Komatsupc58uu 3shopmanualexcavatorrepairbook PDF

SEBM023907
MACHINE MODEL SERIAL NUMBER
PC58UU-3 20001 and up
• This shop manual may contain attachiments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
• PC58UU-3 mounts the 4D88E-3G and 4D88E-5XBB engine.

For details of the engine, see the 68E-88E Series Engine Shop Manual.
© 2004
All Rights Reserved
Printed in Japan 08-04(02) 00-1
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CONTENTS
No. of page
01 GENERAL ........................................................................................................................... 01-1
10 STRUCTURE, FUNCTION AND MAINTENANCE

STANDARD ......................................................................................................................... 10-1
20 TESTING AND ADJUSTING ............................................................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ................................................................. 30-1
90 OTHERS ............................................................................................................................... 90-1
00-2 PC58UU-3
The affected pages are indicated by the use of the
Mark Indication Action required
following marks. It is requested that necessary
actions be taken to these pages according to the Q Page to be newly added Add
table below.
q Page to be replaced Replace
( ) Page to be deleted Discard
Pages having no marks are those previously revised

or made aditions.
LIST OF REVISED PAGES

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q 01-13 (7) 10-36 10-78 10-119 20-106 (6)
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PC58UU-3 00-2-1
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20-116 (1) 20-220 (1) 20-308 (6) 20-402 (6) 20-551 (1)
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20-118 (1) 20-222 (6) 20-310 (1) 20-501 (1) 20-553 (1)
20-119 (1) 20-223 (1) 20-311 (1) 20-502 (1) 20-554 (1)
20-120 (1) 20-224 (1) 20-312 (6) 20-504 (1) 20-555 (1)
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20-123 (1) 20-227 (1) 20-314 (1) 20-507 (1) 20-558 (1)
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20-127 (1) 20-231 (1) 20-318 (6) 20-511 (1) 20-602-1 (6)
20-128 (1) 20-232 (1) 20-319 (6) 20-512 (1) 20-603 (6)
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20-136 (1) 20-240 (6) 20-327 (6) 20-520 (1) 20-609 (6)
20-137 (1) 20-241 (6) 20-328 (6) 20-521 (1) 20-610 (6)
20-138 (1) 20-241-1 (6) 20-329 (6) 20-522 (1) 20-611 (6)
20-139 (1) 20-241-2 (6) 20-330 (6) 20-523 (1) 20-612 (6)
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20-208 (6) 20-252 (1) 20-342 (6) 20-535 (1) 30-2 (2)
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20-210 (6) 20-254 (1) 20-344 (6) 20-537 (1) 30-4 (2)
20-211 (6) 20-255 (1) 20-345 (6) 20-538 (1) 30-5 (2)
00-2-2 PC58UU-3
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30-10 (6)
30-11 (2) 90-1 (5)
30-12 (2) q 90-3 (7)
30-13 (2) 90-5 (5)
30-14 (2) 90-7 (5)
30-15 (6) 90-9 (5)
30-16 (2) 90-11 (5)
30-17 (2) 90-13 (5)
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PC58UU-3 00-2-3
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
}
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume: PAGES next to the CONTENTS page.
Attachments volume: · volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
k
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4
• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to of the load during hoisting, untwisting of
the table below: the rope, or slipping of the rope from its
original winding position on the load, which
Wire ropes can result in a dangerous accident.
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
Rope diameter Allowable load
When hoisting a load with two or more ropes,
the force subjected to each rope will increase
mm kN tons with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6
vertically, at various hanging angles.
14 21.6 2.2
16 27.5 2.8
When two ropes sling a load vertically, up to
18 35.3 3.6 19.6 kN {2000 kg} of total weight can be sus-
20 43.1 4.4 pended. This weight becomes 9.8 kN {1000 kg}
22.4 54.9 5.6 when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.
★ The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
★ When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
• Used to prevent rubber gaskets, rub-

LT-1A 790-129-9030 150 g Tube ber cushions, and cock plug from
coming out.
• Used in places requiring an immedi-
ately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyethyl-
LT-1B 790-129-9050 (2 pcs.) container ene, polyprophylene, tetrafluoroeth-
lene and vinyl chloride), rubber,
metal and non-metal.
• Features: Resistance to heat and
Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and sealant
purpose for bolts and plugs.
Adhesive: • Used as adhesive or sealant for met-
790-129-9060 al, glass and plastic.
(Set of adhesive 1 kg
LT-3 and hardening Hardening Can
agent) agent:
Adhesives 500 g
Polyethylene • Used as sealant for machined holes.
LT-4 790-129-9040 250 g
container
Holtz • Used as heat-resisting sealant for re-

790-126-9120 75 g Tube pairing engine.
MH 705
• Quick hardening type adhesive
Three bond 790-129-9140 50 g Polyethylene • Cure time: within 5 sec. to 3 min.
1735 container • Used mainly for adhesion of metals,
rubbers, plastics and woods.
• Quick hardening type adhesive
Aron-alpha Polyethylene • Quick cure type (max. strength after
201 790-129-9130 2g container 30 minutes)
• Used mainly for adhesion of rubbers,
plastics and metals.
• Resistance to heat, chemicals
Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to high
648-50 container temperatures.
• Used as adhesive or sealant for gas-
LG-1 790-129-9010 200 g Tube kets and packing of power train case,
etc.
• Used as sealant for various threads,
LG-5 790-129-9080 1 kg Can pipe joints, flanges.
• Used as sealant for tapered plugs,
elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance
to heat, cold
• Used as sealant for flange surface,
LG-6 790-129-9020 200 g Tube tread.
• Used as sealant for oil pan, final
Gasket drive case, etc.
sealant
• Features: Silicon based, quick hard-
ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel hous-
ing, intake manifold, oil an, thermo-
stat housing, etc.
Three bond • Used as heat-resisting sealant for re-
1211 790-129-9090 100 g Tube pairing engine.
• Features: Silicone type, heat resist-

Three bond ant, vibration resistant, and impact
1207B 419-15-18131 100 g Tube resistant sealing material
• Used as sealing material for transfer
case
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
LM-G 09940-00051 60 g Can • Used as lubricant for sliding portion

(to prevent from squeaking).
Molybdenum • Used to prevent seizure or scuffling
disulphide of the thread when press fitting or
lubricant LM-P 09940-00040 200 g Tube shrink fitting.
• Used as lubricant for linkage, bear-
ings, etc.
SYG2-400LI • General purpose type
SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA • Used for normal temperature, light

SYG2-350CA load bearing at places in contact
G2-CA SYG2-400CA-A Various Various with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum • Used for heavy load portion

SYG2-400M 400 g × 10 Bellows type
disulphide SYG2-400M-A 400 g × 20 Bellows type
Grease grease SYGA-16CNM 16 kg Can
LM-G (G2-M)
• Seizure resistance and heat resist-
Hyper White SYG2-400T-A ance higher than molybdenum di-
Grease G2-T SYG2-16CNT 400 g Bellows type sulfide grease
G0-T (*) SYG0-400T-A (*) 16 kg Can • Since this grease is white, it does
*: For use in cold SYG0-16CNT (*) not stand out against machine
district body.
Biogrease G2B • Since this grease is decomposed
SYG2-400B by bacteria in short period, it has
G2-BT (*) SYGA-16CNB 400 g Bellows type
*: For high less effects on microorganisms,
SYG2-400BT (*) 16 kg Can animals, and plants.
temperature SYGA-16CNBT (*)
and large load
SUNSTAR • Used as primer for cab side

Glass (Using limit: 4 months)
PAINT PRIMER 20 ml container
580 SUPER
Primer
SUNSTAR • Used as primer for glass side
Glass (Using limit: 4 months)
GLASS PRIMER 20 ml container
580 SUPER 417-926-3910
Adhesive for cab glass
SUNSTAR • "S" is used for high-tempera-

PENGUINE ture season (April - October)
SEAL 580 320 ml Polyethylene and "W" for low-temperature
SUPER "S" or container season (November - April) as
Adhesive "W" adhesive for glass.
(Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
Sikaflex 256HV 20Y-54-39850 310 ml container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass

PENGUINE 417-926-3920 320 ml Polyethylene parts.
SEAL No. 2505 container (Using limit: 4 months)
Caulking
material SEKISUI • Used to seal front window.
SILICONE 20Y-54-55130 333 ml Polyethylene (Using limit: 6 months)
SEALANT container
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 11.8 – 14.7 1.2 – 1.5

8 13 27 – 34 2.8 – 3.5
10 17 59 – 74 6 – 7.5
12 19 98 – 123 10 – 12.5
14 22 153 – 190 15.5 – 19.5
16 24 235 – 285 23.5 – 29.5

18 27 320 – 400 33 – 41
20 30 455 – 565 46.5 – 58
22 32 610 – 765 62.5 – 78
24 36 785 – 980 80 – 100
27 41 1150 – 1440 118 – 147

30 46 1520 – 1910 155 – 195
33 50 1960 – 2450 200 – 250
36 55 2450 – 3040 250 – 310
39 60 2890 – 3630 295 – 370
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 5.9 – 9.8 0.6 – 1.0

8 13 13.7 – 23.5 1.4 – 2.4
10 14 34.3 – 46.1 3.5 – 4.7
12 27 74.5 – 90.2 7.6 – 9.2
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

★ In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5
00-12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

03, 04 20 Varies depending 84 – 132 {8.5 – 13.5} 103 {10.5}
05, 06 24 on type of 128 – 186 {13.0 – 19.0} 157 {16.0}
10, 12 33 connector. 363 – 480 {37.0 – 49.0} 422 {43.0}
14 42 746 – 1010 {76.0 – 103} 883 {90.0}
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque (Nm {kgm})

Norminal No.
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}

10 10 17 9.8 – 12.74 {1.0 – 1.3} 11.27 {1.15}
12 12 19 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8}
14 14 22 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3}
16 16 24 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0}
18 18 27 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0}
20 20 30 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0}
24 24 32 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0}
30 30 32 93.1 – 122.5 {9.5 – 12.5} 107.8 {11.0}
33 33 — 107.8 – 147.0 {11.0 – 15.0} 124.4 {13.0}
36 36 36 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5}
42 42 — 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5}
52 52 — 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 0 2 1.02 0 0.20
8 24 0 4 2.45 0 0.41
10 43 0 6 4.38 0 0.61
12 77 0 12 7.85 0 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Thread size Nominal thread Root diameter
Range Target (mm) size - Threads per (mm) (Reference)
inch, Thread series
9
02 19 34 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Green Yellow Blue & Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL
6
Color — — — Red & Blue Yellow & White Green & Blue
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to 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 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 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
C
A 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
00-16
Millimeters to Inches
1 mm = 0.03937 in
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
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
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
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 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 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 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
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 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
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4 –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 89 192.2
–26.1 –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 0 140.0 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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
01 GENERAL
GENERAL ASSEMBLY DRAWING.................. 01- 2

WORK EQUIPMENT RANGE DRAWING........ 01- 3
SPECIFICATIONS ........................................... 01- 4
WEIGHT TABLE............................................... 01-11
LIST OF LUBRICANTS AND COOLANT......... 01-13
PC58UU-3 01-1
(5)
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING
PC58UU-3
Item Unit
Road liner shoe spec Rubber shoe spec City pad shoe spec
Canopy spec kg 5,330 5,230 5,280
Operating weight
Cab spec kg 5,390 5,290 5,340
Bucket capacity (SAE) m³ 0.22
*1 4D88E-3G
Engine model —
*2 4D88E-5X
Engine flywheel horsepower kW{HP}/rpm 29.4 {40}/2,400
A Overall length mm 5,335
Canopy spec mm 2,625 2,610 2,605
B Overall height
Cab spec mm 2,625 2,610 2,605
C Overall width mm 2,000
D Width of track shoe mm 400
E Tail swing radius mm 1,035
Overall length of *3 mm 2,470 2,460 2,430

F track
*4 mm 2,535 2,520 2,495
Distance between *3 mm 1,910 1,940 1,910
G centers of idler and
sprocket *4 mm 1,980 2,000 1,980
Min. ground clearance mm 335 320 315
Travel speed (Low/High) km/h 2.5/4.2 2.7/4.5 2.5/4.2
Swing speed rpm 10.0
*1. Serial No.: 20001 – 22000
*2. Serial No.: 22001 and up
*3. Serial No.: 20001 – 22300
01-2 PC58UU-3
(7)
GENERAL WORK EQUIPMENT RANGE DRAWING
WORK EQUIPMENT RANGE DRAWING
Unit: mm
Machine Model PC58UU-3
A Max. digging reach 5,660
B Max. digging depth 4,000
C Max. digging height 6,330
D Max. vertical wall depth 2,900
E Max. dumping height 4,600
Min. swing radius of work equip-
F 1,060
ment (when the offset is 0)
G Max. reach at ground level 5,565
H Max. blade lifting amount 400
I Max. blade lowering amount 270
PC58UU-3 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Serial Number 20001 – 22000
Specifications Canopy specification Cab specification
Buket capacity (SAE) m³ 0.22 0.22
Operating weight kg 5,230 [5,330] 5,290 [5,390]
Max. digging depth mm 4,000 4,000
Max. vertical wall depth mm 2,900 2,900
Max. digging reach mm 5,660 5,660
Working ranges
Max. reach st ground level mm 5,565 5,565

Max. digging height mm 6,330 6,330
Max. dumping height mm 4,600 4,600
Bucket offset amount
Performance
mm 910/730 910/730
(left/right)
Max. blade lifting amount mm 400 400
Max. blade lowering amount mm 270 270
Max. digging force (bucket) kN {kg} 39.2 {4,000} 39.2 {4,000}
Swing speed rpm 10.0 10.0
Swing max. slope angle deg. 13 13
Travel speed (Low/High) km/h 2.7/4.5 [2.5/4.2] 2.7/4.5 [2.5/4.2]
Gradeability deg. 30 30
30.4 {0.31} 30.4 {0.31}
Ground Pressure kPa {kg/cm²}
[31.4 {0.32}] [31.4 {0.32}]
Overall length (for transport) mm 5,335 5,335
Overall width mm 2,000 2,000
Overall width of track mm 2,000 2,000
Overall height (for transport) mm 2,625 [2,610] 2,625 [2,610]
Overall height mm 2,625 [2,610] 2,625 [2,610]
Ground clearance of counterweight mm 645 [630] 645 [630]
Min. ground clearance mm 335 [320] 335 [320]
Dimension
Tail swing radius mm 1,035 1,035

