washer

of fuel supply pump drive gear (21). [*9]

3) Rotate the crankshaft so that key way A of

20. Tighten bolt (25) of tool A7 to remove fuel sup-

ply pump assembly (27).



removal.

[*1]

3 Air cleaner hose clamp:

9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}

[*2]

3 Fuel hoses (9) and (10):

14.8 – 19.6 Nm {1.5 – 2.0 kgm}

[*3]

a Install cover (11) with the slit on the cylinder

block side and install cover (16) with the slit di-

rected down.

[*4], [*6], [*10]k Do not correct the high-pressure pipe by bend-

ing before installing it.

k Be sure to use the genuine high-pressure pipe

clamps and tighten them to the specified torque.

k Install the wiring harnesses at least 10 mm apart

from the high-pressure pipe.

a When installing each high-pressure pipe, check

the taper seal of its joint (Part "a": Part of 2 mm

from the end) for visible lengthwise slit "b" andspot "c" and check part "d" (End of taper seal:

Part of 2 mm from the end) for stepped-type wear

caused by fatigue which your nail can feel. If

there is any of those defects, it can cause fuel

leakage In this case replace the high pressure

3) Tighten the fuel supply pump mountingbolts.

4) Tighten the mounting bolts of bracket (26).

5) Tighten 4 high-pressure pipe clamps (12)

temporarily with your fingers.

6) Tighten 4 high-pressure pipe clamps (12) to

the following torque.

3 High-pressure pipe clamp:

8.82 – 14.7 Nm {0.9 – 1.5 kgm}

[*5]

3 Fuel tubes (14) and (15):24.5 – 34.3 {2.5 – 3.5 kgm}

[*7]

3 Lubrication tube (20)

F l l id



leakage. In this case, replace the high-pressure

pipe.Fuel supply pump side:

7.9 – 12.7 Nm {0.8 – 1.3 kgm}

Cylinder block side:

9.8 – 12.7 Nm {1.0 – 1.3 kgm}

Clamp: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}

[*8]

3 Cover: 14.7 – 17.6 Nm {1.5 – 1.8 kgm}

[*9]

3 Fuel supply pump drive gear:

127 – 147 Nm {13 – 15 kgm}

DISASSEMBLY AND ASSEMBLY FUEL INJECTOR

REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY

SPECIAL TOOL




2. Remove air cleaner tube (1) and the bracket

together. [*1]

5. Remove gate-type bracket (4). [*4]

6. Remove injector-side covers (6) and common

rail-side covers (5) from the high-pressure pipe

jo int s acco rd ing to the fue l in je ctors to be

removed and installed. [*5]

7. Remove high-pressure pipe clamp cover (7) and

its clamp (77) according to the fuel injectors to

be removed and installed. [*6]

a Do not remove bracket X. If it is removed,

tighten it permanently after tightening the

high-pressure pipe and all the high-pressure

pipe clamps in the assembly procedure.

8. Loosen common rail-side sleeve nuts (8) and

fuel injector-side sleeve nut (10) and remove

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y

N

e w / R e m o d e l

S k e t c h

A1 795-799-1170 Puller t 1



3. Remove common rail cover (2). [*2]

4. Remove high-pressure pipe clamps (3) accord-

ing to the fuel injectors to be removed and

installed. [*3]

high-pressure pipe (9). [*7]

9. Remove head cover (11). [*8]


10. Remove capture nuts (12) and disconnect wiring

harness (13) from the fuel injector. [*9]

11. Remove holder mounting bolt (14), and then

remove the holder and fuel injector assembly

(16) together. [*10]

aDo not grip the solenoid valve at the top of the injector with pliers, etc.

a If the fuel injector is not removed easily, use

tool A1.


removal.

a Install high-pressure pipe (9) between the

common rail and fuel injector according to

the following procedure.1) Tighten sleeve nuts (8) and (10) of high-

pressure pipe (9).

3 High-pressure pipe sleeve nut:

39.2 – 49.0 Nm {4.0 – 5.0 kgm}


(77) temporarily with your fingers, and then

tighten them permanently.

3) Install common rail cover (2) and gate-type

bracket (4) temporarily.

4) Tighten common rail cover (2) (which is also

used as a high-pressure pipe clamp) perma-

nently first, then tighten gate-type bracket



[*1]

3 Air cleaner tube band:

9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}

[*2] [*3] [*4] [*6] [*7]

k Do not correct the high-pressure pipe by bend-

ing before installing it.

k Be sure to use the genuine high-pressure pipe

clamps and tighten them to the specified torque.

k Install the wiring harnesses at least 10 mm apart

from the high-pressure pipe.

a When installing each high-pressure pipe, check

(4) permanently.

3 Common rail cover:

8.82 – 14.7 Nm {0.9 – 1.5 kgm}


[*5]

a Install common rail-side cover (5) with the slit

on the cylinder block side.

a Set the slit on fuel injector-side cover (6) at

position "a" in the figure and match it to the

center of the clip.

[*8]

3 Head cover mounting bolt:

9.8 ± 1 Nm {1.0 ± 0.1 kgm}

[*9]

3 Wiring harness mounting nut:

2.0 – 2.4 Nm {0.2 – 0.24 kgm}

[*10]

a Install fuel injector assembly (16) according to

th f ll i d

• Checking for fuel leakage

Check the fuel system for leakage. For details,

see TESTING AND ADJUSTING, Checking fuelsystem for leakage.

• Bleeding air

Bleed air from the fuel circuit. For details, see

TESTING AND ADJUSTING, Bleeding air from

fuel circuit.




1) Insert gasket (b) and O-ring (c) in fuel injec-

tor (a).

2) Put holder (d) in injector (a) and install themto the rocker housing temporarily.

a Matching key (g) of the injector to key

way (h) of the rocker housing, insert the

holder securely until the sealing surface

of the injector touches the sealing sur-

face on the cylinder head side.

3) Apply engine oil to the spherical part of

spherical washer (e).

DISASSEMBLY AND ASSEMBLY NOZZLE TIP

REMOVAL AND INSTALLATION OF NOZZLE TIP

a [ERA Regulation]

In a country where EPA Regulation is applied,

replace the nozzle of the common rail engine by

the assembly. In a country where EPA Regula-

tion is not applied, however, only the nozzle tip

can be replaced according to the following pro-

cedure.(EPA: Environmental Protection Agency)

SPECIAL TOOLS

REMOVAL1. Grip tool A8 with vise [1].

a Do not grip the injector directly with the vice.

3. Using 19-mm deep socket [3], loosen retaining

nut (4).

4. Remove retaining nut (4) from injector assembly(3).

5. Lift up and remove nozzle assembly (5) verti-

cally.

a Do not remove tip guide (6). (The tip guide

cannot be disassembled.)

a Take care that dirt will not stick to the parts.

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y


S k e t c h

A8 795T-471-1550 Wrench q 1



2. Set injector assembly (3) to tool A8.

DISASSEMBLY AND ASSEMBLY NOZZLE TIP

INSTALLATION1. Grip tool A8 with vise [1].

a Do not hold the injector directly with the vice.

2. Set injector assembly (1) to tool A8.

3. Clean the lower body and the threads of retain-

ing nut (2) throughly with parts cleaner and blow

air against them.

5. Install nozzle assembly (3) and tighten retaining

nut (2) with the fingers.

6. Set 19-mm deep socket [2] to a torque wrench

and tighten the retaining nut according to the fol-

lowing procedure.

a Apply rust-preventive oil to the nozzle body.

1) Tighten the retaining nut to 88.3 Nm {9.0

kgm}.

2) Make match marks (6) on retaining nut (2)

and lower body (5).3) Tighten the retaining nut by 45° (Angle tight-

ening).



4. Install new nozzle assembly (3), matching it to

the dowel pin of tip guide (4).

a Take care not to drop the tip.

DISASSEMBLY AND ASSEMBLY STARTING MOTOR

REMOVAL AND INSTALLATION OF STARTING MOTORASSEMBLY




2. Disconnect the following 2 starting motor wires.

[*1]

• (1) and (2): Terminal B

3. Remove 3 mounting bolts (3) and starting motor

assembly (4).


removal.

[*1]

3 Mounting nut of starting motor terminalB: 19.6 – 25.5 Nm {2 – 2.6 kgm}



DISASSEMBLY AND ASSEMBLY RADIATOR

REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY

REMOVAL1. Remove cover (1).



3. Erect the engine hood according to the following

procedure.

1) Open engine hood (2) and sling it temporar-

ily.

a When slinging the engine hood, take

care not to damage the rubber seal.

2) Prepare M10 bolt [1].

• When removing the radiator, L = 50 or

longer.

• When removing the oil cooler, L = 70 or

longer

4. Disconnect reservoir tank hose (6).

a Disconnect the hose from the radiator.

5. Disconnect radiator hoses (7), (8), and (9). [*1]




longer.

3) Remove bolt (4).

4) Remove pin (5) from the lower part of stay

(3).5) Adjust the engine hood so that center hole A

of stay (3) will be at the bolt (4).

6) Install stay (3) with bolt [1] and fix engine

hood (2) vertically.


8. Disconnect radiator hose (13). [*1]

DISASSEMBLY AND ASSEMBLY RADIATOR

9. Remove 2 mounting bolts (14).

10. Lift off radiator assembly (15).

4 Radiator assembly: 30 kg


removal.


Add coolant through the coolant fi ller to the

specified level. Run the engine to circulate thecoolant through the system. Then, check the

coolant level again.


[*1]

3 Radiator hose clamps

(7): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}

(8): 4.4 ± 0.49 Nm {0.49 ± 0.05 kgm}(9), (13): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}



DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER

REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLERASSEMBLY

REMOVAL1. Remove cover (1).

2. Remove plug (2) of the hydraulic oil cooler drain

hose to drain the hydraulic oil.

a Before draining, open the hydraulic tank cap

to release the pressure in the tank. Then,

drain the oil through the cooler hose.


5. Remove hydraulic oil cooler tube mounting bolts

(5) and (6)




procedure.

1) Open engine hood (100) and sling it tempo-

rarily.



(5) and (6).

6. Remove right and left hydraulic oil cooler mount-

ing bolts (7).



DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP

REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULICPUMP ASSEMBLY

SPECIAL TOOLS




stop the engine. Then, loosen the hydraulic oil

filler cap slowly to release the internal pressure

of the hydraulic tank.

a Put tags to the disconnected hoses and tubes to

prevent a mistake in re-connecting them.

1. Remove the 4 engine undercovers.

2. Remove the hydraulic tank strainer. Using tool

C, stop the oil.

a When not using tool C, remove the drain plug

t d i th il f th h d li t k d



4. Close the fuel stop valve of the fuel tank.


procedure.

1) Open engine hood (100) and sling it tempo-

rarily.



2) Prepare M10 bolt [1].

3) Remove bolt (102).

4) Remove pin (103) from the lower part of stay (101).

5) Adjust the engine hood so that center hole A

of stay (101) will be at the bolt (102).

