Komatsu PC200-6 Shop Manual

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Shop

Manual

CEBMOOOI 2

Pc2 2 1c4PC21OLC=liPC22OlLliPC25OlbiHYDRAULIC EXCAVATOR

PC200 6 A82001PC2OOLC 6 A82001PC21OLC 6 A82001

SERIAL NUMBERS PC22OLC 6 A82001 andup

PC25OLC 6 A82001This material is proprietary to Komatsu America lnternational Company and is not to be reproduced, used, ordisclosed except in accordance with written authorization from Komatsu America International Company.

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to makechanges or add improvements at any time without incurring any obligation to install such changes on products soldpreviously.

Due to this continuous program of research and development, periodic revisions may be made to this publication.It is recommended that customers contact their distributor for information on the latest revision.

00 l

October 1996 Copyright 1996 Komatsu America International Company 0



CONTENTS

01 GENERAL ............................................. 01-I

IO STRUCTURE AND FUNCTION ............................ IO-I

20 TESTING AND ADJUSTMENT ............................. 20-I

30 DISASSEMBLY AND ASSEMBLY .......................... 30-I

40 MAINTENANCE STANDARD .............................. 40-I

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The affected pages are indicated by using the followingmarks. It is requested that necessary actions be takento these pages according to the table below.

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Pages without marks were previous additions or revisedpages.

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SAFETY SAFETY NOTICE

SAFETY

SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repairtechniques recommended and described in this manual are both effective and safe methods of operation.Some of these operations require the use of tools specially designed for the purpose.

To prevent injury to workers, the symbols A and *$ are used to mark safety precautions in this manual. Thecautions accompanying these symbols should always be followed carefully. If any dangerous situation arisesor may possibly arise, first consider safety, and take the necessary actions to deal with the situation.

GENERAL PRECAUTIONS clean and make sure that there is no dirt or oil on thefloor. Smoke only in the areas provided for smoking.

Mistakes in operation are extremely dangerous. Read the Never smoke while working.

OPERATION & MAINTENANCE MANUAL carefullyBEFORE operating the machine. PREPARATIONS FOR WORK

1.

2.

3.

4.

5.

6.

I

I

i

3efore carrying out any greasing or repairs, read all:he precautions given on the decals which are fixed to:he machine.

7.

When carrying out any operation, always wear safetyshoes and helmet. Do not wear loose work clothes,)r clothes with buttons missing.

Always wear safety glasses when hitting parts witha hammer.

8.

Always wear safety glasses when grinding partswith a grinder, etc. 9.

f welding repairs are needed, always have a trained,experienced welder carry out the work. When carry-ng out welding work, always wear welding gloves, 10,apron, glasses, cap and other clothes suited forMelding work.

JVhen carrying out any operation with two or moreNorkers, always agree on the operating procedureoefore starting. Always inform your fellow workers

Before adding oil or making repairs, park the ma-chine on hard, level ground, and block the wheels ortracks to prevent the machine from moving.

Before starting work, lower blade, ripper, bucket orany otherwork equipment to the ground. If this is notpossible, insert the safety pin or use blocks to preventthe work equipment from falling. In addition, be sureto lock all the control levers and hang warning signson them.

When disassembling or assembling, support themachine with blocks, jacks or stands before startingwork.

Remove all mud and oil from the steps or otherplaces used to get on and off the machine. Alwaysuse the handrails, ladders or steps when getting on oroff the machine. Never jump on or off the machine.If it is impossible to use the handrails, ladders orsteps, use a stand to provide safe footing.

sefore starting any step of the operation. Before PRECAUTIONS DURING WORKstarting work, hang UNDER REPAIR signs on thezontrols in the operator’ s compartment. 11.

<eep all tools in good condition and learn the correctNay to use them.

Decide a place in the repair workshop to keep toolsand removed parts. Always keep the tools and partsn their correct places. Always keep the work area 12.

When removing the oil filler cap, drain plug or hy-draulic pressure measuring plugs, loosen themslowly to prevent the oil from spurting out. Beforedisconnecting or removing components of the oil,water or air circuits, first remove the pressure com-pletely from the circuit.

The water and oil in the circuits are hot when the

00-3



SAFETY SAFETY NOTICE

13.

14.

15.

16.

17.

18.

engine is stopped, so be careful not to get burned.Wait for the oil and water to cool before carrying outany work on the oil or water circuits.

Before starting work, remove the leads from thebattery. ALWAYS remove the lead from the negative(-) terminal first.

When raising heavy components, use a hoist orcrane. Check that the wire rope, chains and hooksare free from damage. Always use lifting equipmentwhich has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane andoperate slowly to prevent the component from hittingany other part. Do not work with any part still raisedby the hoist or crane.

When removing covers which are under internalpressure or under pressure from a spring, alwaysleave two bolts in position on opposite sides. Slowly

release the pressure, then slowly loosen the bolts toremove.

When removing components, be careful not to breakor damage the wiring, Damaged wiring may causeelectrical fires.

When removing piping, stop the fuel or oil fromspilling out. If any fuel or oil drips on to the floor, wipeit up immediately. Fuel or oil on the floor can causeyou to slip, or can even start fires.

As a general rule, do not use gasoline to wash parts.In particular, use only the minimum of gasoline when

19

20.

21.

22.

23.

24.

washing electrical parts.

Be sure to assemble all parts again in their originalplaces. Replace any damaged part with new parts.

When installing hoses and wires, be sure thatthey will not be damaged by contact with otherparts when the machine is being operated.

When installing high pressure hoses, make sure thatthey are nottwisted. Damaged tubes are dangerous,so be extremely careful when installing tubes for highpressure circuits. Also check that connecting partsare correctly installed.

When assembling or installing parts, always use thespecified tightening torques. When installing protec-tive parts such as guards, or parts which vibrateviolently or rotate at high speed, be particularlycareful to check that they are installed correctly.

When aligning two holes, never insert your fingers orhand. Be careful not to get your fingers caught in ahole.

When measuring hydraulic pressure, check that themeasuring tool is correctly assembled before takingany measurements.

Take care when removing or installing the tracks oftrack-type machines. When removing the track, thetrack separates suddenly, so never let anyone standat either end of the track.

00-4



FOREWARD GENERAL

FOREWARD

GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurateunderstanding of the product and by showing him the correct way to perform repairs and make judgements. Make sureyou 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 sections. These sections are further divided into eachmain group of components.

GENERAL

This section lists the general machine dimensions, performance specifications, component weights, and fuel,coolant and lubricant specification charts.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an understanding ofthe structure, but also serves as reference material for troubleshooting.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to be madeat completion of the checks and repairs. Troubleshooting charts correlating “ Problems” to “ Causes” are alsoincluded in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or assembling eachcomponent, as well as precautions to be taken for these operations.

MAINTENANCE STANDARD

This section gives the judgement standards when inspecting disassembled parts.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any advancenotice. Contact your distributor for the latest information.

00-5



FOREWARD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Shop manuals are issued as a guide to carrying outrepairs. They are divided as follows:Chassis volume: Issued for every machine model

Engine volume: Issued for each engine seriesElectrical volume: Each issued as one to cover all

When a manual is revised, an edition mark (000 . ..) isrecorded on the bottom outside corner of the pages.

REVISIONS

modelsAttachment volume: Each issued as one to cover all

Revised pages are shown at the LIST OF REVISEDPAGES between the title page and SAFETY page.

modelsSYMBOLS

These various volumes are designed to avoid duplicationof information. Therefore to deal with all repairs for anymodel, it is necessary that chassis, engine electrical andattachment be available.

So that the shop manual can be of ample practical use,important places for safety and quality are marked withthe following symbols.

DISTRIBUTION AND UPDATINGSymbol Item Remarks

Any additions, amendments or other changes will be sentto your distributors. Get the most up-to-date informationbefore you start any work.

ASafety

Special safety precautions are nec-essary when performing the work.

FILING METHOD * Caution

Special technical precautions orother precautions for preservingstandards are necessary whenperforming the work.

1

2.

3.

See the page number on the bottom of the page. Filethe pages in correct order.Following examples show how to read the pagenumber:Example 1 (Chassis volume):

Y

Item number (10. Structure andFunction)

Consecutive page number foreach item

Example 2 (Engine volume):Refer to the pertinent engine manual.

Additional pages: Additional pages are indicated by ahyphen (-) and numbered after the page number. Fileas in the example.Example:1 o-41 o-4-11 O-4-2 I

Added pages

el Weight

Weight of parts or systems. Cau-tion necessary when selectinghoisting wire or when working pos-ture is important, etc.

Tightening

Places that require special atten-

torque tion for tightening torque duringassembly.

CoatPlaces to be coated with adhesivesand lubricants etc.

Oil, waterPlaces where oil, water or fuelmust be added, and the capacity.

Places where oil or water must be

.t. Drain drained, and quantity to bedrained.

1 o-5

00-6



FOREWARD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

&iHeavy parts (25 kg or more) must be lifted witha hoist etc. In the DISASSEMBLY AND AS-

SEMBLY section, every part weighing 25 kg or moreis indicated clearly with the symbol

6 kg

If a part cannot be smoothly removed from themachine by hoisting, the following checks should bemade:1) Check for removal of all bolts fastening the part

to the relative parts.2) Check for existence of another part causing

interface with the part to be removed.

WIRE ROPES1) Use adequate ropes depending on the weight of

parts to be hoisted, referring to the table below:

Wire ropes(Standard “ Z” or “ S” wist ropes without galvanizing

Rope diameter (mm) Allowable load (tons)

10.0 1.011.2 1.4

12.5 1.614.0 2.216.0 2.818.0 3.620.0 4.422.4 5.630.0 10.040.0 18.050.0 28.060.0 40.0

* The allowable load value is estimated to be 116 or

I/7 of the breaking strength of the rope used.

2) Sling wire ropes from the middle portion of thehook. Slinging near the edge of the hook maycause the rope to slip off the hook during hoisting,and a serious accident can result. Hooks havemaximum strength at the middle portion.

100% 88% 79% 71% 41%

FSO 64

3) Do not sling a heavy load with one rope alone, butsling with two or more ropes symmetrically woundon to the load.

Slinging with one rope may cause turning ofthe load during hoisting, untwisting of the rope,

or slipping of the rope from its original winding posi-

tion on the load, which can result in a dangerousaccident.

4) Do not sling a heavy load with ropes forming a widehanging angle from the hook. When hoisting a loadwith two or more ropes, the force subjected to eachrope will increase with the hanging angles. Thetable below shows the variation of allowable load(kg) when hoisting is made with two ropes, each ofwhich is allowed to sling up to 1000 kg vertically, atvarious hanging angles. When two ropes sling aload vertically, up to 2000 kg of total weight can besuspended. This weight becomes 1000 kg whentwo ropes make a 120” hanging angle. On theother hand, two ropes are subject to an excessiveforce as large as 4000 kg if they sling a 2000 kgload at a lifting angle of 150” .

6 ’ 9

Lifting angle : ct

12 ” 15 ”

FSO 65

00-7



FOREWARD COATING MATERIALS

COATING MATERIALS

The recommended coating materials prescribed in the shop manuals are listed below.

Category 1 Code 1 Part No. Main aoolicationsfeatures

LT-IAI

790-I 29-9030

Qty

150g

790 I 9-9050 20 9 ca

50 g

790 I 9 9060

Set of adhesiveand hardening

agent

Adh 1 kgHard agt

500 kg

790-I 29-9040 250 g

50 cc

790 l 9 9010 200 g

790 I 9-9070 1 kg

790 I 9-9020 200 g

790 I 9 9080 1 kg

09940 00011 250 g

09920-00150 1509

09940 00051

09940-00040

60 g

200 g

SYG-35OLISYG-400LI

SYG-400LI-ASYG-160LI

SYGA-1 GOCNLI

SSG2-400CA

SYG2-350CASYG2-400CA-A

SYGZ-I 60CASYGA-1 GCNCA

Various

Various

SYG2-400M400 g

(1 O/case)

Container

TubeUsed to prevent r ubber gaskets, rubber cushions and cork plugs fromcoming out

Plasticcontainer

Plasticcontainer

Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene. polypropylene,tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.

Features: Resistance to heat, chemicalsUsed for anti-loosenina and sealant ourooses for bolts and oluas.

Can Used as adhesive or sealant for metal, glass or plastic.

Plasticcontainer

Used as sealant for machined holes.

___ Features: Resistance to heat, chemicalsUsed at joint portions subject to high temperature.

TubeUsed as adhesive or sealant for gaskets and packing of power traincase, etc.

Can

Features: Resistance to heatUsed as sealant for flange surfaces and bolts at high temperaturelocations; used to prevent seizure.Used as sealant for heat resistant gasket for at high temperaturelocations such as engine pre-combustion chamber, exhaust pipe.

Tube

Features: Resistance towater, oilUsed as sealant for flange surface, thread.Also possible to use as sealant for flanges wi th lar ge clearance.Used as sealant for mating surfaces of final drive case, transmissioncase.

Plasticcontainer

Used as sealant for various threads, pipe joints, flanges.Used as sealant for tapered plugs, elbows, nipples of hydraulicpiping.

Features: Silicon based, resistant to heat, cold.Tube Used as sealant for flange surface, thread.

Used as sealant for oil pan, final drive case, etc.

TubeFeatures: Silicon based, quick hardening type.Used as sealant for flywheel housing, intake manifold, oil pan,thermostat housing, etc.

Can Used as lubricant for sliding parts (to prevent squeaking).

TubeUsed to prevent seizure or scuffing of the thread when press fitting orshrink fitting.Used as lubricant for linkage, bearings, etc.

Various General purpose type

VariousUsed for normal temperature, light load bearing at places in contactwith water or steam.

Bellows type Used for places with heavy load.

LT-1 B

Adhesive

LG-1

tLG-3

LG-4

Gasket sealant

LG-7

I

Rust oreven- I

Lithium grease G2-Ll

+

Calcium grease G2-CA

I

Molybdenumdisultide grease ---

00-8



FOREWARD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections ofDISASSEMBLY AND ASSEMBLY.

1 kam = 9.806 Nm

Thread diameter of bolt Width across flat 0 0mm mm km Nm

6 10 1.35 *0.15 13.2 *I .4

8 13 3.20 kO.3 31.4 *2.9

10 17 6.70 *0.7 65.7 56.8

12 19 11.5 *I .o 112 kg.8

14 22 18 k2.0 177 *I9

16 24 28.5 &3 279 *29

18 27 39 *4 383 *39

20 30 56 *6 549 i58

22 32 76 *8 745 *78

24 36 94.5 iI0 927 *98

27 41 135 *I5 1320 *I 40

30 46 175 *20 1720 *I 90

33 50 225 *25 2210 &240

36 55 280 *30 2750 i290

39 60 335 i35 3280 *340

k This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are tobe used, or which require tightening to otherwise specified torque.

00-9



FOREWARD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Thread diameter of bolt

mm

10

12

16

Width across flat

mm

14

17

22

Tightening torque

kgm Nm

6.70 *0.7 65.7 k6.8

11.5 &I .o 112 k9.8

28.5 k3 279 *29

TIGHTENING TORQUE FOR FLAIRED NUTS

Use these torques for flaired part of nut. cm483

Thread diameter of bolt Width across flat I Tightening torque

mm mm kgm Nm

14 19 2.5 k0.5 24.5 k4.918 24 5 *2 49 &I 9.6

22 27 8 *2 78.5 *I 9.6

24 32 14 i3 137.3 Q9.4

30 36 18k3 176.5 i29.4

33 41 20 zt5 196.1 zk49

36 46 25 k5 245.2 k49

42 55 30 *5 294.2 *49

00-l 0



FOREWARD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire codetable will help you understand WIRING DIAGRAMS.Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Cable Current ratingO.D. (mm) (A)

Nominalnumber

0.85

2

5

Copper wire

Number of Dia. Of strandstrands (mm)

11 0.32

26 0.32

65 0.32

Applicable circuit

Starting, lighting, signal etc.

Lighting, signal etc.

Charging and signal

Starting (Glow plug)5 1 1 0.454 13.36 I 159.0

40 1 1 0.805 42.73 I ’351.4 Starting

60 1 1 0.8027 63.84 I 783.6 Starting

100 1 217 I 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Priority Lighting Instruments Signal 1 Otherlassification Circuits Charging Ground Starting

R Y1

Code W B BPrimary

Color White Black Black Red Yellow

RW YR2

Code

Color

Code

Color

Code

WR ___

White/Red --

WB ___

White/Black ---

WL _-

BW

Black/White

BY

BlXk/Yt?lOW

BR

Yellow/Red Green/White Bluewhite

RB

Red/Black

RY

YB

Yellow/Black

YG

3

GY I LY4

I Color I White/Blue I --- I Black/Red Red/Yellow Yellow/Green reenNellow BlueNellow

YL

Yellow/Blue

YW

RG

Red/Green

RL

6 Red/Blue Green/Blue I --

00 1



FOREWARD CONVERSION TABLES

CONVERSION TABLES

METHOD OF USING THE CONVERSION TABLEThe Conversion Table in this section is provided to enable simple conversion of figures. For details of the method ofusing 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 0, then draw a horizontal line from

0.(2) Locate the number 5 in the row across the top, take this as @, then draw a perpendicular line down from @.(3) Take the point where the two lines cross as 0. This point @ gives the value when converting from millimeters

to inches. Therefore, 55 millimeters = 2.165 inches.

2. Convert 550 mm into inches.(1) The number 550 does not appear in the table, so divide by IO (move the decimal one place to the left) 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 IO, so multiply 2.165 inches by IO (move the decimal one place

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

Millimeters to Inches1 mm = 0.03937 in

mm 0 1 2 3 4 50 6 7 8 9

0.039 0.079 0.118 0.157 0 197

IO 0.394 0.433 0.472 0.512 0.551 0 591

20 0.787 0.827 0.866 0.906 0.945 0 984

30 1.181 1.220 1.260 1.299 1.339 1.378

40 1.575 1.614 1.654 1.693 1.732 1.772

3 50 1.969 2.008 2.047

60 2.362 2.402 2.441

2.087 2.126

2.480 2.520

2.874 2.913

3.268 3.307

3.661 3.701

2.165

2.559

2.953

3.346

3.740

70 2.756 2.795 2.835

80 3.150 3 189 3.228

90 3.543 3.583 3.622

0.236

0.630

1.024

1.417

1.811

0

2.2052.598

2.992

3.386

3.780

0.276 0.315 0.354

0.669 0.709 0.748

1.063 1.102 1.142

1.457 1.496 1.536

1.850 1.890 1.929

2.244 2.283 2.323

2.638 2.677 2.717

3.032 3.071 3.110

3.425 3.465 3.504

3.819 3.858 3.898

00-l 2



FOREWARD CONVERSIONTABLES

Millimeterstolnches

1 mm=O O3937in

mm 0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0 118 0 157 0 197 0 236 0 276 0 315 0 354

10 0.394 0 433 0 472 0 512 0 551 0.591 0 630 0 669 0 709 0 748

20 0 787 0 827 0 866 0 906 0 945 0 984 1 024 1 063 1 102 1 142

30 1 181 1 220 1 260 1 299 1 339 1 378 1 417 1 457 1 496 1 536

40 1 575 1 614 1 654 1 693 1 732 1 772 1 811 1 850 1 890 1 929

50 1 969 2 008 2 047 2 087 2 126 2 165 2 205 2 244 2 283 2 323

60 2 362 2 402 2 441 2 480 2 520 2 559 2 598 2 638 2 677 2 717

70 2 756 2 795 2 835 2 874 2 913 2 953 2 992 3 032 3 071 3 110

80 3 150 3 189 3 228 3 268 3 307 3 346 3 386 3 425 3 465 3 504

90 3 543 3 583 3 622 3 661 3 701 3 740 3 780 3 819 3 858 3 898

Kilogramto Pound1 kg = 2 2046 lb

Tg 0 1 2 3 4 5 6 7 8 9

02 20 4 41

6 61 8 82 11 02 13 23 15 43 17 64 19 8410 22 05 24 25 26 46 28 66 30 86 33 07 35 27 37 48 39 68 41 89

20 44 09 46 30 48 50 50 71 51 91 55 12 57 32 59 53 61 73 63 93

30 66 14 68 34 70 55 72 75 74 96 77 16 79 37 81 57 83 78 85 98

40 88 18 90 39 92 59 94 80 97 00 99 21 101 41 103 62 105 82 108 03

50 110 23 112 44 114 64 116 85 119 05 121 25 123 46 125 66 127 87 130 07

60 132 28 134 48 136 69 138 89 141 10 143 30 145 51 147 71 149 91 152 12

70 154 32 156 53 158 73 160 94 163 14 165 35 167 55 169 76 171 96 174 17

80 176 37 178 57 180 78 182 98 185 19 187 39 189 60 191 80 194 01 196 21

90 198 42 200 62 202 83 205 03 207 24 209 44 211 64 213 85 216 05 218 26

00-l 3



FOREWARD CONVERSIONTABLES

Literto S Gallon

e = 0 26r

8

I U.S. Ga

90 1 2 3 4 5 6 7

0 0 0 264 0 528 0.793 1 057 1 321 1 585 1 849 2 113 2 378

10 2 642 2 906 3 170 3 434 3 698 3 963 4 227 4 491 4 755 5 019

20 5 283 5 548 5 812 6 076 6 340 6 604 6 869 7 133 7 397 7 661

30 7 925 8 189 8 454 8 718 8 982 9 246 9 510 9 774 10 039 10 303

40 10 567 10 831 11 095 11 359 11 624 11 888 12 152 12 416 12 680 12 944

50 13 209 13 473 13 737 14 001 14 265 14 529 14 795 15 058 15 322 15 586

60 15 850 16 115 16 379 16 643 16 907 17 171 17 435 17 700 17 964 18 228

70 18 492 18 756 19 020 19 285 19 549 19 813 20 077 20 341 20 605 20 870

80 21 134 21 398 21 662 21 926 22 190 22 455 22 719 22 983 23 247 23 511

90 23 775 24 040 24 304 24 568 24 832 25 096 25 361 25 625 25 889 26 153

Literto K Gallon

le = 0 21997 U K Gal

Q 1 2 3 4 5 6 7 8 9

0 220 0 440 0 660 0 880 1 100 1 320 1 540 1 760 1 980

10 2 200 2 420 2 640 2 860 3 080 3 300 3 520 3 740 3 950 4 179

20 4 399 4 619 4 839 5 059 5 279 5 499 5 719 5 939 6 159 6.379

30 6 599 6 819 7 039 7 259 7 479 7 699 7 919 8 139 8 359 8.579

40 8 799 9 019 9 239 9 459 9 679 9 899 10 119 10 339 10 559 10 778

50 10 998 11 281 11 438 11 658 11 878 12 098 12 318 12 528 12 758 12 978

60 13 198 13 418 13 638 13 858 14 078 14 298 14 518 14 738 14 958 15 178

70 15 398 15 618 15 838 16 058 16 278 16 498 16 718 16 938 17 158 17 378

80 17 598 17 818 18 037 18 257 18 477 18 697 18 917 19 137 19 357 19 577

90 19 797 20 017 20 237 20 457 20 677 20 897 21 117 21 337 21 557 21 777

00-I 4



FOREWARD CONVERSION TABLES

kgm to ft. lb1 kam = 7 233 t b

km

0

10

20

30

40

0 1 2 3 4 5 6 7 I 8 9

0 7 2 14 5 21 7 28.9 36 2 43 4 50 6 57.9 65 1

72 3 79 6 86 8 94 0 101 3 108 5 115 7 123 0 130 2 137 4

144 7 151 9 159 1 166 4 173 6 180 8 188 1 195 3 202 5 209 8

217 0 224 2 231 5 238 7 245 9 253 2 260 4 267 6 274 9 282 1

289 3 296 6 303 8 311 0 318 3 325 5 332 7 340 0 347 2 354 4

50 361 7 368 9 376 1 383 4 390 6 397 8 405 1 412 3 419 5 426 8

60 434 0 441 2 448 5 455 7 462 9 470 2 477 4 484 6 491 8 499 1

70 506 3 513 5 520 8 528 0 535 2 542 5 549 7 556 9 564 2 571 4

80 578 6 585 9 593 1 600 3 607 6 614 8 622 0 629 3 636 5 643 7

90 651 0 658 2 665 4 672 7 679 9 687 1 694 4 701 6 708 8 716 1

100 723 3 730 5 737 8 745 0 752 2 759 5 766 7 773 9 781 2 788 4

110 795 6 802 9 810 1 817 3 824 6 831 8 839 0 846 3 853 5 860 7

120 868 0 875 2 882 4 889 7 896 9 904 1 911 4 918 6 925 8 933 1

130 940 3 947 5 954 8 962 0 969 2 976 5 983 7 990 9 998 2 1005 4

140 1012 6 1019 9 1027 1 1034 3 1041 5 1048 8 1056 0 1063 2 1070 5 1077 7

150 1084 9 1092 2 1099 4 1106 6 1113 9 1121 1 1128 3 1135 6 1142 8 1150 0

160 1157 3 1164 5 1171 7 1179 0 1186 2 1193 4 1200 7 1207 9 1215 1 1222 4

170 1129 6 1236 8 1244 1 1251 3 1258 5 1265 8 1273 0 1280 1 1287 5 1294 7

180 1301 9 1309 2 1316 4 1323 6 1330 9 1338 1 1345 3 1352 6 1359 8 1367 0

190 1374 3 1381 5 1388 7 1396 0 1403 2 1410 4 1417 7 1424 9 1432 1 1439 4

00-l 5



kg/cm2 to lb/in2

kg/cm2

0

10

20

30

40

0 1 2 3 4 5 6

Ik

7 8 9

0 14 2 28 4 42 7 56 9 71 1 85 3 99 6 113 8 128 0

142 2 156 5 170 7 184 9 199 1 213 4 227 6 241 8 256 0 270 2

284 5 298 7 312 9 327 1 341 4 355 6 369 8 384 0 398 3 412 5

426 7 440 9 455 1 469 4 483 6 497 8 512 0 526 3 540 5 554 7

568 9 583 2 597 4 611 6 625 8 640 1 654 3 668 5 682 7 696 9

50 711 2 725 4 739 6 753 8 768 1 782 3 796 5 810 7 825 0 839 2

60 853 4 867 6 881 8 896 1 910 3 924 5 938 7 953 0 967 2 981 4

70 995 6 1010 1024 1038 1053 1067 1081 1095 1109 1124

80 1138 1152 1166 1181 1195 1209 1223 1237 1252 126690 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550

110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693

120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835

130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977

140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262

160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404

170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546

180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688

190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973

210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115

220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257

230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399

240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

:m2 14 22331b/in2

00-l 6



FOREWARD

Temperature

CONVERSION TABLES

Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa isto enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigradedegrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and readthe corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider thecenter column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.

“ “F C “F “C “F “ “F

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.226.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

I ( = 33.8”F

00 l 7



01 GENERAL

General assembly drawing (PC200-6, PC2OOLC-6, PC21OLC-6)General assembly drawing (PC22OLC-6, PC25OLC-6) .......Specifications (PC200-6, PC2OOLC-6) .....................Specifications (PC21 OLC-6) .............................Specifications (PC220LC-6) .............................Specifications (PC25OLC-6) .............................Weight table (PC200-6, PC200LC-6) ......................Weight table (PC21 OLC-6) ..............................Weight table (PC22OLC-6, PC25OLC-6) ...................Fuel, coolants and lubricants ............................

.......

.......

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.Ol- 2

.Ol- 4

.Ol- 7

.Ol- 9

. Ol- 11

. Ol- 13

. Ol- 15

. Ol- 17

. Ol- 19

. Ol- 21

01 l



PC200-6, PC200LC-6, PC21 OLC-6

XOlAD 24

Unit: mm



GENERAL GENERAL ASSEMBLY DRAWING

XOlAD025

Unit: mmI I I

A

PC200-6, PC2OOLC-6PC21 OLC-6

Maximum digging height

1.84m 2.4 m

8,895 9,050

Arms

* 2.93 m ** 4.06 m

9,305 9,700

B Maximum dumping height 6,065 6,255 6,475 6,970

C Maximum digging depth 5,535 6,095 6,602 7,725

I IMaximum vertical wallI

4,965I

5,315digging depth

5 980 I 7,075

I

E Maximum digging depth of 5,160 5,840 6,435 7,590cut for 8 ’ evel

F Maximum digging reach 8,915 9,395 9,875 10,880

G Maximum digging reach at 8,720 9,205 9,700 10,705ground

H Minimum swing radius 3,640 3,710 3,630 3,630

Bucket digging force *** + 14,900 kg

Arm crowd force *** 13,200 kg

* - PC21 OLC-6 available with only this arm** - 1 .I 3 m Extension + 2.93 m arm

12,700 kg 12,700 kg 12,700 kg

11,700 kg 10,000 kg 8,200 kg

*** - At power max’ - Optional bucket cylinder is required

01 3



GENERAL

PC22OLC-6, PC25OLC-6

GENERAL ASSEMBLY DRAWING

/F

XOlAD 24

Q Machine cab height 2,020 2,140

R Engine compartment height 2,255 2,375

S Operator’ s cab height 2,905 3,020

01 4




t

1

A

t

1XOlAD025

PC22OLC 6

2.0 m 2.5 m

Arms

Unit: mm

3.05 m 3.5 m

A Maximum digging height 9,070 9,150 9,380 9,620I I I I I

B 1 Maximum dumping height 1 6,120 I 6,215 I 6,515 6,720

D

Maximum digging depth

Maximum vertical walldigging depth

5,720 6,220 6,770 7,220

4,955 5,455 6,005 6,455

E Maximum digging depth of 5,550 6,170 6,440 7,210cut for 8 ’ evel

F

G

Maximum digging reach 9,285 9,655 10,180 10,625

Maximum digging reach at 9,090 9,470 10,000 10,460ground


I I I IBucket digging force * +I 6,700 kg 14,500 kg 14,500 kg 14,500 kg 1

Arm crowd force * 14,700 kg 13,600 kg

’ -At power max ’ - Optional bucket cylinder is required

11,900 kg 10,300 kg

01 5




XOIAD025

Unit: mm

PC25OLC6 Arms

I 2.0 m I 2.5 m I 3.05 m I 3.5 m I

A Maximum digging height 9,300 9,340 9,660 9,780

B Maximum dumping height 6,505 6,350 6,750 7,125

Maximum digging depth 5,610 6,105 6,650 7,105

Maximum vertical wall 4,930 5,055 5,860 6,165digging depth

Maximum digging depth of 5,380 5,895 6,475 6,950cut for 8 ’ evel

F Maximum digging reach 9,285 9,655 10,180 10,625

G Maximum digging reach at 9,035 9,445 9,980 10,385ground


Bucket digging force * +I 6,700 kg 14,500 kg 14,500 kg 14,500 kg

Arm crowd force * 14,700 kg 13,600 kg 11,900 kg 10,300 kg

’ -At power max ’ - Optional bucket cylinder is required

01 6



GENERAL SPECIFICATIONS

PC200-6, PC2OOLC-6

Machine Model

Serial numbers

Bucket capacity (m3)

Operating weight (kg)


Maximum vertical wall depth

Maximum digging reach

Maximum digging reach at ground level


Maximum dumping height

Maximum digging force (when using power max.)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(Wkg))

Swing speed

Swing maximum slope angle

(rpm)

(deg.)

Travel speed

Gradeability

(km/h)

(deg.)

Ground pressure I (standard triple shoe width: mm)

Overall length (for transport)

Overall width

Overall width of track

Overall height (for transport)

Overall height to top of cab

Ground clearance of counterweight

Minimum ground clearance

Tail swing radius

Minimum swing radius of work equipment

Height of work equipment at minimum swing radius

Length of track on ground

Track gauge

Height of machine cab

(MPa(kg/cm*))

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

PC200-6 PC2OOLC-6

A82001 and up A82001 and up

0.8 0.8

19,900 21,300

6,620 6,620

5,980 5,980

9,875 9,875

9,700 9,700

9,305 9,305

6,475 6,475

111.7 (11,400) 111.7 (11,400)(124.5 (12,700)) (124.5 (12,700))

11.5 11.5

20 20

Lo: 3.0 Mi: 4.1 Hi: 5.5 Lo: 3.0 Mi: 4.1 Hi: 5.5

35 35

0.045 (0.46) I(600) 0.037 (0.38) I(700)

9,425 9,425

2,800 2,800

2,780 3,080

2,970 2,970

2,905 2,905

1,085 1,085

440 440

2,750 2,750

3,630 3,630

7,570 7,570

3,270 3,348

2,180 2,380

2,255 2,255

01 7




Machine model

Serial numbers

Model

Type

No. of cylinders - bore x stroke

Piston displacement

(mm)

(cc)

Flywheel horsepower

Maximum torque

High idle in H/O mode

Low idle in H/O mode

Minimum fuel consumption ratio

(kW(HP)/rpm)

(Nm(kgmYrpm)

(rpm)

(rpm)

(g/kWh(g/HPh)

Cranking motor

Alternator

Battery

Type of radiator core

Carrier roller

Track roller

Track shoe

0i

2

a4$2

Type, number

Delivery (Plmin)

Set pressure (MPa(kg/cm’ ))

Type, number

Control method Hydraulic type

Travel motor

Swing motor

Hydraulic cylinder

Hydraulic tank

Hydraulic filter

Hydraulic cooler

PC200-6 PC2OOLC-6


S6D102-1

Ccycle, water-cooled, in-line, vertical, direct injection,with turbocharger

6-102x120

5,880

108.1 (145) / 2,200

576.6 (58.8) / 1,600

2130?60

1066?60

210 (155)

24 V, 5.5 kW

24V,45A

12V, 150Ahx2

cwx-4

~

Variable displacement piston type x 2,gear type x 1

Piston type: 206 x 2

gear type: 30

Piston type: 34.79 (355)gear type: 3.33 (34)

6-spool type x 1

Piston type (with brake valve, parking brake) x 2

Piston type (with safety valve, parking brake) x 1

Reciprocating piston

Box-shaped, open

Tank return side

Air cooled (SF-3)

01 8




PC21 OLC-6

Machine Model

Serial numbers

Bucket capacity

Operating weight

(m’ )

(kg)








(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(Wkg))

Swing speed (rpm)

Swing maximum slope angle (deg.)

Travel speed

Gradeability

(km/h)

(deg.)



Overall width




Ground clearance of countenveight


Tail swing radius




Track gauge


(MPa(kg/cm’ ))

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

PC21 OLC-6

A82001 and up

0.8

23,210

6,620

5,355

9,875

9,700

9,180

6,475

111.7 (11,400)(124.5 (12,700))

11.5

20

Lo: 3.0 Mi: 4.1 Hi: 5.5

35

0.053 (0.54) I(600)

9,515

2,800

3,080

2,970

2,905

1,085

440

2,750

3,630

7,570

3,646

2,380

2,255

01-9



Machine model

Jlodel

fype

\lo. of cylinders - bore x stroke

‘ iston displacement

(mm)

(cc)

Flywheel horsepower

Maximum torque


Low idle in HI0 mode


(kW(HP)lrpm)

(Nm(kgmYrpm)

(rpm)

(rpm)

(g/kWh(glHPh)

Zranking motor

Uternator

3attery


Carrier roller

PC21 OLC-6

A82001 and up

S60102-1

Qcycle, water-cooled, in-line, vertical, direct injection,with turbocharger

6-102x120

5,880

108.1 (145) / 2,200

576.6 (58.8) I 1,600

2130?60

1066?60

210 (155)

24 V, 5.5 kW

24V,45A

12V, 150Ahx2

cwx-4

2 on each side

Track roller 9 on each side

Track shoe Assembly-type triple grouser


Type, number

Delivery (Plmin)


Type, number

Travel motor

Swing motor

iydraulic cylinder

-hydraulic tank

tiydraulic filter

Hydraulic cooler

Piston type: 206 x 2gear type: 30


7-spool type x 1

Hydraulic type




Box-shaped, open

Tank return side

Air cooled (SF-3)

01 10




PC220LC-6

Machine Model

Serial numbers









(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

Maximum digging force (when using power max.) (Wkg))

Swing speed


Travel speed

Gradeability

Ground oressure I (standard triple shoe width: mm)

(rpm)

(deg.)

(km/h)

(deg.)

(MPa(kg/cm’ ))


Overall width






Tail swing radius




Track gauge

Heiaht of machine cab

(mm)

0-W

(mm)

G-4

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

PC22OLC6

A82001 and up

1 o

23,550

6,920

6,010

10,180

10,000

9,380

6,515

130.3 (13,300)(142.1 (14,500))

11.5

17.5

Lo: 3.0 Mi: 4.1 Hi: 5.5

35

0.040 (0.41) / (700)

9,780

3,280

3,280

3,160

2,905

1,085

440

2,860

3,860

7,760

3,830

2,580

2,255

01 11




Machine model

Serial numbers

Model

Type

No. of cylinders - bore x stroke

Piston displacement

(mm)

(cc)

Flywheel horsepower

Maximum torque


Low idle in H/O/ mode


(kW(HP)/rpm)

(Nm(kgm)/rpm)

(rpm)

(rpm)

(g/kWh(g/HPh)

Cranking motor

Alternator

Battery


Carrier roller

PC22OLC-6

A82001 and up

SAGDI 02-I


6-102x120

5,880

129.8 (174) I 2,300

624.7 (63.7) I 1,500

2300 f 60

1066*60

212 (156)

24 V, 5.5 kW

24V,45A

12V, 150Ahx2

cwx-4

2 on each side




Type, number

Delivery (Plmin)

Set pressure (MPa(kg/cm*))

Type, number

Travel motor

Swing motor

Hydraulic cylinder

Hydraulic tank

Hydraulic filter

Hvdraulic cooler



6-spool type x 1

Hydraulic type




Box-shaped, open

Tank return side

Air cooled (SF-3)

01 12




PC25OLC-6

Machine Model

Serial numbers










(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(Wkg))

Swing speed


Travel speed

Gradeability



Overall width






Tail swing radius




Track gauge


(rpm)

(deg.)

(km/h)

(deg.)

(MPa(kg/cm*))

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

(mm)

PC25OLC-6

A82001 and up

1.0

27,500

6,650

6,580

10,180

9,980

9,660

6,750

130.3 (13,300)(142.1 (14,500))

11.5

17.5

Lo: 2.2 Mi: 4.1 Hi: 5.1

35

0.045 (0.46) I(700)

9,780

3,290

3,290

3,250

3,050

1,205

500

2,860

3,860

7,880

3,945

2,580

2,375

01 13




Machine model

Serial numbers

Vlodel

Type

Vo. of cylinders - bore x stroke

‘ iston displacement

(mm)

(cc)

Flywheel horsepower

Maximum torque

High idle in H/O/ mode



(kW(HP)/rpm)

(Nm(kgmYrpm)

(rpm)

(rpm)

(glkWh(glHPh)

Cranking motor

Alternator

3attery


Carrier roller

cwx-4

2 on each side



Type, number

Delivery (Plmin)


Type, number

Travel motor

Swing motor

Hydraulic cylinder

Hydraulic tank

Hydraulic filter

Hydraulic cooler

f

PC25OLC-6

A82001 and up

SAGDI 02-I


6-102x120

5,880

129.8 (174) I 2,300

624.7 (63.7) / 1,500

2300 f 60

1066?60

212 (156)

24 V, 5.5 kW

24V,45A

12V, 150Ahx2




6-spool type x 1

Hydraulic type




Box-shaped, open

Tank return side

Air cooled (SF-3)

01 14



GENERAL WEIGHT TABLE

PC200-6, PC2OOLC-6

Machine model

Serial number

Engine assembly

Engine

Damper

Hydraulic pump

Radiator oil cooler assembly

Hydraulic tank ilter assembly (excl. oil)

Fuel tank assembly (excl. fuel)

Revolving frame

Operator’ s cab

Operator’ s seat

Counterweight

Swing machinery

Control valve

Swing motor

Travel motor

Center swivel joint

Track frame assembly

Track frame

0 Swing circle

Idler

Idler cushion

Carrier roller

Track roller

Travel motor inal drive

Track shoe assembly

Standard triple grouser shoe (600 mm)


Wide triple grouser shoe (800 mm)


PC200-6

A82001 and up

684

480

6

142

144

133

114

1,637

287

29

3,280

205

230

9

123x2

42

4,666

2,374

276

140x2

135x2

21 x4

38x14

425x2

Unit: kg

PC2OOLC-6

A82001 and up

684

48

6

142

144

133

114

1,637

287

29

3,280

205

230

9

123x2

42

5,308

2,864

276

140x2

135x2

21 x4

38x18

425x2

1,310x2 1,425 x 2

1,435x2 1,565 x 2

1,565 x 2 1,705x2

1,690 x 2 1.840x2

01 15




Boom assembly

Arm assembly

Bucket assembly

Boom cylinder assembly

Arm cylinder assembly

Bucket cylinder assembly

Link (large) assembly

Link (small) assembly

Boom pin

Arm pin

Bucket pin

Link pin

Machine model

Serial number

Unit: kg

PC200-6 PC2OOLC-6


1,334 1,334

620 620

623 623

187x2 187x2

251 251

155 155

78 78

22x2 22x2

43+10x2+25+10+20 43+10x2+25+10+20

10x2 10x2

20x2 20x2

13x2 13x2

01 16




PC21 OLC-6

Machine model PC21 OLC-6

Unit: kc

Serial number I A82001 and up

Engine assembly I 685

Engine 480

Damper 6

Hydraulic pump 142

Radiator oil cooler assembly I 144

Hydraulic tank ilter assembly (excl. oil) I 133

Fuel tank assembly (excl. fuel) 114

Revolving frame 1,982

Operator’ s cab

Operator’ s seat

Counterweight

290

29

4,730

Swing machinery 205

Control valve

Swing motor

Travel motor

230

I 9

123x2


Track frame

0 Swing circle

Idler

Idler cushion

0 Carrier roller

Track roller


Track shoe assembly





Center swivel joint 42

5,318

2,870

280

140x2

135x2

21 x4

38x18

425x2

1,425 x 2

1,565 x 2

_

-

01 17




Machine model I PC21 OLC-6 I

Serial number A82001 and up

Boom assembly

Arm assembly

Bucket assembly

Boom cylinder assembly

753

187x2

Arm cylinder assembly

Bucket cylinder assembly

251

155

Link (large) assembly 78

Link (small) assembly 22x2

Boom pin 43+10x2+32+10+26

Arm pin 10x2

Bucket pin

Link pin 13x2

01 18




PC22OLC-6, PC250LC-6

Machine model

Serial number

Engine assembly

Engine

Damper

Hydraulic pump

Radiator oil cooler assembly

Hydraulic tank ilter assembly (excl. oil)

Fuel tank assembly (excl. fuel)

Revolving frame

Operator’ s cab

Operator’ s seat

Counterweight

Swing machinery

Control valve

Swing motor

Travel motor

Center swivel joint


Track rame

0 Swing circle

Idler

Idler cushion

0 Carrier roller

Track roller


Track shoe assembly





PC220LC-6

A82001 and up

699

495

6

142

163

133

114

1,965

287

29

4,300

205

230

9

123x2

42

5,809

3,286

280

140x2

135x2

21 x4

38x20

425x2

Unit: kg

PC25OLC-6

A82001 and up

699

495

6

142

163

133

114

1,910

287

29

4,730

205

230

9

123x2

42

7,682

4,312

716

166x2

257x2

31 x4

52x16

426x2

1480x2 3,730 x 2

1,625 x 2 4,090 x 2

1,770 x 2 4,455 x 2

_ _

01 19




Machine model PC22OLC-6

Unit: kg

PC25OLC-6

Boom assembly

Serial number A82001 and up

1,627

A82001 and up

1,627

Arm assemblv I 710 I 710

Bucket assembly

Boom cvlinder assemblv

747 747

215x2 215x2

Arm cylinder assembly 296 296

Bucket cylinder assembly 183 183

Link (large) assembly

Link (small) assembly

80 80

22x2 22x2

Boom pin

Arm pin

51 +10x2+31 +10+26 51 +10x2+31 +10+26

10x2 10x2

Bucket pin

Link pin

20x2 20x2

17x2 17x2

01-20



GENERAL FUEL, COOLANTS AND LUBRICANTS

AMBIENT TEMPERATURE CAPACITY @‘ )RESERVOIR KIND OF

FLUID Specified Refill22 -4 14 32 50 68 86 104°F-30 -20 -10 0 10 20 30 40°C

Engine oil pan 23.5 22.5

Damper case

Swing machinery case 6.8 6.8

6.3 5.5PC25OLC-6 PC25OLC-6

8.0 7.4Final drive case (each) Engine oil

0.07 - 0.08 0.07 - 0.08

0.19 - 0.21 0.19 - 0.21

Idler (each)

Track roller (each)

0.23 - 0.25 0.23 - .025arrier roller (each)

Pc200,Pc210239

Hydraulic system PC22O,PC250246

166

Fuel tank Diesel fuel 310_

Pc200,Pc21022.6

Coolant See “ Coolant” on page 01-23_

Cooling systemPC22O,PC250

22.8

SPECIFIED CAPACITY: Total amount of oil including oil for components and oil in piping.REFILL CAPACITY: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM:SAE:API:

American Society of Testing and MaterialSociety of Automotive EngineersAmerican Petroleum Institute

REMARK

0 When fuel sulphur content is less than OS%, change the engine oil at the normal periodic maintenanceinterval described in the Operation and Maintenance Manual.Change engine oil according to the following table if fuel sulphur content is above 0.5%.

Fuel sulphur content Change interval of oil inengine oil pan

0.5 to 1 .O%

Above 1 .O%

% of regular interval

1/4of regular interval

01 21



GENERAL FUEL, COOLANTS AND LUBRICANTS

OIL

0 When starting the engine in an atmospheric temperature of lower than 0°C (32°F) be sure to use anengine oil grade of SAE 1 OW, SAE 1 OW-30, or SAE 15W-40, even though the atmospheric temperaturegoes up to 10°C (50°F) more or less in the day time.

0 We recommend genuine Komatsu oil which has been specifically formulated and approved for use inengine and hydraulic work equipment application.

Oil performance recommendations are as follows:

The use of a quality engine lubricating oil combined with appropriate oil and filter change intervals arecritical factors in maintaining engine performance and durability.SAE 15W-40 multi-viscosity oil meeting the American Petroleum Institute (API) performance classificationof CE or CF-4 is recommended.NOTE: CD or CD/SF oils may be used with the interval given in the maintenance schedule in areas whereCE or CF-4 is not yet available.A sulfated ash limit of 1 .O mass percent is suggested for optimum valve and piston deposit and oil con-sumption control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higherash oils can cause valve and/or piston damage and lead to excessive oil consumption.The API service symbol displays the appropriate oil categories; the lower half may contain words to describeoil energy conserving features. The center section identifies the SAE oil viscosity grade.

Oil viscosity recommendations are as follows:

The use of multi-graded lubricating oil has been found to improve oil consumption control and improveengine cranking in cold temperatures while maintaining lubrication a high operating temperatures.While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previouschart for oil viscosity recommendations for extreme climates.NOTE: Single graded oils may be used if multi-graded oil is not available, but be sure to use oil that

matches the temperature in the table.Special “ break-in” lubricating oils are not recommended for a new or rebuilt engine. Use the same typeof oil during the “ break-in” as specified for normal operation.

Additional information regarding lubricating oil availability throughout the world is available in the “ E.M.A.Lubricating Oils Data Book For Heavy Duty Automotive and Industrial Engines.” The data book may beordered from the Engine Manufacturers Association, 401 North Michigan Avenue, Chicago, IL U.S.A. 60611.The telephone number is (312) 644-6610.

ARCTIC OPERATIONIf an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there is no provisionsto keep the engine warm when it is not in operation, use a synthetic API performance oil classification CE orCF-4 engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30.The oil supplier must be responsible for meeting the performance service specifications.

IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oilchange intervals can decrease engine life due to factors such as; corrosion, deposits and wear.

01-22



River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to theengine and radiator, and this will decrease heat exchange and cause overheating.Water should meet the following guidelines.

Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scaledeposits. Water containing dissolved magnesium and calcium (the usual reason for waterhardness) above the specified amount will cause scale deposits to develop in the engine.

Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.

Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion.

Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimizesludge deposits, scale deposits, corrosion or a combination of these.

If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. Todetermine if local water supplies meet these standards, water samples can be tested by water treatmentlaboratories. “ Softened” water that is prepared using common salt (sodium chloride) contains excessiveamounts of chlorides and should not be used.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine isshipped.This anti-freeze is effective in preventing corrosion of the cooling system.The anti-freeze can be used continuously for two years or 2000 hours. Therefore, it can be used as is evenin hot areas.

Anti-freeze is inflammable, so be extremely careful not to expose it to flame or fire.

The proportion of anti-freeze to water differs according to the ambient temperature.For details of the mixing proportions, see the Operation and Maintenance Manual.

If the engine overheats, wait for the engine to cool before adding coolant.

If the coolant level is low, it will cause overheating and will also cause problems with corrosion from the air inthe coolant.

01 23



10 STRUCTURE AND FUNCTION

Enginerelatedparts ....................................................................... IO -2Radiator, oil cooler, aftercooler .............................................................. 10 -3Powertrain ............................................................................... 10 -4Finaldrive ................................................................................ 10 -5Swingcircle .............................................................................. 10 -7Swingmachinery .......................................................................... IO -8Track frame, recoil spring ................................................................... IO -9Trackshoe ............................................................................... IO -10 Hydraulic piping drawing .................................................................... IO -13 Hydraulic circuit diagram .................................................................... 10 -14 Hydraulictank ............................................................................ 10 -15 Hydraulicpump ........................................................................... IO -16 Controlvalve ............................................................................. IO -38 CLSS ................................................................................... 10 -47 Swingmotor .............................................................................. IO -92 Centerswiveljoint ......................................................................... 10 -95 Travelmotor ............................................................................. 10 -96

Valvecontrol ............................................................................. IO-107Work Equipment, Swing PPC valve ........................................................... 1 O-l 08 TravelPPCvalve .......................................................................... IO-112ServicePPCvalve.. ....................................................................... IO-116 Safetylockvalve .......................................................................... IO-119PPCaccumulator ......................................................................... IO-119PPC shuttle, Travel junction valve ............................................................ 1 O-120 EPC,Solenoidvalve ....................................................................... IO-127Hydrauliccylinder ......................................................................... IO-135 Additional filter for breaker .................................................................. 1 O-l 36Overloadwarningdevice .................................................................... IO-137Hose burst protection valve (boom) ........................................................... 1 O-141Workequipment .......................................................................... IO-144Electrical circuit diagram .................................................................... 1 O-l 45Engine control system ...................................................................... 1 O-l 49Electronic control system ................................................................... 1 O-l 54 Machine monitor system .................................................................... 1 O-l 79

1 l



STRUCTURE AND FUNCTION ENGINE RELATED PARTS

ENGINE RELATED PARTS

A-A 6 7 8

B-B c-c D-D E-E

1. Drive plate2. Torsion spring3. Stopper pin4. Friction plate5. Damper assembly6. Air cleaner7. Intake connector8. Muffler9. Rear engine mount

10. Front engine mount

OUTLINEThe damper assembly is a wet type.Oil capacity: 0.75 P

X12AD046

1o-2



STRUCTURE AND FUNCTION RADIATOR. COOLER. AFTERCOOLER

RADIATOR. OIL COOLER. AFTERCOOLER5 6

1. Reservoir tank2. Oil cooler3. Radiator4. Fan5. Radiator inlet hose6. Radiator outlet hose7. Radiator cap8. Net9. Shroud

SPECIFICATIONSRadiator: CWX4Oil cooler: SF-3

1 o-3



STRUCTURE AND FUNCTION POWER TRAIN

POWER TRAIN

6

1. Idler 7. Engine2. Center swivel joint 8. Travel speed solenoid valve3. Control valve 9. Swing brake solenoid valve4. Final drive 10. Swing motor5. Travel motor 11. Swing machinery6. Hydraulic pump 12. Swing circle

l X 7HH 27

1o-4



STRUCTURE AND FUNCTION FINAL DRIVE

FINAL DRIVEPCXOLC-6

I. Level plug2. Drain plug3. No. 1 sun (13 teeth)ear4. No. 2 sun (19 teeth)ear5. Cover6. No. 2 planet (30 teeth)ear7. No. 2 ring (80 teeth)ear8. Spacer9. No. 1 ring (80 teeth)ear

10. No. 1 planet (33 teeth)ear11. Sprocket12. Floating seal13. Travel motor14. Hub15. Retainer16. No. 1 planetary carrier17. No. 2 planetary carrier

SPECIFICATIONS

Reduction ratio:

- (y ) X (y ) + I= -36.275

ii

SectionA A

X 7HH 29

IO 6



STRUCTURE AND FUNCTION SWING CIRCLE

SWING CIRCLE

-_-_-P

L

bmA-A

I ‘ iY-----*-----.

1. Swing circle inner race (110 teeth)2. Ball3. Swing circle outer race (115 teeth)

a. Inner race soft zone S positionb. Outer race soft zone S position

/

2

/8’

I *w \-_-..d’ 3

L_-.-._._J

I

/ I

B-8

X09DD022

PC200-6, PC2OOLC-6 PC25OLC-6SPECIFICATIONS PC21 OLC-6, PC220LC-6

Reduction ratio 110/115=7.333

Amount of grease 21 P (G2-Ll) 1 34P(G2-Ll) 1

1o-7



SWING MACHINERY

XOSDH 24

1. Swing pinion (15 teeth)2. Cover3. Case4. No. 2 planetary carrier5. No. 2 sun (15 teeth)ear

6. No. 2 ring (72 teeth)ear7. Case8. No. 1 ring (72 teeth)ear9. No. 1 sun (21 teeth)ear

10. Oil level gauge12. Cover13. No. 1 planetary (25 teeth)ear14. No. 1 planetary carrier15. Coupling16. No. 2 planetary (28 teeth)ear17. Drain plug

SPECIFICATIONS

(=$)X( 7) = 25.686

IO 8



STRUCTURE AND FUNCTION TRACK FRAME. RECOIL SPRING

TRACK FRAME. RECOIL SPRING

A A

1. Idler2. Track frame3. Carrier roller4. Final drive5. Track roller6. Track shoe7. Center guard8. Recoil spring9. Front guard

X14AH022

The dimensions and number of track rollers maydiffer according to the model, but the basic struc-ture is the same.No. of track rollers

Model No. of rollers (each side)

PC200-6

PC2OOLC-6PC21 OLC-6

9

PC22OLC-6 I IO

PC25OLC-6 I 8

-9



TRACK SHOE

STANDARD SHOE

Item Model PC200-6 PC200LC-6 PC21 OLC-6 PC22OLC-6 PC250LC-6-

Shoe width (triple shoe) 600 mm 700 mm600 mm 700 mm 700 mm

Link pitch 190 mm 190 mm 190 mm 190 mm 203 mm

No. of rollers (each side) 45 49 49 51 50

SELECTION OF TRACK SHOESelect the most suitable track shoe from the following table.

Standard

PC2004 PC220LC-6 PC21 OLC-6 PC22OLC-6, PC25OLC-6

Specifications Category Specifications Category Specifications Category Specifications Category

Option 600 mm triple A 600 mm triple A 600 mm triple A 600 mm triple AOption

Option

-

700 mm triple B 700 mm triple 0 - - 700 mm triple B

800 mm triple C 800 mm triple C - - 800 mm triple C

- - 900 mm triple C - - - -

IO IO



Category Use Precautions when using

A Rocky ground, normal river Travel in Lo speed when traveling on rough ground withsoil obstacles such as large boulders and fallen trees.

B Cannot be used on rough ground where there are largeNormal soil, soft land obstacles such as boulders and fallen trees.

Travel in Hi speed only on flat ground, and when it is impossibleto avoid traveling obstacles, lower the travel speed to approx. halfof Lo speed.

Use only for ground where “ A” and “ B” sink and are impossibleto use.

Extremely soft ground Cannot be used on rough ground where there are large(swampy ground) obstacles such as boulders and fallen trees.

Travel in Hi speed only on flat ground, and when it is impossibleto avoid traveling obstacles, lower the travel speed to approx. halfof Lo speed.

* Categories “ B” and “ C” are wide shoes, so there Sr When selecting the shoe width, select the nar-are restrictions on their use. Therefore, before rowest shoe possible within the range that willusing, check the restrictions and consider care- give no problem with floatation and ground

fully the conditions of use before recommending pressure.a suitable shoe width. If necessary, give the cus- If a wider shoe that necessary is used, there will

tomer guidance in their use. be a large load on the shoe, and this may lead tobending of the shoe, cracking of the links, break-

age of the pins, loosening of the shoe bolts, orother problems.

IO 11



HYDRAULIC PIPING DIAGRAMPC200-6, PC200LC-6PC21 OLC-6, PC22O LC-6PC250LC-6

FOLDOUT I

1. Bucket cylinder2. Arm cylinder3. Boom cylinder4. Hydraulic tank5. LS control EPC valve6. Hydraulic filter7. Filter (for breaker)8. Swing motor9. R.H. travel motor

10. Hydraulic pump11. Control valve12. PPC shuttle. travel junction valve13. Oil cooler14. L.H. travel motor15. Arm holding valve16. Boom holding valve17. PPC safety valve18. L.H. PPC valve19. R.H. PPC valve20. Center swivel joint‘)- Travel PPC valveI

22,23,24

Service PPC valveAccumulatorSolenoid valve

25.26.27.

‘14

24A. LS select solenoid valve24B. 2-stage relief solenoid valve24C. Pump merge-divid er solenoid

valve24D. Travel speed solenoid valve24E. Swing brake solenoid valveL.H. hose burst valveR.H. hose burst valveTiming valve

24c240//

24E

I O- 13



HYDRAULIC CIRCUIT DIAGRAM (2/2)PC250LC-6 TRAVEL MOTOR

150. 3 / 280.0 cc/rev

-....-JOINT

i I

-i i k(B)i ’

I I ‘ go3 j#O,: L,,

/________ ______ --,--,,,,,--,-,A,,

L----_~~-_~~~--~~~-~~-~~-~ -_ s - w I t

P

(B)

10 14 I



STRUCTURE AND FUNCTION HYDRAULIC TANK

HYDRAULIC TANK

1. Hydraulic tank2. Bypass valve3. Oil filler cap4. Sight gauge5. Hydraulic oil level sensor6. Suction strainer7. Filter element

6

7X10BV049

SPECIFICATIONSTank capacity: 230 PAmount of oil inside tank: 166 PPressure valveRelief cracking pressure: 0.017 f 0.004 MPa

(0.17 f 0.04 kg/cm?Suction cracking pressure: 0 - 0.0005 MPa

(0 - 0.005 kg/cm?Bypass valve set pressure: 0.103 f 0.02 MPa

(1.05 f 0.2 kg/cm?

IO 15



STRUCTURE AND FUNCTION HYDRAULIC PUMP

HYDRAULIC PUMP

/6

a. Pump drain port PDFb. Front delivery port PAFc. Rear delivery port PARd. Control pump suction port PGSe. Control pump delivery port PGAf. Front LS pressure port PLSFg. Rear LS pressure port PLSR

h. LS control EPC pressure port PSIGRi. Main pump suction port PSj. LS control EPC pressure port PSIGF

b d

i i

XlOAV240

1 Front main pump2. Rear main pump3. Control relief valve4. Rear TVCoLS valve5. Front TVCoLS valve6. Control pump

IO 16




1. MAIN PUMP (HPV95+95)

b

Z

fl”0

f

0

o”aOfjf $O) 0 0

0 00 00

0’

u23

0

XlOAV24

a. Pump drain port PDFb. Front delivery port PAFc. Rear delivery port PARd. Front control pressure port PANFe. Rear delivery pressure port PAZRf. Front delivery pressure port PAZFg. Rear delivery pressure port PA1 Rh. Rear control pressure port PENRi. Suction port PSj. Front delivery pressure port PA1 F

IO 17




OPERATION1. Operation of pump

1) Cylinder block (7) rotates together with shaft(I), and shoe (5) slides on flat surface A.When this happens, rocker cam (4) movesalong cylindrical surface B, so angle a

etween center line X of rocker cam (4) and

the axial direction of cylinder block (7)changes. (Angle a is called the swashplate angle.)

XlOAV 4

2) Center line X of rocker cam (4) maintainsswash plate angle a in relation to the axialdirection of cylinder block (7), and flat sur-face A moves as a cam in relation to shoe(5).

In this way, piston (6) slides on the inside ofcylinder block (7), so a difference betweenvolume E and F is created inside cylinderblock (7). The suction and discharge is car-ried out by this difference F - E.In other words, when cylinder block (7) ro-tates and the volume of chamber E be-comes smaller, the oil is discharged duringthat stroke. On the other hand, the volumeof chamber F becomes larger, and as the

volume becomes bigger, the oil is suckedin.

7 E

3) If center line X of rocker cam (4) is in linewith the axial direction of cylinder block (7)(swash plate angle = 0), the difference be-tween volumes E‘ and F‘ inside cylinderblock (7) becomes 0, so the pump does notcarry out any suction or discharge of oil. (Inactual fact, the swash plate angle never be-comes 0.)

XlOAV 43

XlOAV 44

IO 18




2. Control of discharge amount

If swash plate angle CI become larger, the differ-ence in volumes E and F becomes larger anddischarge volume Q increases.

0 Swash plate angle c( is changed by servo piston(12).

0 Servo piston (12) moves in a reciprocal move-ment (++) according to the command from theTVC 0 LS valve.This straight line movement is transmittedthrough rod (13) to rocket cam (4), and rockercam (4), which is supported by the cylindricalsurface to cradle (2), moves in a swinging move-ment on the cylindrical surface in ($ direction).

X10AV245

With servo piston (12), the area receiving the pres-sure is different on the left and right, so mainpump discharge pressure (self-pressure) PP is al-ways connected to the chamber receiving thepressure on the small diameter piston side (theself-pressure is brought in).Output pressure PEN of the LS valve is broughtto the chamber receiving the pressure at the largediameter piston end.The relationship in the size of self-pressure PPand the pressure at the small diameter piston end,and the ratio between the area receiving the pres-sure of the small diameter piston and the large

diameter piston controls the movement of theservo piston (12).

IO 19




1. Front shaft2. Cradle3. Front case4. Rocker cam5. Shoe6. Piston

A A

B B

7. Cylinder block8. Valve plate9. End cap

10. Rear shaft11. Rear case12. Servo piston

XlOAV246

1O-20




Splinh 1‘ 2 Spline

XlOAV ‘ 47

FUNCTION

The engine rotation and torque transmitted tothe pump shaft is converted into hydraulic en-ergy, and pressurized oil is discharged acc-ding to the load.It is possible to change the delivery amount bychanging the swash plate angle.

STRUCTURE

Piston (6) carries out relative movement in the

axial direction inside each cylinder chamber ofcylinder block (7).The cylinder block seals the pressure oil to valveplate (8) and carries out relative rotation. Thissurface is designed so that the oil pressure bal-ance is maintained at a suitable level.The oil inside each cylinder chamber of cylinderblock (7) is sucked in and discharged through

Cylinder block (7) is supported to shaft (1) by aspline, and shaft (1) is supported be the frontand rear bearings.The tip of piston (6) is a concave ball, and shoe(5) is caulked to it to form on unit. Piston (6)

and shoe (5) form a spherical bearing.Rocker cam (4) has a flat surface A, and shoe(5) is always pressed against this surface whilesliding in a circular motion.Rocker cam (4) brings high pressure oil at cylin-drical surface B with cradle (2), which is securedto the case, and forms a static pressure bearingwhen it slides.

valve plate (8).

IO 21



STRUCTURE AND FUNCTIONHYDRAULIC PUMP

2. TVC . LS VALVE

d\

a. Port PA2 (Pump delivery pressure inlet port)b. Port PEN (n/C LS valve signal pressure

outlet port)C Port PA1 (Pump delivery pressure inlet port)

d. Port PLS (Control valve LS pressure inlet port)e. Port PSIG (LS control EPC valve pressure inlet

port)

1 o-22




LS VALVE1. Locknut2. Plug3. Spring4. Spool5. Sleeve6. Piston7. Plug

A-A

1 2 3 4 5 6 7

B-B

TVC VALUE8. Solenoid9. Piston

10. Sleeve11. Spring12. Spring13. Piston14. Lever15. Valve body

XlOAV 49

IO 23




FUNCTION1.0

2.

LS VALUEThe LS valve detects the load and controls thedischarge amount.This valve controls the main pump discharge amountQ according to the differential pressure A PLS (=PP -PLS) (the difference between main pump pressure

PP and control valve outlet port pressure PLS){called the LS differential pressure}.Main pump pressure PP, pressure PLS {called theLS pressure} coming from the control valve output,and pressure PSIG {called the LS selection pressure}from the proportional solenoid valve enter this valve.The relationship between discharge amount Q anddifferential pressure A PLS, (the difference betweenmain pump pressure PP and LS pressure PLS)(=PP - PLS) changes as shown in the diagram on

right according to LS selector pressure PSIG.When PSIG changes between 0 and 2.94 MPa (0and 30 kg/cm?, the spool load changes accordingto this, and the selector point for the pump dischargeamount changes at the rated central value between0.64 and 2.11 MPa (6.5 and 21.5 kg/cm?.

a

EzEm

PSIG = 2.94 MPa (30 kg/cm?\

PSIG = 0 MPa (0 kg/cm*)

?i?. I I

I I0.64 (6.5) 2.11 21.5) (MPa (kg/cm211

LS differential pressure A PLS

XlOAV2

NC VALUEWhen the pump discharge pressure PPI (self-pressure) and PP2 (other pump pressure) are high,the NC valve controls the pump so that no more oilthat the constant flow (in accordance with the dis-charge pressure) flows even if the stroke of thecontrol valve becomes larger. In this way it carriesout equal horsepower control so that the horsepowerabsorbed by the pump does not exceed the enginehorsepower.In other words, if the load during the operationbecomes larger and the pump discharge pressurerises, it reduces the discharge amount from thepump; and if the pump discharge pressure drops,it increases the discharge amount from the pump.The relationship between the average of the frontand rear pump discharge pressures (PPI + PP2)/2and pump discharge amount Q is shown on theright, with the current given to the NC valve solenoidshown as a parameter. However, in the heavy-dutyoperation mode, there are cases where it is given thefunction of sensing the actual speed of the engine,and if the speed drops because of an increase in the

load, it reduces the pump discharge amount to allowthe speed to recover. In other words, when the loadincreases and the engine speed drops below the setvalue, the command to the TVC valve solenoid fromthe controller increases according to the drop in theengine speed to reduce the pump swash plate angle.

L

Pump discharge pressure PP

XlOAV

1 o-24




OPERATION1.1)

LS VALVEWhen control valve is at neutral position

lfrom outlet port of

controialve)

(from LS control

J valve)

9(Direction of minimum discharge)

The LS valve is a three-way selector valve, withpressure PLS (LS pressure) from the outlet portof the control valve brought to spring chamber i,and main pump discharge pressure PP brought tochamber j of plug (6). The size of this LS pressurePLS + force F of spring (3) and the main pump pres-sure (self pressure) PP determines the position ofspool (4). However, the size of the output pressure

PSIG (the LS selection pressure) of the EPC valvefor the LS valve entering port e also changes the pos-ition of spool (4). (The set pressure of the springchanges.)Before the engine is started, servo piston (1) is pushedto the right by the spring (7) installed to rod (2). (Seethe diagram on the right)When the engine is started and the control lever is atthe neutral position, LS pressure PLS is 0 MPa(0 kg/cm?. (It is interconnected with the drain circuitthrough the control valve spool.)

XlOAV 5

A-AXlOAV253

At this point, spool (4) is pushed to the left, andport d and port c are connected. Pump pressurepp enters the large diameter end of the pistonfrom port h, and the same pump pressure ppalso enters the small diameter end of the piston,so the swash plate is moved to the minimumangle by the difference in area of piston (1).

1 o-25




2) Operation in maximum direction for pump discharge amount

Small diameter end

(Direction of maximum discharge) XlOAV254

When the difference between main pump pressurePP and LS pressure PLS, in other words, LS differ-ential pressure A PLS, becomes smaller (for ex-ample, when the area of opening of the controlvalve becomes larger and pump pressure PP drops),spool (4) is pushed to the right by the combined forceof LS pressure PLS and the force of spring (3).When spool (4) moves, port b and port c are joinedand connected to the NC valve. When this happens,the n/C valve is connected to the drain port, so

circuit c - h becomes drain pressure PT. (Theoperation of the n/C valve is explained later.)

For this reason, the pressure at the large pistondiameter end of the servo piston (1) becomesdrain pressure PT, and pump pressure PP entersthe small diameter end, so servo piston (1) ispushed to the right. Therefore, rod (2) moves tothe right and moves the swash plate in the direc-tion to make the discharge amount larger.If the output pressure PSIG of the EPC valve forthe LS valve enters port e, this pressure creates aforce to move piston (5) to the left. If piston (5) is

pushed to the left, it acts to make the set pressureof spring (3) weaker, and the difference betweenPLS and PP changes when ports b and c ofspool (4) are connected.

IO 26




3) Operation in minimum direction for pump discharge amount

TVC valve

from outlet port of (from LS control I’ 0 PTcontrol valve) EPC

IDirection of minimum discharge)

The following explains the situation if servo pis-ton (1) moves to the left (the discharge amountbecomes smaller). When LS differential pressuren PLS becomes larger (for example, when thearea of opening of the control valve becomessmaller and pump pressure PP rises), pump pres-sure PP pushes spool (4) to the left.When spool (4) moves, main pump pressure PPflows from port d to port c, and from port h, itenters the large piston diameter end.

XlOAV255

Main pump pressure PP also enters the smallpiston diameter end, but because of the differ-ence in area between the large piston diameterend of servo piston (1) and the small piston di-ameter end, servo piston (1) is pushed to the left.As a result, rod (2) moves in the direction to makethe swash plate angle smaller.If LS selection pressure PSIG enters port e, it actsto make the set pressure of spring (3) weaker.

IO 27




4) When servo piston is balanced

control valve) EP((from outlet port of

Let us take the area receiving the pressure at thelarge piston diameter end as Al, the area receiv-ing the pressure at the small end as AO, and thepressure flowing into the large piston diameter asPEN. If the main pump pressure PP of the LSvalve and the combined force of force F of spring(3) and LS pressure PLS are balanced, and therelationship is A0 x PP = Al x PEN, servo piston(1) will stop in that position, and the swash plate willbe kept at an intermediate position. (It will stop at a

position where the opening of the throttle from portb to port c and from port d to port c of spool (4) isapproximately the same. At this point, the pressureof port c is approximately % pump pressure PP.)

XlOAV255

At this point, the relationship between the areareceiving the pressure at both ends of piston (1)is AO:Al = 1:2, so the pressure applied to bothends of the piston when it is balanced becomesPP:PENk 2:l. The position where spool (4) isbalanced and stopped is the standard center, andthe force of spring (3) is adjusted so that it is deter-mined when PP - PLS = 2.11 MPa (21.5 kg/cm?.However, if PSIG (the output pressure of 0 - 2.94MPa (0 - 30 kg/cm? of the EPC valve of the LS

valve) is applied to port e, the balance stop positionwill change in proportion to pressure PSIG betweenPP - PLS = 2.11 - 0.64 MPa (21.5 - 6.5 kg/cm?.

IO 28




NC VALVE1) When pump controller is normal

irecli on of maxmum dischargePump contrdkr Tvc proitx

OFF Switch

Resistor

a. When the load on the actuator is small andpump pressures PPI and PP2 are low

(1) Movement of solenoid (1)Command current X from the pump controllerflows to solenoid (1). This command currentchanges the internal force pushing solenoid pushpin (1 I).On the opposite side to the force pushing thissolenoid push pin (11) is the spring set pressure ofsprings (3) and (4) and pump pressure PPI andother pump (see *) pressure PP2. Piston (2)stops at a position where the combined force

pushing piston (2) is balanced, and the pressure(pressure of port c) output from the TVC valvechanges according to this position.

XlOAVZ 7

XiOAV 58

* Other pump pressure.This is the pressure ofthe pump at the opp-osite end.For the Front pump, it isthe Rear pump pres-sure. For the Rearpump, it is the Frontpump pressure.

The size of command current X is determined bythe nature of the operation (lever operation), theselection of the working mode, and the set valveand actual value for the engine speed.

-29




(Directton

Resistor

b. When load on actuator is small and pump dis-charge pressure is highWhen the load is large and pump discharge pres-sures PPl and PP2 are high, the force pushingpiston (2) to the left becomes larger and piston(2) moves to the position shown in the diagramabove.

When this happens, as shown in the diagramabove, part of the pressurized oil from port bflows out to port d and the pressurized oil flow-ing from port c to the LS valve becomes approxi-mately half of main pump pressure PPI.When port h and port e of the LS valve are con-nected (see 1. LS valve), the pressure from port fenters the large piston diameter end of servopiston (9) and servo piston (9) stops.

XlOAV 59

XlOAV 58

If main pump pressures PPl and PP2 increasefurther and piston (2) moves further to the left,main pump pressure PPI flows to port c and actsto make the discharge amount the minimum.When piston (9) moves to the left, piston (5) is

moved to the right by cam (7) and lever (6). Forthis reason, springs (3) and (4) are compressedpush back piston (2). Because of this force, piston(2) cuts off the connection from port b to port c,and port c and port d are connected. As a result,the pressure at port c =9 rops, and piston (9)stops moving to the left. The position in whichpiston (9) stops when this happens is further to thethe left than the position when pump pressuresPPI and PP2 are low.

IO-31




The relation of pump pressures PPI + PP2 andthe position of servo piston (9) forms a bent line Q

because of the double-spring effect of springs (3)and (4). The relationship between pump pres-sures PPI + PP2 and pump discharge amount Qis shown in the figure on the right.

If command voltage X sent to solenoid (1) in-creases further, the relationship between pumppressures PPI and PP2, and pump dischargeamount Q is proportional to the pushing force ofthe solenoid and moves in parallel. In otherwords, if the pushing force of solenoid (1) is

added to the force pushing to the left becauseof the pump pressure applied to the piston (2), therelationship between PP and Q moves from A to Bin accordance with the increase in X.

PPl PP2XlOAV260

Q

P

XlOAV261

IO 32




2) When pump controller is abnormal and TVC prolix switch is ON

?PT

(Direction aximum disch

Batterv

arge)Pump controllc

, “ “ “ “ V _

Resistor

a. When load on main pump is lightIf there is a failure in the pump controller, turnTVC prolix switch ON to switch to the resistorside. In this case, the power source is taken di-rectly from the battery. But if the current is usedas is, it is too large, so use the resistor to controlthe current flowing to solenoid (1).When this is done, the current becomes constant,

so the force pushing on solenoid push pin (11) isalso constant.If main pump pressures PPI and PP2 are low, thecombined force of the pump pressure and theforce of solenoid (1) is weaker that the spring setforce, so piston (2) is balanced at a position to theright.

?I TVC prolix- --{itch

XlOAV 58

XlOAV 6

At this point, port c is connected to the drainpressure of port d, and the large piston diameterend of servo piston (9) also becomes the drainpressure PT through the LS valve. When thishappens, the pressure at the small piston di-ameter end is large, so servo piston (9) moves inthe direction to make the discharge amountlarger.

1 o-33




b.

8PT

Direction of minimum discharge) Pump controller TVC prolix

JQzy@gF-

Resstor

When main pump load is heavyIn the same way as in the previous item, whenthe n/C prolix switch is ON, the command cur-rent X sent to solenoid (1) becomes constant. Forthis reason, the force of solenoid push pin (11)pushing piston (2) is constant.If main pump pressures PPI and PP2 increase,piston (2) moves further to the left than when themain pump load is light, and is balanced at aposition towards the left.

In this case, the pressure from port b flows to portc, so servo piston (9) moves to the left (to makethe discharge amount smaller) by the samemechanism as explained in item 2.1)-b. In otherwords, even when the TVC prolix switch is ON, thecurve for the pump pressure P and dischargeamount Q is determined as shown in the diagramfor the value of the current sent to the solenoidthrough the resistor.

XiOAV258

XlOAV263

The curve when the TVC prolix switch in ON iscurve B, which is to the left of curve A for whenthe pump controller is normal.

A when controller is

P

XlOAV264

1 o-34




3. CONTROL PUMP (BAR-016)

L

1 Body2. Driven gear3. Housing4. Drive gear

5. Relief valve6. Filter

0b

A-A

SPECIFICATIONSType: BAR-01 6Theoretical delivery: 16.0 cc/revMax. delivery pressure: 3.23 MPa (33 kg/cm?

XlOBH152

a. Suction portb. Delivery port

1 o-35



STRUCTURE AND FUNCTION CONTROL VALVE

CONTROL VALVE9-SPOOL VALVE (STANDARD + 3 SERVICE VALVE)

hh-

U

pi, pii fi &h g‘ s p;j

Y X

r&

/ i ‘ *\ \W b V

XlOBH 44

IO 38




1. 6-spool valve2. Cover 13. Cover 24. Pump merge-divider valve5. Arm counterbalance valve6. No. 1 Service valve7. No. 2 Service valve

8. No. 3 Service valve

a.b.

:Ie.f.g.

h.i.j.k.I.m.n.0.

P.q.r.

t” .’U.

V.

w.

X.

Y.

Port PPI (from rear main pump)Port PP2 (from front main pump)Port A6 (to arm cylinder head)Port B6 (to arm cylinder bottom)Port A5 (to L.H. travel motor)Port B5 (to L.H. travel motor)Port A4 (to swing motor)

Port B4 (to swing motor)Port A3 (to boom cylinder bottom)Port B3 (to boom cylinder head)Port A2 (to R.H. travel motor)Port B2 (to R.H. travel motor)Port Al (to bucket cylinder head)Port Bl (to bucket cylinder bottom)Port A-l (to attachment)Port B-l (to attachment)Port A-2 (to attachment)Port B-2 (to attachment)Port A-3 (to attachment)Port B-3 (to attachment)Port T (to tank)Port Tl (to travel junction valve)Port T2 (to travel junction valve)Port T3 (to travel junction valve)Port T4 (to travel junction valve)

OUTLINEThis control valve consists of the 6-spool valve (an

integrated composition) and 3 service valves. Thepump merge-divider valve and arm counterbalancevalve are installed to this.

Each valve forms one unit with the connectionbolt, and the passages are internally connected, so

the structure is compact and is very easy to service.This control valve consists of one spool for one

item of the work equipment, so it has a simplestructure.

aa.ab.bb.cc.dd.ee.pa.

pb.PC.pd.pe.Pf.Pg.ph.pi.pj.pk.Pl.pmpn.PO.PP.Pq.pr.ff.gg.hh.kk.

Port PLSI (to rear pump control)Port PLS2 (to front pump control)Port TS (to tank)Port PS (from solenoid valve)Port BP (from solenoid valve)Port PX (from solenoid valve)Port PI2 (from arm PPC/EPC valve)

Port PI 1 (from arm PPC/EPC valve)Port PI 0 (from L.H. travel PPC valve)Port P9 (from L.H. travel PPC valve)Port P8 (from swing PPC/EPC valve)Port P7 (from swing PPC/EPC valve)Port P6 (from boom PPWEPC valve)Port P5 (from boom PPWEPC valve)Port P4 (from R.H. travel PPC valve)Port P3 (from R.H. travel PPC valve)Port P2 (from bucket PPC/EPC valve)Port PI (from bucket PPC/EPC valve)Port P-2 (from service PPC valve)Port P-l (from service PPC valve)Port P-4 (from service PPC valve)Port P-3 (from service PPC valve)Port P-6 (from service PPC valve)Port P-5 (from service PPC valve)Port SA (pressure sensor mount port)Port SB (pressure sensor mount port)Port BP3 (from travel PPC)Port BP2 (from arm PPC)

-39




MAIN STRUCTURE

1 Spool (arm)2. Spool (L.H. travel)3. Spool (swing)4. Spool (boom)

5. Spool (R.H. travel)6. Spool (bucket)7. Spool (service 1)8. Spool (service 2)

K-K \14

XlOBH145

9. Spool (service 3)10. Spool return spring11. Main unload LS relief valve12. Main relief valve (bucket end group)

13. Sub-unload valve (bucket end group)14. Main relief valve (arm end group)15. Sub-unload valve (arm end group)

1 O-40




J J

4 sEE EE

X10BH146

1. LS shuttle valve2. LS select valve3. Pump merge-divider valve (for main)4. Return spring5. Pump merge-divider valve (for LS)6. Return spring7. LS bypass valve

1o-41



7-SPOOL VALVE (STANDARD + 1 SERVICE VALVE)* For details of the names of the ports and the main structure, see 9-SPOOL VALVE

c e 9 e k\ \ 7” O

I II\ \\\\pb pd 4 Pf Pih pj PI Pn ee

Y ?

bb,

5’

W a b v XlOBH149

1o-44




SAFETY-SUCTION VALVE FOR SERVICE VALVE

1 2 3 4 5 6 7 9 9 19

XlOBHlBl

1. Suction valve2. Main valve3. Piston4. Piston spring5. Poppet6. Poppet spring

7. Suction valve spring8. Sleeve9. Adjustment screw

10. Locknut

Part No. Set Pressure Use

709-70-74600 24.5 MPa (250 ka/cm? at 5 Plmin For crusher (Okada)

IO 46



STRUCTURE AND FUNCTION CLSS

CLSSOUTLINE OF CLSS

Actuators

0I-_------- Control valve 7

I I

II

I Pump merge divider valve 1

I

III

II

I

I

1

IL_J_‘ L__ _--l

I

r2 L _ _ k

__ __Jz TVC valve _

III

I

I

III

III

IIIII

IIIII

I

I II II

I4ervo piston

Features Structure

CLSS stands for Closed center Load SensingSystem, and has the following features.

1) Fine control not influenced by load2) Control enabling digging even with fine control

3) Ease of compound operation ensured by flowdivider function using area of opening of spoolduring compound operations

4) Energy saving using variable pump control

III

&Servo pistonXlODD013

The CLSS consists of a main pump (2pumps), control valve, and actuators for

the work equipment.The main pump body consists of the pumpitself, the TVC valve and LS valve.

1o-47




Basic principle1) Control of pump swash plate angle

The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS(the difference between pump pressure PP and control valve outlet port LS pressure PLS) (load pressure ofactuator) is constant. (LS pressure APLS = Pump discharge pressure PP - LS pressure PLS)

If LS differential pressure APLS becomes lower than the set pressure of the LS valve(when the actuator load

pressure is high), the pump swash plate moves toward the maximum position; if it becomes higher than theset pressure of the LS valve (when the actuator load pressure is low), the pump swash plate moves towardsthe minimum position.

Actuatoro f Max.

Control valve

--7---I

/kr I’

I ‘ PLSI ’ w LS passage

Pump passage

I I

%NOpistonm ~

dilferential pressure

2

$P)

5P.c

IS alve sat

pressurej ---- -.