Min. swing radius of work equipment
mm 1,060 1,060
(when offset is 0)
Height of work equipment at min. swing
mm 4,720 [4,705] 4,720 [4,705]
radius
Distance between centers of idler and
mm 1,910 [1,940] 1,910 [1,940]
sprocket
Track gauge mm 1,600 1,600
Overall length of track mm 2,470 2,470
Machine cab height 1,560 [1,545] 1,560 [1,545]
Blade width x height 2,000 x 400 2,000 x 400
★ The values shown in the [ ] are those for the road liner shoe specification.
01-4 PC58UU-3
(5)

Model 4D88E-3G
Type 4-cycle, water cooled, vertical, direct injection
No. of cylinders-bore x stroke mm 4-88 x 90
Piston displacement {cc} 2.189 {2,189}
Flywheel horsepower kW/rpm{HP/rpm} 29.4/2,400 {40/2, 400}
Performance
Maximum torque Nm/rpm{kgm/rpm} 140/1,400 {14.3/1,400}

Engine
High idling speed rpm 2,550

Low idling speed rpm 1,150
Min. fuel consumption ratio g/kWh{g/HPh} 238 {175}
Starting motor 12 V, 2.0 kw
Alternator 12 V, 40 A
Battery 12 V, 64 Ah x 1
Radiator type CF27-2
Undercarriage
Carrier roller 1 on each side

Track roller 5 on each side
Track shoe (road liner shoe) Assembly-type road liner, 38 pieces for one side
(rubber shoe) Integrated rubber shoe
Variable displacement piston type x 1, Gear type x 2

Type x No.
Hydraulic pump
Discharge /min 51 x 2 + 33 + 10
Set pressures
(for work equipment, travel) 26.0 {265}
(for swing) MPa {kg/cm²} 20.6 {210}
(for blade) 21.6 {220}
Hydrualic system
(for control) 3.14 {32}

Type x no. 8-spool type x 1
Hydraulic motor Control
valve
Hydraulically assisted (boom, arm, bucket, offset,

Control method
swing, travel), Direct (blade)
Variable displacement piston type

Travel motor
(with brake valve, parking brake) x 2
Fixed displacement piston type

Swing motor
(with shockless safety valve, holding brake) x 1
Hydraulic tank Box-shaped, open

Hydraulic filter Tank return side
Hydraulic oil cooler Air cooled (AL-CFT-1)
PC58UU-3 01-5
(5)

Type Reciprocating piston
Boom cylinder
Cylinder (inside diameter) mm φ 95

Diameter of piston rod mm φ 55
Stroke mm 895
Max. distance between pins mm 2,133
Min. distance between pins mm 1,238
Arm cylinder

Stroke mm 650
Max. distance between pins mm 845
Min. distance between pins mm 195
Work equipment cylinder

Hydraulic system
Bucket cylinder

Stroke mm 580
Offset cylinder

Stroke mm 260
φ 105
Blade cylinder
Cylinder (inside diameter) mm

Stroke mm 260
Max. distance between pins mm 643.5
Min. distance between pins mm 503.5
01-6 PC58UU-3
(5)
Serial Number 22001 and up

Buket capacity (SAE) m3 0.22 0.22
Operating weight kg 5,230 [5,330] 5,290 [5,390]
Max. digging depth mm 4,000 4,000
Max. vertical wall depth mm 2,900 2,900
Max. digging reach mm 5,660 5,660
Working ranges
Max. reach st ground level mm 5,565 5,565

Max. digging height mm 6,330 6,330
Max. dumping height mm 4,600 4,600
Performance
Bucket offset amount (left/right) mm 910/730 910/730

Max. blade lifting amount mm 400 400
Max. blade lowering amount mm 270 270
Max. digging force (bucket) kN {kg} 39.2 {4,000} 39.2 {4,000}
Swing speed rpm 10.0 10.0
Swing max. slope angle deg. 13 13
Travel speed (Low/High) km/h 2.7/4.5 [2.5/4.2] 2.7/4.5 [2.5/4.2]
Gradeability deg. 30 30
Ground Pressure kPa {kg/cm2} 30.4 {0.31} 30.4 {0.31}

[31.4 {0.32}] [31.4 {0.32}]
Overall length (for transport) mm 5,335 5,335
Overall width mm 2,000 2,000
Overall width of track mm 2,000 2,000
Overall height (for transport) mm 2,625 [2,610] 2,625 [2,610]
Overall height mm 2,625 [2,610] 2,625 [2,610]
Ground clearance of counterweight mm 645 [630] 645 [630]
Min. ground clearance mm 335 [320] 335 [320]
Tail swing radius mm 1,035 1,035
Dimension
Min. swing radius of work equipment

(when offset is 0) mm 1,060 1,060
Height of work equipment at min. swing mm 4,720 [4,705] 4,720 [4,705]

radius
Distance between centers of idler and
sprocket
Serial No.: 22301 and up mm 1,980 [2,000] 1,980 [2,000]
Serial No.: 22001 – 22300 1,910 [1,940] 1,910 [1,940]
Track gauge mm 1,600 1,600
Overall length of track
Serial No.: 22301 and up 2,535 2,535
Serial No.: 22001 – 22300 mm 2,470 2,470
Machine cab height 1,560 [1,545] 1,560 [1,545]
Blade width x height 2,000 x 400 2,000 x 400
a The values shown in the [ ] are those for the road liner shoe specification.
01-8 PC58UU-3
(7)
Model 4D88E-5XBB
No. of cylinders-bore x stroke mm 4 – 88 x 90
Piston displacement l {cc} 2.189 {2,189}
Flywheel horsepower kW/rpm {HP/rpm} 29.4/2,400 {40/2, 400}
Performance
Maximum torque Nm/rpm {kgm/rpm} 140/1,400 {14.3/1,400}

Engine

Min. fuel consumption ratio g/kWh {g/HPh} 238 {175}
Alternator 12V, 40A
Undercarriage

Type x No. Variable displacement piston type x 1, Gear type x 2
l/min
Hydraulic pump
Discharge 51 x 2 + 33 + 10
Set pressures
(for swing) MPa {kg/cm2} 20.6 {210}
(for blade) 21.6 {220}
Hydraulic system

Control
valve

Control method swing, travel), Direct (blade)
Hydraulic
Travel motor
motor

Swing motor
PC58UU-3 01-9
(7)
Model 4D88E-5XBB
No. of cylinders-bore x stroke mm 4 – 88 x 90
Piston displacement l {cc} 2.189 {2,189}
Flywheel horsepower kW/rpm {HP/rpm} 29.4/2,400 {40/2, 400}
Performance
Maximum torque Nm/rpm {kgm/rpm} 140/1,400 {14.3/1,400}

Engine

Min. fuel consumption ratio g/kWh {g/HPh} 238 {175}
Alternator 12V, 40A
Undercarriage

Type x No. Variable displacement piston type x 1, Gear type x 2
l/min
Hydraulic pump
Discharge 51 x 2 + 33 + 10
Set pressures
(for swing) MPa {kg/cm2} 20.6 {210}
(for blade) 21.6 {220}
Hydraulic system

Control
valve

Control method swing, travel), Direct (blade)
Hydraulic
Travel motor
motor

Swing motor
01-9-1 PC58UU-3
(7)

Cylinder (inside diameter) mm 95
Boom cylinder
Diameter of piston rod mm 55

Stroke mm 895
Min. distance between pins mm 1,238
Arm cylinder

Stroke mm 650
Max. distance between pins mm 845
Work equipment cylinder

Hydraulic system
Bucket cylinder

Stroke mm 580
Offset cylinder

Stroke mm 260
Blade cylinder

Stroke mm 260
Max. distance between pins mm 643.5
Min. distance between pins mm 503.5
01-10 PC58UU-3
(5)
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This mass list is for reference in handling or transporting these components.
Unit: kg
Machine model PC58UU-3
Serial Number 20001 – 22000 22001 – 22300
Engine assembly (without water or oil) 270 270

• Engine (without water or oil) 200 200
• Engine mount 12 12
• PTO 8.2 8.2
• Hydraulic pump 28 28
Cooling assembly 20 20
• Radiator 5 5
• Oil cooler 3.4 3.4
Revolving frame 590 590
Canopy 164 164
Operator cab 195 195
Operator seat 26 26
Fuel tank (without fuel) 7 7
Hydraulic tank (without hydraulic oil) 50 50
Control valve 35 35
Counterweight 750 750
Swing motor (with brake valve) 15 15
Swing circle 66 66
Swing machinery 35 35
Center swivel joint 18 18
Track frame assembly 940 940
• Track frame 539 539
• Idler assembly 46 x 2 46 x 2
• Recoil spring assembly 16 x 2 16 x 2
• Carrier roller 2.2 x 2 2.2 x 2
• Track roller 10 x 10 10 x 10
• Travel motor (with speed reducer) 60 x 2 60 x 2
• Sprocket 12 x 2 12 x 2
Track shoe assembly
• Road liner (400 mm) 280 x 2 280 x 2
• Rubber shoe (400 mm) 222 x 2 222 x 2
• City pad shoe (400 mm) 263 x 2 263 x 2
PC58UU-3 01-11
(7)
Unit: kg
Engine assembly (without water or oil) 270

• Engine (without water or oil) 200
• Engine mount 12
• PTO 8.2
• Hydraulic pump 28
Cooling assembly 20
• Radiator 5
• Oil cooler 3.4
Revolving frame 590
Canopy 164
Operator cab 195
Operator seat 26
Fuel tank (without fuel) 7
Hydraulic tank (without hydraulic oil) 50
Control valve 35
Counterweight 750
Swing motor (with brake valve) 15
Swing circle 66
Swing machinery 35
Center swivel joint 18
Track frame assembly 940
• Track frame 546
• Idler assembly 46 x 2
• Recoil spring assembly 16 x 2
• Carrier roller 2.2 x 2
• Track roller 10 x 8
• Travel motor (with speed reducer) 60 x 2
• Sprocket 12 x 2
Track shoe assembly
• Road liner (400 mm) 285 x 2
• Rubber shoe (400 mm) 242 x 2
• City pad shoe (400 mm) 274 x 2
01-11-1 PC58UU-3
(7)
Unit: kg
Serial Number 20001 – 22000 22001 and up
Boom assembly 505 505

• 1st boom 170 170
• 2nd boom 142 142
• 3rd bracket 95 95
• Sub-link 20 20
Arm assembly 104 104
Bucket link assembly 35 35
Bucket assembly (with 680 mm-with side cutter) 133 133
Blade assembly 220 220
Boom cylinder assembly 54 54
Arm cylinder assembly 50 50
Bucket cylinder assembly 30 30
Offset cylinder assembly 34 34
Blade cylinder assembly 30 30
01-12 PC58UU-3
(5)
GENERAL LIST OF LUBRICANTS AND COOLANT
LIST OF LUBRICANTS AND COOLANT

AMBIENT TEMPERATURE CAPACITY (l)
KIND OF
RESERVOIR -22 -4 14 32 50 68 86 104°F
FLUID Specified Refill
-30 -20 -10 0 10 20 30 40°C
SAE 30
*1 9.1 8.7
SAE 10 W
Engine oil pan
SAE 10W-30
*2 8 7.4
Engine oil SAE 15W-30
*3 1.0 1.0
Final drive case (each) SAE 10W
*4 0.8 0.8
SAE 10W-30
Hydraulic system SAE 15W-40 64 38
Hydraulic
HO46-HM (a)
oil
ASTM D975 No. 2

Fuel tank Diesel fuel 80 —
ASTM
D975 No. 1
Grease system Grease Hyper white grease — —
Cooling system Coolant Add antifreeze 6.5 —

*1. Serial No.: 20001 – 22000
*3. Serial No.: 20001 – 22300
PC58UU-3 01-13
(7)
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
PTO .................................................................10- 2
COOLING SYSTEM ........................................10- 3
POWER TRAIN ...............................................10- 4
SWING CIRCLE .............................................10- 5
SWING MACHINERY .....................................10- 6
TRACK FRAME, IDLER CUSHION ................10- 8
IDLER .............................................................10-10
TRACK ROLLER ............................................ 10-11
CARRIER ROLLER ........................................10-12
SPROCKET ....................................................10-13
TRACK SHOE ................................................10-14
HYDRAULIC EQUIPMENT LAYOUT
DRAWING ......................................................10-18
HYDRAULIC TANK AND FILTER ...................10-19
HYDRAULIC PUMP .......................................10-20
CONTROL VALVE ..........................................10-29
CLSS ..............................................................10-37
CENTER SWIVEL JOINT ...............................10-61
TRAVEL MOTOR ............................................10-62
SWING MOTOR .............................................10-70
TRAVEL PPC VALVE .....................................10-77
PPC VALVE ....................................................10-81
HYDRAULIC CYLINDER ................................10-90
SOLENOID VALVE .........................................10-93
MULTI CONTROL VALVE ............................10-98-1
WORK EQUIPMENT ......................................10-99
AIR CONDITIONING PIPING .......................10-105
ENGINE CONTROL .....................................10-106
ELECTRICAL CONTROL SYSTEM ............. 10-108
ELECTRICAL SYSTEM ................................ 10-115
MONITOR SYSTEM .....................................10-133
PC58UU-3 10-1
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PTO
PTO
1. Boss
2. Spring pin
3. Rubber
4. Cover
5. Hydraulic pump
10-2 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM
COOLING SYSTEM
1. Shroud SPECIFICATION
2. Oil cooler Radiator
3. Radiator cap Core type : CF27-2
4. Radiator Fin pitch : 4.0/2 mm
5. Reserve tank Total heat dissipation surface : 10.1 m²
6. Radiator inlet hose Pressure valve cracking pressure :
7. Fan guard 88.3 ± 14.7 kPa {0.9 ± 0.15 kg/cm²}
8. Radiator outlet hose Vacuum valve cracking pressure :
9. Oil cooler outlet -4.9 kPa {-0.05 kg/cm²}
10. Oil cooler inlet
11. Drain valve
Oil cooler
Core type : SF-4
Fin pitch : 4.5/2 mm
Total heat dissipation surface : 3.77 m²
PC58UU-3 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
POWER TRAIN
1. Idler 7. Hydraulic pump (for swing and blade)