6) Install stay (101) with bolt [1] and fix engine

hood (100) vertically.

S

y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y

N e w

/ R e m o d e l

S k e t c h

B 796-601-1110 Stopper t 1 N

C796-460-1210 Oil stopper t 1

796-770-1320 Adapter t 1



to drain the oil from the hydraulic tank and

piping.

6 Hydraulic tank: Approx. 335

6. Remove tube (1). [*1]

a Remove the tube and bracket together.

7. Disconnect clamp (2) and pipe (3). [*2]

a Remove the clamp, pipe, and bracket (4) to-

gether.


8. Disconnect fuel inlet hose (5) and fuel return

hoses (6) and (7). [*3]

9. Disconnect clamp (8) and radiator hoses (9),

(10), and (11). [*4]


11. Remove fan guard (14).

a Bolt [1] is used to fix the engine hood verti-

cally.

15. Disconnect aftercooler hose (21) and heater

hose (22). [*6]




12. Loosen adjustment bolt (15) and remove belt

(16). [*5]

13 R i di i bl

6 e o e co e ( 3)

17. Disconnect radiator hose (24). [*4]


18. Disconnect heater hose (25).

19. Disconnect the following 2 wiring connectors.

• (26): ERO2 (Various sensors)

• (27): ERO3 (Each injector and fuel supply

pump)

20. Remove mounting bolts (28) and bracket (29).

24. Disconnect the following 2 pump wiring connec-

tors.

• (34): V22 (PC-EPC solenoid valve)

Band color: Red• (35): V21 (LS-EPC solenoid valve)

Band color: White

25. Disconnect the following 10 hoses and 1 tube.

• (36): EPC basic pressure port hose

(Band color: Yellow)

• (37): Rear pressure port hose


• (38): Rear pump discharge port hose• (39): Front pump discharge port hose

• (40): Drain port hose

• (41): Front load pressure input port hose

• (42): Rear load pressure input port hose

(Band color: Red)

• (43): Front pressure input port hose



21. Open the main pump side cover.

22. Lift off covers (30) and (31) together.

23. Remove cover (32) and stay (33).

( ) p p p

• (44): Pump suction port tube





removal.

[*1]

3 Hose clamp:

9.8 ± 0.5 Nm {0.1 ± 0.05 kgm}

[*2]

3 Clamp:

10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}

[*3]

3 Fuel hoses (5), (6), and (7):

14.8 – 19.6 Nm {1.5 – 2.0 kgm}

[*4]

3 Radiator hoses:

(9): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}

(10): 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}

(11), (24):

8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}

[*5]

a See TESTING AND ADJUSTING, Testingand adjusting air conditioner compressor

belt tension or REMOVAL AND INSTALLA-

TION OF ENGINE FRONT SEAL.

[*6]

3 Air aftercooler hose clamp:



10.8 ± 1 Nm {1.1 ± 0.1 kgm}

[*7]3 Engine mounting bolt:

824 – 1,030 Nm {84 – 105 kgm}


Add coolant through the coolant fi ller to the

specified level. Run the engine to circulate the

coolant through the system. Then, check the

DISASSEMBLY AND ASSEMBLY SWING CIRCLE

REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLYREMOVAL

1. Remove the revolving frame assembly. For

deta i ls , see REMOVAL OF REVOLVING

FRAME ASSEMBLY.

2. Sling swing circle assembly (1) by 3 points tem-

porarily, remove 40 mounting bolts, and lift off

the swing circle assembly. [*1]

4 Swing circle assembly: 600 kg


removal.

[*1]

2 Mating face of swing circle:


2 Threads of swing circle mounting bolt:

Adhesive (LT-2)

3 Swing circle mounting bolt:

824 – 1,030 Nm {84 – 105 kgm}

Target: 927 Nm {94.5 kgm}

a When installing the swing circle to the track

frame, bring soft zone mark S of the inner

race and soft zone mark P of the outer race

to the right side of the chassis as shown be-low.

2 Quantity of grease in grease bath:

Grease (G2-LI), 33

(Use GLT2-LI for 50°C specification)



DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY

REMOVAL AND INSTALLATION OF SWING MOTOR AND SWINGMACHINERY ASSEMBLY

REMOVALk Release the residual pressure in the hydraulic

circuit. Refer to the Releasing of Residual Pres-

sure in Hydraulic Circuit section in the TESTING

AND ADJUSTING chapter of this manual.

k Lower the work equipment to the ground for oilfiller cap on the fuel tank to release the residual

pressure inside the tank and move the safty lock

lever to the LOCK position.

1. Disconnect five swing motor hoses (1) through

(5).

• (1): Between swing motor and control valve

(MA port)

• (2): Between swing motor and control valve(MB port)

• (3): Suction hose (S port)

• (4): Drain hose (T port)

• (5): Swing brake releasing pilot hose (B

port)

3. Lift and remove swing motor and swing machin-

ery assembly (6).

a When lifting the swing motor and swing ma-

chinery assembly for removal, do so slowly

so that the hoses and other parts will not be

damaged.

aTake good care, when lifting the assem-bly, until the spigot joint portion is pulled

out.

4 Swing motor and swing machinery

assembly: 550 kg

INSTALLATION • Install in reverse order of removal.

[*1]

3 Mounting bolt:



2. Detach the swing motor and swing machinery

assembly (6), using forcing screw [1] after

removing the mounting bolts. [*1]

3 Mounting bolt:

824 – 1,030 Nm {84 – 105 kgm}

• Refilling hydraulic oil

Refill hydraulic oil through the oil filler port to the

specfied level. Let the oil cirdulate in the

hydraulic system by starting the engine. Then

check the oil level again.

• Air bleeding

Refer to the Air Bleeding of Various Parts sec




5. Ring gear Remove the mounting bolts and ring gear (10).

6. No. 2 sun gear

Remove No. 2 sun gear (11).

7. Bolt

Remove holder mounting bolt (12).

8. No. 2 carrier assembly1) Lift of No. 2 carrier assembly (13).

2) Disassemble the No. 2 carrier assembly


i) Push in pin (14) and drive out shaft (15)

from carrier (16).

a After removing the shaft, remove pin

(14).

ii) Remove thrust washer (17), gear (18),

bearing (19), and thrust washer (20).

iii) Remove plate (21).



9. Shaft assembly

1) Turn over case and pinion assembly (24)

and remove 12 mounting bolts (23) of cover

assembly (22).


2) Turn over case and pinion assembly (24)and set it on the press stand. Using push

tool [2], D1 and the press, pull out pinion

shaft assembly (25).

a Set a wood block under the press so that

the pinion shaft will not be damaged

when it comes off.

a A rough standard pressing force is 20

odd tons.

10. Disassemble the pinion shaft assembly (25)


1) Using the push tool, remove cover assembly

(22) and bearing (26) from shaft (27).

a A rough standard pressing force is 30tons.

2) Remove oil seal (28) from cover (29).

11. BearingUsing multiple push tools [3], remove bearing

(30) from case (31).

a Push tool to be set contact with bearing: D2

ASSEMBLYa Clean the all parts and check them for dirt or

damage. Coat their sliding surfaces with engine

oil before installing.

1. Bearing

Using push tool D3 and [4], press fit bearing (26)

to case (31).

a A rough standard pressing force is severaltons.




2. Cover assembly1) Using push tool D4, press fit oil seal (28) to

cover (29).

2 Periphery of oil seal:


a Take care that the gasket sealant (LG-6)

will not stick to the oil seal lip and shaft

assembly (22).

2) Install cover assembly (22) to case (31) and

tighten mounting bolts (23).

a Match the oil path of cover (22) to the

drilled hole of case (31).

2 Cover fitting face:


3 Mounting bolt:

98 – 123 Nm {10 – 12.5 kgm}

2 Oil seal lip: Grease (G2-LI)

3. Case assembly1) Turn over case assembly (32) and set it to

shaft (27). Using push tools D5 and D6 [5],

press fit the bearing inner race.

a When setting the case assembly to the

shaft, take care extremely not to damage

the oil seal.

a A rough standard pressing force is 30

tons.

2) Bearing

Using too D7, press fit bearing (30).

a Press both inner race and outer race of

the bearing simultaneously. Do not

press only the inner race.a A rough standard pressing force is 20

odd tons.

a After press fitting the bearing, check that

the case turns smoothly.




4. No. 2 carrier assembly1) Assemble the No. 2 carrier assembly


a There is a caulking mark made when the

pin was inserted at the end of carrier

side hole "a" and the inside wall of the

hole is swelled at that mark. Flatten the

swelled part in advance.

i) Install plate (21) to carrier (16).

ii) Install bearing (19) to gear (18) and fittop and bottom thrust washers (17) and

(20), and then set the gear assembly to

carrier (16).

iii) Aligning the pin holes of shaft (15) andcarrier, lightly hit the shaft with a plastic

hammer, etc. to install.

a When installing the shaft, revolve the

planetary gear and take care not to dam-

age the thrust washers.

iv) Insert pin (14).

a

When inserting the pin, do not set the 3claws (parts "a") on the periphery to the

thin part of the carrier (part "b").

The thin part may be on the opposite

side, however. Check each carrier and

avoid setting a claw to the thin part.

a After inserting the pin, caulk the pin part

of the carrier.

2) Install No. 2 carrier assembly (13).

5. Bolt and O-ring

1) Tighten bolt (12).

2 Threads of mounting bolt:

Adhesive (LT-2)3 Mounting bolt:

343 – 427 Nm {34 – 43.5 kgm}



2) Fit the O-ring to case (31).


7. Ring gear

Using the eyebolt (M12 x 1.75), install ring gear

(10).

a When installing ring gear (10), set its match

mark (part "d") and the projection of the case

flange (part "c") as shown in the following fig-

ure.

8. No. 1 carrier assembly

1) Assemble the No. 1 carrier assembly


i) Press fit shaft (5) to the carrier in the

direction of the arrow until the snap ring

groove is seen.

ii) After installing snap ring (4), press back

the shaft from the opposite side until the

snap ring is fitted to face P of the carrier.

At this time, take care not to press backtoo much.

iii) After installing plate (9), install thrust

washer (8), bearing (7), gear (6), and

snap ring (4).



2) Install No. 1 carrier assembly (3).


9. No. 1 sun gear assembly

Install No. 1 sun gear (2).

a Take care not to install the No. 1 sun gear

upside down.

a Install the No. 1 sun gear with the tooth (part

"e") down.

10. Swing motor assembly

Install swing motor assembly (1) to ring gear

• Refilling with oil

Tighten the drain plug and add engine oil

(EO30-CD, or SHC 5W-30K for extremely cold

district) through the oil filler to the specified

level.

5 Swing machinery case: Approx. 21



g y ( ) g g

(10).

a When installing the swing motor assembly,set the relief valve (part f ) and the projection

of the case (part c) as shown in the following

figure.

a Degrease the mating faces of swing motor

assembly (1) and ring gear (10).