\

LS ifferential pressure I\pLs

XlODDOlS

XlODDO14

IO 48




OPERATION FOR EACH FUNCTION OF CLSSHydraulic circuit diagram for system

1P,,r_-_I__‘___-

I & 1Tc________-----------.--: ,

P..’ :.____ II.__~______ _ __

I

_I

I___T _-y-.> 1 ________

“ 7 , II II A,10 1’ *_

1___ ___ _____ __

, IIB, 1

.I8

XlODD017

O-50




SYSTEM DIAGRAM* This shows actuator (6A) and the stroke end relief in the merge mode.

26

IA. Main pumpIB. Main pump2A. Main relief valve (for power max.)2B. Main relief valve (for power max.)

3A. Sub unload valve3B. Sub unload valve4. Pump merge-divider valve5A. Control valve5B. Control valve6A. Actuator6B. Actuator7A. Check valve7B. Check valve

(1A

,;j:,.,.:.:..:.:.,.:.:.:.:.:.:.:.:..,,,:$::::.:: :::..‘::.:::.j;

w:.+:,,. . :_.: : ‘.

61, ij

8. Pump passage9. LS circuit

10. Tank pressure11. Valve

12. Spring13. Piston14. Clearance filter15. Poppet16. Spring17. Piston18. Piston19. Piston20. LS bypass valve

-1BXlODD 18

1o-52




3. Introduction of LS pressure* The diagram shows the condition for arm IN.

Upstream pressure ofpressure compensation valve(for spool meter-in downstream)

1. Main pump2. Main spool3. Pressure compensation valve4. Valve5. Ball valve6. LS shuttle valve

XlODD022

FunctionThe upstream pressure (= spool meter-in down-stream pressure) of pressure compensation valve(3) is introduced and goes to shuttle valve (7) asthe LS pressure. When this happens, it is con-nected to port B of the actuator through valve (4),and LS pressure E actuator load pressure. Intro-duction hole a inside the spool has a small diam-eter, so it also acts as a throttle.

OperationWhen spool (2) is operated, the pump pressurepasses through introduction hole a, enters portC, and is taken to the LS circuit. When the pumppressure rises ans reaches the load pressure ofport B, ball valve (5) opens.

1 o-57




5. Pressure compensation valve

1. Main pump2. Valve3. Shuttle valve4. Piston5. Spring6. LS shuttle valve

XlODD024

Function1) During independent operation and at maxi-

mum load pressure (during compound oper-ations, when load pressure is higher thanother work equipment)The pressure compensation valve acts as a loadcheck valve.

OperationIf the pump pressure (LS pressure) is lower thanthe load pressure at port C, shuttle valve (3) in-side pressure compensation valve piston (4)moves to interconnect spring chamber E and portC.From this condition, the force of spring (5) acts tomove piston (4) and valve (2) in the direction ofclosing.

-59




2)

0

6

From LS shuttle valve for otherwork equipment

Upstream pressure of pressurecompensation valve(for spoo meter-in downstream)

Spool meter-in upstream presslreXlODD025

When receiving compensation (during Operationcompound operations, when load pressure Spring chamber E is interconnected with port D.is lower than other work equipment) Piston (4) and valve (2) are actuated by the LSThe pressure compensation valve is closed by circuit pressure from the other work equipmentthe LS pressure of port D, and the spool meter-in at port F in the direction of closing (to the right).downstream pressure of port B becomes the In other words, the valve upstream pressure ifsame as the maximum pressure of the other work port B (= spool meter-in downstream pressure) isequipment. controlled by the LS pressure.The spool meter-in upstream pressure of port Ais the pump pressure, so spool meter-in differen-tial pressure (upstream pressure (pressure of portA) - downstream pressure (pressure of port B))becomes the same for all spools that are beingoperated. Therefore, the pump flow is divided inproportion to the area of the meter-in opening.

IO 60




s3l 2 A 4 B

XlODDO 7

For travel, swingTravel: No holding pressure is generated at port A in

the travel circuit, so a pressure compensationvalve without a shuttle valve is used.

Swing: The holding pressure at the swing port is low,so a pressure compensation valve without ashuttle valve is used.

Reference: When there is no shuttle valve

If there is no shuttle valve, piston (4) and valve(2) will separate. In this condition, if anotheractuator is operated, the piston acts as anaccumulator, so there is a time lag.

Time

XlODD029

IO 62




Shuttle valve Al

From LS circuitI I

To actuatorThrottle

\

meter-in downstream pressure

Surface area ratio of pressure compensation valveThe condition of the flow division changes accordingto the ratio of the area of portion Al and portion A2of the pressure compensation valve.Area ratio = A2lAl

When area ratio = 1:Spool meter-in downstream pressure = Max. loadpressure, and oil flow is divided in proportion toarea of opening of spool.When ratio is more than 1:Spool meter-in downstream pressure > Max. loadpressure, and oil flow is divided in a proportionless than the area of opening of spool.When ratio is less than 1:Spool meter-in downstream pressure e Max. loadpressure, and oil flow is divided in a proportionmore than the area of opening of spool.

XlODD030

Area ratio for each part of work equipment

Bucket

L.H./R.H.

travel

Boom

Swing

Arm

Service

Port A I Port B

0 98

(Dump)

0.98

0.95(Raise)

0 2.0 0.98 0 2.0(Curl)

0 2.0 0.98 0 2.0

0 2.0 0.98 0 2.0(Lower)

0 98 0 0.5 0 98 0 0.5

0.95 0 2.0 0.95 0 2.0(Out) (In)

0.98 0 2.0 0.98 0 2.0

IO 63




7. Boom regeneration circuit

1. Main pump Function2. Main spool3A. Pressure compensation valve3B. Pressure compensation valve4A. Safety-suction valve4B. Suction valve5. Check valve6. LS shuttle valve7. Drain circuit

Cylinder head pressure < cylinder bottompressure (free fall, etc.)A return flow circuit is provided from the cylinderbottom to the cylinder head so that when theboom is lowered, the return flow can be used toincrease the flow of oil from the pump to thecylinder bottom.

8. Regeneration circuit

1)

OperationWhen the cylinder head pressure < cylinder bot-tom pressure, part of the pressurized oil from thecylinder bottom passes through the notch in spool

(2), goes through port B, and enters drain circuit(7). The rest of the oil goes from port C, entersregeneration circuit (8), opens check valve (5),and passes through ports C and D to flow back tothe cylinder head.

XlODD031

IO 64




2)

RAISE LOWE

XlODD032

Cylinder head pressure > Cylinder bottom pres-sure (digging operations, etc.)Check valve (5) in regeneration circuit (8) acts to

shut off the flow from the cylinder head to thecylinder bottom.

IO 65




8. Arm regeneration circuit

1 Main pump2. Main spool3A. Pressure compensation valve3B. Pressure compensation valve4A. Safety valve4B. Safety valve5. Arm counterbalance valve6. Piston7. Spool8. Check valve9. LS shuttle valve

IO. Drain circuit11. Regeneration circuit

7 6 XlODD033

Function1) Cylinder head pressure > cylinder bottom

pressureA return flow circuit is provided from the cylinderhead to the cylinder bottom so that when thearm is moved in, the flow of oil to the cylinderbecomes the pump discharge amount + thereturn flow, and this increases the cylinderspeed.

Operation0 When the cylinder head pressure > cylinder bot-

tom pressure, the pressurized oil from the cylin-der head passes through the notch in spool (2),enters port C and opens check valve (8), thenpasses through ports D and E to flow back toto the cylinder bottom.

1 O-66



X10DD034

2) When load is large 3) Cylinder bottom pressure > Cylinder headDuring arm IN operations, if the load increases pressureand the cylinder bottom pressure exceeds 16.6 0 When the cylinder bottom pressure > cylinder

MPa (170 kg/cm?, counterbalance valve (5) is head pressure, check valve (8) is closed by theactuated to increase the meter-out opening at cylinder bottom pressure and prevents any oilthe cylinder head. This reduces the pressure flowing back from the cylinder bottom to theloss between the cylinder head and the hydraulic head end.tank, and ensures the digging force.

OperationThe cylinder bottom pressure enters port F andpushes piston (6) to the left. Spool (7) movesfully to the left and interconnects port C of regen-eration circuit (11) and tank drain circuit (10). Asa result, the pressure loss in the drain circuit isreduced.

IO 67




9. Arm counterbalance valve

5

From cylinder head

cylinder bon

3 2 XlODD035

I. Piston2. Spool3. Spring4. Check valve5. Regeneration circuit6. Tank drain circuit

OperationDuring arm IN operations, if the actuating pres-sure at the arm cylinder bottom rises, the pres-sure at port A also rises. When the force re-ceived by piston (1) from the pressure at port Abecomes greater than the force of spring (3),piston (1) moves to the left.Spool (2) is pushed by piston (1) and also movesto the left, so ports B and C are interconnected.When this happens, the pressurized oil from the

cylinder head passes through ports B and C, andflows directly to drain circuit (6). (The pressureloss is removed when draining)When this happens, check valve (4) is closed bythe pressure at port A, so it shuts off regenerationcircuit (5), and prevents the oil from flowing backfrom the cylinder bottom to the head end.

I O-68




10. Spool stroke modulation(1) Boom raise modulation

@oom raisePC pressure

1. Spool2. Pistonsto: Spool

No arm operation

Boom raise@ PPC pressure

st1: Spool strokeSt2: Piston stroke

Boom and arm simultaneous operation

stroke

XlODD036

FunctionWhen boom RAISE and arm DIG are operatedsimultaneously, good simultaneous operation is

achieved by restriction of boom spool max.stroke.

Operation1. When no arm operation

When boom raises, spool (1) goes to the left(c) by stroke Sto to touch piston (2).

2. When arm digs(I) Arm DIG PPC pressure goes to L.H. ofpiston (2) from port A, and pushes piston (2)to the right (+).(2) When boom raises, spool (1) goes to the left(c), but spool max. stroke is restricted to St1because piston (2) moves by 32.

O 69




(2) Arm dig modulation

ArmPPC

Arm digPPC pressure c3

No travel operation

SpoolPiston

Arm and travel simultaneous operation XlODD 37

FunctionWhen machine goes up high slope and arm digs,flow to arm cylinder is restricted by limitation ofarm spool stroke to avoid pressure drop of pump.

F pump flow goes to L.H. travel motor throughtravel junction valve.

Operation1. With no travel operation

When arm digs, spool (1) goes to the left(+) by stroke St0 to touch piston (2).

2. With travel operation(1) Travel PPC pressure goes to the right ofpiston (2) from port A, and pushes piston (2) tothe left.(2) When arm digs, spool (1) goes to the right(c), but spool max. stroke is restricted to St1because piston (2) moves by St2.

1O-70




(4) Arm dig modulation (Arm dig PPC timing valve)

PIQ

2 From armPPC valve 2 XlODD038

Function OperationIn simultaneous operation of boom and arm, such as When arm digs and boom raises simultaneously,finishing, arm spool speed is delayed to prevent sud- spool is delayed because PPC circuit is reduced byden speed change of arm and machine operates arm timing valve and pressure which forces spoolsmoothly. (1) is reduced.

8. Movement of arm timing valve

Plpressure ,

Eessure ‘ et

During simultaneous operation XlODD039

FunctionReduce arm PPC pressure to M/V for simultaneous

operation of arm dig and boom up.

Operation1. Simple operation of arm dig

PPC pressure goes to port PI and pushes spool(1) to the right against spring (2) and port PIthrough port P2 via B.

2. Simultaneous operation of arm dig and boomUP

(i

(ii)

When boom raises, PPC pressure goes toport P3 and pushes spool (1) to the left.When levers are fully stroked towards armdig and boom raise simultaneously, spool (1)is pushed to the left by force according to thefollowing formula. PI pressure 5 P2 pressure+ spring force (PI pressure = P2 pressure)Then B is intercepted and PPC pressure ofarm dig goes to port P2 from port PI via ori-fice A.

IO 71




11. Pump merge-divider valve

8’

PS

‘ OFF,

To control valve

To control valve

1. Main spool2. Spring3. LS spool4. Spring5. LS circuit (bucket end)6. LS circuit (arm end)7. LS circuit (arm end)a. LS circuit (bucket end)

P2 Pl

XlODD 4

OperationIi When merging pump flow (when pilot

pressure PS is OFF)Pilot pressure PS is OFF, so main spool (1) ispushed to the left by spring (2) and ports E andF are interconnected.

Function0 This acts to merge or divide (send to its own

control valve group) oil flows Pl and P2 ofpressurized oil discharged from the two pumps.

At the same time, it also carries out merging anddividing of LS circuit pressure.

Therefore, pressurized oil PI and P2 dischargedfrom the two pumps is merged at ports E and F,and is sent to the control valve that demands theoil.In the same way, LS spool (3) is also pushed tothe left by spring (4), so the ports are connectedas follows.

Connected ports: A +-+ D, B * CTherefore, the LS pressure supplied from thespools of each control valve to LS circuits (5), (6),(7), and (8) is all sent to the pressure compensa-tion valve and other valves.

1o-72




PS

‘ONJ

bucket control valve

To arm control valve

‘ 6

P2 Pl

2) When dividing pump flow (when pilotpressure PS is ON)When pilot pressure PS is ON, main spool (1) is

moved to the right by the PS pressure, and portsE and F are disconnected.Therefore, the pressurized oil discharged fromeach pump is sent to its own control valve group.Pressure PI: To bucket, R.H. travel, boom groupPressure P2: To swing, L.H. travel, arm groupIn the same way, LS spool (3) is also moved tothe right by the PS pressure, and the ports areconnected as follows.Connected ports: B * D, others are not conn-ected. Therefore, LS circuits (5), (6) (7), and (8)are all sent to their own control valve group.

XlODDO 4

1o-73




11 LS select valve* The diagram shows the situation when the swing

and left travel are operated at the same time.(BP pressure ON)

1. Valve

BP r)'ON,

l

2.... Armpringistoniston pool

5. Swing spool6. L.H. travel spool

8. L.H. shuttle valve

6

8

i XlODD042

FunctionThis valve is used to increase the ease of operat-ing the work equipment. It prevents high pres-sure from being generated when the swing isoperated. It also prevents the high LS pressurefrom the swing circuit from flowing into any otherLS circuit when the swing is operated togetherwith the work equipment.

Operation1) When pilot pressure BP is OFF

Pilot pressure BP is OFF, so piston (3) is pushedto the left by spring (2). If the swing is then oper-ated, swing LS pressure PI passes throughswing spool (5), and enters port A. It pushesvalve (1) to the left and connects ports A andB. Therefore, swing LS pressure PI flows to LSshuttle valve (8).

2) When pilot pressure is ONWhen pilot pressure BP is ON, piston (3) is moved

to the right against spring (2) by the BP pressure.It pushes valve (1) to the right and closes thecircuit between ports A and B. As a result, swingLS pressure PI stops flowing to LS shuttle valve(8), and even if swing LS pressure PI rises to ahigh pressure, it does not influence any other LScircuit.

9. LS circuit

4 3 2 B t A

BP‘ OFF,

Pl

To LS shuttle valveXlQDD043

4 3 2 B 1 A

*BP

‘ ON,

To LS shuttle valve

XlODD044

1o-74




1.2A.2B.3A.3B.4A.4B.5A.

5B.6.7.8.9.

10.11.12.13.14.15.16.17.18.19.20.21.22.23.24.25.26.27.28A.28B.29A.29B.30A.30B.

31.32.33A.33B.34.

Hydraulic tankMain pump (front)Main pump (rear)n/C valve (front)NC valve (rear)LS valve (front)LS valve (rear)Pump merge-divider valve (for main)

Pump merge-divider valve (for LS)Bucket spoolR.H. travel spoolBoom spoolSwing spoolL.H. travel spoolArm spoolPressure compensation valve (bucket)Pressure compensation valve (R.H. travel)Pressure compensation valve (boom)Pressure compensation valve (swing)Pressure compensation valve (L.H. travel)Pressure compensation valve (arm)Safety-suction valveSuction valveLS shuttle valve (bucket)LS shuttle valve (R.H. travel)LS shuttle valve (boom)LS shuttle valve (L.H. travel)LS shuttle valve (arm)Check valve (for boom regeneration circuit)Check valve (for arm regeneration circuit)Arm counterbalance valveMain unload valveLS relief valveMain relief valve (bucket group)Main.relief valve (arm group)Sub-unload valve (bucket group)Sub-unload valve (arm group)

LS select valveLS check valveMain check valve (bucket group)Main check valve (arm group)LS bypass valve

Note: Groups of control valves by main pump circuitBucket group: Bucket, R.H. travel, boomArm group: Swing, L.H. travel, arm

OperationWhen the levers are at neutral, the pump is atthe minimum swash plate angle, and the oil flowis drained from main unload valve (28A).

The LS pressure is connected to hydraulic tank(1) by LS bypass valve (34). The LS differentialpressure A PLS (unload pressure -tank pres-sure) at this point is A PLS > pump LS controlpressure, so the pump swash plate angle is theminimum.

1 o-77



FOLDPump flow divided, one side actuated, other side neutral

The diagram shows the independent bucket DUMP operation with pump merge.

,

281

f-l

.

\\\

Connection of ports when

pump flow is divided

Connected ports: B - D

Disconnecte d ports: A, C

TS - \I 1 I

\58




Operation

1)0

2)

Pilot pressure PA of pump merge-dividervalve @A) ONBucket groupWhen the bucket is operated, pressurized oilfrom main pump (2B) flows to the bucketgroup. The swash plate angle of main pump(2B) is controlled to match the operation of

bucket spool (6).The LS pressure passing through the inside ofbucket spool (6) goes to main unload spool(28A), and the main unload valve is closed.

Arm groupWhen the pump flow is merged, all spools areat neutral, so the oil flow from the minimumswash plate angle of main pump (2A) is alldrained from sub-unload valve (30B) of thearm group. All spools in the arm group areat neutral, so no LS pressure is generated.If the pump pressure - LS pressure becomesgreater than the set pressure of sub-unloadvalve (3OB), the sub-unload valve is actuatedand the oil is drained. The LS differentialpressure a PLS at this point is a PLS > pumpLS control pressure, so the pump swash plateangle is the minimum.

1o-79




Operation

1)

0

2)

When pump swash plate angle is at a mini-mum (LS relief valve actuate in standardmode)When the arm OUT is operated, if the loadbecomes larger, the LS pressure passingthrough the inside of arm spool (11) rises.The LS circuit pressure is controlled by LS

relief valve (288).When the difference (a PLS) between thepump pressure and LS pressure becomeslarge, main unload valve (28A) is actuatedto suppress the rise in the main circuit pres-sure and regulate it to the standard moderelief pressure.

The LS differential pressure n PLS at thispoint is a PLS > pump LS control pressure,so the pump swash plate angle is the mini-mum. In other words, the automatic cut-offcontrol is carried out.

I O- 81



FOLD Pump flow divided bucket DUMP power max. relief

The diagram shows bucket DUMP, relief with the pump flow divided.

t

PLSl

ILI I

1 I /



Connected ports: B - DDisconnect ed ports: A, C

205FO6071




OperationPilot pressure PA of pump merge-dividervalve (5A) ONPilot pressure PB of LS relief valve (288) ON

I> When the bucket is operated, if the powermax. function is ON, pilot pressure PB actson LS relief valve (28B), so the LS relief valve

is not actuated.

2) When the bucket DUMP is operated and theload pressure becomes greater, pump pres-sure PI and LS pressure PLSI both rise. Pi-lot pressure PB is preventing LS relief valve(28B) from operating at this point, so mainrelief valve (29A) of the bucket group is ac-tuated and controls the relief while the powermax. function is being used.

1 O-83



FOL Pump flow merged boom RAISE

The diagram shows the boom RAISE w ith the pump flow merged. PLSl-

Pl I -1

8A

\ 88

205FO6072

Connection of ports when pump

flow is merged TS




OperationWhen the boom RAISE is operated, mainpumps (2A) and (2B) are both at the maxi-mum swash plate angle, and main unloadvalve (28A) is closed.At this point, for the meter-in opening ofboom spool (8), even if both pumps are atthe maximum swash plate angle, the LS dif-

ferential pressure is set to be smaller than thepump LS control pressure.In other words, LS differential pressure a PLSis a PLS < pump LS control pressure, so thepump swash plate angle becomes the maximum.

0 In addition, the flow of main pump (2A) passesthrough pump merge-divider valve @A)and flows to boom spool (8).

I O- 85




OperationPilot pressure PA of pump merge-dividervalve (5A) ON

0 When the swing is operated, main pump(2A) of the arm group is at the maximumswash plate angle, and main unload valve(28A) is closed.At this point, for the meter-in opening of

swing spool (9) even if main pump (2A) isat the maximum swash plate angle, the LSdifferential pressure is set to be smaller thanthe pump LS control pressure.In other words, LS differential pressure n PLSis a PLS c pump LS control pressure, so thepump swash plate angle of main pump (2A)becomes the maximum.All spools in the bucket group are at neutral,so main pump (2B) is at the minimum swashplate angle, and sub-unload valve (30A) isactuated. For details of the actuation, see 2.Pump flow merged, one side actuated, otherside neutral.

I O- 87



FOLDPump flow divided, travel operated independently

The diagram shows the travel operated independently with the pump flow divided.

/8

\TS \

// \ I

\58



Connected ports: B - D

Disconnecte d ports: A, C

05FO6074



FOLDPump flow merged, compound ope ration

The diagram shows boom RAISE + arm IN with the pump flow merged. PLSl

Connection of ports when pump I

205FO6075

flow i s merged

Connected ports: A - D, B - C. IdL




Operation1) When the arm and boom are operated

simultaneously, the swash plate angle forboth pumps becomes the maximum.When this happens, the load pressure at theboom RAISE side is higher than at the armside, so the LS pressure passes through ports

E and F of boom spool (8), enters LS shuttlevalve (22) and is sent to the LS circuit. ThisLS pressure is transmitted to port G of armpressure compensation valve (17), and actsto increase the set pressure of the pressurecompensation valve. Because of this, thepressure between port H or arm spool (11)and port I or pressure compensation valve(17) rises, and spool meter-in LS differentialpressure (pump pressure - LS pressure =A PLS) becomes the same as that at the boomend.

2)Because of the above operation, the oil flowis divided in proportion to the size of theopening area of boom spool (8) and theopening area of arm spool (11).Meter-in differential pressure A PLS dur-ing boom RAISE + arm IN is A PLS c boomLS control pressure, so the main pump swashplate angle is set to maximum.

1o 91



STRUCTURE AND FUNCTION SWING MOTOR

SWING MOTOR

m

\d c

a. portsb. Port MB (from control valve)C. Port MA (from control valve)d. Port T (to tank)e. Port B (from swing brake solenoid valve)

XlOAV265

Model

item

Type

Theoretical delivery

Safety valve setpressure

PC200-6PC200LC-6 PC22OLC-6PC21 OLC-6 PC25OLC-6

KMFgOAB-2

87.8 cc/rev

27.44 MPa(280 ka/cm*j

Rated speed

Brake releasingpressure

I 2.298 rpm 1 2.403 rDm

1.37 MPa(14 kg/cm2)

1o-92




A A

1 Brake spring2. Drive shaft3. Cover4. Case5. Disc6. Plate

7. Brake piston6. End cover9. Piston

10 Cylinder11 Valve plate12. Air bleed plug13. Center shaft14. Center spring15. Safety valve

16. Check valve17. Check valve spring

c-c

1o-93




SWING HOLDING BRAKE

OPERATION1) When swing brake solenoid valve is

deactivatedWhen the swing brake solenoid valve is deacti-vated, the pressurized oil from the control pump

is shut off and port B is connected to the tankcircuit.Because of this, brake piston (7) is pushed downin the direction of the arrow by brake spring (I),so disc (5) and plate (6) are pushed together andthe brake is applied.

2) When swing brake solenoid is excitedWhen the swing brake solenoid valve is excited,the valve is switched, and the pressurized oil fromthe control pump enters port b and flows to brakechamber a.The pressurized oil entering chamber a over-comes the force of brake spring (I), and brakepiston (7) is pushed up in the direction of thearrow. Because of this, disc (5) and plate (6)separate, and the brake is released.

Swing brakesolenoid valve

- XlOAV267

solenoid valve

XlOAV268

-94



STRUCTURE AND FUNCTION CENTER SWIVEL JOINT

CENTER SWIVEL JOINT4-PORT SWIVEL

A A

1 Cover2. Body3. Slipper seal4. O-ring5. Shaft

Al. From control valve port B2A2. To R.H. travel motor port PBBl From control valve to port B5

Al

Cl

El

A ---I

T2 D2

82 A2 c2

x1 zz 2

82. To L.H. travel motor port PACl. From control valve port A2C2. To R.H. travel motor port PADl . From control valve port A5D2. To L.H. travel motor port PBEl. From travel speed solenoid valveE2. To L.H. and R.H. travel motors port PTl. To tankT2. From L.H. and R.H. travel motors port T

1o-95



STRUCTURE AND FUNCTION TRAVEL MOTOR

TRAVEL MOTORPC200-6, PC200LG6PC21 OLC-6, PC220LG6

i A

a. Port PB (from control valve)b. Port PA (from control valve)c. Port T (to tank)d. Pot-t P (from travel speed solenoid valve)

SPECIFICATIONS

Model

Item

Type

Theoreticaldelivery

Eated speed

Brake releasing pressure

Travel speedswitchingpressure

Differentialpressure

D4

xo7zzoo1

PC200-6PC2OOLC-6PC21 OLC-6

PC22OLC-6

HMVl60ADT-2

110.1 c/rev 1 118.4cclrev

160.8 cc/rev

34.79 MPa(355 kg/cm’ )

1,834 rpm 1,780 rpm

1,004 rpm 1,048 rpm

1.18 MPa(12 kg/cm’ )

0.78 MPa(8 kg/cm*)

1O 96




245878 17 18 19 20

1. Output shaft 9. Regulator valve2. Motor case 10. Spring3. Ball 11. Brake spring4. Rocker cam 12. Brake piston5. Piston 13. Plate6. Cylinder 14. Disc7. Valve plate 15. Regulator piston

8. End cover 16. Spring

XO7ZZOO

17. Check valve spring18. Check valve19. Counterbalance valve20. Spool return spring21. Safety valve22. Slow return valve

1o-97




TRAVEL MOTORPC25OLC-6

x0722003

a. T, port (To tank)b. PB port (From control valve)c. P port (From travel speed solenoid valve)d. PA port (From control valve)e. T, port (To tank)

SPECIFICATIONS

Item Model PC25OLC-6

Ratedspeed

Min.

MaX.

895 rpm

1.430 mm

1 98




245678

B-B

1. Output shaft2. Motor case3. Ball4. Rocker cam5. Piston

6. Cylinder7. Valve plate8. End cover

9. Regulator valve10. Spring11. Brake spring12. Brake piston13. Plate

14. Disc15. Regulator piston16. Spring

D-D 1’ 0 il

x0722004

17. Check valve spring18. Check valve19. Counterbalance valve20. Spool return spring21. Safety valve

22. Slow return valve

-99




OPERATION OF MOTOR1) Motor swash plate angle (capacity) at maximum

The solenoid valve is deactivated, so the pilotpressure oil from the control pump does not flowto port P.For this reason, regulator valve (9) is pushed tothe right in the direction of the arrow by spring(19).Because of this, it pushes check valve (22), andthe main pressure oil from the control valve go-ing to end cover (8) is shut off by regulator valve(9).Fulcrum a of rocker cam (4) is eccentric to pointof force b of the combined force of the propul-sion force of cylinder (6), so the combined forceof the piston propulsion force acts as a momentto angle rocker cam (4) in the direction of themaximum swash plate angle.

At the same time, the pressurized oil at regulatorpiston (15) passes through orifice c in regulatorvalve (9) and is drained to the motor case.As a result, rocker cam (4) moves in the maxi-mum swash plate angle direction, the motorcapacity becomes maximum.

1 l 0




OPERATION OF PARKING BRAKE1)

2)

When starting to travelWhen the travel lever is operated, the pres-sure oil from the pump actuates counterbalancevalve spool (19), opens the circuit to parkingbrake, and flows into chamber A of brake piston(72).It overcomes the force of spring (11) and pushespiston (12) to right in the direction of thearrow.When this happens, the force pushing plate (13)and disc (14) together is lost, so plate (13) anddisc (14) separate and the brake is released.

D-7- \\\14 13 A 12 11 22

When stopping travelWhen the travel lever is placed in neutral, coun-terbalance valve spool (19) returns to the neutral. . . . .posrtron and crrcurt to the parking brake IS closed.The pressurized oil in chamber A of brake piston(12) is drained to the case from the orifice in thebrake piston, and brake piston (12) is pushed tothe left in the direction of the arrow by spring(1%As a result, plate (13) and disc (14) are pushedtogether, and the brake is applied.A time delay is provided by having the pressu-rized oil pass through a throttle in slow returnvalve (22) when the brake piston returns, and thisensures that the brake still effective after themachine stops.

control valve

&xo uoo

14 13 12 11 22

lcontrol valve1

1 l 2




OPERATION OF BRAKE VALVEThe brake valve consists of a check valve, coun-terbalance valve, and safety valve in a circuit asshown in the diagram on the right. (Fig. 1)The function and operation of each component isas given below.

ounterbalance

1) Counterbalance valve, check valveFunction

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 engineat low speed, the motor will rotate without loadand the machine will run away, which is extremelydangerous.To prevent this, these valves act to make themachine travel according to the engine speed(pump discharge amount).

Operation when pressure oil is suppliedWhen the travel lever is operated, the pressu-rized oil from the control valve is supplied to portPA. It pushes open check valve (18A) and flowsfrom motor to inlet port MA to motor outlet portMB.However, the motor outlet port is closed by checkvalve (18B) and spool (19), so the pressure at thesupply side rises. (Fig. 2)The pressurized oil at the supply side flows fromorifice El in spool (19) and orifice E2 in the pis-ton to chamber Sl. When the pressure in cham-ber Sl goes above the spool switching pressure,spool (19) is pushed to the right in the directionof the arrow.As a result, port MB and port PB are connected,the outlet port side of the motor is opened, andthe motor starts to rotate. (Fig. 3)

l

l

(Fig. 2)

,Travel ontrol

valve

(Fig. 3)

1 o-1 03




Operation of brake when traveling downhillIf the machine tries to run away when travelingdownhill, the motor will turn under no load, sothe pressure at the motor inlet port will drop, andthe pressure in chamber Sl through orifices Eland E2 will also drop. When the pressure inchamber Sl drops below the spool switching

pressure, spool (19) is returned to the left in thedirection of the arrow by spring (20), and outletport MB is throttled.As a result, the pressure at the outlet port siderises, resistance is generated to the rotation of themotor, and this prevents the machine from run-ning away.In other words, the spool moves to a positionwhere the pressure at outlet port MB balancesthe pressure at the inlet port and the force gener-ated by the weight of the machine. It throttles theoutlet port circuit and controls the travel speedaccording to the amount of oil discharged from

the pump. (Fig. 4)

2) Safety valve (2-way operation, 24age setsafety valve

FunctionWhen travel is stopped (or when traveling down-hill), the circuits at the inlet and outlet ports ofthe motor are closed by the counterbalance valve,but the motor is rotated by inertia, so the pressureat the outlet port of the motor will become ab-normally high and damage the motor or piping.The safety valve acts to release this abnormalpressure and sent it to the inlet port side of themotor to prevent damage to the equipment.

Operation in both directions

Ii When pressure in chamber MB has becomehigh (when rotating clockwise)When the travel is stopped (of when travelingdownhill), chamber MB in the outlet port circuitis closed by the check valve of the counterbal-ance valve, but the pressure at the outlet portrises because of inertia. (Fig. 5)

If the pressure goes above the set pressure, theforce produced by the difference in area betweenDl and D2 [rr/4(Dl* - D2’ > X pressure] overcomes

the force of the spring and moves the poppet tothe left, so the oil flows to chamber MA in thecircuit on the opposite side. (Fig. 6)

Travel controlvalve

(Fig. 4)XO7ZZO12

xo7zzo13

(Fig. 5)

D2

/Poppet

(Fig. 6)

1O-l 04




2) When pressure in chamber MA has becomehigh (when rotating counterclockwise)When the travel is stopped (or when travelingdownhill), chamber MA in the outlet port circuitis closed be the check valve of the counterbal-ance valve, but the pressure at the outlet portrises because of inertia. (Fig. 7)

If the pressure goes above the set pressure, theforce produced by the difference in area betweenDl and D3 [n/4(D3’ - Dl’ > X pressure] overcomesthe force of the spring and moves the poppet tothe left, so the oil flows to chamber MB in thecircuit on the opposite side. (Fig. 8)

Operation of mechanism for varying set pressure1) When starting travel (high pressure setting)

When the travel lever is operated, the pressurizedoil from the pump actuates counterbalance valvespool (19), and opens the pilot circuit to the safetyvalve. The oil passes from chamber G to passageH and flows into chamber J, pushes the pistonto the right in the direction of the arrow, and comp-resses the spring to make the set load larger.Because of this, the set pressure of the safetyvalve is switched to the high pressure setting, anda large drawbar pull is made available.

xo7zzo15

(Fig. 7)

I

/Poppet XO7ZZO16

Fig. f9

Piston1

Travel ontrol

(Fig. 9)

1 l 5




2) When stopping travel (low pressure setting)When the travel lever is placed at neutral, thepressure in chamber PA drops and counterbal- Piston Spring

ante valve spool (19) returns to the neutral posi-tion. While the counterbalance valve spool isreturning to the neutral position, the pressurizedoil in chamber J passes through passage H, and

escapes to chamber PA from chamber G. Thepiston moves to the left in the direction of thearrow, and the set load becomes smaller. Be-cause of this, the set pressure of the safety valveis switched to the low pressure setting in order torelieve the shock when reducing speed.

[Set pressure of safety valve]

When starting, when traveling When stopping

High pressure setting Low pressure setting37.73 MPa (385 kg/cm*) 27.44 MPa (280 kg/cm*)

Travel control valve

. ,-/- XO7ZZO18

(Fig. 10)

IO 106



STRUCTURE AND FUNCTION VALVE CONTROL

VALVE CONTROLPC200-6, PC2OOLG6PC21 OLC-6, PC22OLC-6PC25OLG6

1

2.3.4.5.6.7.

8.9.

D

Travel PPC valve 10. Control valveService PPC valve 11. PPC shuttle valveService pedal 12. AccumulatorL.H. travel lever 13. Solenoid valveR.H. travel lever 14. L.H. work equipmentR.H. PPC valve leverR.H. work equipment 15. Safety lock valvelever 16. L.H. PPC valveLS control EPC valve 17. Safety lock leverHydraulic pump 18. Timing valve

i

\16

17

Lever positionsA. NeutralB. Boom RAISEC. Boom LOWERD. Bucket DUMPE. Bucket CURLF. NeutralG. Arm INH. Arm OUT

18

IO

/”

12

13

XlOAZo

I. Swing RIGHTJ. Swing LEFTK. NeutralL. Travel REVERSEM. Travel FORWARDN. LOCK0. FREE

1 o-1 07



STRUCTURE AND FUNCTION WORK EQUIPMENT . SWING PPC VALVE

WORK EQUIPMENT. SWING PPC VALVEPC200-6, PC2OOLC-6PC21 OLC-6, PC22OLC-6PC25OLC-6

XOQDH 25

a. Port P (from control pump)b. Port T (to tank)c. Port P2 (L.H.: Arm IN/R.H.: Boom RAISE)d. Port P4 (L.H.: Swing LEFT/R.H.: Bucket DUMP)e. Port PI (L.H.: Arm OUT/R.H.: Boom LOWER)f. Port P3 (L.H.: Swing RIGHT/R.H.: Bucket CURL)

IO 108



STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE

6

I

9

10

1 Spool2. Metering spring3. Piston

4. Disc5. Nut (for connecting lever)

D-D

X09DH026

7. Joint8. Plate9. Retainer

10. Body11. Filter

1o-1 09




OPERATION1) At neutral

2)

Ports A and B of the control valve and ports P,and P, of the PPC valve are connected to drainchamber D through fine control hole f in spool(1). (Fig. 1)

During fine control (neutral + fine control)When piston (4) starts to be pushed by disc (5),retainer (9) is pushed; spool (1) is also pushedby metering spring (2), and moves down.When this happens, fine control hole f is shutoff from drain chamber D, and at almost the sametime, it is connected to pump pressure chamberP,, so pilot pressure oil from the control pumppasses through fine control hole f and goes fromport P, to port A.When the pressure at port P, becomes higher,spool (1) is pushed back and fine control hole fis shut off from pump pressure chamber P,. Atalmost the same time, it is connected to drainchamber D to release the pressure at port P,.When this happens, spool (1) moves up or downso that the force of metering spring (2) is balancedwith the pressure at port P,. The relationship inthe position of spool (1) and body (10) (finecontrol hole f is at a point midway between drain

hole D and pump pressure chamber Pp) does notchange until retainer (9) contacts spool (1).Therefore, metering spring (2) is compressedproportionally to the amount of movement of thecontrol lever, so the pressure at port P, also risesin proportion to the travel of the control lever.In this way, the control valve spool moves to aposition where the pressure in chamber A (thesame as the pressure at port P,) and the forceof the control valve spool return spring arebalanced. (Fig. 2)

Control valve

X09DH027

4 :

7Jr\ r

X09DH028

(Fig. 2)

10 I 0




3) During fine control (when control lever isreturned)When disc (5) starts to be returned, spool (1) ispushed up by the force of centering spring (3)and the pressure at port P,.When this happens, fine control hole f is conn-ected to drain chamber D and the pressure oil

at port P, is released.If the pressure at port P, drops too far, spool (1)is pushed down by metering spring (2), and finecontrol hole f is shut off from drain chamber D.At almost the same time, it is connected to pumppressure chamber P,, and the pump pressureis supplied until the pressure at port P, recoversto a pressure that corresponds to the leverposition.When the spool of the control valve returns, oilin drain chamber D flows in from fine controlhole f ’ n the valve on the side that is not working.The oil passes through port P, and enters cham-ber B

tofill the chamber with oil. (Fig. 3)

4) At full strokeWhen disc (5) pushes down piston (4), and ret-ainer (9) pushes down spool (l), fine control holef is shut off from drain chamber D, and is conn-ected with pump pressure chamber P,.Therefore, the pilot pressure oil from the control

pump passes through fine control hole f and flowsto chamber A from port P,, and pushes the controlvalve spool.The oil returning from chamber B passes fromport P, through fine control hole f ’ and flows todrain chamber D. (Fig. 4)

X09DH029

(Fig. 3.)

Control valve

X09DH030

0%. 4)

1 l 1



STRUCTURE AND FUNCTION TRAVEL PPC VALVE

TRAVEL PPC VALVE

D D

b’C

e

XlOBH 55

a. Port P (from control pump)b. Port T (to tank)c. Port PI (L.H. travel REVERSE)d. Port P3 (R.H. travel REVERSE)e. Port P2 (L.H. travel FORWARD)f. Port P4 (R.H. travel FORWARD)

IO 112




6-

5’

A A

c-c

1. Piston 5. Valve2. Plate 6. Metering spring3. Collar 7. Centering spring4. Body 8. Bolt

D-D

XlOBH156

IO 113




OPERATION

1. At neutralPorts A and B of the control valve and ports PIand P2 of the PPC valve are connected to drainchamber D through fine control hole f in spool (1).(Fig. 1)

2. Fine control (neutral + fine control)When piston (4) starts to be pushed by disc (5),retainer (9) is pushed. Spool (1) is also pushed bymetering spring (2) and moves down.When this happens, fine control hole f is shut offfrom drain chamber D. At almost the same time,it is connected to pump pressure PP, and the pilotpressure of the control pump is sent from port Athrough fine control hole f to port PI. When thepressure at port PI rises, spool (1) is pushedback. Fine control hole f is shut off from pumppressure chamber PP. At almost the same time,it is connected to drain chamber D, so the pres-sure at port PI escapes.As a result, spool (1) moves up and down untilthe force of metering spring (2) is balanced withthe pressure of port PI.The relationship of the positions of spool (1) andbody (10) (fine control hole f is in the middlebetween drain hole D and pump pressure cham-ber PP) does not change until retainer (9) con-tacts spool (1).

Therefore, metering spring (2) is compressed inproportion to the travel of the control lever, so thepressure at port PI also rises in proportion to thetravel of the control lever.In this way, the spool of the control valve moves toa position where the pressure of chamber A(same as pressure at port PI) and the force of thereturn spring of the control valve spool are bal-anced. (Fig. 2)

Control valve

XlOBH157

(Fig. 1)

ii&Control va

(Fig. 2)

IO 114



STRUCTURE AND FUNCTION

Fine control (control lever returned)When disc (5) starts to be returned, spool (1) ispushed up by the force of centering spring (3)and the pressure at port PI.Because of this, fine control hole f is connectedto drain chamber D, and the pressurized oil atport PI is released.

If the pressure at port PI drops too much, spool(1) is pushed up by metering spring (2), so finecontrol hole f is shut off from drain chamber D.At almost the same time, it is connected to pumppressure chamber PP, so the pressure at port PIsupplies the pump pressure until the pressurerecovers to a pressure equivalent to the positionof the lever.When the control valve returns, oil in drain cham-ber D flows in from fine control hole f ’ of the valveon the side that is not moving. It passes throughport P2 and goes to chamber B to charge the oil.(Fig. 3)

4) At full strokeDisc (5) pushes down piston (4), and retainer (9)pushes down spool (1). Fine control hole f is shutoff from drain chamber D, and is connected topump pressure chamber PP. Therefore, the pilotpressure oil from the control pump passesthrough fine control hole f and flows to chamberA from port PI to push the control valve spool.The return oil from chamber B passes from portP2 through fine control hole f ’ and flows to drain

chamber D. (Fig. 4)

TRAVEL PPC VALVE

XlOBH1(Fig. 3)

XlOBH16(Fig. 4)

IO I 5



STRUCTURE AND FUNCTION SERVICE PPC VALVE

SERVICE PPC VALVE

1. Pin2. Cam3. Ball4. Piston5. Cover6. Sleeve7. Centering spring8. Metering spring9. Spool

10. Body

a. Port T (to tank)b. Port P (from control pump)c. Port A (to service valve P,)d. Port B (to service valve PJ

dXlOBHlGl

IO 116




OPERATION

At neutralThe pressurized oil from the control pumpenters from port P and is blocked by spool(9).Port A and B of the control valve and port aand b of the PPC valve are connected todrain port T through fine control hole X ofspool (9).

When operatedWhen cam (2) is moved, metering spring (8)is pushed by ball (3), piston (4) and sleeve (6),and spool (9) is also pushed down by this.As a result, fine control hole X is shut off fromthe drain circuit. At almost the same time, finecontrol portion Y is connected with port a, and thepressurized oil from port A of the control valve.

XlOBH 62

XlOBH 63

IO 117




When the pressure at port a becomes higher,spool (9) is pushed back by the force actingon the end of the spool. When tine controlportion Y closes, fine control hole X is conn-ected to the drain circuit at almost the sametime.As a result, spool (9) moves up and down to

balance the force at port a and the force atmetering spring (8).Therefore, metering spring (8) is compressed inproportion to the amount the control lever ismoved. The spring force becomes larger, sothe pressure at port a also increases in propor-tion to the amount the control lever is operated.In this way, the control valve spool moves to aposition where the pressure of port A (the sameas the pressure at port a is balanced with theforce of the return spring of the control valvespool.

XlOBH 64

IO 118



STRUCTURE AND FUNCTION SAFETY LOCK VALVE. PPC ACCUMULATOR

SAFETY LOCK VALVE

PPC ACCUMULATOR

1. Lever2. Body3. Seat4. Ball

5. End cap

XlOBH165

6-

XlOBH166

1. Gas plug2. Shell3. Poppet4. Holder5. Bladder6. Oil port

SPECIFICATIONSGas capacity: 400 cc

1 l 9



STRUCTURE AND FUNCTION PPC SHUTTLE. TRAVEL JUNCTION VALVE

PPC SHUTTLE. TRAVEL JUNCTION VALVE

1. PPC shuttle valve2. Travel junction valve

XlOBH167

OUTLINEThe PPC shuttle valve and travel junction valveform a combined structure.

1 O-l 20



STRUCTURE AND FUNCTION PPC SHUTTLE TRAVEL JUNCTION VALVE

PPCSHUTTLEVALVE

n

P

r

u

X

ba

cb

ee

XlOBH168

FUNCTIONThis sends the PPC valve output pressure orEPC valve output pressure to the control valveand travel junction valve. It is provided with amount port for the pressure switch for detect-ing the pilot pressure.

IO 121




a. Port PI 1 (from swing PPC valve)b. Port P21 (from swing PPC valve)c. Port P31 (from bucket PPC valve)d. Port P41 (from bucket PPC valve)e. Port P51 (from boom PPC valve)f. Port P61 (from arm PPCYEPC valve)g. Port PLS (from LS select valve)

h. Port P71 (from arm PPC/EPC valve)i. Port P81 (from boom PPC/EPC valve)j. Port PA1 (from R.H. travel PPC valve)k. Port PBI (from L.H. travel PPC valve)I. Port PC1 (from L.H. travel PPC valve)m. Port P91 (from R.H. travel PPC valve)n. Port PI2 [to control valve (swing)]0. Port P22 [to control valve (swing)]p. Port P32 [to control valve (bucket)]q. Port P42 [to control valve (bucket)]r. Port P52 [to control valve (boom)]s. Port P62 [to control valve (arm)]t. Port P72 [to control valve (arm)]

u. Port P82 [to control valve (boom)]v. Port PA2 [to control valve (R.H. travel)]w. Port PB2 [to control valve (L.H. travel)]x. Port PC2 [to control valve (L.H. travel)]y. Port P92 [to control valve (R.H. travel)]zl. Port PR (to travel junction valve)z2. Port PF (to travel junction valve)aa. Port Al (mount port for swing oil pressure switch)bb. Port A8 (mount port for bucket DUMP oil pressure switch)ca. Port A2 (mount port for arm OUT oil pressure switch)cb. Port A4 (mount port for arm IN oil pressure switch)da. Port A5 (mount port for boom RAISE oil pressure switch)db. Port A7 (mount port for boom LOWER oil pressure switch)ee. Port A6 (mount port for travel oil pressure switch)

1 O-l 22




33

2 2

F-F A-A

G G B-B

J-J(2PLACES)

K-K(2PLACES

L__--- --...___J

N-N

L-L E-E

AA-AA XlOBH169

1. Body2. Plug3. Ball

IO 123




TRAVEL JUNCTION VALVE

e f

1. Body2. Plug3. Spring4. Spool

d

A A XlOBH170

a. Port Tl (from R.H. travel control valve)b. Port T2 (from L.H. travel control valve)c. Port T3 (from R.H. travel control valve)d. Pot-t T4 (from L.H. travel control valve)e. Port PF (from PPC shuttle valve)f. Port PR (from PPC shuttle valve)

IO 124




STRAIGHT-TRAVEL SYSTEM

R.H. PPC valveBoom Bucket

PPC shuttle va lve assembly

r.&-I--------A-+-Bucket CURL

FORWARD

L.H. travel motor R.H. travel motor

L

FUNCTION

XlODD045

A travel junction valve is installed between thetravel valve and travel motor to compensate forany difference in the oil flow to the left and righttravel circuits when traveling in a straight line.Because of this, the flow of oil to the left andright travel motors when traveling in a straight

line is almost the same, so there is no traveldeviation.The travel junction valve interconnects the travelcircuits when the straight-travel is operated inde-pendently or when the straight travel + anotheractuator are operated simultaneously.

When steering, if the difference in the movementof the travel levers is more that approximately10 mm, the travel junction valve is switched, andthe left and right travel circuits are shut off.

IO 125




OPERATIONA: PPC output pressure (R.H. travel REVERSE or

L.H. travel FORWARD)B: PPC output pressure (R.H. travel FORWARD or

L.H. travel REVERSE)

When traveling in a straight line in forward or

reverseWhen traveling forward (or in reverse), there isno difference in the pilot pressure from the PPCshuttle valve (the output pressure of each PPCvalve), so the spool is balanced in the middle.In this condition, the R.H. FORWARD and L.H.FORWARD, and R.H. REVERSE and L.H.REVERSE are interconnected through the spool.

When steering in forward or reverseWhen the steering is operated in forward (or re-verse), if the difference in the pilot pressure fromthe PPC shuttle valve becomes greater than theswitching pressure (spring force), the spool movesto the right or left and the L.H. and R.H. forwardand L.H. and R.H. reverse passages are sepa-rated. Because of this, a difference in pressure iscreated in the L.H. and R.H. circuits, and thesteering can be operated.

From control valve From ppc From control valve(L.H. REVERSE) shutt,e va,ve (L.H; FORWARD)

From control valve(R.H. REVERSE)

From control valve(R.H. FORWARD) XlODD046

From control valve(L.H. REVERSE) From ppc

From control valve(L.H. FORWARD)

I shuttle valve I

From control valve From control valve(R.H. REVERSE) (R.H. FORWARD) XlODD047

1 O-l 26



STRUCTURE AND FUNCTION EPC . SOLENOID VALVE

EPC . SOLENOID VALVELS SELECT, PUMP MERGE-DIVIDER, 2 STAGE RELIEF, TRAVEL SPEED,SWING BRAKE SOLENOID VALVE

a

1. LS select solenoid valve2. 2-stage relief solenoid valve3. Pump merge-divider solenoid valve4. Travel speed solenoid valve

5. Swing brake solenoid valve

a.b.

::

e.f.9.h.i.j.

To tankFrom control pumpTo PPCYEPC valveFrom PPC shuttle valve

To LS select valveTo LS relief valveTo pump merge-divider valveTo L.H. and R.H. travel motorTo swing motorTo accumulator

XlOBH 7

1O-l 27




1. Connector2. Variable core3. Coil4. Cage5. Spool

6. Block7. Spring

OPERATION

i XlOBH172

When solenoid is deactivatedThe signal current does not flow from the con-troller, so coil (3) is deactivated.For this reason, spool (5) is pushed to the right inthe direction of the arrow by spring (6).As a result, the circuit between ports P and Acloses and the pressurized oil from the controlpump does not flow to the actuator.At the same time, the pressurized oil from theactuator flows from port A to port T, and is thendrained to the tank.

X1 DD 48

When solenoid is excitedWhen the signal current flows from the controllerto coil (3), coil (3) is excited.For this reason, spool (5) is pushed to the left in IM

the direction of the arrow.As a result, the pressurized oil from the controlpump flows from port P through the inside ofspool (5) to port A, and then flows to the actua-tor.At the same time, port T is closed, and this stopsthe oil from flowing to the tank.

i XlODD 49

IO 128




LS CONTROL EPC VALVE

a 2 3 4 5 6

b

1. Body 5. Coil2. Spool 6. Plunger3. Spring 7. Connector4. Push pin

i

XlOBH173

a. Port C (to LS valve)b. Port T (to tank)c. Port P (from control pump)

1O l 9



STRUCTURE AND FUNCTION EPC SOLENOID VALVE

FUNCTIONThe EPC valve consists of the proportional sole-noid portion and the hydraulic valve portion.When it receives signal current i from the valvecontroller, it generates the EPC output pressurein proportion to the size of the signal, and outputsit to the control valve.

OPERATION1. When signal current is 0 (coil deactivated)

There is no signal current flowing from the con-troller to coil (5), coil (5) is deactivated.For this reason, spool (2) is pushed to the right inthe direction of the arrow by spring (3).As a result, port P closes and the pressurized oilfrom the control pump does not flow to the LSvalve.At the same time, the pressurized oil from the LSvalve passes from port C through port T and isdrained to the tank.

2.94(30)

2.45_(25)

il

?

1.96_

~ = (20)2 “E??ca CD 1.47_5 Y (15)

s T

sr 0.98.(10)

0.49_(5)

200 400 600 800 1000 mA

Current i (mA) XlODD050

LS valve9 I

‘ ~ ,,: :/:/::,:.:j

XlODDOSl

1 o-1 30




When signal current is very small (coil excited)When a very small signal current flows to coil (5),coil (5) is excited, and a propulsion force is gener-ated, which pushes plunger (6) to the left in thedirection of the arrow.Push pin (4) pushes spool (2) to the left in thedirection of the arrow, and pressurized oil flows

from port P to port C.When the pressure at port C rises and the load ofspring (3) + the force acting on the surface a ofspool (2) becomes greater than the proportionforce of plunger (6), spool (2) is pushed to the rightin the direction of the arrow. The circuit betweenport P and port C is shut off, and at the same time,port C and port T are connected.As a result, spool (2) is moved to the left or rightuntil the propulsion force of plunger (6) is balancedwith the load of spring (3) + pressure of port C.Therefore, the circuit pressure between the EPCvalve and the LS valve is controlled in proportion

to the size of the signal current.

When the signal current is maximum (coilexcited)When the signal current flows to coil (5), coil (5)is excited.When this happens, the signal current is at itsmaximum, so the propulsion force of plunger (6)is also at its maximum.For this reason, spool (1) is pushed to the left in thedirection of the arrow by push pin (4).As a result, the maximum flow of pressurized oilfrom port P flows at its maximum to port C, and thecircuit pressure between the EPC valve and LSvalve becomes the maximum.At the same time, port T closes and stops the oilfrom flowing to the tank.

-7 XlODD0

IO 131




BOOM HOLDING VALVE

* For machine equipped with arm holding valve, the structure and function of the arm holding valve is the sameas this valve.

B-B

4

5

I 1-1 II I 1

A-A

0 0

0 0

H0 0

00

XlOBH174

1. Safety-suction valve2. Pilot spring3. Pilot spool4. Poppet spring5. Poppet

1 O-l 32




OPERATION

1) At boom RAISEWhen the boom is raised, the main pressure fromthe control valve pushes poppet (5) up in thedirection of the arrow.Because of this, the main pressure from the con-

trol valve passes through the valve and flows tothe bottom end of the boom cylinder.

2) Boom lever at NEUTRALWhen the boom is raised and the control lever isreturned to NEUTRAL, the circuit for the holdingpressure at the bottom end of the boom cylinderis closed by poppet (5), and at the same time, theoil flowing into poppet (5) through orifice a ofpoppet (5) is closed by pilot spool (3). As a result,

the boom is held in position.

1 O-l 33




3) At boom LOWERWhen the boom is lowered, the pilot pressurefrom the PPC valve pushes pilot spool (3) and thepressurized oil in chamber b inside the poppet isdrained.When the pressure at port C, rises because ofthe pressurized oil from the bottom end of the

boom cylinder, the pressure of the pressurizedoil in chamber b is lowered by orifice a.If the pressure in chamber b drops below the pres-sure at port V, poppet (5) opens, the pressurizedoil flows from port C, to port V, and then flows tothe control valve.If any abnormal pressure is generated in the circuitat the bottom end of the boom cylinder, safety valve(1) is actuated.

iYgg?JXlODD 56

1 o-1 34



STRUCTURE AND FUNCTION HYDRAULIC CYLINDER

HYDRAULIC CYLINDER

SPECIFICATIONSUnit: mm

Item

Outside diameter ofpiston rod

Boom Arm Bucket

PC200-6PC200LC-6 PC22OLC-6

I

PC21 OLC-6 PC25OLC-6

130

I

140

Inside diameter ofcylinder

Stroke

90 1 95 1 80 90

I

1,285 1,285

Max. stroke

Min. stroke

Width across flatsof piston nut

95 95

135

I-

140 115 130

1,490 1,635 1,120 1,020

3,565 3,870 2,800 2,625

2,075 2,235 1,680 1,605

95 95 95 95

1 O-l 35



STRUCTURE AND FUNCTION ADDITIONAL FILTER FOR BREAKER

ADDITIONAL FILTER FOR BREAKER* FOR MACHINES EQUIPPED WITH BREAKER

I. Head cover2. Element3. Case4. Drain plug5. Valve

6. Spring7. Spring set plug

XlOBV051

SPECIFICATIONSRated pressure : 6.86 MPa (70 kg/cm?Flow . 107Plmin

.elief valvecracking pressure : 0.34 + 0.049 MPa

(3.5 f 0.5 kg/cm?Filter mesh size : 6wFiltering area : 3160 cm*

1 O-l 36



STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE

OVERLOAD WARNING DEVICE1. OUTLINE

Battery-.-

Buzzer

Boom controlvalve

/

Hydraulicpu/mps

FUNCTIONThis device is installed to warn the operatorwhen the machine is close to tipping over whenit lifts an excessive weight while being usedas a crane.

STRUCTURE

When an excessive weight is lifted, the oilpressure goes up at the bottom side of theboom cylinders. When this happens, thepressure switch senses the rising pressure,turns the pressure switch on, and lights themonitor lamp to warn the operator. When themonitor lamp lights, immediately lower theweight to the ground or bring the arm closerin to the operator to prevent the machine fromtipping over.

XO8BTOOl

1O-l 37




Control panel

Overload warning pilot lamp

\‘ \

i\

I 4

r’ =.8Bs88

XllAH003

1 O-l 38




3. ADJUSTING PRESSURE OF THE OILPRESSURE SWITCHScrew D: Pressure range adjustment screw

To make an adjustment so that theoil pressure switch acts normallywhen checking the operation of theoverload warning device.

Turning to the left makes the pres-sure range wider.

Screw E: Zero point adjustment screwTurning to the right one completeturn raises the pressure by 57 kg/cm*.Each complete turn to the left lowersthe pressure by 57 kg/cm’ .

A When an adjustment is required, contact your

Komatsu distributor and have him make theadjustment.

1. Body2. Bourdon tube3. Eccentric disc4. Microswitch5. Lever and roller6. Adjustment screw (E)7. Adjustment screw (D)

\Screw E XO8BTOO4

IO 140



STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM)

HOSE BURST PROTECTION VALVE (BOOM)

High pressure fromcontrol valve (v port)

Pilot signal(Pi port)

&3Jpad caution

To cylinder portKY port)

FUNCTION

This valve prevents sudden uncontrolledlowering of the boom, when lifting, due tothe burst of a hose in the boom cylinder line.In such a condition this valve will hold theload until the operator lowers the boom in acontrolled way using the normal wrist control.

To tank (T port)

1. Body2. Spool3. Relief valve4. Check valve

XlOBH175

IO 141



STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM

OPERATIONBOOM RAISE

During boom raising the pilot signal fromwrist control operates control valve spool todirect high pressure oil to port V of hoseburst valve.This pressure lifts check valve (4) from seat

and high pressure oil flows in the bottom of thecylinder, raising the boom

BOOM LOWERDuring boom lowering, the pilot signal reversesthe front through the control valve spool. Highpressure oil flows to the head side of the cylinder.Oil in the bottom side of the cylinder flows throughthe port C, of the valve but cannot flow past thecheck valve. The pilot signal also opens the spool(2) of the hose burst valve and allows oil to flowback to tank.

v port

.~,:.~._:.:,.,...____.._.:_>>:.:..,:.:._.........c:.:.:.:.:.: ..A...... . . . . . . . . . . ..‘.....I....-‘”

~

Boom control

w XlODD057

XlODD058

IO 142



STRUCTURE AND FUNCTION HOSE BURST PROTECTION VALVE (BOOM)

When hose burst occurs (Operation to lower safety)The sudden loss of pressure at port V will causecheck valve (4) to re-seat and so the valve islocked.The boom can be lowered in a controlled way byoperating the wrist control in the normal way.

v port\

mtrol

IO 143



STRUCTURE AND FUNCTIONWORK EQUIPMENT

WORK EQUIPMENT

X1722023

1. Arm2. Bucket cylinder3. Arm cylinder4. Boom5. Boom cylinder6. Bucket

IO 144



ELECTRICAL CIRCUIT DIAGRAM (112)

(TO2/2)

I 2/2) 2/2) 2/2) 2

?=BLUENWHOI

LTO

FOLDOUT 24

EN- HO

(TO2) 2/2 1 2/2)

IO-1450



ELECTRICAL CIRCUIT DIAGRA M (2/2)

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TOl / 2 )

(TOl / 2 )

(TO1/21

(TOl / 2 )

t -_-_ ---___ _________-

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IO-1460



ELECTRICAL WIRING DIAGRAM FOLDPC200-6, PC200LC-6PC21 OLC-6, PC22O LC-6PC25OLG6

i /

P /;i _

l96

12

13

14

15

16

I O



FOLD

483

\55

56

$8205FO629 I

1. Fuel level sensor2. Working lights3. Hydraulic oil level sensor4. LS control EPC valve5. Rear pump pressure sensor6. Front pump pressure sensor7. Rear pump TVC valve8. Front pump TVC valve9. Rear working light

10. Governor motor11. Engine speed sensor12. Engine oil pressure sensor (Hi)13. Engine oil pressure sensor (Lo)14. Air cleaner clogging sensor15. Coolant level sensor16. Window washer motor17. Travel alarm18. Horn (high tone)19. Horn (low tone)20. Battery relay21. R.H. head light22. Battery23. Wiper motor24. Horn switch25. R.H. additional light26. Room lamp27. L.H. additional light28. L.H. knob switch29. Alternator30. Coolant temperature sensor31. Electrical i ntake air heater32. Engine oil level sensor

36. Fuse box37. Caution buzzer38. Starting switch39. Fuel control dial40. Cigarette lighter41. Swing lick switch42. Wiper switch43. Light switch44. Buzzer cancel switch45. Service meter46. Speaker47. Kerosene mode connector48. Air conditioner control panel49. Engine throttle controller50. Pump controller51. Radio52. TVC prolix resisto r53. Wiper motor controller54. Additional light relay55. Light relay56. Monitor panel57. Swing lock prolix switch58. TVC prolix switch59. Swing oil pressure switch60. Bucket CURL oil pressure switch61. Bucket DUMP oil pressure switch62. Arm IN oil pressure switch63. Boom LOWER oil pressure switch64. Arm OUT oil pressure switch65. Travel oil pressure switch66. Boom RAISE oil pressure switch67. Swing brake solenoid valve68. Travel speed solenoid valve69. Pump merge-divider solenoid valve70. 2-stage relief solenoid valve71. LS select solenoid valve

67205F06292



STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM

1. Battery relay2. Battery3. Starting switch4. Fuel control dial5. Governor motor6. Starting motor7. Engine throttle controller8. Fuel injection pump

X12BV078

FUNCTIONThe engine can be started and stopped simplyby using the starting switch.A dial type engine control is used to control theengine speed. The engine throttle controllerreceives the control signal from the fuel controldial, sends a drive signal to the governor motor,and controls the angle of the governor lever in thefuel injection pump.At the same time, the engine throttle controlleralso receives signals from other controllers tocontrol the engine speed.

IO 149




1. OPERATION OF SYSTEMStarting engine

When the starting switch is turned to the STARTposition, the starting signal flows to the startingmotor, and the starting motor turns to start theengine.When this happens, the engine throttle controller

checks the signal from the fuel control dial andsets the engine speed to the speed set by the fuelcontrol dial.

uel control dial

IThrottle

IPower source)-__

signal)X12BV079

Engine speed controlThe fuel control dial sends a signal to the enginethrottle controller according to the position of thedial. The engine throttle controller calculates theangle of the governor motor according to thissignal, and send a signal to drive the governormotor so that it is at that angle.When this happens, the operating angle of thegovernor motor is detected by the potentiometer,and feedback is sent to the engine throttle con-troller, so that it can observe the operation of thegovernor motor.

uel control dial

X12BV080

Stopping engineWhen the starting switch is turned to the STOPposition, the engine throttle controller drives thegovernor motor so that the governor lever is setto the NO INJECTION position.

When this happens, to maintain the electric powerin the system until the engine stops completely,the engine throttle controller itself drives the batteryrelay.

uel control dial

-1 50




2. COMPONENTS OF SYSTEM1) FUEL CONTROL DIAL

HIGH A--i

Front of machine

6

A-AComposition of circuit

X12BV082

FUNCTIONThe fuel control dial is installed at the bottom of themonitor panel. A potentiometer is installed under

the knob, and when the knob is turned, it rotatesthe potentiometer shaft.When the shaft rotates, the resistance of the vari-able resistor inside the potentiometer changes, andthe desired throttle signal is sent to the enginethrottle controller.The shaded area in the graph on the right is theabnormality detection area and the engine speedis set at low idling.

1. Knob2. Dial3. Spring4. Ball5. Potentiometer6. Connector

0 0.25 1 4 4.75 5 Voltage

Characteristics of throttle voltage X12BV

IO 151




2) GOVERNOR MOTOR

FUNCTION

The motor is rotated and the governor lever of thefuel injection pump is controlled by the drive signalfrom the engine throttle controller.A stepping motor is used for the motor which pro-vides the motive power. In addition, a potentio-meter for giving feedback is installed to allowobservation of the operation of the motor.The rotation of the motor is transmitted to thepotentiometer through a gear.

1. Potentiometer2. Cover3. Shaft4. Dust seal5. Bearing6. Motor7. Gear

8. Connector

X12BV085

OPERATION

Motor stationaryBoth A phase and B phase of the motor are con-tinuous, and a holding torque is generated in themotor.

Motor rotatingA pulse current is applied to the A phase and Bphase from the engine throttle controller to givesynchronous rotation with the pulse.

1O-l 52




CN-EOl

X12BV088

Input and output signalsCN-EOI

No. Name of signal I Input/output

Controller power source (24V) I -

2

3

4 Auto deceleration

5

6

7

8

9

Controller power source (24V)-

Network circuit (-)-

I Input

Potentiometer power source (5V) I -

Starting switch ON signal

Fuel control dial

Input

Input

Model selection 1

Model selection 3

Input

Input

Governor motor drive A (+)

Governor motor drive B (+)

output

output

No. Name of signal Input/output

12 GND Input

13 Battery relay drive output

14 Network circuit (pump +)-

5 Network circuit (monitor +)-

16 Potentiometer GND-

17 Governor motor potentiometer signal

18 Model selection 2

Input

Input

9 Model selection 4

20 Governor motor drive A (-)

Input

output

121 Governor motor drive B (-) output

1 O-l 53



ELECTRONIC CONTROL SYSTEMCONTROL FUNCTION

Electronic control system

X12BV087

Pump 2% engine mutual control function

2I I

Pump and valve control functionI

~ Power maximizing function

3

Swift slow-down function

4

Auto-deceleration function

5

Engine automatic warming-up, overheatprevention function

Swing priority function

7

Swing control system

8

- Travel control function

Self-diagnostic function

* For details of the self-diagnostic function, seeTROUBLESHOOTING.

1O-l 54



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STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM

1. PUMP AND ENGINE MUTUAL CONTROL FUNCTION

F ue l c on tr o d a

II Work equipment levers

L H K no b s wi tc h

M on t o r p an e X12BV

FUNCTIONThere are five modes available for selection withthe working mode switch on the monitor panel.These modes are the heavy-duty operation ( H/O)mode, general operation (G/O) mode, finishingoperation (F/O) mode, and the breaker operation(B/O) mode. It is possible to select the mostsuitable engine torque and pump absorptiontorque to match the nature of the work.

The pump controller detects the actual enginespeed and the speed set by the engine governorthrough the fuel control dial in accordance withthe pump absorption torque set for each mode, andcarries out control so that the pump absorbs all ofthe torque at each output point of the engine.

Engine torque cotve Engine horsepower curve

UO+ H/O2 Power max.05

~~

: G/O, F/O, B/O‘6I.5 L/O

Engine speed N Engine speed N

. Pump output curve

Pump discharge amount Q X

1 O-l 56




Lifting operation (L/O) mode

Matching point in lifting operation mode:60 % partial output point

Engine speed N

Power maximizing mode

Pump discharge amount 0

XlZBV092

When the lifting operation mode is selected, theengine speed is automatically lowered to the par-tial position.In this condition, control is carried out in the sameway as for the general operation, finishing opera-

tion, and breaker operation modes to match theload in the pump.In this way, the fuel consumption is reduced andthe fine control ability is improved.

Engine speed N Engine speed N Pump discharge a mount Q

XlZBV093

Matching point in power max. mode: When the pump load increases, the engine speeddrops.When this happens, the pump discharge is reducedto prevent the engine speed from going down andto ensure that the engine is used at near the rated

1O-l 58




3)

Pump control function when traveling

Engine speed N Pump discharge a mount Q

X12BV094

When the machine travels in the heavy-duty opera-tion (H/O) mode, the engine speed rises, and thepump is controlled in the same way as when in thepower maximizing mode.

Engine speed N Pump discharge a mount Q

X12BV095

When the machine travels in any mode other than

the heavy-duty operation (H/O) mode, the workingmode and engine speed are kept as they are, andthe pump absorption torque is increased.

Control function when WC prolix switch is ON

P: ON (Prolix)

N: OFF (Normal)~__I,.____,

Even if any abnormality should occur in the con-troller or sensor, the TVC prolix switch can beturned ON to provide an absorption torque moreor less equivalent to the general operation (G/O)mode, thereby allowing the machine to maintain itsfunctions.

Pump discharge amount 0

X12BVO96

In this case, it is designed to allow a constant cur-rent to flow from the battery to the TVC valve, sooil pressure sensing is carried out only by the TVCvalve.

1 l 9




2. PUMP AND VALVE CONTROL FUNCTION

Solenoid ,- - - - 7valve I ra,L--------7

Fuel control dial

Ingine throttle O~Xldkr

I

ump merge-divider valv

Pump controller

Yi

. /Monitor panel

X12BV097

FUNCTIONThe following two functions are available toprovide the optimum matching under variousworking conditions: a 2-stage relief functionwhich increases the digging power, and a finecontrol mode function which improves the easeof fine control.

IO 160




1)

2)

3)

LS control functionThe switching point (LS set differential pressure)for the pump discharge amount inside the LSvalve is changed by changing the output pressurefrom the LS control EPC valve to the LS valveaccording to the engine speed and operating con-dition of the actuator.

Because of this, the timing of starting the dischargeamount from the pump can be optimized, to giveexcellent ease of compound operation and tinecontrol.

Cut-off functionFor details of the operation, see CLSS

S-stage relief functionThe relief pressure for normal operation is 31.85MPa (325 kg/cm?, but when the 2-stage relieffunction is actuated, the relief pressure rises toapproximately 34.79 MPa (255 kg/cm?.Because of this, the hydraulic pressure is increasedby one stage.

Actuating conditions for 2-stage relief function

Conditions Relief pressure

. When traveling31.85 MPa

. When swing lock switch is ON (325 kg/cm*)

. In lifting operation (L/O) mode0

. When power max. function or 34.79 MPaswift slow-down function are (355 kg/cm’ )actuated

EPC pressure at2.94 MPa (30 kg/cm’ )

0 MPa (0 kg/cm’ )

LS set differential pressure

X12BV09

IO 161




4) Fine control node functionWhen the finishing operation (F/O) mode is selec-ted from the working mode, the pump LS valve iscontrolled, and the pump discharge amount is re-duced to improve the ease of fine control and theprecision when finishing.

Relationship between working mode and pumpdischarge amount (for independent operation)

Actuator

Mode

Heavy-duty operation (H/O)

General operation (G/O)

Finishing operation (F/O)

Lifting operation (UO)

Breaker operation (B/O)

Boom ArmBucket

RAISE LOWER IN OUT

100 1 40 1 100 / 100 1 50

__I00 5050> 40 500 1000 40 3550)

1 40 I 100 I 100 I 50

5

40 (50)

35

50

Breaker

60

***

The figures in () are for the PC200The figures in < > are for when arm IN is operated.In each working mode, the full flow of the pump atthe set engine speed is taken as 100%.

1 O-l 62




3. POWER MAXIMIZING, SWIFT SLOW-DOWN FUNCTION

Fuel control

Pump controller

Monitor panel

X12BV099

FUNCTIONThis function provides an increase in the diggingpower for a certain time or switches the workingmode to the lifting operation (L/O) and reduces thespeed. It is operated using the L.H. knob switch tomomentarily match the operating conditions.

* The power max. function and swift slow-down functionare operated with the same switch. Only one of thesefunctions can be selected at any time; they cannot bothbe operated together.

1 O-l 63




1) Power maximizing functionDuring digging operations, when that extra bitof digging power is needed (for example, whendigging up boulders), the L.H. knob switch canbe pressed to raise the hydraulic pressure byapprox. 10% and increase the digging force.If the L.H. knob switch is pressed ON when the

working mode is at H/O or G/O, each functionis automatically set as follows.

Workingmode

Enginepump control

2-stage relieffunction

Actuatingtime

2) Swift slow-down functionDuring normal operations, if it is desired to carry outlifting operations or finishing operations for a mo-ment, the working mode can be switched to liftingoperation (L/O) mode by operating the L.H. knobswitch.If the L.H. knob switch is pressed ON when theworking mode is at H/O or G/O, each function isautomatically set as follows.

Working mode Actuating time

I Lifting operation While switch is kept pressed I

1 O-l 64




4. AUTO-DECELERATION FUNCTION

R.H. work equipment lever

BoomA &ucket

Monitor panel

=

Engine

Governor motor

Main pump

Fuel control dial 3

Engine throttlecontroller

1L.H. travel OTravel lever’

I I pressure [i switch ,

I In Pump controller

1 1

X12BVlOO

FUNCTIONIf all the control levers are at neutral when waitingfor work or waiting for a dump truck, the enginespeed is automatically reduced to a midrange speedto reduce fuel consumption and noise.If any lever is operated, the engine speed returnsimmediately to the set speed.

1 O-l 65




OPERATIONControl levers at neutral

When control lever is operatedif any control lever is operated when the engine

If the engine is running at above the decelerationactuation speed (approx. 1400 rpm), and all thecontrol levers are returned to neutral, the enginespeed drops immediately to approx. 100 rpmbelow the set speed to the No. 1 deceleration pos-

tion.If another 4 seconds passes, the engine speed isreduced to the No. 2 deceleration position (approx.1400 rpm), and is kept at that speed until a leveris operated.

speed is at No. 2 deceleration, the engine speedwill immediately rise to the speed set by the fuelcontrol dial.

Speed (rpml

No. 1 deceleration

No. 2 deceleration

(1,400)III>

4 Less than 2 Less--

than 1

i ILevers at neutral Lever operated

se4

XlZBVlOl

1 o-1 66




5. AUTOMATIC WARMING-UP AND ENGINE OVERHEAT PREVENTION FUNCTION

(Coolant temperature signal)

I 1

IEngine

Coolant temperature

Governor motor

Fuel control dial 1

Main pump

/LS valve

TTf TVCva vel

t’ =m&OS 0I 5 5 ‘ ZL 5 B 1 .”

a

A c a .?3 ,G

(Network signal)- Engine throttle - .: c

controllerPump controller

(Network signal)c

uu

X12BV102

FUNCTIONIf the coolant temperature is low, this automaticallyraises the engine speed to warm up the engine afterit is started. (Automatic warming-up function)In addition, if the coolant temperature rises too highduring operations, it reduces the load of the pumpto prevent overheating. (Engine overheat preventionfunction)

1 O-l 67




1) Engine automatic warming-up functionAfter the engine is started, if the engine coolanttemperature is low, the engine speed is auto-matically raised to warm up the engine.

Conditions for actuation (both are necessary)

Conditions for cancellation (any one)

1 Coolant temoerature: 30°C or above

X12BV103

1 O-l 68




2) Engine overheat prevention functionThis function protects the engine by loweringthe pump load and engine speed to preventoverheating when the engine coolant temp-erature has risen too far.This system is actuated in two stages. Thefirst stage is when the water temperature is

between 102°C and 105” C, and the secondstage is when the water temperature is 105°Cand above.

Normal operation (coolant temperature below 102°C)-

6-st85Ebz

L

Coolant temperature:Below 102°C

(Coolant temperaturegauge: reen range)

1st stage (Coolant temperature between 102°C and 105°C)

Action. remedy

Coolant temperature:Between 102°C and

(Coolant temperaturegauge: Red range)

Working Pc2Cro-e. PC22oLC-emode

kwckw,general,finishing,breaker

Mode kept as it is,output reduced

Lifting Lifting operation keptas is

l-l

2nd stage (Coolant temperature 105°C and above)

Actuation condition Actuation, remedy

Coolant temperature:

105°C and above

(Coolant temperaturegauge: Red range)

I aution buzzer SoundsI

11 Cancel condition I

Ioolant temperature: Below 102’ C I

When the above condition ismet, the system returns to thecondition before the overheatprevention function was

actuated (automatic reset).

3temporarily to low idling position

When the above conditions aremet, the system returns to thecondition before the overheatprevention function wasactuated (manual reset).

X12BV104

1 l 9




6. SWING PRIORITY FUNCTIONThere is a SWING ACCEL switch on the monitorpanel for the boom/swing priority selection mode.This switch can be turned ON or OFF to changethe matching of the boom RAISE and swing op-erations.The oil flow is divided and sent to the swing tomatch the swing angle to allow compound op-erations to be carried out easily.Boom/swing priority selection mode OFF:

90” swing and loading of dump truckBoom/swing priority selection mode ON:

180” swing and loading of dump truck

X12BV106

STD Swing priority

90 180

Swing angle ( o ) X12BV105

The change in the matching between the boom When boom/swing priority selection mode is OFFRAISE and swing is carried out by changing the l-l r-lsignal to the pump merge-divider valve.

.bmP merge divider valve

pcqX12BV107

Boom RAISE and swing are parallel

When boom/swing priority selection mode is ON

Pump merge divider valve

The boom RAISE and swing use separate pumps, soswing is independent

IO 170




7. SWING CONTROL FUNCTION

Work equipment lever

Control valve

Pump merge- 1 IJ

divider valve ,,

h”nn;mr n=n.aI . T

Control pump

(Swing lock switch signal)

(Drive signal)

Pump controller (Swing lever signal)- .”

I 1 I

X12BV109

FUNCTIONThe system is provided with a swing lockand swing holding brake function.

IO 171



1) Swing lock, swing holding brake functionThe swing lock (manual) can be locked at

Lock Lock Function Operationswitch lamp

any desired position, and the swing holdingbrake (automatic) is interconnected with the When swing lever is placed at

swing, so it prevents any hydraulic drift after Swing neutral, swing brake is applied

the swing is stopped.OFF OFF holding after approx. 4 set; when swing

brake lever is operated, brake is


* Operation of swing lock prolix switchIf any abnormality should occur in the con-troller, and the swing holding brake is notactuated normally and the swing cannot beoperated to cancel the swing lock and allowthe swing to be operated.

* Even when the swing lock prolix switch is turnedON, the swing lock switch stays ON and theswing brake is not canceled.

* When the swing brake is canceled, the swinghas only a hydraulic brake operated by thesafety valve, so if the swing is stopped on aslope, there may be hydraulic drift.

2) Hydraulic oil quick warm-up function whenswing lock switch in ONWhen the swing lock is turned ON, the relief pres-sure rises from 31.85 MPa (325 kg/cm?. If thework equipment is relieved in this condition, the

hydraulic oil temperature will rise more quicklyand the warming-up time can be reduced.

ON ONSwinglock

Swing lock is actuated and swingis held in position. Even whenswing lever is operated, swing lockis not canceled and swing doesnot move.

Swing lockProlix switch

Swing lockswitch

Swing brake

ON (when controller is OFF (when controller isabnormal) normal)

ON OFF ON OFF

Swinglockapplied

Swinglockcanceled

Swinglockapplied

Swingholdingbrakeapplied

XlZBVllO

1O-l 72




8. TRAVEL CONTROL FUNCTION

~-------]rf~i Travelmotor /Travel lever 1

I 1

n n _ . . 1

2%egulator

I, Oil pressure;switch I

tf--- ’

Fuel controldial

Hi

I J5egulator

t- Travel peedsolenoid valve

48 ,-

I

Control pump :

:

,: M - III1

00P0(1-c

L-_--------*-A

(Pressure sensor(Drive signal1

00000(Drive signal1

Engine throttlecontroller (Throttle signal)

Pump controller IPressure sensor signal1

- ,:’ C (Switch signal) 6 “A I- 4’

&“ &

c

XlZBVlll Monitor panel

FUNCTIONWhen traveling, the pump control is carriedout, and the travel speed can be selectedmanually or automatically to give a travelperformance that suits the nature of the workat the jobsite.

10 173



1)

*

2)0

ii)

iii)

Pump control function when travelingIf the travel is operated in any working modeother than the heavy-duty (H/O) mode, thisincreases the pump absorption torque whilekeeping the working mode and engine speedas they are.For details, see PUMP AND ENGINE MUTUAL

CONTROL SYSTEM.

Travel speed selection functionManual selection using travel speed switchIf the travel speed switch is set to Lo, Mi, or Hi,the pump controller controls the pump flow andmotor volume at each speed range as follows toswitch the travel speed.Automatic selection according to engine speedIf the engine speed is reduced to below 1400 rpmby the fuel control dial:0 If the machine is traveling in Lo, it will not

shift even if Mi or Hi are selected.If the machine is traveling in Mi, it will notshift even if Hi is selected.If the machine is traveling in Hi, it will auto-matically shift to Mi.

Automatic selection according to pump dischargepressureIf the machine is traveling with the travel speedswitch at Hi, and the load increases, such as whentraveling up a steep hill, if the travel pressure con-tinues at 33.32 MPa (340 kg/cm? for more than0.5 set, the motor volume is automatically switchedand the travel speed changes to Mi.(The travel speed switch stays at Hi.)The machine continues to travel in Mi, and whenthe load is reduced, such as when the machinetravels again on flat ground or goes downhill, andthe travel pressure stays at 17.64 MPa (180kg/cm? or less for more than 0.5 set, the motorvolume is automatically switched and the travelspeed returns to Hi.

Travelspeedswitch

(Lowtpeed)Mi

(Mid-range

speed)

Hi(High speed)

Pumpflow (%)

Motorvolume

80 80 100

Max. Min. Min.

Travelspeed(km/h)

PCZOO-6 PCZOO-6 PCZOO-6PCZOOLC-6 PC2OOLC-6 PC2OOLC.6PC21OLC-6 PC250LC-6 PC21OLG6 PC21OLC.6 PC25OLC-6PC22OLC-6 PC22OLC.6 PC22OLC.6

PC25OLG6

I 3.0 I 2.2 I 4.1 I 5.5 I 5.1

Hic

‘ 0$z:55C 1Mi ---------

I I

I I1 I

1 I I

17.64 (180) 33.32 1340)

Travel pressure (MPa (kg/cmz))X12BV112

IO 174




9. COMPONENTS OF SYSTEM1 ENGINE SPEED SENSOR

1. Wire

2. Magnet3. Terminal4. Housing5. Connector

2) PPC OIL PRESSURE SWITCH

Composition of circuit

XlZBV113

FUNCTION

The engine speed sensor is installed to the ringgear portion of the engine flywheel. It counts elec-trically the number of gear teeth that pass in frontof the sensor, and sends the results to the pumpcontroller.This detection is carried out by a magnet, and anelectric current is generated every time the geartooth passes in front of the magnet.

1. Plug2. Switch3. Connector

SPECIFICATIONSComposition of points : N.O. pointsActuation (ON) pressure : 0.49 f 0.1 MPa

(5.0 f 1 .O kg/cm?Reset (OFF) pressure : 0.29 f 0.05 MPa

(3.0 f 0.5 kg/cm?