2. Control valve 8. Control pump (for pilot control)
3. Swing motor 9. Center swivel joint
4. Travel motor 10. 2-speed travel changeover solenoid valve
5. Engine 11. Swing machinery
6. Hydraulic pump (for travel and work equip- 12. Swing circle
ment)
10-4 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING CIRCLE
SWING CIRCLE
Unit: mm
No. Check item Criteria Remedy
Clearance in axial direction Standard size Clearance limit

1 Replace
of bearing 0.2 — 0.7 1.4
2. Greasing to swing circle bearing Specification

3. Greasing to swing circle pinion Reduction ratio : 90/10 = 9.0
4. Outer race Grease : G2-LI (ALBANIA EP-2)
5. Inner race
6. Ball
7. Seal
a. Inner race soft zone position
b. Outer race soft zone position
PC58UU-3 10-5
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
Specification
1. Swing motor Reduction ratio : (22 + 86)/22 x (22 + 86)/22 = 24.10
2. No. 1 sun gear (number of teeth: 22) Swing reduction ratio : 24.10 x 9.0 = 216.90
3. No. 1 planetary gear (number of teeth: 32) Swing speed : 10 rpm
4. No. 2 sun gear (number of teeth: 22)
5. Ring gear (number of teeth: 86)
6. No. 2 planetary gear (number of teeth: 32)
7. Swing machinery case
8. Swing pinion (number of teeth: 10)
9. Taper roller bearing
10-6 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
Unit: mm
Backlash of swing motor Standard size Clearance limit
1
shaft and No. 1 sun gear 0.04 ~ 0.11 —
Backlash between No. 1 sun
2 gear and No. 1 planetary 0.12 ~ 0.28 0.6
gear
Backlash between No. 1
3 planetary gear and ring 0.14 ~ 0.38 0.6
gear
4 planetary carrier and No. 2 0.10 ~ 0.26 —
sun gear
Replace
Backlash between No. 2 sun
5 gear and No. 2 planetary 0.12 ~ 0.28 0.6
gear
6 planetary gear and ring 0.14 ~ 0.38 0.6
gear
7 planetary carrier and swing 0.07 ~ 0.21 —
pinion
Backlash between swing
8 0.19 ~ 0.87 2.0
pinion and swing circle
Wear on swing pinion col- Standard size Tolerance Repair limit Apply hardchrome
9 lar’s contact surface against 0 plating recondition,
oil seal 52 51.8 or replace
- 0.074
PC58UU-3 10-7
STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD TRACK FRAME, IDLER CUSHION
TRACK FRAME, IDLER CUSHION

Serial No.: 20001 – 22300
10-8 PC58UU-3
(7)
MAINTENANCE STANDARD TRACK FRAME, IDLER CUSHION
Serial No.: 22301 and up
PC58UU-3 10-8-1
(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME, IDLER CUSHION
Unit: mm
Standard size Clearance limit
Idler guide top Track Rebuild
96 100
1 and bottom frame
width
Idler Rebuild or
94 90
support replace
Track
161 165 Rebuild
Idler guide left frame
2
and right width Idler Rebuild or
159 155
support replace
Standard size Repair limit
Installed Installed Installed
Free length Free length
length load load
3 Recoil spring Road liner 26.9 kN 24.0 kN Replace
302 238.2 294.5
steel shoe {2,748 kg} {2, 446 kg}
Rubber 42.4 kN 39.0 kN
302 202.2 294.5
shoe {4,326 kg} {3,980 kg}
4. Idler Specification
Grease : Hyper white grease
5. Track frame
Amount of filled grease : 120 cc
6. Carrier roller
7. Travel motor
8. Sprocket
9. Track roller
10. Track shoe
11. Idler cushion
11a. Support
11b. Plate
11c. Cover
11d. Rod
11e. Cylinder
11f. Recoil spring
11g. Rear support
11h. Nut
11j. Grease fitting
12. Idler guard (road liner specification,
steel shoe specification)
13. Holding bracket for shipping
PC58UU-3 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
Unit: mm
Outer diameter of Standard size Repair limit

1
protruding portion ø 377 ø 369
2 Outer diameter of tread ø 335 ø 327
Rebuild or
Width of protruding replace
3 39 31
portion
4 Total width 75 70
5 Width of tread 18 22
Standard Tolerance Standard Clearance

Clearance between size Shaft Hole clearance limit
6
idler shaft and bushing
-0.025 + 0.142 0.105 -
ø 35 1.5
-0.064 + 0.080 0.260
Standard Tolerance Standard Interference Replace

Interference between size Shaft Hole interference limit
7
idler and bushing
+0.079 +0.039 0.015 -
ø 42 —
+0.054 0 0.079
Side clearance of idler Standard clearance Clearance limit

8
(on one side) 0.25 1.0
Tread wall thickness Standard size Repair limit Rebuild or

9
(at center of tread) 10.3 6.3 replace
— Oil capacity 20 cc (Engine oil : EO 30-CD) —
10-10 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
Unit: mm
Diameter of flange Standard size Repair limit

1
(outside) ø 123 ø 117 Rebuild or
2 Outer diameter of tread ø 95 ø 87 replace
3 Flange width 41 35
4 Total width 110 — —

Rebuild or
5 Width of tread 34.5 37.5
replace

Clearance between size Shaft Hole clearance limit
6
shaft and bushing
-0.025 + 0.142 0.105 -
ø 35 1.5
-0.050 + 0.080 0.192
Standard Tolerance Standard Interference Replace

7
roller and bushing
+0.079 +0.039 0.015 -
ø 42 —
+0.050 0 0.079
Track roller side clear- Standard clearance Clearance limit

8
ance (on one side) 0.17 - 0.40 0.81
Tread wall thickness Standard size Repair limit Rebuild or

9
(at center of tread) 26.5 22.5 replace
— Oil capacity 135 cc (Gear oil : GO 140) —
PC58UU-3 10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
Unit: mm
Standard size Repair limit Rebuild or
1 Outer diameter of tread
ø 70 ø 65 replace
2 Width of tread 100 — —
Standard Tolerance Standard Interference

3
shaft and bearing
+0.013 0 -0.023 -
ø 25 —
-0.008 - 0.010 0.008
Replace
4
roller and bearing
0 +0.018 -0.031 -
ø 52 —
-0.013 -0.012 0.012
5 Tread wall thickness
9 6.5 replace
— Grease capacity 30 cc (Grease : ALBANIA EP-2) —
10-12 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
SPROCKET
Unit: mm
Standard size Tolerance Repair limit
Wear on tooth bottom
1 +1.0
diameter ø 380.37 ø 368
-2.0
Wear on addendum 0
2 ø 423.99 ø 412
diameter -3.0 Rebuild or
3 Wear on addendum width 26 — 24 replace
Wear on tooth bottom +0.5

4 33 30
width -1.0
Tooth bottom wall thick- +0.492
5 75.185 69.0
ness -1.075
PC58UU-3 10-13
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
ROAD LINER AND TRIPLE GROUSER SHOE
Serial No.: 20001 – 22300
1. Road liner shoe

2. Triple grouser shoe
10-14 PC58UU-3
(7)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
Unit: mm
Standard size Turned limit Repair limit
1 Link pitch Reverse or
135 138 143 replace
2 Bushing outer diameter 35 32 29
3 Grouser height Road liner 35 17 replace
City pad 18 10 Replace
4 Link height 65 59 Rebuild or

replace
Tolerance Standard Interference
Standard size
Interference between Shaft Hole interference limit
5
bushing and link
Shaft ø 35 + 0.030 + 0.040 0.110 ~ —
Hole ø 34.85 0 0 0.180
6 Interference between Shaft ø 22.5 + 0.060 + 0.052 0.148 ~ —

regular pin and link Hole ø 22.3 0 0 0.260
7 Interference between Shaft ø 22.5 -0.030 + 0.052 0.078 ~ — Replace

master pin and link Hole ø 22.3 -0.070 0 0.170
Tolerance Standard Clearance
Standard size
Clearance between regular Shaft Hole clearance limit
8
pin and bushing
Shaft ø 22.5 + 0.060 ± 0.2 0.140 ~ —
Hole ø 22.9 0 0.600
9 Clearance between master Shaft ø 22.5 - 0.200 ± 0.2 0.400 ~ —

pin and bushing Hole ø 22.9 - 0.400 1.000
Standard clearance Standard clearance
Clearance limit
10 Clearance between links (each side) (both sides)
0.7 ~ 1.4 1.4 ~ 2.8 —
Regular pin protrusion Adjust
11 1.5
volume
12 Master pin protrusion 3.25

volume
Rebuild or
Grouser wall Road liner — — replace
13 thickness shoe
City pad 24 16 Replace
shoe
Link wall thickness (at the Rebuild or
14 section where bushing is to 18.075 12.075 replace
be press fit)
Standard size Turned limit Repair limit Reverse or
15 Bushing wall thickness
6.05 4.55 3.05 replace
16 Tightening torque for shoe 140 ± 20 Nm {14 ± 2 kgm} Retighten

bolt
PC58UU-3 10-15
*1. Triple grouser shoe

*2. Road liner
10-15-1 PC58UU-3
(7)
Unit: mm
Standard size Turning limit Repair limit The pin and

bushing are able
1 Link pitch to use in reverse
135 138 143 until reach to
reverse limit.
If these had
2 Outside diameter of bushing 35 32 29 exceeded the
repair limit,
replace pin •
3 Thickness of bushing 6.05 4.55 3.05 bushing or link
assembly.

4 Height of link Repair by
65 59 overlaying
welding or
Thickness of link replace
5 (Bushing fitting part) 18.075 12.075

Interference between bush- size Shaft Hole interference limit
6
ing and link
Shaft ø 35 +0.030 +0.040 0.110 –
Hole ø 34.85 +0.030 +0.030 0.180 —
Interference between regu- Shaft ø 22.5 +0.060 +0.052 0.148 –

7 lar pin and link Hole ø 22.3 +0.030 +0.030 0.260 —
8 Interference between mas- Shaft ø 22.5 –0.030 +0.052 0.078 – — Replace

ter pin and link Hole ø 22.3 –0.070 +0.030 0.170

Clearance between regular size Shaft Hole clearance limit
9 pin and bushing
Shaft ø 22.5 +0.060 ± 0.2 0.140 – —
Hole ø 22.9 +0.030 0.600
10 Clearance between master Shaft ø 22.5 –0.200 ± 0.2 0.400 – —

pin and bushing Hole ø 22.9 –0.400 1.000
Standard clearance Standard clearance Standard clearance
(Each side) (Both sides) (Each side)
11 Clearance of link mating face
0.7 – 1.4 1.4 – 2.8 —
Adjust
12 Projection of regular pin 1.5
13 Projection of master pin 3.25

Repair by over-
laying welding
Height of • Triple 14 10 or replace
14 grouser
• Road liner 35 17 Replace
Thickness of Repair by over-

15 • Triple 20 16 laying welding
grouser or replace
Tightening torque of shoe

16 bolt 137 ± 19.6 Nm {14 ± 2 kgm} Retighten
PC58UU-3 10-15-2
(7)
TRIPLE GROUSER SHOE
Unit: mm

1 Grouser height
14 10
2 Plate thickness 6
3 17
Grouser base length Rebuild or
4 13 replace
5 12
6 Grouser edge length 8
7 12
10-16 PC58UU-3
(7)
RUBBER SHOE
Serial No.: 20001 – 22300
Unit: mm

1 Wear of lug height
25 5
2 Wear of roller guard 38 49 Replace
Standard size Tolerance Repair limit

Wear of sprocket meshing
3
portion 23 ± 0.5 27
PC58UU-3 10-17
(7)
Unit: mm

1 Wear of lug height
25 5
2 Wear of roller guide 47 60

Replace
Wear of meshing parts of
3 2 –3
sprocket
4 Wear of roller tread height 25 19
10-17-1 PC58UU-3
(7)
MAINTENANCE STANDARD HYDRAULIC EQUIPMENT LAYOUT DRAWING
HYDRAULIC EQUIPMENT LAYOUT DRAWING
1. L.H. travel motor 10. Travel PPC valve

2. Control valve 11. R.H. travel motor
3. Hydraulic tank 12. Bucket cylinder
4. Swing motor 13. Arm cylinder
5. Oil cooler 14. Offset cylinder
6. Hydraulic pump 15. Boom cylinder
7. Center swivel joint 16. Blade cylinder
8. R.H. work equipment PPC valve 17. Offset PPC valve
9. L.H. work equipment PPC valve 18. 5-spool solenoid valv
10-18 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK AND FILTER
HYDRAULIC TANK AND FILTER
1. Sight gauge Specification

2. Hydraulic tank Tank capacity : 56 l
3. Drain plug Hydraulic oil amount in tank : 38 l
4. Bypass valve Pressure valve cracking pressure :
5. Filter element 38 ± 15 kPa {0.39 ± 0.15 kg/cm²}
6. Suction strainer Vacuum valve cracking pressure :
7. Oil filler cap 0 ~ 5 kPa {0 ~ 0.05 kg/cm²}
Bypass valve set pressure :
103 ± 19.6 kPa {1.05 ± 0.2 kg/cm²}
PC58UU-3 10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
Type: LPD25 + 25
P1: Pump discharge port P1L : Pump pressure input port