2 Mating faces of swing motor

DISASSEMBLY AND ASSEMBLY SPROCKET

REMOVAL AND INSTALLATION OF SPROCKET

REMOVAL1. Remove track shoe assembly. For details, see

REMOVAL OF TRACK SHOE ASSEMBLY.

2. Swing work equipment 90°, push up chassis

with work equipment and place block [1]

between track frame and track shoe.

3. Remove mounting bolts and lift off sprocket (1).

[*1]

4 Sprocket: 70 kg


[*1]

2 Thread of sprocket mounting bolt:


3 Sprocket mounting bolt:

640 – 785 Nm {65 – 80 kgm}



DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE

REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINALDRIVE ASSEMBLY

REMOVAL1. Remove the sprocket. For details, see Removal

of sprocket.

k Lower the work equipment to the ground

and stop the engine. Then, loosen the hy-

draulic oil filler cap slowly to release the in-

ternal pressure of the hydraulic tank.


3. Disconnect drain hose (2), travel speed selector

hose (3), and motor hoses (4) and (5).

a Remove the nipples, too.

4. Remove the 24 mounting bolts and lift off the

final drive assembly (6). [*1]

a Take care extremely not to damage the nip-

ple sealing faces of the hose joints.

a When slinging the final drive assembly, do

not use the tap hole for the cover.

4 Final drive assembly: 700 kg


removal.

[*1]

3 Mounting bolt:

490 – 608 Nm {50 – 62 kgm}

• Refilling with oil (Hydraulic tank)



Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.Run the engine to circulate the oil through the

system. Then, check the oil level again.

• Bleeding air

See TESTING AND ADJUSTING, Bleeding air

from each part.

DISASSEMBLY AND ASSEMBLY FINAL DRIVE

DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLYSPECIAL TOOLS

DISASSEMBLY

2) Using eyebolt [2], remove cover (1).

3. Spacer

Remove spacer (2).


1) Remove No. 1 carrier assembly (3).

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y


S k e t c h

E

1

796-627-1210Wrench

assembly t 1

• 796-627-1220 • Wrench 1

• 796-427-1140 • Pin 3

• 01314-20612 • Screw 3

2

796T-627-1230 Push tool t 1 Q

790-101-2510 Block q 1

791-122-1130 Plate q 1

790-101-2550 Leg q 2

790-101-2740 Adapter q 2

790-101-2570 Plate q 4

790-101-2560 Nut q

2790-101-2102 Puller (30 tons) t 1

790-101-1102 Pump t 1

3 796-627-1020 Installer t 1



DISASSEMBLY

1. Draining oilRemove the drain plug to drain the oil from the

final drive case.

6 Final drive case: Approx. 11

2. Cover

1) Place the final drive on block [1] and remove


2) Disassemble the No. 1 carrier assembly


i) Push in pin (5) to drive out shaft (6) from

carrier (7).


(5).



5. No. 1 sun gear shaft

Remove spacer (4), No. 1 sun gear (12), and

No. 2 sun gear (13).


1) Sling No. 2 carrier assembly (15) with wires,

etc. and remove it.

2) Disassemble No. 2 carrier assembly accord-

ing to the following procedure.

i) Push in pin (16) to drive out shaft (17)

from carrier (18).


(16).





6. Thrust washer

Remove thrust washer (14).

8. Nut

1) Remove lock plate (23).


2) Using tool E1, remove nut (24).

9. Hub assembly

1) Using eyebolts [3], remove hub assembly

(25) from the travel motor.

2) Disassemble hub assembly (25) according


i) Remove bearing (26) from hub (32).

ii) Remove floating seal (27) from hub

(32).

iii) Remove bearings (28) and (29) from

hub (32).

3) Remove floating seal (30) from travel motor

(31).




4) Using puller [4], remove bearing (34) and

collar (33) together.

a You can remove bearing (34) and collar

(33) without using puller [4] in some cas-

es.

ASSEMBLYa Clean the all parts and check them for dirt or

damage. Coat their sliding surfaces with engine

oil before installing.

1. Hub assembly

1) Using the push tool, press fit bearings (28)

and (29) to hub (32).

3) Install collar (33) and bearing (34) to travel

motor (31).

4) Using tool E3, install floating seal (30)

(which is hidden and not seen behind tool

E3) to travel motor (31).

a Thoroughly degrease and dry the O-ring

and O-ring fitting surface of the floating

seal before installing.



2) Using tool E3, install floating seal (27) to

hub (32).

a Thoroughly degrease and dry the O-ring

seal before installing.

a After installing the floating seal, checkthat its slant is less than 1 mm.

a After installing the floating seal, thinly

apply engine oil to the sliding surfaces.


5) Using eyebolts [3], set hub assembly (25) to

the travel motor. Using the push tool, lightly

hit the bearing to press fit it.

2. Nut

Install the nut according to the following proce-

dure.1) Rotate the hub 2 – 3 turns.

2) Using tool E2, press the bearing inner race.

a Pressing force: 29.4 – 38.3 kN {3.0 – 3.9

tons}

3) While the bearing is pressed, rotate the hub

at least 5 turns in 1 direction.

4) Release the pressing force.

5) Press the bearing again.

a Pressing force: 14.7 – 18.6 kN {1.5 – 1.9

tons}

7) Measure thickness "b" of nut (24).

8) Obtain a – b = c.

9) Using tool D1, tighten nut (24) until dimen-

sion "c" is as follows.

a Dimension "c": c mm

10) Using push-pull gauge [5], measure the tan-gential force of the hub in its revolving direc-

tion on the motor case.

a Tangential force: Max. 765 N {78 kg}

a The tangential force means the maxi-

mum force at the beginning of rotation.

+0.07 –0.03



6) Under the condition in 5) above, measure

11) Install lock plate (23), fitting it to the motor

spline.


Adhesive (LT-2)

3 Mounting bolt:



1) Assemble the No. 2 carrier assembly


a There is a caulking mark made when the

pin was inserted at the end of carrier

side hole "h" and the inside wall of the

hole is swelled at that mark. Flatten the

swelled part in advance.

i) Install bearing (21) to gear (20) and fit

top and bottom thrust washers (19) and(22), and then set the gear assembly to

carrier (18).

ii) Aligning the pin holes of shaft (17) and

carrier, lightly hit the shaft with a plastic


a When installing the shaft, revolve

the planetary gear and take care not

to damage the thrust washers.

iii) Insert pin (16).

a After inserting the pin, caulk the pin

part of the carrier.

a After assembling the carrier assembly,

4. Thrust washer

Install thrust washer (14).

5. No. 2 sun gear

Install spacer (4) and No. 2 sun gear (13).



check that the gear (20) turns smoothly.


i) Install bearing (10) to gear (9) and fit top

and bottom thrust washers (8) and (11),

and then set the gear assembly to car-

rier (7).

ii) Aligning the pin holes of shaft (6) and

carrier, lightly hit the shaft with a plastic


a When installing the shaft, revolve

the planetary gear and take care not

to damage the thrust washers.

iii) Insert pin (5).a After inserting the pin, caulk the pin

part of the carrier.

a After assembling the carrier assembly,

check that the gear (9) turns smoothly.

7. No. 1 sun gear shaft

Install No. 1 sun gear shaft (12).

8. Spacer

Install spacer (2).

9. Cover

Using eyebolts [2], install cover (1) and tighten

the mounting bolts.

2 Cover mounting face:

Gasket sealant (LG-6)3 Mounting bolt:

98 – 123 Nm {10 – 12.5 kgm}



R filli ith il

DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLERASSEMBLY

a Only precautions for assembling the carrier roller

assembly are explained below.

SPECIAL TOOLS

4 Carrier roller assembly: 35 kg

ASSEMBLY • Press fitting of support (2)

1) The threads of shaft (1) must be in the

range of the following figure.

2) Press fitting dimension of shaft: (Shown in

the following figure)

3) Using push tool [1], press fit support (2) toshaft (1). At this time, apply press fitting

force of at least 79 kN {8.1 tons}.

• Floating seal

a When installing the floating seal, thoroughly

clean, degrease, and dry the contact surfac-

es of the O-ring and floating seal (hatched

parts). Take care that dirt will not stick to the

floating seal contact surfaces.

a Be sure to use the installer F to insert thefloating seal assembly in the housing.

a After installing the floating seal, check that its

slant is less than 1 mm and its projection "a"

is 5 – 7 mm.

• Carrier roller

a Using tool F, apply the standard pressure to

the oil filler to check the seal for air leakage.

a Keep the following standard pressure for 10

seconds and check that the pointer of the

gauge does not lower.

Standard pressure: 0.1 MPa {1 kg/cm2}

S y m b o l

Part No. Part Name

N e c e s s i t

y

Q ’ t y

N e w / R e m o

d e l

S k e t c h

F1 791-430-3230 Installer t 1

2 791-601-1000 Oil pump t 1



DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

a Using tool F, fill the carrier roller assembly

with oil and tighten the plug.

5 Carrier roller: 170 – 180 cc (EO30-CD)



DISASSEMBLY AND ASSEMBLY TRACK ROLLER

DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLYa Only precautions for assembling the track roller


SPECIAL TOOLS

4 Track roller assembly: 80 kg

ASSEMBLY• Floating seal






a Be sure to use the installer G to insert thefloating seal assembly in the housing.

a After installing the floating seal, check that its

slant is less than 1 mm and its projection "a"

is 5 – 7 mm.

• Track roller

a Using tool G, apply the standard pressure to

the oil filler to check the seal for air leakage.

a Keep the following standard pressure for 10

seconds and check that the pointer of the

gauge does not lower.

Standard pressure: 0.1 MPa {1 kg/cm2}

a Using tool G, fill the track roller assembly

with oil and tighten the plug.

5 Track roller: 280 – 310 cc (EO30-CD)

3 Plug: 10 – 20 Nm {1 – 2 kgm}

S y m

b o l

Part No. Part Name

N e c e

s s i t y

Q ’ t y


S k e

t c h

G1 791-630-1780 Installer t 1

2 791-601-1000 Oil pump t 1



DISASSEMBLY AND ASSEMBLY IDLER

DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLYSPECIAL TOOLS

4 Idler assembly: 250 kg

DISASSEMBLY

4. Remove floating seal (7) on the opposite side

from idler (5) and shaft and support assembly

(6).

5. Remove nut (8), pull out bolt (9), and then

remove support (10) from shaft (11).

6. Remove bushing (12) from idler (5).

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y


S k e t c h

H791-575-1520 Installer t 1

791-601-1000 Oil pump t 1




ASSEMBLY1. Press fit bushings (12) (on both sides) to idler

(5).

2. Fit the O-ring and install support (10) to shaft

(11) with bolt (9) and tighten nut (8).

a Install the shaft with the UP mark up.

3 U i t l H i t ll fl ti l (7) t idl (5)






a Be sure to use the installer H to insert the

floating seal assembly in the housing.

a After installing the floating seal, check that itsslant is less than 1 mm and its projection "a"

is 9 – 11 mm.

4. Install shaft and support assembly (6) to idler

(5).