FUNCTIONThere are 8 switches installed to the PPC shuttlevalve. The operating conditions of each actuatoris detected from the PPC pressure, and this is sentto the pump controller.

a bYz i?XlZBV114

1 O-l 75




3) PUMP PRESSURE SENSOR

X12BV115

FUNCTIONThis sensor is installed to the inlet port circuitof the control valve. It converts the pump dis-charge pressure to a voltage and sends this tothe controller.

Insulation layer

Gauge layer

OPERATIONWhen the pressurized oil entering from the pres-sure introduction portion pressurizes the diaphragmof the pressure detection portion, the diaphragmdeflects and changes shape.A gauge layer is installed to the face opposite thediaphragm, and the resistance of the gauge layerconverts the deflection on the diaphragm into anoutput voltage and sends it to the amp (voltageamplifier).The voltage is further amplified by the amplifier andis sent to the pump controller.Relationship between P (kg/cm? and outputvoltage(V).V = 0.008 X P + 1 .O* 1 kg/cm* = 0.098 MPa

Diaphragm(stainless steel)

XlZBVll6

0 loo 200 300 400 500

Pressure P g/cm’) X12BV117

1O-l 76




PUMP CONTROLLER

CN-CO2 CN-CO3 CN-CO1

\ i I

X12BV118

nput and output signalsCN-CO1 :N-CO2 ZN-CO3

it :,; IGND Nameofsignal No. I Name of signal I IInput/

outputo Name of signal

Input/output

1 Swing switch Input_

2 GND

3 LS select solenoid Outpui

2 Boom LOWER switch input

3 Travel switch Input

4 1 Pump merge-divider solenoid 1Outpui 4 1 oom RAISE switch I lwt I26 I Auto deceleration Ioutput I

26 Speed sensor (+) Input

27 Network circuit (monitor +)_

6 Travel speed solenoid

7 LC control EPC (-)

Outpui

Outpui

1 utpui 8 I Bucket DUMP switch I Input 28 I Monitor circuit (engine +) I - I

Controller power source 24V

Controller power source 24V

g I Swing lock switch I Input 29 1 Pressure sensor 1 (GND) I - I30 Pressure sensor 2 (GND)

31 I --_

0 Service switch

11 Model selection 5

Input

Input

12 ILS bypass solenoid IOutpui 12 I Swing lock prolix switch I Input

16 IModel selection 4 I Input I 36 I _ I - I6 TVCI (+)

17 ITvcP +)

Outpui

I Outpui 17- -

18 L.H. knob switch Input

I - I

I - I

1 O-l 77




5) TVC PROLIX RESISTOR

1. Resistor2. Connector

SPECIFICATIONResistance; 30 0

6)

7)

8)

FUEL CONTROL DIAL, GOVERNOR MOTOR,

ENGINE THROTTLE CONTROLLER* See ENGINE CONTROL SYSTEM.

MONITOR PANEL* See MONITORING SYSTEM.

NC VALVE* See HYDRAULIC PUMP.

XlZBVllS

FUNCTIONThis resistor acts to allow a suitable currentto flow to the TVC solenoid when the TVCprolix switch is ON.No current flows when the NC prolix switchis OFF.

9) LS CONTROL EPC VALVE

LS SELECT SOLENOID VALVEPUMP MERGE-DIVIDER SOLENOID VALVEZ-STAGE RELIEF SOLENOID VALVETRAVEL SPEED SOLENOID VALVESWING BRAKE SOLENOID VALVE* See EPC, SOLENOID VALVE

IO 178



STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

MACHINE MONITOR SYSTEMMonitor panel

Sensor signal

I=

H O G/O F/O L/O B C

f? l-l

I--

J

Power sourceSensors

u

Buzzer signal

Banery XllAJlOl

FUNCTIONThe machine monitor system uses the networkcircuits between the controllers and sensors in-stalled to all parts of the machine to observe thecondition of the machine. It processes this infor-mation, and displays it on a panel to inform theoperator of the condition of the machine.The content of the information displayed on themachine can broadly be divided as follows.1. Monitor portion

This gives an alarm if any abnormalityoccurs in the machine.

2. Gauge portionThis always displays the coolant tempera-ture and fuel level.

3. Time display1) This normally displays the time,.2) If this is set to the machine data moni-

toring mode, internal data from eachcontroller, including the monitor panelitself, are displayed.

3)

4)

5)

*

If it is set to the trouble data memorymode, the trouble data for each con-troller, including the monitor itself, aredisplayed.It displays that the system has been setto the governor motor adjustment modeand automatic vibration offset adjustmentmode.In emergencies, it displays abnormalitiesin any controller.For details of the content of the displayand the method of operation, see TROU-BLESHOOTING.

The monitor panel has various built-in mode se-lector switches, and also functions as the controlpanel for the electronic control system.

Controllers

1o-1 79




1. MONITOR PANEL

OutlineThe monitor panel consists of the time display,monitor display, and mode selector switches.It has a built-in CPU (Central Processing Unit),and processes, displays, and outputs the datafrom the sensors and controllers.The time display and monitor display panels usea liquid crystal display (LCD).The mode switches are flat sheet switches.

CN-POP

CN PO1

XllAJlO2

Input and output signals

CN PO1 CN PO2

XllAJ103

IO 180




SWITCHES1. Working mode switch2. Auto-deceleration switch3. Boom/swing priority mode switch4. Travel speed switch5. Power max./Swift slow-sown switch

2

XllAJlOS

Switch actuation tableThe switch portion consists of five mode selectionswitches, and the condition of the machine changeseach time that any switch is pressed. The LEDabove the switch lights up to display the present Symbol item Action

condition of the machine.

rl)i ;g;:‘ NG H/O ti G/O t) F/O c) L/O ti B/O

+

aKNOBBUl-rON POWER UP t) SPEED DOWN

=

ON tf OFF

Hi tf Mi t) Lo

OFF H ON

* The bold letters indicate the default positionof the switch when the starting switch isturned ON.

XllAJ1 6

1O-l 82




2. SENSORS

The signals from the sensors are input directlyto the monitor panel.The contact type sensors are always connectedat one end to the chassis GND.

Name of sensorI

Type of sensorI

When normal When abnormal

Coolant level I Contact type I ON (close) OFF (open)

Engine oil level Contact type I ON (close) OFF (open)

Hydraulic oillevel

Contact type ON (close) OFF (open)

Engine oilpressure

Contact type OFF (open) ON (close)

Coolanttemperature

Resistance type -

Fuel level I Resistance type I I-

Air cleanerclogging

Contact type ON (close) OFF (open)

COOLANT LEVEL SENSOR

1. Subtank2. Float3. Sensor4. Connector

XllAJ107

1 O-l 83




2) ENGINE OIL LEVEL SENSOR

1 2 31. Connector2. Bracket3. Float4. Switch

Composition of circuitXllAJlO8

3) HYDRAULIC OIL LEVEL SENSOR

ls=ZXll JlOS

4) ENGINE OIL PRESSURE SENSOR (COMMON FOR BOTH LoAND Hi)

1. Connector2. Plug3. Switch4. Float

1. Plug2. Contact ring3. Contact4. Diaphragm5. Spring6. Terminal

Composition of circuit

Xll JllO

Actuation (ON) pressureLo: 0.05 f 0.02 MPa

(0.5 f 0.2 kg/cm? or lessHi: 0.15 f 0.02 MPa

(1.5 f 0.2 kg/cm? or less

1O l 4




5) COOLANT TEMPERATURE SENSOR1 2 3 1. Connector

2. Plug3. Thermistor

XllAJlll

6) FUEL LEVEL SENSOR

l--~L-_:T-_:~~;=-_-_

c cfkComposition of circuit

1. Float2. Connector3. Cover4. Variable resistor

7) AIR CLEANER CLOGGING SENSOR

EMPTY

XllAJ112

Actuation (OFF) pressure: -7.47 f 0.49 kPa(-762 f 50 mm H,O)

Composition of circuitXllAJ113

1O-l 85



20 TESTING AND ADJUSTING

Table of judgment standard values .......................................................... 20- 2Standard value table for electrical parts ....................................................... 20-14Tools for testing, adjusting and troubleshooting ................................................ 20-23

Measuringenginespeed ................................................................... 20-24 Measuring intake manifold pressure ......................................................... 20-25 Measuring intake air restriction .............................................................. 20-26 Measuring lubricating oil pressure ........................................................... 20-27 Measuring fuel (filter) inlet restriction ......................................................... 20-28 Measuring blowby pressure ................................................................ 20-29 Measuring engine back pressure ............................................................ 20-30 Measuringexhaustcolor ................................................................... 20-31 Measuring coolant temperature ............................................................. 20-32 Measuringvalveclearance ................................................................. 20-33 Checking and adjusting belt tension for air conditioner compressor ................................ 20-34 Adjustingenginespeedsensor .............................................................. 20-35 Testing and adjusting governor motor lever stroke .............................................. 20-36 Testing clearance of swing circle bearing ..................................................... 20-37 Testing and adjusting track shoe tension ...................................................... 20-38 Testing and adjusting hydraulic pressure in work equipment, swing, travel circuit ..................... 20-39 Testing and adjusting TVC valve output pressure (servo piston input pressure) ....................... 20-42 Testing and adjusting LS valve output pressure (servo pistion input pressure) and LS differential pressure . 20-44 Testing and adjusting control pump circuit oil pressure .......................................... 20-47 Testing EPC valve, solenoid valve output pressure .............................................. 20-49 Measuring PPC valve output pressure and testing PPC shuttle valve ............................... 20-51 Adjusting work equipment Swing PPC valve ................................................. 20-53 Adjustingtravellever ...................................................................... 20-54 Testing travel deviation .................................................................... 20-55 Testing location causing hydraulic drift of work equipment ........................................ 20-56 Measuringoilleakage ..................................................................... 20-58 Releasing remaining pressure in hydraulic circuit ............................................... 20-59

Bleedingair ............................................................................. 20-60Troubleshooting .......................................................................... 20-63

A When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety

pins and blocks to prevent the machine from moving.A When carrying out work together with other workers, always use signals and do not let unauthorized people

near the machine.A When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed when

the coolant is still hot, the coolant will spurt out and cause burns.A Be careful not to get caught in the fan, fan belt, or other rotating parts.

20 I

a



TESTING AND ADJUSTING TABLE OF JUDGMENT STANDARD VALUES

TABLE OF JUDGEMENT STANDARD VALUE

. FOR ENGINE

Machine Model PC200-6, PC200LC-6 PC22OLC-6PC21 OLC-6 PC25OLC-6

S6D102-1 SAGDI 02-I

Standard Permissible Standard Permissible

Value Value Value Value2130 f 60 2130 + 60 2300 f 60 2300 f 60

2050 + 60 2050 + 60 2120 f 60 2120 + 60

2050 f 60 2050 f 60 2120 f 60 2120 f 60

1710260 1710&60 1800~60 1800*60

10661?60 1066260 1066+60 1066260

145J2200 145J2200 174J2300 174J2300

850- 1100 850- 1100 960 - 1020 960 - 1020

380 635 380 635

69 (0.70) 69 (0.70)207 (2.11) 207 (2.11)

(03345) (OZ5)

114 508

69 (0.70) 69 (0.70)207 (2.11) 207 (2.11)

(03345) (OY5,

114 508

76 76 76 76

100 100 100 100

0.25 0.25 0.25 0.250.51 0.51 0.51 0.51

Engine model

Item Measurment ConditionsI

Unit


Engine speeds

Engine ratingRated gross powerrated speed

kWJrpm

intake manifoldpressure

At rated speed *j,I

mm Hg

Intake air restrictionNew element - At allspeeds

mm H,O

flith SAE 15W-40 oil andcoolant temperature inoperating range:Minimum at low idleMinimum at rated speed**

kPa(kg/cm*)

Lubricating oilpressure

Fuel filter inletrestriction

Maximum restriction kPa(kg/cm’ )

Service tool orifice size of5.613 mm (0.221 in) andcoolent temperature inoperating range:4t rated speed **

Blowby pressure mm H,O

Exhaust backpressure

Vlaximum at any condition mm Hg

Coolanttemperature

Vlaximum operating:emperature

Engine cold:ntake valvesExhaust valves

alve clearance mm

* For further detailed information, refer to Engine Shop Manual.* * Rated speed for S6D102-1 - 1950 rpm ; for SAGDI 02-I - 2100 rpm.

20-2a




FOR CHASSIS* The standard values and permissible value shown in this table are all values for H/O (heavy-duty

operation) mode.

TMachine model

PC200-6, PC200LC-6, PC2lOLC-6, PC22OLC-6, PC25OLC-6

Standard value I Permissible value

Jnit

‘ pm

Cate-gory

Measurement conditionstem

Speed when auto-deceleration isoperated

Boom control valve

Arm control valve

Bucket controlvalve

Swing control valve

Travel control valve

Boom control lever

Arm control lever

Bucket control

leverSwing control lever

Travel control lever

Play of control lever

Boom control lever

Arm control lever

Bucket controllever

Swing control lever

Travel control lever

) Engine at high idling) Hydraulic oil temperature:

45-55°CbCoolant temperature:

Within operating rangeB -pump relief: Arm relief

BArm relief) Travel lever operated in

small movements) Engine at high idle

4

4

,

4

,

,

4

4

4

4

- 4

,

,

,

,

,

(

2,100 f 100 2,250 f 100 - -

D Fuel control dial at MAX.DControl lever at neutral 1,400 f 120

a b P

9.5 f 0.5 9.5 f 0.5 -

aI

b

-

nm

nm

9.5 f 0.5 9.5 f 0.5

I XlOBH107

b Center of lever knobI Read max. value to end of

travelmEngine stopped# Excluding neutral play

85* IO I Max. 95 Min. 75

85* IO I Max. 95 Min. 75

85i IO

IMax. 95 Min. 75

85*10 I Max. 95 Min. 75

115* 12 I Max. 127 Min. 103

Max. 10

15.7 f 3.9(1.6 f 0.4)

15.7 f 3.9(I .6 f 0.4)

Max. 15

Max. 24.5(Max. 2.5)

Max. 24.5(Max. 2.5)

Engine at high idleOil temperature: 45 - 55” CFit push-pull scale to centerof control lever knob tomeasureMeasure max. value to endof travel

12.7 f 2.9I

Max. 21.6(1.3 f 0.3) (Max. 2.2)N

:kg) 12.7 f 2.9I

Max. 21.6(1.3 f 0.3) (Max. 2.2)

Lever 24.5 f 5.9I

Max. 39.2(2.5 f 0.6) (Max. 4.0)

Pedal 74.5 f 18.6(7.6 f 1.9)

Max. 107.8(Max. 11)

20 3

0




Item Measurement conditions

Unload pressure H/O mode

Boom

Arm

Bucket

Swing

Travel

Control pump

LS differentialpressure

Applicable model

Oil temp: 45 - 55 “ CEngine at high idlingAll levers at neutral

s Hydraulic oi l temp: 45 - 55 “ C

Relief pressure with engine athigh idling (Relieve only circuit tobe measured)n H/O modeFigures in 1 1 re used whenpower max function is used

(reference)Pump outlet port pressure

*I : For travel, measure oilpressure for relief on one side.

*2: For swing, measure oilpressure with swing lockswitch on.

*3: The boom pressure is the oilpressure at RAISE and at thehigh pressure setting (active

mode)Hydraulic oiltemp: 45 - 55 “ CEngine at highidlingn H/O mode

Levers inneutral

Travelspeed HI,rotatingunder noload

Unit

JlPakg/cm’ )

PC200-6, PC200LC-6, PC21 OLC-6PC22OLC-6, PC25OLC-6

Standard value

3.92 f 0 98

(40~10)

31.85 + 0.98(325 + 10)

2.94+;= (30 +; )

2.94 + 0 98

(30 f 10)

2.16 f 0.098(22 f 1)

Permissible value

3.92 + 0.98

(40*10)

Max 33.81

Min 30.38

20 4

a




Cate-gory

Item

Swingbreakangle

Timetaken tostart

swing

Timetaken toswing

Hydraulicdrift ofswing

Leakagefromswingmotor

Machine Model

Measurement conditions

Work equipment posture - Max. reach

Engine at high idlingHydraulic oil temp: 45 - 55°CStop after swinging one turn and measuredistance that swing circle moves

Work eqipment posture -Maxreach

90”

PO0326

Engine at high idlingHydraulic oil temp: 45 - 55°Cn H/O mode

Time taken to swing 90” and180” from startinq positions r

180”

Work equipment posture - Max. reach


Swing on turn, and measure time taken toswing next 5 turns

Engine stoppedHydraulic oil temp: 45 - 55°CSet machine on 15” slope, and set upperstructure at 90” to the side.Make match marks on swing circle outerrace and track frame.Measure distance that match marksmove aoart after 5 min.

Engine at high idlingHydraulic oil temp: 45 - 55°CSwing lock switch ON

s Relieve swing circuitn.

PC200-6, PC2OOLC-6, PC21OLC-6, PC22OLC-6,PC25OLC-6

Standar

PC200PC2OOLCPC21 OLC

lalue

PC22OLCPC25OLC

Max 100 Max 130

3.1 f 0.3

4.4 f 0.8

24 f 3.5

3.2 + 0.3

4.5 ? 0.8

24 f 3.5

Max 5

Permissible value


Max 130

Max 3.7

Max 5.6

Max 30

PC220LCPC25OLC

Max 160

Max 3.8

Max 5.7

Max 30

Max IO

20 5

a




rachine model PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6

Unit Standard value Permissible valueate-gory


PC200PC200LCPC21 OLC

PC220LCPC200

PCZOOLCPC21 OLC

PC22OLC

STD: STD:43-61 45-63

LC: LC:46.5 - 66.5 46.5 - 68.5

STD: STD:50*7 52 f 7

LC: LC:54.5 f 8 56.5 f 8

o

Mi

Hi

Lo

Mi

Hi

STD: STD:31 -44 32.5 - 45.5

LC: LC:34-47 32.5 - 49

STD:25.5 - 31.5

LC:27.5 - 35

20-28

STD: STD:36.5 + 5.5 38 + 5.5

LC: LC:39.5 + 5.5 41.5 f 5.5

STD: STD:27.5 f 2 2922

LC: LC:30 f 2.5 31 f 2.5

iecravel;peed1)

rravelspeed2)

B Engine at high idlingB Hydraulic oil temp: 45 -

55°CB In H/O modeB Raise track on one

side at a time, rotateone turn, thenmeasure time taken for5 turns with no load

STD:27-33

LC:28.5 - 36

20-283.5 f 3.5 23.5 ? 3.5

iec 172 2.5 17k2.5 14.5-21 14.5-21D Engine at high idling

Hydraulic oil temp: 45 -55°CB In H/O mode

Run up for at least1Om, and measuretime taken to travelnext 20 m on flatground

13+1 13*1-T- 12-15 12-15

D Engine at high idlingHydraulic oil temp: 45 - 55°CRun up for at least 10 m, and

fravelfevia-ion

im Max 200 300

measure time taken to travelnext 20 m on flat groundUse a hard horizontal surface.

I_ 1 m _I moio7

* Measuer dimension X

20 6

a




PC25OLC-6achine model

Cate-gory

Item Measurement conditions Unit Standard value Permissible value

Lo

Mi

Hi

Lo

Mi

Hi

83 f 5 78-93

45*3 42-50ravel speed(1)

et

Set

mm

Engine at high idlingHydraulic oil temp: 45 -55°Cn H/O mode

Raise track on one side at atime, rotate one turn, thenmeasure time taken for 5turns with no load

36?2 34-40

30-393+3

17?2

14?2

Travel speed(2)

15.5 - 21.5

Engine at high idlingHydraulic oil temp: 45 -55°Cn H/O mode

Run up for at least 10 m,and measure time taken totravel next 20 m on flatground

12-18

Engine at high idlingHydraulic oil temp: 45 - 55°CRun up for at least 10 m, and

300raveldeviation

Max 200

*

measure time taken to travelnext 20 m on flat groundUse a hard horizontal surface.

L20m . 1

I+IOmPa0107

Sr Measuer dimension 1;

20 7

a




Cate-gory

Machine Model

lydraulic drift of.avel

.eakage ofavel motor

Total workequipment(hydraulicdrift at tipof bucketteeth)

z BoomE.n

cylinder

%

(amount ofretraction

Yb

of cylinder)

3zG ArmL cylinderg (amount of

eextension

Rof cylinder)

I

Bucketcylinder(amount ofretractionof cylinder)

Measurement conditions Unit Standard value Permissible value

Engine stoppedHydraulic oil temp: 45 -55°CStop machine on 12”slope with spocketfacing straight up theslope.Measure the distancethe machine moves in 5min.

Lock‘ DinPoD1W

Engine at high idlingHydraulic oil temp: 45 -55°CLock shoes and relievetravel circuit.

Posture for measurement

-

Place in above posture andmeasure extension orretraction of each cylinderand downward movement attip of bucket teeth.Bucket: Rated loadHorizontal, flat ground

0 Levers at neutralEngine stoppedHydraulic oil temp: 45 -55°CStart measuring immediatelyafter setting.Measure hydraulic driftevery 5 min, and judgefrom results for 15 min.

ie

min.

r PC200-6, PC2OOLC-6, PC21OLC-6, PC22OLC-6,PC25OLC-6


PC22OLC

PC25OLC

13.6 20 27.2 40

Max. 600 Max. 900

Max. 18 Max. 27

Max. 160 Max. 240

Max. 35 Max. 53

0


PC22OLC

PC25OLC

20 8

0




T PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6,PC25OLC-6

Machine model

Jnit

;ec

Permissible valueeasurement conditions Standard valueate-gory

PC220PC250

PC200 PC21 0 PC220PC250

Max 4.3

Max 3.5

Max 4.7

PC200

i.5 + 0.4

PC21 0

4.5 f 0.4

loombucketSeth in:ontactAthlround

5:ylinderully&ended

\rm>ylinderullyetracted

1IlIly&ended

3.4 * 0.4 Max 4.3 Max 5.3

) Engine at high idlingB Hydraulic oil temp:

45-55 “ CB In H/O mode

Max 3.2 Max 3.8.4 f 0.3.8 + 0.3

1.6 0.4

.9 t 0.3

3.1 f 0.3

3.8 f 0.4 Max 4.5 Max 4.7.8? 0.4

3.1 + 0.3P Engine at high idli ngB Hydraulic oil temp:

45-55-cb In HI0 mode

Max 3.5 Max 3.6 Max 3.7.0 f 0.3

bucket:ylinderullyetracted

I%_rlly&ended

Max 3.5.9 f 0.4

2.2 f 0.3

Max 3.6

Max 2.7

Max 3.6

Max 2.8

.8 f 0.4

.I f 0.3

2.8 f 0.4

2.1 + 0.3b Engine at high idlingB Hydraulic oil temp:

45-55°CB In HI0 mode

Max 2.7

Max 1 .O Max 1.2Lower boom and measuretime taken from pointwhere bucket contactsground to point wherechassis rises from theground

b Engine at low idlingB Hydraulic oil temp: 45 -

55°C

Max 1 O Max 2.8oII.5

. Stop arm suddenly andmeasure time for arm tostop

b Engine at low idlingHydraulic oil temp: 45 -55°C

20-9

0




achine model PC2004 PC2OOLC-6, PC21OLC-6,PC220LC-6. PC250LC-6

Unit Standard value Permissible valueate-gory


BEi= Bucket Max 1 O Max 3.6et

XT/nin

Stop bucket suddenly andmeasure time taken forbucket to stop at bottomand then start againEngine at low idlingHydraulic oil temp: 45 -55°C

Cylinders

Centerswivel joint

Hydraulic oil temp: 45 -55°CEngine at high idlingRelieve circuit to be

measured

20.5

50

Engine at high idlingHydraulic oil temp: 45 -55°C

f Use a hard horizontalsurface

PC200‘ C200LC‘ C21 OLC‘ C22OLC

PC200‘ C2OOLC‘ C21OLC‘ C22OLC

‘ C250LC ‘ C250LC

I- 20m clavel deviation whenIrk equipment andvel are operated

kF10m PoOlM

nm

Wax 200 Max 400 Vlax 220

PC200‘ C2OOLC‘ C21OLC

Max440

‘ C22OLC‘ C25OLC

k Measure dimension 2’

PC200‘ C2OOLC‘ C21OLC

‘ C22OLC‘ C25OLCHydraulic oil temp: 45 -

55°CB Measure with engine at

rated speedD At rel ief valve set pressure

3.14 MPa (32 kg/cm’ )

Controlpump

Main pump

Vlin 27.2 Min 29.9 vlin 24.5 Min 26.9

ee next page ee next page

20 I

0




Cate-

goryPCZOO, PC210: Discharge amount of main piston pump (in H/O mode)

0 9.8 (100) 19.6 (ZOO) 29.4 (300) 34.3 (350)

Pump discharge pressure = %$& (MPa (kg/cm2))

Pump speed: At 2200 rpm, TVC current 180 mA

Check Point

As desired

Test pump discharge Discharge Average pressure Standard value for Judgementpressure (MPa pressure of other (MPa (kg/cm’ )) discharge amount standard lower

(kg/cm*)) pump (MPa Q (Urnin) limit Q (Umin)

(kg/cm’ ))

P, P, P,+ P, See graph See graph2

* As far as possible, bring pump discharge pressure P, and P, as close as possible to the average pressure whenmeasuring.The error i s large near the point where the graph curves, so avoid measuring at this point.

* When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specifiedspeed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurment, anduse them as a base for calculating the pump discharge amount at the specified speed.

20 11

a




Cate-gory

PC220, PC250: Discharge amount of main piston pump (in H/O mode)

I0 (0) 9.8 100) 19.6 (200) 29.4 (300) 34.3 (350)

Pump discharge pressure = v (MPa (kg/cm*))

Pump speed: At 2300 rpm, TVC current 180 mA

Check PointTest pump discharge

pressure (MPa(kg/cm*))

Discharge Average pressure Standard value for Judgementpressure of other (MPa (kg/cm’ )) discharge amount standard lower

pump (MPa Q (Umin) limit Q (Umin)

(kg/cm’ ))

As desired P, P* P,+ P,2

See graph See graph

Sr As far as possible, bring pump discharge pressure P, and P, as close as possible to the average pressure whenmeasuring.The error is large near the point where the graph curves, so avoid measuring at this point.

Sr When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the specifiedspeed with the fuel control dial, take the pump discharge amount and the engine speed at the point of measurment, anduse them as a base for calculating the pump discharge amount at the specified speed.

20-I 2

0




Flow control characteristics of WC valve (STD)A The values in this table are used as reference values when carrying out troubleshooting.

Cate-gory

Item

Time taken forswing forboom RAISEand startingswing

PC00246


Load the bucket with the rated load and measurethe time taken from the position of starting theswing to the point of passing the QO’ position.

Unit

et


4.2 f 0.4

PC220LCPC250LC

4.6 f 0.4

20-I 3

0




STANDARD VALUE TABLE FOR ELECTRICAL PARTS

system

Component

‘ uel control dial

Jlotor

‘ ower sourcefoltage

‘ uel controllial

‘ otentiometer

Warming-upiianal

ConnectorNo.

E06 (male)

04 (male)

iO5 (male)

rletwork

Inspec-tion

method

Judgement table Measurementconditions

$ If the condition is as shown in the table below, it is5

1) Turn startingnormal switch OFF.

8 If the condition is as shown in the table below, it is6

1) Turn startingnormal switch OFF.

IE Between (1) - (2) 0.25 - 7 k n

2) Disconnectconnector E04.

?z Between (2) - (3) 0.25 - 7 k f282 Between (1) - (3) 4-6kQ

If the condition is as shown in the table below, it is 1) Turn startingswitch OFF.

8

IIBetween (1) - (2) 2.5 - 7.5 0

2) Disconnect

Econnector E05.

0If the condition is as shown in the table below, it is 1) Turn starting

= normal switch ON.2S Between (1) - (12) 20-30V

2) Insert

3TAadapter.

B Between (2) - (12) 20-30V.c I I I)

1) Turn starting

I f the condition is as shown in the table below, it is 1) Turn startingnormal switch ON.

D Low idling 2.9 - 3.3 v 2) Insert

= BetweenT-adapter

9n

(17) - (16) Hgh idling 0.5 - 0.9 v

7is I,

8

II

IBetween (5) - (16) 4.75 - 5.25 V

IThere must be no network error messages on the monitordisplay.

20 14

a




system

Component

ruto-ecelerationignal

Governorlotor

lattery relay

Aodel IO1

ielection female)

ConnectorNo.

io1

Inspec-tion

method

Judgement table

If the condition is as shown on the table below, i t isnormal.

If the condition is as shown on the table below, it isnormal.

Between (10) - (20) 1.8 - 4.6 U

Between (11) - (21) 1.8 - 4.6 u


Between (13)- (12) 20-30U

Sr This is only for 2.5 set after the starting switch isoperated ON-OFF: at other times it must be 0 U.


PC22OLCPC25OLC

Between 8)- 12)seecton I

No continutiy ContinuityI

Between 19) 12) No continutiy NoSelectIon continutiy

Measutementconditions

1) Turn startingswitch ON.2) InsertT-adapter.



1) Turn startingswitch OFF.2) Disconnectconnector EOI

20-15

a




Measurement conditionsystem

Connector No.Judgement table

Jetworkmonitor,engine, throttle:ontrol)

,f the condition is as shown on the tableoelow. it is normal.

1) Turn starting swithchDN.2) Insert T-adapter.03

Between (7). (8) - (15) I 4-8V I

1) Turn starting switchDFF.

2) Disconnect connectorE07.

If the condition is as shown on the tableoelow, it is normal.

r ~~etween female (1) - (2) 1 500-1000n I

Betweem female (1) - Min. 1 M nchassis I

ingine speediensor

1) Start engine2) Insert T-adapter.

Measure with AC range

Between (1) - (2) 0.5 - 3.0 vLO7

1) Screw in rotation sensor until it contactsring gear, then turn back one turn.2) It must work normally when adjusted asabove.

1) Start engine (chargeaccumulator)2) Disconnect connectorsSO1 - S08.

Travel so13oom raise SO24rm out so33oom lower

so44rm in so53ucket curl

SO63ucket dump

so7Swina SO8

If the condition is as shown on the tablebelow, it is normal.

‘ PC oil,ressure switch

Between (I), (2) -chassis

Min 1 M fI


1) Start engine2) Turn fuel control dial toMAX position.3) Insert T-adapter.etween (1) - (2) 18-28V>ump pressure

sensorCO7 (rear)CO8 (front)

Between (1) -(3) 1-1

1) Turn starting switchOFF.2) Disconnect connectorco2.

If the condition is as shown on the tablebelow, i t is normal.

Between (9) -CND 1 SsS 1 ,% 1O2 (female)wing lock

switch

When Max10switch is

ON


I Between (1) - (2) 1 IO-220

1) Set TVC prolix switchOFF.2) Turn starting switchOFF.3) Disconnect connectorsco4, Cl 3.

1) Turn starting switchOFF.2) DisconnectconnectorV04.

CO4 (rear)(male)Cl 3 (front)(male)

WC valveBetween (2) - chassis Min 1 MC2


Swing brakesolenoid valve 1 Between(l)-(2) 1 20-600 1V04 (male)

Between (2) - chassis Min 1 MfI

20 16

a




Measurementystem

Component Connectorno.

Inspec-tion

method

Judgement table

1 ravel speedS lenoid valve

‘ 06 (male) If the condition is as shown on the table below, itIS normal.

1) Turn starting switchDFF.2) Disconnectconnector V06.

2 -stage reliefS olenoid valve

LS selectS olenoid valve

ump merge-d ivider solenoidv alve

L S control EPCalve

I Between (1) - (2) 1 20-600 1

1 Between (2) - chassis 1 Min 1 MD 1

‘ 05 (male) If the condition is as shown on the table below, itis normal.

I Between (1) - (2) 1 20 - 60 G 1

1) Turn starting switchDFF.2) Disconnectconnector VO5

Between (2) -chassis I Min 1 MD I

‘ 02 (male) If the condition is as shown on the table below, itis normal.

1) Turn starting switchOFF.2) Disconnectconnector V02.Between (1) - (2) 1 20-600 1

Between (2) - chassis I Min I MD I

‘ 03 (male) 1) Turn starting switchOFF.2) Disconnectconnector V03.

If the condition is as shown on the table below, itis normal.

Between (1) - (2) 1 20-600 1

Between (2) - chassis I Min I Mf2 I1) Turn starting switchOFF.2) Disconnectconnector Cl 0.


-

Powersourcevoltage

L.H. knobswitch

Modelselection

-

:I 0 (male)

Between (1) - (2) 7-14G

Between (2) - chassis Min 1 MD


Between (12) (13) -(3), (4)




PC22OLCPC25OLC

Between(13) - GND

Between(14) - GND

Between(15) - GND

Between(16) - GND

No Continuitycontinuity

No Nocontinuity continuity

Continuity Continuity

No Nocontinuity continuity

1) Turn starting switchON.2) Insert T-adapter.1

1) Turn starting switchON.2) Insert T-adapter.

:02

1) Turn starting switchON.2) Disconnectconnector C02.

:02 (female)

20-I 7

a




system

Inspec-tion

method


Component Connector

I No.

-1) Start engine.2) Insert T -adapter.3) Place allevers at neutral.

f the condition is as shown on the table below, it is normal.

n1

f the condition is as shown on the table below, it is normal.

Standard mode ZO-28VBetween

Kerosene mode (17)-GND o-2v

,f the condition is as shown on the table below, it is normal.-ligh idling speed (rpm)

Auto-decelerationoutput signal

co3

Kerosenemode

co2

1) Turn starttingswitch ON.2) Insert T-adapter.

1) Turn starttingswitch ON.2) Set monitoroanel tomonitoring code10or 16.3) OperateNorking modeswitch and L.H.knob switch.

HI0 (working)

PC200PC210

Approx 2230

PC220PC250

Approx 2420I 1

H/O (traveling) Approx 2420 Approx 2530

I G/O I pprox 2100 I Approx 2200 IF/O Approx 2100 Approx 2200

L/O Approx 1700 Approx 1750

No. 2throttlesignal

Monitoringcode 16,lO

Power MaxIApprox 2420

IApprox 2530

(HIO)(GIO) ISwift slow-down

(H/O)(G/O)Approx 1700 Approx 1750

If the condition is as shown on the table below, it is normal. 1) Start engine.2) Turn swinglock switch OFF.3) Set swinglock prolix switchOFF.4) InsertT-adapter.

Swing brakesolenoidvalve co1

-I-If the condition is as shown on the table below, it is normal 1) Start engine

2) Insert T-adapter.3) Turn fuelconrtol dial toMax postion.4) Travel onlevel ground.

Travel brakesolenoid co1valve

1) Turn startingswitch ON.2) Insert T-adapter.3) Chargeaccumulator.

If the condition is as shown on the table below, it is normal.

All levers at nuetral ZO-30VBetween

Travel lever (14)-U), (2) o-3voperated

2-stagereliefsolenoidvalve

co1

i the condition is as shown on the table below, it is normal. 1) Turn startingswitch ON.2) Insert T-adapter.3) Chargeaccumulator.

LS select

solenoidvalve co1

20 18

a




sys-tem

Component Connector No.

-‘ umpnerge-dividersolenoidJalve

TVC valve[defaultJalue)

LS controlEPC valveldefaultvalue)

co2

co1

co1

I

I

L

Inspec-tion

method

Judgement table



Working in G/O mode.

I PC200 PC220PC21 0 PC250 I

Front:between510?80mA 410t80mA


Working in G/O mode.

Between (15)-(7) 900 f8

Measurementconditions

1) Turn startingswitch ON.2) Insert T-adapter.

1) Turn startingswitch ON.2) Turn fuel controldial to MAXpostion.

1) Turn startingswitch ON.2) Turn feul controldial to MAX

postion.

20 I

0




sys

temComponent

Suage

T onnector No. Inspectionmethod

Judgement table

If the conditions is as shoen in the table below, it is normal.Suages

Coolant:emp guage

Measureresistance

betweenPO2

(female)(12) - PO1(famale)

(11)

Fuel levelguage

betweenPO1

(female)(11) - PO2(female)

(11)

Position of guage Display level resistance (Monitor paneldisplay input resistance)

Starting swtich ON Starting switch OFF

Rightside

Dlsplayposition

Left side

Min. - Max. (k0)

0 - 0.646

4.119 - 4.681

4.456 - 5.063

8III

4.820 - 5.744

-11 34.927 - Disconnection I

Position of guagedisplay

Starting swtich ON

Display level resistance (Monitor panelinput resistance)

Starting switch OFF

Rightside

Displayposition

Left side

4

Min. -Max. (kf2)

0 - 13.82

8III

29.18 - 35.22

72.98-91S

638.00 - Disconnection

Measurementconditions

1) Insert a dummyresistance with thestarting switch OFF,or measure theresistance of thesensor.2) Check the displaywith the startingswitch ON.

20-20

0




system

Component ConnectorNo.

nspec-tion

nethod


letweenllternatorsrminal Rnd chassis

When engine is running (half throttle or above)I

1) Start engine.+27.5 - 29.5 Vternator

&If the battery is old, or after starting in cold areas, thevoltage may not rise for some time.

If the condition is as shown in the table below, it is normal. 1) Start engine.

If the condition is as shown in the table below, it is normal.

Between female (l)-(2)

Between female (2)-chassis

500-1000n

Min 1 MD

1) Turn startingswitch OFF.2) Disconnectconnector E07.

Qr cleaneriloggingiensor

II male)‘ I 2 (female)

Engine speediensor Measure with AC range

I Between (l)-(2) 0.5 - 3.0 V

1) Start engine.2) Insert T-adapter.

io7

2aa

1) Screw in rotation sensor until it contacts the ring gear,then turn back one turn.2) It must work normally when adjusted as above.

If the condition is as shown in the table below, it is normal.I

1) Turn startingswitch OFF.

Above LOW level in reservoir tank MaxlfIII

2) Disconnectconnector P08.oolant level

sensorBelow LOW level in reservoir tank Min 1 MC?

3) Insert T-adapterinto connector atsensor end.

‘ 08 (male)

If the condition is as shown in the table below, it is normal. II) Turn startingswitch OFF.2) Disconnectconnector PO53) Drain oil, thenremove sensor.4) Insert T-adapterinto sensor.+ Connect the T-adapter to theconnector andsensor flange.

V’ EFBLPOOO02ngine oil

evel sensor ‘ 05 (male)

q-)/as’ LizBLPGOOO3

If the condition i s as shown in the table below, it is normal. 1) Turn starting

Zoolantemperaturesensor

‘ 07 (male)

20-21

0




sys

temComponent

Engine oil

xessuresensor

Fuel levelsensor

Hydraulic oillevel sensor

Air cleanercloggingsensor

ionnector No.

_

‘ 06 (male)

‘ 09 (male)

VI (female)‘ 12 (male)

nspec-tion

nethod

Judgement table

f the condition is as shown in the table below, it isiormal.Low pressure sensor

11

High pressure sensor

If the condition is as shown in the table below, it isnormal.

the condition is as shown in the table below, it isxmal.

I I

Raisefloat 1 Maxi C? ~r

Lower float Min 1 MD

the condition is as shown in the table below, it isormal.

Air cleaner normal

IContinuity

Air cleaner clogged No continuity

Measurmentconditions

I) Install oil pressureneasuring guage.?) Remove wiringlarness terminal.3) Start engine.1) Put tester in:ontact between

sensor terminal screw2nd chassis.

I) Trun startingswitch OFF.2) Disconnect:onnector P06.3) Drain fuel, then‘ emove sensor.1) Insert T-adapter

nto sensor.k Connect the T-adapter to the:oonnector andsensor flange.

I) Trun startingswitch OFF.2) Disconnect:onnector PO9.3) Drain oil, then‘ emove sensor.4) Insert T-adapter

nto sensor.

1) Start engine.2) Disconnect PI 1,P12.3) Put tester incontact withconnector at sensorend to measure.

20-22

0



TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING

TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTNG

Check or measurmentitem

jymbol Part No. Part Name Remarks

I I II1 I799 203 8001 1Multi-tachometer L: 60 - 2,000 rpm

I I

t 799-203-8901 IClamp setDigital display

hH: 60 - 19,999 rpm

Engine speeds0 Kit part no. : 799-203-9000

Intake manifold pressure See Engine Shop ManualSee Engine Shop Manualntake air restriction

Lubricating oil pressure

Fuel filter inlet restriction

Blow-by pressure

-- I Pressure aauae 1See Engine Shop Manual

Vacuum gauge See Engine Shop Manual

See Engine Shop Manualool, adapter &manometer

Mercury manometer

Digital temperature guage

Exhaust back pressure See Engine Shop Manual

See Engine Shop Manualoolant temperature

Feeler gaugealve clearance

Exhaust gas color11 1799 2649000 Smoke detector Discoloration:

0 - 70% with standard color% x 1 I 0 = Bosch indexmoke meter

790-261-I 311

Pressure gauge: 2.45 (25), 5.88 (60) 39.2 (400)58.8 (600) MPa (kg/cm’ )

Pressure gauge: 68.6 MPa (700 kg/cm*)

Hydraulic tester

Digital hydraulic tester

Hydraulic gauge 0.98 MPa (10 kg/cm*)

Both male and female 14 x 1.5 (female PT I/8)

Both male and female 18 x 1.5 (female PT I/8)

Both male and female 22 x 1.5 (female PT I/8)Adapter

4 799-401-2700

t-k90-261-I 360

5 790-261-I 370

07003-31419

Differential pressuregauge

Oil pressure

Both male and female 14 x 1.5 (female PT l /8)dapter

Nut For 14 x 1.5 blind

For blindasket

161 -I79A-2640020

Hose

1-1 Push-pull scaleIO-294N(O-30kg)

0-490N(O-50kg)perating force H

Stroke, hydraulic drift I Scaleommerciallyavailable

Commerciallyavailable

~ top watchork equipment speed

Measuring voltage andresistance values

Troubleshooting of wiringharnesses and sensors

K 79A-2640210

799-601-2600

Tester

T-adapter boxI

2-

Adapter assembly Kit part no.: T-adapter kit 799-601-8000

I31 ~ dapter

~ lowmeter kitain pump delivery M 1790-303-l 003

20 23

0



TESTING AND ADJUSTING MEASURING ENGINE SPEED

MEASURING ENGINE SPEED

A

1.

2.

When removing or installing the measuring equip-

ment, be careful not to touch any high tempera-ture parts.Measure the engine speed under the followingconditions.

Coolant temperature: Within operating range

Hydraulic oil temperature: 45 - 55 CInstall the digital optical tachometer using the instruc-tions supplied with it.Start the engine, and measure the engine speedwhen it is set to the conditions for measuring.1) Measuring at low idling and high idling:

Measure the engine speed with the fuel controldial set to low idling and high idling.* When measuring at high idling with the work

equipment operated, operate the work equip-ment lever, but not enough to make the workequipment move.

* When measuring at high idling with the travel

(power max.) operated, operate the travel le-ver, but not enough to make the machinemove.

2) Measure the speed at near the rated speed.i) Set the working mode to the H/O mode.ii) Set the power max./swift slow-down switch

to the power max. position.iii) Run the engine at high idling, set the L.H.

knob switch to the ON or OFF position, oper-ate the arm lever, and measure the speedwhen the arm circuit is relieved.* Measuring speed when work equipment

is operated: L.H. Knob switch OFF* Measuring speed when travel is oper-

ated: L.H. Knob switch ON3) Measuring speed at pump relief:

Run the engine at high idling and measure theengine speed when each pump is relieved.* For details of the pump to relieve, see the

TABLE OF JUDGEMENT STANDARDVALUE.

20 24

a



TESTING AND ADJUSTING MEASURING INTAKE MANIFOLD PRESSURE

MEASURING INTAKE MANIFOLD PRESSURE

* Refer to ENGINE SHOP MANUAL for tools and properprocedure

20 25

0



TESTING AND ADJUSTING MEASURING INTAKE AIR RESTRICTION

MEASURING INTAKE AIR RESTRICTION

* Refer to ENGINE SHOP MANUAL for tools and properprocedure.

20 26

0



TESTING AND ADJUSTING MEASURING LUBRICATING OIL PRESSURE

MEASURING LUBRICATING OIL PRESSURE


20-27

a



TESTING AND ADJUSTING MEASURING FUEL (FILTER) INLET RESTRICTION

MEASURING FUEL (FILTER) INLET RESTRICTION


20 28

a



TESTING AND ADJUSTING MEASURING BLOWBY PRESSURE

MEASURING BLOWBY PRESSURE


20-290



TESTING AND ADJUSTING MEASURING EINGINE BACK PRESSURE

MEASURING ENGINE BACK PRESSURE


20 30

0



TESTING AND ADJUSTING MEASURING EXHAUST COLOR

MEASURING EXHAUST COLOR

l

A

1.

When measuring in the field when there is no air orpower supply, use smoke checker GI; when record-ing official data, use smoke meter G2.Raise the coolant temperature to the operating rangebefore measuring.

When removing or installing the measuring equip-

ment, be careful not to touch any high temperaturepart.

Measuring with handy smoke checker GI1) Fit filter paper in tool GI.2) Insert exhaust gas intake port into the exhaust

pipe, accelerate the engine suddenly, and at thesame time operate the handle of tool GI to catchthe exhaust gas on the filter paper.

3) Remove the filter paper and compare it with thescale provided to judge the condition.

2. Measuring with smoke meter G2 I

\

1)

2)

3)

4)

5)6)

7)

Insert probe 0 into the outlet port of exhaust pipe (I),then tighten the clip to secure it to the exhaust pipe.Connect the probe hose, accelerator switch plug, andair hose to tool G2.* The pressure of the air supply should be less than

1.47 MPa (15 kg/cm?Connect the power cord to the AV 1 OOV outlet.* When connecting the port, check first that the

power switch of tool G2 is OFF.Loosen the cap nut of the suction pump, then fit thefilter paper.* Fit the filter paper securely so that the exhaust gas

does not leak.Turn the power switch of tool G2 ON.Accelerate the engine suddenly, and at the sametime, depress the accelerator pedal of tool G2 andcatch the exhaust gas color on the filter paper.Lay the filter paper used to catch the exhaust gascolor on top of unused filter paper (10 sheets ormore) inside the filter paper holder, and read theindicated value.

G2

20 31

a



TESTING AND ADJUSTING MEASURING COOLANT TEMPERATURE

MEASURING COOLANT TEMPERATURE


20 32

0



TESTING AND ADJUSTING MEASURING VALVE CLEARANCE

MEASURING VALVE CLEARANCE

* Refer to ENGINE SHOP MANUAL for tools and proper Iprocedure.

20 33

a



CHECKING AND ADJUSTING BELT TENSIONTESTING AND ADJUSTING FOR AIR CONDITIONER COMPRESSOR

CHECKING AND ADJUSTINGBELT TENSION FOR AIRCONDITIONER COMPRESSOR

CHECKING1. Remove belt guard 0.

2. Press compressor drive belt midway between fanpulley and compressor pulley. The belt should nor-mally deflect by about 15 - 18 mm when pressedwith the finger (with a force of approxiamately 6kg).

ADJUSTING1.2.

3.4.

5.

6.7.

Lossen two nuts and bolts 0.Carefully lever compressor housing as shown totighten belt to tightness criteria. Tighten lower boltto hold in position.Tighten upper bolt.Check each pulley for damage, wear of the V-grooveand wear of the V-belt. In particular, be sure to checkthe V-belt is not touching the bottom of the V-groove.Replace belt if it has streched, leaving no allowance foradjustment, or if there is a cut or crack on the belt.Refit belt guard.When the new belt is set, readjust after operating forone hour.

X13EM006

20 34

a



TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR

ADJUSTING ENGINE SPEEDSENSOR

1 Screw in until the tip of sensor (1) contacts gear (2).2. When gear (2) contacts sensor (I), turn back one turn.3. Tighten locknut (3).* Be particularly careful when securing the sensor wiring

to ensure that no excessive force is brought to bear on

the wiring.* Be careful not to let the tip of the sonsor be scratched or

to let any iron particles stick to the sensor tip.

XlZAD058

1 2

\q

*;,_ 3

I-LClearance

20-35a



TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE

TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE

TESTING* Use the governor motor adjustment mode.1. In the time mode display, keep the time switch +

travel speed R.H. switch + working mode R.H.switch pressed for 2.5 seconds.

2. In this condition, check the governor lever and

spring rod.3. After checking, repeat the procedure in Step 1) tofinish the governor motor adjustment mode.

ADJUSTING1. Turn the starting switch OFF, then remove the nut

and disconnect joint (1) from governor lever (4).2. Repeat the procedure in Step 1 - 1) above to set to

the governor adjustment mode.3. Set governor lever (4) to a postion where it contacts

the full speed stopper (5) of the injection pump, thenadjust the length of spring assembly (2) and rod (3),and connect joint (1) with the nut.

4. From the above position, turn joint (1) back 4 turns,and secure in position with locknut (6).

* CautionWhen the spring assembly is removed and the startingswitch is at the OFF position, if the governor motor leveris moved suddenly, the governor motor will generateelectricity, and this may cause a failure in the enginethrottle controller.

Engine governor lever

Low idle stop

ull s@ed

View “A”

L

I- I

X12AD061

20 36

a



TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING

TESTING CLEARANCE OF SWINGCIRCLE BEARING

Method of testing clearance of swing circle bearingwhen mounted on machine1.

2.

3.

4.

5.

A

6.

Fix a magnet-type dial gauge to the outer circle (orinner circle) of the swing circle, and put the tip of theprobe in contact with the inner circle (or outer circle).Set the dial gauge at the front or rear.

Extend the work equipment to the maximum reach,and set the tip of the bucket to the same height as the

bottom of the revolving frame.When this is done, the upper structure will tilt forward,so the front will go down and the rear will rise.

Set the dial gauge to the zero point.

Set the arm more or less at right angles to the groundsurface, then lower the boom until the front of themachine comes off the ground.

Read the value on the dial gauge at the point. Thevalue on the dial gauge is the clearance of the swingcircle bearing.

When carrying out the measurment, do not put your

hand or feet under the undercarriage.

Return to the condition in Step 2, and check that thedial gauge has returned to the zero point. If it has notreturned to the zero point, repeat Steps 2 to 5.

eve wngframe

Outerir le

or

73nnnerir le

20 37

0



TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION

TESTING AND ADJUSTING TRACKSHOE TENSION

TESTING1. Raise the track frame using the arm and boom, and

measure the clearance between the bottom of thetrack frame and the top of the track shoe.0 Clearance: 303 f 20 mmMeasurement positionPC200 : 4th track roller from sprocketPC2OOLC : 5th track roller from sprocketPC21OLC : 5th track roller from sprocketPC22OLC : Midway between the 5th and 6th

track roller from sprocketPC25OLC : Midway between the 4th and 5th

track roller from sprocket

ADJUSTING* If the track shoe tension is not within the standard

value, adjust as follows.1. When the tension is too high:

Loosen plug (1) gradually, and release the grease.A There is danger that the plug may fly out under

the high internal pressure of the grease, so neverloosen plug (1) more than one turn.

* If the grease does not come out easily, move themachine backwards or forwards slowly.

2. If track is too loose:Pump in grease through grease fitting (2).+r If the grease cannot be pumped in easily, move

the machine backwards and forwards slowly.

/Track frame

\Track shoe

X15AD008

I X15AD009

20 38

a



TESTING AND ADJUSTING HYDRAULIC PRESSURETESTING AND ADJUSTING IN WORK EQUIPMENT, SWING, TRAVEL CIRCUIT

TESTING AND ADJUSTINGHYDRAULIC PRESSURE IN WORKEQUIPMENT, SWING, TRAVELCIRCUIT

MEASURING* Hydraulic oil temperature when measuring: 45 -

55°CA Lower the work equipment to the ground and

stop the engine. Loosen the oil filler cap slowlyto release the pressure inside the hydraulic tank.Then put the safety lock lever in the LOCK posi-tion.Remove pressure pick-up plug (1) or (2) (Threaddia. = IOmm, Pitch = 1.25 mm) from the circuit tobe measured, then install oil pressure gauge CI(58.8 MPa (600 kg/cm?).

Measuring main unload pressure* Unload pressure when front and rear pump flows

are merged.Measure the oil pressure in H/O mode with theengine at high idling and the control levers atneutral.

Measuring sub-unload pressure* The unload pressure in the circuit which is not

under load when the front and rear pump flowsare divided.

1. Set to H/O mode + boom/swing priority selectionmode ON.

2. Measure the pressure in the pump circuit on theopposite side when the arm or bucket circuit is

relieved.Arm relief: Load on front pump, rear pumpunloaded.

Bucket relief: Load on rear pump, front pumpunloaded.

Measuring pump relief pressure1. When LS relief valve is actuated

When hydraulic pressure is 31.9 MPa (325 kg/cm?1)

*

Measure the pressure when each actuatorexcept the travel actuator is relieved in H/Omode with the engine at high idling.Note that the set pressure of the safety valvefor the swing motor and head end of the boomis lower that the LS relief pressure, so the valvemeasured will be the relief pressure of thesafety valve.If the swing lock switch is ON, the pressure willrise, so always keep the lock switch OFF whenmeasuring.

XlOZZO 4

Table 1 Combination of pumps and actuatorscontrolled when flow from front andrear pump is divided.

Pump

Front pump

Controlled actuator

Arm cylinder0 Swing motor %

L.H. travel motor

Boom cylinder %Rear pump Bucket cylnder

R.H. travel motor

g The set pressure of the safety valve at the

head end and the swing motor is lower thanthe set pressure of the main relief valve.

I

20-39

0




2. When pressure rises to 34.8 MPa (355 kg/cm?*V

2)

Main relief valve actuated.When travel is operated.Measure the hydraulic pressure when thetravel is relieved on each side seperately inH/O mode with the engine at high idling.* To relieve the travel circuit, put block 0

under the track shoe grouser, or put block

0 between the sprocket and frame to lockthe track.

When power max. function is actuated.When measuring the oil pressure in G/O orH/O mode with the engine at high idling andthe power max. function actuated, relieve oneof the boom, arm, or bucket circuits, and mea-sure the oil pressure.

ADJUSTING

1. LS relief valve1) Loosen nut (1) so that elbow (2) can move.2) Loosen locknut (3), then turn holder (4) to adjust.

j, Turn the holder to adjust as follows.To INCREASE pressure, turnCLOCKWISETo DECREASE pressure, turnCOUNTERCLOCKWISE.

2. Main relief valveLoosen locknut (I), then turn adjustment screw(2) to adjust. XlOZZO27

Turn the adjustment screw to adjust as follows.To INCREASE pressure, turn CLOCKWISE.To DECREASE pressure, turn COUNTER-CLOCKWISE. 1

* Amount of adjustment for one turn of adjust-ment screw: 12.6 MPa (128 kg/cm?.

20-40a




3. Swing motor safety valveLoosen locknut (I), then turn adjustment screw(2) to adjust.jl Turn the adjustment screw to adjust as follows.

To INCREASE pressure, turnCLOCKWISE.To DECREASE pressure, turnCOUNTERCLOCKWISE.

I x1 zz 3

20-41a



TESTING AND ADJUSTING TVC VALVE OUTPUTTESTING AND ADJUSTING PRESSURE (SERVO PISTON INPUT PRESSURE)

TESTING AND ADJUSTING TVCVALVE OUTPUT PRESSURE (SERVOPISTON INPUT PRESSURE)

MEASURING* Hydraulic oil temperature when measuring : 45 - 55°C

Measure the oil pressure when the circuit is relievedin the power max. mode.1) Remove pressuremeasurement plugs (l), (2), (3),and (4) (Thread dia. = 10 mm, Pitch = 1.5 mm), andinstall oil pressure gauge Cl.* Install a 39.2 MPa (400 kg/cm? gauge to the

servo valve end, and a 58.8 MPa (600 kg/cm?gauge to the pump outlet port end.

2) Set the swing lock switch ON.3) Set the working mode to H/O mode.4) Run the engine at high idling, turn the L.H. knob

switch ON, and measure the oil pressure when thearm IN circuit is relieved.* Check that the servo piston input pressure is %

of the pump discharge pressure.

[Reference]If there is any abnormality in the LS valve or servopiston, the servo piston input pressure will be almostthe same or 0 of the pump discharge pressure.

20 42

0



TESTING AND ADJUSTING TVC VALVE OUTPUTTESTING AND ADJUSTING PRESSURE (SERVO PISTON INPUT PRESSURE)

ADJUSTING* If the load becomes larger, the engine speed will

drop. Or if the engine speed remains normal, thework equipment speed will drop. In such cases, ifthe pump discharge pressure and LS differentialpressure are normal, adjust the TVC valve as follows.* There are two sets, so adjust both the front and

rear to the same angle.

1. Loosen locknut (3), and if the speed is slow, turnscrew (4) to the left; if the engine speed drops, turnthe screw to the right.* If the screw is turned to the left, the pump absor-

ption torque will be increased, and if it is turned tothe right, the pump absorption torque will bereduced.There is also a connection with the angle, so seeNote below.

* The adjustment range for the screw is a maximumof 90” to both the left and right.

2. After completing the adjustment, tighten the locknut.

- Locknut: 29.4 f 4.9 Nm (3.0 f 0.5 kgm)

Note: The screw is an eccentric cam, so if it is turnedfrom position @ in the graph, the stroke of theservo piston will move as shown in the graph. If itis turned on full turn, it will return to the originalposition, but the screw will become looser, sothere will be play in the screw. Therefore, turn thescrew a maximum of 90” to the left and right fromthe position @ set when the machine was ship-ped.

az .ZE :z- . Position when

assembled

“ 90 180 320

Rotation position of eccentric pin ( ’ )

x1ozzo35

Position of screw when shipped

20 43

0



TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVOTESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE

TESTING AND ADJUSTING LSVALVE OUTPUT PRESSURE (SERVOPISTON INPUT PRESSURE) AND LSDIFFERENTIAL PRESSURE* Hydraulic oil temperature when measuring: 45 - 55°CMeasuring1. Measuring LS valve output pressure (servo piston

input pressure)1) Remove pressure measurement plugs (l),(2),(3),

and (4) (Thread dia. = 10 mm, Pitch 1.5 mm), andinstall oil pressure gauge Cl.j, Install a 39.2 MPa (400 kg/cm? gauge to theservo valve end, and a 58.8 MPa (600 kg/cm?gauge to the pump outlet port end.Oil pressure when travel is rotating under no loadon one side.i) Set the working mode to H/O mode, and set

the travel speed switch to Hi.ii) Use the work equipment to raise the track

assembly on one side.iii) Measure the oil pressure with the engine at

high idling and the travel lever operated to theend of its stroke to rotate the track under noload.Run the engine at high idling, operate the travellever to the end of its stroke, and measure theoil pressure when the working mode and travelspeed are switched as shown in Table 1.

-able 1

Working Travelmode lever

l-

H/O mode Neutral

HI0 mode Full

Pumppressure (MPa

(kg/cm*))

3.72 f 0.69 3.72 f 0.69(38 f 7) (38 f 7)

8.82 f 1.96(90 f 20)

ervo

piston inletPort

pressure(MPa

(kg/cm*))

4.41 f 0 98

(45+ 10

Remarks

Aboutsame

pressure

About %of

3ressure

-

l’

20-44

0




2. Measuring LS differential pressure1) Measuring with a differential pressure gauge.

i) Remove oil pressure measurment plugs (5)and (6) (Thread dia. = 10 mm, Pitch = 1.5 mm),and install differential pressure gauge C4.

ii) Set to the conditions in Table 2 and measurethe LS differential pressure.

able 2

..,,.,,,,. Operation

HI0 mode I MAX

H/O mode MAXI-Levers at

neutral

2.16+0.1(22 f 1)

Travel speed:Hi

Travel circuitunder no load

(lever fullyoperated)

2) Measuring with oil pressure gauge

* The maximum differential pressure is 2.94 MPa(30 kg/cm?, so measure with the same gauge.

i) Remove oil pressure measurement plugs (5)and (6) (Thread dia. = 10 mm, Pitch = 1.5 mm),and install the plug inside hydraulic tester CI.

ii) Install oil pressure gauge CI (58.8 MPa (600kg/cm?) to the measurement plug for thepump discharge pressure.jr Use a gauge with a scale in units of 0.98

MPa (10 kg/cm?. (If no 58.8 MPa (600kg/cm? pressure gauge is available, a39.2 MPa (400 kg/cm? pressure gaugecan be used.)

iii) Set to the conditions in Table 2 and measurethe pump discharge pressure.* Stand directly in front of the indicator and

be sure to read it correctly.iv) Remove oil pressure gauge CI, then install to

the LS pressure measurement plug.v) Set to the conditions in Table 2 and measure

the LS pressure.+r Stand directly in front of the indicator and

be sure to read it correctly.Pump discharge pressure - LS pressure =Differential pressure.

X1022024

20- 45

a




ADJUSTING1. Adjusting LS valve

When the differential pressure is measured under theconditions above, and the results show that the differ-ential pressure is not within the standard value, adjustas follows.1) Loosen locknut (7) and turn screw (8) to adjust the

differential pressure.* Turn the screw to adjust the differential pres-

sure as follows.To INCREASE pressure, turnCLOCKWISE.To DECREASE pressure, turnCOUNTERCLOCKWISE.

2) After adjusting, tighten locknut (7).- Locknut : 29.4 f 4.9 Nm (3.0 f. 0.5 kgm)

Note: Always measure the differential pressurewhile adjusting.

20- 46

a



TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE

TESTING AND ADJUSTINGCONTROL PUMP CIRCUIT OILPRESSURE

MEASURINGj, Hydraulic oil temperature when measuring: 45 - 55°C1. Remove pressure pick-up plug (1) (Thread dia.=

1 Omm, Pitch = 1.25 mm), and install oil pressureguage CI (5.88 MPa (60 kg/cm?).

2. Start the engine and measure with engine at highidling.

* When testing for internal leakage of the equipment inthe control circuit, use the parts given below to shut offthe circuit for the follwing sections when measuring therelief pressure.

No. Section of hydraulic circuit shut off Component that can bechecked

1 Control pump outlet port Control pump

2 Solenoid valve inlet port Solenoid valve

3 Travel PPC valve inlet port Travel PPC valve

4 R.H. PPC valve inlet port R.H. PPC valve

5 L.H. PPC valve inlet port L.H. PPC valve

* Items No. 2 and below can be checked if the equip-ment in the previous number is normal.

* Use the following parts to shut off the circuit.For elbowSleeve nut : 07221-20210,07221-20315

07221-20422Plug : 07222-00210,07222-00315

07222-00414For hosePlug : 07376-50210,07376-50315

07376-50422

c1’ +3

XiOAV271

STD/FiipC R.H. PPC -‘ L.H.PPCI

Solenoid valve

valve valve valve

Accumulator

XlOAV273

20- 47

a



TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE

ADJUSTING1. Loosen locknut (2) and turn adjustment screw (3) to

adjust.* Turn the adjustment screw as follows.

To INCREASE pressure, turnCLOCKWISE.To DECREASE pressure, turnCOUNTERCLOCKWISE.

* Amount of adjustment for one turn of adjustmentscrew: 0.53 MPa (5.4 kg/cm?.

- Locknut : 63.7 f 9.8 Nm (6.5 f 1 .O kgm)

* After completion of adjustment, repeat theprocedure in Item 1 to check the set pressureagain.

20- 48

0



TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE

TESTING EPC VALVE, SOLENOIDVALVE OUTPUT PRESSURE

MEASURING* Hydraulic oil temperature when measuring: 45 - 55°C1. Measuring output pressure of LS control EPC valve

1) Disconnect output hose (1) of the LS control EPCvalve, then use adapter C3 in the oil pressuregauge kit to install oil pressure CI (5.88 MPa (60kg/cm?).

2) Measure the output pressure under the conditionsin Table 1.

Table 1

Operation andworking mode

All control leversat neutral

Enginespeed (rpm)

Min 1,500

Output pressure(MPa (kg/cm*)

2.94 (30)

[Reference]Current (A)

900 f 30

H/O mode orG/O modeTravel circuit atneutral, any Min 2,000

0 (0)0

work equipmentlever is operated

j, Monitoring code 10 or 40 for engine speedMonitoring code 15 for LS control EPC current

20-49

0



TESTING AND ADJUSTING TESTING EPC VALVE, SOLENOID VALVE OUTPUT PRESSURE

2. Measuring output pressure of ON/OFF solenoid valve1) Disconnect outlet hose (2) of the solenoid valve,

then use adapter C3 in the oil pressure gauge kitto install oil pressure gauge CI (5.88 MPa (60kg/cm?).

2) Measure the output pressure under the conditionsin Table 2.

-r

r

able 2Name of

IMeasurement conditions Operating

ICondition of

IOil pressure

IRemarks

solenoid condition solenoid (MPa (kg/cm*))

Swingbrakesolenoid

Swing or work equipment operated

All levers except travel at neutral(5 set after returning to neutral)

Brake cancelled

Brake actuated

ON Min 2.74(Min 28)

OFF 8 (8)

Travelspeedsolenoid

Travel speed swi tch at Hi or MiEngine speed 1500 rpm or aboveTravel lever operated

Travel speed swi tch at Lo or enginespeed 1500 rpm or below

Travel speed Hi

Travel speed Lo

ON

OFF

Min 2.74(Min 28)

8 (0)

Motor swashplate angle atminimum

Motor swashplate angle atmaximum

2-stagerelief

Swing lock switch ON + work equipmentlever ooerated

Pressure rise ON Min 2.74(Min 28)

solenoidI I I .

All levers at neutral Normal pressure OFF 8 (0)

LS selectsolenoid

Swing lock switch OFF, compoundoperation of swing + travel or arm OUTor boom RAISE

All levers at neutral

LS circuitdivided

LS circuit notdivided

ON

OFF

Min 2.74(Min 28)

8 (8)

Divided only forcompoundoperations ofswing + travel,arm OUT, boomRAISE

1 I I I

Pumo 1 ever at neutral. or boom. arm bucket 1 low from front 1 OFF I 0 (0) Imerge-dividersolenoid

operated independently

Travel or swing operated independently

and rear pumpsmerged

Flow from frontand rear pumpsdivided

ON

. I

Min 2.74(Min 28)

LS pumpmerge-dividervalve actuated atsame time

The basic pressure of the LS select solenoid valve issupplied from the PPC shuttle valve. Therefore, theoil pressure is not supplied unless one of the travelor arm OUT or boom RAISE is operated.Operation of solenoid valveON: Contunuous (oil pressure generated)OFF: Not continous (oil pressure: 0)

20-50

0



TESTING AND ADJUSTINGMEASURING PPC VALVE OUTPUT PRESSURE

AND TESTING PPC SHUTTLE VALVE

MEASURING PPC VALVE OUTPUTPRESSURE AND TESTING PPCSHUTTLE VALVE

* Hydraulic oil temperature when measuring: 45 - 55°C

1. Measuring PPC valve output pressure1)

2)3)

4)

Disconnect the hose of the circuit to be measured(see next page).Install adapter C3 between the hose and elbow.Install oil pressure gauge CI (5.88 MPa (60kg/cm?) to adapter C3

Run the engine at high idling, operate the controllever of the circuit to be measured, and measurethe oil pressure.

2. Checking PPC shuttle valveIf the output pressure at the control valve end is low,check for leakage of oil from the PPC shuttle valve asfollows.1) Disconnect the hose between the PPC valve and

the shuttle block at the block end.2) Install an adapter for measuring the oil pressure

to the tip of the hose, then install blind plugs tothe tip and shuttle block end.

3) Operate the control lever and measure the outputpressure.

j, If the output pressure becomes normal, there isleakage from the PPC shuttle valve; if there is nochange, the PPC valve is defective.

3. Checking defective operation of PPC shuttle valve1) Remove the oil pressure switch, fit adapter Cs,

then install oil pressure gauge CI (5.88 MPa (60kg/cm?).

2) Operate the applicable lever.If no oil pressure is generated or if oil pressure isgenerated when another lever is operated, theoperation of the PPC shuttle valve is defective.

PPC hose

PPC

CS’

XlOAV282

20- 51

a



TESTING AND ADJUSTINGMEASURING PPC VALVE OUTPUT PRESSURE

AND TESTING PPC SHUTTLE VALVE

Oil pressure switch location diagramShuttle block seen from rear of machine

Swing608)

Bucket CURL(SO6)

Arm OUT603)

Boom RAISE602)

D&&nXlOAV283

0Circuit diagram

IC_i__._- )

XlOAV284

1. Swing PPC shuttle valve2. PPC shuttle valve for LS select3. PPC shuttle valve for OUT, boom RAISE4. PPC shuttle valve for L.H. travel FOWARD, R.H. travel

REVERSE

5. Travel PPC shuttle valve6. PPC shuttle valve for R.H. travel

FORWARD, L.H. travel REVERSE

20-52a



TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT. SWING PPC VALVE

ADJUSTING WORK EQUIPMENT.SWING PPC VALVE

*

A

1.2.3.

4.

5.

If there is excessive play in the work equipment orswing lever, adjust as follows.Lower the work equipment to the groud and stop

the engine. Loosen the oil filler cap slowly to releasethe pressure inside the hydraulic tank. Then set thesafety lock lever to the LOCK position.

Remove the PPC valve.Remove boot (1).Loosen locknut (2) then screw in disc (3) until it con-tacts the 4 heads of piston (4).* When doing this, do not move the piston.Secure disc (3) in position, then tighten locknut (2) tothe specified torque.

- Locknut : 107.8 i 9.8 Nm (11 f 1 kgm)

Install boot (1).* With the above adjustment, the clearance be-

tween disc (3) and piston (4) becomes 0.

20- 53a



TESTING AND ADJUSTING ADJUSTING TRAVEL LEVER

ADJUSTING TRAVEL LEVER

1.

2.

3.

4.

Use bolt (2) to install lever (1) to the PPC valve.* When doing this, install so that clearance @ is

35.3 f 1 mm.In this condition, move left and right travel levers (3)forward and backwards, and check that the levers arefitted securely in the stopper (bolt head) of the PPC

valve.Check also that cover (3) is not contacting portion @.* If it is contacting, adjust with the PPC mounting

bolt or cover mounting bolt.Install damper (4) and adjust so that dimension @ is157.2 f 1 mm when the lever is at neutral.

I - I

XlOAV286

20- 540



TESTING TRAVEL DEVIATIONTravel posture

j, When traveling on level ground.1. Set the machine in the travel posture.

* For the travel posture, extend the bucket and armcylinder rods fully, and hold the boom angle at45” .

2. Travel for 1 Om, then measure the deviation when

traveling for the next 20m.* Set to H/O mode and measure with the engine athigh idling.

Ir Install the hydraulic pressure gauge and measure x14zzoo1

the pump discharge pressure at the same time.

to travel for thewhole distance

Make a mark Make a mark at the10 m midway point

‘ Make a mark

dimension a at this point Mark

x14zzoo2

20-55

0



TESTING AND ADJUSTING TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT

TESTING LOCATIONS CAUSINGHYDRAULIC DRIFT OF WORKEQUIPMENT

* If there is any hydraulic drift in the work equipment(cylinders), check as follows to determine if the causeis in the cylinder packing or in the control valve.

1. Checking for defective cylinder packing1) Checking boom and bucket cylindersi) Set in the same posture as when measuring

hydraulic drift, and stop the engine.ii) Operate the boom control lever to RAISE or

the bucket control lever to CURL.If the lowering speed increases, the pack-ing is defective.If there is no change, the boom holdingvalve (boom) or the control valve (bucket)is defective.

2) Checking arm cylinder

0

ii)

Operate the arm cylinder to move the arm infully, then stop the engine.Operate the control lever to arm IN.

If the lowering speed increases, the pack-ing is defective.If there is no change, the control valve isdefective.

* If the pressure in the accumulator hasdropped, run the engine for approx. IOseconds to charge the accumulator againbefore operating.

[Reference] If the cause of the hydraulic drift is in thepacking, and the above operation is carriedout, the downward movement becomesfaster for the following reasons.

1) If the work equipment is set to the above posture(holding pressure applied to the bottom end), the oilat the bottom end leaks to the head end. However,the volume at the head end is smaller that the volumeat the bottom end by the volume of the rod, so theinternal pressure at the head end increases becauseof the oil flowing in from the bottom end.

2) When the internal pressure at the head end increases,the pressure at the bottom end also rises in proportionto this. The balance is maintained at a certain pres-sure (this differs according to the amount of leakage)by repeating this procedure.

3) When the pressure is balanced, the downward move-

ment becomes slower. If the lever is then operatedaccording to the procedure given above, the circuit atthe head end is opened to the drain circuit (the bottomend is closed by the check valve), so the oil at thehead end flows to the drain circuit and the downwardmovement becomes faster.

Boom, bucket checking posture

Y1?FRO26

Arm checking posture

20- 56

a



TESTING AND ADJUSTING TESTING LOCATIONS CAUSING HYDRAULIC DRIFT OF WORK EQUIPMENT

Checking boom holding valveSet the work equipment at the maximum reach, and

the top of the boom horizontal, then stop the engine.Lock the work equipment control levers and releasethe pressure inside the hydraulic tank.1) Disconnect pilot hose (1) of the boom holding

valve, and install a blind plug in the hose.* Blind plug: 07376-50315j, Leave the boom holding valve end open.

2) Start the engine, charge the accumulator, thenstop the engine.

3) Operate the boom control lever to the LOWERposition.* If any oil leaks from the port that is left open,

the boom holding valve is defective.3. Checking PPC valve

If the hydraulic drift differs when the safety lock leveris in the LOCK of FREE position, (engine running), thePPC valve is defective.

_.

X17FR028

20- 57

0



TESTING AND ADJUSTING MEASURING OIL LEAKAGE

MEASURING OIL LEAKAGE

* Hydraulic oil temperature when measuring: 45 - 55°C1. Work equipment cylinder* If the hydraulic drift of the work equipment is outside

the standard value, measure the leakage inside thecylinder as follows, and judge if the cause of thehydraulic drift is in the cylinder or in the control valve.

If the leakage is withing the standard value, theproblem is in the control valve.If the leakage is greater than the standard value,the problem is in the cylinder.Fully extend the rod of the cylinder to be meas-rued, then stop the engine.Disconnect piping (1) at the head end, the blockthe piping at the chassis end with a blind plug.Be careful not to disconnect the piping at the

bottom end.

0

0

1)

2)

A

3)

4)

Start the engine and apply the relief pressure tothe bottom end of the cylinder with the engine athigh idling.

Continue this condition for 30 seconds, thenmeasure the oil leakage for the next OI minute.

X17FRO29

Bucket cylinder

Posture for measuring boom cylinder

Posture for measuring arm. bucket cylinder

X17FR032

X17FR033

Arm ylinder

20- 58

a



TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT

2. Swing Motor1)

2)3)

4)

*

Disconnect drain hose (1) from the swing motor,then fit a blind plug at the tank end.Set the swing lock switch ON.Start the engine and operate the swing relief withthe engine at high idling.Continue this condition for 30 seconds, thenmeasure the oil leakage for the next one minute.After measuring, swing 180” and measure again.

3. Travel motor1) Disconnect drain hose (2) from the travel motor,

then fit a blind plug at the hose end.2) Fit block 0 under the track shoe grouser, or fit

block 0 between the sprocket and frame to lockthe track.

3) Start the engine and operate the travel relief withthe engine at high idling.

A When measuring the oil leakage from the

travel motor, mistaken operation of the

control lever may lead to a serious acc-ident, so always use signals and checkwhen carrying out this operation.

4) Continue this condition for 30 seconds, thenmeasure the oil leakage for the next minute.

* When measuring, move the motor slightly (tochange the position between the valve plate andcylinder, and piston and cylinder), and measureseveral times.

RELEASING REMAINING PRESSUREIN

*

1.

2.

3.

HYDRAULIC CIRCUITIf the piping between the hydraulic cylinder and thecontrol valve is disconnected, release the remainingpressure from the circuit as follows.The travel circuit is an open circuit, so there is noremaining pressure. It is enough to remove the oilfiller cap.Loosen the oil filler cap slowly to release the pressureinside the tank.Operate the control levers.* When the levers are operated 2 -3 times, the pres-

sure stored in the accumulator is removed.Start the engine, run at low idling for approx. 5 min-utes, then stop the engine and operate the controllevers.* Repeat the above operation 2 - 3 times to release

all the remaining pressure.

X17FR03

20-59

a



TESTING AND ADJUSTING BLEEDING AIR

BLEEDING AIROrder of operations and procedure for bleeding air (Note 2)

Air bleeding item 1 Air bleeding procedure

Nature of work

Replace hydraulic oil0 Clean strainer

Replace return filter element

Replace, repair pumpRemove suction piping

Replace, repair control valve

Replace cylinderRemove cylinder piping

Replace swing motorReplace swing motor piping

Replace travel motorswivelRemove travel motorswivelpiping

0 0 0

Replace EPC valveNote 1: Bleed air from the swing and travel motors only when the oil inside the motor case had been drained.

0 0 0

Note 2: Perform only those procedures marked with a 0 for each tvoe of work.

I. Bleeding air from pump1) Loosen air bleed plug (I), and check that oil

oozes from the plug.2) When oil oozes out, tighten plug (1).

- Plug : 17.15 +2.45 Nm

(1.75 f 0.25 kgm)$r If no oil oozes out from the air bleed plug:3) Leave plug (1) loosened and remove hose (2) and

elbow (3).

4) Pour in oil through the elbow mount hole untiloil oozes out from plug (1).

5) Fit elbow (3) and install hose (2).6) Tighten air bleed plug (1)

- Plug : 17.15 1t2.45 Nm

(1.75 f 0.25 kgm)* Precations when starting the engine

After completing the above procedure and start-ing the engine, run the engine at low idling for 10minutes.

* If the coolant temperature is low and automaticwarming-up is carried out, cancel it by using thefuel control dial after starting the engine.

Ylfi77fiAl

20- 60

a



2. Bleeding air from hydraulic cylinders

1)

2)

3)

4)

Start the engine and run at idling for approx. 5minutes.Run the engine at low idling, then raise and lowerthe boom 4 - 5 times in succession.* Operate the piston rod to approx. 100 mm

before the end of its stroke. Do not relievethe circuit under any circumstances.

Run the engine at high idling and repeat Step 2).After that, run the engine at low idling, and oper-ate the piston rod to the end of its stroke to relievethe circuit.Repeat Steps 2) and 3) to bleed the air from thearm and bucket cylinders.j, When the cylinder has been replaced, bleed

the air before connecting the piston rod.Be particularly careful not to operate thecylinder to the end of its stroke when the pistonrod had been connected to the LOWER end ofthe boom cylinder.

3. Bleeding air from the swing motor1) Run the engine at low idling, loosen air bleed plug

(I), and check that oil oozes out.* If no oil oozes out from the air bleed plug:2) Stop the engine, and pour oil into the motor case

from plug (1).3) Tighten air bleed plug (1).QZ Plug: 166.6 f 19.6 Nm (17 f 2 kgm)

4. Bleeding air from travel motorRun the engine at low idling, loosen air bleed plug (2),and when oil oozes out, tighten the plug again.

20- 61

a



TROUBLESHOOTINGPoints to remember when troubleshooting ....................Sequence of events in troubleshooting .......................Precautions when carrying out maintenance ...................Checks before troubleshooting ..............................Connector types and mounting locations ......................Connector table for connector pin numbers ...................Explanation of control mechanism for electrical system ..........

Display method and special functions of monitor panel ..........Method of using judgement table ............................Details of troubleshooting and troubleshooting procedure ........Troubleshooting of engine throttle controller system (E mode) ....Troubleshooting of engine (S mode) .........................Troubleshooting of pump controller system (C mode) ...........Troubleshooting of pump controller input signal system (F mode) .Troubleshooting of hydraulic and mechanical system (H mode) ...Troubleshooting of machine monitor system ...................

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20- 64 20- 6520- 6620- 7320- 74 20- 76 20- 92

20- 93 20-I 02 20-l 06 20-I 11 20-I 39 20-I 6320-l 95 20-207 20-241

20- 63

a



TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING

POINTS TO REMEMBER WHEN TROUBLESHOOTING

A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securly fitted.

A 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.A 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 any troubleshooting.A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.

A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.

A 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 toprevent reoccurrance of the failure.When carrying out troubleshooting, an inportant point is of course to understand the structure and function.However, a short cut to effective troubleshooting is to ask the operator various questions to form some ideaof possiable causes of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurryto disassemble the components.

If components are diassembled immediately anyfailure occurs:

Parts that have no connection with the failureor other unnecessary parts will be diassem-bled.It will become impossible to find the cause ofthe failure.

It will also cause a waste of manhours, parts, oroil or grease, and at the same time, will also losethe confidence the user or operator.For this reason, when carrying out troubleshoot-ing, it is necessary to carry out thorough priorinvestigation and to carry out troubleshooting inaccordance with the fixed procedure.

2. Points to ask user or operator1)

2)

3)

4)6)

6)

Have any other problems occured apart fromthe problem that has been reported?Was there anything strange about the ma-chine before the failure occured?Did the failure occure suddenly, or were thereproblems with the machine condition beforethis?Under what conditions did the failure occur?Had any repairs been carried out before thefailure?When were these repairs carried out?Has the same kind of failure occurred before?

3. Check before troubleshooting1) Check the oil level.2) Check for any external leakage of oil from the

piping or hydraulic equipment.3) Check the travel of the control levers.

4) Check the stroke of the control valve spool.5) Other maintenance items can be checked ex-

ternally, so check any item that is consideredto be necessary.

4. Confirming failureConfirm the extent of the failure yourself, andjudge whether to handle it as a real failure oras a problem with the method of operation,etc.* When operating the machine to reenact

the troubleshooting symptoms, do notcarry out any investigation or measur-ment that may make the problem worse.

5. TroubleshootingUse the results of the investigation and in-spection in items 2 - 4 to narrow down thecauses of failure, then use the troubleshootingflowcharts to locate the postion of the failureexactly.-k The basic procedure for troubleshooting

is as follows.1) Start from the simple points.2) Start from the most likely points.3) Investigate other related parts or

information.6. Measures to remove the root cause of failure

Even if the failure is repaired, if the root causeof the failure is not repaired, the same failurewill occure again.

To prevent this, always investigate why theproblem occured. Then, remove the rootcause.

20- 64

0



TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLSHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING

Office, shop @-“; m Jobsite

step1 xamination, confirmation of syrnptoms~

1) When a request for reparrs is recerved,

first ask the following points.

. Name of customer

. Type. serial number of machme

. Detarls of jobsite. etc.

2) Ask questrons to gain an outline of the

problem.

* Conditron of failure. Work being arried out at the time

of the failure

\

Ring Ring--------

’ Operating envwonment

* Past history. details of maintenance,

etc.