P2: Pump discharge port P1T : Travel deviation adjustment orifice
P3: Gear pump discharge port P2T : Travel deviation adjustment orifice
P4: Pilot pump discharge port PDA: Air bleeder
P5: Pump suction port PLS : LS pressure input port
1. Main pump (Piston pump) • This pump has a double pump to control the
2. Tandem gear pump (For swing, blade + pilot) pump absorption torque by sensing the
engine speed and a tandem gear pump for
swing and blade + pilot.
10-20 PC58UU-3
(5)
3. Case 7. Cylinder block

4. Rocker cam 8. Valve plate
5. Shoe 9. Spring (in servo piston)
6. Piston 10. Servo piston
11. Ball (for rocker cam supporting)
PC58UU-3 10-21
Function
• Oil in each cylinder of the cylinder block (7) is
• This pump converts engine rotation and
absorbed and discharged through the valve
torque transmitted to the pump shaft into
plate (8).
hydraulic energy and discharges pressurized
oil according to load. • Cylinder block (7) has an even number of
holes, which are alternately fitted to 2 grooves
• This pump can change delivery when the
of valve plate (8).
swash plate angle is changed
• This pump has two discharge ports, which
can supply pressure independently.
Structure
• The cylinder block (7) is supported to the shaft
(1) with the spline a, and the shaft (1) is sup-
ported with the front and rear bearings.
• The shoe (5) is punched tooth tip of the piston
(6) with a concave ball so that the piston (6)
and the shoe (5) form a spherical bearing.
• The shoe (5) is always pressed to the plane A
of the rocker cam (4) and slides in a circle.
Rocker cam (4) is supported by ball (11), and
slides.
• The piston (6) moves in the axial direction rel-
atively in each cylinder of the cylinder block
(7).
• The cylinder block (7) rotates relatively while
sealing pressurized oil against the valve plate
(8), and the plane is designed to balance the
oil pressure properly.
10-22 PC58UU-3
Operation
1. Pump operation
• The shaft (1) rotates together with the cyl-
inder block (7), and the shoe (5) slides on
the plate A. As the rocker cam (4) leans
around ball (11), the inclination α to the
centerline X of the rocker cam (4) and the
axial direction of the cylinder block (7)
changes. The inclination α is called
"swash plate angle".
• When the swash plate angle of the center-
line X of the rocker cam (4) is α to the
axial direction of the cylinder block (7),
the plane A works like the cam against
the shoe (5).
• Therefore, the piston (6) slides inside the
cylinder block (7), and the capacities E
and F of the cylinder block (7) come to
change differently. Then, the pump
absorbs and discharges the difference E-F.
• When the capacity in the E chamber con-
tracts as the cylinder block (7) rotates, the
pump discharges oil during the process.
On the other hand, when the capacity in
the F chamber increases, the pump
absorbs oil during the process. (The fig-
ure shows the end of the absorbing pro-
cess in the Chamber F and the end of the
discharging process in Chamber E.
• When the centerline X of the rocker cam
(4) comes to the axial direction of the cyl-
inder block (7) (when the swash plate
angle is 0), the difference between the
capacities E and F in the cylinder block (7)
comes to 0. And the pump comes to stop
absorbing or discharging oil, i.e., the
pump stops. (However, the swash plate
angle never comes to 0 practically.)
• In other words, the swash plate angle α
and the pump delivery are in the propor-
tional relations.
PC58UU-3 10-23
2. Delivery control While the machine is not travelling, the

• When the swash plate angle α increases, oils merge in the control valve and the
the difference between the capacities E pump functions as a single pump (Merge
and F becomes larger and the delivery Q mode).
increases. The servo piston (12) changes While the machine is travelling, the two
the swash plate angle α. discharge ports of the pump are con-
• The servo piston moves in the direction of nected respectively to the right travel and
straight reciprocation according to signal left travel circuits (Separate mode).
pressures of the PC and LS valves. This • While the machine is travelling straight,
straight movement is transferred to the the pump is in the separate mode
rocker cam (4), which is supported on the explained above. Since both travel pres-
ball (11) and rocks around the ball (11). sures are the same basically, the func-
• The PEN output pressure of the LS valve tions of the pump are the same with a
is led into the pressure chamber of the single pump. (If the work equipment is
servo piston (10). operated while the machine is travelling,
the pump is set in the merge mode.)
• The movement of the rocker cam (4) is
controlled by the balance of the swash • If the machine is steered while it is travel-
plate moment caused by the oil pressure ling, however, the outside track pump
applied to the servo piston (10) and piston pressure rises and the inside track pump
(6). pressure lowers inside the pump. (For
example, high pressure is applied to the
ports of even Nos. on the cylinder block
and low pressure is applied to the ports of
odd Nos.)
• Since the pump operates as explained
above, it generates pressure difference in
the separate mode only when the
machine is steered while it is travelling.
• The PC control is carried out with the
average of the above 2 pump pressures
generated by the 2 throttles of the end
cap.
• The high pump pressure selected from
the 2 pump pressures by a check valve is
used as the pilot pressure to control the
pump.
3. Operation as double pump

• Cylinder block (7) has an even number of
holes. Among those holes, the oval ports
in contact with the valve plate (8) are con-
nected alternately to the long oval ports
on the periphery of valve plate (8).
The 2 long oval ports of valve plate (8) are
equivalent to the 2 discharge ports of the
pump, thus the pump operates as a dou-
ble pump.
10-24 PC58UU-3
4. Advantages of double pump system

• Usually, if the machine is steered while it 2) When double pump system is employed:
is travelling, the motor pressure on the
drive side (outside) rises and that on the While the machine is travelling straight:
driven side (inside) lowers in the double • Right pressure 9.80 MPa {100 kg/cm²} x
pump system. Right oil flow (50.0 l /min) + Left pressure
• In an ordinary single pump system, the 9.80 MPa {100 kg/cm²} x Left oil flow (50.0
pressure compensation valve in the con- l /min) = 8.10 kW [11.0 PS] + 8.10 kW [11.0
trol valve works and the motor pressure PS] = 16.2 kW [22.0 PS]
on the driven side and that on the drive
side are the same, because of the pump's When the machine is steered:
characteristics.
• Right pressure 19.6 MPa {200 kg/cm²} x
• That is, the pressure compensation valve
Right oil flow (50.0 l /min) + Left pressure
on the driven side is closed to heighten
4.90 MPa {50.0 kg/cm²} x Left oil flow (40.0
the pressure on the driven side similarly
to the pressure in the circuit on the drive l /min) = 16.2 kW [22.0 PS] + 2.90 kW [4.0
side. PS] = 19.1 kW [26.0 PS]
• Since the motor pressure on the driven
side in the double pump system is kept Since the pump input horsepower is larger
low, lowering of the oil flow in the motor than the engine horsepower, the PC control is
on the drive side can be prevented. started (to prevent the engine from stalling):
Accordingly, the engine power is con- • Right pressure 19.6 MPa {200 kg/cm²} x
trolled as shown below. Right oil flow (43.0 l /min) + Left pressure
4.90 MPa {50 kg/cm²} x Left oil flow (33.0 l
1) When ordinary single pump system is /min) = 14.0 kW [19.0 PS] + 2.20 kW [3.0
employed PS] = 16.2 kW [22.0 PS]
While the machine is travelling straight: The average of the oil flow on both sides is
• Right pressure 9.80 MPa {100 kg/cm²} x lowered from 50.0 l /min to 38.0 l /min (by
Right oil flow (50.0 l /min) + Left pressure 24%).
9.80 MPa {100 kg/cm²} x Left oil flow (50.0
l /min) = 8.10 kW [11.0 PS] + 8.10 kW [11.0 When the machine is steered, the oil flow is
PS] = 16.2 kW [22.0 PS] lowered by 50% in the ordinary single pump
system but lowered only by 24% in the dou-
When the machine is steered: ble pump system.
l /min) = 16.2 kW [22.0 PS] + 6.60 kW [9.0
PS] = 22.8 kW [31.0 PS]
Since the pump input horsepower is larger

than the engine horsepower, the PC control is
started (to prevent the engine from stalling):
l /min) = 9.6 kW [13.0 PS] + 6.60 kW [9.0
PS] = 16.2 kW [22.0 PS]
The average of the oil flow on both sides is

lowered from 50.0 l /min to 25.0 l /min (by
50%).
PC58UU-3 10-25
LS, EPC VALVE
T : Drain port PH : Pump shuttle pressure port

GH: Gear pump Hi signal port PDE : EPC drain port
GL: Gear pump Lo signal port PAVE: Pump average pressure port
PE: Control piston pressure point PEPC: EPC main pressure input port
1. Lock nut 6. Piston EPC valve

2. Plug 7. Seat 11. Sleeve
3. Spring 8. Plug 12. Spool
4. Spool 9. Lever 13. Washer
5. Sleeve 10. Spool 14. Spring
10-26 PC58UU-3
(5)
Function
1. LS Valve
• The LS valve controls pump delivery to • The PP pump discharge pressure, PLS LS
stroke of the control lever, i.e., requested pressure, and pressures before and after
flows of the actuator. the metering throttle of the swing gear
• The LS valve detects requested flow of pump (GH and GL) are applied to the LS
the actuator from the differential pres- valve. The relationship between the LS
sure, ∆PLS, between the pump discharge differential pressure ∆PLS and Q pump
pressure, PP, and the control valve outlet discharge changes as shown in the figure
pressure, PLS, to control the pump deliv- at right.
ery Q. (Discharge pressure is called PP,
the LS pressure PLS and the LS differen-
tial pressure ∆PLS.)
• This valve detects pressure loss (= LS dif-
ferential pressure ∆PLS) caused by pump
flow passing through the opening area of
the control valve spool, controls the
pump delivery Q so that the pressure loss
remains constant all the time and sup-
plies pump deliveries requested by the
actuator.
• In the range where the pump delivery
does not exceed the maximum flow in the
pump as in fine control operation, etc.,
however, the pump constantly supplies
the flow required by the actuator. Accord-
ingly, the pump discharge at low idling is
the same as that at full throttle. To pre-
vent this, the LS differential pressure is
set low automatically at low idling to
lower the discharge.
• The engine speed is detected by the GH
and GL pressures before and after the
fixed throttle (metering throttle) in the dis-
charge path of the swing gear pump. The
GH and GL pressures are applied to the
a2 and b2 pressure receiving chambers
of the 3rd and 4th LS valves to change the
setting of the LS.
• While the engine is running at low idling,
the discharge of the swing pump is
reduced and the GH and GL pressures
before and after the metering throttle
become almost the same (the metering
differential pressure GH-GL is reduced).
On the other hand, if the engine runs at
full throttle, the discharge of the swing
pump is increased and the metering dif-
ferential pressure is increased.
• When the metering differential pressure is
high (When the engine speed is high), the
LS pressure is set a little high. When the
metering differential pressure is low
(When the engine speed is low), the LS
pressure is set a little low.
PC58UU-3 10-27
2. EPC Valve • Since the pressing force of the EPC valve

• When the pump discharge pressure PP solenoid is added to the pressing force on
rises, the control valve spool stroke will the left side caused by the pump pressure
increase and the opening area will applied to spool (10), the relationship
enlarge. So, the PC valve controls the between the PAVE pump average pres-
pump delivery Q so that the delivery Q sure and Q is translated from (1) to (2) as
does not increase above a certain level X is increased.
depending on the discharge pressure PP.
The valve also controls the pump absorb-
ing hydraulic horsepower to approxi-
mately equal horsepower so that the
pump absorbing horsepower does not
exceed the engine horsepower.
• This means that, when a load to the actu-
ator increases during operation and the
pump discharge pressure PP rises, this
valve will reduce the pump delivery Q, or
when the pump discharge pressure PP
drops, this valve will increase the delivery
Q.
• The relationship between the PAVE pump
average pressure (When the double pump
is employed, the average of P1 and P2 is
sensed) and Q pump discharge is shown
in the figure at right.
• Usually, the swing pump is installed
behind the main pump. When it operates,
the absorption torque on the main pump
side is lowered by the quantity absorbed
by the swing pump so that the total of the
main pump absorption torque and swing
pump absorption torque will be the all
absorption torque (about 100%).
• If the X command current sent to the EPC

valve is increased, the relationship
between the PAVE pump average pres-
sure and Q pump discharge is translated
in proportion to the pressing force of the
EPC valve solenoid.
10-28 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
OUTLINE
★ The outside view of the valve body shows the
standard valve.
★ Each service valve is of the add-on type and
can be added and removed.
★ Add-on the service valve between the 8th
swing valve and cover.
C : To oil cooler PP : To main pump

S : To swing motor A PS : To swing motor B
T : To tank TS : To tank
A1: To L.H. travel motor A PA1 : From L.H. travel FORWARD PPC valve
A2: To R.H. travel motor A PA2 : From right travel FORWARD PPC valve
A3: To boom cylinder head PA3 : From boom LOWER PPC valve
A4: To arm cylinder head PA4 : From arm OUT PPC valve
A5: To bucket cylinder head PA5 : From bucket DUMP PPC valve
A6: To offset cylinder head PA6 : From R.H. offset PPC valve
A7: To blade cylinder head PA8 : From swing to left PPC valve
A8: To swing motor MB PB1 : From L.H. travel REVERSE PPC valve
B1: To L.H. travel motor PB2 : From R.H. travel REVERSE PPC valve
B2: To R.H. travel motor PB3 : From boom RAISE PPC valve
B3: To boom cylinder bottom PB4 : From arm IN PPC valve
B4: To arm cylinder bottom PB5 : From bucket CURL PPC valve
B5: To bucket cylinder bottom PB6 : From left offset PPC/EPC valve
B6: To offset cylinder bottom PB8 : From swing to right PPC valve
B7: To blade cylinder bottom PP1 : P1 pump pressure
B8: To swing motor MB PP2 : P2 pump pressure
LS: To pump LS valve PP3 : Work equipment side pump pressure
P1: From main pump (variable pump) PLS1: L.H. travel LS pressure
P2: From main pump (variable pump) PLS2: R.H. travel LS pressure
P3: From main pump (gear pump) PLS3: Work equipment LS pressure
PI: From boom RAISE PPC valve
PC58UU-3 10-29
(5)
10-30 PC58UU-3
1. Suction valve (travel) 13. Main relief valve