3. Using tool H, install floating seal (7) to idler (5)

and shaft and support assembly (6).

5. Similarly, using too H, install floating seal (4) to

idler (5) and support (3).


a Coat the sliding surface of the floating seal

with oil and take care that dirt will not stick to

it.

a Degrease the floating seal and the O-ring

contact surfaces.

6. Fit the O-ring, set support (3), install bolt (2), and

tighten nut (1).

7. Add oil and tighten the plug.

5 Quantity of oil:

Approx. 345 ± 10 cc (EO-30CD)

3 Plug: 130 – 180 Nm {13 – 18 kgm}



DISASSEMBLY AND ASSEMBLY RECOIL SPRING

DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLYSPECIAL TOOLS

4 Recoil spring (Excluding idler): 900 kg

DISSASSEMBLY

1. Remove piston assembly (2) from recoil spring

assembly (1).

2. Disassembly of recoil spring assembly

1) Set tool J1 to recoil spring assembly (1).

k Since the installed load of the spring is large

and dangerous, set the tool securely.

a Installed load of spring:

239.037 kN {24,375 kg}

2) Apply oil pressure gradually to compress the

spring and remove lock plate (3) and nut (4).a Compress the spring to a degree that

you can loosen the nut.

a Release the oil pressure gradually to re-

duce the spring tension to 0 (zero).

a Free length of spring: 845.3 mm

3) Remove yoke (6), cylinder (7), collar (8),

and dust seal (9) from spring (5).

3 Disassembly of piston assembly

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y


S k e t c h

J

1

791-685-8006 Compressor t 1

791-635-3160 Extension t 1

790-101-1600Cylinder

(686 kN {70 t}) t 3

790-101-1102 Pump t 3

2

790-201-1500 Push tool kit 1

• 790-201-1660 • Plate

• 790-101-5021 • Grip

• 01010-50816 • Bolt



3. Disassembly of piston assembly1) Remove lock plate (11) from piston (10),

and then remove valve (12).

2) Remove snap ring (13), U-packing (14), and

ring (15).

DISASSEMBLY AND ASSEMBLY RECOIL SPRING

ASSEMBLY

1. Assembly of piston assembly

1) Install ring (15) and U-packing (14) to piston

(10) and secure them with snap ring (13).

2) Tighten valve (12) temporarily and secure it

with lock plate (11)

2) Install cylinder (7), collar (8), and yoke (6) to

spring (5), and then set them to tool J1.

2 Sliding parts of cylinder:

Grease (G2-LI)

3) Apply oil pressure gradually to compress the

spring and tighten nut (4) so that installed

length of the spring will be "a", and then

secure it with lock plate (3).

a Installed length of spring "a":

Approx. 690 mm



with lock plate (11).

2. Assembly of recoil spring assembly

1) Using tool J2, install dust seal (9) to cylinder

(7).4) Remove recoil spring assembly (1) from tool

J1.

3. Install piston assembly (2) to recoil spring

assembly (1)

DISASSEMBLY AND ASSEMBLY TRACK SHOE

EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLYSPECIAL TOOLS

EXPANSION OF TRACK SHOE1. Start the engine and set the master pin to above

the idler.

2. Remove track shoes (2) on the right and left

sides of master pin (1). [*1]

3. Lower the work equipment to the ground and

loosen lubricator (3) to slacken the track shoe.

[*2]k Since the internal pressure of the adjust-

ment cylinder is very high, do not loosen the

lubricator more than 1 turn. If the grease

does not come out sufficiently, move the

machine forward and in reverse.

4. Using tool K, remove master pin (1). [*3]

5. Move the master pin forward and set block [1]

under the track shoe in front of the idler.

6. Pull out pusher K.

7. Move the machine in reverse slowly to expand

the track shoe. [*4]

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y


S k e t c h

K

791-650-3000 Remover andinstaller

t 1

790-101-1300Cylinder (980

kN {100 t}) t 1

790-101-1102 Pump t 1



DISASSEMBLY AND ASSEMBLY TRACK SHOE

INSTALLATION OF TRACK SHOE • Carry out installation in the reverse order to

expansion.

[*1]

2 Mounting bolt: Anti-seizure com-

pound (MARUZEN MOLYMAX No. 2or equivalent)

3 Mounting bolt: Tighten the 4 bolts first

to 392 ± 39 Nm {40 ± 4 kgm}. Check

that the mating faces are fitted, then

retighten each bolt by 120° ± 10°.

[*2]

a Adjust the tension of the track shoe. For de-

tail, see TESTING AND ADJUSTING, Test-

ing and adjusting track shoe tension.

3 Tightening torque for lubricator:

58.8 – 88.3 Nm {6 – 9 kgm}

[*3]

a Using the tool, press fit the master pin so that

its projection "a" will be as follows.• Dimension "a": 4.4 ± 2 mm

2 Apply grease to the contact faces of

dust seal (5) and bushing (4) (all over

the end face of the dust seal or bush-

ing) (parts marked Q). Do not apply

grease to the pars marked X, however.

R: Detail of regular pin position

M: Detail of master pin position(Pins are not inserted, however)

[*4]

Set the track shoe and sprocket (4) as shown in

the following figure (on both right and left sides).



2 Supply grease to the space between

the bushing and pin so that filling rate

DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT

REMOVAL AND INSTALLATION OF AIR CONDITIONER UNITASSEMBLY

SPECIAL TOOLS

REMOVAL

k Disconnect the cable from the negative (–) ter-


1. Swing the upper structure by 90°.


3. Connect tool Q to cap [1] and collect the air con-

ditioner refrigerant.

4. Remove rear covers (1), (2), (3), and (4).

5.Remove duct (5), cover (6), and plate (7).

6. Remove plate (8) and duct (9).

a Remove the duct lock clip.

7. Remove ducts (10) and (11).

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y


S k e t c h

Q

799-703-1200 Service tool kit t 1


(100V) t 1


(220V) t 1


(240V)

t 1

799-703-1401Gas leak detec-

tor t 1



8. Disconnect connectors D01 (12), D02 (13), C09

(14), R22 (15), R20 (16), and K19 (17).

9. Remove and sling controller (18).

10. Remove plate (19).

DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT

12. Remove the air conditioner unit undercover.

a Part A

13. Remove mounting bolt (24) and connector (25).

[*1]

14. Disconnect heater hoses (22) and (23) and air

conditioner tube (26). [*1]

a Put tags to the disconnected hoses and

tubes to prevent a mistake in re-connecting

them.


removal.

a When installing the air conditioner circuit

hoses, take care that dirt, water, etc. will not

enter them.

a When connecting each air conditioner hose,

check that the O-ring is fitted to the joint.a Check that each O-ring is free from flaw and

deterioration.

[*1]

a Apply compressor oil (ND-OIL8) to the

threads of the refrigerant pipe joints and

tighten each nut with double spanner.

3 Hose clamp (M6 bolt):8 – 12 Nm {0.8 – 1.2 kgm}

3 Hose screw of M16 x 1.5:

12 – 15 Nm {1.2 – 1.5 kgm}


20 – 25 Nm {2.0 – 2.5 kgm}


30 – 35 Nm {3.0 – 3.5 kgm}

• Charging air conditioner with refrigerant gas

Using tool Q, charge the air conditioner circuit

with refrigerant (HFC R134a) from the compres-

sor.

a Quantity of refrigerant: 950 ± 50 g



15. Remove the 7 mounting bolts and air condi-

tioner unit assembly (27).

DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB

REMOVAL AND INSTALLATION OF OPERATOR’S CAB



1. Remove rear covers (1), (2), (3), and (4).

2. Remove duct (5), cover (6), and plate (7).

3. Remove plate (8), duct (9) and the element.

a Remove the duct lock clip.

6. Disconnect connectors M71 (15), H10 (16), H11

(17), and H12 (18).

7. Disconnect upper and lower duct joints (19) and

(20).

8. Remove controller sub-plate (21) and incline it

against the air conditioner.

9. Remove cover (22) and floor mat (23).



4. Remove clip (10) and disconnect cab wiring

connectors M45 (11), H08 (12), and H09 (13).

5. Remove air conditioner connector plate (14).

10. Move right console (24) into the cab.

11. Remove monitor panel undercover (25).


12. Disconnect cab wiring connector W04 (26)

(Wiper motor).

13. Remove ducts (27) and (28).

a Both (27) and (28) are 2 in number.

a Cut the tie-wrap on the monitor wiring har-

ness.

14. Remove cover (29) and monitor assembly (30).

15. Disconnect radio antenna (31).

16. Remove clip (32) and take wiring harness (33)

out of grommet (34).

20. Using lever block [1], lift off operator's cab

assembly (39).

4 Operator's cab assembly: 300 kg

21. When starting the engine while the operator's

cab is removed (for transportation, etc.), use the

following brackets.

1) Bracket (41) for controller (40)

Part No.: 208-53-13920



17. Take grommet (35) out of the right front of the

cab.

18. Disconnect the windshield washer hose from


2) Bracket (42) for monitor panel assembly

(30)Part No.: 208-53-13910

INSTALLATION

• Carry out installation in the reverse order toremoval.



DISASSEMBLY AND ASSEMBLY MONITOR

REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY



1. Remove cover (1) and disconnect wiring con-

nector P15 of air conditioner sunlight sensor (2).

a Raise and remove the cover.

2. Remove the 3 mounting screws and monitor

assembly (3).

a Disconnect monitor panel wiring connectors

P01, P02, and P70 before removing the

monitor assembly.


removal.



DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER

REMOVAL AND INSTALLATION OF PUMP CONTROLLER



1. Remove covers (1), (2), and (3).

2. Disconnect pump controller wiring connectors

C01 (4), C02 (5), and C03 (6).

3. Remove the 4 mounting bolts and pump control-

ler assembly (7).


removal.



DISASSEMBLY AND ASSEMBLY ENGINE CONTROLLER

REMOVAL AND INSTALLATION OF ENGINE CONTROLLER



1. Open the right side cover (cooler).

2. Remove bracket (1).

3. Remove the 4 mounting bolts and engine con-

troller assembly (2).

4. Disconnect engine controller wiring connectorsCB1 (3), CB2 (4), and CB3 (5).


removal.



DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

REMOVAL AND INSTALLATION OF REVOLVING FRAMEASSEMBLY

REMOVALk Extend the arm and bucket fully, lower the work

equipment to the ground, and set the safety lock


1. Remove the work equipment assembly. For

details, see REMOVAL AND INSTALLATION OFWORK EQUIPMENT.

2. Remove the counterweight assembly. For

details, see REMOVAL AND INSTALLATION OF

COUNTERWEIGHT.

3. Disconnect 4 boom cylinder hoses (1).

a Plug the hoses to stop oil.

4. Sling boom cylinder assembly (2) temporarily.

5. Remove plate (3) and pin (4) and lift off boom

cylinder assembly (2).

a Remove the boom cylinder on the oppositeside similarly.