1 I Look at the troubleshooting sectron of the

shop manual to find locations of possrble

causes

step 3

1 reparation of troubleshootmg tools]

1 I Look at the table of troubleshooting tools

in tlie shop manual and prepare the

necessary tools.

* T-adapter. Hydraulic pressure gauge kit, etc.

2) Look in the parts book and prepare the

necessary replacement parts.

Drive and operate the machrne to confirm

the condition and judge rf there is really a

Was there anything strange about the

machine before the failure occurred?

Did the failure occur suddenly’

Had any repairs been carried out before thefailure?

lODD060

20- 650



TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

PRECAUTIONS WHEN CARRYING OUT MAINTENANCE

To maitain the performance of the machine over along period, and to prevent failures or other troublesbefore they occur, correct operation, maintenanceand inspection, troubleshooting, and repairs mustbe carried out. This section deals particularly withcorrect repair procedures for mechatronics and is

aimed at improving the quality of repairs. For thispurpose, it gives sections on “ Handling electricequipment” and “ Handling hydraulic equipment”(particlularly hydraulic oil).

1. PRECAUTIONS WHEN HANDLINGELECTRIC EQUIPMENT

1) Handling wiring harnesses and connectorsWiring harnesses consist of wiring connectingone component to another component, conn-ectors used for connecting and disconnectingone wire from another wire, and protector or

tubes used for protecting the wiring. Comparedwith other electrical components fitted in boxesor cases, wiring harnesses are more likely to beaffected by the direct effects of rain, water, heat,or vibration. Furthemore, during inspection andrepair operation they are frequently removed andinstalled again, so they are likely to suffer defor-mation or damage. For this reason, it is nec-ssary to be extremely careful when handlingwiring harnesses.

Main failures occuring in wiring harness(1) Defective contact of connectors (defective

contact between male and famale). Problemswith defective contact are likely to occur becausethe male connector is not properly inserted intothe female connector, or because one or bothof the connectors is deformed or the position isnot properly inserted into the female connector,or because one or both of the connectors is de-formed or the position is not correctly aligned, orbecause there is corrosion or oxidization of thecontact surfaces.

Improper insertion

=3X$&$&

20- 66

a




(2)

(3)

(4)

(5)

Defective compression or soldering of connectorsThe pins of the male and female connectors arein contact at the compressed terminal or sold-ered portion, but there is excessive force on thewiring, and the plating peels to cause improperconnection or breakage.

Disconnections in wiringIf the wiring is held and the connectors are pulled

apart, or components are lifted with a crane withthe wiring still connected, or a heavy object hitsthe wiring, the compression of the connector maybe lost, or the soldering may be damaged, or thewiring may be broken.

High pressure water entering connectorThe connector is disigned to make it difficult forwater to enter (drip-proof structure), but if high-pressure water is sprayed directly on the conn-ector, water may enter the connector dependingon the direction of the water jet. The connectoris designed to prevent water from entering, but

at the same time, if the water does enter, it isdifficult for it to be drained. Therefore, if watershould get into the connector, the pins will beshort-circuited by the water. If any water getsin, immediately dry the connector or take otherappropriate action before passing electricitythrough it.

Oil or dirt stuck to connectorIf oil or grease are stuck to the connector and anoil film is formed on the mating surface betweenthe male and female pins, the oil will not let theelectricity pass, so there will be a defective con-tact. If there is oil or grease stuck to the conn-ector, wipe it off with a dry cloth or blow dry withair, and spray it with a contact restorer.* When wiping the mating portion of the conn-

ector, be careful not to use excessive force ordeform the pins.

* If there is water or oil in the air, it will increasethe contamination of the points, so clean withair from which all the water and oil has beenremoved.

XOSDD060

XOSDD061

20- 670




2) Removing, installing, and drying connectorsand wiring harnesses

(1)

(2)

Disconnecting connectorsHold the connectors when disconnecting.When disconnecting the connectors, hold theconnectors and not the wires. For connectorsheld by a screw, loosen the screw fully, thenhold the male and female connectors in eachhand and pull apart. For connectors which havea lock stopper, press down the stopper with yourthumb and-pull the connectors apart.

Action to take after removing connectorsAfter removing any connector, cover it with a /

Lock

I - X08DD064

vinyl bag to prevent any dust, dirt, oil, or waterfrom getting in the connector portion.

Connecting connectors(1) Check the connector visually.

Check that there is no oil, dirt, or water stuckto the connector pins (mating portion).

Check that there is no deformation, defectivecontact, corrosion, or damage to the conn-ector pins.

a.

b.

C.

*

*

Check that there is no damage or breakageto the outside of the connector.If there is any oil, water, or dirt stuck to theconnector, wipe it off with a dry cloth. If anywater has gotten inside the connector, warmthe inside of the wiring with a dryer, but becareful not to make it too hot as this willcause short circuits.If there is any damage or breakage, replacethe connector.

20- 68

0




(2) Fix the connector securely.Align the position of the connector correctly, theninsert it securly. For connectors with lock stop-per, push in the connector until the stopper clicksinto position.

CM.5 into position

(3) Correct any protrusion of the boot and any mis-alignment of the wiring harness. For connectorsfitted with boots, correct any protrusion of theboot. In addition, if the wiring harness is mis-aligned, or the clamp is out of postion, adjust itto its correct position.* When blowing with dry air, there is danger

that the oil in the air may cause improper

contact, so clean with air from which all thewater and oil has been removed.

Drying wiring harnessIf there is any oil or dirt on the wiring harness, wipe itoff with a dry cloth. Avoid washing it in water or usingsteam. If the connector must be washed in water, donot use high pressure water or steam directly on thewiring harness. If water gets directly on the conn-ector, do as follows.(1) Disconnect the connector and wipe off the water

with a dry cloth.* If the connector is blown dry with air, there is

the risk that oil in the air may cause defectivecontact, so avoid blowing with air.

(2) Dry the inside of the connector with a dryer.If water gets inside the connector, use a dryer todry the connector.Ir Hot air from the dryer can be used, but be

careful not to make the connector or relatedparts too hot, as this will cause deformationor damage to the connector.

X08DD068

20- 69

a




(3) Carry out a continuity test on the connector,After drying, leave the wiring harness dis-connected and carry out a continuity testto check for any short circuits between pinscaused by water.* After completely drying the connector, blow

it with contact restorer and reassemble.

3) Handling control box(1) The control box contains a microcomputer

and electronic control circuits.These control all of the electronic circuitson the machine, so be extremely carefulwhen handling the control box.

(2) Do not open the cover of the control boxunless necessary.

(3) Do not place objects on top of the control

box.(4) Cover the control connectors with tape or a

vinyl bag.(5) During rainy weather, do not leave the control

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 weldingWhen carrying out arc welding on the body,disconnect all wiring harness connectorsconnected to the control box. Fit an arcwelding ground close to the welding point.

T-adapter

X08DD070

XOBDDOZI

/I XORDDO72

20- 70

a




2. POINTS TO REMEMBER WHEN HAN-DLING HYDRAULIC EQUIPMENT

With the increase in pressure and precision of hy-drauic equipment, the most common cause of failureis dirt (foreign material) in the hydraulic circuit. Whenadding hydraulic oil, or when disassembling or ass-embling hydraulic equipment, it is necessary to be

particularly careful.

1)

2)

3)

4)

Be careful of the operating environmentAvoid adding hydraulic oil, replacing filters, orrepairing the machine in rain or high winds,or places where there is a lot of dust.

Diassembly and maintenance work in the fieldIf diassembly or maintenance work is carried outon hydraulic equipment in the field, there isdanger of dust entering the equipment. It is alsodifficult to confirm the performance after repairs,so it is desirable to use unit exchange. Diassem-bly and maintenance of hydraulic equipmentshould be carried out in a specially prepareddustproof workshop, and the performance shouldbe confirmed with special test equipment.

Sealing openingsAfter any piping or equipment is removed, theopenings should be sealed with caps, tapes, orvinyl bags to prevent any dirt or dust from enter-ing. If the opening is left open or is blocked witha rag, there is a danger of dirt entering, or of thesurrounding area being made dirty by leaking oil.Do not simply drain oil out on to the ground,collect it and ask the customer to dispose of it, or

take it back with you for disposal.

Do not let any dirt or dust get in duringrefilling operations.Be careful not to let any dirt or dust get in whenrefilling with hydraulic oil. Always keep the oilfiller and the area around it clean, and also useclean pumps and oil containers. If an oil cleaningdevice is used, it is possible to filter out the dirtthat has collected during storage, so this is aneven more effective method.

XlODD061

XlODDOGP

XlODD063

20- 71

0




5) Change hydraulic oil when the temperature ishigh.When hydraulic oil or other oil is warm, it flowseasily. In addition, the sludge can also be drain-ed 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 ofthe old hydraulic oil must be drained out. (Do notdrain the oil only from the hydraulic tank; alsodrain the oil from the filter and from the drain plugin the circuit.) If any old oil is left, the contam-inants and sludge in it will mix with the new oiland will shorten the life of the hydraulic oil.

6) Flushing operationsAfter disassembling and assembling the equip-ment, or changing the oil, use flushing oil toremove the contaminants, sludge, and old oilfrom the hydraulic circuit.Normally, flushing is carried out twice: primaryflushing is carried out with flushing oil, andsecondary flushing is carried out with the spec-

ified hydraulic oil.

7) Cleaning operationsAfter repairing the hydraulic equipment (pump,control valve, etc.) or when running the machine,carry out oil cleaning to remove the sludge orcontaminants in the hydraulic oil circuit.The oil cleaning equipment is used to remove theultrafine (about 3~) particles that the filter builtinto the hydraulic equipment cannot remove, so itis an extremely effective device.

XlODD064

20- 72

0



CHECKS BEFORE TROUBLESHOOTINGItem Judgement standard

1.

2.

3.

4.

5.

6.

7.

a.

9.

Check fuel level

Check for dirt or water in fuel

Check hydraulic oil level

Check hydraulic oil strainer

Check swing machinery oil level

Check engine oil level (Level of oil in oil pan)

Check cooling water level

Check condition of dust indicator

Check hydraulic oil filter

1. Check for loose or corroded battery terminals Tighten or replace

2. Check for loose or corroded alternator terminals

3. Check for loose or corroded straight motorterminals

Check for abnormal noise or smell

Check for oil leakage

Bleed air from system

1.

2.

3.

4.

5.

6.

7.

a.

Check battery voltage (engine stopped) ZO-30V

_Check level of battery electrolyte

Check for discolored, burnt, or bare wiring-

Check for missing wiring clamps, hanging wires-

Checks for getting wet onto wiring (checkcarefully getting wet at connectors andterminals)

_

_Check for broken or corroded fuses

Check alternator voltage (engine running at overhalf throttle)

Noise when battery relay is operated (swi tchstarting switch from ON to OFF)

27.5 - 29.6 V Replace

_

_

-

-

-

_

_

_

-

-

_

-

_

_

Remedy

Add fuel

Clean, drain

Add oil

Clean, drain

Add oil

Add oil

Add coolant

Clean or replace

Replace

Tighten or replace

Tighten or replace

Repair

Repair

Bleed air

Replace

Add or replace

Replace

Repair

Disconnect connectorand dry connection

Replace

Replace

20-73

a



CONNECTOR TYPES AND MOUNTING LOCATIONS

1Co ictor 1 Type 1 o:s 1 Electrical component 1Address:onnector

No. 1ype 12s 1 Electrical component IAddress

co1 (MIC 1 17 1 Pump controller 1 R7

co2 I 040 I 20 I Pump controller 1 R6

MO2 IX I2 I Starting motor 1 J2

MO6 1 M I 3 I Heater switch I 08

co3 I 040 I 16 I Pump controller 1 R7

co4 lx I2 l Rear pump TVC valve I H9

MO7 IM I2 I Light switch 1 08

MO8 I M I 1 1 Right front light 1 D5

co5

CO6 1 sI 10 1 TVC prolix switch

1 05IM 12 1 Tvc prolix resistor I Q6

MO9

Ml0 IM

I 1 1Working lamp (boom)

IF9

1 M 1 1 IIntermediate connector I F5

I co7 1 x 1 3 1 RearP~;;s~- 1 I9 Ml1 IL 12 1 Fusible link I E5

CO8 X 3Front pump pressure

I5sensor

co9 S 8Model selection

connectorR7

Ml2 KESI 3 Heater-

Ml3 KESO 2 Speaker Q9

I Cl0 I x I 2 I ~~;;g I F8 Ml4 1 L 1 2 1 Fusible link E5

Cl3 Ix I l Front pump TVC valve I H9

DO1 IKESI I 2 IWindow washer circuit I J5

Ml6

Ml7

_1 1 I Horn (high sound) 1 G4

_I 1 I Hoorn (low sound) 1 F4

1 DO3 IKESI 1 2 1 Ls se;;;;;enoid 1 - ~18 I M I 4 1Wiper, washer switch I 08

M20 I - ( - I Cigarette lighter I 08

M21

M22

PA 9 Radio Q6

M 2 Intermediate connector_

I I I I

M23 M 2Horn switch, R.H.

knob switchF2

t DO8 IKESI I 2 Heater circuit_

M26 I M I 6 I Air conditioner I R6

Dll

D13

EOI

E04

KESI 2 Alarm buzzer circuit M6

KESI 2Battery relay drive

circuitR8

MIC 21 Engine throttle controller R8

X 3 Governor potentiometer H9

M28 KESO 2

M34 ,:$$,, 1

Window washer motor

Electromagnetic clutchfor air conditioner

compressor

J5

13

M35

M38

X 2Condenser for air

conditioner (PC220)I5

M 2 Liaht switch P8

M40 M 1 Right working light D3

M41 M 1 Left working light D3

M42_

1 Intermediate connector I5

M45 IM I3 I Network bus 1 M5

M46 I M I 3 I For troubleshooting I ~6

FOI Ix I2 Travel alarm 1 G4

HOI I S I 16 I Intermediate connector I ~8

PO1 040 20 Monitor panel N7

PO2 040 16 Monitor panel N7

PO3 M 2 Buzzer cane1 switch 08HO2 i S I 16 I Intermediate connector I R9

HO3 IS 116 1 ntermediate connector 1 Q9

HO4 I S I 16 I Intermediate connector I Q9

PO4 IM I2 I Alarm buzzer 1 N7

PO5 I X I 1 IEngine oil level sensor I J2

PO6 X

PO7 -

1 Fuel level sensor F5

2Coolant temperature

I3sensor

HO5

HO6

M 6 Intermediate connector R8

L 2 Intermediate connector R9

* The Address column in the table above shows the address in the connector arrangement drawing (2-dimensional drawing).

* This table includes connectors that are not in the drawing.

20-74

0



TROUBLESHOOTING CONNECTOR TYPES

IonnectorNo.

No. IType of Electrical component Address

I pins

PO8 I x 2 Coolant level sensor K8I I I I

’ ‘-.-‘-- llic oil levelG9

I I I ensor

PI 0 ] KEsI 1 I 1 Service meter P9I I ’ n’- ‘--ier clogging

J6ensor

3ging J8

I I IR04 Shinagwa 5 I Light relay P5

R05 Shinagwn15 1 Light relay P5I I ii pressure

witchR2

RAISE oilJre switch I

R3 I

t CURL oilJre switch

R4I

: DUMP oil.rre switch I R3 I)il pressurewitch

zsure 1 - I

vo2

vo3

X 2 LS select solenoid valve Nl

X 2Pump merge-divider

solenoid valveNl

W08 070 18 Wiper motor controller P6

WI0 M 4 Rear limit switch P6

x01 MIC 21 Intermediate connector P9

t x05I I I -----

x07 1MIC 1 17 1 ntermediate car

1 M 1 4 1 Swina lock switch

inector

08

P9

MOUNTING LOCATIONS

j, The Address column in the table above shows the address in the connector arrangement drawing (Z-dimensional drawing).

* This table includes connectors that are not in the drawing.

20- 750



A

I

\

u_

I>”

\

I



M46\

M38

M45 \ R04co5

/HO2

Ml3\

LUO ‘ M26

205F06389

/SO8

so4

so5i

so3 :

so1

so2



TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* The terms male and female refer to the pins, while the terms male housing and female housing refer to thematinn nnrtinns of the housino..__... _._. ..- -. _..- ..---...

No. of X type connectorpins Male (female housing) Female (male housing)

X08DDO73 XO8DDO74

XO8DDO75 2XO8DDO76

3 a

XO8DDO77XO8DDO78

4

XO8DD079 4 2 X08DDO80

20- 78

a




No. ofpins Male (female housing)

M type connector

Female (male housing)

X08DD081 X08DD082

2 %7 E 9

1X08DD083 X08DD084

3 ezl @

X08DD086 1 X08DD086

4 mX08DD087 4 2 X08DD088

20-79

a




No. ofpins

M type connector

Male (female housing) Female (male housing)

1 4

6

X08DD089

ES

6 3 X08DD090

20- 80

0




10 L I

5 10 1X08DD093 X08DD094

No. ofpins

S type connector


I 5 5 1

8

XOSDDOSl X08DD092

16

1 XOBDD095 16 7 X08DD096

20- 81a




No. ofpins

16

AMP040 type connector


6 16 16 8

X08DD097 X08DD098

20

1 11 X08DD099 11 1 XO8DDlOO

20- 820




No. ofpins

AMP070 type connector


14

XOSDDlOl XOSDD102

18

XCr8DD103 XOSDDlO4

20- 83

a




No. ofpins

3

l- AMP250 tv ? connector

Male (female housing)

X08DDlOS

1Female (male housing)

X08DD106

20- 84

0




No. ofpins

14

SWP type connector


1 4 8 11

3 7 10 14X08DD107 X08DD108

20- 85

a




No. ofpins

MIC type connector


1

17

X08DDlOS L_._1 X08Dqllo

l i '

111 0 oao

2121 12

21

XOSDDlll

20- 86

a




No. ofpins

5

Relay connector

2 I

5

3 XOSDD113

No. ofpins Male (male housing)

Simple connector

Female (female housing)

1

XOSDD114 X08DD115

No. ofpins

Ring connector

1

X08DD116

20- 87

a





L type connector


ED

1

1

0

20

2

2X08DDll7 XOSDDllB


PA type connector


g a B ;B H

X08DDllSXOSDD120

20-880




No. of Automobile connector (KESO)pins Male (female housing) Female (male housing)

2

:il N1 X08DD121 1XOSDD122

20- 89

a




No. ofpins

Automobile connector (KESi)

Female (female housing) Male (male housing)

2

2 I i F?1

FB

X08DD123X08DD124

32 3

3 2X08DD125

X08DD126

4

3 4 4X08DD127 X08DD128

20-90

0



TROUBLESHOOTING EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM

EXPLANATION OF CONTROL MECHANISM FOR ELECTRICAL SYSTEM

1. Explanation of machine control functions

2.

The control mechanism for the electrical system consistsj of the monitor panel, pump controller and enginethrottle controller. The monitor panel and each controller all input the signals that are necessary, and to-gether with the signals selected by the monitor panel, the controllers output or input the necessary signalsand control the pump absorption torque and engine outout.

Monitor panel Engine speed sensor

N. WOrt

lock signal

iE”z

m RAISE

IN/OUT

ret CURL

i/l

A

.OWER

>UMP

Explanation of networking functionsWith this system, a networking method has been adopted for the first time for the transmission and receptionof data between the controllers. With the conventional system, the necessary data is transmitted and recievedthrough an independent signal line between each controller. With the new method, this system had been

replaced by two dedicated networking wires; in the new system, all the data that is needed is transmitted andrecieved between the controllers by usiing these networking wires.

20-92

0



TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL

1.

2.

Display on machine monitorWhen the starting switch is turned ON, all the monitor gauge lamps light up for approx. 3 seconds, and thebuzzer sounds for approx. 1 second. During this time, the monitor itself carries out a self diagnosis, andafter it has finished, it gives the normal display.

Recording of service codes and user code display function

1)

2)

*

3)

All theabnormality date for the engine throttle controller and pump controller is received by the monitorpanel. When the monitor panel receives this data, it records the abnormality date, and at the same time,depending on the nature of the abnormality, it displays the user code on the time display panel to advisethe operator of the action to take.However, in cases of abnormalities which are not urgent and do not require the user code to be displayed,only the content of the abnormality is recorded, and no display is given.

E05 1 G overnor motor system

For details of the service codes includes in the user code, see ACTION TAKEN BY THE CONTROLLERWHEN AN ABNORMALITY OCCURS, THE SYMPTOMS ON THE MACHINE or JUDGEMENT TABLE.Displaying user codeIf it becomes necessary to display the user code, the time displayed panel is automatically switched toadvise the operator to take the necessary action.

Actual display i) Example: Disconnection in the swing brake solenoid system

: m- Blank ’

1 Component code ’ F’ ashes

Blank

20-93

a




4) Display of service codeThe monitor panel records both service codes which are included in the user code, and service codeswhich are not included. This data can be displayed on the time display as follows.

* For details of the service codes that are not included in the user code, see ACTION TAKEN BY CON-TROLLER WHEN ABNORMALITY COOURS AND PROBLEMS ON MACHINE.

Time display, 7 Time

Workingmode SW

L.H. tr avelspeed swit

fitch

ch

Front of monitor panel Rear of monitor panel

205FO6376

I, ,“,G’ LI I”” “ I uKJp,ay,,,y a=:1 “IbC b” “ G

Operation Display

1. To set to the service code display 1. Time display goes outmode, keep the time switch + L.H. On the display panel, the service code and numbertravel speed switch pressed for 2.5 of hours (service meter hours) since the occur-seconds. ence of the abnormality are displayed in turn.

* Example of displayNote: It is possible to call it up at thefollowing times.1) In the time display mode (normal

mode)2) In the user code mode

When E2: 12 occurs 12 hours ago (service meter)1) Display of service code 2) Elapsed time

(service meter display)

3) In the machine data monitoringmode

4) In the time adjustment mode.

20-94

0




Operation Display

2. To go to the next service code 3) If any abnormality exists at this time, the E mark is

display, displayed.

Press the time switch + R.H. work-ing mode switch. ~I/q7q7Jq-~

- -

?z

-

3. To go back to the previous servicecode display,

If there is an abnormality, or the controller is

Press the time switch + L.H. workingcarrying out self diagnosis, the output is shutoff, and E is displayed.

mode switch.

4. To finish with the service codemode,Use the sam’ e procedure as in Item1.

4) If there is no service code in memory

0 o_) : 1-1-1-1 is displayed.

5. To erase the memory,Keep the time switch pressed, turnthe starting switch from OFF to ON,

and keep the time switch pressedfor 5 seconds.

3. Machine data monitoring mode functionThe input signals from the monitor panel and controller sensors and the output signals to drive the solenoid

can be checked by displaying them on the time display.

Time display, 6 Time

Working III”mode switch \

function switch

Front of monitor panel Rear of monitor panel

7

205FO6378

20-95a



I) Method of displaying monitoring mode

Ooeration Display

I. To set to the monitoring mode, do 1. Goes off the time display, and display as follows.as follows. 2. Example of displayKeep the time switch + lever switch 1) When pump controller engine speed is monitoredfunction switch pressed for 2.5 sec-

onds.O~]::ll”1u151

Note: This is possible at the follow-ing times. The 3rd digit is for the tens,

1) During the ti,me display mode---I- so this display means 2050

(normal mode)Blank rpm.

2) During the user code mode ---c3) During the time adjustment

Lonitoring code(Engine speed)

mode4) During the service code mode 2) When front TVC output current is displayed

2. To go to the next monitoring codedisplay,

Press the time switch + R.H. work-0 11 :‘ Wl

ing mode switch.-T

The 3rd digit is for the tens,

3. To go back to the previous moni- Blankso this display means 180 mA(0.18 A)

toring code display,Press the time switch + L.H. workingmode switch.

---I Loniioring code(Front TVC output current)


4. Bit pattern display1) Set to the bit pattern display code

m m$jl $jj fi

0 .o 0Monitoring code

206FO6362

5. To finish with the. machine data 3. Example of bit pattern displaymonitoring mode, use the same 1) For code 08 (connection of S-NET components)

procedure as in Item 1. If the display is set to code 08, the applicable bits-light UP.2) For code 20 (input condition of pump controller oil pressure

switch)Set to code 20, and operate the lever of the system to bedisplayed.When the switch is turned ON, the applicable bits light UP.

20- 960




2) Table of machine data monitoring codes

* For details of the B in the Unit column, see the bit pattern chart.

?odeNo. item Unit Name of component

01 Monitor panel model code Monitor panel

02 Pump controller model code Pump controller

03Engine throttle controller model code Engine throttle controller

08 S-NET condition display B Monitor panel

10 Engine speed 1Orpm Pump controller

11 Front pump discharge pressure input kg/cm* Pump controller

12 Rear pump discharge pressure input kg/cm2 Pump controller

13 Front TVC current output IOmA Pump controller

14 Rear TVC current output IOmA Pump controller

15 LS control EPC current output 1OmA Pump controller

16 No. 2 throttle signal value IOrpm Pump controller

20 Oil pressure switch input signal (1) B Pump controller



23 Pump controller solenoid actuation B Pump controller

30 Fuel control dial input value IOmV Engine throttle controller

31 Governor potentiometer voltage IOmV Engine throttle controller

32 VBB voltage (battery voltage) IOOmV Engine throttle controller

33 Governor motor A phase current IOmA Engine throttle controller

34 Governor motor B phase current IOmA Engine throttle controller

35 Battery relay output voltage IOOmV Engine throttle controller

36 Engine throttle controller input condition B Engine throttle controller

37 Engine throttle controller output condition B Engine throttle controller

38 Engine throttle controller internal condition B Engine throttle controller

40 Engine speed IOrpm Monitor panel

41 Coolant temperature sensor voltage IOmV Monitor panel

42 Fuel level sensor input voltage IOmV Monitor panel

43 Battery charge input voltage IOmV Monitor panel

44 Monitor panel input 1 B Monitor panel



47 Monitor panel output B Monitor panel

20-97

0




3) Bit pattern chartAs shown in the diagram below, the time display has bit numbers which light up to show that the signalis being transmitted. (For details, see method of displaying monitoring code.)

0 0 aMonitoring c ode

205FO6382

:ode 1. . Content 1 Bit 1 Details (condition when liahted UD)No.

a Pump controller connected (ID=2)

0 Engine throttle controller connected (ID=31

08 Connection of S-NET components 0

0

0

8’

0 Swing switch ON

0 Travel switch ON

20 Input condition of pump controller 0 Boom LOWER switch ONPPC oil pressure switches@ Boom RAISE switch ON

0 Arm IN switch ON

8 Arm OUT switch ON

0 Bucket CURL switch ON

0 Bucket DUMP switch ON

21Input condition of pump controller PPCoil pressure switches and other switches 0 Swing lock switch ON

0 Service switch ON

0 TVC prolix switch ON

@ Swing lock prolix switch ON

. 0 Model selection 1 GND connected

0 Model selection 2 GND connected

22Input condition of pump controller model @ Model selection 3 GND connectedselection, etc.

@ Model selection 4 GND connected

0 Kerosene mode input GND connected

69 L.H. knob switch ON

20-98

0




CodeNo.

Content Bit Details (condition when lighted up)

23

36

Drive condition of pump controllerON/OFF solenoid valves

a0 LS select solenoid ON

0 Swing brake solenoid Ohi

0 Pump merge-divider solenoid ON

0 2-stage relief solenoid ON I

Input condition of enginethrottle controller

8 Travel speed solenoid ON



0 Model selection 3, GND connected


0 Starting switch ON

8 Auto-deceleration signal ON

0 Battery relay drivedI

37Output condition of engine throttle 0controller

0

38Internal condition of engine throttlecontroller

0

0

I0 I8 Ia Coolant level sensor OPEN

0 Swing lock switch OFF

44 1 Input condition of monitor panel 1. 0 Buzzer cancel switch OFFI

I 0 I

45 Input .condition 2 of monitor panel

00 Starting switch ON

0Swing lock prolix switch OFF

0 Time set switch OFF

0 Hydraulic oil level sensor OPEN

I 0 I

20-990




46

47

68

69

Content

input condition of monitor panel 3.

Output condition 1 of monitor panel

Input condition of valve controller(HYPER GX)

Input condition of valve controller(HYPER GX)

Bit Details (condition when lighted up)

0 Starting switch HEAT

0 Light switch ON

0 Air cleaner clogging sensor OPEN

0 Engine oil level sensor OPEN

0 Engine oil pressure Lo sensor OPEN

0 Engine oil pressure Hi sensor OPEN

0

0 Alarm buzzer actuated

0

0

0

8

0 .L.H. knob switch signal 1 ON

0 L-H. knob switch signal 2 ON




8 Option selection terminal GND connected

0 Safety relay 1 actuated

0 Safety relay 2 actuated

0

0

0

8

4. Governor motor adjustment modeThis is used when adjusting the linkage between the governor motor and the injection pump. For details ofthe procedure, see TESTING AND ADJUSTING.

20-I 00

a




5. lime adjustment modeTo adjust the time, do as follows.

Operation Display

1.

2.

3.

4.

To set to the time adjustmentmode,Keep the time switch depressedfor 2.5 seconds.

Use the L.H. working mode switchto advance the hour..

Use the R.H. working modeswitch to advance the minute.

To return to the time displaymode use the same procedure asin Step 1.

1. The time display flashes

m m : II]]- Blank

L Minute

L L Hour

Flashes

20- 101

0



TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE

METHOD OF USING JUDGEMENT TABLEThis judgement table is a tool to determine if the problem with the machine is caused by an abnormality in theelectrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used todecide which troubleshooting table (E-00, S-00, F-00, H-00, K-00, M-00) matches the symptoms.

The judgement table is designed so that it is easy to determine from the user code and service code whichtroubleshooting table to go to.t The abnormality display (caution) given by the monitor panel leads directly to troubleshooting of the machine

monitor (M-00). (See troubleshooting of the machine monitor system)1. When using judgement table for engine throttle controller and engine related parts

If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of thejudgement table (E-00).(A mark is put at the places where the failure mode and service code match.)If a problem has appeared but no service code is displayed on the monitor panel, go to the point wherethe failure mode matches the troubleshooting code on the right of the judgement table (E-00 or S-00).

<Example> Failure mode “Engine do& not start”.Procedure: Check if the service code is being displayed on the monitor panel.

[Judgementl1) If a service code is being displayed on the monitor panel:

go to troubleshooting E-00 for the engine throttle controller system.2) If no service code is displayed on the monitor panel, and the engine does not start:

Check that starting motor rotates

cStarting motor rotates . Go to troubleshooting S-2 of mechanical systemStarting motor does not rotate . Go to troubleshooting E-11 of electrical system

20- I 02

a




2. When using judgement table for pump controller and hydraulic related partsIf a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of thejudgement table (C-00).(A o-mark is put at the places where the failure mode and service code match.)

0 If a problem has appeared but no service code is displayed on the monitor panel, go to the point wherethe failure mode matches the input signal, and check the display for the input signal (the display at theplace with a o mark).

If it is displayed normally, go to the troubleshooting code on the right of the judgement table (H-00).If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the bottomof the judgement table (F-00).

<Example> Failure mode “Auto-deceleration does not work”.Procedure: Check if the service code is being displayed on the monitor‘ panel.

[Judgementl1) If a service code is being displayed on the monitor panel:

go to troubleshooting C-00 for the pump controller system.2) If no service code is displayed on the monitor panel, and the auto-deceleration does not work:

Check pump controller input signal

cThere is a signal . Go to troubleshooting H-5 of mechanical systemThere is no signal . Go to troubleshooting F-00 of electrical system

(F mode for applicable system)

20- 103

a




METHOD OF USING TROUBLESHOOTING CHARTS1. Category of troubleshooting code number

TroubleshootingCode No.

Component I Service code____ ._

E-00

s-00

Troubleshooting of electrical system for engine throttle controller

Troubleshootino of engine related parts

E3: 00

c-00 Troubleshooting of electrical system for pump controller

F-00 Troubleshooting of input signal system for pump controller

H-00 Troubleshooting of hydraulic, mechanical system for pump controller

E2: 00

-

K-00

M-00

Troubleshooting of electrical system for valve controller (HYPER GX)

Troubleshooting of machine monitor system

E4: 00

El: 00

2. Method of using troubleshooting table for each troubleshooting mode

I) Troubleshooting code number and problemThe title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode(problem with the machine). (See Example (1))

2) Distinguishing conditionsEven with the same failure mode (problem), the method of troubleshooting may differ according to themodel, component, or problem. In such cases, the failure mode (problem) is further divided into sectionsmarked with small letters (for example, a)), so go to the appropriate section to carry out troubleshooting.If the troubleshooting table is not divided into sections, start troubleshooting from the first check item inthe failure mode. (See Example (2))

3) Method of following troubleshooting chartCheck or measure the item inside

iand according to the answer follow either the

YES line or the NO line to go to the next -1. (Note: The number written at the top right cornerof the -1 is an index number; it does not indicate the order to follow.)Following the YES or NO lines according to the results of the check or measurement will lead finallyto the Cause column. Check the cause and take the action given in the Remedy column on theright.(See Example (3))Below the I] there are the methods for inspection or measurement, and the judgementvalues. If the judgement values below the (1 are correct or the answer to the question insidethe 1-1 is YES, follow the YES line; if the judgement value is not correct, or the ans_wer to thequestion is NO, follow the NO line.Below the I] is given the preparatory work needed for inspection and measurement, and thejudgement values. If this preparatory work is neglected, or the method of operation or handling ismistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged.Therefore, before starting inspection or measurement, always read the instructions carefully, aqdstart the work in order from Item 1).

4) General precautionsWhen carrying out troubleshooting for the failure mode (problem), precautions that apply to all items aregiven at the top of the page and marked with Ir. (See Example (4))The precautions marked * are not given in the 1-1 , but must always be followed when carryingout the check inside the -1 .

5) Troubleshooting toolsWhen carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, seeTOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.

20-I 04a




6). Installation position, pin numberA diagram or chart is given for the connector type, installation position, and connector pin numberconnection. When carrying out troubleshooting, see this chart for details of the connector pin numberand location for inspection and measurement of the wiring connector number appearing in the trouble-shooting flow chart for each failure mode (problem).

<Example>(1) M-7 When starting switch is turned ON (engine stopped), check item flashes

(4) * Before carrying out troubleshooting, check that all the. related connectors are properly inserted.* Always connect any disconnected connectors before going on the next step.t Check that the coolant is at the specified level before carrying out troubleshooting

(2) al (coolant level) flashes

sl1

Divided into sections a) and b)

b) @ (engine oil level) flashes

(3)

I Cause Remedy

)I Defective coolant level

1Does display goout when shortconnector is con- -netted to PO8(female)?

YES2

Turn startingswitch ON. Is there continuityL between PO8

~0 (female) (2) andchassis ground?

sensor (reservoir tank)system (see M-23)

-

Is continuitv be-31 i” “ ------_l Defective monitor panel

~ $ig;No (gjigzl;connect short connector to PO8 female).

. Turn starting switch OFF.

Replace

Ilean (defective

contact) orreplace

Table

Short connector

ConnectedDisconnected

Continuity

YesNo

20-I 05

0



TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE

DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTINGPROCEDUREIf any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accordance with the

judgement table for that type of failure (engine throttle controller, pump controller, valve controller). For details ofthe troubleshooting and troubleshooting procedure, refer to this flow chart. .When carrying out troubleshooting, ask the operator as much as possible about the condition of the machine, andcheck the following items before starting.

(1) Condition of controller connection (check with monitoring code 02 - 04)

(2) Blown fuses (monitoring code 32)

(3) Battery voltage (monitoring code 32)

(4) Electricity generation (charge input) voltage (monitoring code 43)

The procedure for carrying out check items No. 3 and No. 4 in the flow chart below is given on the followingpages.

Is there a user~n~h~isplay

monitorpanel?

f

E02 (Pump TVC system)

ESE03 (Swing holding brake system) Go to Item No.2

L E05 (Governor motor system)

E2:OO o E2:99 for pump controller system (C mode)Carry out troubleshooting for~;rnn;~;troller system

7

I

Is servicecodedisplayed on

1 monitorpanel?

Operate andcheck servicecode.

LE3:00 to E3:OO or engine throttle controller system (E mode) Carry out troubleshooting forengine throttle controller-systemfE mode, El-El01

.

Are monitorpanel switchsignalsoutputcorrectly?

I*Check

condition ofS-NET inmonitoringcode 08.

*Note (seenext page)

1

Check usingmonitoringmode.Engine thron

(Es

I

1le h

controller30 - 35‘ 37

YE5

Afteradjusting oilpressurejudge fromengine speed.Is all workequipmentslow, doesengine speeddrop under_

Is engineelectricalsystem forwhich there isno service;o;erJ;;pfay

Go o flowchart forsectionwhere is noservice codedisplay onj$,ment

‘ ES Carry out troubleshooting for

r

engine system (S mode)

LCarry out troubleshooting forNOengrne system fE mode, Eli-E15)

Car.ry ?ut troubleshooting for

0nyaraulrc mechanrcal system(H mode)

Carry out troubleshooting forpump controuer rnput srgnarsystem (F mode).

rump controllerlo-23Valve controller50-69

heavy load?

10

*Note-(see next page)

NOIf the display is not given, thecontroller is defective.

20- 106

0




* NOTEIf there is no abnormality display in the networking system transmitted in S-NET, it can be taken that the outputsignal from the monitor panel has been transmitted. However, even if there is no abnormality display, if the oper-ation is defective, use the following procedure when checking directly.If any abnormality occurs in the S-NET system, the system is automatically switched to the following default mode,so be careful when carrying out troubleshooting.

Default mode1

Auto-deceleration

power max. posse

1 8 1 Automatic warming-up-

ON (automatic warming-up mode)

2. When networking cannot be carried out for the monitor and engine throttle controller, only throttle signalis recognized as FULL; normal control is carried out for others.

Procedure for checking monitor panel output signal* For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL

FUNCTIONS.1. Connection condition of components

1) Set to the monitoring mode and display monitoring code 08.2) The time display (bits) will light up to display the components that are connected.

* 0 Pump controller, 0 engine throttle controller, 0 valve controller will light up.

2. Checking working mode signal (check No. 2 throttle signal at the same time)1) Set to the monitoring mode and display monitoringcode 40.

2) Switch the working mode as shown in Table 1 and check that the engine speed changes.

20-I 07

a




3. Checking travel speed selection signal1) Set to the monitoring mode and display monitoring code 23.2) Change the travel speed switch to Mi or Hi, run the engine at 1500 rpm or above, and operate the control

lever. Check that bit 8 lights up when this is done.

4. Checking boom/swing priority selection mode signalj, If the travel oil pressure switch signal is not input to the controller, the flow from the front and rear pumps

will remain divided.1) Turn the boom/swing priority switch to ON.2) Set to the monitoring mode and disply monitoring code 23.3) Check that bit @ lights up when the boom, arm, bucket, and swing are operated independently or together.

* Check the operating condition of the pump merge-divider solenoid valve.

Checking input signal of engine throttle controller, pump controller* Check the input signal for each controller as follows.0 Pump controller1. Checking input signal

1) Check oil pressure switchi) Set to the monitoring mode and display monitoring codes 20 and 21.ii) Operate each work equipment lever, and check how the bit pattern lights up.

* For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIALFUNCTIONS.

2) Check engine speed sensor (check engine speed)i) Set to the monitoring mode and display monitoring code 10.ii) Use the fuel control dial to change the speed, and measure the engine speed when this is done.

3) Check pump pressure sensori) Set to the monitoring mode and display monitoring code 11 and 12.

* Code 11 is for the front pump, and code 12 is for the rear pump.ii) Refer to Table 2 and measure the hydraulic pressure at the front and rear pumps.

Table 2. Pump merge-divided flow logic and pumps actuated by control levers.

Boom/swing priority selection mode OFF Boom/swing priority selection mode ON *I

Basically flow is mergedFlow merged i f there is n el + compound operation

* When the travel is operated independently divided flow, travel + compound operationsbecomes the merged flow.

20- 108

a



4) Check L.H. knob switch input signali) Set to the monitoring mode, and display monitoring code 22.ii) Push the L.H. knob switch ON and check that bit @ lights up.

2. Check output signals

1) Check LS control EPC solenoid output currenti) Set to the monitoring mode, and display monitoring code 15.ii) Run the engine at high idling with all the levers at neutral and in the G/O or H/O mode, and

measure the current.* All levers at neutral: 900 f 80 mA

Engine at high idling, travel speed Hi, travel lever operated: 0 A

2) Check No. 2 throttle signali) Set to the monitoring mode, and display monitoring code 16.ii) Use the procedure in Item 2 for checking the monitor panel output signal, and measure the

engine speed.

3) Check ON * OFF solenoid conditioni) Set to monitoring mode, and display monitoring code 23.ii) Refer to Table 3 and check that the applicable bit lights up.

Table 3. Types of solenoid and conditions for actuation

Name of solenoid Actuation condition Bit that lights up

LS select Swing + travel lever operated 0

Swing brake Swing operated 0

Pump merge-divider L/O mode @

2-stage relief Travel lever operated 0

Travel speed Travel speed switch: HiFuel control dial at midway position or above 8Travel lever operated

4) Check TVC solenoid output currenti) Set to the monitoring mode, and display monitoring codes 13 and 14.

Code 13 is for the front pump, and code 14 is for the rear pump.ii) With the starting switch kept at the ON position and in the G/O mode, measure the current

when the fuel control dial is turned to the MAX position.PC200, PC21 0: 510 f 80 mAPC220, PC250: 410 f 80 mA


J

20-I 09

a




Engine throttle controller1. Check input signal

1) Check fuel control dial input voltagei) Set to the monitoring mode, and display monitoring code 30.ii) Measure the voltage when the fuel control dial is turned from low idling to high idling.

* Voltage: 0.25 - 4.75 V

2. Check output signal1) Check governor motor drive current

i) Set to the monitoring mode, and display monitoring codes 33 and 34.* Code 33 is the A phase (direction for increasing engine speed), and code 34 is the B phase

(direction for reducing engine speed).ii) Measure the governor motor drive current when the fuel control dial is turned in the acceleration

direction and deceleration direction.* Current: 700 f 70mA

2) Measure battery relay drive voltage

0ii)

iii)iv)

Set to the monitoring mode, and display monitoring code 35.Measure the battery relay drive voltage when the starting switch is turned from ON to OFF.orSet to the monitoring mode, and display monitoring code 37.Check that bit 0 lights up when the starting switch is turned from ON to OFF.

(Min. 4 seconds - Max. 7 seconds)

20-I 10

0



TROUBLESHOOTING OF ENGINE THROTTLECONTROLLER SYSTEM

(E MODE)

Points to remember when carring out troubleshooting of engine throttle controller systemEngine throttle controller system circuit diagram .................................Action taken by controller when abnormality occurs and problems on machine ........Judgement table for engine throttle controller and engine related parts ..............Troubleshooting flow charts for each failure mode

E- 1 Abnormality in engine throttle controller power source system(engine speed stays at low idling) ......................................E- 2 [E3:08] Abnormality in fuel control dial input value is displayed .......... ....E- 3 [E3:17] Abnormality (disconnection) in governor motor drive system is displayedE- 4 [E3:18] Abnormality (short circuit) in governor motor drive system is displayed . .E- 5 [E3:01] Abnormality in network reception system is displayed ...............E- 6 [E3:05] Abnormality in model code is displayed ...........................E- 7 [E3:06] Abnormality in governor potentiometer system is displayed ...........E- 8 [E3:07] Abnormality in pump controller throttle system is displayed ...........E- 9 [E3:15] Abnormality (short circuit) in battery relay output system is displayed ...E-10 [E3:16] Abnormality (step-out) in governor motor system is displayed .........E-l 1 Enginedoesnotstart ................................................E-12 Engine speed is irregular .............................................

a) Idling speed is irregular ............................................b)Thereishunting ..................................................

E-l 3 Lack of output (engine high idling speed is too low) .......................E-l 4 Enginedoesnotstop ................................................E-l 5 Defective operation of battery relay system (engine does not stop) ...........

. . .

. . .

. . .

. . .

. . .

. . .. .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. .

. . .

. . .

. . .

. . .

. . .. .. .

. .

. . .

. . .

. .

. . .

. . .

. . .

. . .

. . .

. . . 20-I 12

. . . 20-I 13

. . . 20-I 15. . 20-I 16

. . 20-l 17. . . 20-I 18. . . 20-I 19. . . 20-l 20 . . . 20-I 21 . . . 20-I 23 . . . 20-I 24 . . . 20-l 25

. . 20-I 25

. . 20-I 26

. . 20-I 28

. . 20-I 30 . . 20-I 30 . . . 20-I 32 . . . 20-I 34 . . . 20-l 36 . . . 20-I 38

20- I 11

a



POINTS TO REMEMBER WHEN CARRYING OUT TROUBLE-TROUBLESHOOTING SHOOTING OF ENGINE THROTTLE CONTROLLER SYSTEM

POINTS TO REMEMBER WHEN CARRYING OUT TROUBLESHOOTINGOF ENGINE THROTTLE CONTROLLER SYSTEM

1. Points to remember when there is abnormality which is not displayed by codeThe engine is controlled by engine throttle contoller.The problems that may occur with this system include the following.1. Idling speed is too high (too low)2. High idling speed is too low3. Auto-deceleration speed is too high (too low)4. Engine speed for automatic warming-up operation is too high (too low)5. There is hubting6. Engine does not stopIf any abnormality occurs, and the abnormality is displayed on the time display portion of the monitor panel,use the troubleshooting table to determine the appropriate troubleshooting flow chart from El to El 0.However, if there is any abnormality in the machine and no abnormality display is given, it is necessary todetermine whether the problem is in the mechanical system or in the electrical system. If the linkage betweenthe governor motor and the injection pump is not properly adjusted, problems 1 to 6 listed above may occur.Therefore, if there is no abnormality display, but one of problems 1 to 6 above has occured, carry out trouble-shooting as follows.

2 YESIf linkage between

YES q+ynor motor and_ mlechon pump is dis-

1 connected, does opara--

If linkage betweention of governor motorbecome normal?

governor motor andinjection pump s _disconnected and

* With starting switch NO

pump lever is operatedat ON, operate fuel

bv hand or is fixed withcontrol dial and. .__.Lng mode

[ fi;ikd~~i” ‘ ~~ 1 ,0&y;,,.

*If engine does not stop, pushgovernor lever to STOP positionand check if engine stops.

Defective adjustment of governor motor linkageSee TESTING AND ADJUSTING.

Go o troubleshoot ing E-12 - E-15 of electrical system

Go io troubleshooting S-l - S-16 of engine system

Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting flow chartfor the mechanical system or electrical system.* For details of the procedure for adjusting the linkage, see TESTING AND ADJUSTING.

2. Points to remember if abnormality returns to normal by itselfIn the following cases, there is a high probability that the same problem will occur again, so it is desirable tofollow up this problem carefully.

1)2)

*

If any abnormality returns to normal by itself,If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and theconnector is returned to its original position when carrying out troubleshooting of the failure, and theservice code is no longer displayed, or if the monitor display returns to normal.After completing troubleshooting, always erase the user code from memory.

3. Service code memory retention functionWhen displaying the service code in memory and carrying out troubleshooting, note down the content of the

display, then erase the display. After trying to re-enact the problem, carry out troubleshooting according to theservice code that is displayed.(There are cases where mistaken operation or abnormalities that occur when the connector is disconnectedare recorded by the memory retention function. Erasing the data in this way saves any wasted work.)

20- 112

a



ENGINE THROTTLE CONTROLLER SYSTEM CIRCUIT DIAGRAMFOLD

Starting switchFuel control dial

I 1

E06 I I(M3) I: $$\

Pump controller 1 0.5WB dCO3(040) 0. 5G

I 10) - - -

X07(M C17)

\ 20 6 a hI I r r

Governor motor7-----

Potentiometer

0. 85RG. ,2 .

0.85BR .l . f

I

-- +5LgRNetwork (Engine -I-)

90.100rrn

E05 X4) Motor

I

120130

v+go._ 16Q_

7

1*0. 85WB

0.85G

50.75G

I I :

-&In cmrn- 0. 5BW AI I I I I

I I I 1 I I I n 5R I I

________________--_- ______-__------ -2

6*7e 0.75R

8 0.75w

i-+

_ H02tM C).

CO9(S8) PC200 PC220

Fusible link

M14(L2)

EO( MC21)‘

Engi ne hrottle controller

3W*a

1 H06(L2)Fuse box LT

3N

33LDLO 5w 5w

2‘

2w 462w 2R

R E 14

H05t M6)

, kO. 58 a

07

0605

0.5RL. ,4

0. 5YG., 3o. 5YB

Monitor panel

1O2(040)

I I 10L -

Model selection COnrWtOr

H05( M6)

3Ml (L2)

I Fusible link

7 k

ti 45(M3)

20



FOLD

ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE

Jser code Service code Abnormal system Nature of abnormality Condition when normal voltage, current, resistance) Action by controller when abnormality is detected Problem hat appears on machine when there is abnormality

I Short circuit in wiring harness bet weenEOI (5) - (16), (5) - (17), (16) - (17)

2. Short circuit in wiring harness betweenE04 (I) - (2), (I) - (3), (2) - (3) EOI (female) E06 (male) Resistance alue

3. Short circuit in wiring harness be tweenE06 (I) - (2), (1) - (3), (2) - (3) (5) - (7) (I) - (2) 0.25 - 7kR I. Does not become partial speed when set at

4. Short circuit in wiring harness betweenhigh idling position

E3:08Abnormality in fuel

EOI (5) - (7). (7) - (16) (7) - (16) (2) - (3) 0.25 - 7kR Maintains engine speed at position Of fuel COntrOl 2. Does not reach high idling when set at partialcontrol dial input value

5. Disconnection in wiring ha rness betweendial immediately before abnormality occurred

EOI (5) - X07 (6) - E06 (I)(5)-(16) -

speed2-3kQ 3. There are cases of hunting

6. Disconnection in wiring harne ss between (I) - (3) 4-6kQ4. Lacks output (max . spe ed of engine is too low)

-EOI (7) - X07 (5) - E06 (2)

7. Disconnection in wiring harne ss between Betweeneachpin and chassis - Min. 1 MR

EOI (16) -X07 (4) - E06 (3)8. Defective fuel control dial9. Defective contact of EOI, X07, E06 connectors

E : 05 E3:17

E05 (male) EOI (female) Resistance alue

1. Disconnection inside governor motor (l)-(2) (IO) - (20) 2.5 - 7Q2. Disconnection in wiring harn ess between

I. When there is a disconnection in both the A

EOI (10 ) - HO2 (4) - E05 (1 ) (3) - (4) (II)-(21) 2.5 - 7Rphase and 8 phase at the same time, the

Abnormality 3. Disconnection in wiring ha rness betweenproblem is the same as for a short circ uit in the

(disconnection) in EOI ( I 1) - HO2 (7) - E05 (3 )4. Disconnection in wiring harness between

(I) - (3) (IO) - (II) Min. 1 MRgovernor motor system

governor motor driveTakes no particular action 2. When there is a disconnection in only one of A

system EOI (20) - HO2 (5) - E05 (2)phase or B phase

5. Disconnection in wiring ha rness between(I) - (4) (IO) - (21) Min. 1 MQ 1) Engine does not stop

EOI (21) - HO2 (8) - E05 (4) Between pins IO),2) Stops moving at position immedia tely before

6. Defective contact of EOI, H02, E05 connectors ~~~~nn$~~~$i~2) ’ (ll), (20) (21) and Min. 1 MRfailure, so engine speed can not be controlled

chassis 3) There are cases of hunting

Motor drive current : Hold : 0.7 AStart : 0.84 A

E05 (male) EOI (female) Resistance alue

(I) - (2) (IO) - (20) 2.5 - 7R

1. Short circuit inside gover nor motor (3) - (4) (II)-(21) 2.5 - 7R1. If during operation

2. Wiring harness between EOI (IO) - HO2 (4) - E051) Set to low idling

Abnormality (short (I) short circuiting with wiring harness between2) Engine does not stop

E3:18 circuit) in governor EOI (20) - HO2 (5) - E05 (2) (l)-(3) (10) -(II) Min. I MR 3) There are cases of hunting

motor drive system 3. Wiring harness between EOI (I I) - HO2 (7) - E05 Sets motor drive current to 0 2. When sto pped

(3) short circuiting with wiring ha rness between (I) - (4) (IO) - (21) Min. 1 MRI) Engine s tarts, but stays at low idling

EOI (21) - HO2 (8) - E0 5 (4)2) Engine does not stop after starting

4. Wiring harness in Items 2 and 3 short circuiting Between pins I), (2), Between Pins 1%3) There are cases of hunting

with ground (3), (4) and chassis $JJ $?so)’ *I) and Min. 1 MR

Motor drive current : Hold : 0.7 AStart : 0.84 A

E3:Ol

I. When monitor pan el and pump controllerI. When monitor pane l and pump controller

1. %;ntcrcuit, disconnection in network wiringcannot receive signal

Abnormality in network 1) Working mode: H/O cannot receive signal

reception system1) Even when working mode is switched,

2.Abnormality in pump controller2) Automatic warming-up: ON

3.Abnormality in engine throttle controller.3) Overheat signal: OFF engine speed does not change

2. Same as normal when only pump cont rollerp 2. Same as normal when only pump control ler

cannot receive signal cannot receive signal



JUDGEMENT TABLE FOR ENGINE THROTTLE CONTROLLER AND ENGINE RELATED PARTS Figure in0 shows position of bit pattern

Engine hrott le controller, engine related pans (E3 : 00 system)

L

z

Self-diagnostic displayChecking monitoring, check items

Machinemonitorcheck item

display is given

User code E05 Monitoring code Coolanttemperature

Failure mode Service code E3:08 E3:17 E3:18 E3:Ol E3:05 E3:06 E3:07 E3:15 E3:16 36 35 16 30 31 33 34 41 gauge

1 Engine does not start easily S-l

2 Engine does not start 0 s-2

3Engine speed sta ys at low idling, and does not follow a ccelerator, orengine pickup is poor 0 0 0 0 0 . .x .x .x 0 s-3

4 Engine stops during operation s-4

Engine When idling speed is irregular E-12a), S-55 rotation is

irregular When there is hunting 0 0 0 0 0 % E-12a), S-5

6 Lack of output (engine high idling speed is too low) 0 0 z s 0 S-6

7 Auto-dece leration does not work 0 E-3 , E-4

6 Engine does not stop 0 0 0 0 0 0 0 0 *x E-14

g Automatic warming-up operation is defective 0 0 E-3 , E-4

10 Exhaust gas is black s-7

11 Oil consumption is excessive, or exhaust gas is blue S-8

12 Oil becomes dirty prematurely s-9

13 Fuel consumption is excessive, or exhaust gas is blue S-IO

14 Oil is mixed in coolant s-1 1

15 Oil pressure caution lamp lights up s-12

16 Oil level rises s-13

17 Coolant temperature rises too high 0 0 s-14

16 Abnormal noise is generated s-15

19 There is excessive vibration S-16

20 Engine speed does not change even when working mode is switched 0 % E-3 , E-4

Troubleshooting code when service code is displayed E-1 E-2 E-3 E-4 E-5 E-5 E-7 E-9 E-9 E-10 - - - - - - - - - - -

Troubleshooting code when there is abnormality in monitoring mode ormachine monitor check

__ _- - --- -- C-15 E-15 - - - - - M-14 M-13 M-13 E-11

20-1160

0 : This shows applicable item for service code 0 : This shows item to check with monitoring mode or machine mo nitor

+Z This shows item that need.s.only c hecking with monitori ng mode



TROUBLESHOOTING E-l

E-l Abnormality in engine throttle controller power source system(engine speed stays at low idling)

*

****

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.Check that fuses 2 and 14 are not blown .Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-l 1.)

I

1

Is voltage betweenEOl (l)(Z) and (12)normal?

IES

:I

:h

NO

0-30V21; starting switc

Isvoltage betweenEOl (6) and (12)

20 - 3ov-Turn starting )

switch ON.

ES

3 YES

pijiij -

*20-30V NOTurn starting switchON.

4 YESI I I

+20-30V NOTurn starting switchON. . ‘

E-l Related electric circuit diagram

X07 (MIC17) Fuse

Starting switch

L IEngine throttle controller . .

E01 (MlC2I I 1

Cause

Defective engine throttle:ontroller

Defective contact, or dis-:onnection in wmng harnesssetween starting switch ACC-X07 (17) - EOl (female) (6)

Defective starting switch[between B and ACC)

Defective contact, or dis-connection in wmng harnessbetween fuse 2 and EOl(female) (1) (2)

Defective contact,, or dis-connection in wmng harnessbetween fuse 2 - HO6 (2) -Ml4 (2) (1) -battery relay M

M14(L2)

Remedy

eplace

:epair oraplace

lepair oreplace

lepair oreplace

20- 117

a



TROUBLESHOOTING E-2

*

**

E-2 [E3:08] Abnormality in fuel control dial input value is displayed

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.Before carrying out troubleshooting, check that all the related connectors are properly insertedAlways connect any disconnected connectors before going on to the next step.

YE1

tween E06 (male)(1) - (2). (2) - (3) asshown in Table l?

- Turn startingswitch OFF.

* Disconnect E06.

2r II is esistance between I

each pin of EOlIfemale) 15) (7) (16). or _I-etween each pin andchassis as shown inTable l?

*Turn starting NOswitch OFF.

- Disconnect EOl.

YES

Cause

Defective engine throttlecontrolier

Defective wiring harness insystem with defectiveresistance

Defective fuel control dial

Remedy

Replace

Repair orreplace

Replace

Note: If E3:06 also occurs at the same time, check the wiring harness below.Wiring harness between EOI (female) (5) - HO2 (1) - E04 (female) (1) short circuiting with ground, orcontact with other wiring harness.

Table 1

E01 (female)

(5) - (7)

E06 (female) Resistance value

(1) - (2) 0.25 - 7kLI

(7) - (16)

(5) - (16)

(2) - (3)

_

0.25 - 7kfI

2-3kLI

-(1) - (3) 4-6k0

I 1

I Between each _

pin and chassis IMin. 1 MQ

E-2 Related electric circuit diagram

Engine throttle controtterEil6 (M3)

Throttle powersource (c)

Feedback signal

Throttle powersource I-)

E04 (X3)

Fuel controldial

Governor

potentiometer

X08DD130

20- 118

0



TROUBLESHOOTING E-3

E-3 [E3:17] Abnormality (disconnection) in governor motor drivesystem is displayed

*

*

*

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.During operation, if there is

1) a simultaneous disconnection in A phase and B phase:0 the engine will run at low idling0 the engine will not stop

2) a disconnection in either A phase or B phase:the engine speed will remain the same as before the abnormality occured

If the problem occurs when the engine is stopped,1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.

A Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position) before

checking.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

Cause Remedy

shown in Table l? 1 1

urn srarung I\”#witch OFF.\:_______. rn.


I

* Turn startingswitch OFF. NO Defective governor motor

*Disconnect E05.

Table 1

E05 (male)

(1) - (2)

EOI (female)

(10) - (20)

Resistance value

2.5 - 7k0

(3) - (4)

(1) - (3)

(ll)-(21)

(lD)-(11)

2.5 - 7kfI

Min. 1 MfI

(1) - (4)

Between pins (1)(2) (3) (4) and

chassis

(10) - (21)

Between pins (10)(11) (20) (21) and

chassis

Min. 1 MfI

Min. 1 M0


Replace

Repair orreplace

Replace

X08DD131

20-I 19

0



TROUBLESHOOTING E-4

E-4 [E3:18] Abnormality (short circuit) in governor motor drive system

*

*

*

is displayed

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the abnormality occurs during operation, because of the force of the spring,

1) the engine will run at low idling, or 2) the engine will not stopIf the problem occurs when the engine is stopped,

1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.A Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position) before

checking.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

Cause Remedy

YES

* Turn starting Iswitch OFF.Disconnect E05.

O

Table 1

E05 (male) EOI (female) Resistance value

2.5 - 7kQ

2.5 - 7kL’

Min. 1 MfI


Defective engine throttlecontroller


Defective governor motor

ED (MIC21) E05 (X4) GOVWflOrmcitw

Replace

Repair orreplace

Replace

X08DD131

20- 120

a



TROUBLESHOOTING E-S

E-5 [E3:01] Abnormality in network reception system is displayed

*

*

**

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the starting switch is turned ON when there is a disconnection in the wiring harness between the monitorpanel and the controller, or the positive end (+) of the network wiring harness or the inside of the controllerare short circuited, the controller cannot carry out networking, so the monitor panel does not display any

abnormality.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

When E3:Ol is displayed independently

YES

I1

Disconnect E01connector, then YESconnect it again. -Does service code

display go out? A 2. Turn starting switch

OFF. Is connection of 4 YES*Disconnect connec- - pump controller _

tar, then connect NO displayed?connector again. YES Is voltage between

*Turn starting switch -ON.

S y CO3(7)-W,(8)- -

* Turn starting,~, (15) normal?

switch ON. Does LED of pump - -* W~o;onitor ing _ controller light up - . Turn starting NO

NO or flash? switch ON.* 4-8’ J

* p;,n starting switch Lo

When E2:18 and E3:Ol are displayed simultaneously

YES

1

1Disconnect PO2 1

Ionnector, thenconnect it again. u- YES

lntinuity‘ 02

Iremater \7), (8) and_.*__I

Hi3 YES

Connect connectors I I

switch OFF.* Disconnect P02,

C03, and EOl.. Shake wiring

harness aroundcontroller whenchecking forcontinuity.

u

* Turn starting NOswitch OFF.

- Shake wiringharness aroundwhen checking f

controlleror continuity.

Connect PO2 last.

switch OFF.

* Disconnectconnector, thenconnectconnector again.

* Turn startingswitch ON anddelete servicecode.

Cause

Defective contact or matingof engine throttle controllerconnector EO


Defective pump controller Replace

Defective contact, ordisconnection in networkwiring harness

See C- l

Remedy

Repair

Replace

Repair orreplace

-

If monitor panel connector‘ 02

Positive (+I end of networkwiring harness in contactwith ground

Controller which has beenconnected is defective

Defective monitor panel

20- I 21

a



TROUBLESHOOTING E-5

Monitoring display (Time display portion)

5P

(1) “pump controller connected”display

E2

a “Engine throttle controllerconnected” displayc


CO3(04016)

X08DD133

Check for the LED display for the engine throttlecontroller and pump controller from the direction Engine throttle controller

\/Pof the arrow as shown in the diagram on the right.

Note 1: Push the operator’ s seat down to the front,then remove the two rear covers to check.

Note 2: The LED display for the pump controller isdifficult to see, so use a mirror.

X08DD134

20- 122

0



TROUBLESHOOTING E-6

E-6 [E3:05] Abnormality in model code is displayed

*

**

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

YES1

Is engine throttlecontroller monitor-ing code display as 2 YESshown in Table l?

Is resistance be-

-Turn startingtween EOl (female)

switch ON. - (8).(9).(18).(19) and -

*Set to monitoringNO GND as shown in

code 03 and 36.Table 2?

*Turn starting NOswitch OFF.

- Disconnect EOl.

.:ON

Table 1 Monitoring display (Time display portion) C~ ~FF

Condition of engine Engine throttlethrottle controller input controller model code

PC200_-_, ,‘ - ‘ , , ‘ -‘ ,

PC21 0

I Ic-_ _-_ c-w

PC220

360 ,_,’_/ ,__’

PC250 o c:zr 0 0 u”3:z c12 I

CauseI

Remedy


Replace

Defective model selectionconnector, or short circuit, Repair orshort circuit with ground, or replacedisconnection in applicablewiring harness

Table 2 Resistance value

r

Between EOI (female)(18) and GND

Min. 1 MQ Min. 1 Mf2


EOl MIC21) CO9tS8) Model selection connector

PC200 PC220X08DD135

20- 123

a



TROUBLESHOOTING E-7

*

**

E-7 [E3:06] Abnormality in governor potentiometer system isdisplayed

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

Cause Remedy

2 YES

Is esistance betweenDefective engine throttle

each pin of EOcontroller

YES (female) k5)(16)(17). or _1 between each pin and

-, chassis as shown in

Is resistanceTable l? Defective wiring harness in

system with defectivebetween E06 (male) _ * Turn starting NO resistance(1) - (21, (2) - (3) as switch OFF.shown in Table l? * Disconnect EOl.

* Turn starting Iswitch OFF. NO Defective governor motor Replace

*Disconnect E04.

Note: If E3:08 also occurs at he same time, check the wiring harness below.Wiring harness between EOI (female) (5) - X07 (6) - E06 (female) (1) short circuiting with ground, orcontact with other wiring harness.

Table 1

EOI (female)

(5) (17)

E04 (male)

( l ) - (2)

Resistance val ue

0.25 - 7 kf 2

I (17) (16) I (2) - (3) I 0.25 - 7 kQ

I - I U)- (3) 4-6kQ

and chassis_ I Min. 1 M I2


X07(MIC17)EO 1 (MI C211

E06 (M3)

333

Fuel control dial

HO2 (S16) E04 (X3)X08DD136

20-I 24

0



TROUBLESHOOTING

E-8 [E3:07] Abnormality in pump controller throttle system isdisplayed

E-8, E-9

* Start troubleshooting from E-6 [E3:05] or C8 [E2:17].

E-9 [E3:15] Abnormality (short circuit) in battery relay output system

* This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.

A Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position).

Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

Note: This only occurs when the engine is stopped and the starting switch is turned OFF.

is displayed

2 YESIs resistance betweenEOl (female) 113) and

YES_ battery relay terminal _1 &and between

- wmng harnessand

Is resistance be-chassis normal?

tween EOl (female) _ * Between E01 NO(13) and chassisnormal?

(female) (13) and battery relay BR: Max 1 R* Between wiring harness and chassis: Min. 1 MQ* Turn starting switch OFF.

* Approx. 100 D * Disconnect E01 and battery relay BR.- Turn starting

switch OFF.NO

Disconnect EOl.


Cause


Defective battery relay qeplace

1) Contact between otherwiring harness and wiringharness between EOl(female) (13) - HO2 (9) -battery relay BR

2) When light is connected

Remedy

Replace

?epair or,eplace

X07(MIC17) Fuse

Engine throttle controller

XOSDD137

20-I 25

a



TROUBLESHOOTING E-l 0

E-IO [E3:16] Abnormality (step-out) in governor motor system is

*

***

**

displayed

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If any other service code [E3:01] - [E3:18] has occured at the same time, start troubleshooting from that code.Check that fuse 2 is normal.Read the precautions given in TESTING AND ADJUSTING, “ Adjusting stroke of governor motor lever” beforecarrying out troubleshooting.Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

Are E3:06, E3:17,

* Turn starting switchON.

YES

YES

YESjeflT

n

Is adjustment oflinkage normal?

I

* Turn startingswitch ON.

- Turn auto-deceleration OFF.

*Set to governormotor adjustmentmode.

operation normal?

* 2r.n starting switch

* Turn auto-deceleration OFF.

yz&K&t$toyH

Set to governor motoradjustment mode. Disconnect E05. NO(Only when checking Q isconnectoperation of governor linkage at gover-motor at FULL.) nor motor end.

NO

Cause

30 to applicableroubleshooting code


I) Defective linkageI Defective injection pump

Iefective governor motor

Defective adjustment ofinkage

Remedy

-

Replace

Adjust orreplace

Replace

Adjust (Fordetails, see

TESTINGANDADJUSTING)

20- 126

a




E-11 Engine does not start

* When starting motor does not rotate.* Check that fuse 14 is not blown before starting troubleshooting.j, Before carrying out troubleshooting, check that all related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

4 YES

YE

Is voltage andspecific gravity ofbattery normal?

‘ I

* Min. 24V

YI

*Turn startingswitch ON -- OFF.

OFF, is sound heardfrom battery relay?

1NO

. Turn startingswitch START

YE

* Connect 1-1 end oftester to batteryterminal f-j.

.20-29v

. Turn starting NOswitch ON.

- Approx. 24V

5 YESI

Is voltage betweenstarting switchterminal C andchassis normal?

-Turn startingswitch to START.

. Approx. 24V

NO

Is there continuity * Between startingswitch BR and bat- NOtery relay BR: Max. 1 Q

- Between wiring harness and chassis: Min. 1 MQ- Disconnect both starting switch and battery relay


ends.

- Remove terminal B. No

NOE-l 1 Related electric circuit diagram

M2 (X2) 26 CTwP14) HO3(516)

HO5 U46) ruse Starting switch

ID13

XOBDD138

20- 128

0




Cause Remedy

Defective starting motor Replace

Defective contact of wiringharness between batterv (+)

Defective starting switch(between terminals 6 and C)

Defective battery relay

Defective contact of wiringharness between batteryrelay terminal E andrevolving frame groundconnection terminal

(between 5 and BR)

Defective contact, or dis-connection in wrrr ng harnessbetween battery terminal t+j-Mll-H05(6)-X07(1)-starting switch terminal 6(including fusible link)

Repair orreplace

Repair orreolace

Replace

Replace

Repair orreplace

Repair orreplace

Replace

Repair orreplace

1 Lack of battery capacity 1Charge or

20- I 29

0



TROUBLESHOOTING

E-12 Engine speed is irregular

E-l 2

**

4

Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

Idling speed is irregular

controller modelcode as shown in

*Turn startingswitch ON.

- %;EO;onitoring

Is E3:Ol displayed? 1

- 2d.n starting switct

disconnected andmotor lever is placed

YE


N

4

When linkage bet-ween governor motorand injection pump is -adjusted, does condi-tion become normal?

. See TESTING ANDADJUSTING.

Start signal 7 YESI It-

:sE

Fuel control dial 5-1

~ ormal and stable?

. At low idling:4.0 - 4.75V I

NO

. At low idling: IPC200 : 2.8 - 3.2 VPC220 : 2.9 - 3.3 v

NO

Table 1 NO

PC220PC250 332 13

20- 1300




Cause

FISeeE-j Defective adjustment of

linkageidjust

Defective injection pump #ee S mode

7 Defective governor motor

Defective contact of wiringharness between startingswitch ACC - X07 (17) - EOl

(female) (6). or defectivestarting switch

See E-7

See E-2

See E-6


Engine throttle controller

Starting switch X07 (Ml C 17)

Remedy

-

eplace

epair orsplace

EOl(MIC21)I- i 1 x"PK17) I

Starting switchON signal

Throttle signal

Feedback signalThrottle powersource (4

33

H02tS16) E04(X3)

Governor

potentiometer

X08DD139

20- 131

a




b) There is hunting

controller modelcode as shown in

. Turn s tartingswitch ON.

. &;rg;onitoring

Is E3:Ol displayed?


YEIS

3I I

When linkage is dis-connected and motorlever is matched with

*Turn startingswitch ON.Turn fuel controldial from MIN toMAX and stopalso at midwayposition.

4When linkage betweengovernor motor andinjection pump isadjusted, doescondition becomenormal?

* See TESTING ANDADJUSTING.

Fuel control dial 5

Is voltage between- EOl (7) and (16)

NO normal and stable?

YES

Deceleration signal 7I sPotentiometer 6

YAt low idling:

2.9 - 3.3v- At high idling: NO

0.5 - 0.9v

*At low idling:4.0 - 4.75v

*At high idling:0.25v - 1 ov NO

0Table 1I I

Engine throttle controllermodel code

PC200PC21 0

PC220PC250

20- 132

a




Start signal 8 YES

Is voltage between- EOl (6) and (12) -

normal and stable?

. During ope;t:;;” NO

-5 ;ee E-5

-c Defective adjustment of

iinkage

-I: jefective injection pump

-c efective governor motor

cefective contact of wiringh arness between start ing

‘ S witch ACC - X07 (17) - EOl( emale) (6). or defectiveS atting switch

s ice C-15

s ;ee E-7

-S ;ee E-2

-S #ee E-6

Startingswitch X07(MIC171 Fuse

otentiometer

Pump controller

X08DD140

E-12 Related electrical circuit diagram

Cause Remedy

-

rdjust

NeeS mode

eplace

epair oreplace

-

-

-

-

20-I 33

a



E-13 Lack of output (engine high idling speed is too low)

* Before carrying out troubleshooting, check that all related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

Is engine throttlecontroller modelcode as shown inTable l?


. .SS;;gTonitoring

Table 1

Is E3:Ol displayed?

* Turn startingswitch ON.

3

Does injectionL pump governor

NO lever contact FULLstopper?

. Start engine.

. Set fuel controldial to MAX.

* H/O mode.

INO

YE

4

Is adjustment oflinkage betweengovernor motorand injection pumpnormal?

YE

Fuel control dial 5

normal and stable?

I-NC

*At low idling:4.0 - 4.75V

- At high idling:0.25v - l.OV

YES

Potentiometer 6 rIs voltage betweenEOl (17) and 116)normal and stable?

H* At low idling:2.9 - 3.3v ‘ L*t high idling: NO0.5 - 0.9v

YES

. See TESTING AND NOADJUSTING.

PC220

PC250

20- 134

0




Start signal YESI I I

~

. During ope;t?;;V NO

* At deceleration: 1Max. 1V NO

-When cancelled:8-12V

E-13 Related electric circuit diagramStartingswitch X07CMIC17) FlJse

Eng,ne throttle controller

Cause

See E-5

Defective injection pump

Defective governor motor

Defective contact of wiringharness between startingswitch ACC - X07 (17) - EOl(female) (6). or defectivestarting switch

See C-15

See E-7

See E-2

Defective adjustment ofgovernor motor linkage

See S mode

See E-6

Remedy

-

e S mode

place *

-

-

-

-

-

20-I 350




E-14 Engine does not stop

A Stop the engine (push the fuel control lever of the fuel injection pump to the NO INJECTION position) before

***

checking.Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.Read the precautions given in TESTING AND ADJUSTING, “ Adjusting stroke of governor motor lever” beforecarrying out the troubleshooting.

YE

Is engine throttlecontroller modelcode as shown inTable l?

t

Turn starting switchON.

* ~;&;9~onitoring

Table 1

lever contact STOP

condition becomenormal? and Does

. See TESTING AND

ADJUSTING.

Potentiometer 6 YESWhen starting

YES switch is OFF, is

Relay drive signal 5- voltage between -

_ E01 (17) and (16)When starting normal?

YES switch is OFF, does- voltage between 601 - *When engine is NO

Start signal 4 (13) and (12) changestopped

_ as shown in Table 2? * PC200: 2.9 - 3.3vWhen starting p *PC220: 2.9 - 3.2Vswitch is OFF, is *20 - 3ovvoltage between -EOl (6) and (12)

NO

normal?

.Max.lV

Engine throttle controllermodel code

PC200PC21 0

PC220PC250 u”3:z cf

Table 2When OF

Voltage from starting (APPrOx. 24V)

“ ‘ k ’ - To battery relay (BR)OFF

(Note) -.----When ON

- Voltage output from controller when startin g switch is OFF

Condition of actuation of1 (Approx. 24v)controllercircuit 1 To battery relay (BR)

(EO@)OFFL A Min. 4 sec.

Drive timea Max. 7 sec.

(when it is impossible to set to NO INJECTION because of failure in motor)

Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30 V is alwaysflowing from starting switch BR, so if the voltage is measured at EOI (13), there is a voltage of 20 - 30 V.

20- 136

0




E-15 Defective operation of battery relay system (engine does not stop)

Note: This only occurs when the engine is stopped and the starting swtich is turned OFF.Stop the engine (push the governor lever of the fuel injection pump to the NO INJECTION position) beforea

**checking.Before carrying out troubleshooting, check that all related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

1

YES

1 Is E3:15 displayed? [ YESRelay drive signal 2 )

* TurnON.

defective battery relay f

1) Disconnection in wiringharness between E01(female) (13) - HO2 (9) - f

*BetweenEOl NO battery relay BR r

(female) (13) and battery relay BR: Max. 1 R 2) When light is connected* Between wiring harness and chassis: Min. 1 MQ* Turn starting switch OFF.- Disconnect EOl and battery relay BR.

Table 1 When ON

Voltage from starting (APP~O X. 24V)

1 To battew relay (BR)OFF

Cause


fSeplace

Ieplace

tepair oreplace

,, y Voltage Output from Controller when starti ng switch is OFF

IWhen ON

Condition of actuation of(Note) (Approx. 24V). I

-To battery relay (BRI77-L 1 Min. 4 sec.

Drive time- Max. 7 sec.

(when it is impossible to set to NO INJECTION because of failure in motor)

See E-9 -

_

Remedy

Note: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30 V is alwaysflowing from starting switch BR, so if the voltage is measured at EOI (13), there is a voltage of 20 - 30 V.

E-l 5 Related electric circuit diagram

XDi’ (MlC17) Fuse

E01 (MIC21)HOZ(S16)

D13

XOSDDl37

20-I 38

a



TROUBLESHOOTING OF ENGINE(S MODE)

Method of using troubleshooting chart . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-l 40s- 1s- 2

s- 3s- 4s- 5S- 6s- 7S- 8s- 9S-l 0S-l 1S-l 2S-l 3S-l 4S-l 5

S-l 6

Starting performance is poor (Starting always takes time) .................Enginedoesnotstart ............................................0 Enginedoesnotturn ............................................0 Engine turns but no exahaust gas comes out (Fuel is not being injected) .0 Exhaust gas comes out but engine does not start (Fuel is being injected)Engine does not pick up smoothly (Follow-up is poor) ....................Engine stops during operations .......................................Engine does not rotate smoothly. .....................................Engine lacks output (no power) ......................................Exhaust gas is black (incomplete combustion) ..........................Oil consumption is excessive (or exhaust gas is blue) .....................Oil becomes contaminated quickly ....................................Fuel consumption is excessive .......................................Oil is in cooling water, or water spurts back, or water level goes down .......Oil pressure lamp lights up (drop in oil pressure) ........................Oil level rises ..........................................Water temperature becomes too high (overheating) ......................Abnormal noise is made ............................................

Vibration is excessive ............................................

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. . ...

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20-I 4420-l 4520-I 4520-l 46 20-I 47

20-I 48 20-I 49 20-I 50 20-I 51 20-I 52 20-I 53 20-l 54 20-I 55 20-I 56 20-I 57 20-I 58 20-I 59 20-I 60

20-I 61

20- I 39

a



TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHART

The basic method of using the troubleshooting chart isas follows.Items listed for [Questions] and [Check items] that havea relationship with the Cause items marked with 0, andof these, causes that have a high probability are mark-ed with @.Check each of the [Questions] and [Check items] inturn, and marked the 0 or @ in the chart for itemswhere the problem appeared. The vertical column

(Causes) that has the highest number of points is themost probable cause, so start troubleshooting for thatitem to make final confirmation of the cause.

rl

%2

For (Confirm recent repair history) in the [Ques-tions] Section, ask the user, and mark the Causecolumn with A to use as reference for locatingthe cause of the failure. However, do not use thiswhen making calculations to narrow down thecauses.Use the A in the Cause column as reference for(Degree of use (Operated for long period)) in the[Questions] section as reference. As a rule, do notuse it when calculating the points for locating thecause, but it can be included if necessary to deter-mine the order for troubleshooting.

, t%l

-----Ionfirm recent repair history

%2 Degree of use Operated for long period A A A

20- 141

a




Example of troubleshooting when exhaust gas is blackLet us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptomshave causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weak-er], and [Dust indicator is red].If we look from these three symptoms to find the cause, we find that there is a relationship with five causes.Let us explain here the methos of using this causal relationship to pinpoint the most probable cause.

c




I Five causes I

Clarify the relationship between the three symptomsin the [Questions] and [Check items] section andthe five Cause items in the vertical column.

Three symptoms

i h 1,

I

Step 2

Add up the total of 0 and 0 marks where the hori-zontal lines for the three symptoms and the vertical

columns for the causes intersect.(1)(2)

(3)(4)(5)

Clogged air cleaner element: 908Air leakage between turbocharger andhead: 00Clogged, seized injection nozzle: 0Defective contact of valve, valve seat: 0Worn piston ring, cylinder: 0

Step 3

The calculations in Step 2 show that the deepestrelationship is with [Clogged air cleaner element].Follow this column down to the troubleshootingarea and carry out the troubleshooting item marked0. The Remedy is given as [Clean], so carry outcleaning, and the exhaust gas color should return

, to normal.

20- 143CD



TROUBLESHOOTINGS-l

S-l Starting performance is poor (Starting always takes time)

* Check that there is no abnormality display for the engine throttle controller on the monitor panel.General causes why starting performance is poor

Defective electrical system0 Insufficient supply of fuel

Insufficient intake of air0 Improper selection of fuel

(At ambient temperature of - ?O” C or below, use ASTM D975 No. 1, and - 10°C or above, use ASTM D975No. 2 diesel fuel.)

* Charging rate of battery.

20x 1.28 1.2 ‘ 6 / 1.24 1.23 1.22

O’C 1.29 1.2. , .._.I 175 1 1.24 1 1.23

-10% 1.30 1.28 1.2L , ..__ , .._-I 176 I 174

. The specific gravity should be for the charging rate of 70% or more in

the above table.

. In cold weather the specific gravity must be for the charging rate of atleast 75% in the above table.

I Confirm recent re*au histow

5 _ Engine oil must be added more frequently-.i: RePlaCement of filters has not been carried ou t according t o2 operation manual

: AKCleanerlogingampightE P IA, / I I I I II I I I I I I /

Non-spectied fuel has been used

/ Battery cha rge lamp is ON

/

Match marks on fuel injection pump we out of ahgnment I ) 1 1 101 1 /I 0

: Mud is stuck to fuel tank cap I I I I I I.s When engine is cranked with starting motor,

% 1I Little fuel comes out even when injection pump sleeve nut 1sI I I I I

When control rack is pushed, it is found 10 be heavy or does not returnI/ (when blind plug at reer of pump IS removed, it can be seen that

plunc,er ~onfrol sleeve does not move,



TROUBLESHOOTING s-2

S-2 Engine does not start0 Engine does not turn

General causes why engine does not turninternal parts of engine seized* If internal parts of the engine are seized, carry out troubleshooting for “ Engine stops during

operations” .Failure in power train

Defective electrical system I Causes I

Confirm recant repair historyE.g Degree of use Operated for long period

2 Condition of horn when startina 1 Horn does not sound

z 1 switch is turned ON _ Horn sound level is low

When starting switch is

turned to START. pinion

moves out, but

Rotating speed is slow

Makes rattling noise and

does not turn

EC When starting switch is turned to START, pini on does not move out%r”

When starting switch is turned to ON, there is no clicking sound

u Battery terminal is loose

When battery is checked, battery electrolyte is found to be low

Specific gravity of electrolyte, volta ge of battery is low

For the following conditions 1) -. 5). turn the starting switch OFF,

connect the cord, and carry out troubleshooting at ON

1) When terminal B and terminal C of starting switch are connected,

engine starts

-21 When ternimal E and terminal C of starting motor are connected,

z engine starts‘ G8 3) When terminal B and ierminal C of safety relay are connected,52

engine starts

z 4) When terminal of safety switch and terminal B of starting motorg are connected, engine starts

5) There is no 24V voltage between terminal b and terminal E of

I battery relay

When ring gear is inspected directly, tooth surface is found to be

I chipped

Remed)

20- 145a



TROUBLESHOOTINGs-2

0 Engine turns but no exhaust gas comes out (Fuel is not being injected)

* Check that there is no abnormality display for the engine throttle controller system on the monitor panel.General causes why engine turns but no exhaust gas comes out

Supply of fuel impossible0 Supply of fuel extremely small0 Improper selection of fuel (partucularly in winter)

Standards for use of fuel

When fuel cap is inspected directly, it is found to be clogged 0

0 8 zRemedy 9 a S :

L L @

$ z?5 ‘ I ‘ g p

,odb,g $ 00 a e oz

20- 1460



TROUBLESHOOTING s-2

COExhaust gas comes out but engine does not start (Fuel is being injected)

General causes why exhaust gas comes out but engine does not startLack of rotating force due to defective electrical system

0 Insufficient supply of fuelInsufficient intake of air

0 Improper selection of fuel

/-

manual

starting motor,

1) Little fuel comes out even when injection pump sleeve nut is

20- 147

a



TROUBLESHOOTING S-4

S-4 Engine stops during operations

* Check that the display for the fuel level on the monitor panel indicates that there is still fuel left.General causes why engine stops during operations

Seized parts inside engine0 Insufficient supply of fuel

Overheating* If there is overheating and insufficient output, carry out troubleshooting for overheating.