2. Suction valve (travel) 14. Suction valve (travel)
3. Suction valve (boom bottom) 15. Suction valve (travel)
4. Suction valve (arm bottom) 16. Spool (L.H. travel)
5. Suction valve (bucket bottom) 17. Spool (R.H. travel)
6. Safety valve with suction (blade bottom) 18. Unload valve
7. Safety valve 19. Spool (boom)
8. Safety valve with suction (blade head) 20. Spool (arm)
9. Suction valve (offset head) 21. Spool (bucket)
10. Suction valve (bucket head) 22. Spool (offset)
11. Suction valve (arm head) 23. Spool (blade)
12. Suction valve (boom head) 24. Spool (swing)
25. Unload valve
PC58UU-3 10-31
1. Lift check valve 14. Pressure compensation valve R (arm)

2. Pressure compensation valve F (L.H. travel) 15. Pressure compensation valve R (boom)
3. Pressure compensation valve F (R.H. travel) 16. LS bypass plug (LS2)
4. Spool (pump merge-divider valve) 17. Pressure compensation valve R (R.H. travel)
5. Pressure compensation valve F (boom) 18. Pressure compensation valve R (L.H. travel)
6. Pressure compensation valve F (arm) 19. Cooler bypass valve
7. Pressure compensation valve F (bucket) 20. Spool (L.H. travel)
8. Pressure compensation valve F (offset) 21. Suction valve
9. Spool (boom assist valve) 22. Suction valve
10. Swing relief valve (for gear pump)
11. Plug (boom assist valve) ★ The above F and R means the following valves:
12. Pressure compensation valve R (offset) F: Flow control valve
13. Pressure compensation valve R ( R: Pressure reducing valve
10-32 PC58UU-3
1. Pressure compensation valve F (R.H. travel) 14. Unload valve

2. Spool (R.H. travel) 15. Pressure compensation valve F (boom)
3. Suction valve 16. Spool (boom)
4. Suction valve 17. Suction valve
5. Pressure compensation valve R (R.H. travel) 18. Boom hydraulic drift prevention valve
6. Unload valve 19. Check valve
7. Check valve 20. Check valve
8. Main relief valve 21. Suction valve
9. Unload valve 22. Pressure compensation valve R (boom)
10. LS bypass plug (LS2)
11. Spool (pump merge-divider valve) ★ The above F and R means the following valves:
12. Unload valve F: Flow control valve
13. Check valve R: Pressure reducing valve
PC58UU-3 10-33
1. Pressure compensation valve F (arm) 14. Spool offset

2. Spool (arm) 15. Suction valve
3. Suction valve 16. Pressure compensation valve R (offset)
4. Check valve 17. Spool (boom assist valve)
5. Suction valve 18. Spool (blade)
6. Pressure compensation valve R (arm) 19. Suction valve
7. Pressure compensation valve F (bucket) 20. Check valve
8. Spool (bucket) 21. Safety valve with suction
9. Suction valve 22. Plug (boom assist valve)
10. Check valve
11. Suction valve ★ The above F and R means the following valves:
12. Pressure compensation valve R (bucket) F: Flow control valve
13. Pressure compensation valve F (offset) R: Pressure reducing valve
10-34 PC58UU-3
1. Spool (swing)
3. Safety valve
4. Pressure bleeding plug
PC58UU-3 10-35
Unit: mm
Spool return spring Free length Installed Installed Free length Installed
A (travel, boom, arm, offset, x O.D. length load load
swing)
29.0 x 17.5 28.5 22.6 N — 18.0 N
{2.30 kg} {1.84 kg}
B Spool return spring 29.15 x 17.5 28.5 22.6 N — 18.0 N

(bucket) {2.30 kg} {1.84 kg}
C Spool return spring 42.0 x 20.0 25.4 74.53 N — 59.62 N

(blade) {7.60 kg} {6.08 kg}
D Unload valve spring 27.2 x 12.5 20.5 55.41 N — 44.33 N

{5.65 kg} {4.52 kg}
E Boom assist valve spring 33.77 x 17.5 28.5 120.92 N — 96.69 N

{12.33 kg} {9.86 kg}
F Pressure compensation 20.0 x 8.40 12.0 6.86 N — 5.49 N

valve spring {0.70 kg} {0.56 kg}
G Pressure compensation 22.75 x 8.40 17.0 16.57 N — 13.24 N Replace

valve spring {1.69 kg} {1.35 kg} spring if any
Pressure compensation 8.34 N 6.67 N damages or
H 21.55 x 8.40 17.0 — deformations
are found
J Pressure compensation 22.36 x 8.40 17.0 9.81 N — 7.85 N
K Pump merge-divider valve 41.1 x 13.8 22.0 44.33 N — 35.50 N

spring {4.52 kg} {3.62 kg}
L Lift check valve spring 29.0 x 13.3 21.0 15.30 N — 12.26 N

{1.56 kg} {1.25 kg}
M Cooler bypass valve spring 27.2 x 13.2 21.0 78.85 N — 63.06 N

{8.04} {6.43 kg}
N Check valve spring 13.0 x 6.50 9.0 2.26 N — 1.77 N

{0.23 kg} {0.18 kg}
P Check valve spring 21.9 x 5.0 15.8 1.96 N — 1.57 N

(arm, bucket, blade) {0.20 kg} {0.16 kg}
Q Check valve spring 21.9 x 5.0 15.8 1.96 N — 1.57 N

(boom) {0.20 kg} {0.16 kg}
R Check valve spring 16.4 x 7.50 9.90 2.26 N — 1.77 N

(boom) {0.23} {0.18 kg}
10-36 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
Features
CLSS stands for Closed Center Load Sensing System and is featured as follows:
• Fine controlability without affect of load
• Controlability that allows digging even in the fine control mode.
• Ease of compound operation in which the flow distribution performance depends on spool opening
area during compound operation.
• Saving of energy by variable pump control
Configuration
• The CLSS consists of a variable displacement piston pump, a control valve and actuators.
• The pump body consists of a main pump, a PC valve and LS valve.
PC58UU-3 10-37
(5)
Basic principle
1. Control of pump swash plate angle

• The pump swash plate angle (pump deliv-
ery) is controlled so that the LS differential
pressure ∆PLS, which is the difference
between the pump discharge pressure PP
and the LS pressure PLS (actuator load
pressure) at the control valve outlet,
becomes constant.
(LS differential pressure ∆PLS = Pump
pressure PP - LS pressure PLS)
• When the LS differential pressure ∆PLS

reduces below the set pressure of the LS
valve (when actuator load pressure is
high), the pump swash plate angle will
move in the direction of maximum. When
the set pressure is raised (when the actua-
tor load pressure is low), the pump swash
plate angle will move in the direction of
minimum.
★ For the detail of the operation, see the
paragraph of "Hydraulic Pump".
10-38 PC58UU-3
2. Pressure compensation control

• A valve (pressure compensation valve) is mounted on the outlet side of the control valve. In case of
compound operation of the actuator with this valve, the differential pressure ∆P between the spool
upstream (inlet) and the downstream (outlet) of each valve becomes constant irrespective of load
(pressure). So, the flow from the pump is distributed (compensated) in proportion to the opening
areas S1 and S2 of each valve being operated.
PC58UU-3 10-39
EACH FUNCTION AND OPERATION OF EACH VALVE
Hydraulic circuit diagram and valve names
10-40 PC58UU-3
(5)
1. Unload valve
Set pressure : LS pressure + 2.45 MPa {25.0 kg/cm²}
2. Safety valve with suction
Set pressure : 28.9 MPa {295 kg/cm²}
3. Main relief valve
4. Pump merge-divider valve
5. Logic valve
6. Pressure compensation valve
7. Suction valve
8. Pilot pressure check valve
9. Check valve
10. Lift check valve
Set pressure : 0.14 MPa {1.40 kg/cm²}
11. Cooler bypass valve
Set pressure : 0.39 MPa {4.0 kg/cm²}
PC58UU-3 10-41
UNLOAD VALVE
1. When the control valve is neutral
Function
• When the control valve is neutral, the delivery 1. Spool
Q equivalent to the pump minimum swash 2. Spring
plate angle is released to the tank circuit. At
the time, the pump discharge pressure PP1
and PP2 are set to 2.45 MPa {25.0 kg/cm²} PLS1 and PLS2: LS circuit (pressure)
with the spring (3) inside the valve. (The LS PP1 and PP2 : Pump circuit (pressure)
pressure PLS1 and PLS2 are 0 MPa {0 kg/ T : Tank circuit
cm²}.)
Operation
• The pump discharge pressure PP1 and PP2
are applied to the left end face of the spool (1)
and the LS pressure PLS1 and PLS2 are
applied to the right end face.
• Since the LS pressure PLS1 and PLS2 are 0
when the control valve is neutral, the pump
discharge pressure PP is only applied and is
set with the load to the spring (2).
• When the pump discharge pressure PP1 and
PP2 rises to the spring (2) load (2.45 MPa
{25.0 kg/cm²}, the spool (1) will move toward
the right side and the pump circuit PP1 and
PP2 will interconnect to the tank circuit T
through the drill hole.
• Therefore, the pump discharge pressure PP1
and PP2 are set to 2.45 MPa {25.0 kg/cm²}.
10-42 PC58UU-3
(5)
2. When the control valve is in the fine control mode
Function • When the differential pressure between the

• When the control valve is in the fine control pump discharge pressure PP1, PP2 and the
mode and the requested flow of the actuator LS pressure PLS1, PLS2 overcomes the
is less than the pump minimum swash plate spring (2) load (2.45 MPa {25.0 kg/cm²}), the
angle, the pump discharge pressure PP1 and spool (1) will move to the right side and the
PP2 are set to the LS pressure PLS1, PLS2 + pump circuit PP1, PP2 will interconnect to
2.45 MPa {25.0 kg/cm²}. the tank circuit T.
When the differential pressure between the • This means that the pump discharge pressure
discharge pressure PP1, PP2 and the LS PP1 and PP2 are set to the spring force (2.45
pressure PLS1, PLS2 overcomes the spring MPa {25.0 kg/cm²}) + LS pressure PLS1,
(2) load (2.45 MPa {25.0 kg/cm²}), the unload PLS2, and the differential pressure ∆ PLS
valve will open and the LS differential pres- becomes 2.45 MPa {25.0 kg/cm²}.
sure ∆PLS becomes 2.45 MPa {25.0 kg/cm²}.
Operation
• When the control valve is operated in the fine 1. Spool
control mode, the LS pressure PLS1, PLS2 2. Spring
will occur and will be applied to the right end
face of the spool (1). At the same time, the dif-
ferential pressure between the LS pressure PLS1 and PLS2: LS circuit (pressure)
PLS1, PLS2 and the pump discharge pres- PP1 and PP2 : Pump circuit (pressure)
sure PP1, PP2 increases because the open- T : Tank circuit
ing area of the control valve spool is small.
PC58UU-3 10-43
3. When the control valve is operated
Function
• If required flow of the actuator increases over 1. Spool
the pump minimum swash plate angle when 2. Spring
the control valve is operated, the flow to the
tank circuit T will be interrupted and the
pump delivery Q1, Q2 will be completely PLS1 and PLS2: LS circuit (pressure)
flown to the actuator circuit. PP1 and PP2 : Pump circuit (pressure)
Operation T : Tank circuit
• When the control valve is operated with large
stroke, the LS pressure PLS1, PLS2 will
occur and will be applied to the right end face
of the spool (1). At the same time, the differ-
ence between the LS pressure PLS1, PLS2
and the pump discharge pressure PP1, PP2
is small because the opening areas of the
control valve spool are large.
• Therefore, the differential pressure between
the pump discharge pressure PP1, PP2 and
the LS pressure PLS1, PLS2 does not over-
come the spring (2) load (2.45 MPa {25.0 kg/
cm²}) and the spring (2) pushes the spool to
the left side.
• As a result, the pump circuit PP1, PP2 and
the tank circuit T are interrupted, and the
pump delivery Q1 and Q2 are completely
flown to the actuator circuit.
10-44 PC58UU-3
4. When the control valve is operated (when only travel valve is operated)
Function
• The swash plate angle of the pump becomes 1. Spool
maximum when the machine travels. At this 2. Spring
time, the oil flow is controlled according to
the opening ratio of the spool.
Operation PLS1 and PLS2: LS circuit (pressure)
PP1 and PP2 : Pump circuit (pressure)
• If the travel control valve is operated singu-
T : Tank circuit
larly, it is set in the separate mode by the
pump merge-divider valve. Accordingly, each
unload valve on the PP1 and PP2 sides oper-
ates according to the respective opening
ratios of right and left travel spools.
PC58UU-3 10-45
LEADING OF LS PRESSURE
Work equipment valve (boom, arm, bucket, and offset)
Function • At the same time, the LS circuit PLS3 is con-