6. Disconnect 7 hoses (5) – (11).

• (5): Center swivel joint (Port D) – Swing mo-

tor (Port T)

• (6): Center swivel joint (Port D) – Hydraulic

tank

• (7): Center swivel joint (Port E) – Solenoid

valve

• (8): Center swivel joint (Port B) – Control

valve left travel (Port B2)

• (9): Center swivel joint (Port D) – Controlvalve right travel (Port B5)

• (10):Center swivel joint (Port A) – Control

valve left travel (Port A2)

• (11):Center swivel joint (Port C) – Control

valve right travel (Port A5)

7. Pull out pin (12) on the center swivel joint side

and disconnect the lock plate from the center

swivel joint.



4 Boom cylinder assembly: 360 kg


8. Remove 29 mounting bolts (13), leaving 3 each

at the front and rear sides.

9. Using a lever block, sling the revolving frame

assembly temporarily, balancing it in each direc-

tion.

a Put wood liners to the rear side of the frame.• Rough standard length of sling:

Front: 8 m in total

Rear: 6 m

a If the engine hood interferes with the sling,

erect the engine hood, referring to REMOV-

AL AND INSTALLATION OF RADIATOR

ASSEMBLY.

10. Remove the remaining 6 bolts and lift off revolv-ing frame assembly (14). [*1]

k When removing the revolving frame assem-

bly, take care that it will not interfere with the

center swivel joint assembly.

4 Revolving frame assembly: 10,000 kg

INSTALLATION


[*1]

• Match the soft zone point (P) of the outer

race and the soft zone point (S) of the inner

race.

2 Mating face of swing circle:


2 Threads of revolving frame mountingbolt: Adhesive (LT-2)




3 Revolving frame mounting bolt

1. Tighten the bolts marked with A (at 4 places)according to the following steps 1) – 3).

1) Tighten each bolt to 392 Nm {40 kgm} first.

2) Then, tighten the bolt by 90° ± 5°.

• Make a mark on the bolt head with a

marker pen (to check the angle).

3) The tightening torque of the bolt tighten in 2)

above must be 1,176 Nm {120 kgm} or

larger.

2. Tighten each bolt 208-25-71230 which is not

marked withA according to above steps 1) – 3).If the tightening torque reaches 2,254 Nm {230

kgm} before completing the above steps and the

tightening angle is 35° – 95°, however, stop

tightening.



a Marks P and S are the soft zone points.


Add oil through the oil filler to the specified level.

Run the engine to circulate the oil through the

t Th h k th il l l i

DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT

REMOVAL AND INSTALLATION OF COUNTERWEIGHTASSEMBLY

REMOVAL1. Set eyebolt [1] to counterweight assembly (1).

2. Remove 4 mounting bolts (2). [*1]

a Check where shims have been used.

3. Lift off counterweight assembly (1). [*2]

a When lifting off the counterweight, take care

not to strike it against the engine, radiator

and cooler assembly, etc.

4 Counterweight assembly: 9,500 kg


removal.

a If heat insulation cover (3) of the engine com-

partment is flattened, replace it.

[*1]


Adhesive (LT-2)

3 Mounting bolt:

3,430 – 4,212 Nm {350 – 430 kgm}

[*2]

a Installation and adjustment of counterweight

1) Adjust the level difference from the

exterior parts (horizontal clearance) with

shims.

• Kinds of shim thickness: 0.5 mm, 1

mm

2) Insert the shims so that the clearance

between the door and counterweightand that between the revolving frame

and counterweight will be 10 ± 5 mm



and counterweight will be 10 ± 5 mm

evenly.

DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY

REMOVAL1. Remove 3 lower covers (1).

2. Drain the oil from the hydraulic tank.

6 Capacity of hydraulic tank:

Approx. 335

3. Open engine hood (2) and remove control valve

top cover (3).

7. Disconnect drain hoses (8), (9), and (10).

8. Disconnect 2 clamps (11).

9. Remove side cover (12).

10. Remove sensor (13).

11. Disconnect suction tube (14).

12. Sling the hydraulic tank assembly temporarily

and remove 6 mounting bolts (15).




5. Disconnect drain hoses (5) and (6). 13. Lift off hydraulic tank assembly (16).

4 H d li k bl 200 k

DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK


removal.



Run the engine to circulate the oil through thesystem. Then, check the oil level again.

5 Capacity of hydraulic tank:

Approx. 335

Quantity of oil in tank (Center of oil

level gauge): 248

• Bleeding air

See TESTING AND ADJUSTING, Bleeding air from each part.



DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

REMOVAL AND INSTALLATION OF HYDRAULIC PUMP

ASSEMBLY

SPECIAL TOOLS






of the hydraulic tank.

a Put tags to the disconnected hoses and tubes to

prevent a mistake in re-connecting them.

1. Remove 2 lower covers (1).

3. Drain the oil from the flywheel housing.

4. Open the main pump side cover.


6. Lift off covers (2) and (3) together.


8. Remove stay (5).

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y

N

e w / R e m o d e l

S k e t c h

C796-460-1210 Oil stopper q 1

796-770-1320 Adapter q 1



2. Remove the hydraulic tank strainer. Using tool

C, stop the oil.

a When not using tool C, remove the drain plug

DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP

9. Disconnect the following 2 pump wiring connec-

tors.• (6): V22 (PC-EPC solenoid valve)

Band color: Red

• (7): V21 (LS-EPC solenoid valve)

Band color: White

10. Disconnect the following 10 hoses and 1 tube.

• (8): EPC basic pressure port hose


• (9): Rear pump pressure input port hose(Band color: Red)

• (10): Rear pump discharge port hose

• (11): Front pump discharge port hose

• (12): Drain port hose

• (13): Front load pressure input port hose

• (14): Rear load pressure input port hose

(Band color: Red)

• (15): Front pump pressure input port hose

• (16): Pump suction port tube

11. Sling hydraulic pump assembly (18) temporarily


12. Lift off hydraulic pump assembly (18). [*1]

4 Hydraulic pump assembly: 255 kg



DISASSEMBLY AND ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT

REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC

PUMP INPUT SHAFT

REMOVAL1. Remove the hydraulic pump assembly. Refer to

the REMOVAL OF HYDRAULIC PUMP

ASSEMBLY section.

2. Remove snap ring (1) and then remove spacer

(2).

3. Pry off oil seal (3) with a screwdriver. [*1]

a When attempting to pry off the seal, do not

damage the shaft.


[*1]

2 Oil seal lip portion: Grease (G2-LI)

2 Oil seal outer circumference:

Grease (G2-LI)a Coat the oil seal outer circumference thinly

with grease.

a Press-fit oil seal (3), using tool .



DISASSEMBLY AND ASSEMBLY CONTROL VALVE

REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY

REMOVALk Lower the work equipment to the ground and



of the hydraulic tank and set the safety lock lever

to the LOCK position..

a Put tags to the disconnected hoses and tubes toprevent a mistake in re-connecting them.

1. Open engine hood (1).

2. Remove control valve top cover (2).

3. Remove partition covers (3), (4), and (5)

between the engine and control valve.

6. Disconnect the following 4 control valve hoses:

• (16): Port PPS1 hose (Front pump)

• (17): Port PLS2 hose (Hose band: Red)• (18): Port PLS1 hose

• (19): Port PX1 hose (Hose band: Blue)

7. Remove relay bracket (20) and clamp (21).

8. Disconnect drain hose (22). (To tank)

9. Disconnect the following 6 left PPC hoses.

• (23): In order from top

Bucket CURL (Hose band: White)

Left travel REVERSE

Boom RAISE (Hose band: Green)

Left SWING (Hose band: Red)

Right travel REVERSE (Hose band: Blue)

Arm DUMP (Hose band: Yellow)




10. Disconnect 4 boom hoses (24).

11. Remove boom tube clamps (25) and (26).

12. Disconnect port TSW hose (27) (Swing motor

port S).

13. (28): In order from top

Remove port A-1 tube (Boom Hi bottom side).

Remove port A1 tube (Bucket bottom side).

Disconnect port A2 hose (Swivel joint port A).

After removing the hoses from ports B, remove

port A3 tube (Boom bottom side).

Remove port A4 hose (Swing motor port MB).

Disconnect port A5 hose (Swivel joint port C).

Remove port A6 tube (Arm head side).

14. (29): In order from top

Disconnect port B-1 hose (Arm Hi bottom side).

Disconnect port B1 hose (Bucket head side).

Disconnect port B2 hose (Swivel joint port B).

Remove port B3 tube (Boom head side).

Remove port B4 hose (Swing motor port MA).

Disconnect port B5 hose (Swivel joint port D).

Remove port B6 tube (Arm bottom side).

15. Disconnect the following 6 right PPC hoses.

• (30): Bucket DUMP (Hose band: Black)• (31): Left travel FORWARD

(Hose band: Red)

• (32): Boom LOWER (Hose band: Brown)

• (33): Right SWING

• (34): Right travel FORWARD

(Hose band: Green)

• (35): Arm IN (Hose band: Blue)

16. Disconnect the following 3 control valve hoses.

a Do not disconnect hose C.

• (36): Port BP5 hose (To solenoid)

• (37): Port PX2 hose

• (38): Port TS hose




17. Sling control valve assembly (40) temporarily


18. Lift off control valve assembly (40).

4 Control valve assembly: 250 kg

INSTALLATION






• Bleeding air

See TESTING AND ADJUSTING, Bleeding air from each part.




DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY

a Only precautions for assembling the pressure

compensation valve assembly and control valve


SPECIAL TOOLS

REPLACEMENT PROCEDURE FOR PRES-

SURE COMPENSATION VALVE SEALa Since there many types of the pressure compen-

sation valves, make a mark on each valve to in-

dicate from where it was removed.

1. Remove piston (2), plug (3), and spring (4) from

pressure compensation valve (1).

2. Remove seal (5) and O-ring (6) from piston (2).

a There many types of the pistons.

a Clean the pressure compensation valve

thoroughly. Then, using the tool, install sealsas shown in the figure.

3. Fit O-ring (6) to piston (2).

4. Set tool L1 to piston (2) and push it in with your

hand slowly so that seal (5) will expand evenly.

a You may push in the seal to the flat part of

the tool first, and then install the tool to thepiston and push in the seal further.

S y m b o l

Part No. Part Name

N e c e s

s i t y

Q ’ t y


S k e t

c h

L

1

796-946-1310 Guide 21.81

(For 723-46-40100, 723-46-40601)

796-946-2110 Guide 20.91

(For 723-46-44100)

796-946-2210 Guide 20.61

(For 723-46-45100, 723-46-45500)

2

796-946-1320 Guide1

(For 723-46-40100, 723-46-40601)

796-946-1420 Guide 21.61

(For 723-46-42800)

796-946-2120 Guide1

(For 723-46-44100)

796-946-2220 Guide1

(For 723-46-45100, 723-46-45500)

3

796-946-1330 Sleeve1

(For 723-46-40100, 723-46-40601)

796-946-1430 Sleeve1

(For 723-46-42800)

796 946 2130 Sleeve



796-946-2130 Sleeve1

(For 723-46-44100)

796-946-2230 Sleeve1


5. Set tool L2 to piston (1) for other seal (3) and

push it in with your hand slowly so that seal (3)

will expand evenly.

a You may push in the seal to the flat part of

the tool first, and then install the tool to the

piston and push in the seal further.