Failure of power train* If the engine stops because of a failure in the power train,

carry out troubleshooting for the chassis.

Condition when engine

stopped

Try to turn by hand using bar

I Remove oil pan and check directly 1.101 1 1 1 1 1 1 1 1 2Remove head cover and check directlv I.1 I I I I I I I



TROUBLESHOOTING s-5

S-5 Engine does not rotate smoothly* Check that there is no abnormality displayed for engine throttle controller system on the monitor panel.General causes why engine does not rotate smoothly (hunting)

Air in fuel systemDefective governor mechanismDefective electrically controlled throttle mechanism (electrically controlled throttle type)* If there is no hunting when the electrically controlled throttle rod is disconnected, carry out trouble-

shooting for the electrical system.

Condition of hunting

20- 150

a



TROUBLESHOOTING S-6

S-6 Engine lacks output (no power)* Check that there is no abnormality displayed for the engine throttle controller system on the monitor panel.General causes why engine lacks output

Insufficient intake of air0 Insufficient supply of fuel

Improper condition of fuel injection0 Use of improper fuel

(if non-specified fuel is used, output drops)

Lack of output due to overheatingjr If there is overheating and insufficient output,

carry out troubleshooting for overheating.



TROUBLESHOOTING

S-7 Exhaust gas is black (incomplete combustion)

General causes why exhaust gas is blackInsufficient intake of airImproper condition of fuel injectionExcessive injection of fuel

36

Engine oil must be added more frequently I, I I I ISuddenly C. I IAl I I Ir\l I In

Power was lostGraduallv

I I I I-8 I I

Non-specified fuel has been used I I lol I

E temperature of some cylinders is low I I I IDI Ia.Z Match marks on fuel injection pun.

::2 Seal on injection pump has come off I Iu Clanging sound is heard from around cylinder head I , I I

>o are out of alianmentI 1

0

I ji0

Exhaust noise is abnormal lol I lo1 It Q

Muffler is crushed 0

Leakage of air between trubocharger and head, loose clamp 0

20 I 52

0



TROUBLESHOOTING S-8

S-8 Oil consumption is excessive (or exhaust gas is blue)

* Do not run the engine at idling for more that 20 minutes continously. (Both low and high idling).General causes why oil consumption is excessive

Abnormal conbustion of oilExternal leakage of oilWear of lubrication system

I/ I , one IArea around enaine is dirtv with oil

There is oil in engine cooling water

When exhaust oipe is removed, inside is found to be dim, with oil CT3 I lo-G

-0

2Inside of turbocharger intake pipe is dirty with oil 8

Oil level in clutch or TORQFLOW transmission damper chamber rises QClamps for intake system are loose @

When compression pressure is measured, it is found to be low 0 0

When breather element is inspected, it is found to be clogged with0

Pdirty oil

‘ Z There is external leakage of oil from engine 0 0 0

Pressure-tightness test of oil cooler shows there is leakage 0

20-I 53

0



TROUBLESHOOTING s-9

S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quicklyIntake of exhaust gas due to internal wearClogging of lubrication passageImproper combination

0 Use of improper oilOperation under excessive load

Confirm recent repair history

z Degree of use Operated f or long period A A A.gz

Engine oil must be added more frequently 8Non-soecified fuel has been used 0

IWhen oil filter is inspected, metal particles are found 0 ci,-, , ,

u When exhaust pipe is removed, inside is found to be dirty with oil @Fnrrin,z nil tPmnPllt,,rL liCLI n,,irk,v I IBI I

1L.‘)..‘ - _.. ._... r_._._._ ..___ _I_._ . . . .

I I I I 1-1 , :w

I When compression pressure is measur&d, it is found to be low I.1 I I 1 I I 1

When safety valve is directly inspected, spring is found to bl

20- 154

0



TROUBLESHOOTING S-l 0

S-IO Fuel consumption is excessive

General causes why fuel consumption is excessiveLeakage of fuelImproper condition of fuel injectionExcessive injection of fuel

IllllllljConfirm recent repair history

Degree of use Operated for long period .4 A A

z More than for other machines

.g 6 0of same model

t Condition of fuel consumption

zGradually increased 0 0

Suddenly increased 0 0

Exhaust gas colorBlack @o 0 0

White 0

( Engine low idling speed is high lOI I I I I I ISI

20- 155

0




S-l 1 Oil is in cooling water, or water spurts back, or water level goesdown

General causes why oil is in cooling waterInternal leakage in lubrication systemInternal leakage in cooling system

20- 156

0




S-12 Oil pressure lamp lights up (drop in oil pressure)j, If engine oil level lamp on monitor panel is not lighted up.* If oil pressure sensor is normal (see item for M mode).General causes why oil pressure lamp lights up

Leakage, clogging, wear of lubricating systemDefective oil pressure control

0 Use of improper oil (improper viscosity)Deterioration of oil due to overheating

* Standards for engine oil selection

Type of oilSelection of oil SAE number according

to ambient temperature

Condition when oil pressure

20- 157

a




S-13 Oil level rises

* If there is oil in the cooling water, carry out troubleshooting for “ Oil is in cooling water” .Water in oil (cloudy white)Fuel in oil (diluted, and smells of diesel fuel)Entry of oil from other component I Causes

yn engine 1s irst started, drops o

20- 1580



TROUBLESHOOTING s-14

S-14 Water temperature becomes too high (overheating)

* If coolant level lamp on monitor panel is not lighted up.j, If coolant temperature gauge on monitor panel is normal (see M mode)General causes why water temperature becomes too high

Lack of cooling water (deformation, damage of fan)Drop in heat dissipation efficiencyDefect in cooling circulation system

Rise in oil temperature of power train* Carry out troubleshooting for chassis.

Water temperature gauge

Temperature difference between top and bottom radiator tanks is0

excessive

Temperature difference between top and bottom radiator tanks

1 .; [inspected, the core is found to be clogged

When a function test is carried out on the thermostat, it does not open ( ( ( ( _ ( ( ( ( ( ( I2:

even at the cracking temperature

E0’

When water temperature is measured, it is found to be normal 0

c When oil cooler is inspected directly, it is found to be clogged 0

When measurement is made with radiator cap tester, set pressure is

I I found to be low I I I I I I I 1-1 IWhen compression pressure is measured, it is found to be low 0

Remove oil pan and check directly 0

z .L .b 8 z .= 8 8 ERemedy $ g 0 z $

x“p22SZ_m

ZeaZ$ Caa% $ L+?$-

cc

20- I 59a




S-15 Abnormal noise is madej, Judge if noise is an internal noise or an external noise.General causes why abnormal noise is made

Abnormality due to defective partsAbnormal combustion noiseAir sucked in from intake system

Speed of some cylinders does not change when operating on

20- 1600




S-16 Vibration is excessive

* If there is abnormal noise together with the vibration, carry out troubleshooting for “ Abnormal noise is made” .General causes why vibration is excessive

Defective parts (abnormal wear, breakage)0 Improper &ignn+ent

Abnormal combustion

I outside standard I I I I I I I I IRemove front cover and check directlv

Remove head cover and check directly

/ Injection pump test shows that injection amount is incorrect 0

8 8 g ?j z - .L gRemedy $ $ $ $ $ ‘ $ p z .$

ggg ggaa d 4

20- 161

a



TROUBLESHOOTING OFPUMP CONTROLLER SYSTEM

(C MODE)

Points to remember when troubleshooting pump controller system .................Action taken be controller when abnormality occurs and problems on machine ........Judgement table for pump controller and hydraulic related parts ...................Pump controller system circuit diagram ........................................Troubleshooting flow charts for each failure modec- 1c-2

c- 3

Abnormality in pump controller power source system (swing brake is not canceled, etc) . . . . . 20-171

c-4c- 5C-6

c- 7

C- 8c- 9C-l 0C-l 1C-l 2

[E2:32][E2:36][E2:33][E2:37][E2:03][E2:13][E2:02][E2:04][E2:05][E2:06][E2:12][E2:14][E2:15][E2:16][E2:17][E2:18][E2:22][E2:23][E2:24][E2:25]

C-l 3 [E2:26]C-l 4 [E2:27]C-l 5 [E2:28]

. .

. .

. .

. .

. .

. .

. . . 20-I 64 . . 20-I 65

. . 20-169

. . 20-I 70

Short circuit in front pump TVC solenoid system is displayedShort circuit in rear pump TVC solenoid system is displayed .........Disconnection in front pump TVC solenoid system is displayedDisconnection in rear pump TVC solenoid system is displayed .......Short circuit in swing brake solenoid system is displayed ............Disconnection in swing brake solenoid system is displayed ..........Short circuit in LS select solenoid system is displayedShort circuit in pump merge-divider solenoid system is displayedShort circuit in 2-stage relief solenoid system is displayedShort circuit in travel speed solenoid system is displayed ............Disconnection in LS select solenoid system is displayedDisconnection in pump merge-divider solenoid system is displayedDisconnection in 2-stage relief solenoid system is displayedDisconnection in travel speed solenoid system is displayed ..........Model selection input error is displayed ..........................Network response overtime error is displayed .....................Short circuit in LS control EPC solenoid system is displayed ..........Disconnection in LS control EPC soleniod system is displayed ........Abnormality in front pump pressure sensor system is displayedAbnormality in rear pump pressure sensor system is displayed .......Abnormality in pump pressure sensor power source system is displayedAbnormality in engine speed sensor system is displayed ............Abnormality in auto-deceleration output system is displayed .........

. .

. .

. .

.

. .

. .

. .

. .

. . . . . 20-I 80

. ..

. .

.

. .

. .

. . . 20-I 72

. . . 20-I 74

. . . 20-I 76

. . . 20-I 78

. . . 20-I 82

. . . 20-I 84

. . . 20-I 85

. . 20-I 87

. . 20-I 88

. 20-I 90

. . . 20-I 92

. . 20-I 93

. . . 20-I 94

20-I 63

a



TROUBLESHOOTINGPOINTS TO REMEMNBER WHEN TROUBLE-

SHOOTING PUMP CONTROLLER SYSTEM

1. Points to remember if abnormality returns to normal by itselfIn the following cases, there is a high probability that the same problem will occur again, so it is desirable tofollow uo this oroblem carefully.

1)2)

*

If any abnormality returns to normal by itself,If the connector is disconnected and the T-adapter is inserted, or if the T-adapter is removed and theconnector is returned to its original position when carrying out troubleshooting of the failure, and theservice code is no longer displayed, or if the monitor display returns to normal.After completing troubleshooting, always erase the user code from memory.

2. Service code memory retention functionWhen displaying the service code in memory and carrying out troubleshooting, note down the content of thedisplay, then erase the display. After trying to re-enact the problem, carry out troubleshooting according to theservice code that is displayed.(There are cases where mistaken operation or abnormalities that occur when the connector is disconnectedare recorded by the memory retention function. Erasing the data in this way saves any wasted work.)

20-I 64

a



User code Service code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) Action b y controller when abnor mality is detected Problem hat appears on machine when there is abnormality

1. Short circuit inside sole noid or betweensolenoid ( ‘I) and (2) (when internal resistance of

1. With swi ng + boom RAISE, the boo m is slow.

- E2:02 Short circuit in LS select solenoid i s extremely low), and excess current Resistance of solenoid: 20 - 60 RMakes power to solenoid 0 2. With s wing + arm OUT, the ar m OUT i s slow.

solenoid system is flowing.Resets power source to restore 3. With swing + travel, there is a big drop in the

2. Abnormality in pump controllertravel speed.

1. Short circuit inside solenoid or between The pump merge-divi der valve continues toShort circuit in pump solenoid ( I ) and (2) (when internal resistance of

E2:04 merge-divider solenoid Solenoid is extremely low), and excess current Makes power to solenoid 0merge the oil flow.

- Resistance of solenoid: 20 - 60 R 1. In the L/O and S/O modes, the work equipment

system is flowing. Resets power source to restore

2. Abnormality in pump controllerand swing speeds become faster .

2. The steering is difficult to turn.

1. Short circui t inside solenoid or between

Short circuit in 2-stagesolenoid (I) and (2) (when internal resistance of When traveling or using the power max. function,

- E2:05 solenoid is extremely low), and excess CUrrefIt Resistance Of Solenoid: 20 - 60 fi Makes power to solenoid 0relief solenoid system the relief pressur e is not raised, so there is lack of

is flowing. Resets power source to restore

2. Abnormality in pump controllerpower.

1. Short circui t inside solenoid or between

Short circuit in travelsolenoid (I ) and (2) (when internal resistance of

E2:06 solenoid i s extremely low), and excess current Resistance of solenoid: 20 - 60 R Makes power to solenoid 0 Even if the travel speed is switched, the travelspeed solenoid system

is flowing.Resets power source to restore speed does not change (remains at Lo)

2. Abnormality in pump controller

1. In the case of 1 and 2, the current stops flowingto the solenoid, so no particular action is taken.Therefore, if the abnormality is restored by thevibration of the machine, the condition wil lreturn to normal.*However, the display does not go out.

2. In the case of 3, the current continues to flow tothe solenoid, bu t the controller takes noparticular action.

1. Short circuit inside solenoid (when inter nal Therefore, if the abnormality is restored by the 1. In the case of 1 and 2, it is the same as E2:02.

resistance of solenoid is extremely high) vibration of the machine, the condition wil l 2. In the case of 3, when the boom/swing priority

E2:12 Disconnecti on in LS2. Disconnection in wiring har ness between

return to normal. selection mode is OFF and the travel is OFF, amselect solenoid system Resistance of solenoid: 20 - 60 R

solenoid (2) and controller*However, the display does not go o.ut. there is combined operation with the swing

3. Solenoid 12) short circuiting with ground*If the controller gives a signal to turn the (except for boom RAISE an d arm OUT),

4. Abnormality in pump controllersolenoid current OFF, the voltage at portion(a) should be 20 - 30V. If there is a

pressure compensation cannot be carried outfor the swing LS pressure.

disconnectio n or short circuit with the ground,the voltage at portion (a) is low (almost OV),so it is judged that there is an abnormality.

I

E-2 IL

- ,,,PFuse

Pump r24”controller

Solenoid +--A

205FO6365

1. Short circuit inside solenoid (when inter nal 1. In the case o f 1 and 2, the current stops flowing

Disconnecti on in pump resistance of solenoid i s extremely high) to the solenoid, so no particular action i s taken.1. In the case of 1 and 2, it is the same as E2:04.

E2:14 merge -divider solenoid 2. Disconnection in Wiring harness betweenTherefore, if the abnormality is restored by

- Resistance of solenoid: 20 - 60 Q 2. In the case of 3, the pump merge-di vider valvesolenoid (2) and controller

the vibration of the machine, the condition willsystem remains divided, so the arm and boom are

3. Solenoid (2) short circuiting with groundreturn to normal.*However, the display does not go out. slow.

4. Abnormality in pump controller 2. In the case of 3, the current continues to flow tothe solenoid, but the controller t akes no

particular action.Therefore, if the abnormality is restored by thevibratio n of the machine, the condition willreturn to normal.*However, the display does not go out.

1. Short circuit inside solenoid (when inter nal *If the controller gives a signal to turn the 1. In the case of 1 and 2, it is the same as E2:05.resistance of solenoid is extremely high)

Disconnecti on in 2-stage 2. Disconnection in wiring harn ess betweensolenoid current OFF, the voltage at portion 2. In the case of 3, it becomes the same condition

E2:15 Resistance of solenoid: 20 - 60 R (a) should be 20 - 30V. If there is a as when the 2-stage relief is used, so the reliefrelief solenoid system solenoid (2) and controller disconnecti on or short circuit with the ground, pressure remains increased

3. Solenoid (2) short circuiting with ground the voltage at portion (a) is low (almost OV), (34.8MPa(355kg/cmz)).

4. Abnormality in pump controller so it is judged that there is an abnormality. (The solenoid stays ON)

20-166a



FOLD

Jser code Service code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) Action by controller when abnormality is detected Problem that appears on machinewhen there s abnormality

1. In the case o f 1 and 2, the current stops flowingto the solenoid, so no particular action is taken.Therefore, if the abnormality is restored by thevibration of the machine, the condition willreturn to normal.*However, the display does not go out.

2. In the case of 3, the current continues to flow tothe solenoid, but the controller takes no

1. Short circuit inside solenoid (when internalparticular action.Therefore, if the abnormality is restored by the

E2:16 Disconnection in travel resistance of solenoid is extremely high) vibration of the machine, the condition will 1. In the case of 1 or 2, it is the same as the E2:06speed solenoid system 2. Disconnection in wiring harness between Resistance of solenoid: 20 - 60 R return to normal. 2. In the case of 3, the solenoid remains actuated,

solenoid (2) and controller *However, the display does not go out. so the Lo speed is fast.

,3. Solenoid (2) short circuiting with ground *If the controller gives a signal to turn the

4. Abnormality in pump controllersolenoid current OFF, the voltage at portion (a)should be 20 - 30V. If there is a disconnectionor short circuit with the ground, the voltage atportion (a) is low (almost OV), so it is judgedthat there is an abnormality.

PumpcOntrOller

Solenoid205FO6365

E2:17

1. PC210Between CO3 (15) and chassis: M ax. 1 R

Model selection input 1. Disconnection, short circuit in model selection Between CO3 (13), (14), (16) and chassis: Detects abnormality in input1) Retains data when starting switch is ON 1. Travel deviation

error wiring harness Min. 1 MQ2. Abnormality in controller 2. PC240

2) Functions as PC100 when non-set conditions 2. Engine stalls

Between CO3 (13), (15) and chassis: Max. 1 R are input

Between CO3 (14), (16) and chassis: Min. 1 MR

1. When networki ng are impossible with themonitor panel and engine throttle controller(1) Working mode: G/O 1. I) Even when travel is operated, the power(2) Priority mode: OFF does not increase

1. Disconnection, short circuit, short circuit with (3) Travel speed: Lo (2) The swift slow-down function does not work

E2:18 Network response ground in network wiring harness (4) Auto-deceler ation: ON (3) The auto-deceleration cannot be canceled-

overtime error 2. Abnormality in engine throttle controller (5) Power max. : ON (4) The travel speed does not increase

3. Abnormality in pump controller (6) Automatic mode: OFF (HYPER GX) (5) The priority mode has no effect

2. When networki ng are impossible with engine (6) The automatic mode has no effect

throttle controller (HYPER GX)

Control is carried out by recognizing the throttle 2. The engine speed may dropsignal as FULL (others are as usual)

Short circuit in LS1. Short circuit inside solenoid or between

solenoid (1) and (2) (when internal resistance of1. The Lo travel speed is too fast.

- E2:22 control EPC solenoidsystem solenoid is extremely low), and excess current

Resistance of solenoid: 7 - 14 Q Makes power to solenoid 0 2. In L/O and F/O modes, the work equip ment

is flowing. Resets power source to restore speed is too fast.

2. Abnormality in pump controller3. When the engine is running at low idling, the

swing speed is too fast.

1. Disconnection inside solenoid or disconnection1. In the case of 1, the current stops flowing to the

in wiring harness between controller CO1 (15),solenoid, so no particular action is taken.

Disconnect ion in LS (7) and LS control EPC solenoidTherefore, if the abnormality is restored by the 1. In the case of 1, it is the same as E2:22

- E2:23 control EPC solenoid 2. Wiring harness between controller CO1 (7) andCurrent: Approx. 800 mA vibration of the machine, the condition will 2. In the case of 2, electric current continues to

LS control EPC solenoid Cl0 (2) short circuiting(Levers at neutral, low idling) return to normal. flow to the LS control EPC solenoid, so the worl

systemwith ground

*However, the display does not go out. equipment, travel, and swing speeds are slow

3. Abnormality in pump controller2. In the case of 2, the current continues to flow to

the solenoid.



User code Service code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) Action by controller when abnormality is detected Problem that appears on machine when there is abnor

bnormality in front 1. Abnormality in front pump pressure sensor 1. Between CO3 (I) and (9): 0.5 - 4.5 V-

E2:24 pump pressure sensor 2. Disconnection, short circuit in wiring harness 2. Resistance between CO3 (female) (1) and (9), (I) Takes front p ump pres sure as 0 MPa (0 kg/cm’) 1. The travel speed does not automatically shift (ii

system between CO8 and CO3 and chassis : Min. 1 MR when actuating. does not change fr om Hi to Lo).

3. Abnormality in pump controller (Disconnect pressure sensor connector CO8 andIf abnormality is restored, it actuates as normal. *If the button is operated manually, the panel

connector at CO31*However, the display does not go out. display is switched.

Abnormality in rear 1. Abnormality in rear pump pressure sens or1. Between CO3 (2) and (IO): 0.5 - 4.5 V

Takes r ear pump pressure as 0 MPa (0 kg/cm’)- E2:25 pump pressure sensor 2. Disconnection, short circuit in wiring harness

2. Resistance between CO3 (female) (2) and (IO), 1. The travel speed does not automatically shift (it

system between CO7 and CO3(2) and chassis : Min. 1 MR when actuating. does not change fro m Hi to Lo).(Disconnect pressure sensor connector CO7 and If abnormality is restored, it actuates as normal.

3. Abnormality in pump controller connector at CO3) *However, the display does not go out.*If the button is operated manually, the panel

display is switched.

Takes front pump and rear pump pressure as

Abnormality in pressure 1. Defective pressure sensor0 MPa (0 kg/cm’) when actua ting.

1. Voltage between CO3 (3) and (9) and between When abnormality is detected, it switches the1. The travel speed does not automatically shift

- E2:26 sensor power source 2. Wiring har ness between press ure sensor (2) (it does not change from Hi to Lo).

system and controller short circuiting with groundCO3 (3) and (10): 18 - 28 V output OFF, and when all levers are returned to

neutral, it outputs again.*if the button is operated manually, the panel

*This automatic resetting is repeated up to 3display is switched.

times.

E2:27

1. Disconnection, short circuit in speed sensor1. It functions as the equivalent of the G/O mode

Abnormality in engine 2. Disconnection, short circuit in wiring harness(the speed rises)

Resistance: 500 - 7000 0speed sensor system between E7 and CO2 Voltage (AC range) : 0.5 - 3.0 V

*However, the display does not go out. It operates about the same as G/O mode (prol ix)

3. Abnormality in pump contro ler2. When the sensor is lost, such as when ther e i s a (the power is slightly lower)

disconnection inside the speed sensor,monitoring code 10 is not displayed. -

E2:28Abnormality in auto-deceleration outputsystem

1. Disconnection, short circuit in wiring harness 1. Voltage between CO3 (5) and chassis

of CO3 (5) and EOI (4).At deceleration: 8 - 12 V When t here is a short circuit, it stops the output,When canceled: 0 - 1 V

It is controlled as usual

2. Abnormality in engine throttle controllerand restores by resetting the power. (there may be a delay i n response)

3. Abnormality in pump controller2. Resistance between CO3 (5) and chassis

:When there is a disconnection, it continues to

Min 1 MQ move as it is.

20-1680



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MP CONTROLLER SYSTEM CIRCUIT DIAGRAM

Al

Fusible link

Puma controller__--___

I’I IIIII I I III IIIII I I I

II .,,I -I I

IiiI

I

-11I

I

iEO1L _ I

Enqine throttle ContrOller

Model selection connector

Travel 2-stage Swinq Pumb merqe- LSspeed relief brake divider select I.. H. knob

SWtch Rear Front i_S control TVC TVCSolenoid Valve DuniQ DumD E P C valve YIIlYP “RI”0

oressure Dressuresensor sensor

.I.._ ._..”



TROUBLESHOOTING C-l

C-l Abnormality in pump controller power source system (swingbrake is not canceled, etc.)


j, Check that fuses 1 and 14 are not blown.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.j, Always connect any disconnected connectors before going on to the next step.j, When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-l 1.)

YES1 Defective pump controller Replace

Is voltage betweenCO1 (10) (11) and -(1) (2) normal? 2yEs

-.20-30V

Is voltage between

- Turn starting- fuse 1and GND -

switch ON.NO normal?

Defective contact: or dis-connection in wmng harnessbetween fuse 1 and CO1(female) (lO)(ll)

Defective contact, or dis-connection in wtnng harness

Repair orreplace

.20-30V NObetween fuse 1 HO6 (2) -

- 2i.n starting switchMl4 (2)(l) - battery relayterminal M

Repair orreplace

C-l Related electric circuit diagram

Pump controller

CO 1 (MlC21)I \ I

Ml4 (L2)

XOY’ (MIC17)

Startingswitch

20- 171

0



TROUBLESHOOTING c-2

C-2 [E2:32] Short circuit in front pump TVC solenoid system isdisplayed[E2:36] Short circuit in rear pump TVC solenoid system isdisplayed


* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:32or E2:36 are displayed. (If they are not displayed, the problem has been removed.)

* Always turn the TVC prolix switch OFF.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.Jr Always connect any disconnected connectors before going on to the next step.

3 YES

Is resistanceYES between each pin

2 - fortroubleshooting -3 in the table 1Is resistance normal?

ym between each pinr for troubleshooting _ Turn starting switch NO

1 2 in the table 1 OFF.- normal? - Disconnect COl.

Interchange wiringwith other TVCsolenoid. Is

* (Ju;F: tarting switch

applicable service Disconnect CO4 orNO

code displayed? C13, whichever is

Go toA

Cause

Iefective pump controller

* Interchange wiring.applicable.

. Turn starting switch Applicable TVC solenoid isON again. NO defective

A-b

Applicable one of wiring har-ness between CO1 female) (8)

5 YES and CO5 female) (2) (F pump. TX), or wiring harness

Is resistance between CO1 female) (4) andYES between each pin CO5 female) (7) (R pump TVC)4 r fortroubleshooting - in contact with power

5 in the table 1 source wiring harness

Is resistance normal?L Defective TVC prolix switch,etween each pin

I for troubleshooting - -Turn starting switch NO4 in the table 1 OFF.

or applicable one of wiring

normal? - Disconnect CO5harness between NC prolixswitch - CO5 male) (2) (F

T~II starting switch pump TVC solenoid) or CO5

Disconnect C05.NO

(male) (71 R pump TVCsolenoid) in contact withpower source wiringharness

Applicable one of wiringharness between Cl3(female) (2) and CO5 female)(4) tF pump WC solenoid),or wiring harness betweenCO4 female) (2) and CO5(female) (9) (R pump TVCsolenoid) in contact withpower source wiring harness

Remedy

leplace

leplace

lepair oreplace

lepair oreplace

lepair oreplace

20- 172

a



TROUBLESHOOTING c-2

Service code

Service code Troubleshooting 2

Between Cl3 (male) (1) and

(2)

Measurement location

Troubleshooting 3

Between CO1 (female) (16) and(8)

Troubleshooting 4


Resistancevalue

IO-22n

CL. 3L

Between Cl 3 (male) (2) and Between CO1 (female) (8) andchassis chassis

Between CO4 (male) (1) and Between CO1 (female) (17) and(2) (9)

Between CO5 (female) (4) andchassis

Between CO5 (female) (8) and

(9)

Min. 1 MO

IO-22n

CL. 30

Between CO4 (male) (2) andchassis


Between CO5 (female) (9) andchassis Min. 1 MO

\Troubleshooting 5: Between CO5 (male) (1) - (3) (2) - (4) (6) - (8) (7) - (9)

IMax. 10 I

I I I

C-2 Related electric circuit diagram

co4

TVC prolix switch

1Prolix resistor

II I II II I I I 1 1

(X2) -

Rear ump c- a

Tvc valve _ G-

X08DD143

20-I 73

0



TROUBLESHOOTING c-3

C-3 [E2:33] Disconnection in front pump TVC solenoid system isdisplayed[E2:37] Disconnection in rear pump TVC solenoid system isdisplayed

*

*

*

****

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid.If the No. 2 pin of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues to flowto the solenoid.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:33or E2:37 are displayed. (If they are not displayed, the problem has been removed.)Always turn the TVC prolix switch OFF.Before carrying out troubleshooting, check that all the related connectors are properly insertedAlways connect any disconnected connectors before going on to the next step.Check that fuse 1 is normal.

3 YESIs esistance

YES between each pin2 - for troubleshooting -

3 in the table 1Is resistance ’ normal?

YES between each pinP for troubleshooting - T” rn starting

NO-GotoA

1 2 n the table 1 switch OFF.

P normal? * Disconnect CO1interchange wiringwith other NC -Turn startingsolenoid. Is - switch OFF.applicable service Disconnect CO4 or

NOcode displayed? C13, whichever is

applicable.* Turn starting

switch OFF. V* Interchange wiring. NO

*Turn startingswitch ON again.

Y:

A,--p\* Turn starting

switch OFF.*Disconnect 05.

between each pinfor troubleshooting5 in the table 1

Turn startingswitch OFF.

*Disconnect Cg5.r10

IO


4pplicable NC solenoid is defective

disconnection in applicable one of

wiring harness between CO1female) (16) and CO6 (female) (1).301 (female) 16) and CO5 Ifemale (2:F pump NC) or wiring harnesswween CO1 (female) 117) and CO5Ifemale) 16). CO1 Ifemale) (91 andt05 (female) ( 7) (R pump NC). ordisconnection in applicable one ofwiring harness between CO1Ifemale) (3) and CO5 (female) (2) (Fpump). or CO1 (female) (9)and CO5 (female) 17) (R pump)

Defective prolix switch, ordisconnection in applicable one ofwiring harness between NC prolixswitch - CO5 (female). ordisconnection in applicable one ofwiring harness between CO5(female) (2) -NC prolix switch (Fpump) or CO5 (female) (7) -NCprolix switch (Fi pump)

Disconnection in applicable one ofwiring harness between Cl3(female) (1) and CO5 (female) 13).Cl3 (female) (2) - CO5 (female) (21 (pump NC solenoid), ordisconnection in applicable one ofwiring harness between Cl3(female) 12) and CO5 (female) 14) (Fpump solenoidl. or disconnection iapplicable one of wiring harnessbehween CO4 (female) (2) and CO5(female) (9) (R pumpNC solenoid)or applicable one of wiring harriesbehveen Cl3 (female) (2) and CO5(female) I41 IF pump solenoid1wiring harness between CO4(female) (2) and CO5 (female) 19) (Rpump NC solenoid) shortcircuiting with ground

?place

eplace

epair orrplace

lepair oreplace

iepair oreplace

20-I 74

a



‘ able 1

Service code Measurement location Resistance

Service code Troubleshooting 2 Troubleshooting 3 Troubleshooting 4value

Between Cl 3 (male) (1) and Between CO1 (female) (16) and Between CO5 (female) (3) and

(2) (8) (4)IO-220

E2:33Between Cl 3 (male) (2) and Between CO1 (female) (8) and Between CO5 (female) (4) andchassis chassis chassis

Min. 1 ML?

E2 : 37

Between CO4 (male) (1) and

(2)

Between CO4 (male) (2) andchassis

Between CO1 (female) (17) and

(9)




IO-220

Min. 1 MQ

Troubleshooting 5: Between CO5 (male) (1) - (3) (2) - (4) (6) - (8) (7) - (9) I Max. In


TVC prolix switch

i j ’I Illrrllrl Prolix resistor

0 c c c cF R F I?

1-J (-) (t) f+)

co1

(MICl'?)

X08DD143

20- 175

a



TROUBLESHOOTING C-4

C-4 [E2:03] Short circuit in swing brake solenoid system is displayed


* If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the swing, and checkif E2:03 is displayed. (If it is not displayed, the problem has been removed.)

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.

* Always connect any disconnected connectors before going on to the next step.* Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.

3

_ __. _- .__etwen ~04 ~rna~e\I - Turn startina

111 I .TUTurn star+- SW

solenoid. Is E2:03swi+ak nr

*Dis..,,,,,,

switch OFF.-

1 1z&% in’ T%le l? 1 1 *Disconnect Ol.rn swing lockIitch OFF.,,I ,y

.c, , GF.“ ^“ -ct vo4.

NO

YES

cOGo to A

. Turn startingswitch OFF.

- Interchange wiring. NOTurn startingswitch ON again.

5 YES

A--

Is resistance

Is resistance betweenye X05 (female) (4) and

4- chassis, and between -

V04 (male) (2) andchassis normal?

between X05 _ . Turn starting NO(male) (4) and (3) switch OFF.normal? Disconnect X05 and V04.

* Resistance value: Min. 1 MR*Turn starting I

switch OFF.- Disconnect X05.

NO* Between (4) and

(3): Max. 1 R

V04 (male) CO1 (female) Resistance valueI I

Between (1) and (2) Between (IO) (11)and (13)

20-60C

Cause

lefective pump controller

refective swing brakeolenoid

:ontact of power sourcetiring harness with wi ringarness between X05female) (3) and CO1 female:13)

:ontact of power sourcefiring harness with wiringlarness between X05femaleh4) and V04fmale) (2

Defective swing lock switch

Contact of power sourcewiring harness with wiringharness between X05(male) (4) -swing lockswitch -X05 (male) (3)

;eplace

lepair oreplace

lepair oreplace

leplace

lepair oreplace

Between (2) and Between (13) andchassis chassis

Min. 1 MC

20- 176

a



TROUBLESHOOTING C-4


Pump controller

Cl

Swing lock prolix switch Swing lock switch

GND

*v4

Swing brake H4

Fuse X08DD144

20-I 77

0



TROUBLESHOOTING c-5


Pump controller

ClI I

Swing lock prolix switch Swing lock switch

Swing brakesolenoid valve

Hl

I H4

1

Fuse X08DD145

20- I 79a



TROUBLESHOOTING C-6

C-6 [E2:02] Short circuit in LS select solenoid system is displayed[E2:04] Short circuit in pump merge-divider solenoid system isdisplayed[E2:05] Short circuit in 2-stage relief solenoid system is displayed[E2:06] Short circuit in travel speed solenoid system is displayed

*

*

**

This troubleshooting is carried out when there is still an abnormality, so when disconnecting the

connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if anyservice code is displayed. (If it is not displayed, the problem has been removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

3 YES

Is resistanceYE between each pin2 - fortroubleshooting -_ 3 in the table 1

Is resistance normal?YES between each pin

for troubleshooting - * Turn starting NO

1 2 in the table 1 switch OFF.normal? *Disconnect COI.

‘ 1Interchange wiringwith other solenoid.Is applicable service

*Turn startingswitch OFF.

*Interchangewiring.

* Turn startingswitch ON again.

.Turn startingswitch OFF.

- Disconnectconnector V02, VO3, V05,or V06, whichever ISapplicable.

NO

Table 1

Cause

Defective pump controller

Contact between wi ringharness for power sourceand applicable wiringharness between solenoid(2) and controller.

One of following solenoids isdefectiveE2:02 . LS select solenoidE2:04 . .Pump merge-divider

solenoidE2:05 . 2-staoe relief

solenoidE2:06 . Travel speed

Service codeTroubleshooting 2

Measurement location

Troubleshooting 3

E2 : 02Between V02 Between CO1 (female) (IO), (11) and (3) 20 - 60 0

(male) (1) and (2)20-60Q

Between CO1 (female) (3) and chassis Min. 1 MQ

E2 : 04Between V03 20-60 J

Between CO1 (female) (IO), (1 I), and (4) 20 - 60 0

(male) (1) and (2) Between CO1 (female) (4) and chassis Min. 1 M J

E2 : 05Between V05 20-600 Between CO1 (female) (IO), (11) and (14) 20 - 60 0

(male) (1) and (2)Between CO1 (female) (14) and chassis Min. 1 MCI

E2 : 06Between V06 20-60fI

Between CO1 (female) (IO), (11) and (6) 20-60L2

(male) (1) and (2)Between CO1 (female) (6) and chassis Min. 1 MfI

lepair oreplace

lepair oreplace

teplace

20- 180

a



TROUBLESHOOTING C-6


Pump co1controller MIC17)

LS select

Pumpnerge-divider

rravel speed

VB

VB

Z-stage relief

I-El -HO2

,s

@\

-LS select

1

Travel speedsolenoid valve

Fuset- 1

’O4(SlS)

II

VO6(X2)

X08DD146

20- 1810



TROUBLESHOOTING c-7

C-7 [E2:12] Disconnection in[E2:14] Disconnection indisplayed[E2:15] Disconnection indisplayed[E2:16] Disconnection indisplayed

LS select solenoid system is displayedpump merge-divider solenoid system is

2-stage relief solenoid system is

travel speed solenoid system is

*

*

*

***

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If there is a disconnection in the solenoid or wiring harness, the solenoid is not actuated.If the No. 2 pin of the solenoid is short circuiting with the ground, the solenoid continues to be actuated.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON, operate accordingto Condition 2 in Table 1, and check if any service code is displayed. (If it is not displayed, the problem hasbeen removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.Check that fuse 1 is normal.

3Isvoltage between

ya each pin for2 - troubleshooting 3 F GotoA

in the table 1Is resistance normal?

YJZJ between each pinfor troubleshooting - Turn starting

1 2 in the table 1 switch ON.- normal? . When ON: Max. 3V

When OFF: 20 - 30VInterchange wir ingwith other solenoid.

. Turn starting Operate according to Condition 1.

Is applicable service - switch OFF. NOcode displayed? Disconnect

connector VO2,.VO3, VO5,or V06, whichever is

-Turn startingswitch OFF.

applicable. t* Interchange wi ring. NO-Turn starting

switch ON again.- Operate according

to Condition 2. 5 YES

Is applicable

Is resistance Turn starting NObetween each pin switch ON.

- for troubleshooting -4 in the table 1

. Operate

NO normal?according toCondition 2. )

*Turn starting NO

switch OFF.* Disconnect COl.

Cause

kre of following solenoids islefectivei2:12 . LS select solenoidL2:14 Pump merge-divider

solenoidi2:15 . . 2-stage relief

solenoidi2:16 . Travel speed

solenoid


Disconnection in applicablewiring harness between CO1female) (101, 11) - CO1 31,4), (14) or (6). or applicablewiring harness betweensolenoid (2) - CO1 3). (4).14) or (6) shortcircuitingnrith ground

ieplace

leplace

tepair oreplace

20- 182

0



TROUBLESHOOTING c-7

able 1

1easurment location

jetvicecode Troubleshooting 2

Troubleshooting 3 Condition 2

Voltage between eachI

Troubleshooting 4 Ipin Condition 1 I

Betweeni2:12 V02 (male)

(1) and (2)

When ON: same as

20 - 60 n Between CO1 (female)(3) and chassis lever slightly to RAISE position

chassis * (Note)


(1) and (2)20-60f2 Between CO1 (famale)

(4) and chassisWhen OFF: Whencontrol levers are atneutral in modeother than L/O

Set working mode switch toL/O mode


(1) and (2)20-60f2 Between CO1 (female)

(14) and chassis

When ON: same as (femate) (lo),

~~ Turn wingockwitchN

1Between CO1 I~ I

Betweeni2:16 VO6 (male)

(1) and (2)20 - 60 0

When ON: same asBetween CO1 (female)(6) and chassis

chassis

lote: When the accumulator is charged, it is pos si ble to carry out the same operation with the starting switch ON.


Pump CO1controller (MICl?)

LS select

Pumpmerge-divider

Travel speed

VB

VB

- LS select

solenoid

03(X2)

Z-stage relief

‘ 05(X2)

FuseHO4

(S16)

A07 X08DD146

20- 183

a



TROUBLESHOOTING C-8

C-8 [E2:17] Model selection input error is displayed* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the

connector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.

* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:17is displayed. (If it is not displayed, the problem has been removed.)

* Before carrying out troubleshooting, check that all the related connectors are properly inserted* Always connect any disconnected connectors before going on to the next step.

YES1

Is monitoringmode display ofpump controller as -shown in Table l? 2 YES

_ Is esistance* Turn starting between CO2

switch ON. - (female) U3), (14). -*Set to monitoring NO (15). (16) -GND as

code 02,22. shown in Table 2?

A

* Turn starting NOswitch OFF.* Disconnect C02.

Table 1 Monitoring display (Time display portion)1 I

.:ONO:OFF

I

Condition of engineI

Engine throttlethrottle controller input controller model code I


Cause


Defective model selectionconnector, or disconnection,short circuit with ground, or

short circuit in applicablewiring harness

Remedy

Replace

Repair orreplace

Table 2 Resistance value

Applicable wiringharness

Between CO2 (female)(13) and GND




PC200 PC220PC210 PC250

Min. 1 MQ Max. 1 0

Min. 1 MQ Min. 1 MD

Max. 1 D Max. 1 0

Min. 1 MD Min. 1 MD

CO2( 040-20.) CO9(S8)z:LE8E”2

PC220

X08DD147

20- 184

0



C-9 [E2:18] Network response overtime error is displayedj, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the


* If the starting switch is turned ON when there is a disconnection in the wiring harness between the monitorpanel and the controller, or the positive end (+) of the network wiring harness or the inside of the controllerare short circuited, the controller cannot carry out networking, so the monitor panel does not display anyabnormality.

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

When E2:18 is displayed independently

YES

Y

1

Disconnectconnector C03, thenconnect it again. -Does service codedisplay go out?

2*Turn startingswitch OFF. Is connection of

* Disconnect engine throttle;,“ ;c;;or, then NO cCJsT;;:;;?

connector again.Turn startingswitch ON.


- Sz;~o;OnitoringN controller light up

- Turn startingswitch ON.

When E2:18 and E3:Ol are displayed simultaneously

1Disconnectconnector PO2 thenconnect it agam. -Does service codedisplay go out?

YES2

*Turn starting Is there continuity

switch OFF. _ between PO2Disconnect NO 3 YESconnector, then

pNn$;e) (7). (8) and

connectConnect connectors

- removed in Item 2connector again.

* Turn startingTurn startingswitch OFF.

_ one at a time. Is there

switch ON and Disconnect P02,NO continuity betwean

PO2 female) (71, 81delete service C03, and EOl. and GND?code. Shake wiring

harness aroundTurn starting NO

controller whenswitch OFF.

checking for*Shake wiring harness around controller

continuity.when checking for continuity.Connect PO2 last.

Cause

Defective contact or matingof pump controller connect0co3



Defective contact, ordisconnection in networkwiring harness

See E-l

Cause

Defective contact or matingof monitor panel connector

Positive (+) end of networkwiring harness in contactwith ground

Controller which has beenconnected is defective

Iefective monitor panel

Repair orreplace

Replace

Repair orreplace

-

Remedy

Repair orreplace

Repair orreplace

qeplace

?elace

20- 1850



TROUBLESHOOTING c-9

Monitoring display (Time display portion)

n e ooau ‘ “oom

%

P

C;L) “ pump controbr connected”dwlay

Em “Engine throttle controller‘ - cu connected” display28

f

X08DD132


X08DD133

Check for the LED display for the engine throttlecontroller and pump controller from the direction

Engine throttle controller\/-C

of the arrow as shown in the diagram on the right.Note 1: Push the operator’ s seat down to the front,

then remove the two rear covers to check.Note 2: The LED display for the pump controller is

difficult to see, so use a mirror.

X08DD134

20- 186

0



TROUBLESHOOTING

C-IO [E2:22] Short circuit in LS control EPC solenoid system is

C-l 0

*

*

**

displayedThis troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E222is displayed. (If it is not displayed, the problem has been removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

2 YES,Is resistance

YES between CO1

1- (female) (15) - (7). -

_ (7) -chassis asIs resistance shown in Table l?between Cl0(male) (1) - (2). (2)

Turn starting NO--chassis s shown

switch OFF.

I in Table l? I- . __.Disconnect COl.


- Disconnect ClO.

Table 1

NO

Cl 0 (male) CO1 (female)

Between (1) and (2) Between (15) and (7)

Resistance value

7-140

Between (2) andchassis

Between (7) andchassis I

Min. 1 MfII

Cause

Defective controller

Contact of power sourcewiring harness with wiringharness between CO1;;rnale) (7) and Cl0 (female)

Defective LS control EPCsolenoid

C-IO Related electric circuit diagram

Pump controller

LS controlEPC valve

X08DD148

leplace

lepair oreplace

leplace

20-I 87

0



TROUBLESHOOTING C-l 1

C-II [E2:23] Disconnection in LS control EPC solenoid system isdisplayed

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if E2:23is displayed. (If it is not displayed, the problem has been removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

2 YES Defective controller ReplaceIs resistance_ II

YES between CO1

1- (female) (15) - (7), -

(7) -chassis asDisconnection in wiring

I- shown in Table l?harness between CO1

Is resistance(female) (15) and (7). or Repair or

between Cl0 _ Turn starting NO wirin g harness between CO1 replace

(male) (1) - (2) as switch OFF.(female) (7) and Cl0 jfemal e)

shown in Table l? Disconnect COl. ;Jo;Fdti circuiting with

ReplaceI’

. Turn starting Defective LS control EPCswitch OFF.

. Disconnect ClO.NO solenoid

Table 1

Cl 0 (male) CO1 (female) Resistance value

I Between (1) and (2) I Between (15) and (7) I 7-1421 I

C-l 1 Related electric circuit diagram

Pump controller

LS controlEPC valve

X08DD148

CO1 (ME211

LS-EPC +)

20- 188

0




C-12 [E2:24] Abnormality in front pump pressure sensor system isdisplayed[E2:25] Abnormality in rear pump pressure sensor system isdisplayed


* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON, start the engine,and check if any service code is displayed. (If it is not displayed, the problem has been removed.)


Remedyause

3 YES

ml-


. Disconnect C03.

I

NO


Disconnection in wiringharness between CO3(female) (l)- HO1 11) - CO8

(female) (3) (Front), betweenCO3 female) (2) - HO1 13) -CO7 female) (3) (Rear), orshort circuit with ground

Repair orreplace

Applicable pressure sensoris defective

Replace

n

* Run engine at high

switch ON.

1 nterchange wiring*Repeat arm relief. p


Disconnection in wiringharness between CO3(female) (3) (9) - HO1 14)(12) -CO8 ( female) (2) (1)(Front), CO3 female) (3) (10)- HO1 (14) (15) - CO7 female)(2) (l), or short circuit withground

Replacewith other pressure

cable service code

* Interchange

Turn startingswitch ON again.

. Run engine at

Repair orreplaceTurn starting

switch OFF.* ;go;;a co3,

NO

1p’ plicable pressure sensor

is defectiveReplaceNO

Table 1 I I

ServiceMeasurement location

code Troubleshootina 2 1 roubleshooting 3 1 roubleshooting 4 Troubleshooting 5

Between CO8(2) and (1)

Between CO3 (female)

Between CO3 (female)Min. 1 MC

I etween CO3 (female)(1) and (9)Between CO8

(3) and (1) Ietween CO3 (female)(I), (9) and chassis

Min. 1 MfI 18-28”

Between CO7(2) and (1)

(3). (10) and chassis’2), (10) and chassis

20- I 900




C-l 2 Related electric circuit diagramPump controller

(RI pressuresensor (4

24vtt

(F) pressuresensor

If% pressuresensor

l(S16) CO8tX3)

F pump pressuresensor

X08DD149

20- 191

a




C-13 [E2:26] Abnormality in pump pressure sensor power sourcesystem is displayed




1

* 18-28V

- Turn startingswitch ON. NC

I Cause

Defective rear pump Replace

.-IL

I

I

1

Isvoltage between I 1 I

Replace

1O3 (3) and (9)normal?tl d -1 Defective pump controller

*18-28V-N/#ii~~ H 1Turn startingswitch ON.

*Min. 1 MR*Turn starting

switch OFF.-* Digxyg;ct co3,

C-l 3 Related electrical circuit diagramPump controller

CO3 040-16) HOl S16) CO8 X3)

F pump pressuresensor

R pump pressuresensor

Remedy

Replace

Repair orreplice

X08DD149

20- 192

a



TROUBLESHOOTING c-14

C-14 [E2:27] Abnormality in engine speed sensor system is displayed* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the




Cause Remedy

2 YES

Is resistanceYES between CO31 (female) (6) - (14)

- normal?Is resistancebetween E07 _ *500- 1OOOR NO(male) (1) - (2)normal?

*Turn startingswitch OFF.

. nicmnnc.r+-n700- 1OOOR I

* Turn startingswitch OFF. NO

- Disconnect E07.


Monitor panel


Disconnection in wiringharness between CO3 Repair or(female) (6). (14) -E07 (1). (2) replaceor short circuit with ground

Defective engine speedsensor

Replace

Pump controller I ICO3(04016)

Speed sensorI-1

Speed sensor(+I

H03(S16) E08ISWP14) E07 (X2)

,@ Enginespeed

*@ sensor

X08DD150

20- I 93

0




C-15 [E2:28] Abnormality in auto-deceleration output system isdisplayed

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.When the auto-deceleration switch is ON.If the starting switch is turned OFF after an abnormality occurs, start the engine, operate the control lever(neutral ++ operated) with the auto-deceleration ON, and check if E2:28 is displayed. (If it is not displayed,the problem has been removed.)Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

CO3 5) and chassisas shown in Table


N

When CO3 s~ isconnected, isvoltage between -EOl (4) and (12) 3 YESnormal? Is resistance etween P Defective engine throttle

P CO3 (female) (5) and controller*8-12V ~ EOl (female) (41, and _- Turn starting

switch ON.NO between CO3 (female)

(5) and chassis as Disconnection in wiringshown in Table Z? harness between CO3

NO(female) (5) and 501 ffemale)t$oo;hort crrcurt wrthTurn starting

switch OFF.Disconnect CO3and EOI.

Cause

t--ES

I7 Defective pump controller ieplace

YES2

teplace

lepair oreplace

Table 1

~1

Auto-deceleration switchOFF, levers at neutral

O-IVI

Remedy

Table 2I I

Connector Resistance value

Between CO3 (female) (5)and CO1 (female) (4)

Max. 1 0I

Between CO3 (female) (5)and chassis

Min. 1 MC


X08DDl51

20- 194

0



TROUBLESHOOTING OF PUMP CONTROLLERINPUT SIGNAL SYSTEM

(F MODE)

* When the monitoring mode is checked, if the following input signals are not displayed or do not light up, carryout troubleshooting for that item.

Troubleshooting flow charts for each failure mode

F- 1F- 2F- 3F- 4F- 5F- 6F- 7F- 8F- 9F-l 0

F-l 2

Bit pattern 20-(l) Swing oil pressure switch does not light up . . . . . . . .Bit pattern 20-(2) Travel oil pressure switch does not light up _ . . .Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up .Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up . .Bit pattern 20-(5) Arm IN oil pressure switch does not light up . . . . . . .Bit pattern 20-(6) Arm OUT oil pressure switch does not light up . . . . .Bit pattern 21-(l) Bucket CURL oil pressure does not light up . . . . . . .Bit pattern 21-(2) Bucket DUMP oil pressure does not light up . . . . . . .Bit pattern 21-(3) Swing lock switch does not light up . . . . . . . _ . . .Engine speed is not displayed in monitoring code 10

. .

.. . . . .

. .. . .. . .. . .. . .. . .. . .. . .

. . .

. . .

. . .

. . .

. .

. .

. .

(abnormality in engine speed sensor system) . . . . . . . . . . . . . . . . . . . . . . .Bit pattern 22-(6) L.H. knob switch does not light up . . . . . . . . . . . . . . . . . . . .

...... 20-I 96...... 20-l 97

...... 20-I 98

...... 20-I 99

...... 20-200

...... 20-20 1

...... 20-202

...... 20-203

...... 20-204

...... 20-205

...... 20-206

20-I 95

a



TROUBLESHOOTING F-l

F-l Bit pattern 2041) Swing oil pressure switch does not light up* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the


* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.a Turn the swing lock ON before operating the swing lever.

* If there is no display when the lever is operated on one side, the PPC shuttle valve is defective.

1

Is voltage betweenCO2 (1) and chassis

Lever at neutral:

20 - 3ovSwing Levero,p,e:$ I+

Start engine.

3YE-sIs esistance betweenSO8 (female) (2) and

i” _ CO2 (female)Jl)normal, and IS circui t

- insulated fromIs resistance between chassis?SO8 (male) (1) and (2)*normal, and is circuit - Between SO8 and

~- NO1 nsulated from C02: Max. 1 Q

chassis? Between wiring harness and chassis: Min. 1 MC- Disconnect SO8 and C02.

Swing LeveroMpae:aY$ NO

Lever at neutral: Min. 1 MRStart engine.

- Disconnect S08.

tlt is also possible to fit a short connector and judge the condition.In this case, check the voltage between CO2 1) and the chassis inItem 1 on the flow chart.*If it is 20 - 3OV:

G? o YESlff;; 1;; than 1V:


jefective contact, orlisconnection in wiringlarness between SO8female) (1) and chassis

defective contact, short:ircuit with ground, or

lisconnection in wiringrarness between SO8female) (2) - HO4 7) - CO2female) (I)

M$ive swing oil pressure

t If the condition does notreturn to normal evenwhen the switch isreplaced, go to H-5.

F-l Related electric circuit diagram

Pump controller

CO2(04020) H04(S16) SOEJ(X2) _

Swingswitch

swmg oil pressure switch

L

XOBDD152

Replace

Repair orreplace

Replace

20- I 96

0



TROUBLESHOOTING F-2

F-2 Bit pattern 2042) Travel oil pressure switch does not light up* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the


* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.a Before operating the travel lever, check that the surrounding area is safe.

j, If there is no display when the travel lever is operated on one side, the PPC shuttle valve is defective.

Is voltage betweenCO2 3) and chassisnormal?

I

Is resistance betweenSO1 male) (1) and (2)

Lever at neutral:20 - 3ovTravel Leveroperated:Max. 1 V

- Start engine.

3 YES

~

Between SO1 andC02: Max. 1 RBetween wiring harness and chassis: Min. 1 MQDisconnect SO1 and C02.

. Travel lever Ioperated: Max. 1 R NOLever at neutral:Min. 1 MQStart engine.

* Disconnect Sol.

*It is also possible to fit a shot? connector and judge thecondition. In this case, check the voltage between CO2 3)and the chassis in Item 1 on the flow chart.*Ifitis20-30V:

Go to YES* If it is less than 1V:

Go to NO

F-2 Related electric circuit diagram

Pump controller

CO2(04020) HOU(S16) SOl(X2)

-0

_:

bC

-Eia-c

i

Cause Remedy


lefective contact, orisconnection in wiringarness between SO1:emale) (1) and chassi s

befective contact, shortircuit with ground, or

,isconnection in wiringarness between SO2female) (3) - HO4 (11) SO1female) (2)

befective ravel oil pressurewitcht If the condition does not

return to normal evenwhen the switch isreplaced, go to H-5.

eplace

epair orzplace

:epair or

splace

leplace

Travel oil pressure switch

X08DD153

20-I 97

a



TROUBLESHOOTING F-3

F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not lightUP


a When measuring with the engine running, make sure that the work equipment does not move when the lever

is operated.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.* When mesuring with the engine stopped, charge the accumulator before starting.

YES

I


------+ IIs voltage between;i;;;\Fd chassrs

H_I. Lever at neutral:

20 - 3ov. Boom LOWER I

hy;.apt: NC

Start engine.

Defective contact, or3 YES disconnection in wiring

Is resistance between harness between SO4

SO4 (female) (2) and (female) (1) and chassism_ CO2 female) (2)2 normal, and is circuit

- insulated from Defective contact, short

Is resistance between chassis?_ circuit with ground, or

SO4 (male) (1) and (2) - BeWeen SO4 and Nodisconnection in wiring

normal, and is circuit - ~02: ~~~~ 1 Q harness between SO4

insulated from (female) (2) - HO4 (9) - CO2

chassis?. Between wiring harness and chassis: Min. 1 MR. Disconnect SO4 and C02.

(female) (2)

* Boom LOWER Defective boom LOWER oiloperated: Max. 1 0 NO pressure switchLeverat neutral: * If the condition does notMin. 1 MR. return to normal even

*Start engine. when the switch isDisconnect S04. replaced, go to H-5.

*lt is also possible to fit a short connector and judge the condition .tn this case, check the voltage between CO2 (2) and the chassis in ltem1 on the flow chart.*Ifitis20-30V:

Go TO YESllff;; leg than 1V:


Pump controller

CO2(040201 H04(S16) SOQ(X2) Boom LOWERoil pressure switch

XOSDD154

1I3place

epair orplace

epair ortplace

,eplace

20- 198

0



F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not lightUP


A When measuring with the engine running, make sure that the work equipment does not move when the lever

is operated.Sr Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.* When mesuring with the engine stopped, charge the accumulator before starting.

IIs voltage between 3 YESCO2 4) and chassis 7s resistance between

SO2 female) (2) andYES_ CO2 female) (4)2 normal, and is circuit

. &veg;neutral: insulated fromIS resistance between -chassis?

Boom RAISE SO2 male) 11 and (2)operated: - normal, and is circuit c

Beve;exSp2Cand No

Max. 1 V NO nsulated romchassis?

Be$een wiring harness and chassis: Min. 1 MD* Start engine. _ . Disconnect SO2 and C02.

. Boom RAISEoperated: Max. 1 R NOLever at neutral:Min. 1 MD

* Start engine.Disconnect S02.

tit is also possible to fit a short connector and judge the condition. .In this case, heck the voltage between CO2 4) and the chassis in hem1 on the flow chart.

If it i s 20 - 8OV:Go to YES

. lf$;; F; than 1V:


Cause


lefective contact, orisconnection in wiringarness between SO2Female) 1) and chassis

fefective contact, shortircuit with ground, orIisconnection in wiringlarness between SO2female) (2) - HO4 10) - CO2female) (4)

jefective boom RAISE oilBressure witcht If the condition does not


Pump controller

CO2(04020) H04(S16) SO2(X2) Boom RAISEoil pressure switch

X08DD155

Remedy

,eplace

;epair oreplace

iepair oreplace

teplace

20- 199

a



TROUBLESHOOTING F-S

F-5 Bit pattern 2045) Arm IN oil pressure switch does not light upj, This troubleshooting is carried out when there is still an abnormality, so when disconnecting the


A When measuring with the engine running, make sure that the work equipment does not move when the lever

is operated.* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

* When mesuring with the engine stopped, charge the accumulator before starting.

t

YES

3 YESIs esistance betweenSO5 (female) (2) and

YES ~ 2 (female) (5)

7rnormal, and is circuit

. Arm IN operated:Max. 1 V

. Start engine.

SO5 (male) (1) and (2)

S05: Max. 1 <I. Between wiring harness and chassis: Min. 1 ML

Disconnect CO2 and S05.

* Arm IN operated:Max. 1 (1 Nfl

* iever at neutral:Min. 1 M61

* Start engine.*Disconnect S05.

*It is also possible to fit a short connector and judge the condition.In this case, check the voltage between CO2 (5) and the chassis in Item1 on the flow chart.*Ifitis20-30V:

Go to YES* f it is less than 1V:

Go to NO


F-

.C

CC

:

[CC

i

-I

Cause

fefective pump controller

lefective contact, orlisconnection in wiringrarness between SO5female) (1) and chassis

Iefective contact, short:ircuit with ground, orjisconnection in wiringtarness between SO5female) (2) - HO4 (12) - CO2female) (5)

IDefective Arm IN oiloressure switch* If the condition does not


Pump controller

CO2(040201 H04(Sl6) SO5(X2) Arm IN

Remedy

eplace

epair orzplace

epair orsplace

leplace

XOSDD156

20-200

a



TROUBLESHOOTlNG F-6

F-6 Bit pattern 209(6) Arm OUT oil pressure switch does not light upSr This troubleshooting is carried out when there is still an abnormality, so when disconnecting the


a When measuring with the engine running, make sure that the work equipment does not move when the lever

is operated.j, Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

* When mesuring with the engine stopped, charge the accumulator before starting.

YES

I1

1s voltage betweenCO2 (6) and chassis -normal? YI

2Lever at neutral:20 - 3ov

* Arm OUToperated:Max. 1 V

* Start engine.

Is esistance betweenSo3 (male) (1) and (2)

- normal, and is circuit 'N3 nsulated from

chassis?

;~,“ ,.~rJ~ operated:

Lever at neutral:Min. 1 MQ

. Start engine.

. Disconnect S03.

@HiBetween ~02 and NOS03: Max. 1 RBetween wiring harness and chassis: Min. 1 MD

- Disconnect CO2 and S03.

*It is also possible o fit a short connector and judge the condition.In this case, heck the voltage between CO2 (6) and the chassis in Item1 on the flow chart.

Ifi& 1,“ ; than 1V:


Cause

jefective p ump controller

Iefective contact, orlisconnection in wiringrarness between SO3female) (1) and chassis

)efective contact, short:ircuit with ground, orjisconnection in wiringiarness between SO3female) (2) - HO4 (8) - CO2female) (8)

Iefective arm OUT oilsressure switch* If the condition does not


Pump controller

CO2(04020) H04(Sl6) SO3(X2) Arm OUToil pressure switch

Remedy

eolace

lepair oreplace

repair oreplace

teplace

XOSDD157

20- 2010



F-7 Bit pattern 2141) Bucket CURL oil pressure switch does not light

*

a

***

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.When measuring with the engine running, make sure that the work equipment does not move when the lever

is operated.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.When mesuring with the engine stopped, charge the accumulator before starting.

Is voltage between;zZ;;I;nd chassis

Lever at neutral:20 - 3ovBucket CURLo,p,e:“ :“ ;: I

- Start engine.

YE

,I3 YE3

Is esistance betweenSO6 female) (2) and

YE_ CO2 female) (7)2 normal, and is circuit

insulated romIs resistance between chassis?SO6 male) (1) and (2)

_ normat, and is circuit _ ’ Between CO2 and No3 insulated rom SO& Max. 1 R

chassis? Between wiring harness and chassis: Min. 1 MRDisconnect CO2 and S06.

*Bucket CURLoperated: Max. 142. NOLever at neutral:Min. 1 MR.Start engine.

*Disconnect S06.

tit is also possible to fit a short connector and judge the condition.In this case, check the voltage between CO2 7) and the chassis in Item1 on the flow chart.

If it i s 20 - 30V:Go to YESIf it is less than 1V:Go to NO

Cause


lefective contact, orisconnection in wiringarness between SO6‘ emale) 1) and chassis

refective contact, shortircuit with ground, orisconnection% wiringarness between SO6female) (2) - HO4 14) -CO2female) (7)

refective bucket CURL oillressure switchI If the condition does not



Pump controller

CO2(04020) H04(S16) SO6(X2) Bucket CURLoil pressure switch

Remedy

eplace

epair orsplace

:epair orsplace

qeplace

XOBDD158

20-202

0



F-8 Bit pattern 2142) Bucket DUMP oil pressure switch does not light

*

a

***

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.When measuring with the engine running, make sure that the work equipment does not move when the lever

is operated.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.When mesuring with the engine stopped, charge the accumulator before starting.

1

Is voltage betweenCO2 8) and chassis

I 2Lever at neutral:20 - 3ov Is resistance betweenBucket DUMP

. ‘ HO7 male) (1) and (2)

zpeeye$ normal, and is circuitNO insulated from

Start engine. chassis?

$$vee;xC;2Dand NO

Bet&aen wiring harness and chassis: Min. 1 MC* Disconnect CO2 and S07.

* Bucket DUMP Iooerated: Max. 1 R NnLever at neutral: AT_Min. 1 MR.

*Start engine.Disconnect S07.

*It is also possible to fit a short connector and judge the condition.In this case, check the voltage between CO2 8) and the chassis in Item1 on the flow chart.*Ifitis20-30V:

Go to YES

If it i s less than 1V:Go to NO


Defective contact, short:ircuit with ground, orjisconnection in wiringiarness between SO7female) (1) and chassis

Defective contact, short:ircuit with ground, orfisconnection in wiringlarness between SO7female) (2) - HO4 13) - CO2female) (8)

Defective bucket DUMP oilxessure switcht If.the condition does not



Pump controller

Cl ( BBC171

BucketDUMP @switch

SO7(X2) Bucket DUMPoil pressure switch

XOBDD159

teplace

tepair oreplace

tepair oreplace

Replace

20- 203

0



TROUBLESHOOTING F-9

F-9 Bit pattern 2%(3) Swing lock switch does not light up*

***

This troubleshooting is carried out when there is still an abnormality, so when disconnecting theconnector and inserting the T-adapter, or when removing the T-adapter and returning the connectorto its original position, if the service code is not displayed, the problem has been removed.If the panel display is normal, go to M-22 when panel swing lock lamp does not light up.Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

YYES1 I


IReplace

Is voltage betweenDefective swing lock switch

CO2 (9) and CO1 (1) - Disconnection or short

(2) normal? 2 YES circuit with ground in wiring

Is there continuity1 harness between CO1

- between CO2(female) (1) ;2) and swing

. Swing lock switch lock switch (2)ON: Max. 1V - (female)_(g) and ‘ -

OFF: 18 - 28V NO swing lock switch Disconnection in wiring

. Turn starting (112 harness between CO2

switch ON. . Turn starting NO (female) (9) and swing lock

switch OFF.switch (1)

Disconnect C02.

F-9

COl(MIC17)Swung brakesolenoid valve

GNDIND

co2(04020)

\ I

Repair orreplace

Repair orreplace

Related electric circuit diagram

HOl(S16)

solenoid valve

switch

X08DD160

20-204a



TROUBLESHOOTING F-l 0

F-IO Engine speed is not displayed in monitoring code IO (abnormalityin engine speed sensor system)

* Before carrying out troubleshooting, check that all related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

YE

1

between CO3 female)(6) - (14). (81 chassisis normal, is circuit

. 500-1OOOR* Turn starting

switch OFF.Disconnect C03.

Cause

kES2

Defective adjustment ofengine speed sensor

Does condition3s ecome normal

r when engine speed 4 YESsensor is adjusted? P Defective pump COntrOkr

f See TESTING AND _Is voltage between

ADJUSTING. NO $t;;;\;nd ‘ 14)

Defective engine speed

. Measure in AC NO sensor

range.* 0.5-3v

(Reference)Low: 1.9v Defective contact, or

Start engine. Decel: 2.4V disconnection in wiring

3YES High: 2.79V harness between E07(female) (1) (2) - E08 (9) (10)

Is resistance between - HO3 (15) (16) - CO3 (female)E07tmale) (1) - (2). (2)

- -chassis normal, and -(6) (14) or between PO2

JO s circuit insulated(female) (14) (15)

from chassis?Defective engine speed._^

Between (1) andchassis: Min. 1 MR

- Turn startingswitch OFF.

- Disconnect E07.


. Between (1) and NV sensor(2):500-1OOOR

Remedy

4djust

3eplace

Replace

Replace

Pump controller

CO3(04016)

XOSDD161

20-2050



TROUBLESHOOTING F-12

F-12 Bit pattern 22-(6) L.H. knob switch does not light up* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the


* Set the working mode to G/O or H/O and the power max. /swift slow-down to the power max. position.j, When fuse 5 is not blown.* Before carrying out troubleshooting, check that all related connectors are properly inserted.jl Always connect any disconnected connectors before going on to the next step.

1

Is voltage between 3 YESCO2 181 andchassis normal? Is resistance

YES between terminals _

2L.H. knob switch

cUa,:“ Ob swrtch

ON: 20 - 30VOFF: Max. 1 V Is voltage of L.H. - NO- knobswitch inlet - - .H. knob switch

NO erminal normal? ON: Max. 1 ROFF: Min. 1 MD

Starting switch ION: 20 - 30V NO


Cause


Defective contact, ordisconnection in wiringharness between knobswitch - M23 (2) - M22 (2) -HO1 16) - CO2 female) (18)

Defective L.H. knob swi tch

Defective contact, ordisconnection in wiringharness between L.H. knobswitch-M23(1)-M22(1)-HO4 16) -fuse 5

Remedy

eplace

epair wiringarness

replace

lepair wiringlarness

20- 206

0



TROUBLESHOOTING OF HYDRAULICAND MECHANICAL SYSTEM

(H MODE)

Table of failure modes and causes for hydraulic and mechanical system ....................Pump merge-divider logicTroubleshooting flow charts for each failure modk’ ......................................

All work equipment, travel, swingH- 1 Speeds of all work equipment, swing, travel are slow or lack power .................H-2 There i s excessive drop in engine speed, or engine stall s ..........................H- 3 No work equipment, travel, swing move ........................................H-4 Abnormal noise generated (around pump) .....................................H- 5 Auto-deceleration does not work (when PPC shuttle valve is cause) .................H-6 Fine control ability i s poor or response is poor ...................................

Work Equipment H- 7 Boom is slow or lacks power . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . . .H- 8 Arm is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .H- 9 Bucket is slow or lacks powerH-IO Work equipment (boom, arm, bucket)‘&& not move (but irave; and’swing are normal) :H-l 1 Excessive hydraulic drift (boom, arm, bucket) . . . . . . _ . . . . . . . . . . . . . . . . . . . . . . . . .H-l 2 Excessive time lag (engine at low idling) . . . . . . . . _ . . . . . . . . . . . . _ _ . . . . . . . . . . .H-l 3 Lack of power when pressure risesH-14 Other equipment moves when single circuit ~s.relieveb’ : : : : : : : : : : : : : : : : : : : : : : : : : : : :H-l 5 In L/O, F/O modes, work equipment speed is faster that specified speed . . . . . . . . . . .

Compound operationsH-l 6 In compound operations, work equipment with larger load is slow ...................H-17 In swing + boom RAISE, boom RAISE isslow ...................................H-18 Inswing+armOUT,armOUTisslow .........................................H-l 9 In swing + travel, travel speed drops excessively .................................

Travel systemH-20 Travel deviation ..........................................H-21 Travel speed is slow ..........................................H-22 Steering does not turn easily or lacks power ....................................H-23 Travel speed does not switch or is faster than specified speed .....................H-24 Travel does not move (one side only) ..........................................

Swing systemH-25 Does not swingH-26 Swing acceleration is poor or swing speed isslow (both’ left and’r/ght\ bnedirec~dn b&jH-27 Excessive overrun when stopping swing . . . . . . . . . . . . . . . . . _ . . . . . . . . . . . . . . . . . . .H-28 Excessive shock when stopping swing (one direction only) . _ . . . . . . . . . . . . . . . . . . . _ .H-29 Excessive abnormal noise when stopping swing . _ . . . . . . . . . . . . . . . . . . . . . . . . . . .H-30 Excessive hydraulic drift of swing . . . _ . . . . . _ . . . . . . _ . . . . . . . . . . . . . . . . . . . . .H-31 Swing speed is faster than specified swing speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .20-208 20-211

. . . . 20-I 12

. . . . 20-I 14

. . . . 20-I 15

. . . . 20-I 15

. . . . 20-I 16

. . . . 20-I 16

. . . . 20-218

. . . . 20-220

. . . . 20-222

. . . . 20-223

. . . . 20-223

. . . . 20-224

. . . . 20-224

. . . . 20-224

. . . . 20-225

. . . 20-225

. . . 20-226

. . . 20-226

. . . 20-226

. .

. .

. .

. .

. .

. .

. .

. .

. .. . .

20-227 20-22820-23020-23220-232

20-23320-23420-23620-23720-23720-23820-239

20-207a



LE OF FAILURE MODES AND CAUSES FOR HYDRAULIC AND MECHANICAL SYSTEM

Parts causing failure

Piston pump Control valveFront Rear

? re’ief For For $

main front rear Pump merge. Regenerationdivider valve

Tg

unload pump pumpcircuit

valve 2”9

b sE 2

ailure mode

Speeds of all work equipment, swing, travel are slow or lack power A A AAA A0 OOAAAA H-l

There is excess ive drop in engine speed, or engine stalls 000 000 H-2

No work equipment, travel, swing move D a0 0 0 H-3

Abnormal noise generated (around pump) 0 0 0 H-4

Auto-deceleration does not work 0 H-5

Fine control ability is poor or response s poor 0 0 0 H-5

Boom is slow or lacks power 0 000 0 0 00 0 H-7

Arm is slow or l acks power Q 000 0 0 00 0 H-9

Bucket s slow or lacks power 0 0 0 H-9

Boom does not move 0

Arm does not move 0 0 H-1(

Bucket does not move 0 0

Excessive hydraulic drift 0 0 0 H-l ’

Excessive ime lag (engine at low idling) 0 0 H-l:

Lack of power when pre ssure rises 00 0 H-l:

Other equipment moves when single circuit s relieved 0 H-11

In L/O or F/O mode, work equi pment speed is faster han set speed 0 0 00 H-l

H l in compound operations, work equipment with larger load is slow 00 0 . H-l’In swing + boom RAISE, boom is slow

In swing + arm OUT, arm is slow 6 0 H-ll

n swing + travel, travel speed drops excessively _ 10 0 H-l

Travel deviationDeviation is excessive 0 00

H-2(Deviation s excessive hen starting

Travel speed is slow 0 0 0 0 00 H-2’

Steering does not turn or lacks power 0 0 000000 0 H-2

Travel speed does not switch or is faster than set speed H-2:

Does not move (one side only)< 0 H-21

Does not swingBoth left and right H-2One direction only 0 0

Swing acceleration s poor or Both left and right ‘0 0 000 H-2(swing speed is slow One direction only 0 0 00

Excessive overrun.when stopping Both left and rightswrng One direction only 0 0 0

H-2

Excessive shock when stopping swing (one direction only) 0 0 H-21

Excessive abnormal noise when stopping swing H-2

Excessive hydraulic drift of swingWhen br ake is ON

-When brake s OFF

Swing spee d s faster than specified swing speed. _.. . _ .

modes tor compound operatrons are useohe tarlure modes,

20-208a

H-3(0 0

0 0 0, H-3’_. . ..,. _* . .~ . ~_. mI.L __ --I- *-__* __I _-_

operatrons are normal. A : wnen mere Is an aonormarny ror oorn nom ano rear

FOLDO



TROUBLESHOOTING PUMP MERGE-DIVIDER LOGIC

PUMP MERGE-DIVIDER LOGIC

Categon/ Flow divided Flow merged Flow divided Flow merged

Mode

Boom/swing priority selection mode OFF Boom/swing priorin/ selection mode ON

Pump merge-divider solenoid ON Pump merge-divider solenoid OFF P”mp merge-divider Pump merge-dividersolenoid ON solenoid OFF

L/o - All operations x

With travel ONIndependent operation of travel

* independent operation of swing

With travel ON*Except independent operation of

*Independent Compound operation

travel (compound operation with operation of travel with travel

travel) *Independent*Except independent operation of operation of boom,swing (compound operation withtravel)

arm, bucket,service, swing with

Operations A, B and C with travel Operations except operations A, B travel OFF, and

OFF and swing lock switch OFF and C with travel OFF and swing lock compound Operationswitch OFF of each of these

A Arm IN *Compound operation with

Swing + boom LOWERtravel

*Swing + bucket CURLSwing + arm IN*Swing + arm OUT

Swing + bucket DUMP *Swing + boom RAISE

xF/O *Swing + service

*Independent operation ofu boom

;*Arm IN + bucket CURL ai -Independent operation ofwhen condition is * d arm

P -Arm OUT + bucket DUMPii t *Independent operation of

5B and front or rear pump .o bucket

5 pressure more than 3.92Ii *Arm IN + bucket CURL5

MPa (40 kg/cm’ ) 2with pressure less than

-Arm OUT + service and14.7 MPa (156 kg/cm’ )or

5more than 24.5 MPa

front or rear pump :: (250 kg/cm’ ) (except * )pressure more than “.I *Arm OUT + bucket DUMP

19.6MPa (200 kg/cm’ ) and pressure less than3.92 MPa (40kg/cmz)

*Arm OUT + service andpressure less than

*For HYPER GX : 19.6 MPa (2OOkg/cm’ )C Boom priority 2 mode + boom -AlI others

RAISE + arm OUT

With travel ON

G/O Independent operation of travel

H/O* Independent operation of swing D*Operations B and C with travel

Except operation D

OFF and swing lock switch OFFI

With swing lock OFF: With swing lock OFF:

LS select *Separated for swing + travel, boom RAISE, arm OUT (solenoid ON), not *Separated for swing + travel (solenoid ON),

separated for other operations not separated for other operations (solenoidOFF)

x I ne pressure of tne tront or rear pumps is as tollows:

When pressure rises: 24.5 MPa (250 kg/cm%(For details, see Fig. 1)

When pressure goes down: 14.7 MPa (150 kg/cm?I

ON

OFF

B

------

fII

14.7 (150) 24.5 (250)

Pressure tMPatkg/cm%

Fig. 1 205Po6228_ -21 1

0



TROUBLESHOOTING H-l

H-l Speeds of all work equipment, swing, travel are slow or lackpower

* Carry out troubleshooting with the swing priority mode OFF and in the H/O mode.* Check that no abnormal noise is being generated from the main pump before carrying out troubleshooting.

(If there is any abnormal noise, carry out troubleshooting for H-4.)YES

5

Does conditionm_ become normal

when TVC valve isadjusted?

6 YES

Does condition

4 . See TESTINGbecome normal

AND - when servoNO

Is input pressure of ADJUSTING. assembly is

YE.6 servo pistonreplaced?

approx. 112 of main NO

3

~ Is output pressureof LS control EPC

d

valve normal?

* 0.2 2 0.2 MPa

pressure normal?

Is control pumpcircuit pressurenormal?

* Check andmeasure circuitoil pressure. Fordetails, seeTESTING ANDADJUSTING.

* See below7yEs

Does conditionbecome normal

- when servoNO assembly is

replaced?

* Distribution of NOservo (LS and TVC)and piston pump(servo piston)

(2 2 2 kg/cm’ )* Engine at high

. ZZelief

YES8 I

become normalwhen LS relief *un-load valve assembly

* 31.9 2 1.0 MPa(325 f 10 kg/cm21

* Engine at highidling

* Arm relief* Turn swing lock

switch OFF.

~31.9 + 1.0 MPa become normalwhen sub-unloadvalve is replaced?

idlrng _ I I*Arm relief

Turn swing lock-31.9 t 1.0 MPa kir----

.switch OFF.

(325 210 kg/cmz)* Engine at high idling

Arm relief* Turn swing lock switch OFF.

* Measuring servo piston inlet port pressureMeasure the input pressure to the large diameter end of the servo piston when the pressure rises and the armis relieved. (Approx. 17.64 MPa (Approx 180 kg/cm?)[Basically, the pressure at the large diameter end is approx. % of the small diameter end. For details, seeTESTING AND ADJUSTING.]

20-212

0



TROUBLESHOOTING H-l

Cause Remedy

Defective adjustment of NC Adjustvalve

Defective servo assembly Repair orreplace

Defective piston pump(servo piston)

Correct orreplace

Defective operation of LScontrol EPC solenoid valve

Replace

Defective operation of sub- Repair orunload valve replace

Defective operation of main Replacerelief valve

Defective hydraulicequipment in control pump

1 circuitAdjust or

(See TESTING ANDreplace

ADJUSTING)

20- 2130



TROUBLESHOOTING H-2

H-2 There is excessive drop in engine speed, or engine stalls

* Carry out troubleshooting with the swing priority mode OFF and in the H/O mode.* Check that the main relief pressure is normal.

Cause Remedy

YESI Clogged throttle inside servo CleanI 1or &gged filter inside servo

1,I IIs throttle insideservo or filterinside servoclogged?

3YES

Does conditionyEs become normal when

2- Tvc valve kWv0

valve assembly) s- replaced?

_ Is engine speed atNO arm relief normal?

NO

Defective lVC valve orMztive adjustment of TVC

Defective servo piston

I ’ I I- See below.

Adjust orreplace servovalve assembly

Replace (pistonpump assembly)

-

* Replace the servo valve assembly on the defective side with a new part, and if the engine speed is lower thanthe reference value below, carry out troubleshooting for S mode. If it is higher, it can be judged that the TVCvalve (servo valve assembly) is defective, so replace it.

Engine speed (reference) at arm relief when engine and pump are normal

ModelEngine speed at arm

reliefConditions

1 i E ~ 1 : .%~~l~~,“ ~~iti~~?N1: ~~~~ 111Measure the speed at the point where the drop in engine

speed is greatest when the arm cylinder is at the end of strokeand the lever is operated slowly to the full position.

20-214

a



H-3 No work equipment, travel, swing move

Y1

Is safety lock valveworking properly?

H-4 Abnormal noise generated

Cause

2mWhen main pump

pressure pickupplug is removed,does oil come out?

Defective control pump,control relief valve, ordefective control circuit

* Crank with NODefective damper

starting motor.

Defective operation of safetylock valve or safety locklinkage

I(around pump)

Cause

Is hydraulic tank oillevel normal?

Are there bubblesinside hydraulictank?

3 YES

\KH-Goto4

NO

Is suction strainer

- External object:Cloth, etc.

Is uction strainerclogged with metal

Defective hydraulic oil

Clogged by external object(cloth, etc.)

Defect inside pump

Operate for a short time andwatch for any change insymptoms

Lack of hydraulic oil

Remedy

leplace

ieplace

\djust

Remedy

teplacerydraulic oil

temove

3epair or,eplace

nspect again’depending on:hanges insymptoms)

Idd hydraulic a il

20-215

0



TROUBLESHOOTING H-5, H-6

H-5 Auto-deceleration does not work (when PPC shuttle valve iscause)

j, The control pressure for the travel and swing passes through the PPC shuttle valve and is supplied to the oilpressure switch.

*1YES

Does conditionbecome normal _when oil pressureswitch is replaced?

NO

H-6 Fine control ability is poor or response is poor

Defective oil pressure switch

Defective operation of PPCshuttle valve in applicablesystem (swing or travel)

Replace

Repair orreplace

Cause

Clogged throttle in LS circuit

Defective servo valveassembly (LS valve), ordefective servo piston

Remedy

Clean

Replace

20- 216

a



TROUBLESHOOTING H-7

H-7 Boom is slow or lacks power* When travel and swing speeds are normalIr Carry out troubleshooting with the swing priority mode OFF and in the H/O mode.