• The LS pressure is load pressure to the actua- nected to the tank circuit T from the LS
tor on the outlet side of the control valve. bypass plug (4). (For details, see "LS Bypass
• In case of a work equipment valve, the pres- Plug".)
sure reducing valve (3) of the pressure com- • The A actuator circuit pressure is applied to
pensations valve reduces the pump discharge the left side of the pressure reducing valve (3)
pressure PP3 to the same level as the actua- and the PP3 reduced pump pressure is
tor circuit pressure PA (= A) and leads the applied to the opposite side.
pressure to the LS circuit PLS3. • Therefore, the pressure reducing valve bal-
Operation ances at the position where the actuator cir-
• When the spool (1) is operated, the pump dis- cuit pressure A becomes equal to the
charge pressure PP3 will be led to the actua- pressure of the spring chamber PLS’. The
tor circuit A through the bridge passage b pump discharge pressure PP3 reduced at the
from the flow control valve (2) and the spool notch a’ comes to the actuator circuit pres-
notch a. sure A and is led to the LS circuit PLS3.
• As the pressure reducing valve (3) moves to
the right, the pump discharge pressure PP3
is reduced due to pressure loss at notch c and
is led to the LS circuit PLS3 and to the spring
chamber PLS’.
10-46 PC58UU-3
(5)
LS BYPASS PLUG
Function
• This plug releases residual pressure of the LS
pressure PLS.
• This plug slows the rising speed of the LS
pressure PLS, causes pressure losses at the
spool and the throttle of the shuttle valve by
the discarded throttled flow, and reduces the
effective LS differential pressure for higher
safety.
Operation
• Pressurized oil in the LS circuit PLS flows
from the filter a to the tank circuit T through
orifice b.
PC58UU-3 10-47
(5)
PRESSURE COMPENSATION VALVE
Function
• When the load pressure becomes lower than
another actuator and the flow is going to • The flow control valve (2) and the pressure
increase during a compound operation, this reducing valve (1) balance each other where
valve compensates the load pressure. (At the the pressure difference between PA applied
same time, the load pressure of another actu- to the both end faces of the pressure reducing
ator under compound operation (the right valve (1) and PLS becomes the same as the
side) is higher than that of the actuator on this pressure loss between PP before and after
side (the left side).) the flow control valve and PPA.
Operation • So, the pressure differences between the
• When the load pressure of another actuator upstream pressures PPA and the down-
side (the right side) fuses during a compound stream pressures PA of the both spools
operation, the flow in the actuator circuit A under compound operation become the
on this side (the left side) is apt to increase. same, and the pump flow is distributed in
• In this case, the LS pressure PLS of another proportion to the opening area of each spool
actuator is applied to the spring chamber notch a.
PLS’ and pushes the pressure reducing valve
(1) and the flow control valve (2) to the left
side.
• The flow control valve (2) throttles the open-
ing area between the pump circuit PP and the
spool upstream PPA and causes a pressure
loss between PP and PPA.
10-48 PC58UU-3
(5)
AREA RATIO OF PRESSURE COMPENSATION VALVE
Function
• The pressure compensation valve slightly adjusts the ratio (S2/S1) of the area S1 on the left side of the
flow control valve (2) and the area S2 on the right side of the pressure reducing valve (1) to suite the
characteristics of each actuator and determines the compensation characteristics.
S1: Area of the flow control valve (2) - area of the piston (3)
S2: Area of the pressure reducing valve (1) - area of the piston (3)
Area ratio (S1:S2) and compensation characteristics
• When the ratio is 1.00 : The expression [Pump (discharge) pressure PP - Spool notch upstream pressure
PPB] = [LS circuit pressure PLS - Actuator circuit pressure PA (= A)] can be held,
and the flow is distributed as per the spool opening area ratio.
• When the ratio is more than 1.00 : The expression PP - PPB > PLS - PA (= A) can be held, and the flow
is distributed less than the spool opening area ratio.
• When the ratio is less than 1.00 : The expression PP - PPB < PLS - PA (= A) can be held, and the flow
is distributed more than the spool opening area ratio.
PC58UU-3 10-49
(5)
LS INTRODUCTION THROTTLE OF PRESSURE COMPENSATION VALVE
Function
• If another actuator is relieved during com- • Accordingly, even if the above actuator is
pound operation, more oil is divided from the relieved, a difference is made between PP
b LS introduction throttle of the pressure and PLS to supply more oil from the actuator
compensation valve (1) to the compensated circuit A on this side (left side).
side.
Operation
• If another actuator (one on the right side) is
relieved during compound operation, the cir-
cuit pressures (PPA, PA) of that actuator
become equal to the pump circuit pressure
(PP = Relief pressure).
• In this case, the PLS2 spring chamber pres-
sure of the above actuator becomes equal to
the PP pump circuit pressure because of bal-
ancing of pressure reducing valve (1).
• PLSB is set to PLS through the b LS intro-
duction throttle of pressure compensation
valve (1). Since PLS is connected through
the LS bypass plug (4) to the T tank circuit,
some pressure is lost in the b LS introduction
throttle (PLS < PLSB).
10-50 PC58UU-3
(5)
L.H. and R.H. travel junction circuit
1. When traveling straight
Function
• When the L.H. and R.H. travel spool is oper-
ated to compensate flow errors in the L.H.
and R.H. travel circuits during straight travel,
the junction circuit will open.
• Then, the flows to the L.H. and R.H. travel
motors will become the same during the
straight travel, and travel deviation will
decrease.
• The b damper is installed to relieve the tran-
sient characteristics of sudden opening and
closing of the junction circuit when the travel
lever is operated sharply.
Operation
• The bridge circuits PA of the control valves in
both travel circuits are connected to each
other by the junction circuit L. If a difference
is made in the flow between both travel
motors, it is corrected to reduce the travel
deviation.
PC58UU-3 10-51
2. When operating travel steering
Operation
• If the right travel spool (Right 1) is returned
from the straight travel position to the neutral
position to steer the machine, a difference is
made in the load pressure between both PA
travel actuator circuits (Left A > Right A).
• At this time, the main pump is in the separate
mode and the oil flow in both travel motors
changes according to the open area of the
spool.
10-52 PC58UU-3
SWING AND BLADE VALVE
Structure
• The swing and blade sections are the open
center valve of the gear pump. The blade sec-
tion is arranged in tandem in the rear of the
swing section.
10-54 PC58UU-3
(5)
Operation
Swing section
• If pressure is applied from the PPC valve to
the PB8 port, the spool moves to the left and
oil flows in the B8 port.
• If pressure is applied from the PPC valve to
the PA8 port, the spool moves to the right
and oil flows in the A8 port.
• The load check valve has A port and B port,
one each, in its spool.
• The relief valve (1) for the gear pump is
installed to the swing section.
Blade section
• If the blade spool is pushed to move the spool
to the left, oil flows in the B7 port.
• If the blade spool is pulled to move the spool
to the right, oil flows in the A7 port.
• The load check valve has A port and B port,
one each, in its spool.
PC58UU-3 10-55
SWING HOLDING BRAKE RESET SYSTEM
Function Operation
• The swing holding brake reset system resets • Both swing PPC pressures and arm IN PPC
the swing holding brake by using both swing pressure are output respectively through the
PPC pressures and arm IN PPC pressure as check valve in the spring case to the BR port
signals. of the swing motor (The highest pressure is
output to the BR port of the swing motor).
• The arm and swing control valves are con-
nected to each other by the internal pilot
path.
10-56 PC58UU-3
(5)
LOGIC VALVE
Function • Accordingly, the pump merge-divider

• The logic valve changes the pilot pressure to valve is not changed but kept in the
change the divider valve. merge mode. Even if the travel PPC pres-
Operation sure is applied under this condition, the
spool (1) is kept pressed in the merge
1. In separate mode position.
• If only the travel PPC valve is applied to
the b port, it is applied as it is to the c out-
put port of the pump merge-divider valve.
This pressure changes the pump merge-
divider valve to set the pump in the sepa-
rate mode.
2. In merge mode
• If the work equipment PPC pressure
(excluding the swing PPC pressure) is
applied to the a port, the c output port of
the pump merge-divider valve is con-
nected through the spool (1) to the d
spring chamber and the PPC pressure is
used as the seal drain pressure.
PC58UU-3 10-57
(5)
PUMP MERGE-DIVIDER VALVE
1. When only travel valve is operated
Function
• When the travel valve is operated singularly,
the pump merge-divider valve separates the
PP1 and PP2 pump (discharge) pressures
with the merge-divider spool.
Operation
• When the travel valve is operated singularly,
the travel PPC pressure is applied through the
logic valve spool to the right side of the pump
merge-divider valve spool (1). If the travel
PPC pressure exceeds the force of the spring
(2), the pump merge-divider valve spool (1) is
pushed to the right and left to separate the
PP1, PP2, and PP3 pump pressures.
• At this time, the PLS1, PLS2 and PLS3 LS
pressures are separated, too. The pump pres-
sure is output as the PLS output pressure to
the pump LS valve.
10-58 PC58UU-3
(5)
2. Work equipment operation, Travel and work equipment compound operation
Function
• At work equipment operation or travel and
work equipment compound operation, pump
discharge pressure PP1 and PP2 are
merged.
Operation
• When work equipment is operated, logic
valve output pressure is drained and spool
operating pressure of pump merge-divider
valve goes to zero.
• So, spool of merge-divider valve is pressed to
the R.H. end, and PP1, PP2 and PP3 are
merged. PLS1, PLS2 and PLS3 are also
merged.
• At travel and work equipment compound
operation, travel PPC pressure is not applied
to the pump merge-divider valve but is
drained because the logic valve is switched.
• At neutral, pressure PP1 and PP2 are
merged because spring force is stronger that
travel PPC spool pressing force.
PC58UU-3 10-59
BOOM ASSIST VALVE
Function
• When the boom is raised and the upper struc-
ture is swung simultaneously (When the
machine starts swinging), the boom assist
valve sends the oil from the gear pump circuit
to the main pump circuit.
Operation
• If the boom is raised, the boom raising PPC
pressure is applied to the a port to move the
boom assist valve to the left.
• If the machine swings, the swing starting
pressure rises higher than the main circuit
pressure and moves the c spool in the b
boom assist valve spool to the left to supply
oil from the gear pump to the main pump.
10-60 PC58UU-3
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
A: From L.H. travel control valve A1: To L.H. travel motor

B: From L.H. travel control valve B1: To L.H. travel motor
C: From R.H. travel control valve C1: To R.H. travel motor
D: From R.H. travel control valve D1: To R.H. travel motor
E: From travel 2nd speed selector solenoid E1: To travel 2nd speed selector valve
F: From Blade control valve F1: To blade cylinder head
G: From Blade control valve G1: To blade cylinder bottom
T: To hydraulic tank T1: From travel motor drain port
1. Rotor 3. Slipper seal

2. Shaft 4. Cover
Unit: mm
Clearance between rotor Standard size Standard Clearance Clearance limit
5 Replace
and shaft ø 60 0.055 - 0.085 0.090
PC58UU-3 10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
A: From travel control valve

B: From travel control valve
D: To hydraulic tank
P: From travel 2nd speed selector solenoid valve
10-62 PC58UU-3
1. Check valve 13. Shaft

2. Counterbalance valve 14. Cover
3. Regulator valve 15. Drain plug
4. Valve plate 16. Case
5. Brake piston 17. Regular piston
6. Cylinder 18. Swash plate
7. Pivot 19. Piston
8. RV gear 20. Floating seal
9. RV gear 21. Spindle
10. Spring 22. Disc
11. Driven gear 23. Plate
12. Drive gear 24. Check valve
25. End cover
SPECIFICATION
Type : GMO6VN
Theoretical delivery (Hi) : 15.3 cm³/rev {15.3 cc/rev}
(Lo) : 26.4 cm³/rev {26.4 cc/rev}
Speed change pressure : 1.96 - 4.41 MPa{20-45 kg/cm²}
Reduction ratio : 57.9
PC58UU-3 10-63
OUTLINE
• The swash plate (1) has two planes x and y

on the back and is supported with the pivot
(2).
• To change the travel speed, the pressurized
oil in the control chamber a is sent to the reg-
ulator piston (3) to maximize or minimize the
angle of the swash plate (1).
10-64 PC58UU-3
(5)
OPERATION
At slow speed (the motor swash plate angle is maximized).
• Since the 2nd speed selector solenoid valve

(1) is demagnetized, the pressurized oil from
the control pump does not flow to the Pi port.
• Therefore, the spring (3) has pressed the reg-
ulator valve (2) to the left side
• So, the regulator valve (2) stops the main
pressurized oil led from the control valve to
the end cover (5) by pushing the check valve
(6).
• The pressurized oil in the control chamber
drains in the motor case through the passage
b of the regulator valve (2).
• Then, the main pressurized oil from the cylin-
der c chamber pushes the swash plate (7) in
the direction to maximize the swash plate
angle and the motor capacity is increased to
the maximum for slow speed travel.
PC58UU-3 10-65
(5)
At high speed (the motor swash plate angle is minimized).
• When the travel 2nd speed selector solenoid

valve (1) is energized, the pilot pressure from
the control pump will flow in the Pi port and
push the regulator valve (2) in the right direc-
tion.
• Therefore, the main pressurized oil from the
control valve passes through the passage c of
the regulator valve (2), flows in the control
chamber a and pushed the regulator piston
(6) in the left direction.
• Then, the swash plate (7) is pressed in the
direction to minimize the swash plate angle,
and the motor capacity is minimized for high
speed travel.
10-66 PC58UU-3
Operation of brake valve

• The brake valve consists of the check valves
(1a) and (1b), the counterbalance valve (2),
and the circuit configuration is as per the
right figure.
• Functions and operations of these compo-
nents are as follows:
Function
• When traveling down a slope, the own weight
falling force will make the machine travel
faster than the motor rotation. So, traveling
with reduced engine speed is very dangerous
because the motor idles and runs away.
These valves let the machine travel at a speed
appropriate for the engine speed (pump
delivery) to prevent this danger.
Operation at oil supply

• When the travel lever is operated, the pres-
surized oil from the control valve will be sup-
plied to the PA port, push and open the check
valve (1a) and flow from the MA port on the
motor inlet side to the MB port on the motor
outlet side.
At this time, the pressurized oil flows through
the c orifice of the spool (2) into the D cham-
ber. If its pressure rises higher than the pres-
sure of spring (3), the spool (2) is pushed to
the left. As a result, the MB and PB ports are
connected to each other and the motor outlet
opens and the motor starts revolution.
Since the PA and E ports are connected to
each other at this time, too, the pressurized oil
moves the parking brake piston (4) to release
the parking brake.
PC58UU-3 10-67
Operation at oil stop Braking operation for travelling down slope