6. Install correcting tool L3 to piston (1) for about 1

minute to fit seals (2) and (3).

a Check that the seal are not projected or bro-

ken.

7. Fit plug (3) and spring (4) to piston (2) and

ASSEMBLY • Apply engine oil to the sliding surfaces of the

parts before installing.

• When installing spools (7) and (10) in the valve

chamber, direct drilled holes (8) and (11) toward

cylinder ports (9) and (12).

• Install filters (13) to the bottom of ports PLS1

and PLS2 as shown below.



p g ( ) p g ( ) p ( )

assemble pressure compensation valve (1).

a If these parts are difficult to install, do not

push them in forcibly, but install them to cor-

recting tool L3 to fit the seals and then install


• Control valve top and bottom covers

2 Mating faces of control valve top and

bottom covers:

SEALEND 242 or equivalent

a Use 2 washers (W2) each for only 2 places

of the control valve top cover.

• Tighten the mounting bolts of the control valve

top and bottom covers in the following order.

(A o D o C o B)

3 Mounting bolt of control valve top and

bottom covers:

156.9 – 176.5 Nm {16 – 18 kgm}

3 Mounting bolt of boom Hi check valve,

quick return valve, lock valve, and armplate: 58.8 – 73.6 Nm {6 – 7.5 kgm}



• Merge-divider valve

2 Mating face of merge-divider valve:


3 Mounting bolts of back-pressure valve,

boom Hi check valve, quick returnvalve, lock valve and arm plate:

58.8 – 73.6 Nm {6 – 7.5 kgm}

• Pressure compensation valve

a When installing each pressure compensa-

tion valve, check the mark made when it was

removed.

• Main relief valve assembly After installing the main relief valve to the control

valve, see TESTING AND ADJUSTING, Testing

and adjusting oil pressures in work equipment,

swing, and travel circuits.



DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT

ASSEMBLY

REMOVALk Replace the remaining pressure in the hydraulic

circuit. For details, see TESTING AND AD-

JUSTING, release of remaining pressure in hy-

draulic circuit.

a Mark all the piping with tags to prevent mistakes

in the mounting position when installing.

1. Disconnect six hoses (1) through (6) between

travel motor and center swivel joint.

• (1): Center swivel joint (T port) – Left travel

motor (T port)

• (2): Center swivel joint (T port) – Right trav-

el motor (T port)

• (3): Center swivel joint (B port) – Left travel

motor (PA port)• (4): Center swivel joint (D port) – Right trav-

el motor (PB port)

• (5): Center swivel joint (A port) – Left travel

motor (PB port)

• (6): Center swivel joint (C port) – Right trav-

el motor (PA port)

2. Disconnect nine hoses (7) through (15).

3. Pull out pin (16) on the side of center swivel joint

and remove the jam plate from the center swivel

joint.

4. Remove four mounting bolts (17).

5. Remove center swivel joint assembly (18). [*1]

4 Center swivel joint assembly: 40 kg



• (7): Center swivel joint (E port) – Left travel

motor (P port)

• (8): Center swivel joint (E port) – Right trav-

el motor (P port)



[*1]

Install the center swivel joint facing in the direc-

tion shown in the diagram.

(The diagram shows the machine as seen fromabove)

• Refilling with oil (hydraulic tank)



system. Then check the oil level again.

• Bleeding air

Bleed the air from the travel motor. For details

see TESTING AND ADUSTING, Air Bleeding of

Various Parts.




DISASSEMBLY AND ASSEMBLY OF OF CENTER SWIVEL JOINT

ASSEMBLYSPECIAL TOOLS

DISASSEMBLY


2. Remove snap ring (2).

3. Using tool M, pull out swivel rotor (4) and ring (3)

from swivel shaft (5).

4. Remove seal (6) from swivel shaft (5).

5. Remove O-ring (7) and slipper seal (8) from

swivel rotor (4).

ASSEMBLY1. Assemble slipper seal (8) and O-ring (7) to

swivel rotor (4).

2. Assemble seal (6) in swivel shaft (5).

3. Set swivel shaft (5) to block, then using push

tool, tap swivel rotor (4) with a plastic hammer toinstall.

2 Contact surface of rotor, shaft:

Grease (G0-LI or G2-LI)

a When installing the rotor be extremely care

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y

N

e w / R e m o d e l

S k e t c h

M

790-101-2501 Push puller q 1

• 790-101-2510 • Block 1

• 790-101-2520 • Screw 1

• 791-112-1180 • Nut 1

• 790-101-2540 • Washer 1

• 790-101-2630 • Leg 2

• 790-101-2570 • Plate 4

• 790-101-2560 • Nut 2

• 790-101-2650 • Adapter 2



a When installing the rotor, be extremely care-

ful not to damage the slipper seal and the O-

ring.

DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VELVE

DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC

V ALVE ASSEMBLYa Only precautions for assembling the work equip-

ment PPC valve assembly are explained below.

ASSEMBLY • Work equipment PPC valve assembly

a Install springs (11 ) with the small-diameter

(inside diameter) end on the shim (12) side.

a Springs (10 ) having different number of

turns are used for the following hydraulic

ports. Take care when installing them.

a When installing pistons (8), apply grease to

their outside and the inside of the valve body

holes.

3 Mounting bolt of plate (5):

11.8 – 14.7 Nm {1.2 – 1.5 kgm}

2 Sliding parts of joint (4):

2 – 4 cc of Grease (G2-LI)

2 Female threads of body (A):

Adhesive (LT-2)

a Apply a drop (about 0.02 g) of LOCTITE to

each of the 2 threaded parts of the body as

shown in the figure, and then tighten joint (4).

3 Joint (4): 39 – 49 Nm {4 – 5 kgm}

a Observe the tightening torque of the joint.

2 Contact parts of piston and disc

(2): Grease 0.3 – 0.8 cc (G2-LI)

3 Nut (1): 69 – 88 Nm {7 – 9 kgm}

a When installing disc (2), adjust the play to

0.5 – 3mm at 200 mm from the turning center

of the lever.



p g

Installed height: 31.9 mm (Common to all

springs)

Installed load:

DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE

DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE

ASSEMBLY

DISASSEMBLYa Only precautions for assembling the travel PPC

valve assembly are explained below.

ASSEMBLY • Travel PPC valve assembly

a Insert shim (3) of the thickness and quantity

checked when disassembled.

Standard shim thickness 0 3 mm



Standard shim thickness: 0.3 mm

a Since spring (4) is not symmetric vertically,

install it with the small-diameter (inside diam-

DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER


DISASSEMBLY1. Piston rod assembly

1) Remove the piping from the cylinder assem-

bly.

2) Remove the mounting bolts and disconnect

cylinder head assembly (1).

3) Pull out piston rod assembly (2).

a Put a container under the cylinder to re-

ceive oil.

4) Disassemble the piston rod assembly


i) Set piston rod assembly (2) to tool N1.

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y


S k e t c h

N

1 790-502-1003Cylinder repair

stand t 1

2790-102-4300

Wrench assem-

bly t 1

790-102-4310 Pin t 2

3 790-720-1000 Expander q 1

4

796-720-1680 Ring (For boomand bucket) q 1

07281-01589

Clamp (For

boom and

bucket)

q 1

796-720-1690 Ring (For arm) q 1

07281-01919 Clamp (For arm) q 1

5


• 790-201-1851• Push tool

(For bucket)1

• 790-201-1861• Push tool

(For boom)1

• 790-201-1871• Push tool

(For arm)1

• 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1

790-201-1500 Push tool kit 1

790 101 5021 G i 1



ii) Remove piston assembly lock screw

(3).

• 790-101-5021 • Grip 1

• 01010-50816 • Bolt 1


a If screw (3) is so caulked that you cannot

remove it, tighten it temporarily and tap

the threads on it, and then remove it.

iii) Using tool N2, remove piston assembly

(4).

• When not using tool N2, loosen the

piston assembly by using the drilledholes (Ø10: 2 places) (in which the

pins of N2 are inserted in the follow-

ing figure).

iv) Remove plunger (5).• Perform this work for only the boom

and arm cylinder.

v) Remove collar (6).

Perform this work for only the boom

vii) Remove cap (8), 11 balls (9), and

plunger (10).

• Perform this work for only the arm

cylinder.

a Since cap (8) is made of nylon, tight-

en a screw into it and pull it with pli-

ers.

2. Disassembly of piston assembly

1) Remove rings (11).

2) Remove wear rings (12).

3) Remove piston ring (13).

4) Remove the O-ring and backup rings (14).

3. Disassembly of cylinder head assembly

1) Remove the O-ring and backup ring (15).

2) Remove snap ring (16) and dust seal (17)



• Perform this work for only the boom

and arm cylinder.

vi) Remove head assembly (7).

2) Remove snap ring (16) and dust seal (17).

3) Remove rod packing (18).

4) Remove buffer ring (19).


ASSEMBLYa Take care not to damage the packings, dust

seals, O-rings, etc.

a Clean the all parts. After installing them, cover

the piping ports and pin holes to prevent dirt from

entering.

a Do not insert each backup ring forcibly, but warm

it in water at 50 – 60°C and then insert it.

1. Assembly of cylinder head assembly

1) Using tool N5, press fit bushing (20).

2) Install buffer ring (19).

3) Install rod packing (18).

4) Using tool N6, install dust seal (17) and

secure it with snap ring (16).

5) Install backup ring and O-ring (15).6) Install snap ring (21).

2. Assembly of piston assembly

1) Using tool N3, expand piston ring (13).

a Set piston ring (13) to tool N3 and turn

the handle 8 – 10 times to expand the

piston ring.

2) Set tool N4 and contract piston ring (13).

3) Install backup ring and O-ring (14).4) Install wear ring (12).

5) Install ring (11).

a Do not increase the closed gap of the

ring too much.

2 Ring groove: Grease (G2-LI)




3. Piston rod assembly

1) Set the piston rod to tool N1.

2) Install cylinder head assembly (7) to the pis-

ton rod.

3) Fit the O-ring and backup ring to collar (6),

and then install them.

• Perform this work for only the boom and

arm cylinders.

4) Install plunger (5).

• Perform this work for only the boom and

arm cylinders.

5) Set plunger (10) to the piston rod. Install 11

balls (9) and secure them with cap (8).

a After installing the plunger, check that it

has a little play at its end.


cylinder.

6) Assemble piston assembly (4) according to


• When reusing the rod and piston as-

sembly (4)

i) Tighten piston assembly (4). Then,

using tool N2, tighten piston assembly

(4) until the screw holes are aligned.

a Remove the burrs from the threads

with a file.

Go to iv).