YI

1

switch for boom

. TreeJ;DGEMENT

. Note:If auto-decelerationis canceled whenboom RAISE orboom LOWER soperated, system isnormal.

Yl

2

Is output pressureof PPC (EPC) valve

* Min. 2.74 MPa(Min. 28 kg/cm21Engine at highidling

n

5Is relief pressure offront and rearpumps normalwhen boom RAISEcircuit is relieved?

P

31.9 + 1.0 MPa(325 * 10 kg/cm?Engine at highidling

normal, or does pres-sure compensationvalve piston move

Does control valvespool movesmoothly?

It is also possible tointerchange withother compensationvalve. I

After inspection, do

position.

* 4.9 5 219 MPa(50 + 30 kg/cm2)

. Engine at highidling

YES6

Dois LS shuttle,valve move

Hmoothly?

* Check LS shuttl e:c~R~i. travel and NO

.[ Front is low ]-

yEs [

Cigh ]-

NO C Low ]-

NO

NO

20- 218a



TROUBLESHOOTING H-7

d YES

Is operatingpressure normal ,when boom RAISEis being operated?

Defective boom cylinderpiston packing

. Pc200: NOW7& 5MPa ( 150+ 15kg/ cm ~

16. 7 + . 5MPa~170~15kg/c m2)- Engine ath$hidi i ng. Atmax.r eac , nol oad

- efective operation of boomholding valve

Defective operation of LSshuttle valve (LS shuttle forR.H. travel or bucket)

9YEs Defective operation of mainmerge-divider valve or LS

Is pump merge- merge-divider valvedivider solenoidvalve outputpressure normal?

Defective operation of pump*When boom is NO merge-divider solenoid valve

raised:0 MPa (0 kg/cm?

Defective boom holdingvalve or suction valve ofcontrol valve

Defective operation of boom Repair orholding valve replace

Defective operation of boomregeneration valve

Repair orreplace

Defective operation ofpressure compensationvalve or pressurecompensation valve piston

Repair orreplace

Defective operation ofcontrol valve spool

Repair orreplace

Defective PPC valve Replace

Defective boom RAISE orboom LOWER oil pressureswitch

Replace

Remedy

Repairorreplace

Repair orreplace

Repair orreplace

Repair orreplace

Repair orreplace

Replace

20-219a



TROUBLESHOOTINGH-8

H-8 Arm is slow or lacks power* When travel and swing speeds are normal* Carry out troubleshooting with the swing priority mode OFF and in the H/O mode.

n

r-----G

- Note:If auto-decelerationis canceled whenarm IN or arm OUTis operated, systemis normal.

Is output pressureof PPC vaii$ ‘ ..normal? -.

1Min. 2.74 MPa(Min 28 kg/cm*)

. Engine at highidling

Yl

Does control valve

Y

A

normal, or does pres-sure compensationvalve piston move

It is also possible tcinterchange withother compensationvalve.Note:After inspection, danot forget to returnto the originalposition.

31.9 f 1.0 MPa(325 t 10 kg/cm*)Engine at highidling

Check LS shuttle

boom, R.H. raveland bucket

1Rearislow ]-

NO

1oth front andrear are low

J

20-2200



Cause Remedy

7YJ3 Defective operation of armregeneration valve or arm Repair or

counterbalance valve replaceIs leakage from- arm cylinder

normal?

Max. 20 cc/minEngine at highidling

-

NODefective arm cylinder pistonpacking

Defective operation of LSshuttle valve (LS shuttle forL.H. travel, boom, R.H. ravelor bucket)

8YE-S Defective operation of mainmerge-divider valve or LS Repair or

Is pump merge- merge-divider valve replace

_ divider solenoidvalve outputpressure normal?

0 MPa (0 kg/cm’ ) NOArm lever operatedEngine at high idling

Defective operation of pump Repair ormerge-divider solenoid valve replace

Defective PPC valve

Defective arm IN or arm OUT‘ ~I pressure swatch

Replace

20- 221

0



TROUBLESHOOTING H-9

H-9 Bucket is slow or lacks power* When travel and swing speeds are normal.* Carry out troubleshooting with the swing priority mode OFF.

Is oil pressureswitch for bucketCURL, DUMPnormal?

. ;ree;fDGEMENT

Note: ’

If auto-decelerationis canceled whenbucket CURL orbucket DUMP isoperated, system isnormal.

*Min. 2.74 MPa(Min. 28 kg/cm*)Engine at highidling

NO

* Max. 20 cc/min* Et&e at high

NO

w&pP~;+; to+other compensationvalve.

- Note:After inspection, donot forget to return tothe original position.

Cause

refeciive operation ofontrol valve spool

refective PPC valve

defective bucket CURL orucket DUMP oil pressurewitch

refective operation ofafety-suction valve

defective bucket cylinder lepair orliston packing eplace

refective operation oflressure compensationalve or pressureompensation valve piston

lepair oreplace

leplace

Leplace

lepair oreplace

lepair oreplace

20-222

a



TROUBLESHOOTING H-l 0, H-l 1

H-IO Work equipment (boom, arm, bucket) does not move (but traveland swing are normal)

jr When boom, arm, and bucket are each operated independently.

Is output pressureof PPC’ alvenormal?

Min. 2.14 MPa(Min. 28 kg/cm21Engine at highidling

YESDefective control valve spool

NODefective PPC valve

H-II Excessive hydraulic drift (boom, arm, bucket)

YES1 1

Does speed ofdownwardmovement become -faster when lever is YES

operated? 2

See TESTING AND Does conditionADJUSTING. become normal

- ~oi~~;;$;ssible No when safetv-suction valve is 3YEsinterchanged? Is slipper seal of pree e GotoA

leakage ofcylinder. - sure compensation

* Max. 20 cc/minvalve ree of damage?

At relief N- Or does pressure orn- -- Engine at high idling

O pensatron alve pistonmove smoothly?

* his also possible o NOinterchange withother compensation valve.

- Note: After nspection, o not forget oreturn o the original position.

[ Arm, bucket ]

C Boom

Cause

Iefective hydraulic cylinderciston packing

Defective operation ofsafety-suction valve

Damaged slipper seal ofpressure compensationvalve, or defective operationof pressure compensationvalve piston

Defective control valve spool teplace

Defective operation of boomholding valve

Remedy

Repair orreplace

Remedy

leplace

lepair oreplace

iepair oreplace

20-223

0



H-12 Excessive time lag (engine at low idling)

compensation valvenormal, or does pres-sure compensation

1 t Note:See elow. I After inspection, do not forget to return to the original position.

NODefective operation of LScontrol EPC valve

3epair or.eplace

* Output pressure of LS control EPC solenoidAoorox. 2.06 MPa (Approx. 21 kg.cmZ) output from the LS control EPC solenoid when the engine is at low

Cause

Defective safety-suctionvalve, or defective boomregeneration valve

Defective safety-suctionvalve

Defective operation ofpressure compensationvalve or pressurecompensation valve piston

Remedy

TROUBLESHOOTING H-l 2, H-l 3, H-l 4

Replace

3epair or.eplace

. .idling (approx. 1306 rpm or below) regardless of the working mode.

H-13 Lack of power when pressure risesCause

* If condition is normal except when pressure rises.j, Carry out troubleshooting with the swing priority mode OFF. F-

switch normal?

Min. 2.74 MPa(Min 28 kg/en?)

/Omode

/iiEii&HLNO

Defective LS relief valve

Defective main relief valve

Defective operation of 2-stage relief solenoid valve

Operate eachcontrol lever, and ifauto-deceleration is NOcanceled, conditionis normal

1Defective oil pressure switch

h-rote: f PPC shuttle is normal)

Remedy

3eplaca

Xepair orpeplace

3eplace

H-14 Other equipment moves when single circuit is relievedCause Remedy

Defective operation ofI pressure compensation

valve slipper sealReplace

* The slipper seal in the pressure compensation valve of the circuit that moved is defective.

20-2240




H-15 In L/O, F/O modes, work equipment speed is faster than specifiedspeed

2 YE-S

Yl

1

Is oil pressurer-lormal whenpump is relieved?

* At arm reliefFront pump:Approx. 34.6 MPa(Approx. 355 kg/cm’ )Rear pump:Approx. 5.9 MPa N(Approx. 60 kg/cm?)

* At bucket reliefFront pump:

Approx. 5.9 MPa(Approx. 60 kg/cm’ )Raer pump:Approx. 34.6 MPa(Approx. 355 kgfcm*)

* Swing priority mode

Is output pressure

i of LS control EPCsolenoid valvenormal?

See below. NO

. Min. 2.7 MPa(Min. 28 kg/cm?

I* L/O mode

NO

Defective LS valve Repair orreplace


Repair orreplace

Defective operation of LSmerge-divider valve

Repair orreplace

Defective operation of mainmerge-divider valve

?epair or,eplace

Defective operation of pumpmerge-divider solenoid valve

qepair or,eplace

Remedy

* Output pressure of LS control EPC solenoid (travel OFF)Approx. 2.06 MPa (Approx. 21 kg/cm? is output from the LS control EPC solenoid when the engine is at lowidling (approx. 1300 rpm or below) regardless of the working mode.

H-16 In compound operations, work equipment with larger load is slow

Cause RemedyDefective operation of pressure

compensation valveReplace

(replace pressure compensation valve on side where load is lower)

Combination of compound operation Side where load is larger I

I I Boom RAISE + arm IN I Boomerang

2 Boom RAISE + arm OUT Arm OUT

3 Boom RAISE + bucket CURL Boom RAISE

I I Arm OUT + bucket CURL I Arm OUT-1

I I Boom LOWER + arm OUT I Arm OUT I

20-225

a



TROUBLESHOOTING H-l 7, H-l 8, H-l 9

H-17 In swing + boom RAISE, boom RAISE is slow* If swing and boom RAISE work normally when operated independently.* Carry out troubleshooting with the swing priority mode OFF.

Cause T

solenoid valve

*Min. 2.74 MPa(Min. 28 kg/cm*) p

- Operate boomRAISE (operatelever slightly)

Defective operation of LSselect valve

2 YES Defective operation of LS

Does LS shuttleselect solenoid valve

- valve move’ smoothly?

Defective operation of LS

NOshuttle valve (LS shuttle forboom RAISE, LS select)

Remedy

Repair orreplace

Repair orreplace

Repair orreplace

H-18 In swing + arm OUT, arm OUT is slow* See H-17

(

If the operation is normal when the swing and arm OUT are operated independently, carry out trouble-shooting with the swing Priority mode OFF. If the Cause column shows that there is defective operation ofthe LS shuttle valve, the cause is in the shuttle valve for the arm OUT and LS selec t.

H-19 In swing + travel, travel speed drops excessively

If the operation is normal when the swing and travel are operated independently. carry outroubleshootingwith the swing priority mode OFF. If the Cause column shows that there iS efective peration of the Ls

shuttle valve,_the cause is in the shuttle valve for the LS select.

>

>

20- 226

0



TROUBLESHOOTING H-20

H-20 Travel deviation

j, Carry out troubleshooting in the H/O mode.

a) When there is deviation in normal travel

3 YE3-II

n2

Check as anindividual part

- Output pressure:Min. 2.74MPa(Min. 28 kg/cm2)

- Difference inoutput pressurebetweenFORWARD andREVERSE:Max. 0.4 MPa(Max. 4 kg/cm?

- Engine at highidling

- Travel relief

Note 1:

Note 2:

1 Does control valve 1 1, spool move

smoothly?

NO

IO

5 YES-III Is OUtDUt Dressure I I

(shuttle bjock inletend) of PPCvalve normal?

H. Same conditionsas for Rem 1

NO

Remove PPC shuttle block inlet hose,fi;zzlP:er, and block tip.

NO

Cause

Defective travel motor Repair orassembly (Note 2) replace


Defective operation of traveljunction valve

Defective PPC shuttle

Defective PPC valve

Defective adjustment oftravel lever linkage

Repair orreplace

Repair orreplace

Repair orreplace

Replace

Adjust

If the adapter for blocking the circuit is not available, interchange swing with one of arm (IN), boom(LOWER), or bucket (CURL, DUMP).When measuring the speed of the travel motor under no load 9 Remove connector of LS control EPCvalve solenoid, and measure travel speed in Lo and Hi.

b) Excessive travel deviation when starting

I Cause Remedy

Defective operation of travelcounterbalance valve

Repair or replace

20-2270



TROUBLESHOOTING

H-21 Travel speed is slow

H-21

* Check that the spool of the travel PPC valve is moving the full stroke before carrying out troubleshooting.j, Carry out troubleshooting in the H/O mode.

1Is speed slow inboth FORWARD

1

and REVERSE, or isit slow in onedirection only?

Note 1:

Note 2:

I 1

* See JUDGEMENTTABLENote:If auto-decelerationis canceled whentravel is operated,system is normal

Y

4

[Slow in onedirection nly ]jF[

normal?

Is output pressureof LS control EPC l-lsolenoid valvenormal?

- Note 1 NO

- Difference inoutput pressurebetweenFORWARD andREVERSE: WithinMax. 0.4 MPa(Max. 4 kg/cm*)Output pressure:

f

Min. 2.14 MPa(Min. 28 kg/cm*)

* Engine at highidling

* Travel relief

NO

yl

6

compensation valvenormal, or does pres-sure compensationvalve piston move

.- It is also possible ointerchange with othercompensatron valve.

N~

- Note:After inspection, do,notforget to return to theoriginal position.

10 YES

Is output pressurem_ (shuttle block inlet

9 end) of PPC- valve normal?

Is lever of PPC. v&e) contacting

_ Same conditions es NOfor Item 4

stopper? - Remove PPC shuttle block inlethose, fit adapter, and block tip.(NOTF 2)

NO

Output pressure of LS control EPC solenoid (travel OFF) Approx. 2.06 MPa. (Approx. 21 kg/cm? is outputfrom the LS control EPC solenoid when the engine is at low idling (approx. 1300 rpm) regardless of theworking mode.When measuring the speed of the travel motor under no load ti Remove connector of LS control EPCvalve solenoid, and measure travel speed in Lo and Hi.

20-2280




Does condition_ become normal

when suction valve_

is replaced?

O

Cause

Defective operation of LSshuttle valve (for boom,bucket)


Defective travel oil pressureswitch

Defective operation ofcontrol valve suction valve

Defective travel motorassembly

Defective pressurecompensation valve, ordefective operation ofpressure compensationvalve piston


Defective operation of traveljunction valve

Defective PPC shuttle

Defective PPC valve

Defective adjustment oftravel lever linkage

Remedy

iepair orsplace

lepair or,eplace

3eplace

7eez-a

Iepair oreplace

lepair oreplace

iepair oreplace

tepair oreplace

lepair oreplace

leplace

rdjust

20-2290




H-22 Steering does not turn easily or lacks powerj, Carry out troubleshooting in the H/O mode.

2I I

Is it difficult to turnYES to both left and

- right, or is it difficult 8to turn in onedirection only?

1

Is travel oil pressureswitch normal?

See JUDGEMENTTABLENote:If auto-decelerationis canceled whentravel is operated,system is normal

k

-Difficult toturn to bothleft and right when relieved on

Pressure high only onside not being relieved

4 YES

p$;;pqj~H-

- in. 2.74 MPa NO(Min. 28 kg/cm’ )

- Engine at high idling* Set swing priority mode ON

Pressure high only on side being reli eved(oil pressure is normal)

[Both left and right high]

‘ Neither fron:

nor rearreach reliefpressure

I I

* Interchacye left andright spools.

YE

34.8 :::: MPa(355 ::: kg/cm?

* Engine at highidlingArm IN relief

Does not

c

[urn to left -or right

t -

IO

3

20- 230

a




I Cause

valve

Defective operation of pump iepair ormerge-divider solenoid valve eplace

1Defective operation of traveljunction valve spool

iepair oreplace

Defective operation of LScircuit check valve

lepair oreplace

Defective operation ofcontrol valve main circuitcheck valve (remains open)

iepair oreplace

Defective control valvesuction valve

ieplace

YESDefective travel motor check lepair or

eplace

-I 8 YESDoes conditionbecome normal

Defective travel motor safetyvalve

INO

t

See troubleshooting forH-13 Lack of power whenpressure rises

Defective travel oil pressureswitch

Remedy

Zonnect:orrectly

iepair oreplace

leplace

-

lepair oreplace

leplace

20-231

a



TROUBLESHOOTING H-23. H-24

H-23 Travel speed does not switch or is faster than specified speed* Carry out troubleshooting in the H/O mode.

Is travel oil

Is pump pressuresensor normal? NO

Using monitoringcode 11 and 12.

* En?;; at high NOMeasure pumppressure.See JUDGEMENT

TABLENote:If auto-deceleration

NOis canceled whentravel is operated,system is normal.

rable 1 Output pressure of LS control EPC valve

Lo Mi

i-I

i l

Cause

Iefective operation of travelspeed selector servo piston

3efective operation of travelspeed solenoid valve

Defective operation of LScontrol EPC valve

Defective pump pressuresensor

Dek;;;ive travel oil pressure

I

Hi

PC200 2.0 f 0.2 MPaPC21 0 (20 fi 2 kg/cm?

PC220 1.8 f 0.2 MPaPC250 (18 f 2 kg/cm?

2.0 f 0.2 MPa(20 h 2 kg/cm?

1.8 f 0.2 MPa(18 f 2 kg/cm?

0.2 f 0.2 MPa(2 + 2 kg/cm?

0.2 f 0.2 MPa(2 f 2 kg/cm?

RemarksEngine at high idlingTravel lever at fine control position (auto-deceleration canceled)

H-24 Trave #Idoes not move (one side only)

1

1

F Cause

Remedy

?eplace

Repair orreplace

Repair orreplace

Replace

Replace

Es . Defective final drive

3 YESDoes ondition

yEs become normal whenleft nd right suction -

2 valves of control valve- are nterchanged?

Is drain amount of NOtrrzaytor

Defective operation ofsuction valve of control valv

Defective counterbalancevalve, or defective operatiorof travel motor safety valve

Max. : 30 IlminEngine at high NO

Defective travel motor

idlingAt travel relief

eReplace

20-232

0



TROUBLESHOOTING

H-25 Does not swing

H-25

a) Does not swing to either left or rightCause Remedy

n

See JUDGEMENTTABLE_.- Note: hif autodecelerationis canceled whenswing is operated,

system is normal.

- Min. 2.74 MPa(Min. 28 kg/cm*)

- EI;te swung

. Tz+;F;s lock

IO

n.

Is PPC valveoutput pressurenormal?

NO

b) Does not swing in one direction

Min. 2.74 MPa(Min. 28 kg/cm*)CIcFte swmg

Tu&sw$g lock

Defective swing machinew Repair orreplace

Defective swing holding Repair orbrake or swing motor replace

Defective operation of swingbrake solenoid valve

Repair orreplace

DeIective swing oil pressure Replace

Cause

2YE.s

Does control valvespool movesmoothly?

Defective swing motor safetyvalve

NODefective operation ofcontrol valve spool

yk PPC valve

Remedy

Repair orreplace

Replace

20- 233

a




H-26 Swing acceleration is poor or swing speed is slow (both left andright, one direction only)

* Carry out troubleshooting in the H/O mode. YES

a) Swing acceleration is poor4

Does conditionyes become normal

- when servoassembly isreplaced?

5YE-s

3-

Is discharge

Does LS shuttle

YE3 pressure of front - valve move- pump normal

NO smoothly?

when swing isrelieved ?2_ NO

or in one direction

. [ Both left and right ] *Is dischargepressure of rearpump normal whenswing s relieved? H

Front pumpdischargepressure:28.9 f 1.5 MPa(295 * 15 kg/cm*)

NO

. Rear pumpdischargepressure when Iswing is relieved: NO1.8 2 0.2 MPa(80 t 20 kg/cm*)

* Flow chart when speed is slow

gr

Defective LS valve

7 Y

See STANDARD NOGo to Item 5 8,

VALUE TABLE.

n

6

[One direction only]

Min. 2.74 MPa(Min. 28 kg/cm*)Engine at highidlingTurn swing lockswitch ON (lock).

yes Does control valvespool move

7smoothly?

Is output pressure, fat shuttle block

end) of PPC valve_

normal?

compensation valvenormal, or does pres-sure cwnpensationvalve piston move

* It is also possible ointerchange ith othercompensation valve.

YES

IIO- Note:

After inspection, o notforget o return o theoriginal position.

IO

Same conditionsas for Item 6Remove PPCshuttle block inlet NOhose. fit adapter,and block tip.(Note)

Note: If the adapter for blocking the circuit is not available, interchange PPC hose of swing with one of bucket(CURL, DUMP), boom (LOWER), or arm (IN).

b) When swing speed is slowChange Item 2 marked with * under flow for a) Swing acceleration is poor, and omit Item 4 when carrying outtroubleshooting.

20- 234

0




Cause Remedy

Defective servo assembly Replace

v7i ikfkf~;swing motor 1Replace

1i Defective operation of LS Repair orshuttle valve fall LS shuttles) replace

Defective LS circuit check Repair orvalve replace

Defective main circuit check Repair orvalve replace

10 YESDoes condition become normal when

- left and right safety -valves of motor areinterchanged?

* It is also possible to NOmeasure reliefpressure of motor.

*Relief pressure: 27.4 -23.4 MPa (280 - 310 kg/cm*). Note: After inspection , do not forget to return to the original position.

Defective swing motor safety Replacevalve

Defective swing motor Replacesuction valve

Defective pressurecompensation valve, or Repair ordefective operation of replacecompensation valve piston

7Defective operation ofcontrol valve spool

Defective operat ion of PPCshuttle valve

1 Defective PPC valve

Repair orreplace

Replace

20- 235

0




H-27 Excessive overrun when stopping swinga) One direction only

Cause Remedy

3 YES - Defective swing PPC slowIs problem reversed return valve

YES when left and right

2- swmg PPC slow

return valves are

Is problem reversedinterchanged?

_ _YES when left and right

Defective PPC valve

- outout hoses of PPC -

Repair orreplace

Does control valve

smoothly?

Defective swing motor safety Replace

b) Both directions

Cause Remedy

I Defective swing motor Correct or replace

20- 2360




H-28 Excessive shock when stopping swing (one direction onCauseF

YE.SDoes conditionbecome normal whenleft and right swingPPC slow returnvalves areinterchanged?

NO

1 Defective swing PPC slowreturn valve (check valve)

Defective PPC valve

H-29 Excessive abnormal noise when stopping swing

become normalwhen safety valve YES

2

Does condition, becomenormal _

when suction valveis cleaned?

3YEs

Is dirt found inNO swing machinery?

NO

-c\I

-tS

-C

-c

Cause

Ie&ztive swing motor safety

pefective swing motor,uction valve

hsfective swing machinery

hafective lift check valve

0Remedy

Repair orreplace

Replace

Remedy

20- 237a




H-30 Excessive hydraulic drift of swinga) When swing brake is released

Is hydraulic dimexcessive in bothdirections or onedirection only?

-[One direction only]

3yE:Is problem

, eversed when leftand right safety

Hvalves areinterchanged?

NO

NO

{=I=-*[ Both directions ] from motor

20 I/minEngine at highidlingAt swing relief

b) When swing brake is applied

Cause 1

Defective swing motor safetyvalve

Defective swing motorsuction valve

Defective pressurecompensation valve, ordefective operation ofpressure compensationvalve piston

1yEs

Is output pressure- Defective operation of swing

of swing brakeholding brake

solenoid valvenormal? I

L

0.2 + 0.2 MPa(2 + 2 kg/cm*)TG;-rv//;g lock

Remedy

Replace

Repair orreplace

Repair orreplace

Replace

Repair orreplace

Repair orreplace

20-2380




H-31 Swing speed is faster than specified swing speed* Carry out troubleshooting in the H/O mode.

Yl

* 5.8 - 1.8 MPa(60 - 80 kg/cm*)

- Engine at highidling

p

At bucket relief

2 YES

Is LS control EPCsolenoid valveoutput pressurenormal?

* See Table 1. NO

3YEzi

Is pump merge-divider solenoid _

, valve outputpressure normal?

3.0 + 0.2 MPa NO(31 + 2 kg/cm?

*At swing relief. Turn swing lock

switch ON.

cause

lefective operation of LSalve

qeplace servosssembly

reeztive LS control EPC Repair orreplace

refective operation of mainTerge-divider valve or LSlerge-divider valve

Repair orreplace

tefective operation of pump Repair ornerge-divider solenoid valve replace

Table 1 Output pressure of LS control EPC valveEngine at high idling

H/O mode G/O mode

PC200 0.2 f 0.2 MPa 0.2 f 0.2 MPaPC21 0 (2 f 2 kg/cm? (2 f 2 kg/cm?

PC220 0.2 f 0.2 MPa 0.2 f 0.2 MPaPC250 (2 f 2 kg/cm? (2 + 2 kg/cm?

F/O mode

1.5 f 0.2 MPa(15.5 f 2 kg/cm?

0.2 + 0.2 MPa(2 + 2 kg/cm?

L/O mode

1.5 f 0.2 MPa(15.5 + 2 kg/cm?

1.5 f 0.2 MPa(15.5 + 2 kg/cm?

20-239

0



TROUBLESHOOTING OFMACHINE MONITOR SYSTEM

(M MODE)Action taken by monitor panel when abnormality occurs and problems on machine . . . . . . . . . . . . . . . 20-242 Machine monitor system cir cuit diagramroubleshooting flow charts for each failure.mobe’ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-243

M- 1M-2M- 3

M-4

M- 5M- 6

M- 7

M- 8M- 9

M-l 0

M-l 1

[El :Olr Abnormality in error data is displayed ........................................ 20-245

[El :02] Error in clock data is displayed ............................................. 20-245

[El :03] Short circuit in buzzer output or contact of 24V wiring harness with buzzer driveharness is displayed 20-245

When starting switch is turned ON; nbnk’df.the’lampsiigh; upor.3 seconds’ : : : : : : : : : : : : : : : 20-246a) None of the lamps on monitor panel light up. ..................................... 20-246b) Some of the lamps on monitor panel (gauge display, time display) do not light up ....... 20-246When starting switch is turned ON, monitor panel lamps all stay lighted up and do not go out . 20-247When starting switch is turned ON, items l ighted up on monitor panel are different frommachinemodel .............................................................. ..20-24 7When starting switch is turned ON, (engine stopped), CHECK items flash (Fl uid levels forCHECK items are at specified level) ................................................ 20-248

a) Coolantlevelflashes ........................................................ 20-248b) Engineoillevelflashes.. ................................................... ..20-24 9c) Hydraulic oil level flashes ..................................................... 20-249Preheating is not being used but preheating display lights up ............................ 20-250

When starting switch is turned ON and engine is started, CHECK items flash............... 20-251

a) Alternator system ........................................................... 20-251b) Engine oil pressure sensor system ............................................. 20-252When starting swit ch is turned ON (engine stopped), CAUTION items flash (but whencharge level, engine oil pressure do not light up) ..................................... 20-253a) Alternator system ........................................................... 20-253b) Engine oil pressure sensor system ............................................. 20-253When starting switch is turned ON and engine is started, CAUTION items flash (but whenthere is no abnormality in engine or CHECK items) .................................... 20-254a) Engine oil pressure flashes ................................................... 20-254b) Coolantlevelflashes ...................................................... ..20-25 5c) Coolant temperature flashes .................................................. 20-255d) Batterychargeflashes ........ . 20-256e) Fuellevelflashes ......................................................... ..20-25 6

M-l 2(a) When starting switch is turned ON (engine stopped), buzzer does not sound for 1 secondCAUTION items are flashing but buzzer does not sound ............................ 20-257

M-l 2(b) No abnormality is displayed on monitor but buzzer sounds .......................... 20-257M-13 Liquid crystal night lighting on monitor panel does not light up (Liquid crystal display is normal) 20-258 M-14 Coolant temperature gauge does not rise ........................................... 20-259

M-l 5 Coolant t emperature gauge does not give any display ( none of the gauge lamps li ght upduringoperation) ............................................................. ..20-26 0

M-16 Fuel level gauge always displays FULL ............................................. 20-261M-l 7 Fuel level gauge does not give display .............................................. 20-261M-18 Swing lock switch is turned ON (LOCK) but monitor panel parking display does not light up ... 20-262

M-l 9 Swing lock prolix switch is ON (prolix), but monitor panel parking display does not flash ...... 20-262M-20 Defective fuel level sensor system ................................................. 20-263

M-21 Defective coolant temperature sensor system ........................................ 20-264

M-22 Defective engine oil level sensor system ............................................ 20-265M-23 Defective coolant level sensor system .............................................. 20-266

M-24 Defective hydraulic oil sensor system ............................................... 20-267M-25 Working light, panel lighting do not light up, or switch is not being used but lights light up ..... 20-268

a) Working l ight does not light up ................................................. 20-268b) Panel lighting does not light up ................................................ 20-268c) Light switch is not being used but working light lights up ............................ 20-269

M-26 Wiper motor does not work or switch is not being used but wiper is actuated ............... 20-270a) Wiperdoesnotwork.......... .......... .......... .......... .......... .......20-27 0b) Wiper switch is not being used but wiper is actuated ............................... 20-272

20-241a



FOLDOUT 22

ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY’ OCCURS ND PROBLEMS ON M CHINE

User code Service code Abnormal system Nature of abnormality Condition when normal (voltage, current, resistance) Action by controller when abnormality is detected Problem that appears on machine when there is abnormality

1. Abnormality in internal memory1. Service code cannot be cleared- El:01 Abnormality in error data

2. Excess voltage (more than 36V) has occurred3. Low voltage (less than 12V) has occurred 1. When there is abnormality in engine throttle 2. Time becomes 0O:OO.

4. Connector has separatedWhen starting switch is turned ON, keep time controller, control cannot be carried out.

switch pressed for 5 seconds to actuate clear2. When there is abnormality in pump controller,

function the output is cut off, so control cannot be

1:Abnormality in internal clock function carried out.

El:02 2. Excess voltage (more than 36V) has occurred1. Service code cannot be cleared

- Abnormality in clock data3. Low voltage (less than 12V) has occurred

2. Time becomes 0O:OO.3. Clock does not advance.

4. Connector has separated

El:03

1. Short circuit inside buzzerVoltage between PO1 (13) - (11) (12)

Short circuit in buzzer 2. Power line in contact with wiring harnessBuzzer ON: Max. 1V

between monitor panel POl(13) -buzzerBuzzer OFF: 20 - 30V Buzzer does not sound

output system

3. Abnormality in monitor panel

*When there is disconnection, El:03 is not

displayed and buzzer does not sound

20-242a



MACt

Mon tor Dane1

C au t i on

buzzer

m

011

p&q%

\ R at te ry re la y

Battery

B uz ze r c an ce

PO(KES12)

w ndow washer

W iD er

contro

P um a c------

Eng ne o

level sensor

c oo a n t t em De ra tu re

ngincontro

Mode se lec t o n c onn ecto r

F ue l l ev el

E ng n e s De ec i se ns or

20

sensor

FOLDOUT 23



TROUBLESHOOTING M-l, M-2, M-3

M-l [El:Ol] Abnormality in error data is displayed

* This is not a mechanical failure.It is not an abnormality if this occurs when the system has been reset after disconnecting connector PO1 fromthe monitor panel, or after fuse 13 has blown, or after connector HO5 has been disconnected.

Turn the starting switch OFF. Then keep the time switch depressed, switch the starting switch ON again,and keep the time switch depressed for 5 seconds to return the system to normal.

M-2 [El:021 Error in clock data is displayedj, This is not a mechanical failure.

It is not an abnormality if this occurs when the system has been reset after disconnecting connector PO1 fromthe monitor panel, or after fuse 13 has blown, or after connector HO5 has been disconnected.

Turn the starting switch OFF. Then keep the time switch depressed, switch the starting switch ON again,and keep the time switch depressed for 5 seconds to return the system to normal.

M-3 [El:031 Short circuit in buzzer output or contact of 24V wirinharness with buzzer drive harness is displayed

* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if El :03is displayed. (If it is not displayed, the system has been reset.)


(male) I) - (21, 2)

Table 1

PO4 (male)

Between (1) and (2)

2 YES Defective monitor panel Replace

Yfi Is voltage between, - PO4 (2) and chassis -_ normal?

_ I startin g switch NO

* B&r ON: Max. 1 V

Contact of 24V wirin gharness with wiring harnessbetween PO1 (female) (13)and PO4 (female) (2). orcontact of wiring harness

betw een PO4 (1) and (2)

Repair orreplace

* Buzzer OFF: 20 - 30 V

NO1Defective buzzer Replace

Resistance value

200 - 300 n

Between (2) andchassis

Min. 1 MO

M-3 Related electric circuit diagram

XOBDOle3

20-245

a



TROUBLESHOOTING M-4

M-4 When starting switch is turned ON, none of lamps on monitorpanel light up for 3 seconds


a) None of the lamps on monitor panel light up

NO

. Voltage: 20 - 30 V* Turn starting

switch ON. NO


Monitor panel

POl(O4020)Power

a Fusesource

1 13a W

6 H05tM6)

GND @.

@--

g

X08DD164

b) Some of lamps on monitor panel (gauge display, time display) do notlight up

Cause


Iefective contact, orjisconnection in wiringiarness between fuse 13 -‘ 01 (female) (l)(2) or PO1female) (11)(12) - HO5 3)(4)-chassis round, or betweer

‘ use - PO1 6)

3lown fuse


Remedy

Replace

Repair orreplace

Iheck for cause>f blown fuse,:hen replace

leplace

20- 246

a



TROUBLESHOOTING M-5, M-6

M-5 When starting switch is turned ON, monitor panel lamps allstay lighted up and do not go out

Cause


Remedy

Replace

lighted up on monitor-6 When starting switch is turned ON, itemspanel are different from machine model


YES

1

Is display ofmonitoring code 01as shown in Tablel? 2

. Turn starting Do bits (I),, (‘ 2), 3)switch ON. _ of monitonng code .

*Set to NO 36 light up asmonitoring code shown in Table l?01

Turn starting* switch ON.

Set toh

monitoring code36

1 A

I ES

3 YES

Is voltage between_ PO2 4) (5) (6) -

10 chassis as shownm Table 2?

- Turn startino NOswitch ON.

able 1.:ON

D: OFF_ Table 2

Cause


Defective contact, ordisconnection in wiringharness of PO2 female) (4)

(5) (6)

Remedy

i-

Replace

Repair orreplace

Connector PO2

Between (4) - GND

PC200PC21 0

20-30V

PC220PC250

Max. 1 V

Between (5) - GND

Between (6) - GND

20-30V

Max. 1 V

20-30V

Max. 1 V

20- 247

0



TROUBLESHOOTING M-7

M-7 When starting switch is turned ON (engine stopped), CHECK itemsflash (Fluid levels for CHECK items are at specified level)

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.Ir Check that the coolant is at the specified level before carrying out troubleshooting.

4 63 coolant level) flashes

1Does display goout when shor t 3 YESconnector isconnected to PO8

Is continuity

(female)?ys between PO1

2 - (female) (17) and -

. Turn starting(3) as shown in the

switch ON. Is there continuitytable?

_ between PO8 . Connect ct disconnect NONO (female) (2) and short connector to PO8

chassis ground?(female).

* Turn starting switch OFF.

Turn starting* Disconnect POl.

switch OFF.- Disconnect P08.

NO

Table

Short connector Continuity

Connected I Yes

Disconnected I No

M-7 a) Related electric circuit diagram

POl(O4020)\ I

H03( 516

Monitor

1 POS(X

Cause

Defective coolant levelsensor (reservoir tank)system (see M-23)

Defective monitor panel Replace

Defective contact, ordisconnection in wiringharness between PO8(female) (1) - HO3 (11) - PO1(female) (10)

Defective contact, ordisconnection in wiringharness between PO8(female) (2) -chassis ground

2)Coolant level sensor

panel

Remedy

-

Repair orreplace

fW;reor

XOSDD165

20- 248

0



b) 0 (engine oil level) flashes

* Use the level gauge to check that the engine oil level is correct before carrying out troubleshooting.

Cause Remedy

3efective engine oil level

sensor system (see M-22)

-

When PO5 (female)(1) is connected to

2YEsIscontinuitybetween PO1(female) (18) and -fllLf12) as shown

. Connect PO5(female) (1) and 1chassis ground.Turn starting

in table? IIswitch ON. NODisconnect POl,

Connect tfdisconnect PO5

PO5 (female) (1) andchassis ground.Disconnect POl,PO5.Turn startingswitch OFF.

Table

teplace

Defective contact, ordisconnection i n wiringharness between W5(female) (1) - E08 (5) - (18)

lepair oreplace

M-7 b) Related electric circuit diagram

EOB(SWP14)orConnection with ground Continuity

Connected Yes

Disconnected

X08DD166

cl cl (hydraulic oil level) flashesRemedyause

Y1

5

When PO9 female)(1) is connected ochassif ground,cllte,s isplay go

Defective hydraulic oil levelsensor system lsee M-24)

. T~;x&tt$g

Disconnect w9.f

2YEsIs continuitybetween PO1

- (female) 13)) Ulh3) as shown in

the table?

Turn startingswitch OFF.Disconnect F’ Ol.

NO


Defective contact, ordisconnection in wiring

’ harness between PO9(female) (1) - HO2 15) PO1(female) 13)

M-7 c) Related electric circuit diagram

-

repair oreplace

Table

Hydraulic oillevel sensorOl(O4020) H02(516) PO9fXl)

Monitpanel

X08DD167

Between PO9 (female)and chassis

Continuity

Connected I Yes

Disconnected I No

20-249

0



TROUBLESHOOTING M-8

M-8 Preheating is not being used but preheating display lights up* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.

2YEs Defective monitor panel

yEs Is voltage between

1 - PO1 8) and chassis -_ ground normal? Contact of 24V wiring

Is voltage betweenharness with wiring harness

wiring of startings between starting switch

switch terminal Rl - Ov NO terminal Rl - HO3 21, or

and chassis ground TurTurctaarti.“ g between PO1 8) - HO3 2) -

normal?El1 (male) (1)

ov Defective starting switch* Turn starting NO (contact between terminal 8

switch ON. and terminal Rl)Disconnectterminal Rl.

M-8 Related electric circuit diagramHO3

Starting switch M 1 ( M4 ) Ell(X2) t24v

f

Monitor panel r relay

:-i

Electrical intakeair heater

Remedy

Replace

Repair orreplace

Replace

rfT XOSDD188

20-250

a



TROUBLESHOOTING M-9

M-9 When starting switch is turned ON and engine started, CHECKitems flash

* Before carrying out troubleshooting, check that all the related connectors are properly inserted.Ir Always connect any disconnected connectors before going on to the next step.j, Check both the alternator system and the engine oil pressure system.

a) Alternator systemCause

I I or above.26-30V

* Start engine andrun at half throttle

NO

or above.


Iefective contact, orkzonnection in wiringiarness between alternator:erminal R - E08 (2k- HO3 7)- PO2 female) (13). ordefective alternator

Defective alternator

Remedy

Replace

Repair orreplace

20-25 1

a



TROUBLESHOOTING M-9

b) Engine oil pressure system

* When engine oil pressure is normal

I Cause

When angina isrunning at low idlingand wiring harness of

.

oil pressure sensor sremoved, doesdis la o out?

. Engine at lowidling

2YESIs here continuitybetween PO1 16)

j (female) (17) and -chassis ground?

I I I

* Turn starting NOswitch OFF.Disconnect wiringharness PO1 of oilpressure sensor.


Defective oil pressure sensor Replace

Contact of chassis groundwith wiring harnessbetween PO1 (female) (17)- HO3 (13) - E08 (8) - o ilpressure sensorPO1 (female) (16) - HO3(12) - E08 (7)


PO2(04016) H03tS16) EOEterminal D

3(SWPl4) Altematc

Monitorpanet PO1 (04020)

Id-4 - I Pll

) i-y HOi) ,

I_

-nh

Engine oilpressure Sensor

Remedy

X08DD169

Repair orreplace

Replace

20-252

a



TROUBLESHOOTING M-l 0

M-IO When starting switch is turned ON (engine stopped), CAUTIONitems flash (but when charge level, engine oil pressure do notlight up)

**

4

Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.

Alternator system

-i.yIrIs voltage between

YES PO2 fema e) (13)1 ~MJSIS ground

_Contact of 24V wiringharness with wiring harness

Is voltage betweenalternator terminalR and chassisground normal?

. When engine isstopped: Max. 3 V

m urn startingswitch ON.

. .

NObetween alternator terminal

_ . When engineis R - E08 (2) - HO3 7) - PO2stopped: Max. 3 V (female) (13)Turn startingswitch ON.Disconnect P02. Defective alternator

NO

Remove wmngharness fromterminal R.

b) Engine oil pressure sensor system* When engine oil pressure is normal

7 YES_-- Defective monitor panelIs here cont$rity

yEs between wmng_ harness f Wl 17)Defective contact, or

_

1 (female) 16) and disconnection in Wiringe terminal of oil harness between oil

Is there continuity Pressure ensor? pressure sensor terminalbetween oil * - I38 (8) - HO3 (13) - i’ Of

- NOpressure sensor - Turn starting

terminal and switch OFF.(female) (17) PI1 ( 1138(7) - HO3 (12) - PO1

chassis ground? Disconnect POl. (female) (16)

Turn startingswitch OFF.Remove wiringharness from oilpressure sensorterminal.

Id/x__ oil pressure sense

Remedy

eplace

epair orIplace

leplace

?eplace

qepair or,eplace

Replace

20- 253

a



M-II When starting switch is turned ON and engine is started,CAUTION items flash (but when there is no abnormalityengine or CHECK items)


in

4

0(engine oil pressure) flashes

kl1

harness at terminal

sensor is removed,

. Engine at lowidling. B

B

I0Is there continuitybetween PO1(female) (17) - (11)(12)?

. Turn startingswitch OFF.

* Disconnect POl.

*NO

Cause

Defective engine oil pressuresensor

Contact of chassis groundwith wiring harnessbetween EO6 (male)(l) -HO3 (13) - PO1 (female) (171EO6(7) - HO3 (12) - FOI (16)


M-l 1 a) Related electric circuit diagram

HO3(S16) E08( SWP14 1\A “ A/ w\

:zor PO1 (04>20 1 /MC\ -2

Remedy

Replace

20- 254

0




b) r63coolant level) flashes

Cause Remedy

See Item M-7 a). -

cl 09 coolant temperature) flashes

Cause Remedy

2 YESWhen short Defective coolant -

ym connector is temperature sensor, F connected to PO7 - system (see M-21)

_ (female) does

Is coolantdisplay go out?

temperature _ -Start engine. NO Defective monitor panel Replacegauge in redrange?

. Start engineand run at half * Defective monitor panel Replacethrottle orabove.

M-l 1 c) Related electric circuit diagramPO2 HO3 E08(04016) (516) (SWP14 1 PO7(X2)

Coolant temperature sensor

Monitorpanel

X08DD171

20-2550




d) I_ (battery charge) flashes

2YF3

Isvoltage betweenF_ PO2 fema e) (13)

a+%~lc~;ss~s round_

Isvoltage between p _alternator terminal _ .20-30V NORand chassisground normal?

Start engine.

. 20-30VStart engine andrun at half throttle

~0

or above.

M-l 1 d) Related electric circuit diagram

PO2 HO3(04016) (516)

E08(SWP14)

Monitorpanel

0 Alternator terminal R

e) EBfuel level) flashes

* Check that there is fuel before carrying out troubleshooting.

Yl1

. Start engine andrrn,;;;;lf throttle

2 YES

When PO6 s’ emoved, does

display go out?-

. Disconnect P06.Start engine.

NO

Wait for approx. 2 minutes.t The fuel level may vary, so the display s given a time delay.

M-l 1 e) Related electric circuit diagram

PO2(04016)

lonitoranel

Cause


Defective contact, ordisconnection n wiring

harness between alternatorterminal R and PO2(femaleNl3)

Defective alternator

Cause

HO3(516) PO6(X1)

Fuel level sensor

Defective uel level sensorsystem (see M-20) orinterference with sensorinside uel tank



Remedy

Replace

Replace

Replace

X08DD173

20- 256

a



TROUBLESHOOTING M-12

M-12 (a) When starting switch is turned ON (engine stopped), buzzerdoes not sound for 1 second, CAUTION items are flashing butbuzzer does not sound

***

Before carrying out troubleshooting, check that all the related connectors are properly inserted.Always connect any disconnected connectors before going on to the next step.Of the CAUTION items, the buzzer will not sound even if there is an abnormality in the battery charge or fuellevel.

1YES

When PO1 female)(13) and chassi sare connected,fioe; zer

Tz;c;;arng NO


Disconnection in wiringharness between PO1(female) (13) - PO4 2) -buzzer, or between t24V -PO4 1) -buzzer t, ordefective buzzer

Replace

Repair orreplace

M-12 (b) No abnormality is displayed on monitor but buzzer sounds

1YEZ.S

When PO1 sremoved, doesbuzzer sound?

Remove POl.TJ-yct$g

NO


Cause I Remedy

Contact of chassis groundwith wiring harness betweenPO1 female) (13) and buzzer


PO1 POU(M2)

X08DD174

Repair orreplace

Replace

20-257

0




M-13 Liquid crystal night lighting on monitor panel does not light up(Liquid crystal display is normal)

* When the working light lights up normally.

Cause

wES

1Blown bulb or’ defectivecontact of bulb

Is bulb blown, or isthere defectivecontact? 2 yEsm Defective monitor panel

ARemove bulb.

Does bit (2) of

Check bulb- monitoring code 46 -

visually.NO light up? Defective contact, or

disconnection in wiring

NO harness between MO7 (male)(1)-X01 Ill-POl(female) (7)

M-l 3 Related electric circuit diagram

Monitor panel

POl(O4020)

X08DD175

R

R

Remedy

lepair oreplace

leplace

lepair oreplace

20- 258a




M-14 Coolant temperature gauge does not rise* Before carrying out troubleshooting, check that all the related connectors are properly inserted.* Always connect any disconnected connectors before going on to the next step.* If the coolant temperature actually does not rise, check the engine system.

1

nector is connectedto P07, do all gauge 2YF S

1 s here continuitv i 1

Ietween PO2 ’(female) and chassiswhen short l-l

. Turn startina NOswitch OFF.-

. Disconnect P02.

Defective coolanttemperature sensor system(see M-21)


Defective contact, ordiiconnection in wiringharness between PO2,(female) (12) - HO3 (6) - EOf(6) - PO7 (female) (A) or POi(female) (B) - E08 (11) - HO:fg3/o;;35 (4)(3) - chassis

Repair orreplace

M-14 Related electric circuit diagramPO2 HO3 E08(04016) (S16) (SWP14 1 PO7(X2)


Monitorpanel

-

X08DD171

20-259

0




M-15 Coolant temperature gauge does not give any display (none ofgauge lamps light up during operation)

When PO7 sremoved, doescoolanttemperature gauge ,_ 2 YESdisplay appear?

- Is there continuityTurn startingswitch ON.

_ betweenP02f12) _NO ;;gducnhF

- urn starting NOswitch OFF.

- k7connect P02,

M-l 5 Related electric circuit diagramPO2 HO3 E08(04016) (516) (SWP14 ) PO7(X2)

Monitorpanel

Cause Remedy

Defective coolanttemperature sensor system(see M-21)

Contact of chassis groundwith wiring harness betweenPO7 female)(A) - E08 (6) -HO3 6) - PO2 female) (6)



PO1(04020)

I I

a.

H05tM6)

X08DD171

-

Iepair oreplace

Ieplace

20- 260

0



TROUBLESHOOTING M-l 6, M-l 7

M-16 Fuel level gauge always displays FULL* Check if the tank is actually full before carrying out troubleshooting.

Cause Remedy

YES1

Defective fuel level sensor -system (see M-20)

When PO6 sremoved, does fuel _gauge displaydisappear?

2YE.sContact of chassis groundwith wiring harness betweenPO6 female) 11) HO3 5) -

Repair orreplace

^* Turn starting

Is there continuity PO2 female) (11)

switch-ON._ between PO2 11) _

- Wait for approx.NJ and-chassis

2 minutes.ground?

- The fuel level Turn starting NO Defective monitor panel Replacemay vary, so thedisplay is given a

switch OFF.

time delay.Disconnect P02,P06.

M-17 Fuel level gauge does not give display* Check that there is actually no fuel before carrying out troubleshooting.

Does displayappear when PO6(female)(l) and -chassis ground are 2connected? Is here continuity

- between m2 (female)

Turn starting_ (11)andchassisground

switch ON. NO when w6 (female) 1)and chassisgrwnd areccnnsctsd?

Turn starting NOswitch OFF.Disconnect P02,P06.

M-16, M-17 Related electric circuit diagram

Cause

PO2(04016)

Monitorpanel

HO3(516) PO6(XlI

Fuel level sensor

Defective fuel level sensorsystem (see M-20)


Defective contact, ordisconnection in wiringharness between PO6Ifemale) (1) - HO3 (5) - PO2(female) (11)

Remedy

-

qepair or.eplace

XOSDD173

20- 2610



TROUBLESHOOTING M-18, M-19

M-18 Swing lock switch is turned ON (LOCK) but monitor panelparking display does not light up

* Carry out this troubleshooting only if the swing lock is actually being actuated.

Cause Remedy

1YESIs voltage betweenPO2 9) and (16) as -shown in Table 11

. Turn startingswitch ON.

flE,


Disconnection in wiringharness between swing lock Repair orswitch 1) -X05 (1) - X01 (4) replace- PO2 female) (9)


P2 x01 Swing lock switch(040161 (MIC21) X05(M4)

11

2Monitor panel 3-b

4”w6, 205CAO6540

M-19 Swing lock prolix switch is ON (prolix), but monitor panel

parking display does not flash* Carry out this troubleshooting only if the swing prolix is actually being actuated.

Cause Remedy

1 YES

is voltage betweenPO2 3) and (16) as -shown in Table l?

Turn starting NOswitch ON.


Disconnection in wiringharness between swing lock Repair orprolix switch (4) and PO2 replace(female) (3)

Table 1 VoltageM-19 Related electric circuit diagram

Swing lock prolix switch ON Max. 1 V

Swing lock prolix switch OFF 20 - 30 v

205CA06541

20- 262a




M-20 Defective fuel level sensor system

Note 1: Difference between fuel level and gauge displayFor gauge display position 10 (F), the amount of fuel is 78 - 100%; and for display position 1 (E) it is below14.5%. If the chassis is at an angle, the displayed amount of fuel will be different from the actual amount.Therefore, when checking, stop the machine at a horizontal place and wait for at least 2 minutes beforechecking the gauge. (The display is given a time delay so that the gauge can deal with sudden changes inthe fuel level.)

* Remove the fuel level sensor when carrying out the troubleshooting.

YE

resistance betweenconnector (1) and

3 YESinterference with sensor Replace (Note 2)

m Is there any large’

2- crack, chip, or

damage to float?

inside tank

Does arm movesmoothly?

_P Defective contact ofNO connector

Clean connectoror replace

’ W/afl*sensor

Table 1

Top (FULL) stopper posit ion Max.lZRI

I I

Iottom (EMPTY) stopperposition

Approx. 85 - 110 RI

Replace

Replace sensor

Replace

Top (FULL)

Bottom (EMPTY)

F20205053

Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so be carefulwhen installing.

Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.

20- 2630




M-21 Defective coolant tern perature sensor system

YES1

Is esistance betweentemperature sensorconnector (male) (1) _and (2) as shown inTable l?

2yEs

- Check wiringharness visually. -

NO IS it broken?

NO

Table 1

Sensor

Connector

Cause

Iefective contact ofzonnector (Note 1)

Iisconnection in wiringlarness (Note 2) (defective:lamp) (external forceapplied)

3efective sensor

Remedy

:lean connectorir replace

ensor

leplace sensor

leplace

Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check theconnector and wiring harness at the chassis end.

Note 2: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.

20- 2640




M-22 Defective engine oil level sensor system

Note 1: Variations in oil levelThe oil level may change according to the angle of the machine, the engine speed, or the temperature ofthe oil, so if there is any display, check the oil level again with the machine at a horizontal place.

* Remove the engine oil level sensor when carrying out troubleshooting.

‘ I

resistance betweenconnector 11 andflange as shown in

Es

IOI I I

NO

Check wiringharness visually.Is t broken? H

I IINO

Cause

Defective movement of floatdue to dirt

Resonance of mount

Defective contact ofconnector (Note 2)

Disconnection in wiringharness (Note 3) (defectiveclamp) (external forceapplied)

Defective sensor

UP

lean

eplace sensorJote 4)

lean connectorr replace

,eplace sensor

leplace


Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check

for any vibration of the mount, and if there is excessive vibration, take the appropriate action.

20- 2650




M-23 Defective coolant level sensor system

Note 1: Variations in coolant levelThe coolant level may change according to the angle of the machine, or the swaying of the machine, so ifthere is any display, check the coolant level again with the machine at a horizontal place.

* Remove the coolant level sensor when carrying out troubleshooting.

YE

1

When float i s movedup and down, is

Etesistance between

connector (1) and (2)as shown in Table l?

P

Note 2:

Note 3:Note 4:

r1

Is any dirt stuck tomoving part offloat?

I ,piijiGJNO

I II

NO

Table 1

I Float UP Max. 1 Q

I Float DOWN Min.1 MD

ri==lloat

-II

I

,

Cause

Iefective movement of floatdue to dirt

Resonance of mount (Note 2

Defective contact ofconnector (Note 2)

Disconnection in wiringharness (Note 3) (defectiveclamp) (external forceapplied)

Defective sensor

F20205056

Iean


Replace sensor

If the problem occurs again, the connector (female) at the chassis end is probably defective, so check theconnector and wiring harness at the chassis end.Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.Defective installation is a possible cause, so be careful when installing. If the problem occurs again, checkfor any vibration of the mount, and if there is excessive vibration, take the appropriate action.

20- 266

0



TROUBLESHOOTING M 24

M-24 Defective hydraulic oil level sensor system

Note 1: Variations in hydraulic oil levelThe hydraulic oil level may change according to the angle of the machine, or the swaying of the machine,so if there is any display, check the hydraulic oil level again with the machine at a horizontal place.

j, Remove the hydraulic oil level sensor when carrying out troubleshooting.

YI

resistance betweenconnector (1) and

K

-r----G

IIINO

4YES

Check wiringaharnessvisually. -

Is it broken?

NO

befective movement of floatlue to dirt

-G lesonance of mount

C befective contact ofC nnector (Note 2)

_:Ca

hsconnection in wiringlarness (Note 3) (defectivelamp) (external forcepplied)

tefective sensor

Cause Remedy

Clean

Replace sensor(Note 4)


Replace sensor

Replace

Table 1

)I,

F20205055


Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again, check

for any vibration of the mount, and if there is excessive vibration, take the appropriate action.

20- 267




M-25 Working light, panel lighting do not light up, or switch is notbeing used but lights light up

a) Working light does not light up* Check that fuse 4 is normal.

Is resistancebetween MO7(fmrnl$ (1) and (2)

I

Connect 24V to pin(1). and connectpin (2) to ground.Max. ID

I t Disconnect R04.Ivrn light switch I

@IL. Checkvisually. NO

_. .Max. 1 R NODisconnect M07.

Cause

Iefective contact,lisconnection in lamp

lepair oreplace

kfective contact, or disconnection1 iring harness between MO7male) (2) -X01 (3) -fuse (4).etween MO7 (male) (1) -X01 (1) -IO4 11, RO4 (2) - HO5 (1) -chassi sIround, between RO4 (3) and fuse0). betw een RO4 (5) - HO2 (10) -flWfemale)ll) or between RO4(5) -102110) M Ot11 - MOS(female)1)

defective light relay leplace

defective light switch

b) Panel lighting does not light upj, When the lamp light up normally.

Cause

IYES

Is resistancebetween MO7(male) (1) -X01 (1) ---o~-;~maleH7)

Turn starting NOswitch OFF.

- F)slconnect M07,

Max. 1 R

Defective contact,disconnection in lamp forlighting inside monitor panel

Defective contact, ordisconnection in wiringharness between MO7 (male1(11 X01 (1) - PO1 female) (7

Remedy

leplace

Remedy

Repair orreplace

Repair or

20- 268a



c) Light switch is not being used but working light lights up

YE

1

~When MO7 sdisconnected, doesworking light lightup?

2I I

When R04 is IContact of 24V wiringharness or power sourcewith wir ing harness betweenMO7 (male) (1) -X01 (1) -R04 (1)

Defective light relay. Disconnect R04. NO* Min. 1 MR

0


Light switch

Defective light switch

LH decklamp

Rear lamp

Boom lamp,

RH decklamp

HO6

Floor

205CA06542

Remedy

3epair or.eplace

3epair orpeplace

Replace

20- 269a




M-26 Wiper does not work or switch is not being used but wiper isactuated

a) Wiper does not work* Check that fuse 7 is normal.

Wo8 (I) and (5)

Is resistancebetween Ml8Hfemale) (1) - (2).(1) - (4) as shownin Table l?


NC,

Is resistancem between WlO

1 1 * Disconnect M18.

20-30V

- (male) (3) (4) - W08 - ' urn tartingswitch ON.NO

1 (4) (18) normal?

Is resistance . Max. 1 Qbetween WlO _ - Turn starting(ferr;lej (3) and (4) switch OFF. NO

Disconnect WIO,W08.Front windowclosed position:Min. 1 MR

- Turn starting NOswitch OFF.

* Disconnect WlO.

A-c-

Table 1

n

5Is resistance betweeneach pin of Ml8

1

(female) 1) (2) (4) and

W08 (female) l2lI14)‘ 1;“) s shown In Table

b Turn startingswitch OFF.

*~,inect M18,

6

Is voltage of eachpin of W04 asshown in Table 3?

I

Turn starting 1switch ON. NC

7YEsIs resistancebetween each pin

H

of W04 (male) -W08 (female) asshown in Table 2?

..^

)

1T$;c;t;rrng NW

zinect W04,

I3

0

, fActuation mode Ml8 (female) W08 (female) Resistance

Between (1) - (4) Between (12) - (15) Max. 1 QINT mode Between (1) - (2) Between (12) - (14)

.Between (2) - (4) Between (14) - (15)Min , MR

Between (1) - (2) Between (12) - (14)OFF mode Between (I) - (4) Between (12) - (15) Min 1 MQ

Between (2) - (4) Between (14) - (15)

Between (1) - (2) Between (12) - (14) Max. 1 R

ON mode Between (1) - (4) Between (12) - (15)Between (2) - (4) Between (14) - (15)

Min , MR

Table.2

Cause Remedy

- GotoA

Defective wiper washerswitch

Defective contact, ordisconnection in wiringharness between fuse (7) -W08 (female) (51, betweenFtl8 pNyle) (1). (8) - HO6

Defective contact, ordisconnection in wiringharness between Ml0 (male)

(3) (4) - W08 (female) (4) (18)

p Defective rear limit switchI Front window is open

Defective wiper motor

Defective wiper motorcontroller

Contact between wiringharnesses of system withdefective resistance

Contact of wiring harnessbetween Ml8 (male) (1) (2);;;,,:I; (y(l$E~l- WO8

leplace

lepair oreplace

tepair oraplace

Replace%S~;~~ow in

comsctly.

leplace

leplace

lepair oreplace

Iepair oreplace

Between W04 (female) (1) - W08 (female) (7)Between W04 (female) (3) - W08 (female) (6)Between W04 (female) (4) - W08 (female) (11)Beb,veen W04 (female) (5) - W08 (female) (9)Between W04 (female) (6) - W08 (female) (10)

Between W04 (female) (l )(3)(4)(5)(6) - GND

20-270

0




Table 3

Timing chart (when wiper switch is ON)

Timing chart (when wiper switch is HUTI

I


item Symbol Set time

Length of pause untilnext actuation Tla 0.13 set

Safety circuit duringoperation of wiper Tsa 10 set

[safety function (111

Set time

10 set

Item Symbol

Length of pause untilnext actuation Tla 4 set

Safety circuit duringoperation of wiper. Tsa[safety function (111

Length of pause whenstowing wiper blade TIPSafety circuit duringoperation of wiper Tsp 10 set[safety function ( 211

1.5 set

gyver wiperswitch (OPT)

PCZIO-A018

20- 271

0




b) Wiper switch is not being used but wiper is actuated

M

Is resistancebetween WlO

. Front windowclosed position:Min. 1 MDTurn startingswitch OFF.

- Disconnect WlO.

YESGotoA

NO

Is resistanceyEs between Ml8

2 - (female) (1) - (21,(1) - (41, 2) - (4) asshown in Table l?

Is resistancebetween WlO(male) (3) and (8)normal?

Max. 1 MR* Turn starting

switch OFF.Disconnect WlO,W08.

NO

IO

5v

i

Is voltage of eachpin of W04 asshown in Table 3?

Max. 1 MRTurn startingswitch OFF.

* Disconnect W04,

b

Table .l

Between (14) - (15)

Dek;;ive wiper washer Ieplace

Defective contact, ordisconnection in wiringharness between Ml0 (male1(3) (4) - W08 (female) (4) (18)

b Defective rear limit switch1Front window is open

Defective wiper motor

Defective wiper motorcontroller

Contact between wiringharnesses of system withdefective resistance

Contact of wiring harnessbetween Ml8 (male) (1) (2)(4)-X01 t21)tl1)(2o)-wO8(female) (12) (14) (15)

Remedy

Iepair or,eplace

ReplaceSet window inpositioncorrectly.

qeplace

?eplace

qepair orreplace

Repair orreplace

20- 2720




Table 3

Timing chart (when wiper switch is ON)

Timing chart (when wiper switch is INTI

F

Item

Length of pause untilnext actuation

Safety circuit duringoperation of wiper[safety function (l)]

Length of pause whenstowing wiper blade

Safety circuit duringoperation of wiper[safety function WI

Symbol’ Set time

Tla 0.13 set

Tsa 10 set

TIP 1.5set

Tsp 10 set

Item 1 ymbol 1 Set time 1

Length of pause untilnext actuation /Tla / 4sec /

Safety circuit duringoperation of wiper[safety function (l)]

Tsa 10 set

Length of pause whenstowing wiper blade TIP 1.5 set

Safety circuit duringoperation of wiper Tsp 10 set[safety function (2)l

20- 273a



30 DISASSEMBLY AND ASSEMBLY

METHOD OF USING MANUAL . . . . . . . . . . . . 30-4

PRECAUTIONS WHEN CARRYING OUT OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-5

SPECIAL TOOL LIST ...................... 30-7REMOVAL ....................... 30-I 1

AIR CONDITIONER COMPRESSOR ........ 30-I 1INSTALLATION ......... .......... 30-I 1REMOVAL ....................... 30-I 2

CONDENSER ASSEMBLY ................ 30-12INSTALLATION ................... 30-12REMOVAL ....................... 30-I 3

GOVERNOR MOTOR .................... 30-I 3INSTALLATION ......... .......... 30-I 3REMOVAL ....................... 30-14

HYDRAULIC OIL COOLER ................ 30-14INSTALLATION ................... 30-14REMOVAL ....................... 30-I 5

RADIATOR. HYDRAULIC OIL COOLER. . . . 30-15INSTALLATION . . . . . . . . . . . . . . . . 30-16REMOVAL . . . . . . . . . . . . . . . . . . . 30-I 7

....... HYDRAULIC ................. 30-17INSTALLATION ................... 30-20.............................. 30-21

DAMPER .............................. 30-21INSTALLATION ................... 30-21REMOVAL ....................... 30-22

FUEL TANK ............................ 30-22INSTALLATION ................... 30-22REMOVAL ....................... 30-23

CENTER SWIVEL JOINT. ................. 30-23INSTALLATION ................... 30-23DISASSEMBLY ................... 30-24ASSEMBLY ...................... 30-24REMOVAL ....................... 30-25

FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . 30-25INSTALLATION . . . . . . . . . . . . . . 30-25DISASSEMBLY OF FINAL DRIVE ASSEMBLY

PC200-6, PC2OOLC-6, PC21OLC-6,

PC22OLC-630-26

ASSEMBLY & hi’ &‘ dl%k&tibLYPC200-6, PC2OOLC-6, PC21OLC-6,PC22OLC-6

30-29~is~ss~ki_v & F~NAL’ ~R~VEASSEMBLY

PC25OLC-630-33

ASSEMBLY & hk.‘ dl$k’ f%&ti~LYPC25OLC-6

30-36DlSASSEhi_V : : : : : : : : : : : : : : : : : : : 30-41

TRAVEL MOTOR ........................ 30-41ASSEMBLY ...................... 30-46 REMOVAL ....................... 30-54

SPROCKET ............................ 30-54INSTALLATION ................... 30-54REMOVAL ....................... 30-55

SWlNG MOTOR ......................... 30-55INSTALLATION ................... 30-55REMOVAL ....................... 30-56

SWING MACHINERY ..................... 30-56INSTALLATION ................... 30-56DISASSEMBLY ................... 30-57 ASSEMBLY ...................... 30-60 REMOVAL ....................... 30-64

REVOLVING FRAME ..................... 30-64INSTALLATION ................... 30-65 REMOVAL ....................... 30-66

SWING CIRCLE ......................... 30-66 INSTALLATION ................... 30-67 REMOVAL ....................... 30-68

...... RECOIL SPRING .. _ ............. 30-68INSTALLATION ..... _ ............. 30-68DISASSEMBLY ................... 30-69

RECOIL SPRING ........................ 30-69ASSEMBLY ...................... 30-70 DISASSEMBLY ................... 30-71

IDLER.. ............................... 30-71 ASSEMBLY ...................... 30-72 REMOVAL ....................... 30-74

30-I0



TRACK ROLLER ........................ 30-74INSTALLATION ................... 30-74DISASSEMBLY ................... 30-76 ASSEMBLY ...................... 30-77 REMOVAL ....................... 30-79

CARRIER ROLLER ...................... 30-79INSTALLATION ................... 30-79DISASSEMBLY ................... 30-80

ASSEMBLY ...................... 30-81 REMOVAL ....................... 30-83

TRACK SHOE .......................... 30-83INSTALLATION ................... 30-83REMOVAL ....................... 30-84

HYDRAULIC TANK ...................... 30-84 INSTALLATION ................... 30-85 REMOVAL ....................... 30-86

CONTROL PUMP ....................... 30-86INSTALLATION ................... 30-86

REMOVAL ....................... 30-87

MAIN PUMP ............................ 30-87INSTALLATION ................... 30-88 DISASSEMBLY ................... 30-89 ASSEMBLY ...................... 30-95 REMOVAL ...................... 30-I 11

MAIN PUMP INPUT SHAFT OIL SEAL ...... 30-I 11INSTALLATION .................. 30-I 11REMOVAL ...................... 30-I 12

CONTROL VALVE ...................... 30-I 12

INSTALLATION .................. 30-I 13 REMOVAL ...................... 30-I 14

CONTROL VALVE ASSEMBLY * -/-spool control valve(1 service valve) ................. 30-I 14INSTALLATION .................. 30-I 15 DISASSEMBLY .................. 30-I 16 ASSEMBLY ..................... 30-I 18 DISASSEMBLY .................. 30-120

TVC . LS VALVE ASSEMBLY FOR FRONT PUMP30-124

IN&hTb~ : : : : : : : : : : : : : : : : : : 30-124REMOVAL . . . . . . . . . . . . . . . . . . 30-125

TVC LS VALVE ASSEMBLY FOR REAR PUMP30-I 25

lN&kk& : : : : : : : : : : : : : : : : : : 30-125REMOVAL . . . . . . . . . . . . . . . . . . . . . 30-126

LS CONTROL EPC VALVE ............... 30-126INSTALLATION .................. 30-126REMOVAL ...................... 30-127

SOLENOID VALVE ..................... 30-127INSTALLATION .................. 30-127REMOVAL ...................... 30-128

WORK EQUIPMENT. SWING PPC VALVE . 30-128INSTALLATION .................. 30-128DISASSEMBLY .................. 30-129 ............................ _ 30-I .. ............................. 30-I ..

TRAVEL PPC VALVE. ................... 30-131INSTALLATION .................. 30-131DISASSEMBLY .................. 30-132ASSEMBLY ..................... 30-132REMOVAL ...................... 30-I 34

BOOM LOCK VALVE .................... 30-I 34INSTALLATION .................. 30-134REMOVAL ...................... 30-135

BOOM CYLINDER ...................... 30-135INSTALLATION .................. 30-136

REMOVAL ...................... 30-137

ARM CYLINDER ....................... 30-137 INSTALLATION .................. 30-138 REMOVAL ...................... 30-I 39

BUCKET CYLINDER .................... 30-139 INSTALLATION .................. 30-140 DISASSEMBLY .................. 30-141

PUMP MERGE-DIVIDER VALVE. .......... 30-120 HYDRAULIC CYLINDER ................. 30-141 ASSEMBLY ..................... 30-120 ASSEMBLY ..................... 30-143DISASSEMBLY .................. 30-121 REMOVAL ...................... 30-146

PRESSURE COMPENSATION VALVE ...... 30-121 WORK EQUIPMENT .................... 30-146ASSEMBLY ..................... 30-121 INSTALLATION .................. 30-147 DISASSEMBLY .................. 30-122 REMOVAL ...................... 30-148

MAIN RELIEF VALVE ................... 30-122 BUCKET .............................. 30-148 ASSEMBLY ..................... 30-I 23 INSTALLATION .................. 30-149 REMOVAL ...................... 30-I 24 REMOVAL ...................... 30-I 50

30- 20



ARM ................................. 30-150INSTALLATION .................. 30-151REMOVAL ...................... 30-I 52

BUCKET ARM ....................... 30-152INSTALLATION .................. 30-153REMOVAL ...................... 30-I 54

BOOM ............................... 30-154INSTALLATION .................. 30-155

REMOVAL ...................... 30-I 56

OPERATOR’ S CAB ..................... 30-I 56INSTALLATION .......... ........ 30-I 58 REMOVAL ...................... 30-I 59

COUNTERWEIGHT ............ : ........ 30-159INSTALLATION .................. 30-159REMOVAL ...................... 30-I 60

ENGINE THROTTLE CONTROLLER ....... 30-160INSTALLATION .................. 30-160REMOVAL ...................... 30-I 61

PUMP CONTROLLER ................... 30-161INSTALLATION .................. 30-161REMOVAL ...................... 30-162

MONITOR ............................ 30-162INSTALLATION .................. 30-162

30-30



DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

PRECAUTIONS WHEN CARRYING OUT OPERATION[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautionsgiven below when carrying out the operation.]

Precautions when carrying out removal workIf the coolant contains antifreeze, dispose of it correctly.After disconnecting hoses or tubes, cover them or fit 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 when assembling.To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnectingthe connectors.Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.Check the number and thickness of the shims, and keep in a safe place.When raising components, be sure to use lifting equipment of ample strength.When using forcing screws to remove any components, tighten the forcing screws alternately.Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering afterremoval.Precautions when handling piping during disassemblingFit the following blind plugs into the piping after disconnecting it during disassembly operations.1) Hoses and tubes using sleeve nuts

Nomnalnumber

02

03

Pl ug (nut end)

07376-50210

07376-50315

Sl eeve nut (elbow end)Use the two i t ems below as a set

07221-20210(Nut) , 07222-00210(Pl ug)

07221-20315(Nut) , 07222-00312(Pl ug)

04 I 07376-50422 I ' 07221-20422(Nut) , 07222-00414(Pl ug)

05 07376-50522 07221-20522(Nut) , 07222-00515(Pl ug)

06 07376-50628 07221-20628(Nut) , 07222-00616(Pl ug)

10 07376-51034 07221-21034(Nut) , 07222-01018(Pl ug)

12 07376-51234 07221-21234(Nut) , 07222-01219(Pl ug)

2) Split flanae tvoe hoses and tubesNomnalnumber

04

Fl ange( hose end)

07379- 00400

Sl eevehead( tubeend)

07378-10400

Split flange

07371-30400

05 07379- 00500 07378-10500 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.

Nomnalnumber

Part number1 D Drnsdi ons, L

06 07049- 00608 6 5 8

08 07049- 00811 8 6. 5 11

10 1 07049-01012 1 10 1 8. 5 1 12

I I I I

22 1 07049-02228 1 22 1 18. 5 1 28

24 1 07049-02430 1 24 1 20 1 30

27 1 07049-02734 1 27 1 22. 5 1 34

30-50



DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION

Precautions for installation operations

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

2-3 drops of adhesive.When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirtor 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 antifriction compound (LM-P).After fitting snap rings, check that the snap ring is fitted securely in the ring groove.When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the directionof the hook.When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulicequipment removed for repair, always bleed the air as follows:

1. Start the engine and run at low idling.2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 100 mm from

end of its stroke.3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.4. After doing this, run the engine at normal speed.

+ When using the machine for the first time after repair or long storage, follow the same procedure.

Precautions when completing the operations

If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engineto circulate the coolant through the system. Then check the coolant level again.If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run theengine to circulate the oil through the system. Then check the oil level again.

If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed forrepair, always bleed air from the system after reassembling the parts.* For details, see TESTING AND ADJUSTING, Bleeding air.Add the specified amount of grease (molybdenum disulfide grease) to the work equipment related parts.

30- 60



DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST

SPECIAL TOOL LIST

Iymbol Part No. Part Name I Q’ @ I Remarksature of work

Engine hydraulic pumpRadiator hydraulic oil cooler

Control pump Hydraulic pumpRemoval, installation of TVC LSvalve assembly

B 796- 460- 1210 Oil stopper I

Push-puller Iisassembly of center swivel joint

assemblyD

790- 101- 2501

790-331- l 1 O Wrench I 1 I Tightening of circle boltemoval, installation of swing circle

Disassembly, assembly of swingmachinery assembly

G

E

F

1-

2

-

3-

4

-

I

H

-

2

-

796-426-I 120 Push tool 1 Press fitting of bearing

796427-l 120 Wrench I

796-427-I 130 Push tool I

790-l 01-2510

792- I 04-3940

01580-11631Press

fitting ofbearing

inner race

01643-31645Disassembly, assembly of finaldrive assembly 790-I 05-2100 Jack 1 I 1

790- 101- 1102 Pump I I796-570- l O Plate I PC25OLC

790-331- I 110

791- 545- 1510

791- 580- 1510

791-600-2001

794-6:;-8005

Installer

Compressor (A)

Compressor (B)

Extension

Cylinder (70 ton)

I PC250LC

I

I PC200PCZOOLC

I PC21 OLC

I PC22OLC

791-935-3160

790-101-1600Removal,

pressfitting of

master pin

790- 101- 1102 Pump I i - 1791- 600- 2001

791-6: ; - 8003

791-935-3160

Removal, installation ofrecoil spring assembly

790- 101- 1600 Cylinder (70 ton) I I I

790- 101- 1102 Pump I 1 I790-201 -I 500 Push tool kit

. 790-201 -I 620 0 Plate790-l 01-5021 Grip

.OIOIO-50816 Bolt

I Installation of recoil springI piston dust sealI

30-70




Nature of work Symbol 1 Part No. I Part Name 1 Q’ ty 1 Remarks

Removal, installation of track shoeassembly

Assembly of idler assembly J

Disassembly, assembly of trackroller assembly

Disassembly, assembly of carrierroller assembly

Installation of track roller M 790- 331- 1110 I Wrench I 1 l Tightening of track roller bolt

Replacement of pump shaft oil seal N

790- 630- 3000790-101-1300

790-101-1102

Remover & installerCylinder (70 ton)

Pump

PC200PC200LCPC210LCPC22OLC

I 791-630-3000 I Remover & installer I 1 I790- 101- 1300

790-101-1102790-434-I 630

Cylinder (100 ton) 1 PC25OLC

Pump 1Installer 1 Installation (

Iff

Removepress fitting

of master pin

Toating seal

791- 601- 1000 Oil pump 1Charging with oil, checking

for air leakage

790434- l 640 I Installer I 1 l Installation of floating seal

791- 601- 1000 I Oil pumpI I

1Charging with oil, checking

for air leakage

790- 331- 1110 I WrenchI I

1Tightening of track roller

mounting bolt

797- 101- 1121 I Wrench I 1 I Removal, installation of nut

796-430-I 110 1 Push tool I 1 1 Press fitting of bearing

791-434-I 650 Installer

791-601-1000 Oil pump

1 Installation of floating seal

1Charging with oil, checking

for air leakage

791-463-1141 Push tool 1

790-201-2740 Spacer 1

30- 80




r: Tature of work Symbol Part No. Part Name Q’ty Remarks-

1

-

2

-

3-

4

-

790-502-I 003Cylinder repair

stand

790- 101- 1102 Pump

ARMPC200

PC2OOLCPC21 OLCPC22OLCPC25OLC

BOOMPC200

PC2OOLCPC21 OLCPC22OLCPC250LC

BUCKET

PC220LCPC25OLC

Socket (widthacross flats: 95 mm)

90- 302- 1450

BUCKETPC200

PC2OOLCPC21 OLC

Hydraulic cylinder 0 Socket (widthacross flats: 85 mm)

90-302-I 350 1

790- 720- I 00 Expander 1Expansion of piston

ring

ARM &BOOMPC22OLCPC25OLC

BOOMPC200

PC2OOLCPC21OLC

BUCKETPC22OLCPC25OLC

BUCKETPC200PC200LCPC21 OLC

796-720-I 68007281-01589

RingClamp

11

796-720-I 670 Ring07281-01279 Clamp

796-720-I 660 Ring07281-01159 Clamp

30-90




Nature of work

Hydraulic cylinder

Removal, installation ofwork equipment

Boom assembly

Symbol-

0

-

P

-

5

-

6

-

Part No. Part Name

790-201-I 702 Push tool kit790-201-I 831 . Push tool

.790-101-5021 Grip0 01010-50816 . Bolt

790-201-I 702. 790-201-I 8410 790-101-5021. OlOlO-50816

Push tool kit. Push tool

Grip. Bolt

790-201-1702790-201-I 851790-101-502101010-50816


GripBolt

790-201-I 702. 790-201-I 930

. 790-101-502101010-50816


GripBolt

790-201-I 500. 790-201-I 640

790-101-502101010-50816


GripBolt

790-201-1500790-201-I 650790-I 01-5021

.OlOlO-50816


GripBolt

790-201-I 5000 790-201-I 6600 790-I 01-5021

01010-50816


GripBolt

790-201-I 990790-I 01-502101010-50816

PlateGripBolt

796-900-I 200790-101-4000790-101-1102

RemoverPuller (50 ton long)

Pump (30 ton)

Remarks

BUCKETPC200

PC200LCPC21 OLC

BOOMPC200

PC2OOLCPC21OLC

BUCKETPC22OLCPC25OLC

ARM &BOOM

PC22OLCPC25OLC

ARMPC200

PC2OOLCPC21OLC

BUCKETPC200

PC200LCPC21 OLC

BOOMPC200

PC2OOLCPC21 OLC

BUCKET

PC22OLCPC25OLC

ARMPC22OLCPC25OLC

BOOMPC220LCPC250LC

ARMPC200

PC2OOLC

PC21 OLC

Removal of boom footpin

30- 100



DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR

REMOVAL OF AIR CONDITIONERCOMPRESSOR ASSEMBLY

A

1.

2.

3.

4.

5.

Under pressure, precautions must be taken toprotect eyes and skin. Never loosen any part of therefrigerant circuit while charged with gas. The airconditioner system should only be serviced by

qualified personnel.

Remove refrigerant gas (R134a) using dischargeports (1). Don’ t release gas into the atmosphere.

Remove fan guard (2).

Disconnect hoses (3) and (4) and disconnectelectrical connector.

Loosen bolts (5) and (6) and rotate compressorabout bolt (5) towards the engine and remove drivebelt (7).

Remove bolts (8) then remove air conditionercompressor (9).

INSTALLATION OF AIRI

CONDITIONER COMPRESSORASSEMBLY

Carry out installation in reverse order of removal.* Check O-rings of hoses are not damaged or

deteriorated.* Adjust the belt tension (see TESTING AND

ADJUSTING).

Fill with refrigerant (R-134a).

30- 110



DISASSEMBLY AND ASSEMBLY CONDENSER

REMOVAL OF CONDENSERASSEMBLY

1. Open forward left side cover and remove top cover.

2. Remove overfill tank bracket (2) by removing bolts

and washers (1).

3. Disconnect electrical connector and hoses (3) and(4).j, Loosen the sleeve nut slightly and release the

refrigerant (RI 34a) completely beforedisconnecting hoses and tubes.

* Fit plugs to hoses and tubes to prevent ingressof moisture, dust or dirt.

4. Remove condenser assembly (5) by removing boltsand washers (6).

INSTALLATION OF CONDENSERASSEMBLY

0 Carry out installation in the reverse order toremoval.* Check that the O-ring is not damaged or

deteriorated.0 Fill with refrigerant (RI 34a).

_ -

X13ED017

30- 120



DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR

REMOVAL OF GOVERNORMOTOR ASSEMBLY

A1.

2.

3.

4.

Disconnect the cable from the negative (-) terminalof the battery.

Open engine hood and disconnect governor motor

connector (1).

Remove motor cover (4).

Remove motor rod (2).

Remove governor motor assembly (3).Sr

mRotate the shaft of the governor motor and donot stop it suddenly.

INSTALLATION OF GOVERNOR

MOTOR ASSEMBLY0 Carry out installation in the reverse order to

removal.

/-%q* Adjust the rod. For details, see TESTING AND

ADJUSTING, Testing and adjusting of governormotor lever stroke.

X12BV120

30-I 30



DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER

REMOVAL OF HYDRAULIC OILCOOLER ASSEMBLY

1. Remove tool box and under cover, and set oilcontainer under chassis.

2. Disconnect hoses (4) and (5).

* Disconnect hose (4) at the cooler end, andhose (5) at the chassis end.

* Put blind plugs in the places that have beendisconnected.

3. Remove mounting bolts (6) at side of hydraulic oilcooler assembly.

4. Sling hydraulic oil cooler assembly (7 ), remove 2mounting bolts each on left and right, then lift offhydraulic oil cooler assembly (7).

6Hydraulic oil cooler assembly: 55 kg

kg

INSTALLATION OF HYDRAULICOIL COOLER ASSEMBLY

Carry out installation in the reverse order toremoval.

0 Refill with oil (hydraulic tank)* Add oil through the oil filler to the specified

level. Run the engine to circulate the oil throughthe system. Then check the oil level again.

6

30- 140



DISASSEMBLY AND ASSEMBLY RADIATOR HYDRAULIC OIL COOLER

REMOVAL OF RADIATOR.HYDRAULIC OIL COOLERASSEMBLY

A

0

0

1.

2.

3.

4.

5.

Lower the work equipment completely to the ground and stop the engine. Then loosen the oil fillercap slowly to release the pressure inside thehydraulic tank.Remove the hydraulic tank strainer, and using toolB, stop the oil.

When not using tool B, remove the drain plug,and drain the oil from the hydraulic tank andinside the system.

Hydraulic tank: Approx. 170 P

Drain engine coolant.