• If the travel lever is returned to neutral, the • If the machine starts running away while it is
pressurized oil from the control valve is travelling down a slope, the motor runs idle
stopped and the spool (2) is returned to the and the oil pressure on the motor inlet side
right by the force of the spring (3). lowers. The pressure in the D chamber con-
At this time, the oil flows through the c orifice nected through the c orifice lowers, too.
of the D chamber to the PA port and back The pressure in the D chamber lowers below
pressure is generated by the throttling effect the pressure of the spring (3), the spool (2) is
of the c orifice and that back pressure con- returned to the right.
trols the speed of the spool (2) returning to At this time, the oil in the G chamber flows
the right. through the f orifice into the PB port. A nega-
Even if the pressurized oil is in the PA port is tive pressure is generated by the throttling
stopped, the motor continues revolution by effect of the f orifice, and it controls the
inertia. returning speed of the spool (2) by returning
At this time, the returning oil is controlled it to the right. The MB port on the outlet side
gradually to stop the motor gently according is closed.
to the changing speed of the spool (2) and the As a result, the pressure on the outlet side
shape of the cut. rises to give revolution resistance to the
The motor continues revolution by inertia and motor to prevent it from running away.
can cause cavitation. Since the (1a) valve is That is, the spool (2) moves to a position
operated by a very low negative pressure, the where the weight of the machine and the
PA and MA ports are opened to prevent cavi- pressure on the inlet side are balanced with
tation. the pressure in the MB port on the outlet side
and the outlet circuit is closed to control the
speed according to the pump discharge.
10-68 PC58UU-3
Operation of parking brake
When travel lever is operated When travel lever is set to neutral during
travel
• If the travel lever is operated, the pressurized • If the travel lever is set to the neutral, the
oil from the pump moves the spool (1) to the pressurized oil from the pump is stopped.
left and flows through the E port into the A The pressurized oil in the a chamber of the
chamber of the brake piston (2) to move the brake piston (2) is drained through the orifice
brake piston (2) to the left. of the check valve (6) into the case and the
As a result, the pressing force of the spring (5) piston (2) is pressed by the spring (5) to the
applied to the plate (3) and disc (4) is lost and right.
the plate (3) and disc (4) are separated to As a result, plate (3) and disc (4) are pressed
release the brake. against each other and the brake works.
PC58UU-3 10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
TYPE: LMF16
Specification
B: From control valve Type: LMF16
S: From tank Theoretical delivery: 16.1 cc/rev
T: To tank Rated speed: 2,100 rpm
MA: From control valve Rated flow capacity: 33.8 /min
MB: From control valve Safety valve set pressure: 20.6 MPa {210 kg/cm²}
Suction valve cracking pressure: 0.044 MPa
{0.45 kg/cm²}
10-70 PC58UU-3
(5)
12
1. Output shaft 9. Cylinder 17. Plate

2. Housing 10. Brake piston
3. Shoe 11. Swash plate
4. Piston 12. Brake spring
5. Center spring 13. Safety valve
6. Valve plate 14. Check valve
7. Disc 15. Check valve spring
8. Plate 16. Hydraulic timer valve
Unit: mm

Free length Installed Installed Free length Installed Replace
A Timer valve spring x O.D. length load load spring if any
1.96 N 1.47 N damages or
12.6 x 6.5 10.5 {0.2 kg} — {0.15 kg} deformations
are found
B Valve return spring 13.0 x 6.5 7.0 3.43 N — 2.55 N
{0.35 kg {0.26 kg}
PC58UU-3 10-71
HYDRAULIC MOTOR SECTION
Function
• This hydraulic motor is a swash plate-type
axial piston motor, which converts the pres-
sure of the oil sent from the hydraulic pump
into rotation.
Principle of operation
• The oil sent from the hydraulic pump flows

through the valve plate (7) into the cylinder
block (5). This oil can flow on only 1 side of
the Y-Y line connecting the top dead center
and bottom dead center of the piston (4).
• The pressurized oil sent to the 1 side of the
cylinder block (5) presses the pistons (4) (3 or
4 pieces) and generates the F1 force (F1 kg = P
kg/cm² x π/4D² cm²).
• This force is applied to the thrust plate (2).
Since the thrust plate (2) is fixed to the angle
of α° to the output shaft (1), the force is
divided into the F2 and F3 components.
• The F3 radial component generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = Σ (F3 x ri)]
rotates the cylinder block (5) through the pis-
ton.
• Since the cylinder block (5) is coupled with
the output shaft by means of spline, the out-
put shaft revolves to transmit the torque.
10-72 PC58UU-3
(5)
BRAKE VALVE
Outline
• The brake valve consists of the check valve

and the safety valve.
Function
• When the swing stops, the control valve (1)

will close the outlet circuit of the motor, but
the inertia will keep the motor rotating. So,
the motor output pressure rises abnormally
and the motor is damaged. So, the brake
valve leads the abnormally high pressure
from the outlet side (high pressure side) to
the S port to prevent the motor from being
damaged.
Operation
1. When swing starts

• When the swing operation lever is turned to
the left, the pressurized oil from the pump
will be led to the MB port through the control
valve (1). Then, the pressure at the MB port
will rise, generate starting torque to the
motor and start the motor rotating. The oil
from the motor outlet will return to the tank
from the MA port through the control valve
2. When swing stops

• When the swing operation lever returns to the
neutral position, the pressurized oil from the
pump will not be led to the MB port. Since
the control valve (1) closes the return circuit
to the tank, the oil from the motor outlet will
raise the pressure at the MA port and gener-
ate rotation resistance to the motor to work
the brake
• The pressure at the MA port rises to the set
pressure of the safety valve. Accordingly, a
large braking torque is applied to the motor
to stop the motor.
• While the safety valve is operating, the oil
relieved from the safety valve and the oil
from the S port are supplied through the CB
check valve to the MB port to prevent cavita-
tion at the MB port.
PC58UU-3 10-73
(5)
12
SWING BRAKE
Operation 2. When swing and arm levers are operated

• The pressurized oil from the PPC flows
1. When swing and arm levers are in neutral through the B port into the a brake chamber.
• Since the PPC output pressure is 0 MPa {0 kg/ The oil in the a chamber presses down the
cm2}, the brake piston (12) is pressed up by brake spring (13). Accordingly, the brake pis-
the brake spring (13). Accordingly, the brake ton (12) moves down and the disc (14) and
piston presses the disc (14) and plate (15) to plate (15) are separated to release the brake.
apply the brake.
10-74 PC58UU-3
(5)
3. Operation of hydraulic timer valve

• When the swing motor stops, if the swing
brake works sharply, the motor parts are bro-
ken. The hydraulic timer valve (16) makes the
swing brake delay working to prevent break-
age of the motor parts and decelerate the
upper structure smoothly.
• If the PPC lever is operated, the PPC output
pressure is applied to the a chamber and the
swing brake is released. Under this condi-
tion, if the PPC lever is set in neutral, pressur-
ized oil is not supplied to the B port and the
pressure in the a chamber lowers. Accord-
ingly, the oil in the a chamber is pushed out
by the brake spring (13).
• Since there is a check valve in the PPC on the
B port side, the oil does not flow through the
B port but flows into the C path. Since the oil
path is throttled by the orifice (ø 0.4) of the
hydraulic timer valve (16), however, the oil in
the a chamber flows at a very low rate.
Accordingly, the swing brake delays working
for a certain time.
PC58UU-3 10-75
12
MODULATING RELIEF VALVE
Function
• The characteristic of the swing motor relief

valve is to restrain sharp rise of relief valve
(as shown in the right figure) and to reduce
shocks when starting and stopping swing.
Operation
1. When circuit pressure is PO

• The relief valve does not work.
2. When circuit pressure rises sharply

• When the circuit pressure reaches P1, the oil
pressure will push the spring (4) due to the
area difference (D1>D3) of the valve (3).
Then, the valve (3) will start opening.
• At this time, the oil pressure will work on the
seat (1) due to the area difference (D2>D1),
and the seat will be apt to follow the valve (3).
• But the seat is going to compress the oil in
the a chamber and moves more slowly than
the valve (3) because the passage through
which the oil escapes to the S port is throttled
with the ball (2).
• So, the relief pressure will rise slowly from
P1 to P2 until the seat (1) comes to the sleeve
(5).
10-76 PC58UU-3
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
12
TRAVEL PPC VALVE
P : From main pump P3: R.H. reverse

P1: L.H. reverse P4: R.H. forward
P2: L.H. forward T : To tank
PC58UU-3 10-77
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
12
1. Plate 5. Metering spring

2. Body 6. Centering spring
3. Piston 7. Valve
4. Collar 8. Bolt
Unit: mm

Free length Installed Installed Installed Replace
A Metering spring x O.D. length load Free length load spring if any
16.7 N 13.7 N damages or
26.56 x 8.15 24.9 {1.7 kg} — {1.40 kg} deformations
are found
B Centering spring 52.06 x 15.5 30.25 146.4 N — 117.7 N
{14.94 kg {12.0 kg}
10-78 PC58UU-3
MAINTENANCE STANDARD TRAVEL PPC VALVE
Operation
1. In the neutral mode

• P1 and P2 ports of the operation valves A, B and
PPC valve are connected to the drain chamber D
via the fine control hole f on the spool (1).
2. In the fine control mode

(Neutral o fine control).
• As the piston (4) is pushed by the lever (5), the
retainer (9) is pushed too. At the same time, the
spool (1) is also pushed down via the metering
spring (2).
• By this move, connection of the final control hole
f is switched from the drain chamber D to the
pump pressure chamber PP, and pilot pressur-
ized oil for the main pump is conducted from P1
port to A port.
• As P1 port pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure chamber PP to the drain chamber D,
thereby relieving P1 port pressure.
• As a result, the spool (1) moves up and down so
that force of the metering spring (2) and P1 port
pressure may be balanced.
Positional relationship between the spool (1) and
body (10) (fine control hole f is situated at mid
point between the drain chamber D and pump
pressure chamber PP) remains unchanged until
the retainer (9) is contacted against the spool (1).
• The metering spring (2) is, therefore, com-
pressed in proportion to the strokes of the opera-
tion lever. Thus, the P1 port pressure also
increases in proportion to strokes of the opera-
tion lever.
• As a result, the operation valve spool moves to
the position where the pressure of chamber A
(the same as P1 port pressure) is balanced
against the force of the operation valve spool
return spring.
PC58UU-3 10-79
(5)
MAINTENANCE STANDARD TRAVEL PPC VALVE
3. In the fine control mode (when the operation

lever is shifted back to its original position)
• As the lever (5) starts returning, the spool (1) is
pushed up by force of the centering spring (3)
and P1 port pressure.
• By this move, the fine control hole f is connected
to the drain chamber D and relieves pressurized
oil of port P1 to it.
• If P1 port pressure goes excessively low, the
spool (1) is pushed down by the metering spring
(2) and passage between the fine control hole f
and the drain chamber D is shut down. And,
almost at the same time, the hole is connected to
the pump pressure chamber PP and starts sup-
plying pump pressure. This supply continues
until P1 port pressure is reconverted to the level
equivalent to the lever position.
• When the operation valve spool returns, oil in
drain chamber D flows in through fine control
hole f' on the non moving side valve. Oil is then
conducted via port P2 and fills up chamber B.
4. In the full stroke mode

• When the lever (5) pushes down the piston (4)
and the retainer (9) pushes down the spool (1),
connection of fine control hole f is switched from
drain chamber D to the pump pressure chamber
PP.
• Thus, pilot pressurized oil from the main pump
passes through fine control hole f and is con-
ducted to chamber A via port P1 to push the
operation valve spool.
• Return oil from chamber B is conducted from
port P2 to the drain chamber D via fine control
hole f'.
10-80 PC58UU-3
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC VALVE
12
PPC VALVE
FOR WORK EQUIPMENT AND SWING
P : From PPC lock valve P3: Left; Swing to left/Right; Bucket CURL
P1: Left; Arm OUT/Right; Boom LOWER P4: Left; Swing to right/Right; Bucket DUMP
P2: Left; Arm IN/Right; Boom RAISE T : To tank
PC58UU-3 10-81
(5)
12
1. Spool 5. Disk 9. Retainer

2. Metering spring 6. Nut (for linking the lever) 10. Body
3. Centering spring 7. Joint 11. Filter
4. Piston 8. Plate
10-82 PC58UU-3
12
Unit: mm

Centering spring Free length Installed Installed Free length Installed
A (for P3 and P4 ports) x O.D. length load load Replace
9.8 N 7.8 N spring if any
38.7 x 15.5 34.0 {1.0 kg} — {0.8 kg} damages or
Centering spring 17.7 N 14.1 N deformations
B (for P1 and P2 ports) 42.5 x15.5 34.0 {1.8 kg — {1.44 kg} are found
C Metering spring 26.5 x 8.20 24.9 16.7 N — 13.3 N

{1.70 kg} {1.36 kg}
PC58UU-3 10-83
12
Operation

• Ports P1 and P2 of operation valves A and B
and the PPC valve are connected to drain
chamber D via the fine control hole on the
spool (1).

(neutral → fine control)
• When the piston (4) is pushed by the disk (5),
the retainer (9) is also pushed, thereby driving
the metering spring (2) down via the spool
(1).
• As a result, the fine control hole f is isolated
from the drain chamber D, and almost at the
same time, it is connected to the pump pres-
sure PP. Then, pilot pressurized oil for the
main pump is conducted from port P1 to port
A via the fine control hole f.
• As pressure on port P1 is increased, the spool
(1) is pushed back thereby disconnecting the
fine control hole f from the pump pressure
chamber PP, The disconnected spool (1) is in
no time connected to the drain chamber D,
resulting in relieving pressure on port P1.
• Thus, the spool (1) is moved up and down so
that the force of the metering spring (2) and
pressure on port P1 may be balanced. The
positional relationship the spool (1) and body
(10) (fine control hole f is situated at mid
point between the drain chamber D and
pump pressure chamber PP) remains
unchanged until the retainer (9) is contacted
against the spool (1).
• Therefore, the metering spring (2) is com-
pressed in proportion to the strokes of the
operation lever. So, pressure on port P1 is
also increased in proportion to the strokes of
the operation lever.
• As a result, the operation valve spool is
moved up to the position where pressure in
chamber A (the same pressure level as that
on port P1) and force of the operation valve
spool return spring is balanced.
10-84 PC58UU-3
12
3. In the fine control mode (operating lever

shifted back to its original position)
• As the disk (5) starts returning, the spool (1) is
pushed up by the force of the centering
spring (3) and the pressure port P1.
• Thus, passage between the fine control hole f
and drain chamber D becomes available,
thereby relieving pressurized oil of port P1.
• Of port P1 pressure goes excessively low,
the spool (1) is pushed down by the metering
spring (2) and passage between the fine con-
trol hole f and drain chamber D is shut down.
Almost at the same time, the hole is con-
nected to the pump pressure chamber PP
and starts supplying pump pressure. This
supply continues until the port P1 pressure
has recovered to the level equivalent to the
lever position.
• When the operation valve returns, oil in the
drain chamber D flows in through the fine
control hole f’ on the non moving side valve.
Oil is then conducted via port P2 to fill up
chamber B.