• When replacing either or both of the

rod and piston assembly (4) with new

ones

a Make a mark of the cushion plug position

on the end of the rod having the bottom

cushion.


cylinder.

ii) Using the tool, tighten piston assembly

(4) until it reaches the end of the rod.

3 Piston assembly:

294 ± 29.4 Nm {30 ± 3.0 kgm}

a After tightening the piston, checkthat plunger (5) has some play.

• Perform this work for only the boom

and arm cylinders.




iii) Make a screw hole to install screw (3).

a Apply a drill to the V-groove of the

threaded parts of piston (4) and rod

(2) and make a hole.

a When making a hole on the cylinder

(arm cylinder) having the bottom

cushion, make it around the cushion

plug.

• Dimensions of screw hole (mm)

iv) Tighten screw (3).

a Clean the parts thoroughly and re-

move metal chips, dirt, etc.

2 Threads of screw:

Adhesive (LOCTITE No. 262)

3 Screw:

58.9 – 73.6 Nm {6 – 7.5 kgm}

v) Caulk the threaded part by 4 placeswith a punch.

7) Install piston rod assembly (2).

a Set the abutment joint of the ring at a

side and insert the piston rod, aligning it

with the cylinder tube.

a After inserting the piston rod, check that

the ring is not broken or removed, and

then insert to the end.

8) Tighten the mounting bolts of cylinder head

assembly (7).

3 Mounting bolt:

9) Install the piping.

Tap drill diameter Tap to be used

10.3 12 x 1.75

Tap drill

hole depth

Tapping

depth

Bucket/Boom 27 20

Arm 36 29

Cylinder

nameTightening torque

Bucket 530 ± 78.5 Nm {54.0 ± 8 kgm} Arm 892 ± 137 Nm {91.0 ± 14 kgm}

Boom 530 ± 78.5 Nm {54.0 ± 8 kgm}



DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

REMOVAL AND INSTALLATION OF WORK EQUIPMENT


REMOVALk Extend the arm and bucket fully, lower the work

equipment to the ground, and set the safety lock


k See TESTING AND ADJUSTING, Releasing re-

sidual pressure in hydraulic circuit.

1. Disconnect grease hose (1).

2. Sling boom cylinder assembly (2) temporarily

and remove lock bolt and nut (3). [*1]

3. Remove plate (4) and head pin (5). [*2]

4. Start the engine and retract the piston rod.

a Bind the rod with wires, etc. so that it will not

be extracted and lower it onto a stand or put

a wood block to the bottom side so that the

cylinder will not lower. When putting the

wood block, remove the grease fitting on the

bottom side.

a Disconnect the boom cylinder on the oppo-site side similarly.

a When slinging the boom cylinder, if the sling

interferes with the work equipment lamp, re-

move the work equipment lamp.

5. Disconnect intermediate connector A42 (6) for

the work equipment lamp.

6. Disconnect 3 arm cylinder hoses (7) and 2

bucket cylinder hoses (8).

a Put oil stopper plugs and secure the hoses to

the valve side with ropes.

7. Sling work equipment assembly (12) tempo-

rarily.

8. Remove cover (9), plate (10), and foot pin (11)

to disconnect work equipment assembly (12)

S y m b o l

Part No. Part Name

N e c e s s i t y

Q ’ t y


S k e t c h

P

796-670-1100 Remover q 1

• 796-670-1110 • Sleeve 1

• 796-670-1120 • Plate 1

• 796-670-1130 • Screw 1

• 796-870-1110 • Adapter 1

• 01643-33080 • Washer 1

• 01803-13034 • Nut 1

790-101-4000Puller (490 kN

{50t}, long) q 1

790-101-1102Pump (294 kN

{30t}) q 1



p ( ) p ( ) [ ]

a Check the quantity and positions of the in-

serted shims.

to disconnect work equipment assembly (12).

[*3]


• When removing with tool P

Remove plate (10). Sling and set tool P and

remove foot pin (11) to disconnect work

equipment assembly (12).

a Check the quantity and positions of the in-

serted shims.

9. Move the machine in reverse to remove work

equipment assembly (12).

4 Work equipment assembly:

PC400-7, PC400LC-7: 7,400 kg

PC450-7, PC450LC-7: 8,400 kg


removal.

[*1]

a Tighten the locknut so that clearance "a" be-

tween the plate and nut will be 0.5 – 1.5 mm.

[*2]

2 Inside wall of bushing before assem-

bling pin:

Anti-friction composition (LM-P)

2 Greasing after assembling pin:Grease (LM-G)

k When aligning the pin holes, never insert

your fingers in them.

a Adjust the shim thickness so that clearance

"b" between cylinder rod (12) and plate (4)

will be 1.5 mm or less.

Standard shim: 1.0, 2.0 mm




[*3]

2 Inside wall of bushing before assem-

bling pin:

Anti-friction composition (LM-P)

2 Greasing after assembling pin:

Grease (LM-G)

k When aligning the pin holes, never insert

your fingers in them.a Adjust the shim thickness so that clearance

"c" between boom (13) and bracket (14) will

be 1 mm or less.

Standard shim: 2.0, 2.5, 3.0, 3.5 mm

• Bleeding air

See TESTING AND ADJUSTING, Bleeding air

from each part.







DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)

REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS

(STUCK GLASS)




SPECIAL TOOLS

REMOVALa Remove the window glass to be replaced ac-

cording to the following procedure.

1. Using seal cutter [1], cut the adhesive between

broken window glass (7) and operator's cab

(metal sheet) (8).

a If a seal cutter is not available, make holes

on the adhesive and both-sided adhesive

tape with a drill and pass a fine wire (piano

wire, etc.) [2] through the holes. Grip the

both ends of the wire with priors [3], etc. (or

hold them by winding them onto something)

and move the wire to the right and left to cut

the adhesive and both-sided adhesive tape.

Since the wire may be broken by the friction-

(The figure shows the operator's cab of a

wheel loader.)

a If the window glass is broken finely, it may be

removed with knife [4] and a screwdriver.

a Widening the cut with a screwdriver, cut the

adhesive and both-sided adhesive tape with

knife [4].


wheel loader.)

2. Remove the window glass.

S y m b o l

Part No. Part name

N e c e s s i t y

Q ' t y

N e w / R e m o d e

l

S k e t c h

Y1 793-498-1210

Lifter

(Suction cup) t 2

2 20Y-54-13180 Adapter t 2



y y

al heat, apply lubricant to it.


INSTALLATION1. Using a knife and scraper [5], remove the

remaining adhesive and both-sided adhesivetape from the metal sheets (glass sticking sur-

faces) of the operator's cab.

a Remove the adhesive and both-sided adhe-

sive tape to a degree that they will not affect

adhesion of the new adhesive. Take care

not to scratch the painted surfaces. (If the

painted surfaces are scratched, adhesion

will be lowered.)


wheel loader.)

2. Remove oil, dust, dirt, etc. from the sticking sur-

faces of cab (8) and window glass (9) with white

gasoline.

a If the sticking surfaces are not cleaned well,

the glass may not be stuck perfectly.

a Clean the all black part on the back side of

the window glass.

a After cleaning the sticking surfaces, leave

them for at least 5 minutes to dry.


wheel loader.)

3. Apply primer (10).

a The using limit of primer (10) is 4 months af-

ter the date of manufacture. Do not use prim-er (10) after this limit.

a Use the primer within 2 hours after unpack-

ing it.

a Even if the primer is packed again just after

it is unpacked, use it within 24 hours after it

is unpacked for the first time. (Discard the

primer 24 hours after it is packed.)

1) Stir the primers for paint and glass suffi-

ciently before using them.

a If the primer has been stored in a refrig-

erator, leave it at the room temperature

for at least half a day before stirring it. (If

the primer is unpacked just after taken

out of the refrigerator, water will be con-

densed. Accordingly, leave the primer at

the room temperature for a sufficient

time.)2) When reusing primer brush (11), wash it in

white gasoline.

a After washing the brush, check it again

for dirt and foreign matter.

a Prepare respective brushes for the paint

primer glass primer.




3) Evenly apply paint primer to the surfaces to

stick both-sided adhesive tapes and the sur-

faces out of those surfaces on operator'scab (8) which will be coated with the adhe-

sive.

2 Paint primer:

SUNSTAR PAINT PRIMER

580 SUPER or equivalent

a Do not apply the primer more than 2

times. (If it is applied more than 2 times,

its performance will be lowered.)

a Parts to be coated with primer: Apply the

primer all over dimension (a).

• Dimension to apply primer (a): 25 mm

a In addition to the above parts, apply the

primer to right side window glass (1) and

door lower window glass (3).• Range to apply primer additionally for

right side window glass (1): (b)

• Range to apply primer additionally for

door lower window glass (3): (c)

a After applying the primer, leave it for at

least 5 minutes (within 8 hours) to dry.

a Never apply wrong primer. If the glass

primer is applied by mistake, wipe it off with white gasoline.




4) Evenly apply glass primer to the sticking

surfaces of window glass (9).

2 Glass primer:SUNSTAR GLASS PRIMER

580 SUPER or equivalent

a Do not apply the primer more than 2

times. (If it is applied more than 2 times,

its performance will be lowered.)

a Parts to be coated with primer: Apply the

primer to the sticking surfaces of window

glass (9) and all over dimension (d)

which will be on both-sided adhesive

tape (6) and operator's cab (8).

a Do not apply the primer to the boarder

about 5 mm wide between the black part

and transparent part of the glass.

a After applying the primer, leave it for at

least 5 minutes (within 8 hours) to dry.

a Never apply wrong primer. If the glass

primer is applied by mistake, wipe it off

with white gasoline.

4. Stick both-sided adhesive tape (6) along the

inside edge of the glass sticking section.

a Do not remove the release tape of the both-sided adhesive tape on the glass sticking

side before sticking the glass.

a When sticking the both-sided adhesive tape,

do not touch the cleaned surface as long as

possible.

a Take that the both-sided adhesive tape will

not float at each corner of the window frame.

a When sticking both-sided adhesive tape (6)

around a frame, do not lap its finishing end

over the starting end but make clearance e of

about 5 mm between them.

1) Stick both-sided adhesive tape (6) for right

side window glass (1) as shown in the fig-

ure.




a Stick both-sided adhesive tape (6a) addition-

ally for right side window glass (1).

• Positions to stick additional both-sided adhe-sive tape for right side window glass:

(f ) : 50 mm

(g) : 90 mm

(h) : 250 mm

2) Stick both-sided adhesive tape (6) for left

side rear window glass (2) as shown in the

figure.

3) Stick both-sided adhesive tape (6) for door lower window glass (3) as shown in the fig-

ure.

a Stick both-sided adhesive tape (6b) ad-

ditionally for door lower window glass

(3).a Positions to stick additional both-sided

adhesive tape for door lower window

glass:

( j) : 110 mm

(k) : 90 mm

(m) : 200 mm

4) Stick both-sided adhesive tape (6) for front

window glass (4) as shown in the figure.

a Stick both-sided adhesive tape (6c) of

the lower side of the front window glass

along the outside edge of the lower line,

differently from other both-sided adhe-

sive tapes (6). (If it is stuck along the in-



p ( ) ( g

s ide, i t w i l l be seen through the


5. Position the new window glass.

1) Check the clearance between the window

glass and the operator's cab on the right,left, upper, and lower sides, and then adjust

it evenly.