Remove undercover under radiator.

Disconnect small diameter from radiator (near cap)to reservoir tank.

Disconnect cooler hoses (4) and (5).

Disconnect radiator upper hose (9) and removeclamps of heater hose (10) from right side ofradiator assembly.

Remove fan guard (11).

I

30- 150



DISASSEMBLY AND ASSEMBLY RADIATOR. HYDRAULIC OIL COOLER

6. Disconnect radiator support rods (12) and (13).* Loosen the mounting bolts, then remove the

top mounting bolts and move the rods towardthe rear of the engine.

7. Disconnect radiator lower hose (14) and heaterhose (15).* The radiator lower hose is fixed by a clamp to

the radiator, so always disconnect the clamp.

8. Sling radiator and hydraulic oil cooler assembly(16) remove 4 bottom mounting bolts, then lift offradiator and hydraulic oil cooler assembly.* When raising the radiator and hydraulic oil

cooler assembly, check the position carefullyand do not let it hit the fan when removing it.

Radiator hydraulic oil coolerassembly: 125 kg

INSTALLATION OF RADIATOR.HYDRAULIC OIL COOLERASSEMBLY


Refilling with coolant.* Add coolant through the water filler to the

specified level. Run the engine to circulate thecoolant through the system. Then check thecoolant level again.

Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified


30- 160



DISASSEMBLY AND ASSEMBLY ENGINE. HYDRAULIC PUMP

REMOVAL OF ENGINE.HYDRAULIC PUMP ASSEMBLY

AA

0

1.

2.

3.

Disconnect the cable from the negative (-) terminalof the battery.Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler

cap slowly to release the pressure inside thehydraulic tank.Remove the hydraulic tank strainer, and using toolB, stop the oil.



Mark all the piping with tags to prevent mistakes inthe mounting position when installing.

Drain engine coolant.

Remove cotter pin (1) of stopper, then removeengine hood (2).

Remove side cover and mounting frame (3).

Remove engine hood mounting bracket (4), cover(5) and engine room partition plate (6).

XiOARO14

30-I 70




4. Disconnect hoses (7) (8) and (9) from NC LSvalve.

5. Pull out connectors (10) and (11) from holder anddisconnect.* Remove the connector wiring clamps

completely.

6. Disconnect hoses (12) and (13) from control pump.

7. Remove suction tubes (14) and (15).

8. Disconnect hoses (16) and (17) installed to top ofmain pump assembly.

9. Remove cover (18) and disconnect hose bracket(19) from pump.

10. Remove bracket (20) at counterweight end.

30- 180



DISASSEMBLY AND ASSEMBLY ENGINE HYDRAULIC PUMP

11. Disconnect connector (21).

12.

13.

14.

15.

16.

Disconnect governor motor connectors (22) andremove wiring clamp (23).

Disconnect starting motor wiring (24). Disconnectintake heat wiring (24A) and engine earth (24B).

Disconnect air conditioner compressor hoses (25)and (26). (If fitted)* Loosen the sleeve nut slightly and release the

refrigerant (gas) completely beforedisconnecting the hoses.

* Fit blind plugs to prevent the entry of moisture,dust or dirt into the hoses.

Disconnect fuel hoses (27) and ground connection(26).

Remove radiator upper hose (29), heater hose (30)air cleaner connector (31) and fan guard (32).

XlOAR022

30- I 90




17. Remove fan (33), and disconnect radiator lowerhose (34).

18. Remove mount bolt, and raise engine and hydraulicpump assembly (36) slowly, then move to right sideof chassis and lift off.j, When removing the engine and hydraulic pump

assembly, check that all the wiring and piping

has been disconnected.

Engine hydraulic pump assembly:750 kg

INSTALLATION OF ENGINE.HYDRAULIC PUMP ASSEMBLY

0 Carry out installation in the reverse order toremoval.

\

Engine mount bolt: 276.9 f 31.9 NmI r ,J XlOARO25

m (28.3 f 3.3 kgm)

Refilling with coolant.* Add coolant through the water filler to specified

level. Run the engine to circulate the coolantthrough the system. Then check the coolantlevel again.

Refilling with oil (hydraulic tank)

j, Add oil through the oil filler to the specifiedlevel. Run the engine to circulate the oil throughthe system. Then check the oil level again.

Bleeding air* Bleed air from the hydraulic pump. For details,

see TESTING AND ADJUSTING, Bleeding air.

30-200



DISASSEMBLY AND ASSEMBLY DAMPER

REMOVAL OF DAMPERASSEMBLY

1. Remove main pump assembly. For details, seeREMOVAL OF MAIN PUMP ASSEMBLY.

2. Remove damper assembly (1).

INSTALLATION OF DAMPERASSEMBLY


30- 210



DISASSEMBLY AND ASSEMBLY FUEL TANK

REMOVAL OF FUEL TANKASSEMBLY

1.

2.

3.

4.

5.

6.


Loosen drain valve (1) of fuel tank and drain fuel.

tFuel tank: Approx. 315 0 (when tank is

u full)

Disconnect fuel supply hose (2) and return hose(3).

Remove handrail (4) battery case (5) and cover(6).

Remove connector (7) from holder, and disconnectit.* Remove the wiring from the clamp, then

disconnect from the fuel tank.

If refueling pump is fitted, disconnect hose (9) fromtank tube.

Remove mounting bolts and lift off fuel tankassembly (8). j-%q

el Fuel tank assembly: 120 kgkg

INSTALLATION OF FUEL TANKASSEMBLY

a Carry out installation in the reverse order toremoval.

Fuel tank mounting bolt: 276.9 + 31.9Nm (28.25 f 3.25 kgm)

0 Refilling with oil (fuel tank)

Add fuel.

X12BD009

XlZBDOH

30- 220



DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

REMOVAL OF CENTER SWIVELJOINT ASSEMBLY

A

*1.

2.

3.4.

5.

6.7.8.

Release the remaining pressure in the hydrauliccircuit. For details, see TESTING ANDADJUSTING, Releasing remaining pressure fromhydraulic circuit.

Mark all the piping with tags to prevent mistakes inthe mounting position when installing.Disconnect hoses (I), (2) (3) and (4) and tubes (5)and (6), and remove filter and bracket assembly.* Machines equipped with additional attachment

circuit.

&Filter, bracket assembly: 95 kg

kgDisconnect hoses (7) (8) (9) and (10) betweentravel motor and swivel joint.Remove elbow (11).Disconnect drain hose (12).

Disconnect hoses (13) and (14) between controlvalve and swivel joint.Disconnect travel speed selector hose (15).Disconnect plate (16).Remove center swivel joint assembly (17).

Center swivel joint assembly: 45 kg

INSTALLATION OF CENTERSWIVEL JOINT ASSEMBLY

0 Carry out installation in the reverse order to

removal.

* Assemble the center swivel as shown in thediagram below.

Center swivel ’

+ s-6

2Pprocket

@@ X09DDO23



Bleeding airJr Bleed the air from the travel motor. For details,


30- 230



DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT

DISASSEMBLY OF CENTERSWIVEL JOINT ASSEMBLY

1. Remove cover (1).2. Remove snap ring (2).3. Using tool D, pull out swivel rotor (4) and ring (3)

from swivel shaft (5).

4. Remove O-ring (6) and slipper seal (7) from swivelrotor.

ASSEMBLY OF CENTER SWIVELJOINT ASSEMBLY

1. Assembly slipper seal (7) and O-ring (6) to swivel

rotor.2. Set swivel shaft (5) to block, then using push tool,tap swivel rotor (4) with a plastic hammer to install.

Contact surface of rotor, shaft: Grease- (G2-LI)

XOSDDO28

* When installing the rotor, be extremely carefulnot to damage the slipper seal and the O-ring.

3. Install ring (3) and secure with snap ring (2).4. Fit O-ring and install cover (1).

Mounting bolt: 31.4 + 2.9 Nm (3.2 + 0.3kgm)

30- 240



DISASSEMBLY AND ASSEMBLY FINAL DRIVE

REMOVAL OF FINAL DRIVEASSEMBLY

1.

a

2.3.

Remove sprocket. For details, see REMOVAL OFSPROCKET.Lower the work equipment completely to the ground and stop the engine. Then loosen the oil filler

cap slowly to release the pressure inside thehydraulic tank.

Remove cover (1).Disconnect 4 travel motor hoses (2) and lift off finaldrive assembly (3).j r Be extremely careful not to damage the

tool surface of the hose mount.Final drive assembly: 425 kg

INSTALLATION OF FINAL DRIVEASSEMBLY


m

Final drive mounting bolt: 276.9 f31.9 Nm (28.25 f 3.25 kgm)

Bleeding air* Bleed the air from the travel motor. For details,



level.Run the engine to circulate the oil through thesystem. Then check the oil level again.

.---I

X07HH034

30-250




DISASSEMBLY OF FINAL DRIVEASSEMBLYPC200-6, PC2OOLC-6, PC21 OLC-6, PC22OLC-6

1.

2.

3.

4.

Draining oilRemove drain plug and drain oil from final drivecase.

Final drive case: Approx. 5.5 I?

CoverRemove mounting bolts, then remove cover (1)using eyebolts 0.

X07HH037

SpacerRemove spacer (2).

No. 1 sun gear shaftRemove No. 1 sun gear shaft (3).

5. No. 1 carrier assembly1) Remove No. 1 carrier assembly (4).

X07HH039

2) Disassembly No. 1 carrier assembly as follows.i) Push in pin (5) and pull out shaft (6) from

carrier (7).9

j, After removing the shaft, remove pin

(5).ii) Remove thrust washer (8) gear (9),

bearing (IO), and thrust washer (11). 6XO7HHO40

30- 260




6. Ring gearUsing eyebolts 0, remove ring gear (12).

7. No. 2 sun gearRemove No. 2 sun gear (13).

8. Thrust washerRemove thrust washer (14).


2) Disassemble No. 2 carrier assembly as follows.i) Push in pin (16) and pull out shaft (17) from

carrier (18).* After removing the shaft, remove pin

(16).

ii) Remove thrust washer (19) gear (20)bearing (21), and thrust washer (22).

10. Nut1) Remove lock plate (23).2) Using tool G,, remove nut (24).

12

XO7HHO41

19 17 21 18

20

---_---22

30- 270




11. Hub assembly1) Using eyebolts 0, remove hub assembly (25)

from travel motor.

2) Disassemble hub assembly as follows.i) Remove floating seal (26).ii) Remove bearings (27) and (28) from hub

(2%

3) Remove floating seal (30) from travel motor(31).

X07HH045

26 XO7HHO46

X07HH047

30- 280




ASSEMBLY OF FINAL DRIVEASSEMBLYPC200-6, PC2OOLC6, PC21OLC-6, PC22OLC-6*

1.

2.

Clean all parts, and check for dirt or damage. Coatthe sliding surfaces of all parts with engine oilbefore installing.

Hub assembly1) Using push tool, press fit bearings (27) and (28)

to hub (29).2) Using tool Gq, install floating seal (26).

G4.

*

*

*

X07HH049

Remove all oil and grease from the O-ringand O-ring contact surface, and dry theparts before installing the floating seal.After installing the floating seal, check thatthe angle of the floating seal is within 1 mm.After installing the floating seal, coat thesliding surface thinly with engine oil.

3)

4)

Using tool G,, install floating seal (30) to travelmotor (31).* The procedure for installation is the same

as in Step 2) above.

Using eyebolts 0, set hub assembly (25) totravel motor, then using push tool, tap to pressfit bearing portion.

Nut1) Install nut as follows.

i) Using tool G,, push bearing inner raceportion.* Pushing force: 8.82 - 12.74 kN (0.9 -

1.3 ton)

j, Rotate the hub 2 - 3 times beforeapplying the pushing force to thebearing inner race.

ii) Measure dimension “a” in the condition inStep i) above.

&IIX07HH047

I

25

X07HH045

a

-.-.. --__- _ XO7HHO45

30-290




iii) Measure thickness “b” of nut itself.iv) Calculate a - b = c.v) Using tool G,, tighten nut (24) to a point

where dimension “d” is cj,,

vi) Using push-pull scale 8, measuretangential force in direction of rotation ofhub in relation to motor case.* Tangential force: Max. 294.2 N (30 kg)* The tangential force is the maximum

force when starting rotation.vii) Install lock plate (23).

* Install the lock plate as shown in thediagram below.

\Casting notch

X07HHOSO

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

* Do not coat the tap portion of the nutwith thread tightener (LT-2).

3. No. 2 carrier assembly1) Assemble No. 2 carrier assembly as follows.

* There are the remains of the caulking whenthe pin is inserted at the end face of hole hat the side of the carrier, so remove the

caulked metal from the inside diameter ofthe hole before starting to assemble.i) Assemble bearing (21) to gear (20) fit top

and bottom thrust washers (19) and (20)and set gear assembly in carrier (18).

30-300




ii) Align position of pin holes of shaft andcarrier, then tap with a plastic hammer toinstall shaft (17).* When installing the shaft, rotate the

planetary gear. Be careful not todamage the thrust washer.

iii) Insert pin (16).* After inserting the pin, caulk the pin

portion of the carrier.* After assembling the carrier assembly,

check that gear (20) rotates smoothly.

2) Install No. 2 carrier assembly (15).

4. Thrust washerInstall thrust washer (14).

5. No. 2 sun gearInstall No. 2 sun gear (13).


* There are the remains of the caulking whenthe pin is inserted at the end face of hole hat the side of the carrier, so remove the

caulked metal from the inside diameter ofthe hole before starting to assemble.

i) Assemble bearing (10) to gear (9) fit topand bottom thrust washers (8) and (11) andset gear assembly to carrier (7).

Ii -X07HH056

h9

XO7HHOS

30-3 10




ii) Align position of pin holes of shaft andcarrier, then tap with a plastic hammer toinstall shaft (6).* When installing the shaft, rotate the

planetary gear. Be careful not todamage the thrust washer.

iii) Insert pin (5).* After inserting the pin, caulk the pin

portion of the carrier.* After assembling the carrier assembly,

check that gear (9) rotates smoothly.2) Install No. 1 carrier assembly (14).

7. No. 1 sun gear shaftInstall No. 1 sun gear shaft (3).

8. SpacerInstall spacer (2).

9. Ring gearFit O-ring to hub end, then using eyebolts Q, align

position of bolt holes of hub and ring gear (12) andinstall.j, Remove all grease and oil from the mating

surface of the ring gear and hub.* Do not put any gasket sealant on the mating

surface of the ring gear and hub under anycircumstances.

IO. CoverUsing eyebolts 0, fit cover (I), then tightenmounting bolts with angle tightening wrench G,.

Mounting surface of cover: GasketJ=E& sealant (LG-6)

Mounting bolt: 1st pass98 Nm (10 kgm) 2nd pass Turn 70 - 80”

II. Refilling with oilTighten drain plug and add engine oil through oilfiller.

Q 1Final drive case: Approx. 5.5 4

* Carry out a final check of the oil level at thedetermined position after installing the finaldrive assembly to the chassis.

6’

30- 320




DISASSEMBLY OF FINAL DRIVEASSEMBLYPC25OLC-6

1. Draining oilRemove drain plug and drain oil from final drivecase.

Final drive case: Approx. 8.0 Q

2. CoverUsing forcing screws and eyebolts 0, remove cover(1).

3. Thrust washerRemove thrust washer (2).

4. No. 1 sun gear shaftRemove No. 1 sun gear shaft (3).

5. No. 1 carrier assembly1) Remove carrier assembly (4).2) Disassemble carrier assembly as follows.

i) Remove mounting bolts (5), then removeholder.

ii) Set carrier assembly (4) in press, thenusing push tool Q, pull out pin (6) andremove gear assembly (7).

iii) Remove bearing (9) and spacer (10) fromgear (8).

iv) Remove outer race (11).

I X07HH066

30-330




6.

7.

8.

9.

10.

11.

12.

Ring gear1) Remove ring gear (12).2) Remove ring (13).

No. 2 sun gearRemove sun gear (14).

Thrust washer

Remove thrust washer (15).No. 1 carrier assembly1) Remove carrier assembly (16).

2) Disassemble carrier assembly as follows. I - 10

ii)

iii)

iv)

Remove mounting bolts (i7), then removeholder.Set carrier assembly (16) in press, thenusing push tool 0, pull out pin (18) andremove gear assembly (19).

Remove bearing (21) and spacer(22) fromgear (20).Remove outer race (23).

No. 2 ring gearRemove ring gear (24).

Gear couplingRemove mounting bolts, then remove gear coupling

(25).

SpacerRemove spacer (26).

7

XO7HHO64

I 2425-/

I

X07HH071

30-340




13. Hub assembly1) Using eyebolts a,, remove hub assembly (27)

from travel motor.

2) Remove floating seal (28).3) Remove cage (29), then remove floating seal

(30).4) Remove bearing (31) and (32).

30-350




ASSEMBLY OF FINAL DRIVEASSEMBLYPC250LC-6

*

1.

*

*

*

*

2.

Clean all parts, and check for dirt or damage. Coatthe sliding surfaces of all parts with engine oilbefore installing.

Hub assembly1) Using push tool, press fit bearings (32) and

(31).2) Using tool G,, install floating seal (30) to cage,

then install cage (29).Cage mounting surface: Gasket

- sealant (LG-6)

Mount bolt: 11.2 + 7.4 Nm (6.75 f.75 kgm)

Remove all oil and grease from the O-ring and O-

ring contact surface, and dry the parts beforeinstalling the floating seal.

After installing the floating seal, check that the angleof the floating seal is within 1 mm.

After installing the floating seal, coat the slidingsurface thinly with engine oil.

3) Using tool G,, install floating seal (28).

The procedure for installation is the same as in step2) above.

4) Using eyebolts @,, set hub assembly (27) ontravel motor, then using push tool, tap to pressfit bearing.

Adjusting bearing clearance1) Using tool G2, hold bearing and temporarily

tighten 2 bolts.2) Rotate hub 2 - 3 turns to settle bearing.3) Loosen bolts of tool G, and then tighten again.

Bearing clearance bolts: 24.5 + 4.9Nm (2.5 f 0.5 kgm)

30- 360




4) Using a depth micrometer, measure steppeddifference “ a” between end face of shaft andinner race.j, Measure two places and take the average

value.5) Select a spacer to give a value of “ a” between

0.15 - 0.1 mm.* Select the suitable thickness of spacer

from the 7 types of spacers.6) Install the selected spacer (26).

3. Gear coupling1) Fit gear coupling (25), and tighten with the

mount bolts.Mount bolt: Thread tightener (LT-2)

Mount bolt: 720.3 f 44 Nm (73.5 f4.5 kgm)

2) Check adjustment of bearing clearance again.

Hook spring balance 0 in the tap hole for thesprocket mount bolt, pull to rotate the hub onthe shaft and measure the starting force.j, Starting force: See Tightening Torques and

Standard Values Table.* If the starting force is higher than the

standard value, there is a preload on thebearing, so adjust again.

4. No. 2 ring gearFit ring gear (24).

Ring gear mounting surface: Gasket- sealant (LG-6)

*

*

*

Coat thread tightener only on ring gear uppersurface.

Remove all grease and oil from the matingsurface on the ring gear and hub.

Do not put any gasket sealant on the matingsurface of the ring gear and hub under anycircumstances.

X07HH019

24

X07HH070 I

30-370




5. No. 2 carrier assembly1) Assemble carrier assembly as follows.

* The inner race, outer race and spacer fromone set are similar to the other set, soassemble the sets with the same marks.

i) Using push tool, press fit outer race (23) ingear (20).

ii) Assemble spacer (22) and bearing (21).

iii) Set carrier assembly (16) in press,assemble gear assembly (19) then usingpush tool 0, press fit pin (18).* When press fitting the pin, be ex

tremely careful of the angle of the pin,and rotate the gear while press fitting.

* After assembling the carrier assembly,check that gear (19) rotates smoothly.

iv) Fit holder and tighten with mount bolts (17).Mount bolt: Thread tightener (LT-2)

Mount bolt: 382.2 + 39.2 Nm (39 f

4 kgm)

2) Install carrier assembly (16).

6. Thrust washerAssembly thrust washer (15).

7. No. 2 sun gearAssemble sun gear (14).

8. No. 1 ring gear1)

2)

Install ring (13).Mounting surface of ring: Gasket

0C& sealant (LG-6)

Align with teeth surface of carrier, and installring gear (12).

-Ring gear mounting surface:Gasket sealant (LG-6)

X07HH068

15 16

30- 380




9.

10.

11.

12.

No. 1 carrier assembly1) Assemble carrier assembly as follows.

* The inner race, outer race and spacer fromone set are similar to the other set, soassemble the sets with the same marks.

i) Using push tool, press fit outer race (11) ingear (8).

ii) Assemble spacer (10) and bearing (9).

iii) Set carrier assembly (4) in press, assemblegear assembly (7), then using push tool 0,press fit pin (6).* When press fitting the pin, be ex

tremely careful of the angle of the pin,and rotate the gear while press fitting.

* After assembling the carrier assembly,

check that gear (19) rotates smoothly.iv) Fit holder and tighten with the mount bolts

(6).

A&i Mount bolt: Thread tightener (LT-2)

Mount bolt: 60.8 f 7.4 Nm (6.75 +0.75 kgm)

2) Align with teeth surface of ring gear, and installcarrier assembly (4).

.

No. 1 sun gear shaft

Assemble sun gear shaft (3).

Thrust washerAssembly thrust washer (2).

Cover1) Using eyebolts 0, install cover (1).

Cover mountingA sealant (LG-6)

surface: Gasket

30-390




13.

2) Tighten bolts to specified initial torque.Mount bolt: 98 Nm (10 kgm) Stan mark

on cover

3)

4)

5)

Set angle of hexagonal head of bolt tostandard, then make start marks on cover andsocket.Make end mark at specified angle from start

mark.* Make the end mark only on the cover.A Bolt tightening angle: 120” - 130”Tighten until start mark on socket is alignedwith end mark on cover.

Mounting boll Stan mark00 ocket

X07HH076

j, When disassembling or assembling thefinal drive, replace cover mounting bolt @with bolt @, and tighten according to theabove procedure.

Refilling with oilTighten drain plug and add engine oil through oilfiller to the specified level.

Final drive case: 8.0 I

* Carry out the final check of the oil level afterinstalling the final drive assembly to themachine. Check the level again at the specifiedposition.

30-400



DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR

DISASSEMBLY OF TRAVELMOTOR ASSEMBLY

1. Travel motor assemblySet travel motor assembly (1) on tool A.

Tool A: Unit repair stand (790-501-5000)Bracket (790-901-2110)

Plate (790-901-I 350)

*

2.

A

Piston plugLoosen plug (2) slowly and remove, then removespring (3) and piston (4).There is a force of approx. 294 N (30 kg) applied tothe plug, so push the removal tool at a right anglewhen loosening the plug.

3. End cover assembly and valve plate

Xl OAV14t

1)

2)3)

4)

5)

Turn over tool A and remove safety valveassembly (5).Loosen plug (6) slowly.Lift off end cover (7).* The valve plate may be stuck to the end

cover, so be careful not to drop it.

Remove valve plate (8).* When reusing, keep in a safe place and be

careful not to scratch or damage thecylinder block contact surface.

Remove outer race (9) then remove spacer

(10).

8 9 IO 7

6

30- 410




6) Disassembly of end cover assembly

0

A

ii)

iii)

iv)

v)

Loosen plug (6) slowly and remove, thenremove spring (1 I), piston (12) and spool(13).There is a force of approx. 441 N (45 kg)applied to the plug, so push the removaltool at a right angle when loosening theplug.Remove plug (14) then remove spring (15)and valve (16).Remove ring (17) then remove seat (18)spring (19), and spool (20).Remove plug (21) then remove ball (22).Remove plug (23) then remove valve (24).

4. SpringRemove parking brake spring (25).

30- 420




5. Brake pistonBlow in compressed air with tool C, and removebrake piston (26).* Tool C: Oil leak tester (799-301-1600)* Air pressure: 0.2 MPa (2 kg/cm2)* Be careful that the air pressure is not too high.

The brake piston will fly out.

6. BearingUsing bearing race puller 0 and gear puller Q,remove bearing (27).* Be careful not to apply force to the bearing

holder.* When reusing the cylinder block, put gasket

paper on the valve plate contact surface to

protect the surface.* Never allow the puller to scratch or damage the

cylinder block sliding surface.

7. Cylinder block and piston assembly1) Rotate tool A 90” , and remove cylinder block

and piston assembly (28) from motor case (29).Sr The cylinder block and piston assembly

may come off separately, so be careful notto drop them.

2) Disassemble piston assembly as follows.i) Remove plate (30) and disc (31).ii) Pull out piston assembly (33) from cylinder

block (32) and remove retainer guide (34)and preload pin (35).

* When removing the piston assemblyfrom the cylinder block, the preload pinmay come out, so be careful not tolose it.

28

30-430




8.

iii) Pull out piston (37) from retainer shoe (36).

I36

3) Disassemble cylinder block as follows. I 40 320

ii)

iii)

iv)

Set tool Q to cylinder block (32).-k Tool Q: Bolt (790-201-3610)

Washer (796-465-l 110)Washer (01643-32460)Washer (01643-32060) x 2Nut (01582-02016)

Hold bolt of tool Q with wrench, tighten nutto compress spring, then remove snap ring(36).

38

39Loosen nut slowly to relieve tension ofspring (39) then remove tool Q.Remove spacer (40), spring (39), andspacer (40) from cylinder block (32).

Xl QAVI 5I

Rocker cam and shaft assembly1) Remove rocker cam (41) together with shaft

assembly (42) from motor case (29).

2) Using push tool 0, remove bearing (44) fromshaft (43).

30-440




9. Disassembly of motor case1)2)

3)4)

Remove ball (45).Rotate tool A 90”, then remove snap ring (46)from motor case (29), then remove spacer (47).Remove oil seal (48).Remove outer race (49).

10. If above disassembly operation is not neededand only the oil seal is replaced, replace the oilseal as follows.1) Remove snap ring (46) and spacer (47).2) Using bar 8 (hit end face with hammer), hit

through to core of oil seal (48) then twist toremove.

* Hit at a point midway between the insideand outside circumference of the oil seal,and twist at two places on opposite sides(A and B in diagram) to remove.

* Be careful not to damage the shaft case.

46

47

48

30-450




ASSEMBLY OF TRAVEL MOTORASSEMBLY

Clean all parts, remove all burrs, and check for dirt ordamage. Coat the rotating and sliding surfaces of allparts with engine oil before installing.

Always check the following parts before assembling.

*

0

1.

2.

This check is unnecessary if both the cylinder blockand valve plate are replacement parts (new parts).

Check contact between cylinder block and valveplate (For details, see procedure for checkingcontact.)

Motor case1) Using push tool a,, press fit outer race (49).2) Set motor case (29) to tool A.3) Install ball (45).

Rocker cam and shaft assembly1)

**

*

2)*

*

Using tool R, press fit bearing (44) to shaft (43)to make shaft assembly (42).Tool R: Push tool (709-465-I 120)When press fitting the bearing, push the endface of the bearing inner race with tool R andpress fit until it is in tight contact with the endface of the shaft.Press fitting load: 2.39 - 9.69 kN (224 - 988 kg)

QPress-fitting surface of bearing:Lubricating oil (EO-IOCD)

Install rocker cam (41) together with shaftassembly (42) to motor case (29).When installing three rocker cam, check thecontact with the ball, and check that the rockercam moves smoothly without interfering withthe motor case or shaft.Coat the ball hole in the rocker cam with grease (G2-LI). (To prevent it from coming outwhen the cylinder block and piston assemblyare assembled.)

49XlOAV164

44

42

43

30- 460




3. Cylinder block and piston assembly1) Assembly of cylinder block. 40 32 1

0

ii)iii)

iv)

Assembly spacer (40) spring (39), andspacer (40) to cylinder block (32).Set tool Q to cylinder block (32).Hold bolt of tool Q with wrench, tighten nutto compress spring (39), then install snapring (38).

* Check that the snap ring is fittingsecurely in the groove.

Remove tool Q.

2) Assembly of piston assembly.Assemble piston (37) to retainer shoe (36).

3) Assembly of cylinder block and pistonassembly.i) Assemble 3 preloaded pins (35) to cylinder

block (32).j, Coat the preload pins with grease (G2-

Ll) to prevent them from coming out.

ii) Assemble retainer guide (34) to cylinderblock (32) then assemble piston assembly(33) to make cylinder block and pistonassembly (28).* Align the cylinder block and the soline

38

36XlOAVl5j

35

34 33Xl OAVI 6E

of the retainer guide.

iii) Install cylinder block and(38) to motor case (29).

28

piston assembly

30-470




4. Plate, disc and piston1) Assemble plate (30) and disc (31) in order.

* Do not wash the discs in trichlene or drizol,or blow strongly with air.

Front face of disc: Lubricating oilA (EOIO-CD)

Method of placing plates and discs on

top of each other.i) Align cutout arc teeth areas G, H and I

of the discs.ii) Protrusions A, B, C, D, E, and F on the

outside of the plates can be set at anyposition in relation to discs G, H, and I.

A G A G A G A

b ’ b ’ d b

XlOAV172

2) Fit O-ring and backup ring, and install brakepiston (26).* Assemble so that the grove in the brake

piston is aligned with the dowel pin in theend cover.

* Assemble the backup ring in the directionshown in the diagram.

5. Adjusting end play of shaft1)

2)

3)

Using tool S and puller 8, press fit bearing (27)to shaft (43).

* Tool S: Push tool (796-460-I 120)* When press fitting the bearing, push the

end face of the bearing inner race with toolS and press fit until it is in tight contact withthe end face of the shaft.

* Press fitting load: 2.67 - 10.96 kN (272 -1118 kg)

-Press fitting surface of bearing:Lubricating oil (EOIO-CD)

Assemble spacer (10) to end cover (7), andinstall outer race (9).Align with dowel pin and install valve plate (8)

to end cover (7).*

*

Check that there is no interference with thebearing and pin.Do not hit the valve plate or apply anyimpact when assembling. (There is dangerthat this will damage the sliding surface orcause distortion.)

26

Backup ring

O-ring

4

Backup ring

8 9 10 7

30- 480




4) Install end cover (7) to motor case (29).j, Do not install the O-ring and spring of the

parking brake.-Mounting bolt: 460.9 + 29.4 Nm (47+ 3 kgm)

5) Fit dial gauge @ o motor case (29) move shaftin axial direction, and measure end play

between shaft and bearing.* End play: 0.05 - 0.25 mm

6) If dimension is not within standard value, adjustagain as follows.i) Remove end cover.ii) Remove valve plate and outer race.iii) Set outer race (9) to bearing, then measure

dimension a between end face of outerrace and case, and calculate spacer b from

the following formula.b = 12.95 -a

iv) Select spacer from table below.

XlOAV17:

al

b(mm) 1 1.70- 1.79 1 1.80- 1.89 1 1.90- 1.99 1 2.00-2.09

Spacer to 708-8H- 708-8H- 708-8H- 708-8H-select 32220 32230 32240 32250

v) Assemble selected spacer, then assembleagain according to assembly Steps 5-2 thru5-5, and measure end play.

vi) After completion of adjustment, removeend cover, then remove valve plate.

6. End cover assembly1) Assembly of end cover assembly.* Precautions when installing plug.

Remove all oil and grease from the plugand male thread (end cover), and drycompletely.When coating with adhesive, coat with two

drops (approx. 0.04 g) at a point 2-3 mmfrom the tip of the thread of the plug.Plug: Thread tightener (loctite

a 638/648)

XlOAV175

Do not apply any pressure to the plug for30 minutes after tightening.

30-490




i) Assemble valve (24), then fit O-ring andinstall plug (23).

Plug: 23.5 f 3.9 Nm (2.4 ~tr 0.4kgm)

ii) Assemble ball (22) then fit O-ring andinstall plug (21).

Plug: 23.5 f 3.9 Nm (2.4 f 0.4

kgm)

iii)

iv)

Assemble spool (20) spring (19) and seat(18) in order, then fit O-ring and install ring(17).Assemble valve (16) and spring (15) inorder, then fit backup ring and O-ring andinstall plug (14).

Plug: 137.3 f 14.7 Nm (14 + 1.5kgm)

v) Assemble spool (13) piston (12) andspring (11) in order, then fit O-ring and

tighten plug (6) temporarily.

2) Align with dowel pin, and install valve plate (8)to end cover (7).j, Check that there is no interference with the

bearing and pin.j, Do not hit the valve plate or apply any

impact when assembling. (There is danger

that this will damage the sliding surface orcause distortion.)

30-500




3) Install parking brake spring (25).4) Fit O-ring, align dowel pin with groove portion of

brake piston, and install end cover (7).* Be extremely careful that the O-ring does

not come out or get caught.Mating surface of motor case:

- Gasket sealant (LG-7 or LG-5)(Loctite 572/575)

Mounting bolt: 460.9 f 29.4 Nm (47f 3 kgm)

5) Tighten plug (6).Plug: 419.2 f 46.6 Nm (42.75 f4.75 kgm)

6) Fit backup ring and O-ring, and install safetyvalve assembly (5).

Safety valve assembly: 318.7 f24.5 Nm (32.5 f 2.5 kgm)

7. Piston plugAssemble piston (4) and spring (3) then fit O-ringand install plug (2).* Precautions when installing plug.

1) Remove all oil and grease from the plugand male thread (motor case), and drycompletely.

2) When coating with adhesive, coat with twodrops (approx. 0.04 g) at a point 2-3 mmfrom the tip of the thread of the plug.

Plug: Thread tightener (LoctiteA 638/648)

3) Do not apply any pressure to plug for 30minutes after tightening.

Plug: 362.8 + 39.2 Nm (37 f 4 kgm)

8. Installation of oil seal1) Check that there are no burrs or flashes at the

corners of the shaft.2) Using tool T, press fit oil seal (48).

j, Tool T: Push tool (796-465-l 130)Grip (790-101-5221)Bolt (01010-51225)

* Clean the oil seal lip.

- Tip of oil seal (wholecircumference) Grease (G2-Ll-S)

25

6

6

30- 510




3) Assemble spacer (47), and install snap ring(46). 46 47

30-520




CHECKING CONTACT BETWEENCYLINDER BLOCK AND VALVEPLATE

* This check is unnecessary if both the cylinder blockand valve plate are replacement parts (new parts).

* This check applies if one of the parts is areplacement part or a restored part.

* If the contact is defective, use a surface plate andcorrect by lapping.

1. Make a centering tool for the cylinder block andvalve plate.* The tool can be made from plastic, bakelite or

any other soft material.2. Remove all oil and grease from the parts to be

checked.* Do not wipe with a cloth.

3. Set the tool in position, then paint the cylinder blockwith inspection paint.* Coat thinly with paint.

4. Push the valve plate with a force of 39.2 - 49.0 N (4- 5 kg) against the cylinder block, turn the valveplate 90” , then turn it back to the original position.Repeat this process two or three times.

5. Remove the valve plate, transfer the contactsurface to a tape, and check the contact surface.* The contact of the plane surface of the valve

plate and cylinder block must fulfill the conditionbelow and cover the whole circumferencewithout any break.1) The contact at the seal portion (range of 0

84.4 - 0 116.5 from the inside) must be atleast 80%.

2) The contact at the land portion (range of 0128 - 0 142) must be at lease 60%.

*

30-530



DISASSEMBLY AND ASSEMBLY SPROCKET

REMOVAL OF SPROCKET

1. Remove track shoe assembly. For details, seeREMOVAL OF TRACK SHOE ASSEMBLY.

2. Swing work equipment 90” , then push up chassiswith work equipment and set block 0 between track

frame and track shoe.

3. Lift off sprocket (1).

INSTALLATION OF SPROCKET


AThread of sprocket mounting bolt:Thread tightener (LT-2)

Sprocket mounting bolt:

PC200-6, PC2OOLC-6, 465.8 f 24.5 Nm (47.5 fPC21 OLC-6, PC220LC-6 2.5 kgm)

PC25OLC-6 637 f 49 Nm (65 + 5kgm)

30-540



DISASSEMBLY AND ASSEMBLY SWING MOTOR

REMOVAL OF SWING MOTORASSEMBLY

A Lower the work equipment completely to the groundand stop the engine. Loosen the oil filler cap slowlyto release the pressure inside the hydraulic tank.Then set the safety lock lever to the LOCK position.

I. Disconnect hoses (I), (2), (3), and (4), and tubes(5) and (6) then remove filter and bracket assembly0.* 0 For machines equipped with additional

attachment circuit.

&

Filter, bracket assembly: 95 kgkg

2.

3.

Remove hose clamps (7) and (8).

Disconnect swing motor inlet and outlet hoses (9)(IO), and (11).

4. Remove bracket (12).

5. Disconnect drain hoses (13) and (14).

6. Disconnect pilot hose (15).

7. Remove swing motor assembly (16).Swing motor assembly: 65 kg

INSTALLATION OF SWINGMOTOR ASSEMBLY


0 Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specified


k Bleeding air* Bleed the air from the swing motor. For details,


30-550



DISASSEMBLY AND ASSEMBLY SWING MACHINERY

REMOVAL OF SWINGMACHINERY ASSEMBLY

1. Remove swing motor assembly. For details, seeREMOVAL OF SWING MOTOR ASSEMBLY.

2. Using eyebolts 0, remove swing machinery

assembly (1). Jx 1* When removing the swing mach;nkry

assembly, lift off slowly and be careful not todamage the hoses.

Swing machinery assembly: 215 kg

INSTALLATION OF SWINGMACHINERY ASSEMBLY


Swing machinery mounting bolt: 548.8?r49 Nm (56 f 5 kgm)

Refilling with oil (hydraulic tank)j, Add oil through the oil filler to the specified

level. Run the engine to circulate the oil throughthe system. There check the oil level again.

Bleeding air* Bleed the air from swing motor. For details, seeTESTING AND ADJUSTING, Bleeding air.

30- 560




DISASSEMBLY OF SWINGMACHINERY ASSEMBLY

1. Draining oilRemove drain plug and drain oil from swingmachinery.

Swing machinery case: Approx. 6.8 e

2. CoverRemove mounting bolts, then remove cover (1).

3. No. 1 ring gearRemove No. 1 ring gear (2).

2) Disassemble No. 1 carrier assembly as followsi) Remove snap ring (5) then remove thrust

washer (6) gear (7) bearing (8), and thrustwasher (9).

XO9DH042



I

30-570




6.

7.

ii) Remove holder (10).iii) Remove shaft (11) from carrier (12).iv) Remove snap ring (13) from shaft.

CouplingRemove coupling (14).

CoverRemove mounting bolts, then using eyebolts 0,remove cover (15) .

8. No. 2 ring gearRemove No. 2 ring gear (16).


10. BoltRemove holder mounting bolt (18).


12 10 11

13

XOSDHO4j

30- 580




2) Disassemble No. 2 carrier as follows.

9

*ii)

iii)

Push in pin (20), and knock out shaft (21)from carrier (22).After removing the shaft, remove pin (20).Remove thrust washer (23) gear (24)bearing (25) and thrust washer (26).Remove plate (27).

12. Shaft assembly1) Remove mounting bolts (28).2) Set shaft and case assembly to press, then

using push tool 0, remove shaft assembly (29)from case assembly (30).

21

23

24

25

262j

\ 20XOSDH050

3) Disassemble shaft assembly as follows. I0

ii)

Using push tool 0, remove cover assembly(31) and bearing (32) from shaft (33).Remove oil seal (34) from cover (35).

13. BearingUsing push tool, remove bearing (36) from case(37).

30-590




ASSEMBLY OF SWINGMACHINERY ASSEMBLY

* Clean all parts, and check for dirt or damage.Coat the sliding surfaces of all parts withengine oil before installing.

1.

2.

BearingUsing push tool @), press fit bearing (32) to case(37).

Cover assembly1) Using push tool 0, press fit oil seal (334) to

cover (35).

aOutside circumference of oil seal:Gasket sealant (LG-6)

* Be careful not to let the gasket sealant(LG-6) get on the oil seal lip when pressfitting.

2) Fit cover assembly (31) to case (37), andtighten mounting bolts (28).

Cover mounting surface: Gasketa sealant (LG-6)

Mounting bolt: 66.2 f 7.4 Nm (6.75+ 0.75 kgm)

Lip of oil seal: Grease (G2-Ll)

Case assemblySet case assembly (30) to shaft (33), then usingpush tool @, press fit bearing inner race portion.

* When setting the case assembly to the shaft,be extremely careful not to damage the oil seal.

30- 600




4. BearingUsing tool F, press fit bearing (36).* Press the bearing inner race and outer race at

the same time when press fitting. Do not pressonly the inner race when press fitting.

* After press fitting the bearing, check that thecase rotates smoothly.

5. No. 2 carrier assembly1) Assemble No. 2 carrier assemblv as follows

0ii)

iii)

There are the remains of the caulking whenthe pin is inserted at the end face of hole hat the side of the carrier, so remove thecaulked metal from the inside diameter ofthe hole before starting to assemble.

Assemble plate (27) to carrier (22).Assemble bearing (25) to gear (24) fit topand bottom thrust washers (23) and (26)and set gear assembly to carrier (22).Align position of pin holes of shaft andcarrier, then tap with a plastic hammer toinstall shaft (21).

iv)

* When installing the shaft, rotate theplanetary gear. Be careful not todamage the thrust washer.

Insert pin (20).* After inserting the pin, caulk the pin

portion of the carrier.

2) Install No. 2 carrier assembly (19).

6. BoltTighten bolt (18).

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

Mounting bolt: 176.4 + 19.6 Nm (18 +

2.0 kgm)

30- 610




7. No. sun gearInstall No. sun gear (17).

8. No. 2 ring gearInstall No. 2 ring gear (16).

ARing gear mounting surface:Gasket sealant (LG-6)

9. CoverUsing eyebolts 0, sling cover (15) align position ofholes for oil filler port as shown in diagram, theninstall.

Cover mounting- sealant (LG-6)

surface: Gasket

Mounting bolt: 276 ?s 31.9 Nm (28.25 +3.25 kgm)

10. CouplingInstall coupling (14).


i) Fit snap ring (13) to shaft (1 I), and tap witha plastic hammer to install shaft to carrier(12).

ii) Assemble holder (10).

Position ofoil filler port

XO9DHOl

30- 620




iii) Assemble thrust washer (9), bearing (8),gear (7), and thrust washer (6), and installsnap ring (5).* After assembling the carrier assembly,

check that gear (7) rotates smoothly.Sr Replace thrust washer (6) with a new

part.

iv) Install No. 1 carrier assembly (4).

12. No. 1 sun gearInstall No. 1 sun gear (3).

13.

14.

15.

No. 1 ring gearAlign position of holes for oil filler port of No. 1 ringgear (2) with cover (15) then install.

Ring gear mounting surface: GasketA sealant (LG-6)

CoverInstall cover (1).

Cover mountingA sealant (LG-6)

surface: Gasket

Mounting bolt: 110.3 f 12.3 Nm (11.25+ 1.25 kgm)

Refilling with oilTighten drain plug and add engine oil through oilfiller.

Swing machinery case: Approx 6.8 e

30 63

0



DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

REMOVAL OF REVOLVINGFRAME ASSEMBLY

1.

2.

3.

4.

5.

6.

Remove 2 boom cylinder assemblies. For details,see REMOVAL OF BOOM CYLINDER ASSEMBLY.

Remove work equipment assembly. For details, see

REMOVAL OF WORK EQUIPMENT ASSEMBLY.

Remove counterweight assembly. For details, seeREMOVAL OF COUNTERWEIGHT ASSEMBLY.

Disconnect top mounting hoses (I), (2) and (3) ofswivel joint assembly at swivel joint assembly end.

Remove stopper link (4).

Remove mounting bolts, then lift off revolving frameassembly (5). 1*

A

Leave 2 bolts 0 each at the front and rear, use

a lever block to adjust the balance of therevolving frame assembly to the front and rear,and left and right, then remove the remainingbolts, and lift off.When removing the revolving frame assembly,be careful not to hit the center swivel jointassembly.

Revolving frame assembly: 5,200kg

30- 640



DISASSEMBLY AND ASSEMBLY REVOLVING FRAME

INSTALLATION OF REVOLVINGFRAME ASSEMBLY


Mating surface of swing circle: GasketA sealant (LG-1)

AThread of revolving frame mountingbolt: Thread tightener (LT-2)

Revolving frame mounting bolt:

ItemMounting bolt

Mounting bolttightening torque

Model

PC200-6PC21 O-6

PC220-6PC250-6

Size

22-l 10

24-l 50



Bleeding air* Bleed the air. For details, see TESTING AND

ADJUSTING, Bleeding air.

30- 650



DISASSEMBLY AND ASSEMBLY SWING CIRCLE

REMOVAL OF SWING CIRCLEASSEMBLY

1. Remove revolving frame assembly. For details, seeREMOVAL OF REVOLVING FRAME ASSEMBLY.

2. Remove swing circle mounting bolts (I), leaving 1

bolt each in front and rear direction m* Swing circle assembly mounting bolts: 36

3. Sling swing circle assembly (2) at three points, thenremove remaining mounting bolts.

4. Lift off swing circle assembly (2).Swing circle assembly:

m

PC200-6, PC2OOLC-6 280 kgPC21 OLC-6, PC220LC-6

PC25OLC-6 I 716 ka

30- 660



DISASSEMBLY AND ASSEMBLY SWING CIRCLE

INSTALLATION OF SWINGCIRCLE ASSEMBLY


m/

1st pass:

2nd pass:

Thread of swing circle mounting bolt:Thread tightener (LT-2)

Swing circle mounting bolt: PC200-6,PC2OOLC-6, PC21 OLC-6, PC22OLC-6

Tighten to 191.3 f 19.6 Nm (19.5 f 2kgm)1)

2)i)

ii)

iii)

When using tool E.Set tool E to bolt (I), install clip toother bolt, then tighten bolt 48 f5” .

When not using tool E.Using the angle of the bolt head asthe base, make start marks on theswing circle and socket.Make an end mark at a point (onswing circle) 48 + 5” from the startmark.Tighten so that the start mark onthe socket is aligned with the endmark on the swing circle at the 48f 5” position.

Swing circle mounting bolt: PC250LC-6926.7 f 103.0 Nm (94.5 + 10.5 kgm)

G2et the soft zone S mark on the inside ring of

the inner race facing the right side as shown inthe diagram, then install to the track frame.

aSwing circle: Grease (G2-Ll)PC200-6, PC2OOLC-6, PC21 OLC-6,PC22OLC-6 = 21 QPC25OLC-6 = 34 P

lip

Swing circle start mark

Socketstart mark

socket&;zz2z$eerk

Socket start mark

Outer raoe soft zone

30- 670



DISASSEMBLY AND ASSEMBLY IDLER. RECOIL SPRING

REMOVAL OF IDLER. RECOILSPRING ASSEMBLY

1. Remove track shoe assembly. For details, seeREMOVAL OF TRACK SHOE ASSEMBLY.

2. Sling idler and recoil spring assembly (I), and pull

out to the front to remove.Idler recoil spring assembly:

*

3. Disconnect recoil spring assembly (3) from idlerassembly (2). m

Idler Recoil spring

PC200-6, PC200LC-6PC21 OLC-6, PC22OLC-6 I I

140 kg 135 kg

PC25OLC-6 166 kg 257 kg

INSTALLATION OF IDLER.RECOIL SPRING ASSEMBLY


PC200-6, PC200LC-6, PC21OLC-6, and PC220LC-6* When installing the idler assembly and recoil spring

assembly, assemble so that the position of thegreasing plug on the idler is on the outside for theright side of the machine and on the inside for theleft side of the machine.

PC25OLC-6* Install recoil spring assembly (3) to idler assembly

(2) so that the mud removal hole in the yoke is atthe bottom.

0

6ii?\ s

0

0

\Mud removal ole

30- 680



DISASSEMBLY AND ASSEMBLY RECOIL SPRING

DISASSEMBLY OF RECOILSPRING ASSEMBLY

1

--_ .- - - .--. I

[

II’L

1. Remove piston assembly (2) from recoil springassembly (1).

2. Disassembly of recoil spring assembly1) Set recoil spring assembly (1) to tool H,.a The recoil spring is under large installed load,

so be sure to set the tool properly. Failure to dothis is dangerous.

* Installed load of spring:PC200: 108,780 N (11,100 kg).PC200LC,PC210LC,PC22OLC: 126,420 N (12,900 kg)

PC25OLC: 173,260 N (17,680 kg)2) Apply hydraulic pressure slowly to compress

spring, and remove lock plate (3), then removenut (4).* Compress the spring to a point where the

nut becomes loose.* Release the hydraulic pressure slowly and

release the tension of the spring.* Free length of springPC200: 558 mmPC2OOLC, PC210LC, PC22OLC: 603.5 mmPC25OLC: 795 mm

3) Remove yoke (6) cylinder (7) and dust seal

(8) from spring (5).3. Disassembly of piston assembly

1) Remove lock plate (10) from piston (9) thenremove valve (11).

2) Remove snap ring (12), then remove U-packing(13) and ring (14).

30- 690



DISASSEMBLY AND ASSEMBLY RECOIL SPRING

ASSEMBLY OF RECOIL SPRINGASSEMBLY

1. Assembly of piston assembly1) Assemble ring (14) and U-packing (13) to

piston (9) and secure with snap ring (12).2) Tighten valve (11) temporarily, and secure with

lock plate (10).

2. Assembly of recoil spring assemblyUsing tool H,, install dust seal (8) to cylinder(7).

1)

2)

3)

4)

Assemble cylinder (7) and yoke (6) to spring(5) and set in tool H,.

Sliding portion of cylinder: GreaseA (G2-Ll)

Apply hydraulic pressure slowly to compressspring, and tighten nut (4) so that installedlength of spring is dimension “a”, hen secure

with lock plate (3).Jr Installed length “a” of spring:PC200: 437 mmPC2OOLC,PC21OLC, PC22OLC: 466 mmPC25OLC: 648 mmRemove recoil spring assembly (1) from tool

HI .

3. Assemble piston assembly (2) to recoil springassembly (1).

Sliding portion of piston, wear ring:A Grease (G2-Ll)

* Assemble the cylinder assembly so that themounting position of the valve is 90” to theside.

j, Fill the inside of the cylinder with 300 cc ofgrease (G2-Ll), then bleed air and check thatgrease comes out of the grease hole.

“ 2,

30-700



DISASSEMBLY AND ASSEMBLY IDLER

DISASSEMBLY OF IDLERASSEMBLY

1. Remove dowel pin (I), then remove support (2).

2. Remove floating seal (3) from support (2) and idler(4).

3. Pull out idler (4) from shaft (5) and support (7)assembly.* It is filled with oil, so drain the oil at this point or

lay a cloth to prevent the area from becomingdirty.

4. Remove floating seal (6) on opposite side fromidler (4) and shaft (5) and support (7) assembly.

5.

6.

Remove dowel pin (8), then remove support (7)from shaft (5).

Remove bushings (9) and (19) from idler (4).

30- 710



DISASSEMBLY AND ASSEMBLY IDLER

ASSEMBLY OF IDLERASSEMBLY

1. Press fit bushings (9) and (10) to idler (4).

2. Fit O-ring and install support (7) to shaft (5) withdowel pin (8).

3. Using tool G,, install floating seal (6) to idler (4) andshaft (5) and support (7) assembly.* Coat the sliding surface of the floating seal with

oil, and be careful not to let any dirt or dust getstuck to it.

* Remove all grease and oil from the contactsurface of the O-ring and the floating seal.

4. Assemble shaft (5) and support (7) assembly toidler (4).

10

X14AVO21

6

X14AVO23

30- 720



DISASSEMBLY AND ASSEMBLY TRACK ROLLER

REMOVAL OF TRACK ROLLERASSEMBLY

1. Lower work equipment, then loosen lubricator (1)and relieve track tension. mA The adjustment cylinder is under extremely

high pressure. Never loosen the lubricator more

than one turn. If the grease does not come outeasily, move the machine backwards andforwards.

2. Remove mounting bolts of track roller, then swingwork equipment 90” , jack up machine, and removetrack roller assembly (2) towards outside ofmachine.

Track roller assembly:PC200, PC2OOLC, PC21 OLC, PC220LC40 kgPC25OLC52 kg

INSTALLATION OF TRACKROLLER ASSEMBLY


* Adjust the track tension. For details, seeTESTING AND ADJUSTING, Testing andadjusting track tension.

lace the plug on the outside of the chassis,

*

*

and set the-track roller assembly in themounting position.Operate the work equipment levers to lower themachine slowly, then tighten the mounting boltstemporarily.Operate the work equipment levers to lower themachine completely to the ground, then tightenthe mounting bolts fully.

Track roller assembly mounting bolt:PC200, PC2OOLC, PC21 OLC, PC22OLC

--

i--I-

I

,K3

1st pass: Tighten to 196.1 + 19.6 Nm (20 + 2kgm)

2nd pass: 1. When using tool K,.Using an angle tightening wrench,tighten bolt 90 f 5” .

2. When not using tool KJ.

30-740




1)

2)

3)

Using the angle of the bolt head asthe base, make start marks on thetrack roller and socket.Make an end mark at a point 90 +5” from the start mark.Tighten so that the start mark onthe socket is aligned with the endmark on the track roller.

Track roller start mark

Socket I

End mark

2nd pass: I:0

21)

2)

3)

When using tool K,.Using an angle tightening wrench,tighten bolt 105 + 5” .When not using tool K,.Using the angle of the bolt head asthe base, make start marks on thetrack roller and socket.

Make an end mark at a point 105 +5” from the start mark.Tighten so that the start mark onthe socket is aligned with the endmark on the track roller.

track roll r end mark ISocket start markw Track roller assembly mounting bolt:

PC25OLC

I X14BR015

1st pass: Tighten to 196.1 f 19.6 Nm (20 f 2kgm)

Track roller start mark

. “..._.. _.

’rade roller end mark Socket start mark

30-750




DISASSEMBLY OF TRACKROLLER ASSEMBLY

1. Remove pin (I), then remove collar (2).

2. Remove floating seal (3) from collar (2) and roller(4).

3. Pull out roller (4) from shaft (5).* It is filled with oil, so drain the oil at this point or

lay a cloth to prevent the area from becomingdirty.

4. Remove floating seal (6) on opposite side fromroller (4) and shaft (5).

5. Remove pin (7) then remove collar (8) from shaft(6).

6. Remove bushings (9) and (10) from roller (4).

Xl4BROl7

X14BR018

I X14BROl

30- 760




ASSEMBLY OF TRACK ROLLERASSEMBLY

1. Using push tool 0, press fit bushings (9) and (10) toroller (4).

2.

3.

Assemble collar (8) to shaft (5) and install pin (7).

Using tool K,, install floating seal (6) to shaft (5).* When assembling the floating seal, clean the

contact surface of O-ring (6~) and floating seal(6a), remove all grease and oil, and dry it.Make sure that no dirt or dust sticks to thecontact surface of the floating seal.

4. Using tool K,, install floating seals (6) and (3) to theroller (4).* For details of the precautions when installing

floating seals (6b) and (6d), and (3b) and (3d),see the precaution for Step 3.

5. Assemble shaft (5) to roller (4).

6.

7.

Turn over roller (4) and shaft (5) assembly.

Using tool K,, install floating seal (3) to collar (2).* For details of the precautions when installing

floating seals (3a) and (3c), see the precautions

for Step 3.

8. Assemble collar (2) to shaft (5) and install pin (1).

,KI

K1

3-c;

30-770



DISASSEMBLY AND ASSEMBLY CARRIER ROLLER

REMOVAL OF CARRIER ROLLERASSEMBLY

1. Lower work equipment, then loosen lubricator (I),and relieve track tension. mlA The adjustment cylinder is under extremely

high pressure. Never loosen the lubricator more

that one turn. If the grease does not come out,move the machine backwards and forwards.

2. Using hydraulic jack 0, push up the track to aposition where carrier roller assembly can beremoved, then remove carrier roller assembly(2).

Carrier roller assembly:m

PC200, PC2OOLC PC21 OLC, PC220LC21 kgPC25OLC31 kg

INSTALLATION OF CARRIERROLLER ASSEMBLY



?%2

read of carrier roller assembly mounting bolt:Thread tightener (LT-2)

--

r-=--l-

X14BR028

30-790




DISASSEMBLY OF CARRIERROLLER ASSEMBLY

1. Remove plug (1) and drain oil.

:Carrier roller assembly:

u PC200, PC200LC PC21OLC, PC22OLC230 - 250 ccPC25OLC450 - 500 cc - X14BRO31

2.

3.

4.

5.

6.

Set carrier roller assembly on stand 0.

Remove cover (2).

Remove ring (3).

Using tool L,, remove nut (4).

Using push tool 0, pull out shaft assembly (5) fromroller (6) with press, then remove inner race (7).

6

lIsE l9

7. Remove outer races (8) and (9) from roller (6). -i X14BR032

8. Disassembly of shaft assembly1) Using puller 0, remove inner race (10).2) Remove floating seals (11).3) Using push tool a,, remove collar (12) from

shaft (13).

X14BR030

30- 800




ASSEMBLY OF CARRIERROLLER ASSEMBLY

1. Using push tool 6, press fit outer races (8) and (9)to roller (6).

2. Assembly of shaft assembly

1) Using push tool @, press fit collar (12) to shaft(13).jr When press fitting, be careful that there is

no scuffing.Fitting portion of shaft: SAE30

2) Using tool LJ, assemble floating seals (11).* When assembling the floating seal, clean

the contact surface of O-ring (11~) andfloating seal (1 la), remove all grease andoil, and dry it. Make sure that no dirt or duststicks to the contact surface of the floating

seal.3) Assemble floating seals (1 I), then using push

tool 8, press fit inner race (10).* For details of the precautions when

installing floating seals (11 b) and (1 Id),see the precaution for Step 2).

3. Assemble roller (6) to shaft assembly (5).

4. Using push tool @), press fit inner race (7).* When press fitting the bearing, rotate the roller,

and press fit to a point where the rotationbecomes slightly heavier.

5. Using tool L,, tighten nut (4) to a point where drillhole in shaft is aligned with drill hole in nut.

6. Install ring (3).

7. Using push scale 8, check that it rotates smoothly.

lla

llc 1

30- 810




9.

10.

Using tool L,, apply basic pressure to roller oil fillerport, and check for leakage of air from seal.* Basic pressure: 98 kPa (1 kg/cm2)* Method of checking: The basic pressure shall

be maintained for 10 seconds and the indicatorof the gauge shall not go down.

Using tool L,, fill carrier roller assembly with oil,then tighten plug (1).

Carrier roller oil:PC200, PC2OOLC, PC21 OLC, PC22OLC230 - 250 cc (SAE30)PC25OLC450 - 500 cc (SAE30)

To vacuum tank

30- 820



DISASSEMBLY AND ASSEMBLY TRACK SHOE

REMOVAL OF TRACK SHOEASSEMBLY

1.

2.

3.

4.

5.

Stop machine at a point where master pin ismidway between idler and carrier roller, and wherethere is space to lay out track assembly on ground.

Lower work equipment, then loosen lubricator (1)and relieve track tension. m/A The adjustment cylinder is under extremely

high pressure. Never loosen the lubricator morethan one turn. If the grease does not come out,move the machine backwards and forwards.

Using tool I, pull out master pin (2). m

Remove tool I, and move machine forward so thatthe position of temporary pin 0 is at front of idler,and set block 0 in position.

Remove temporary pin Q, and remove dust seal,then drive machine in reverse to lay out track (3).

INSTALLATION OF TRACK SHOEASSEMBLY



se tool I and press fit so that the protrusion ofthe master pin is dimension “a”.Protrusion ‘a” of master pin:PC200, PC2OOLC, PC21 OLC, PC22OLC4*2mmPC25OLC4.2 + 2 mm

hen assembling the dust seal, coat thebushing contact surface with grease (G2-Ll).

30- 830



DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

REMOVAL OF HYDRAULIC TANKASSEMBLY

1.

2.

3.

4.

5.

Drain oil from hydraulic tank.Hydraulic tank: 170 P

Remove R.H. side cover together with covermounting frame.

Remove engine hood (I), hood mounting bracket(2), cover (3), and engine room divider board (4).

Disconnect pump outlet hoses (5).

Remove pump suction tube (6) together with jointhose (7).

6. Remove connector (8) at side of hydraulic tank fromholder and disconnect, then open wiring harnessmounting clamp 0 and disconnect wiring harness(9) from hydraulic tank.

I

7. Disconnect hoses (IO), (1 I), (12) and (12A).

XlOBVOW

30- 840



DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK

8. Remove nut of U-bolt (14) for clamp of hydraulic oilreturn tube (13) then disconnect tube (13) fromhydraulic tank, and pull towards muffler with rope.

9. Remove mounting bolts, and lift off hydraulic tankassembly (15).

Hydraulic tank: 135 kg

INSTALLATION OFTANK ASSEMBLY

Carry out installation inremoval.

HYDRAULIC

the reverse order to

Hydraulic tank mounting bolt: 276.9 f

31.9 Nm (28.25 f 3.25 kgm)

Refilling with oil (hydraulic tank)jr Add oil through the oil filler to the specified


Bleeding air* For details, see TESTING AND ADJUSTING,

Bleeding air.

lOBV056

30- 850



DISASSEMBLY AND ASSEMBLY CONTROL PUMP

REMOVAL OF CONTROL PUMPASSEMBLY

A

0

1.

2.

3.

Lower the work equipment completely to the groundand stop the engine. Then loosen the oil filler capslowly to release the pressure inside the hydraulictank.

Remove the hydraulic tank strainer, and using toolB, stop the oil.


Hydraulic tank: Approx. 170 e

Remove control pump inlet tube (1).

Disconnect control pump outlet hoses (2).

Remove control pump assembly (3) then remove

coupling (4). m

INSTALLATION OF CONTROLPUMP ASSEMBLY


Control pump mounting bolt: 66.2 r 7.4Nm (6.75 f 0.75 kgm)

r----



30- 860



DISASSEMBLY AND ASSEMBLY MAIN PUMP

REMOVAL OF MAIN PUMPASSEMBLY

A

0

0

1.

2.

3.

4.


Remove the hydraulic tank strainer, and using toolB, stop the oil.


Drain oil from damper case.

Remove engine hood cover, side cover by pump,chassis cover on top of main pump assembly, andmounting frame.

Disconnect control pump hoses (1) and (2) and Fservo hoses (3) and (4) then disconnect tube (5) at

pump end.

Remove connectors (6) and (7) from holder anddisconnect.j, Disconnect the clamps of the connector wiring

from the body also.

Disconnect R servo hose (8) and remove divider

board (9) between engine and pump.

5. Disconnect top mounting hoses (IO), (II), (12)(13), and (14) of main pump assembly.

6. Disconnect suction tube (15) at bottom of mainpump, move down together with tube (5) andsecure.

7. Remove cover (16) behind hoses (10) - (15).

r

30- 870




8. Remove main pump assembly as follows. I1)2)

3)

4)

5)

Leaving 2 - 3 bolts, remove mounting bolts.Sling main pump assembly (17) and removeremaining mounting bolts.Install 2 guide bolts 0 on diametrically oppositesides.Using forcing screws 0, disconnect main pumpassembly (17).

Lift off main pump assembly (17). mj

Main pump assembly: 147 kg

INSTALLATION OF MAIN PUMPASSEMBLY


&Involute spline of main pump: Anti-friction compound (LM-G)

AMating surface of main pump case:Gasket sealant (LG-6)

0 Refilling with oil (damper)* Add engine oil through the oil filler to the

specified level. Then check the oil level again.

Refilling with oil (hydraulic tank)

j, Add oil through the oil filler to the specifiedlevel. Run the engine to circulate the oil throughthe system. Then check the oil level again.

Bleeding air* Bleed air from the main pump. For details, see

TESTING AND ADJUSTING, Bleeding air.

30- 880




DISASSEMBLY OF MAIN PUMPASSEMBLY (HPV95 + 95)

1.

2.

3.

0

4.

a

Pump assemblySet pump assembly (1) to tool A.* Tool A: Unit repair stand (790-501-5000)

Bracket (790-901-2110)

Plate (790-901-2150)

HoseRemove hose (2) elbow and tee.

Rear pump assembly1) Sling rear pump assembly2) Remove eight bolts at rear pump end, then

remove rear pump assembly (3).* Leave the end cap at the front end.* Be careful not to drop the rear valve plate,

cylinder block, piston assembly or otherparts.

Disassembly of front pump assembly

Control valve assembly1) Remove control valve assembly (4).2) Disassembly of control valve assembly.lVC valve

9

ii)

iii)

iv)

v)

vi)

Remove solenoid assembly (5) thenremove sleeve (6) and spool (7).Remove seat (8) then remove springs (9)and (10).Remove plug (1 I), then remove piston(12).

Remove locknut (13) then remove plug(14) and lever assembly (15).Remove nut (16) from lever assembly (15),then remove washer (17), bearing (18), pin(19) and lever (20).Remove snap ring (21) then remove plug(22).

LS valvei) Remove locknut (23) then remove plug

(24) seat (25) spring (26) and seat (27).j, Measure the dimension between the end

face of locknut (23) and the end face ofplug (24).

ii) Remove plug (28) then remove sleeve(29), piston (30) and spool (31).

Remove filter (32) then remove spacer (33) andorifice (34).

Xl OAV18i




5.

6.

End cap and valve plate1) Remove bolt (35) then remove washer (36)

shim (37) and seat (38).* Check the number and thickness of the

shims, and keep in a safe place.2) Remove end cap (39).

* When the valve plate is stuck to the endcap, be careful not to drop it.

3) Remove valve plate (40).

Disassembly of end capi) Remove dowel pin (41) from end cap (39).ii) Remove bearing (42).iii) Remove snap ring (43).iv) Remove coupling (44) and ring (45).

Cylinder block and piston assemblyRemove cylinder block and piston assembly (46)from pump case (47).j, The cylinder block and piston assembly may

come off separately, so be careful not to dropthem.

XlOAV18

42

30-900




Disassembly of cylinder block and pistonassemblyPull out piston assembly (49) from cylinder block(48) and remove retainer guide (50) and preloadpin (51).j, When removing the piston assembly from the

cylinder block, the preload pin may come out,so be careful not to lose it.

0 Disassembly of piston assemblyPull out piston (53) from retainer shoe (52).

Disassembly of cylinder blocki) Set tool U to cylinder block (46).

* Tool U:Bolt (790-201-3330)Washer (792-422-l 120)Washer (01643-32460)

Washer (01643-31845)Nut (01580-01815)

ii) Hold bolt of tool U with wrench, tighten nut tocompress spring, and remove snap ring (54).

iii) Loose nut of tool U slowly to release tension ofspring (55) then remove tool U.

iv) Remove seat (56), spring (55) and seat (57)from cylinder block (48).* Check the assembly direction of seat (57).

7. Servo piston assembly1) Remove plug (58). (Front pump only)2) Remove plug (59), then remove spring (60).

48 ’

1XlOAV19'

53\

48/

58 59 60 Y 0AV201

30-9 10




3)

4)

5)

6)

8. Shaft and cradle assemblyRemove rocker cam (64) from shaft and cradleassembly (65).

1)

2) Remove four bolts, then remove shaft andcradle assembly (65) from pump case (47).

Using bolt (6mm), remove stopper (61).

Set tool V in position, and assemble spacer 0to left side of rod (62).* Tool V:

Holder assembly (791-463-l 100)Plate (791-463-I 150)Bolt (791-463-I 160)

Move to side and loosen piston (63) so that

width across flats of rocker cam comes off fromwidth across flats of cradle.Remove piston (63) then remove rod (62).* Check the assembly direction of rod (62).

I

I \64’ 1 \

30-920




Disassembly of shaft and cradle assembly1)

2)

3)

Push cradle (67) with push tool 0 to remove itfrom shaft (66). When removing, be careful tokeep cradle (67) straight.Remove snap ring (68) then remove washer(6%

Using push tool 0, remove bearing (70) fromshaft (66).* Bearing (70) divides into the flange ring

and the bearing, so be careful not to loseeither part.

A Check the installation direction of thebearing.

9. Disassembly of pump case.1) Loosen locknut (72) of minimum swash plate

angle adjustment screw (71) and removescrew (71) and seal washer.\j, Before loosening the locknut, measure

dimension L between the end face of thecase and the end face of the screw.

2) Rotate tool A 90”, remove snap ring (73) frompump case (47), then remove spacer (74).

3) Remove oil seal (75).

IO. If above disassembly operation is not needed,and only oil seal is replaced, replace oil seal asfollows.1) Remove snap ring (73) and spacer (74).2) Using bar 8, hit end face with hammer. Hit

through to core of oil seal (75), then twist toremove.j, Hit at a point midway between the inside

and outside circumference of the oil seal,and twist at two places on opposite sides(A and B in diagram) to remove.

* Be careful not to damage the shaft.

69

30-930




0

11.

12.

13.

14.

15.

16.

17.

Disassembly of rear pump assembly

Rear pump assemblySet rear pump assembly (3) to tool W.* Tool W: Unit repair stand (790-501-5000)

Bracket (790-901-2110)Plate (790-901-1371)Plate (790-901-I 390)

Control valve assemblySame operation as in Item 4.

Control pump assemblyRemove control pump assembly (76) then removecollar (77) and coupling (78).

Cylinder block and piston assemblySame operation as in Item 6.

Servo piston assemblySame operation as in Item 7.

Shaft and cradle assemblySame operation as in Item 8.

Disassembly of pump caseLoosen locknut (80) of minimum swash plate angle

adjustment screw (79) then remove screw (79).* Before loosening the locknut, measure thedimension between the end face of the locknutand the end face of the screw.

76

77

80/

30-940




ASSEMBLY OF MAIN PUMPASSEMBLY (HPV95 + 95)

Clean all parts, remove all burrs, and check for dirt ordamage. Coat the rotating and sliding surfaces of allparts with engine oil (EOI O-CD) before installing.

Always check the following parts before assembling.1)

ii)

iii)

1.

Check contact of cradle and rocker cam (for details,see procedure for checking contact)Check contact between cylinder block and valveplate (for details, see procedure for checkingcontact).Check contact between valve plate and end cap (fordetails, see procedure for checking contact).

Assembly of front pump assembly

Shaft and cradle assemblyAssembly of shaft and cradle assembly

1) Assemble flange ring to shaft (66) then usepush tool @to press fit bearing (70).

Press-fitting surface of bearing: Grease- (G2-Ll)

2)

0

* When press fitting the bearing, push theend face of the bearing inner race withpush tool @.

Assembly washer (69), and install snap ring(68).Method of selecting lock washer (69).I) After press fitting bearing (70) to shaft (66)

assemble washer (69) (removed during

disassembly).ii) Measure clearance dimension a betweenend face of assembled washer (69) andsnap ring groove.j, Clearance dimension a: 1.45 - 1.60

mmiii) If clearance is not within above standard

value, select washer from table below andassemble.

WasherPart No.

Xl OAV214

Snap ring groove

66 Xl OAV215

Washer

thickness(mm)

3.1 3.0 2.9 2.8

30-950




3) Using push tool 6, press fit cradle (67) to shaft(66) to make shaft and cradle assembly (65).

Press-fitting surface of bearing:A Grease (G2-Ll)

* When press fitting the bearing, push theend face of the bearing outer race withpush tool 6.

4) Set pump case (47) to tool A. (front pump only)Set the rear pump to tool W.

5) Fit dowel pin and O-ring to bottom surface ofinside of pump case (47) then install shaft andcradle assembly (65).

Cradle mounting bolt: 110.3 f 12.3Nm (11.25 f 1.25 kgm)

* Be careful that there is no rising and thatthe pin does not fail out.

* Be extremely careful that the O-ring doesnot come out or get caught.

2. Rocker camAssemble rocker cam (64) to shaft and cradleassembly (65).

.67

30- 960




3. Piston1) Assemble spherical portion of rod (62) to rocker

cam.* When assembling the rod, assemble with

the spring seat surface facing to the left.2) Fit piston (63) set tool V on top of rod (opposite

from when loosening), set spacer 0 on left sideof rod (62), and tighten piston (63).

* Before tightening piston (63), move to theside so that the width across flats of therocker cam comes out from the widthacross flats of the cradle. (This is to Xl OAV2l i

prevent damage to the rocker cam andcradle when tightening the piston.

-Near # area of piston thread indiagram on right. Coat with threedrops of adhesive (Loctite 648).

Coat with three drops near area

Piston: 318.7 f 24.5 Nm (32.5 + 2.5kgm)

4. Positioning minimum swash plate angle.1) Set tool X in position.

* Tool X:Cage assembly (796-460-1400)Plate (796-460-1410)Plate (796460-1420)Bolt (01010-51025) X2Bolt (01010-51435) X2

2) Assemble backup ring and O-ring, and tightenscrew (71) until it contacts piston (63).* Install the seal washer and locknut (72) to

screw (71) at position A in the diagram onthe right before the tip of screw (71) entersthe piston hole of the case.

Screw: 12.3 f 2.5 Nm (1.25 f 0.25kgm)

3) Tighten locknut (72).Between case and screw: Gasket

- sealant (LG-7 or LG-5 (Loctite

5721575))

w Locknut: 220.6 + 24.5 Nm (22.5 +2.5 kgm)

Pump case

72

71 63

4) After completion of assembly, carry out a benchtest to check the minimum flow.

30-970




5) Assemble backup ring and O-ring to stopper(61) and install to case.

5. Cylinder block and piston assemblyAssembly of cylinder blockAssemble seat (57), spring (55) and seat (56)to cylinder block (48).* Assemble with the tapered portion on the

inside of seat (57) facing down.

0

1)

2)3)

4)

Set tool U to cylinder block (48).Hold bolt of tool U with wrench, tighten nut tocompress spring (55) then install snap ring(54).j, Check that the snap ring is fitted securely

in the groove.Remove tool U.

Assembly of piston assemblyAssemble piston (53) to retainer shoe (52).

Xl OAV20:

30- 980




6.

5)

6)

7)

Assemble three preload pins (51) to cylinderblock (48).* To prevent the preload pin from coming

out, coat the pin with grease (G2-Ll).Assemble retainer guide (50) to cylinder block(48), then install piston assembly (49) to makecylinder block and piston assembly (46).* Align the spline for the cylinder block and

retainer guide.

Install cylinder block and piston assembly (46)to pump case (47).* Before assembling the cylinder block and

piston assembly, assemble the widthacross flats of the rocker cam to the cradlesecurely.

End cap and valve plate1) Assembly of end cap

i) Assemble ring (45) to coupling (44) thenassemble to end cap (39).

ii) Install snap ring (43).iii) Using push tool 8, press fit bearing (42) to

end cap (39).Press-fitting surface of bearing:

a Grease (G2-Ll)

iv) Install dowel pin (41) to end cap (39).

2) Assemble valve plate (40) to end cap (39) andinstall to pump case.* Check that there is no interference with the

bearing and pin.* Do not hit the valve plate or apply any

impact when assembling. (There is dangerthat this will damage the sliding surface orcause distortion.)

XlOAV191

41 42. \ r-l *@ ?9

Xi OAVtg

30-990




3) Assemble dowel pin and O-ring to end cap(39), then assemble coupling (44) and ring (45)to shaft (66), and install pump case.* Be careful that there is no rising and that

the pin does not fall out.* Be extremely careful that the O-ring does

not come out or get caught.Mating surface of pump case:

A Gasket sealant (LG-7 or LG-5(Loctite 5721575))

Mounting bolt: 176.5 ?r 19.6 Nm (18+ 2 kgm)

7. Measuring rotating torque of pump assembly1) Set tool Y to pump shaft.

* ToolY:Bolt (01435-01014)Torque wrench (795-630-I 803)

2) Set torque wrench to tool Y, rotate shaft at low

speed (3 - 5 set/l turn) and measure rotatingtorque.* Check that the shaft rotates smoothly when

measuring the rotating torque.Variation range: Max. 0 - 2.9 Nm (0 -0.3 kgm)Rotating torque: Max. 0 - 24.5 Nm (0 -2.5 kgm)

* If there is any abnormality in the rotatingtorque, disassemble again and check.

8. Spring and plug1) Assemble spring (60) then fit O-ring and install

plug (59). Plug (59): 107.9 + 14.7 Nm (11 +1.5 kgm)

2) Install plug (58). Front only.

WPlug (58): 126.0 f 39.7 Nm (12.85 +4.05 kgm)

XIOAVIS

58 59 60 Y, a\, 40‘

30- 1000




9. Positioning maximum swash plate angle1) Install seat (38), shim (37), washer (36) and

bolt (35) to end cap (39).* Install the same shim (37) (for determining

position of max. swash plate angle) as wasremoved during disassembly, or assemblethe standard shim shown below.

Shim part No. Thickness(mm)

No. of standardshims

708-21-24170 1 0.1 I ~~ 2

708-21-24180 0.2 2

708-21-24190 0.5 2

Bolt (35): 156.9 + 9.8 Nm (16 + 1 kgm)

2) After completion of assembly, carry out a bench

test of the performance, and make the finalshim adjustment.

IO. Installation of oil seal.1)

2)

3)

Check that there are no burrs or flashes at thecorners of the shaft.Using tool Z, press fit oil seal (75).j, Tool 2:

Push tool (791-463-1141)Spacer (790-21 o-2740)

Assemble spacer (74) and install snap ring(73).

I_

30- 1010




II_ Control valve assembly1) Assembly of control valve assembly0 LS valve

i) Assembly spool (31) piston (30) andsleeve (29) to body, then fit O-ring andinstall plug (28).

.Plug‘ (28): 110.3 f 12.3 Nm (11.25f 1.25 kgm)

j, Check that the relative movements ofthe body and spool (31), sleeve (29)and piston (30) are smooth.

ii) Assemble seat (27) spring (26) and seat(25) then fit backup ring and O-ring andinstall plug (24).

iii) Install locknut (23).Locknut (23): 68.6 4 9.8 Nm (7 f 1

kgm)

* Install so that the dimension betweenthe end face of locknut (23) and the

end face of plug (24) is the dimensionmeasured during disassembly.

iv) After completion of assembly, carry out abench test of the performance and makefinal adjustment of plug (24).

0 TVC valvei) Fit O-ring and assemble plug (22), then

install snap ring (21).ii) Install pin (19), washer (17) bearing (18)

and nut (16) to lever (20) to make leverassemblv (15).

Nut‘ (l6): 10.8 f 1.0 Nm (1.1 f 0.1

kgm)

Nut (16):A 648)

Thread tightener (Loctite

j, Check that the movement of lever (20)and bearing (18) is smooth.

15

30- 1020




iii) Fit O-ring to plug (14), then install to leverassembly (15) and body.* Tighten to a point where the tip of the

plug is in contact with plug (22) thenturn back at least 180” and move fromthe mark to the position in the diagramon the right @=O.

iv) install locknut (13).

w Locknut (i3): 29.4 + 4.9 Nm (3 f0.5 kgm)

* Check that the movement of lever (20),plug (22) and plug (14) is smooth.

v) Assemble piston (12) then fit O-ring andinstall plug (11).

Plug (11):0.15 kgm)

vii) Install O-ring,assembly (5).

11.3 ?_ 1.5 Nm (1.15 +

then install solenoid

Solenoid assembly mounting bolt:

13.2 f 1.5 Nm (1.35 + 0.15 kgm)

- Mating surface of solenoidassembly: Gasket sealant (LG-7 orLG-5 (Loctite 5721575))

viii) Using tool AA, check that there is noleakage of oil or air from the mating surfacewith the solenoid assembly.

ix)

* Tool AA:Oil leak tester (799-301-1500)

* Air pressure: 0.5 MPa (5 kg/cm2)After completion of assembly, carry out abench test of the performance and make

final adjustment of plug (14).

Direction to loosen plug

Position I#J 0” when mark0

AAXlOAV221J

30- 1030




12. Rear pump assemblyAssemble dowel pin and O-ring to end cap, slingrear pump assembly (3), then align with spline ofshaft and install.* When slinging, be careful not to drop the

cylinder block, piston assembly, or other parts.

-Mating surface of pump case: Gasketsealant (LG-7 or LG-5 (Loctite 572/575)

mMounting bolt: 176.5 f 19.6 Nm (18 + 2

kgm)

13.

14.

HoseInstall elbow, tee and hose (2).

DHose: 24.5 f 4.9 Nm (2.5 + 0.5 kgm)

Pump assemblyRemove pump assembly from tool A.

2)

3)

Assemble orifice (34), and install spacer (33)filter (32) and O-ring.

Orifice (34): 9.8 f 2.0 Nm (I .O f 0.2kgm)

After completion of assembly, carry out benchtest of servo valve assembly (4) as anindividual part to check performance and carry

out adjustment.Fit O-ring and filter to control valve assembly(4) and install to pump case.* Be extremely careful that the O-ring and

filter do not fall out.* Tighten the mounting bolts gradually in turn

on opposite sides.Mounting bolt: 66.2 + 7.3 Nm (6.75+ 0.75 kgm)

Mating surface of servo valve:a Gasket sealant (LG-7 or LG-5

(Loctite 572/575)

Xl 0AV223

30- 1040




0

15.

Assembly of rear pump assembly

Shaft and cradle assemblySame operation as in Item 1. (Set pump case totool W.)

16. Rocker camSame operation as in Item 2.

17. PistonSame operation as in Item 3.

18. Positioning minimum swash plate angle

1)2)

3)

4)

Set toolX in position. _ -Assemble backup ring and O-ring, tightenscrew (79) until it contacts piston (63) thentighten locknut (80).

Screw: 12.3 + 2.5 Nm (1.25 f 0.25kgm)

Locknut: 220.6 f 24.5 Nm (22.5 +2.5 kgm)

After completion of assembly, carry out a benchtest to check the minimum flow.Assemble backup ring and O-ring to stopper(61) and install to case.

19.

20.

Cylinder block and piston assemblySame operation as in Item 5.

Pump case1) Remove rear pump case from tool W. Xl OAV2O

30- 1050




21.

22. Spring and plugSame operation as in Item 8.

23. Positioning maximum swash plate angle

Same operation as in Item 9.

2) Set front pump and end cap assembly (81) totool A.

Xl OAK’25

3) Assemble dowel pin and O-ring to end cap,sling rear pump case (82), then align spline ofshaft and install.* When slinging, be careful not to drop the

cylinder block, piston assembly or otherparts.

Mating surface of pump case:

- Gasket sealant (LG-7 or LG-5(Loctite 572/575)

Mounting bolt: 176.5 + 19.6 Nm (18f 2 kgm)

XlOAV22E

Measuring rotating torque of pump assembly1) Set tool Y to pump shaft.2) Set torque wrench to tool Y, rotate shaft at low

speed (3 - 5 set/l turn) and measure rotatingtorque.

* Check that the shaft rotates smoothly whenmeasuring the rotating torque.

Variation range: Max. 0 - 2.9 Nm (0 -0.3 kgm)Rotating torque: Max. 0 - 49 Nm (0 - 5kgm)

* If there is any abnormality in the rotatingtorque, disassemble again and check.

XlOAVlSE

30- 1060




24. Control pump assembly1) Install collar (77).2) Fit coupling (78) to drive shaft, fit O-ring and

install control pump assembly (76).Mounting bolt: 66.2 + 7.4 Nm (6.75 +0.75 kgm)

Mating surface of control pump: Gasket

- sealant (LG-7 or LG-5 (Loctite5721575))

25. Control valve assemblySame operation as in Item1 1.

26. HoseSame operation as in Item 13.

27. Pump assemblySame operation as in Item 14.

78

30-I 070




CHECKING CONTACT BETWEENCYLINDER BLOCK AND VALVEPLATE, ROCKER CAM ANDCRADLE

Valve plate and end cap

1. Checking contact between cylinder block andvalve plate.*

*

1)

2)

3)

4)

5)

This check is unnecessary if both the cylinderblock and valve plate are replacement parts(new parts).This check applies if one of the parts is areplacement part or a restored part.

Make a centering tool for the cylinder block andvalve plate.Jr The tool can be made from plastic, bakelite

or any other soft material.

Remove all oil and grease from the parts to bechecked.* Do not wipe with a cloth.Set the tool in position, then paint the cylinderblock with inspection paint.* Coat thinly with paint.Push the valve plate with a force of 39.2 - 49.0N (4 - 5 kg) against the cylinder block. Turn thevalve plate 90” , then turn it back to the originalposition. Repeat this process 2 or 3 times.Remove the valve plate, transfer the contactsurface to a tape, and check the contactsurface.

* The contact of the spherical surface of thevalve plate and cylinder block must fulfillthe conditions below and cover the wholecircumference without any break.I) The contact at the seal portion (range

from bottom to a90.5) must be at least80%.

ii) The contact at the land portion (rangefrom 490.5 to 4112) must be at least60%.

1 Seal portion 1 Land portion

Valve plate 1 Min. 80% I Min. 60%

Cylinder blockI

Centering tool

Xl OAV22i

Contact at seal pot-ho

Cylinder block Min. 80% Min. 60%

30- 1080




2. Checking contact of rocker cam and cradle*

*

1)

2)

3)

4)

This check is unnecessary if both the rockercam and cradle are replacement parts (newparts).This check applies if one of the parts is areplacement part or a restored part.

Remove all oil and grease from the parts to be

checked.j, Do not wipe with a cloth.Paint the cradle with inspection paint.* Coat thinly with paint.Put the rocker cam on top and push with aforce of 39.2 - 49.0 N (4 - 5 kg), and move itbetween the maximum swash plate angle andthe position where it contacts the stopper.Repeat this process 2 or 3 times.Remove the rocker cam, transfer the contactsurface to a tape, and check the contactsurface.*

1)

ii)

iii)

The standard for the contact surface is as

given below.

Contact within the central portion (32 - 44mm) must be at least 90%.Contact in range between central portion(32 - 44 mm) and 60 mm must be 50 -90%.Contact of area outside 60 mm width(outside) must be less than 50%. (It is notpermitted to have contact only at theoutside and no contact at the center.)

[Reference] If the contact IS not wlthln the

standard value, and lapping is carried out, itmust always be carried out for both partstogether.* Parts with any scratches or damagemust not be used.

Rocker cam

30- 1090




3. Checking contact between valve plate and endcap.*

*

1)

2)

3)

4)

This check is unnecessary if both the valveplate and end cap are replacement parts (newparts).This check applies if one of the parts is areplacement part or a restored part.

Remove all oil and grease from the parts to bechecked.* Do not wipe with a cloth.Paint the end cap with inspection paint.j, Coat thinly with paint.Push the valve plate with a force of 39.2 - 49.0N (4 - 5 kg) against the end cap, turn the valveplate 90” , then turn it back to the originalposition. Repeat this process 2 or 3 times.Remove the valve plate, transfer the contactsurface to a tape, and check the contactsurface.* The contact of the plane surface between

the valve plate and end cap must cover atleast 80% without any variation.

Contact must cover at least 80%of this surface without any

30-I 100



DISASSEMBLY AND ASSEMBLY MAIN PUMP INPUT SHAFT OIL SEAL

REMOVAL OF MAIN PUMP INPUTSHAFT OIL SEAL

1. Remove main pump assembly. For details, seeREMOVAL OF MAIN PUMP ASSEMBLY.

2. Remove snap ring (I), then remove spacer (2).

3. Lever up oil seal (3) with a screwdriver to remove.

j , When removing the oil seal, becareful not to damage the shaft.

INSTALLATION OF MAIN PUMPINPUT SHAFT OIL SEAL

0 Carry out installation in the reverse order to

removal.

Lip of seal: Grease (G2-Ll)

-Coat the outside circumference of theoil seal with grease (G2-Ll) thinly, thenpress fit.

* Using tool N, press fit oil seal (3).

30- 1110



DISASSEMBLY AND ASSEMBLY CONTROL VALVE

REMOVAL OF CONTROL VALVEASSEMBLY

A Run the engine at low idling, operate the cylinder tothe end of its stroke without relieving the circuit,

0

a

1.

2.

3.

4.

5.

lower the work equipment to the ground, then stopthe engine. For details, see TESTING AND

ADJUSTING, Releasing pressure in hydrauliccircuit. After stopping the engine, do as follows.Loosen the oil filler cap slowly to release thepressure inside the tank.Operate the control levers.* Operate the control levers several times to

release the pressure in the accumulator.Start the engine and run at low idling for approx. 5seconds, then stop the operation and operate thecontrol levers.j, Repeat the above operation several times to

release the remaining pressure completely.

Open engine hood and remove divider covers (l),then disconnect intake connector.

Disconnect hoses (2) (3) and (4) remove 2connectors (5) from holder, then disconnect.* Remove the hose mounting elbow from the

valve body.

Remove block (6).

Disconnect hoses (7) and (8) and block (9).* When disconnecting block (9) loosen the

mounting bolts of the block tube flange first.

Disconnect tubes (IO), (II), and (12) and hoses(13), (14) and (15).* Disconnect 6 tubes and 7 hoses.* With hoses (15) there is another hose under

each of the hoses.

II \/ -’ XlOBHlSO

30- 1120




6. Disconnect hoses (16) and (17).

7. Sling control valve assembly (18) then removemounting bolts, and lift off control valve assembly.

Control valve assembly: 170 kg

INSTALLATION OF CONTROLVALVE ASSEMBLY




Bleeding air* Bleed the air from the circuit between the valve

and the hydraulic cylinder. For details, seeTESTING AND ADJUSTING, Bleeding air.

30-I 130




REMOVAL OF CONTROL VALVEASSEMBLY

*

1.

2.

3.

4.

5.

6.

7-spool control valve (1 service valve)

Release the remaining pressure in the hydrauliccircuit. For details, see TESTING AND

ADJUSTING, Releasing pressure in hydrauliccircuit.

Open engine hood and chassis bodywork cover,remove divider cover (I), then disconnect intakeconnector (2).

Disconnect hoses (3) (4) and (5) and remove 2connectors (6) from clip, then disconnect.* Remove the hose mounting elbow from the

valve body.

Remove block (7).

Disconnect hoses (8) and block (9).* When disconnecting block (9) loosen the

mounting bolts of the flange for the tubes at thebottom first.

Disconnect hose (IO), and remove tube (11) andblock (12).

Disconnect hoses (13) and (14), and remove tubes(15) and (16).

30- 1140




7. Remove tubes (17) (18), and (19) and disconnecthoses (20) and (21).

8. Disconnect hosesbottom of valve.

(22), (23), and (24) mounted to

9. Lift off control valve assembly (25).

PlControl valve assembly: 185 kg

kg

INSTALLATION OF CONTROLVALVE ASSEMBLY

7-spool control valve (1 service valve)




Bleeding air* Bleed the air from the circuit between the valve

and the hydraulic cylinder. For details, seeTESTING AND ADJUSTING, Bleeding air.

30-I 150




DISASSEMBLY OF CONTROLVALVE ASSEMBLY

*

a

1.

2.

3.

4.

The set pressure of the safety valve and armcounterbalance valve cannot be adjusted when theyare installed on the machine, so do notdisassemble.

The following explanation describes the 6-spoolcontrol valve.

Main relief valve, main unload LS relief valves1) Remove main relief valve (1).2) Remove main unload LS relief valve (3).

Unload valves, safety-suction valves, suctionvalves1) Remove unload valves (4) and (5).2) Remove safety-suction valves (6) (7) (8) (9)

(IO), and (11).3) Remove suction valves (12) (13) (14), and

(15).

Pressure compensation valvesj, Before moving any pressure compensation

valve, check and mark its mounting position.1) Remove bucket DUMP pressure compensation

valve (16) R.H. travel REVERSE pressurecompensation valve (17) boom RAISEpressure compensation valve (18), right swingpressure compensation valve (19), L.H. travelREVERSE pressure compensation valve (20)and arm IN pressure compensation valve (21).* After removing the pressure compensation

valves, remove check valve (22) from eachpressure compensation valve mount.

2) Remove bucket CURL pressure compensationvalve (23) R.H. travel FORWARD pressurecompensation valve (24) boom LOWERpressure compensation valve (25) left swingpressure compensation valve (26) L.H. travelFORWARD pressure compensation valve (27),and arm OUT pressure compensation valve(28).* After removing the pressure compensation

valves, remove check valve (29) from eachpressure compensation valve mount.

LS select valveRemove LS select valve (30).

5. LS shuttle valves, pump merge-divider valve,arm counterbalance valve1) Remove LS shuttle valves (31) and (32).2) Remove pump merge-divider valve (33), then

remove spring (57) and valve (58).3) Remove arm counterbalance valve (34) then

remove spring (59) and (60).

6. Remove covers (35) and (36).

7. Arm control valve, boom control valve, bucketcontrol valve1) Remove case (37) then remove spring (38)

and retainer (39).2) Remove spool assembly (40).

* Do not disassemble spool assembly (40).3) Remove case (41) then remove spring (42),

shim (43) and retainer (44).j, Shim (43) is only for the boom control

valve.

8. Swing control valve1) Remove case (45) then remove spring (46),

shim (47), and retainer (48).2) Remove spool assembly (49).

* Do not disassemble spool assembly (49).3) Remove case (41) then remove spring (42)

and retainer (44).

9. R.H. travel control valve, L.H. travel control

valve1) Remove case (50) then remove spring (51)

and retainer (52).2) Remove spool assembly (53).

* Do not disassemble spool assembly (53).3) Remove case (54) spring (55) and retainer

(56).

30- 1160




Right side of machineFrom front of machine

16 17 18 19 29 2122

Left ide of machine

From rear of machine

Front of machineFrom top of machine

11 15 10 14 9 XlOBH202

XlOBH203

30- 1170




ASSEMBLY OF CONTROL VALVEASSEMBLY0 Before assembling, coat the sliding surface with

engine oil.1. R.H. travel control valve, L.H. travel control

valve1)

2)

3)

Assemble spool assembly (53) to valve body.

Assemble retainer (56) and spring (55) tospool, then fit O-ring to case (54) and install.Case mounting bolt: 30.9 f 3.4 Nm(2.9 f 0.5 kgm)

Assemble retainer (52) and spring (51) tospool, then fit O-ring to case (50) and install.

Case mounting bolt: 30.9 f 3.4 Nm(2.9 + 0.5 kgm)

2. Swing control valve1)2)

3)

Assemble spool assembly (49) to valve body.Assemble retainer (44) and spring (42) tospool, then fit O-ring to case (41) and install.

Case mounting bolt: 30.9 + 3.4 Nm(2.9 f 0.5 kgm)

Assemble retainer (48), shim (47) and spring(46) to spool, then fit O-ring to case (45) andinstall.

Case mounting bolt: 30.9 + 3.4 Nm(2.9 f 0.5 kgm)

3. Arm control valve, boom control valve, bucketcontrol valve1) Assemble spool assembly (40) to valve body.2) Assemble retainer (44), shim (43) and spring

(42) to spool, then fit O-ring to case (41) andinstall.

Case mounting bolt: 30.9 f 3.4 Nm(2.9 f 0.5 kgm)

* Shim (43) is only for the boom controlvalve.

3) Assemble retainer (39) and spring (38) tospool, then fit O-ring to case (37) and install.

Case mounting bolt: 30.9 + 3.4 Nm(2.9 + 0.5 kgm)

4. Covers1) Fit O-ring to cover (36) and install.2) Fit O-ring to cover (35) and install.

Mounting bolt: 166.7 + 9.8 Nm (17 f

1 kgm)* Tighten the mounting bolts in the order

shown in the diagram.

5. LS shuttle valve, pump merge-divider valve, armcounterbalance valve1) Assemble valve (60) and spring (59) to valve

body, and install arm counterbalance valve(34).

Mounting bolt: 66.2 f 7.4 Nm (6.8 +0.8 kgm)

* Tighten the mounting bolts in the ordershown in the diagram.

2) Assemble valve (58) and spring (57) to valvebody, and install pump merge-divider valve(33).

Mounting bolts: 166.3 f 9.4 Nm (17+ 1 kgm)

* Tighten the mounting bolts in the ordershown in the diagram.

3) Install LS shuttle valves (32) and (31).

Mounting bolt: 66.2 + 7.4 Nm (6.8 +0.8 kgm)6. LS select valve

Install LS select valve (30).LS select valve: 127.5 f 19.6 Nm (13 f2 kgm)

7. Pressure compensation valvesCheck marks made on each pressurecompensation valve when disassembling andinstall in correct position.

1) Before installing pressure compensation valvesbelow, install check valves (29) and (22).

2) Fit O-rings, then install arm IN pressurecompensation valve (28) L.H. travelFORWARD pressure compensation valve (27),left swing pressure compensation valve (26)boom LOWER pressure compensation valve(25), R.H. travel FORWARD pressurecompensation valve (24) and bucket CURLpressure compensation valve (23).

3) Fit O-rings, then install arm OUT pressurecompensation valve (21) L.H. travel REVERSEpressure compensation valve (20) right swingpressure compensation valve (19) boomRAISE pressure compensation valve (18), R.H.travel REVERSE pressure compensation valve(17) and bucket DUMP pressure compensationvalve (16).

Pressure compensation valve:225.5 f 19.6 Nm (23 + 2 kgm)

8. Unload valves, safety-suction valves, suctionvalves1) Fit O-rings and install suction valves (15) (14)

(13) and (12).Suction valve: 147.1 + 9.8 Nm (15 f1 kgm)

2) Fit O-ring and install safety-suction valves (1 I),(IO), (9) (8) (7) and (6).

Safety-suction valve: 147.1 ?I 9.8Nm (15 f 1 kgm)

3) Fit O-ring and install unload valves (5) and (4).Unload valve: 98.1 f 9.8 Nm (10 f1 kam)

9. Main relief valve, main unload LS relief valve1) Fit O-ring and install main unload LS relief

valve (3).

wMain unload LS relief valve: 85.9f 7.4 Nm (8.8 + 0.8 kgm)

2) Fit O-ring and install main relief valve (1).

Q=Main relief valve: 53.9 f 4.9 Nm(5.5 f 0.5 kgm)

30- 1180




Right side of machineFrom front of machine

16 17 18 19 20 21 22 Left side of machine

From rear of machine 29 23 24 25 30 26 27 288 13 7 12 6

Front of machineFrom top of machine

0

3

1

il r’ s lb i4

XlOBH204

30-I 190



DISASSEMBLY AND ASSEMBLY PUMP MERGE-DIVIDER VALVE

DISASSEMBLY OF PUMPMERGE-DIVIDER VALVEASSEMBLY

1.

2.3.

4.

Remove plug (2) from valve body (I), then removespring (3) and spool (4).Remove plate (5).Remove plug (6), then remove spring (7) and spool(8).Remove plug (9).j, After disassembling, if there is any abnormality

in body (1) or spools (4) or (8) replace thewhole pump merge-divider valve assembly.

ASSEMBLY OF PUMP MERGE-DIVIDER VALVE ASSEMBLY

0 Before assembling, coat the sliding surface with 3. Fit O-ring to plate (5) and install to valve body.engine oil. 4. Assemble spool (4) and spring (3) then fit O-ring to

plug (2) and install.1. Fit O-ring to plug (9) and install to valve body (1).

mPlug (2): 152.3 f 24.8 Nm (15.5 f 2.5

Plug (9): 38.7 f 5.4 Nm (4.0 f 0.6 kgm) kgm)

2. Assemble spool (8) and spring (7) then fit O-ring toplug (6) and install.

Plug (6): 38.7 f 5.4 Nm (4.0 + 0.6 kgm)

30- 1200



DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE

DISASSEMBLY OF PRESSURECOMPENSATION VALVEASSEMBLY

(A-D1

0 The structure of the parts for pressurecompensation valves A, B, C, and D is the same,but the part number for the assembly is different, sobe careful when assembling.

1. Remove piston sub-assembly (2) and piston (3)from sleeve (I), then remove seals (4).* Sub-piston assembly (2) is assembled to

pressure compensation valve A and D, andpiston assembly (3) is assembled to pressurecompensation valves B and C.

2. Remove spring (5), then remove ring (6) and O-rings (7) and (8) from sleeve (1).

* After disassembling, if there is any abnormality insleeve (I), seal (4), piston sub-assembly (2) orpiston (3) replace the whole pressurecompensation valve assembly.

ASSEMBLY OF PRESSURECOMPENSATION VALVEASSEMBLY

0 Before assembling, coat the sliding surface withengine oil.

1. Install O-rings (8) and (7), and ring (6) to sleeve (1).2. Assemble spring (5), then assemble seals (4) to

piston sub-assembly (2) and piston (3), and installto sleeve.

Pressure compensation valvesA: For bucket CURL/DUMP, boom RAISEB: For R.H. travel FORWARD/REVERSE, L.H. travel

FORWARD/REVERSEC: For left/right swingD: For boom LOWER. arm IN/OUT

30- 1210



DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE

DISASSEMBLY OF MAIN RELIEFVALVE ASSEMBLY

1.

2.

3.

4.

*

/ ' 3

, _

3 - - - - - o17

4/ *C/ g

Loosen nut (I), and remove sleeve (2), piston (3)retainer (4) spring (5) piston (6) and poppet (7)then remove nut (1) from sleeve (2).

Remove sleeve (8), then remove sleeve (9), spring(IO), retainer (1 I), piston valve (12), and valve (13).

Remove seal (4), backup ring (15), and O-ring fromsleeve (8).

Remove plug (16), then remove rings (18) and (19)and O-ring from sleeve (17).

After disassembling, if there is any abnormality inany part marked s, replace the whole main reliefvalve assembly.

30- 1220



DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE

ASSEMBLY OF MAIN RELIEFVALVE ASSEMBLY

0

1.

2.

3.

4.

5.

*

Before assembling, coat the sliding surface withengine oil.

Fit plug (16) to sleeve (17) and install rings (19) and(18), and O-ring.

Plug: 22.1 f 2.5 Nm (2.25 + 0.25 kgm)

Assemble valve (13) to sleeve (17) and installpiston (12) retainer (II), spring (IO), and sleeve

(9).

Install sleeve (8) and assemble poppet (7) piston(6) and spring (5).

Sleeve: 85.9 f 7.4 Nm (8.8 ?r 0.8 kgm)

Assemble nut (I), O-ring, retainer (4) and piston (3)to sleeve (2), and install to sleeve (8).

Tighten nut (1) to specified torque.Nut: 68.7 f 9.9 Nm (7 f 1 kgm)

After installing to the control valve assembly, adjustthe pressure. For details, see TESTING ANDADJUSTING, Testing and adjusting oil pressure ofwork equipment, swing, travel circuits.

30- 1230



DISASSEMBLY AND ASSEMBLY TVC . LS VALVE ASSEMBLY FOR FRONT PUMP

REMOVAL OF TVC . LS VALVEASSEMBLY FOR FRONT PUMP

aa

1.

2.

3.

Disconnect the cable from the negative (-) terminalof the battery.Lower the work equipment completely to the groundand stop the engine. Then loosen the oil filler cap

slowly to release the pressure inside the hydraulictank.Remove the hydraulic tank strainer, and using toolB, stop the oil.


Hydraulic tank: Approx. 170 e

Disconnect TVC LS valve inlet hose (1).

Disconnect n/C solenoid wiring connectors (2).

Remove TVC LS valve assembly (3). m

INSTALLATION OF TVC . LSVALVE ASSEMBLY FOR FRONTPUMP


* Be careful not to let the O-ring or filter fall outwhen installing.

* Tighten the mounting bolts gradually onopposite sides in turn.

mTVC LS valve mounting bolts: 66.2 +7.4 Nm (6.75 + 0.75 kgm)

f m XlOAV287

XlOBH208



30- 1240



DISASSEMBLY AND ASSEMBLY NC. LS VALVE ASSEMBLY FOR FRONT PUMP

REMOVAL OF TVC . LS VALVEASSEMBLY FOR REAR PUMP

AA

a

1.

2.

3.

4.

5.

Disconnect the cable from the negative (-) terminalof the battery.Lower the work equipment completely to the ground

and stop the engine. Then loosen the oil filler capslowly to release the pressure inside the hydraulictank.Remove the hydraulic tank strainer, and using toolB, stop the oil.



Disconnect TVC LS valve inlet hose (1).

Disconnect hose (2).

Disconnect NC solenoid wiring connectors (3).

Remove bracket (4).

Remove TVC LS valve assembly (5). MI

INSTALLATION OF TVC . LS

VALVE ASSEMBLY FOR REARPUMP


* Be careful not to let the O-ring or filter fall outwhen installing.

* Tighten the mounting bolts gradually onopposite sides in turn.

TVC LS valve mounting bolts:66.2 + 7.4 Nm (6.75 & 0.75 kgm)



; --.XlOAV287

30-I 250



DISASSEMBLY AND ASSEMBLY LS CONTROL EPC VALVE

REMOVAL OF LS CONTROL EPCVALVE ASSEMBLY

1. Remove cover.

2. Disconnect wiring connector (1).

3. Disconnect hose (2).

4. Remove LS control EPC valve assembly (3)m

INSTALLATION OF LS CONTROLEPC VALVE ASSEMBLY


LS control EPC valve mounting bolt:11.3+ 1.5 Nm (1.15 f 0.15 kgm)

30-I 260



DISASSEMBLY AND ASSEMBLY SOLENOID VALVE

REMOVAL OF SOLENOID VALVEASSEMBLY

A

1.

2.

3.

4.


Remove 5 solenoid wiring connectors (1) from clip

and disconnect.* Mark the male and female ends of each

connector with tags to prevent mistakes whenconnecting.

Disconnect hoses (2) and (3) installed to bottom ofvalve.* Fit tags on the hoses.

Disconnect hoses (4) installed to top of valve.* Fit tags on the hoses.

Remove mounting bolts, then remove solenoid

valve assembly (5).

When removing solenoid valve as an individualpart.i) If mounting nut (6) is removed, only coil

assembly needs to be removed. %ii) qhen washing valve, loosen mounting nut 7

and remove. ml

INSTALLATION OF SOLENOIDVALVE ASSEMBLY


w Nut (6): 7.4 f 0.98 Nm (0.8 f 0.1 kgm)

XlOBH213

Nut (7): 50.5 f 3.4 Nm (5.2 + 0.35 kgm)

30- 127 .0



DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT. SWING PPC VALVE

REMOVAL OF WORKEQUIPMENT. SWING PPCVALVE ASSEMBLY

A

1.

2.

3.

4.

5.


Remove armrest and rubber boot, remove cover,and disconnect wiring connector (1).

Remove boot (2) from cover, raise boot, thenremove lever (3).* Mark the mounting position of the lever before

removing.

Remove 4 mounting bolts (5) of cover (4) thenremove.jr Remove the lock with a screwdriver and

gradually lift the cover up to remove.

Remove joint bolt (6), and disconnect hose(7).F]

Remove mounting bolts, raise PPC valve assembly(8), then disconnect hoses (9) and (IO), andremove.

mj, Mark the connecting position of the hoses

before disconnecting.

INSTALLATION OF WORKEQUIPMENT. SWING PPCVALVE ASSEMBLY


Hose mounting joint bolt: 29.4 f 4.9 Nm(3.0 + 0.5 kgm)

m

Hose mounting joint bolt: 39.2 + 4.9 Nm(4.0 + 0.5 kgm)

* If there is excessive play in the control levers,adjust the PPC valve. For details, see TESTINGAND ADJUSTING, Adjusting PPC valve.

30- 1280

v/ ” XlOBH215




DISASSEMBLY OF WORKEQUIPMENT. SWING PPCVALVE ASSEMBLY

1.

2.

3.

4.

5.

Remove nut (l), then removedisc (2) and boot (3).

Remove bolt, then remove plate (5).* Do not remove joint (4) unless it is to be

replaced.

Remove seal (6) and collar (7).

Pull out piston (8), and remove retainer (9) springs(10) and (11) and shim (12).* Spring (1) consists of a set of two types of

springs with different installed loads, so checkthe mounting position (oil port) and mark withtags to prevent mistakes when installing.

Pull out valve (13) from body (14).

L XlOBH218

30- I 290




ASSEMBLY OF WORKEQUIPMENT. SWING PPCVALVE ASSEMBLY

1.

2.

Assemble valve (13) to body (14).

Assemble shim (12) and spring (11) to valve (13).* When assembling spring (1 I), set the end with

the small coil diameter (inside diameter) at shim(12) end.

3. Assemble spring (IO), retainer (9) and piston (8).* The number of loops in the coil for spring (10)

is different for each of the hydraulic portsbelow, so be careful when installing.

*

* The position of each port is marked on thebottom of the valve body.

Piston: Grease (G2-Ll)

* When assembling piston (8), coat theoutside of the piston and the inside of thehole in the body with grease.

4. Fit O-ring to collar (7) and assemble in body (14)then install seal (6).

5. Install plate (5).

mMounting bolt: 13.2 f 1.5 Nm (1.35 f0.15 kgm)

6. Install joint (4).Sliding portion of joint: Grease (G2-Ll)

Female thread of body: ThreadA tightener (LT-2)

* Coat two places on the female thread with onedrop each of Loctite as shown in the diagrambelow.

5-7m

_.(zzl-XlOBH219

Joint: 44.1 f 4.9 Nm (4.5 + 0.5 kgm)

* Keep strictly to the tightening torque.

7. Assemble boot (3) and disc (2), and tighten with nut(I).

Nut: 112.7 f 14.7 Nm (11.5 f 1.5 kgm)

* After assembling the disc, adjust the height ofthe disc. For details, see TESTING ANDADJUSTING, Adjusting PPC valve.

30-I 300



DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE

REMOVAL OF TRAVEL PPCVALVE ASSEMBLY

A

1.

2.

3.

4.

5.

6.

7.

Lower the work equipment completely to the groundand stop the engine. Loosen the oil filler cap slowlyto release the pressure inside the hydraulic tank.Then set the safety lock lever to the LOCK position.

Remove floor mat.

Remove travel PPC valve bottom cover.

Remove pedals (1) and levers (2).

Remove cover (3).

Remove covers (4) then remove springs (5).

Disconnect dampers (6). m

Disconnect 6 PPC hoses (7) and remove travelPPC valve assembly (8). ml

INSTALLATION OF TRAVEL PPCVALVE ASSEMBLY

0 Carry out installation inremoval.

the reverse order to

--Adjust the travel lever. For details, seeTESTING AND ADJUSTING, Adjusting travel

Cover mounting bolt: 19.6 + 2 Nm (2.0f 0.2 kgm)

Sliding portion of pin: Grease (G2-Ll)

Hose mounting joint bolt (width acrossflats: 30 mm): 39.2 f 4.9 Nm (4.0 f 0.5kgm)

Hose mounting joint bolt (width acrossflats: 22 mm): 29.4 f 4.9 Nm (3.0 + 0.5kgm)

\\ &_ [I

XlOBH223

30-I 310




DISASSEMBLY OF TRAVEL PPCVALVE ASSEMBLY

1. Remove cover and cam assembly (1) then removeshims (2).* Check the number and thickness of shims (2)

for each mounting position, and keep in a safe

place.

2. Remove plate (3).

3. Remove seal (4) and collar (5).

4. Pull out piston (6) and remove retainer (7) springs(8) and (9) and shims (10).* Check the number and thickness of shims (10)

for each mounting position, and keep in a safeplace.

5. Pull out valve (11) from body (12.)

ASSEMBLY OF TRAVELVALVE ASSEMBLY

PPC

1. Assemble valve (11) in body (12).

2. Assemble shims (10) and spring (9) to valve (11).It Assemble the same number and thickness of

shims (10) as was removed duringdisassembly.Standard shim thickness: 0.3 mm

* Spring (9) is not symmetrical at the top andbottom, so assemble with the small coildiameter (inside diameter) at the shim end.

3. Assemble spring (8) retainer (7), and piston (6).

aOutside circumference of piston, bodyhole: Grease (G2-Ll)

4. Fit O-ring to collar (5) and assemble in body (1 I),then install seal (4).

5. Assemble plate (3).

6. Fit cover and cam assembly (1) and assembleshims (2) then tighten with bolt.

eSliding portion of shaft, connectingportion of lever and piston: Grease (G2-Ll)

30- 1320




* Assemble the same number and thickness ofshims (2) as was removed during disassembly.Standard shim thickness: 1.6 mm

WMounting bolt (a): 27.9 + 3.4 Nm(2.85 f 0.35 kgm)

Mounting bolt (b): 30.9 f 3.4 Nm(3.15 + 0.35 kgm)

XlOBH225

30-I 330



DISASSEMBLY AND ASSEMBLY BOOM LOCK VALVE

REMOVAL OF BOOM LOCKVALVE ASSEMBLY

A

1.

2.

3.

Lower the work equipment completely to theground, then release the remaining pressure in thehydraulic circuit. For details, see TESTING ANDADJUSTING, Releasing pressure in hydraulic

circuit.

Disconnect tube (1) and hoses (2).

Disconnect tube (3).

Remove mounting bolts of bracket (4) then removeboom lock valve (5) together with bracket (4).

INSTALLATION OF BOOM LOCK

VALVE ASSEMBLYCarry out installation in the reverse order toremoval.

Refilling with oil (hydraulic tank)Jr Add oil through the oil filler to the specified


Bleeding airj, Bleed the air. For details, see TESTING AND

ADJUSTING, Bleeding air.

30-I 340



DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

REMOVAL OF BOOM CYLINDERASSEMBLY

A Extend the arm and bucket fully, lower the workequipment completely to the ground, and put thesafety lock lever in the lock position.

1.

2.

Disconnect grease hose (1).

3.

Sling boom cylinder assembly (2) and remove lockbolt (3). m

Remove plate, then remove head pin (4).* V

g 2There are shims installed, so check the num erand thickness, and keep in a safe place.

4. Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out.* Set stand 0 under the cylinder assembly, and

adjust the position for slinging.

A Release the remaining pressure in thehydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.

5. Disconnect hoses (5).

6. Remove plate, then using forcing screws 0, removebottom pin (6) and remove boom cylinder assembly(2). m* There are shims installed, so check the number

and thickness, and keep in a safe place.Boom cylinder assembly:

PC200-6, PC210-6: 200 kgPC220-6, PC250-6: 255 kg

30-I 350



DISASSEMBLY AND ASSEMBLY BOOM CYLINDER

INSTALLATION OF BOOMCYLINDER ASSEMBLY


en tightening the locknut, tighten so that theclearance between the plate and nut is 0.5 - 1.5mm.

m

AInside surface of bushing whenassembling pin: Anti-friction compound(LM-P)

Greasing after assembling pin: GreaseA (LM-G)

A When aligning the position of the pin hole,

never insert your fingers in the pin hole.* Adjust the shim thickness so that the clearance

between cylinder rod (7) and plate (8) is below1 mm.* Standard shim thickness: 0.8 mm, 1.5 mm

m

Inside surface of bushing whena assembling pin: Anti-friction

compound (LM-P)

Greasing after assembling pin:- Grease (LM-G)

A When aligning the position of the pin hole,never insert your fingers in the pin hole.

* Adjust the shim thickness so that the clearancebetween cylinder bottom (9) and bracket (IO) isbelow 1 mm.* Standard shim thickness: 0.8 mm, 1.5 mm



Bleeding airj, Bleed the air from the cylinder. For details, seeTESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.

0. 5 - 1. 5 mmXlOBM006

IMax. 1 mm

i o

30- 1360



DISASSEMBLY AND ASSEMBLY ARM CYLINDER

REMOVAL OF ARM CYLINDERASSEMBLY

A

1.

2.

3.

4.

5.

6.

Extend the arm cylinder piston rod approx. 200 mm,lower the work equipment completely to the ground,then set the remaining safety lock lever to the LOCKposition.

Set block 0 between arm cylinder and boom.

Remove plate, then remove head pin (1). m

Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out.A Release the remaining pressure in the

hydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.

Disconnect hoses (2).


Raise arm cylinder assembly, remove plate ,remove bottom pin (4), then remove arm cylinderassembly (5).* There are shims installed, so check the

and thickness, and keep in a safe place.Arm cylinder assembly:PC200-6, PC210-6: 270 kgPC220-6, PC250-6: 310 kg

30- 1370



DISASSEMBLY AND ASSEMBLY ARM CYLINDER

INSTALLATION OF ARM t LI I.-lCYLINDER ASSEMBLY I


aInside surface of bushing whenassembling pin: Anti-friction compound(LM-P)

Greasing after assembling pin: Grease- (LM-G)


m

-

Inside surface of bushing when

assembling pin: Anti-friction compound(LM-P)

Greasing after assembling pin: Grease- (LM-G)


j, Adjust the shim thickness so that the clearancebetween cylinder boom (6) and bracket (7) isbelow 1 mm.j, Standard shim thickness: 0.8 mm, 1.5 mm

Refilling with oil (hydraulic tank)* Add oil through the oil filler to the specifiedlevel. Run the engine to circulate the oil throughthe system. Then check the oil level again.

Bleeding air* Bleed the air from the cylinder. For details, see

TESTING AND ADJUSTING, Bleeding air fromhydraulic cylinder.

30- 1380



DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

A Extend the bucket cylinder piston rod approx. 200mm, lower the work equipment completely to theground, then set the safety lock lever to the LOCKposition.

1.

2.

Set block 0 under arm top.

Set block 0 between link and arm, and block 0between bucket cylinder and arm.

3.

4.

Remove lock bolt (1). p1

Remove plate, then remove head pin (2).*

mThere are shims installed, so check the numberand thickness, and keep in a safe place.

5. Start engine, and retract piston rod, then tie piston

rod with wire to prevent it from coming out.A Release the remaining pressure in the


6. Disconnect 2 hoses (3).

7. Raise bucket cylinder assembly, remove plate,remove bottom pin (4) then remove bucket cylinderassembly (5).* There are shims installed, so check the

and thickness, and keep in a safe place.

Bucket cylinder assembly:PC200-6, PC210-6: 170 kgPC220-6, PC250-6: 200 kg

REMOVAL OF BUCKETCYLINDER ASSEMBLY

30- I 390



DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER

INSTALLATION OF BUCKETCYLINDER ASSEMBLY


W]* When tightening the locknut, tighten so that the

clearance between the plate and nut is 0.5 - 1.5mm.

m1

A

A

When aligning the position of the pin hole,

Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)

Greasing after assembling pin: Grease(LM-G)

never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween link (6) and link (7) is below 1 mm.* Standard shim thickness: 0.8 mm, 1.5 mm

Inside surface of bushing whenA assembling pin: Anti-friction

compound (LM-P)

Greasing after assembling pin:

a Grease (LM-G)

When aligning the position of the pin hole,never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween the cylinder bottom (8) and bracket (9)is below 1 mm.* Standard shim thickness: 0.8 mm, 1.5 mm





0.5 - 1.5 mmX10BM006

Max. 1 mm

‘ 7XlOBMOl:

XlOBM014

30- 1400



DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER

DISASSEMBLY OF HYDRAULICCYLINDER ASSEMBLY

1. Piston rod assembly1) Remove piping from cylinder assembly.2) Remove mounting bolts, and disconnect head

assembly (1).

3) Pull out piston rod assembly (2).* Place a container to catch the oil under the

cylinder.4) Disassemble piston rod assembly as follows.

i) Set piston rod assembly (2) in tool 0,.ii) Using tool O,, remove nut (3).

* Width across flats of nut. Unit: mm

PC200,PC210 1 95 1 95 1 85

PC220,PC250

95 95 95

iii) Remove piston assembly (4).iv)

v)

vi)vii)

Remove plunger (5).Boom and arm cylinder only.

Remove collar (6).Boom and arm cylinder only.

Remove head assembly (7).Remove cap (8), and pull out 12 balls (9)then remove plunger (10).

Arm cylinder only.

30- 1410




2. Disassembly of piston assembly1) Remove rings (11).2) Remove wear rings (12).3) Remove piston ring (13).

3. Disassembly of cylinder head assembly1) Remove O-ring and backup ring (14).2) Remove snap ring (ICI), then remove dust seal

(W.3) Remove rod packing (17).4) Remove buffer ring (18).5) Remove bushing (19).

XlOBR051

19

19

17

30- 1420




ASSEMBLY OF HYDRAULICCYLINDER ASSEMBLY

* Be careful not to damage the packing, dust seals,and O-rings.

j, Do not try to force the backup ring into position.Warm it in warm water (50 - 60°C) before fitting it.

1. Assembly of cylinder head assembly1) Using tool O,, press fit bushing (19).2) Assemble buffer ring (18).3) Assemble rod packing (17).4) Using tool 06, install dust seal (16), and secure

with snap ring (15).5) Install backup ring and O-ring (14).

2. Assembly of piston assembly1) Using tool O,, expand piston ring (13).

* Set the piston ring on the tool O,, and turnthe handle 8 - IO times to compress thering.

2) Set tool O4 in position, and retract piston ring

(13).

3) Assemble wear ring (12).4) Assemble ring (1 I).

* Be careful not to open the end gap of thering too wide.

Ring groove: Grease (G2-Ll)

13

14

30-I 430




3. Piston rod assembly I1)

2)3)

4)

5)

6)7)

Set plunger (IO) to piston rod, and assemble 12balls (9) then secure with cap (8).* Check that there is a slight play at the tip of

the plunger.Arm cylinder only.

Assemble head assembly (7).Fit O-ring and backup ring, and assemble collar(8).

Boom and arm cylinder only.Assemble plunger (5).

Boom and arm cylinder only.Assemble piston assembly (4).

Set piston rod assembly (2) to tool 0,. I titUsing tool 02, tighten nut (3).

Nut: Thread tightener (LT-2)

m Nut:

Unit: Nm (kgm)Cylinder

I Boom I Arm I Bucket

8) Assemble piston rod assembly (2).Seal: Grease (G2-Ll)

*

*

30- 1440

Set the end gap of the ring at the horizontal(side) position, align the center of shaft andcylinder tube, then insert.After inserting, check that the ring is notbroken and has not come out, then push infully.

XlOBR049

L

End Sap in ring

XlOBRO56




9) Tighten head assembly (1) with mounting bolts.

WMounting bolt:

Cylinder Tightening torque

PC200, PC21 0Boom

270 f 39 Nm (27.5 * 4.0 kgm)

PC220, PC250Boom I

373 f 54 Nm (38.0 f 5.5 kgm)

1 373 + 54 Nm (38.0 f 5.5 kgm)

Bucket 270 * 39 Nm (27.5 + 4.0 kgm)

IO) Install piping.

30- 1450



DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

REMOVAL OF WORKEQUIPMENT ASSEMBLY

A Extend the arm and bucket fully, lower the workequipment to the ground, and set the safety locklever to the LOCK position.

1.

2.


Sling boom cylinder assembly (2), and remove lockbolt (3). mj

3. Remove plate, then remove head pin (4). m* There are shims installed, so check the number


4. Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out, andlower it onto block.*

A

Disconnect the boom cylinder on the opposite

side in the same way.Release the remaining pressure in thehydraulic circuit. For details, see TESTINGAND ADJUSTING, Releasing remainingpressure in hydraulic circuit.

5. Disconnect hoses (5) and (6) and secure it to valvewith rope.* Hoses (6) are for machines equipped with an

additional attachment circuit.

6. Disconnect wiring connector (7) for working lamp.

7. Sling work equipment assembly, remove plate, thenremove foot pin (8) using tool P, and remove workequipment assembly (9).j, There are shims installed, so check the

and thickness, and keep in a safe place.Work equipment assembly:PC200-6: 3,300 kgPC210-6: 3,650 kgPC220-6: 3,850 kgPC250-6: 4,250 kg

30- 1460



DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT

INSTALLATION OF WORKEQUIPMENT ASSEMBLY

0.5-1.5mmXlOBM006


&IlhFl

en tightening the locknut, tighten so that theclearance between the plate and nut is 0.5 - 1.5mm.

AInside surface of bushing whenassembling pin: Anti-friction compound(LM-P)

Grease after assembling pin: Grease- (LM-G)


* Adjust the shim thickness so that the clearancebetween cylinder rod (10) and plate (11) isbelow 1 mm.j, Standard shim thickness: 0.8 mm, 1.5 mm

m

Inside surface of bushing whenassembling pin: Anti-friction

compound (LM-P)

Grease after assembling pin:a Grease (LM-G)


* Adjust the shim thickness so that the clearancebetween boom (12) and bracket (13) is below 1mm.j, Standard shim thickness: 0.8 mm, 1 O mm,

1.5 mm





I

IMax. 1 mmx17FRo42

30- 1470



DISASSEMBLY AND ASSEMBLY BUCKET

REMOVAL OF BUCKETASSEMBLY

A Set the back of the bucket facing down, lower thework equipment completely to the ground, and setthe safety lock lever to the LOCK position.

1. Remove lock bolt (1). m

2. Remove connecting pin (2) between link andbucket.

L$%2

* There are shims installed, so check the num erand thickness, and keep in a safe place.

3. Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out.

4. Remove lock bolt (3). ml

5. Remove plate (4) then remove connecting pin (5)between arm and bucket. mlj, There are shims installed, so check the number


6. After raising work equipment, swing to disconnectbucket assembly (6).

Bucket assembly: See your Operator’ sManual, beginning on page 5-16.

6

30- 1480



DISASSEMBLY AND ASSEMBLY BUCKET

INSTALLATION OF BUCKETASSEMBLY


en tightening the locknut, tighten so that theclearance between the plate and the nut is 0.5 -1.5 mm.

-Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)


A When aligning the position of the pin hole,never insert your fingers in the pin hole.* Adjust the shim thickness so that the clearance

between bucket boss (7) and link (8) is below 1mm.* Standard shim thickness: 0.8 mm, 1.5 mm

m

-Inside surface of bushing whenassembling pin, inside surface, endface of collar (10): Anti-frictioncompound (LM-P)Grease after assembkng pin:

- Grease (LM-G)


*

*

Set the O-ring at the end face of the bucketboss securely.Adjust the shim thickness so that the clearancebetween arm top (9) and spacer (10) is 0.5 -1.0 mm.j, Standard shim thickness: 0.5 mm, 1 O mm

0.5 - 1.5 mmXlOBM006

Max. 1 mm

0.5- l.Omm

Coat with anti-frictioncompound ILM-P)

30 I 490



DISASSEMBLY AND ASSEMBLY ARM

REMOVAL OF ARM ASSEMBLY

1.

2.

3.

4.

5.

6.

Remove bucket assembly. For details, seeREMOVAL OF BUCKET ASSEMBLY.

Secure front link to arm with wire.

Pull in arm so that it is easy to remove pin at armcylinder head, then lower arm and bucket cylinderassembly (1) on to block 0.A Set the safety lock lever to the LOCK position.

Set block 0 between arm cylinder and boom.

Remove plate, then remove arm cylinder head pin(2). WJ

Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out.A Release the remaining pressure in the


Disconnect 2 hoses (3) and 2 hoses (4).* Install blind plugs at the male end and in the

disconnected hoses.* Hoses (4) are for machines equipped with an


Remove plate, then remove connecting pin (5)between arm and boom.j, There are shims installed, so check the


After raising boom, swing to remove arm andbucket cylinder assembly (1).

Arm, bucket cylinder assembly:PC200-6: 950 kgPC210-6: 1,100 kgPC220-6: 1,100 kgPC250-6: 1,250 kg

0’ Xl7FRO43

30-I 500



DISASSEMBLY AND ASSEMBLY ARM

INSTALLATION OF ARM 6 7ASSEMBLY








* Adjust the shim thickness so that the clearancebetween boom top (6) and arm bottom (7) isbelow 1 mm.* Standard shim thickness: 0.8 mm





30- 1510



DISASSEMBLY AND ASSEMBLY BUCKET. ARM

INSTALLATION OF BUCKET. 6 7ARM ASSEMBLY



A When aligning the position of the pin hole,never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween the boom top (6) and arm bottom (7)is below 1 mm.* Standard shim thickness: 0.8 mm

I-

Inside surface of bushing whenassembling pin: Anti-friction compound(LM-P)



X17FR04r






30-I 530



DISASSEMBLY AND ASSEMBLY BOOM

REMOVAL OF BOOM ASSEMBLY

1. Remove bucket and arm assembly. For details, seeREMOVAL OF BUCKET, ARM ASSEMBLY.

2. Lower boom assembly completely to the groundand set safety lock lever to LOCK position.

3.

4.

Disconnect grease hose (1)

Sling boom cylinder assembly (2), and remove lockbolt (3). ml

5. Remove plate, then remove head pin (4).* There are shims installed, so check the


6. Start engine, and retract piston rod, then tie pistonrod with wire to prevent it from coming out, andlower it onto block.* Disconnect the boom cylinder on the opposite

side in the same way.A Release the remaining pressure in the


7. Disconnect hoses (5) and (6), and secure to valvewith rope.* Hoses (6) are for machines equipped with an


8. Disconnect wiring connector (7) for working lamp.

9. Raise boom assembly and remove plate, removefoot pin (8) using tool P, then remove boomassembly (9).* There are shims installed, so check the

and thickness, and keep in a safe place.Boom assembly:PC200-6: 1,650 kgPC210-6: 1,750 kgPC220-6: 1,950 kgPC250-6: 2,000 kg

30-I 540



DISASSEMBLY AND ASSEMBLY BOOM

INSTALLATION OF BOOMASSEMBLY


A*

WI

A*

When tightening the locknut, tighten so that theclearance between the plate and nut is 0.5 - 1.5mm.


compound (LM-P)

Grease after assembling pin:- Grease (LM-G)

When aligning the position of the pin hole,never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween cylinder rod (10) and plate (11) isbelow 1 mm.j, Standard shim thickness: 0.8 mm, 1.5 mm


compound (LM-P)

Grease after assembling pin:- Grease (LM-G)

When aligning the position of the pin hole,never insert your fingers in the pin hole.Adjust the shim thickness so that the clearancebetween boom (12) nd bracket (13) is below 1mm.* Standard shim thickness: 0.8 mm, 1 O mm,

1.5 mm





0.5-1.5mmXlOBM006

I_

IMax. 1 mmX17FRO42

30-I 550



DISASSEMBLY AND ASSEMBLY OPERATOR’ S CAB

REMOVAL OF OPERATOR’ S CABASSEMBLY

A

1.

2.

3.

4.

5.


Remove floor mat (1).

Remove operator’ s seat assembly (2).Operator’ s seat assembly: 40 kg

Remove knob (3).

Remove 4 caps (4) and clip (5) then remove middlepanel (6).

Remove bottom panel (7).j, The panel is held by a clip, so remove the clip

when removing the panel and be careful not todamage it.

6. Disconnect washer hose (8).

7. Remove plate (9) then remove cover (10).

X13CHOOS

30-I 560



DISASSEMBLY AND ASSEMBLY OPERATOR’ S CAB

8. Disconnect air conditioner hose (11) and speakerwiring connector, then remove cover (12).* When removing the cover, the speaker wiring

connector cannot be seen, so lift up the coverto disconnect the wiring.

9. Remove divider board (13).

10. Remove air conditioner ducts (14) (15) and (15A).

11. Disconnect wiring connectors CN-HOI (16) CN-HO2 (17), CN-HO3 (18) CN-HO4 (IS), CN-HO5 (20)CN-HO6 (21) and CN-ACI-AC2 (23).

12. Disconnect air conditioner cable (24).

19

__-

I 24 . .

30- 1570



DISASSEMBLY AND ASSEMBLY ENGINE THROTTLE CONTROLLER

REMOVAL OF ENGINETHROTTLE CONTROLLERASSEMBLY

A Disconnect the cable from the negative (-) terminalof the battery.

1. Remove plate (I), then remove cover (2).

2. Disconnect air conditioner hose (3) and speakerwiring connector, then remove cover (4).* When removing cover (4), the speaker wiring

connector cannot be seen, so be careful.

3. Remove divider board (5).

4. Disconnect wiring connector (6) and removeengine throttle controller assembly (7).

INSTALLATION OF ENGINETHROTTLE CONTROLLERASSEMBLY


30- 1600



DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER

REMOVAL OF PUMPCONTROLLER ASSEMBLY

A

1.

2.

3.

4.

4.


Remove plate (I), then remove cover (2).

Disconnect air conditioner hose (3) and speakerwiring connector, then remove cover (4).* When removing cover (4) the speaker wiring

connector cannot be seen, so be careful.

Remove divider board (5).

Remove air conditioner duct (7).

Disconnect 3 wiring connectorspump controller assembly (9).

(8) then remove

INSTALLATION OF PUMPCONTROLLER ASSEMBLY


XOECHO14

30- 1610



DISASSEMBLY AND ASSEMBLY MONITOR

REMOVAL OF MONITORASSEMBLY

A1.

2.


Remove screws (I), then lift up monitor assembly

(2).

Disconnect wiring connectors (3), then removemonitor assembly (2).

INSTALLATION OF MONITORASSEMBLY


30- 1620



40 MAINTENANCE STANDARD

Final drive (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) .............Final drive (PC25OLC-6) ...........................................Swing machinery.. ...............................................Swingcircle .....................................................Track frame, recoil spring (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6)Track frame, recoil spring (PC25OLC-6) ..............................Idler (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) ..................Idler (PC250LC-6) ................................................Carrier roller (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6) ...........Carrier roller (PC25OLC-6) .........................................Track roller (PC200-6, PC2OOLC-6, PC21 OLC-6, PC220LC-6) ............Track roller (PC25OLC-6) ..........................................Track shoe (PC200-6, PC2OOLC-6, PC21 OLC-6, PC22OLC-6) ............Trackshoe(PC250LC-6) ..........................................Hydraulicpump ..................................................Controlvalve ....................................................Safety-suction valve for service valve .................................Swing motor .....................................................Travel motor (PC200-6, PC200LC-6, PC21 OLC-6, PC22OLC-6) ...........Travel motor (PC25OLC-6) .........................................Work equipment, swing PPC valve ...................................Travel PPCvalve .................................................Service PPC valve ................................................PPC shuttle, travel junction valve ....................................EPCsolenoidvalve ..............................................Center swivel joint ................................................Boom holdingvalve ...............................................Hydraulic cylinder (PC200-6, PC2OOLC-6, PC21 OLC-6) ..................Hydraulic cylinder (PC22OLC-6, PC25OLC-6) ..........................Workequipment .................................................

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

. . .

..................... 40- 2

..................... 40- 4

..................... 40- 6

..................... 40- 8

..................... 40- 9

..................... 40- 10

..................... 40- 11

..................... 40- 13

..................... 40- 15

..................... 40- 16

..................... 40- 17

..................... 40- 18

..................... 40- 19

..................... 40- 21

..................... 40- 23

..................... 40- 25

..................... 40- 31

..................... 40- 32

..................... 40- 33

..................... 40- 34

..................... 40- 35

..................... 40- 36

..................... 40- 37

..................... 40- 38

..................... 40- 40

..................... 40- 41

..................... 40- 43

..................... 40- 44

..................... 40- 46

..................... 40- 48

40-I



FINAL DRIVEPC200-6, PC200LC-6PC21 OLC-6, PC22OLC-6

m524.5283.5Nm47.5f2.5kQm)

\

1st :98Nm( I OkQm

2nd:75f5’

277+32Nm28i3kQm)

(-__A i__-___--l_ _ ___--_----’

X07HH031

40- 2



Unit: mm

Check item Criteria 1 Remedy

Backlash between No. 1 sun Standard clearance Clearance limit1 gear and No. 1 planetary gear 0.19 - 0.52 1 .oo

2 1 Backlash between No. 1 0.20 - 0.61 1. 10planetary gear and ring gear

3 Backlash between No. 1 0.06 - 0.22 -

planetary carrier and motor

4 Backlash between No. 2 sun 0.15 - 0.49 1 .ooaear and No. 2 olanetarv aear Replace

5 Backlash between No. 2 0.19 - 0.60I

1.10planetary gear and ring gear I

6 Backlash between No. 2 0.15 - 0.44 1 .ooplanetary carrier and No. 1 sungear

7 End play of sprocket shaft 0 - 0.10 -8 Amount of wear on sprocket Repair limit: 6

tooth

Standard size Repair limit Rebuild or

9 Width of sprocket tooth replace71 68

40-3



MAINTENANCE STANDARD FINAL DRIVE

FINAL DRIVEPC250LC-6

wInitial tightening t orque: 98 N-M

w

(10 kgm) 382.2 +39.2 N

Additional tightening angle: 120”: (39 +4 kgm)

\ \

533

-M2

\

m 60.8 27.4 N-M ,(6.75 50.75 kgm) \

637 +49 NM(65 +5 kgm)

-66.2 +7.4 N-M(6.75 to.75 kgm)

w 68.6 +9.8 N-M-

r

.8 258.8?6 kgm)

WM

40-4



MAINTENANCE STANDARD FINAL DRIVE

Unit: mm

Check item Criteria 1 Remedy

1Backlash between No. 1 sun Standard clearance Clearance limitgear and No. 1 planetary -ear 0.19 - 0.54 1 .oo


1.10planetary gear and ring gear

3 Backlash between No. 1 0.06 - 0.22 -

planetary carrier and motor

4 Backlash between No. 2 sun 0.19 - 0.54 1 .oo1gear and No. 2 planetary gear 1


1.10planetary gear and ring gear I

6 Backlash between No. 2planetary carrier and No. 1 sungear

0.39 - 0.67 1.20

Replace

7 End play of sprocket shaft 0.10 - 0.15 -8 Amount of wear on sprocket Repair limit: 6

tooth

Standard size Repair limit Rebuild or

9 Width of sprocket tooth replace87 84

40-5



MAINTENANCE STANDARD SWING MACHINERY

SWING MACHINERY

110.5+12.5Nm(11.25i1.25kgm:

277 + 32Nm(28, .25+3.25kgm)

5

1

6

Ip_.r-----7

6

\‘ fi6.5+19 .5Nm

(18+2kgm 1

X09DH031

40- 6



MAINTENANCE STANDARD SWING MACHINERY

Unit: mm

No.

planetary carrier and swingpinion

9 Backlash between swing pinion 0.22 - 1.32 2.00and swing circle

10 Clearance between plate and 0.38 - 1 .I6 - Apply hardplanetary carrier chrome plating,

Wear of swing pinion surface Standard size Repair limit recondition, or

11 contacting with oil seal125 PO.100

replace124.7

40-7



MAINTENANCE STANDARD SWING CIRCLE

SWING CIRCLE

pzi-1 / ‘ 11PC200, PC210, PC220 1 St:

PC250:

2nd:

823.8- 1029.7 Nm(84- 105 kgm)

191.3 ‘ 19.6 Nm(19.5 22 kgm)48 +5

PC200, PC210: 804.4 283.4 Nm(82 28.5 kgm)

PC220:

PC250:

A-A

999.6 2102.9 Nm

(102 210.5 kgm)

823.8-1029.7 Nm(84-105 kgm)

X09DH032

No. Check Item Criteria I Remedy

Axial clearance of bearing Standard clearance Clearance limit1 (when mounted on chassis) Replace

0.5 - 1.6 3.2

40- 8



TRACK FRAME, RECOIL SPRINGPC250LC-6

X14AH013

Unit: mm

No. Check Item Criteria Remedy

Standard size Tolerance Repair limit

1 Vertical width of idler gear Track frame 123 +2 127-1

I I II I

Idler support 120 f 0.5 118 Rebuild orreplace

Track frame 266 +3 2712 Horizontal width of idler guide -1

_Idler support 261 259

Standard size Repair limit

Free limit Installed Installation Free length Installation3 Recoil spring length load load Replace

795 X 241 646 173.3 Nm(17,680 kg) -

138.6 Nm(14,140 kg)

40-I 0



MAINTENANCE STANDARD IDLER

IDLERPC200-6, PC2OOLC-6PC21 OLC-6, PC22OLC-6

21 + 5kgm)

t

,:

“ : ,: :

,’ :’

:j ::

,’‘ _ _f’

.

m--J--k4I .

_,’iI? I/--.

i

ZPI

I-I

X14AVOO8

40- 11



Unit: mm

No.

1

2 Outside diameter of

3 Width of protrusion

4

5 Width of tread

6

7

8

9

Check item

Outside diameter ofprotrusion

Standard size

560

Criteria

Repair limit

-

Remedy

tread Rebuild or

85 - replace

Total width I 164 I - I

Clearance betweenshaft and bushing

Clearance betweenshaft and support

65 -0.250 -0.110-0.290 -0.220

0.03 - 0.180 - Replace

Interferencebetween idler andbushing

Standardsize

72

Tolerance

Shaft Hole

+0.089 -0.006+0.059 -0.072

Standard Interferenceinterference limit

0.065 - 0.161 - Replacebushina

1 I I

Side clearance of I Standard clearance I Clearance limit Iidler (each)

0.39 - 1 .oo 1.5

40- 12



MAINTENANCE STANDARD IDLER

IDLERPC25OLC-6

2

4151.9 224.5 Pm

15.5 22.5 kgm)\

4c

--

X14AVOO9

40-I 3



No.

1

2

3 Width of protrusion

4

5

6

7

8

9

Unit: mm

Check item

Outside diameter ofprotrusion

Standard size

630

Criteria

Repair limit

-

Remedy

Outside diameter oftread

590 578

Rebuild or

101 - replace

Total width I 190 I - I

Width of tread

Clearance betweenshaft and bushing

Clearance betweenshaft and support

Interferencebetween idler andbushing

Side clearance ofidler (each)

Standard Tolerancesize

Shaft Hole

80 -0.225 +0.130

-0.325 -0.010

80 -0.225 -0.085-0.290 -0.195


Shaft Hole

87.6 +0.087 -0.027+0.037 -0.079

Standard clearance

0.68 - 1.22

Standard Clearanceclearance limit

Replace

0.215bushing

- 0.455 1.5

0.030 - 0.205 - Replace


0.064 - 0.166 - Replacebushing

Clearance limit

2

40- 14



MAINTENANCE STANDARD CARRIER ROLLER

CARRIER ROLLERPC200-6, PC2OOLC-6PC21 OLC-6, PC220LC-6

w 14.7i4.9Nm(1.5+_0.5kgm)

X14BR008

No.

1

2

3

4

5

6

Check item

Outside diameter of flange (outside)

Outside diameter of tread

Width of tread

Standard size

165

140

43

Criteria

Repair limit

-

130

50

Remedy

Rebuild orreplace

interference between shaft andbearing

Interference between roller andbearing

Side clearance of roller


Shaft Hole

50 0 0-0.016 -0.012

80 0 -0.021-0.013 -0.051

Standard clearance

0.01 - 0.18

Standard interferenceinterference limit

- 0.016 - -0.012 Replace

0.008 - 0.051

Clearance limit

-

40- 15



MAINTENANCE STANDARD CARRIER ROLLER

CARRIER ROLLERPC25OLC-6

No. Check item Criteria Remedy

1 Outside diameter of flange (outside)Standard size

200

Repair limit

_

14.7 a.9 Nm(1.5 +a5 kgm)

X14BR009

3

Outside diameter of tread

Width of tread

168

49.5

158

57.5

rieuull” “ I

replace

4

5

Clearance between shaft andbearing

Interference between roller andbearina

Standardsize

55

80

Tolerance

Shaft Hole

+ 0.021 0+ 0.002 -0.015

0 -0.021-0.013 -0.051


0.002 - _0.036 Replace

0.009 - 0.059 _

6 Side clearance of rollerStandard clearance

0. 01 - 0.24

Clearance limit

-

40- 16



MAINTENANCE STANDARD TRACK ROLLER

TRACK ROLLERPC200-6, PC2OOLG6PC21 OLC-6, PC22OLC-6

No. Check item I Criteria I Remedy

Outside diameter of flange(outside)

Standard size

186

Repair limit

_

Outside diameter of tread 1 154 I 142 1 Rebuild or

7 Side clearance of roller

a=14.724.9Nm(1.5tO.Skgm)

244.1 Nm54.5 kgm)

------- I -I

_ 3-4 X14BROlO

Unit: mm

Width of tread

Width of flange

ral-“ dc;e44.5 52

24.5_

Clearance between shaftand bushing

Standardsize

Tolerance Standard Clearance limitclearance

Shaft Hole I I

Interference between rollerand bushing

60

Standard

size

- 0.215 + 0.195 0.215 - 0.510 1.5- 0.315 0

ReplaceTolerance Standard Interference bushing

interference limitShaft Hole

_67 + 0.153 + 0.030 0.023 - 0.153

+ 0.053 0

Standard clearance Clearance limit

0.41 - 0.95 1.5Replace

40-I 7



MAINTENANCE STANDARD TRACK ROLLER

TRACK ROLLERPC250LC-6

u 666.6 t-66.6 Nm(67 57 kgm)

No. Check item Criteria I Remedy

1

2 Outside diameter of tread

3 Width of tread

-_

--i__ _._A

3 4

X14BROll

Unit: mm

Outside diameter of flange(outside)

Width of flange

Clearance between shaffand bushing

Interference between rollerand bushing

Side clearance of roller


216

180

49

-

168

55

Rebuild orreplace

Standardsize

Tolerance Standard Clearance limitclearance

Shart Hole

65 - 0.215 + 0.186 0.151 - 0.501 1.5- 0.315 - 0.064

Standardsize

ReplaceTolerance Standard Interference bushing

interference limitShaft Hole

72 0.108_

+ - 0.006 0.014-0.144+ 0.008 - 0.036

Standard clearance Clearance limit

0.41 - 0.95 1.5Replace

40- 18



MAINTENANCE STANDARD TRACK SHOE

TRACK SHOEPC200-6, PC200LC-6PC21 OLC-6, PC22OLC-6

\\ -

9 X15AD006

40- 19




Unit: mm

No.

1

2

3

4

5

6

7

8

Check item Criteria I Remedy

Link pitch

Outside diameter ofbushinn


190.25 194.25

59.3 54.3

Turn orreplace

Height ofgrouser

Height of link

Triple 26 16

Swamp 102.5 90.5Lugwelding,

. -^L..:IA ^-, ~““ I I” “ I

replace

Interference betweenbushing and link

Interference betweenregular pin and link

Interference betweenmaster pin and link

Protrusion of bushing

Standardsize

59 1 MM& 1 +0;74 1 o.lgll 1 0.100

37.8 +0.230 +0.062 0.138 - 0.130+0.200 0 0.230

4.85

Replacewith oversize

Adjust

9 Tightening torque of shoe Initial tightening torque: 392 f 39.2 Nm (40 f 4 kgm) Tightenbolt Additional tightening angle: 120” f IO”

40-20



TRACK SHOEPC25OLC-6

4

3

9

40- 21




No.

1

2

5

6

7

8 Protrusion of bushing

9 Tightening torque ofshoe bolt

Check item

Link pitch

Outside diameter ofbushing

Height of grouser

Height of link

Interference betweenbushing and link

Interference betweenregular pin and link

Interference betweenmaster pin and link

Criteria


61.9

31

116

Standardsize

44.6 (Shaft)44.35 (Hole)

44.4 (Shaft) +0.230 +0.062 0.188 - 0.08044.35 (Hole) +0.200 0 0.280

5.25 f 0.3

Initial tightening torque: 390 f 49 Nm (40 f 5 kgm)Additional tightening angle: 120” f IO”

Unit: mm

Remedy

Turn orreplace

Lugwelding,rebuild orreplace

Rebuild orreplace

Replace

Replacewith oversize

Adjust

Tighten

40- 22



MAINTENANCE STANDARD HYDRAULIC PUMP

HYDRAULIC PUMP

Qa 66.1L7.35Nrn(6.75+0.75kgm)

-2

_ 17.151t2.45Nm(1. 5+0.25kgm)

15*7.35Nm.75+0.75kgm)

\

m 66.15f7.35Nm(6f5f0.75kgm)

_ 68:6f9.8Nm(7f lkgm)

XlOAV269

40- 23



MAINTENANCE STANDARD HYDRAULIC PUMP

CONTROL PUMP, RELIEF VALVE

w 53.9*4.9Nm(5.5&0.5kgm)

No.

4

P-B

1

l--B

,66.15+7.35Nm(6.75+0.75kgm)

XlOAV270

Unit: mm

Radical clearance between gear

Control relief valve springor deformations



CONTROL VALVE

* Figure shows 9-spool control valve (with 3 service valve).9-spool control valve includes 6-spool, 7-spool and 8-spool control valves.

w 166.7 f 9.8 Nm w 166.7 2 9.8 Nm17,= 1 kgm) 17 e 1 kgm)

30.9 z 3.4 Nm3.15 f 0.35 kgm)

w 66.2 ~7.4 Nm m 66.2 +7.4 Nm w 30.9 =3.4 Nm6.75 +0.75 kgm) 6.75 + 0.75 kgm)

\ / /3.15 2 0.35 kgm)

a 66.2 2 7.4 Nm m‘l66.7 * 9.6 Nm6.75 2 0.75 kgm) 17 + 1 kgm)

XlOBH176

40- 25



MAINTENANCE STANDARD CONTROL VALVE

No.

1

2

3

m 75.5 2 9.; Nm7.7 2 1 kgm)

75.5 * 9.8 Nm7.7 2 1 kgm)

XlOBH177

Unit: mm

Check item Criteria Remedy, I I I

Spool return spring

Spool return spring

Spool return spring

Free lengthX O.D.

54.2 X 34.8

54.2 X 34.6

54.2 X 34.8

Standard size

installedlength

51.2

51.2

51.2

Installed load

416.5 N(42.5 kg)

420.4 N(42.9 kg)

393.0 N(40.1 kg)

-

-

333.2 N(34 kg)

336.1 N(34.3 kg)

Replace spring ifany damages ordeformations arefound.

314.6 N(32.1 kg)

40- 26




m 166.7 2 19.6 Nm m 166.7 * 19.6 Nm(17 + 2 kgm)

\ 5 6

w75.5&9.8Nm

/ (7.7+lkgm)

75.5f9.8Nm

‘ 6

4 3 \m 53.9f4.9Nm

K-K (5.5f0.5kgm)

No. Check item

1 Main unload spring

4 Relief spring

4 3 \m 53.9+4.9Nm

(5.5+0.5kgm)L-L

85 .85f7.35Nm(8 .75+0:75kgm)

XlOBH178

Unit: mmI

Criteria I Remedv

Free lengthX O.D.

43x19. 4

20.9 X 17.2

23.2 X 7.2

30.7 X 9.6

Standard size

Installedlength Installed load

Rep2

Free length

32 260.7 N(26.6 kg)

26.3I

369.5 N(37.7 kg) -


5 Unload spring

6 Check valve spring

110.7 N(11.3 kg)

--i4.4 N

(0.45 ka)

40- 27



w 147.1 2 9.8 him w 392.3 L 19.6 Nm

15 + 1 kgm) 40 +2 kgm)

\ /

w 14<1*9.8Nm m 3i2.3 + 19.6 Nm m 16.1 r 9.8 Nm A 19.6 Nm15 or 1 kgm)

w i2.3

D-D40 2 2 kgm) 15 + 1 kgm) E-E 40 2 2 kgrri

147.7 = 9.8 Nm15 t 1 kgm)

m 392.3 + 19.6 Nm

40 t 2 kgm)

w 392.3 2 19.6 Nm m 147.1 * 9.8 Nm w 392.3 2 19.6 hlmMO+2 kgm) 15 * 1 kgm) (40 + 2 kgm)

I

w 392.3 it 19.6 Nm40 k 2 kgm)

F-F

107.9 - 147.1 Nm11-15 kgm)

w 147 =9.8Nm 392.3 + 19.6 Nm

15 t 1 kgm) 40 = 2 kgm)

G-GXlOBH179

40- 28




-147.li9.8Nm m 392.3F19.6Nm(15+lkgm) (40 +Zkgm)

\ /

147.1+9.8Nm(15+lkgm)

/ \W 147.lf9.8Nm m 392.3+_19.6Nm(15* Ikgm) (40+2kgm)

H-H

m 392.3+19.6Nm(40+2kgm)

m 147.1’ &9.8Nm w 392.3+19.6Nm(15+lkgm) (40+2kgm)

N-NXlOBH180

Unit: mm


Standard size Repair limitArm counterbalance valve

1 spring Free length Installed Installed load Free length Installed loadx O.D. length

70.8 X 16.1 55 192.1 N 153.9 N(19.6 kg)

_(15.7 kg)

Regeneration valve spring 31.5x10.3 19.5 5.9 N 4.4 N(0.6 kg) - (0.45 kg)

ifPiston return spring 48.1 X 10.8 30 15.7 N 12.7 N

Replace spring

(1.6 kg)_

(1.3 kg)any damages ordeformations arefound.

Check valve spring 13.0 X 6.5 9.5 2.0 N 1.5 N(0.2 kg)

-(0.15 kg)

5 Load spring 30.4 X 16.7 27 428.3 N 343N(43.7 kg) - (35.0 kg)

6 Check valve spring 13.6 X 5.5 10 2.0 N 1.5 N(0.2 kg)

_(0.15 kg)

7 Piston return spring 36.9 X 11 .I 28 29.4 N

(3 kg)_ 23.5 N

(2.4 kg)

40-29




SAFETY-SUCTION VALVE FOR SERVICE VALVE

1

w 140+22Nm

(14.25+2.25kgm)

m 147 + 1ONm(15 + lkgm)

XlOBH182

Unit: mm



Suction valve spring

1Free length Installed Installed load Free length Installed load

X O.D. length Replace spring ifany damages or

16.3 X 21.3 1.5 2.1 N 1.6 N deformations are(0.21 kg) - (0.16 kg) found.

2 Piston spring 20X7 14 2.1 N 1.6 N(0.21 kg)

_(0.16 kg)

40- 31



MAINTENANCE STANDARD SWING MOTOR

SWING MOTOR

m 166.7+19.6Nm

(17.0tZ.Okgm)m 122.6f63.7Nm

(12.5f6.5kgm)

n

m 373t49.ONm(38.0+5.0kgm)

X09DH033

Unit: mm


Standard size Repair limitReplace spring if

1 Check valve spring Free length Installed Installed load Free length Installed any damages orX O.D. length load deformations are

found.62.5 X 20.0 35.0 3.5 N 2.8 N_

(0.36 kg) (0.29 kg)

40-32



MAINTENANCE STANDARD TRAVEL MOTOR

TRAVEL MOTORPC200-6, PC2OOLC-6PC21 OLC-6, PC220LC-6

8.83+0.98Nm(0.9+0.lkgm)

23.5F3.9Nm

18.63*8.83Nm(l.g+O.gkgm) w 279+24_5Nm m 419k46.6Nm

-23.5&3.9Nm(28.5&2.5kgm) (42.8f4.7kgm)

(2.4f0.4kgm)

X07HH032

Unit: mm



1 Spool return spring Free length Installed Installed load Free length Installed loadX O.D. length

58.43 X 30.0 42.0 426.3 N 341 .O N Replace spring if_(43.5 kg) (34.8 kg) any damages or

deformations are2 Check valve spring 33.0 X 13.8 23.0 1.3 N 1.0 N found.

(0.13 kg) -(0.10 kg)

3 Regulator piston spring 61.1 X23.2 30.0 398.9 N 319.5 N(46.7 kg) - (32.6 kg)

40-33



MAINTENANCE STANDARD WORK EQUIPMENT, SWING PPC VALVE

WORK EQUIPMENT, SWING PPC VALVE

m 6.8 + 1.9Nm(0.7 ko.2kgm)

B-B

m 12.7 + 2.9Nm(1.3+0.3k9m)

D-D

E-EX07HH033

Unit: mm



1 Centering spring (for P3, P4) Free length Installed Installed load Free length Installed loadX O.D. length

42.4X 15.5 34 17.6 N 13.7 N(1.8 kg)

-(1.4 kg)

2 Centering spring (for PI, P2) 44.4 x 15.5 34 29.4 N 23.5 N(3.0 kg)

-(2.4 kg)

3 Metering spring 26.5 X 8.2 24.9 16.7 N 13.7 N(1.7 kg)

-(1.4 kg)


40-35



MAINTENANCE STANDARD TRAVEL PPC VALVE

TRAVEL PPC VALVE

m 27.9+3.4Nm(2.85+0.35kgm)

m 17.6&3.9Nm(1.8+0.4kgm)

w 30.9&3.4Nm(3.15t0.35kgm)

XlOBHl83

Unit: mm


I I IStandard size Repair limit

I I 1 I1 Metering spring Free length Installed Installed load Free length Installed load

X O.D. length Replace spring ifany damages or

26.5 X 8.15 24.7 16.7 N 13.7 N deformations are(1.7 kg)

_(1.4 kg) found.

2 Centering spring 48.1 x 15.5 32.5 107.8 N 86.2 N

(11 kg)_

(8.8 W

40- 36



MAINTENANCE STANDARD SERVICE PPC VALVE

SERVICE PPC VALVE

w 78.5Nm(8.0’(p)

m 2.9Nm(0.3kgm)

XlOBH184

Unit: mm



1 Centering spring Free length Installed Installed load Free length InstalledX O.D. length load

Replace spring if

64.6 X 16.6 40.5 46.1 N 44.1 N any damages or_

(4.7 kg) (4.5 kg) deformation arefound.

2 Metering spring 26.0 X 10.5 25.0 25.5 N 24.5 N_(2.6 kg) (2.5 kg)

40-37



MAINTENANCE STANDARD PPC SHUTTLE, TRAVEL JUNCTION VALVE

PPC SHUTTLE, TRAVEL JUNCTION VALVE

m34.3?4.9Nm(3.5+0.5kgm)

34.3r4.9Nm\(3.5+0.5kgm)

17.15+2.45Nm

107.8+14.7Nm

3

m 66.15&/7.35Nm(6.75*0.75kgm)

XlOBH185

40-38



MAINTENANCE STANDARD PPC SHUTTLE, TRAVEL JUNCTION VALVE

A-A

XlOBH186

Unit: mm

No. Check item CriteriaRemedy

Standard size I Repair limit II I I I

1 Spool return spring Free length Installed Installed load Free length Installed load Replace spring if

X O.D. length any damages ordeformations are

23.6 X 13.3 20 14.7 N 11.8 N found.

1 (1.5W- 1 (1.2kg) 1

40-39



MAINTENANCE STANDARD EPC, SOLENOID VALVE

EPC, SOLENOID VALVE

LS CONTROL EPC VALVE

m 11.3F1.5Nm(1.15+0.15kgm)

w 9:8+_2.ONm(1 +0.2kgm)

XlOBH187

Unit: mm


Standard size Repair limitReplace EPC

1 Return spring Free length Installed Installed load Free length Installed valve assembly if

X O.D. length load any damages ordeformations are

9.0 x 11.4 7.9 3.1 N(0.32 kg)

_found.

_

40-40



MAINTENANCE STANDARD CENTER SWIVEL JOINT

CENTER SWIVEL JOINT

4 PORT SWIVEL JOINT

x10zz021

Unit: mm


Standard size Standard clearance Clearance limit1 Clearance between rotor and shaft Replace

90 0.056 - 0.105 0.111

40-41



MAINTENANCE STANDARD CENTER SWIVEL JOINT

6 PORT SWIVEL JOINT

x1ozzo22

Unit: mm


Standard size Standard clearance Clearance limit

1 Clearance between rotor and shaft Replace100 0.056 - 0.105 0.111

40- 42



MAINTENANCE STANDARD BOOM HOLDING VALVE

BOOM HOLDING VALVE

* For machines equipped with arm holding valve, the Maintenance Standard of the arm holding valve is the sameas this valve.

IA

2

/m 15.0fl.Okgm

AA

No. Check item Criteria

XlOBH188

Unit: mm

Remedy

1

2

Pilot valve spring

Check valve spring

Free lengthX O.D.

26.5 x 11.2

37.2 X 16.2

Standard size

Installedlength

25.0

30.0

Repair limit

Installed load

4.7 N(0.48 kg)

Free length Installed load Replace spring ifany damages ordeformations are

3.7 N found._(0.38 kg)

35.3 N 28.4 N

(3.6 kg)_

1 (2.9 kg) 1

40-43



MAINTENANCE STANDARD HYDRAULIC CYLINDER

HYDRAULIC CYLINDERPC200-6, PC2OOLC-6PC21 OLC-6

BOOM CYLINDER

-270+39.ONm(27.,5&4.Okgm)

m 8.6k0.86kNt-n(880Ifr88kgm) (Width ac ross flat: 95mm)

XIQBR042

ARM CYLINDER

-372.4+53.9Nm(38.0i5.5kgm)

m 10.2+1.0kNm(1 ,FO? 104kgm) (Width across flat: 95mm)

XIOBR043

BUCKET CYLINDER

m 270+_39Nm m 7.1*0.7kNrn(720+72kgm) (Width across flat: 85mm)

XIOBR044

40-44




Unit: mm

Remedyo. Check :em Crite Ia

Cylinder -ante Standard Clearanceclearance limit

Hole

+0.257+0.048

BoomClearancebetweenpiston rodand bushing

Replacebushing+0.222

+0.047Arm

Bucket 80 -0.030 +0.258-0.076 +0.048

0.078 - 0.334 0.434

Clearancebetweenpiston rodsupport pin

and bushing

Boom 80 -0.030-0.060

80 -0.030

-0.076

+0.457+0.370

+0.457

+0.370

Arm

Bucket +0.424+0.350

0.380 - 0.500 1.0

I

0.400 - 0.533 I 1 .o0.211+0.124

Replacepin orbushing

Clearancebetweencylinderbottomsupport pinand bushing

Boom

Arm 80 -0.030-0.076

-t70 -0.030

-0.076

+0.457+0.370

0.400 - 0.523 1.0

+0.424+0.350

Bucket

40-45




HYDRAULIC CYLINDERPC22OLG6, PC250LG6

BOOM CYLINDER

m 270+39Nm(27.5i4.Okgm)

m 10.2+1.0kNm(1,040 + 104kgm) (Width across flat: 95mm)

ARM CYLINDER

m 373k54Nm(38iOF5.5kgm)

m 10.2 l .OkNm(1 y + 104kgm) (Width across fiat: 95mm)

BUCKET CYLINDER

w 270+39Nm(27.5f4.0kgm)

w 10.2+1.0kNm(1,1?40+ 104kgm) (Width across flat: 95mm)

XlOBR047

40- 46




Unit: mm

Remedyo. Check item Criteria

Cylinder

BoomClearancebetweenpiston rodand bushing

ReplacebushingArm 100 1 XI:&;; 1 ;;:W;; 1 0.083 - 0.347 1 0.447

90 1 XLCI;; 1 N:Wt; 1 0.084 - 0.347 1 0.447ucket

Boom 80 1 4:;;; 1 Ml:tl;; 1 0.400 - 0.517 1 1 Olearancebetweenpiston rodsupport pin

and bushing

Arm 80 1 4l:tl;; 1 ;;:;A; 1 0.400 - 0.533 / 1 .O

Bucket 80 1 4:;;; 1 G:;;; 1 0.400 - 0.533 1 1.0

Boom 80 1 4:CD& ) W& 1 0.400 - 0.533 1 1.0 Replacepin orbushing

Clearancebetweencylinderbottomsupport pinand bushing

3Arm 80 1 4:;;; 1 4:;;; 1 0.400 - 0.533 1 1.0

Bucket 80 1 4:;;; 1 NM; / 0.400 - 0.533 / 1 .O

40-47



MAINTENANCE STANDARD WORK EQUIPMENT

WORK EQUIPMENTD

G

I

A-A

B-B

E-E

F-F

D-D G-G X17FR024

40- 48




No.

3

4

Check item

Clearance betweenconnecting pin andbushing of revolvingframe and boom

Clearance betweenconnecting pin andbushing of boomand arm

Clearance betweenconnecting pin andbushing of arm andlink

Clearance betweenconnecting pin andbushing of arm andbucket

Clearance betweenconnecting pin andbushing of link andbucket

Clearance betweenconnecting pin andbushing of link andlink

T-Standard

size

90

90

70 (PC200)(PC21 0)

80 (PC220)(PC250)

80

80

70 (PC200)(PC21 0)

80 (PC220)(PC250)

Criteria

Tolerance I Standard I Clearance

-0.036 +0.153 0.133 - 1.0-0.071 +0.097 0.224

-0.030 +0.335 0.305 - 1 .o-0.076 +0.275 0.411

-0.030-0.076

-0.030 +0.337 0.303 - 1 .o-0.076 +0.273 0.413

-0.030 +0.335 0.303 - 1 .o-0.076 +0.275 0.411

rUnit: mm

Remedy

Replace

40-49




DIMENSION OF WORK EQUIPMENT

1. ARM PORTION

i

, 1 ,I I

x-x

X17FRO25

40-50



MAI NTENANCESTANDARD WORKEQUI PMENT

Uni t: mm

Appl i cabl e machi ne

No.

PC200- 6 PC210- 6 PC220- 6PC250- 6

1 080 ' 0 080 ' o . ' 080 ; I

2 107. 3-y 107. 3+I . 5O 107. 3y

3+0. 5

3100+0. 5

3100+0. 5

3100

4 09~0. 0710. 036 09~0. 071 0. 036 - 0. 03609~0. 071

5 361. 7+1 361. 7k. l 403. 9 f 1

6 187. 2 f 0. 5 187. 2 f 0. 5 200 f 0. 5

7 829. 1 f 1 829. 1 f 1 920*1

8 2, 919 2, 919 3, 038

9 2, 631. 3 I 2, 631. 3 I 2, 563. 2 1

10 410*1 41Okl 4651t l

11 640 f 0. 2 640 f 0. 2 585 f 0. 2

12 600 f 0. 5 600 f 0. 5 600 f 0. 5

13 458. 1 458. 1 446. 3

14 1, 486 1, 498. 3 1, 551. 7

15 080 080 080

16 326. 5 *I 326. 5 f 1 326. 5 f 1

17 080 080 080

Arm w dth0

183 - o. 5 31l _oq5

03 - o. 5

Bushi ng nst al l ed 325 325 325

M n. 1, 680 1, 680 1, 60519

Max. 2, 800 2, 800 2, 625

40-51




2. BUCKET PORTION

Adjustable Device Configuration View B -B

6

7

Standard Configuration

Komatsu PC200-6 Shop Manual

Documents

Transcript of Komatsu PC200-6 Shop Manual