2) Stick tapes [6] between window glass (9)

and operator's cab (8) and draw positioning

line n.

a Stick tapes [6] to the right, left, and lower

parts of the right side window glass, left

side rear window glass, and door lower

window glass for accurate positioning.

3) Cut the tape between window glass (9) and

operator's cab (8) with a knife, and then

remove the window glass.

a Do not remove the tapes left on the win-

dow glass and operator's cab before in-

stalling the window glass.

a When positioning front window glass (4),

set its horizontal position to the frame

width and set its vertical position so thatheight difference (p) between it and the

frame top will be 3 mm.

6. Apply adhesive.

a Use either of the 2 types of the adhesive.2 Adhesive (Summer):

SUNSTAR PENGUINE

SEAL 580 SUPER "S"

2 Adhesive (Winter):

SUNSTAR PENGUINE

SEAL 580 SUPER "W"

a The using limit of the adhesive is 4 months

after the date of manufacture. Do not use the

adhesive after this limit.a Keep the adhesive in a dark place where the

temperature is below 25°C.

a Never heat the adhesive higher than 30°C.

a When reusing the adhesive, remove the all

hardened part from the nozzle tip.

1) Break aluminum seal (13) of the outlet of

adhesive cartridge (12) and install the noz-

zle.




2) Cut the tip of the adhesive nozzle (14) so

that dimensions (q) and (r) will be as fol-

lows.• Dimension (q): 10 mm

• Dimension (r ) : 15 mm

3) Set adhesive cartridge (12) to caulking gun

[7].a An electric caulking gun is more efficient.

4) Remove the release tape of the both-sided

adhesive tape on the glass side.

5) Apply adhesive (15) to the outside of both-sided adhesive tape (6) of the operator's

cab.

a Apply adhesive (15) to dimensions (s)

and (t) of both-sided adhesive tape (6) of

operator's cab (8).• Dimension (s) : 10 mm

• Dimension (t) : 15 mm

a Apply adhesive (15) higher than both-

sided adhesive tape (6).

a Apply the adhesive evenly.

a Apply adhesive (15) additionally for ad-

ditional both-sided adhesive tape (6a) of

the right side window glass and addition-

al both-sided adhesive tape (6b) of door

lower window glass.




7. Install the window glass.

1) Install window glass (9), matching it to the

lines of the positioning tapes drawn in step5.

a Since the window glass cannot be re-

moved and stuck again, stick it very

carefully.

a Stick the glass within 5 minutes after ap-

plying the adhesive.

2) After sticking window glass (9), press all

around it until it is stuck to the both-sided

adhesive tape.

a Press the corners of the window glass

firmly.

a You can perform this work efficiently by

pulling window glass (9) from inside of the operator's cab with suction cup Y1.

a After installing front window glass (4), fill

the clearances between it and center

trim seal (16) with caulking material inrange (s) to dimensions (t) and (u).

After applying the primer to glass (4) of

section A – A, apply adhesive as caulk-

ing material.

• Caulking dimension (t) : 2 mm

• Caulking dimension (u) : 5 mm

a When caulking, mask the glass side and

form the adhesive with a rubber spatula

as shown in the figure.

a Wipe off projected adhesive.

2 Glass primer:

SUNSTAR GLASS

PRIMER 580 SUPER

2 Adhesive:

SUNSTAR PENGUINE

SEAL 580 SUPER "S" or "W"




8. Fix the window glass.

1) After installing right window glass (1) to the

operator's cab, insert stopper rubbers Y2 to

2 places (v) at the bottom of the glass to fix

the glass.

2) Using styrene foam blocks [9] and rubber

bands [10], fix the window glass and both-

sided adhesive tape to fit them completely.

9. After installing the window glass, remove the

primer and adhesive from the operator's cab

and window glass.

a Using white gasoline, wipe off the adhesive

before it is dried up.

a When cleaning the glass, do not give an im-

pact to it.

10. Protect the stuck window glass.1) Keep the stopper rubbers, styrene foam

blocks, and rubber bands installed for 10

hours (at temperature of 20°C and humidity

of 60%).

2) After removing the stopper rubbers, styrene

foam blocks, and rubber bands, wait at least

14 hours, at least 24 hours in total, before

operating the machine actually.



DISASSEMBLY AND ASSEMBLY FRONT WINDOW

REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY


stop the engine.

a To replace the front window glass, the front win-

dow assembly must be removed from the opera-

tor's cab. The procedure for removing and

installing the front window assembly (front frame

and front window glass) is explained below.

REMOVAL1. Raise the front window assembly to the ceiling

and fix it with the rear locks (on both sides).

2. Remove left corner blocks (1) and (2) and right

corner block (3). [*1]

3. Remove left striker bolt (4), right striker bolt (5),

left corner block bracket, and right corner block

bracket (7). [*2]

4. Install left striker bolt (4) to the operator's cab

again and tighten it lightly.

a This bolt will be used to hang the pull-up as-

sist cable in step 8.

5. Release the rear locks.

6. Lower the front window assembly carefully a lit-

tle. Put out rollers (8) and (9) under the both

sides of the front window through the portion

from which the corner blocks were removed in

step 3 (the portion where the rail is open) and

hold them.

7. Remove rollers (8) and (9) under the both sides

of the front window.




8. Remove left lower pin (10). [*3]

a If left lower pin (10) is removed, plate (12) at

the end of pull-up assist cable (11) comesoff.

a Hang plate (12) on the left striker bolt.

k The return load of 58.8 N {6 kg} is applied to

the rear of the operator's cab. Accordingly,

take care when removing left lower pin (10)

to disconnect pull-up assist cable (11).

9. Put out the bottom of front window assembly

(13) through the rail opening portion and lower itgradually.

10. Lower front window assembly (13) completely.

a Do not let the front window assembly touch

the monitor.

11. Twist front window assembly (13) to the right

and left to remove both upper rollers (14) and

(15) from the rails, and then remove front win-

dow assembly (13).




INSTALLATION


[*1] [*2]

• Adjust opening and closing of the front window

assembly according to the following procedure.

1. Open and close the front window to check that it

does not interfere with the rails and the rollers

are not hitch.

2. If there is any problem in opening or closing of

the front window, loosen the mounting bolts of

roller adjustment brackets (16) and (17) and

adjust the condition of the front window, and

then tighten the mounting bolts again.

3 Mounting bolt: 98 Nm {1.0 kgm}




3. Raise the front window assembly and fix it with

the rear locks (on both sides).

a Check that the locks in the rear of the opera-tor's cab are applied securely.

4. Install right corner block (3) and fix right corner

block bracket (7) with right striker bolt (5).

a Tighten the striker bolt securely after adjust-

ing it in step 6.

a Install the right corner block so that there will

be no level difference at part (a).

a Install the right corner block so that level dif-ference (b) between the rail and right corner

block (3) at part PF will be 0 – 1.0 mm.

Check that the right corner block is not pro-

jected from the rail at the rolling surface of

the roller.

a Secure roller clearance (c) at part PJ.

5. Install left corner blocks (1) and (2) and secure

left corner bracket (6) with left striker bolt (4).

a Tighten the striker bolt securely after adjust-ing it in step 6.

a Install the left corner blocks so that there will

be no level difference at 2 part (d).

a Secure roller clearance (e).




6. Adjust the striker bolts according to the following

procedure (Adjust the "CLOSE" positions of the

front window assembly locks).1) Tighten left striker bolt (4) and right striker

bolt (5) at roughly right positions so that

front window glass (18) will be fitted to cab-

side trim seal (19).

2) Open and close the front window assembly

and check the working condition of both

locks (20) and (21).i) If both locks do not work normally, move

the striker bolts toward the rear of the

cab and tighten them again.

ii) After moving the striker bolts, check the

fitness of the front window glass and

cab-side trim seal which was checked in

step 6.

iii) Repeat the work in i) and ii) until the fit-

ness of the front window and the work-ing condition of both locks (20) and (21)

are acceptable, and then tighten the

striker bolts.

7. After adjusting the striker bolts, splash water heavily over the front window glass and check

that the water does not leak into the cab.




8. Adjust the "opening" lock of the front window

assembly.

1) After adjusting the "closing" lock of the frontwindow in step 6, raise the front window

assembly to the ceiling.

2) Set the right and left front window assembly

locks at the rear of the operator's cab to the

"OPEN" positions, and then check the fol-

lowing items.

• Check that right and left locks (20) and

(21) are closed normally.

• Check that right and left locks (20) and(21) are inserted in parallel in right and

left striker plates (22).

• Check that right and left rubber stoppers

(24) are in contact with the front window

assembly and their deflection allowance

is 1.5 – 3.0 mm.

3) After checking the above items, if neces-

sary, adjust them by moving right and left

striker plates (22) at the rear of the opera-

tor's cab.

9. Adjust the front window stoppers.

1) After adjusting "closing" lock of the front win-

dow assembly in step 9, check the contactof both front window stoppers (23).

2) If both stoppers (23) do not contact nor-

mally, adjust and fix them at places where

they contact normally.

10. Check the latching effort of the front window

assembly.

1) After finishing steps 6 – 9, check that latch-

ing efforts of both locks (20) and (21) are

even.

a Check the latching efforts on both "clos-

ing" side (in the front of the operator's

cab) and "opening" side (in the rear of

the operator's cab).

[*3]



HYDRAULIC CIRCUIT DIAGRAM (1/2)........................................................................................................90- 3

HYDRAULIC CIRCUIT DIAGRAM (2/2)........................................................................................................90- 5

ELECTRICAL CIRCUIT DIAGRAM (1/5) ......................................................................................................90- 7



ELECTRICAL CIRCUIT DIAGRAM (4/5) ......................................................................................................90- 13ELECTRICAL CIRCUIT DIAGRAM (5/5) ......................................................................................................90- 15

AIR CONDITIONER ELECTRICAL CIRCUIT ...............................................................................................90- 17

ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)..............................................................................................90- 19

CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)........................................................ 90- 21

90 OTHERS



HYDRAULIC CIRCUIT DIAGRAM (1/2)

PC400/450(LC)-7 90-3



PC400/450(LC)-7 90-5

HYDRAULIC CIRCUIT DIAGRAM (2/2)



PC400/450(LC)-7 90-7(4)

ELECTRICAL CIRCUIT DIAGRAM (1/5)



PC400/450(LC)-7 90-9(4)




PC400/450(LC)-7 90-11(4)




PC400/450(LC)-7 90-13(4)




PC400/450(LC)-7 90-15(4)




PC400/450(LC)-7 90-17

AIR CONDITIONER ELECTRICAL CIRCUIT



PC400/450(LC)-7

ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) PC400, 450-7

parts manual - pc400

Documents