• When the disk (5) pushes down the piston (4)
and the retainer (9) pushes down the spool
(1), connection of the fine control hole f is
switched from drain chamber D to the pump
pressure chamber PP.
• Thus, pilot pressurized oil from the control
pump passes through the fine control hole f
and is conducted to chamber A via port P1 to
push the operation valve spool.
port P2 to drain chamber D via the fine con-
trol hole f’.
PC58UU-3 10-85
(5)
12
FOR OFFSET
FOR SERVICE
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
8. Body
9. Filter
P : From main pump

P1: To service valve
P2: To service valve
T : To tank
10-86 PC58UU-3
(5)
12
Unit: mm

Free length Installed Installed Free length Installed Replace
A Centering spring x O.D. length load load spring if any
125 N 100 N damages or
33.9 x 15.3 28.4 — deformations
{12.7 kg} {10.2 kg}
are found
16.7 N 13.3 N
B Metering spring 22.7 x 8.10 22.0 {1.70 kg} — {1.36 kg}
PC58UU-3 10-87
(5)
MAINTENANCE STANDARD PPC VALVE
Operation

• Ports P1 and P2 of operation valves A and B and
the PPC valve are connected to drain chamber D
via the fine control hole f on the spool (1).

(Neutral o fine control)
• As the piston (4) is pushed by the disk (5), the
retainer (7) is pushed too. At the same time, the
spool (1) is also pushed down via the metering
spring (2).
• By this move, connection of the fine control hole
f is switched from the drain chamber D to the
pump pressure chamber PP, and pilot pressur-
ized oil fro the control pump is conducted from
port P1 to port A.
• As port P1 pressure increases, the spool (1) is
pushed back. By this move, connection of the
fine control hole f is switched from the pump
pressure chamber PP to the drain chamber D,
thereby relieving port P1 pressure.
• As a result, the spool (1) moves up and down so
the force of the metering spring (2) and port P1
pressure may be balanced.
• The positional relationship between the spool (1)
and body (8) (fine control hole f is situated at mid
point between the drain chamber D and pump
pressure chamber PP) remains unchanged until
the retainer (7) is contacted against the spool (1).
• The metering spring (2) is, therefore, com-
pressed in proportion to the strokes of the opera-
tion lever. Thus, port P1 pressure, too, increases
in proportion to the strokes of the operation lever.
• As a result, the operation valve spool moves to
the position where pressure of chamber A (the
same as port P1 pressure) is balanced against
the force of the operation valve spool return
spring.
10-88 PC58UU-3
(5)
MAINTENANCE STANDARD PPC VALVE
3. In the fine control mode (when the operation

lever is shifted back to its original position)
• As the lever (5) starts returning, the spool (1) is
pushed up by the force of the centering spring
(3) and port P1 pressure. By this move, the fine
control hole f is connected to the drain chamber
D and relieves pressurized oil of port P1 to it.
• If port P1 pressure goes excessively low, the
spool (1) is pushed down by the metering spring
(2) and passage between the fine control hole f
and the drain chamber D is shut down. Almost at
the same time, the hole is connected to the
pump pressure chamber PP and starts supplying
pump pressure. This supply continues until the
P1 port pressure recovers to the level equivalent
to the lever position.
• When the operation valve spool returns, oil in the
drain chamber D flows in through the fine control
hole f' on the non moving side valve.
Oil is then conducted via port P2 to fill up the
chamber B.

• When the disk (5) pushes down the piston (4)
and the retainer (7) pushes down the spool (1),
connection of the fine control hole f is switched
from the drain chamber D to the pump pressure
chamber PP.
• Thus, pilot pressurized oil from the control pump
passes through the fine control hole f and is con-
ducted to chamber A via port P1 to push the
operation valve spool.
port P2 to the drain chamber D via the fine con-
trol hole f'.
PC58UU-3 10-89
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
12
HYDRAULIC CYLINDER
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
10-90 PC58UU-3
(5)
12
OFFSET CYLINDER
BLADE CYLINDER
PC58UU-3 10-91
(5)
12
Unit: mm

Cylinder
size Shaft Hole clearance limit
-0.030 +0.163
Boom ø55 0.036 - 0.267 0.567
-0.104 +0.006
-0.030 +0.163
Clearance between Arm ø55 0.036 - 0.267 0.567
-0.104 +0.006 Replace
1 piston rod and
-0.025 +0.164 bushing
bushing Bucket ø50 0.032 - 0.251 0.551
-0.087 +0.007
-0.025 +0.164
Offset ø50 0.032 - 0.251 0.551
-0.087 +0.007
-0.025 +0.164
Blade ø50 0.032 - 0.251 0.551
-0.087 +0.007
-0.147 +0.142
Boom ø50 0.227 - 0.351 1.0
-0.209 +0.080
-0.025 +0.142
Arm ø50 0.105 - 0.206 1.0
-0.064 +0.080
Clearance between
-0.170 -0.011
2 piston rod support Bucket ø45 0.105 - 0.219 1.0
-0.230 -0.065
shaft and bushing
-0.025 +0.142
Offset ø50 0.105 - 0.206 1.0
-0.064 +0.080
Replace
-0.030 +0.174
Blade ø55 0.130 - 0.250 1.0 pin and
-0.076 +0.100
bushing
-0.147 +0.142
Boom ø50 0.025 - 0.351 1.0
-0.209 +0.080
Clearance between Bucket -0.025 +0.142
ø45 0.105 - 0.206 1.0
cylinder bottom -0.064 +0.080
3
support shaft and -0.025 +0.142
bushing Offset ø50 0.105 - 0.206 1.0
-0.064 +0.080
-0.030 +0.174
Blade ø55 0.130 - 0.205 1.0
-0.076 +0.100
Clearance between
-0.080 +0.137
4 trunnion shaft and Arm ø55 0.158 - 0.263 1.0
-0.126 +0.078
bushing
Boom 735 ± 73.5 Nm {75 ± 7.5 kgm}
Arm 1.08 ± .011 kNm {110 ± 11.0 kgm}
Order: 1) Tighten to 863 Nm {88 kgm}
Cylinder head tight-
5 Bucket 2) Loosen to 0 Nm {0 kgm}
ening torque
3) Tighten to 863 Nm {88 kgm}
Offset 676 ± 67.6 Nm {69 ± 6.9 kgm}
Re-
Blade 863 ± 86.5 Nm {88 ± 8.8 kgm} tighten
Boom 1.67 ± 0.17 kNm {170 ± 17.0 kgm} (width across flats 55mm)
Arm 1.67 ± 0.17 kNm {170 ± 17.0 kgm} (width across flats 55mm)
Cylinder piston
6 Bucket 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (width across flats 55mm)
tightening torque
Offset 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (width across flats 55mm)
Blade 1.42 ± 0.14 kNm {145 ± 14.5 kgm} (width across flats 55mm)
10-92 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
12
SOLENOID VALVE
PC58UU-3 10-93
12
A1: From control pump

A3: From offset PPC valve "Left"
A4: From left work equipment PPC valve "ARM
IN"
A5: From right work equipment PPC valve
"BOOM RAISE"
B1: To PPC valve
B2: To 2nd speed selector valve
B3: To control valve "LEFT OFFSET"
B4: To control valve "ARM IN"
B5: To control valve "BOOM RAISE"
T : To hydraulic oil tank
1. Boom RAISE stop EPC valve

2. Arm IN stop EPC valve
3. Offset left stop solenoid valve
4. 2nd speed selector solenoid valve
5. PPC lock solenoid valve
Solenoid valve
6. Coil (ON - OFF type)
7. Push pin
8. Valve spool
9. Return spring
10. Valve body
EPC valve
11. Return spring
12. Guide
13. Valve spool
14. Push pin
15. Coil (proportional type)
Check valve
16. Plug
17. Spring
18. Ball
Control relief valve

19. Adjustment screw
20. Shim
21. Locknut
22. Return spring
23. Valve spool
10-94 PC58UU-3
12
2ND TRAVEL SPEED SELECTOR SOLENOID VALVE
PPC LOCK SOLENOID VALVE
OPERATION
When solenoid is "demagnetized"
• When signal current does not flow from the

PPC lock switch or travel booster pedal, sole-
noid (1) is demagnetized.
• Thus, the spool (2) is pushed up by the spring
(3).
• Since port A is closed by this spool, flow of
pilot oil pressure to the actuator is blocked. At
the same time, oil from the actuator is led
from port B to port T, then drained to the
hydraulic oil tank.
When solenoid is "magnetized"
• When signal current flows from the PPC lock

switch or travel booster pedal to the solenoid
(1), solenoid (1) is magnetized.
• Thus, the spool (2) is pushed down by the
push pin (4).
• As a result, pilot oil pressure is conducted
from port A through the spool (2) and port B
up the actuator.
At the same time, port T is closed, thereby
blocking flow of oil to the hydraulic oil tank.
PC58UU-3 10-95
(5)
MAINTENANCE STANDARD SOLENOID VALVE
OFFSET LEFT STOP SOLENOID VALVE
OPERATION
When solenoid is "magnetized" (circuit is in con-
nection)
• The solenoid (1) is magnetized by signal current
conducted to it from the controller.
• Thus, the spool (2) is pushed down by the push
pin (3).
• As a result, pressurized oil from the PPC valve is
conducted to port A through the spool (2) and
port B up to the operation valve.
At the same time, port T is closed, thereby block-
ing oil flow to the tank.
When solenoid is "demagnetized" (circuit is iso-

lated)
• The solenoid (1) is demagnetized when signal
current from the controller to it is stopped.
• Thus, the spool (2) is pushed up by the return
spring (4).
• As a result, port A is closed, thereby stopping
flow of oil pressure from PPC valve to the opera-
tion valve.
At the same time, oil from the operation valve is
conducted to port B through port T and finally
drained to the tank.
10-96 PC58UU-3
(7)
12
BOOM RAISE STOP EPC VALVE
ARM IN STOP EPC VALVE
Operation
When signal current is maximized (coil mag-

netized and circuit pressure is at maximum
level)
• The coil (1) is magnetized when signal current

is conducted to it from the controller.
Thrust of the coil (1) is magnetized at this
time.
• Thus, the spool (2) is pushed down by the
push pin (3).
• As a result, all pressurized oil from the PPC
valve is conducted to port A through the
spool (2) and port B up to the operation valve.
At the same time, port T is closed, thereby
blocking flow of oil to the tank.
When signal current is reduced (coil is mag-

netized and circuit pressure is at a reduced
level)
• If signal from the controller to the coil (1) is

reduced, the coil thrust is reduced in propor-
tion to the reduction in signal current though
the coil (1) still remains magnetized.
• Thus, the push pin (3) pushes the spool (2)
downward, thereby conducting pressurized
oil from port A to port B.
• If working force of the spool (2) against face a
becomes greater than the thrust of the coil (1)
because of increased pressure on port B, the
spool (2) is pushed up thereby disconnecting
port A from port B and, at the same time,
connecting port A to port T.
• As a result, the spool (2) moves up and down
so that the thrust of the coil (1) and pressure
on port B may be balanced.
• Circuit pressure between PPC valve and oper-
ation valve is , as seen above, adjusted in pro-
portion to the magnitude of the signal
current.
PC58UU-3 10-97
(5)
12
Signal current 0 (coil is demagnetized and

circuit is in isolation)
• If signal current from the controller to the coil

goes to 0, the coil (1) is demagnetized.
• Thus, the spool (2) is pushed up by the return
spring (4).
• As a result, port A is closed, thereby blocking
flow of pressurized oil from the PPC valve to
the operation valve.
At the same time, oil from the operation valve
is passed through ports B and T, and finally
drained to the tank.
Signal current 0 → increased → maximum
• Operation takes place in the above order of 3

→ 2 → 1.
CONTROL RELIEF VALVE

• If the oil pressure from the control pump
rises, the oil in the A port pushes spool (1)
and its reaction force compresses spring (2)
to move the spool (1) to the right and open
the A and T ports to relieve the oil.
Set pressure: 2.9 MPa {30 kg/cm²}
10-98 PC58UU-3
(5)
MAINTENANCE STANDARD MULTI CONTROL VALVE
MULTI CONTROL VALVE
(1) JIS pattern (2) J/D pattern
Operation pattern selection drawing (The port names correspond to the symbols in the drawing).
PC58UU-3 10-98-1
(4)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
12
WORK EQUIPMENT
PC58UU-3 10-99
12
10-100 PC58UU-3
12
Unit: mm

Clearance between 1st boom size clearance limit
Shaft Hole
1 and revolving frame mounting
pin and bushing -0.025 +0.142
ø50 0.105 - 0.206 1.0
-0.064 +0.080
Clearance between 1st boom
+0.145 +0.335
2 and 2nd boom mounting pin ø80 0.125 - 0.276 1.0
+0.059 +0.270
and bushing
Clearance between 1st boom
-0.025 +0.142
3 and sub-link mounting pin and ø50 0.105 - 0.206 1.0
-0.064 +0.080
bushing
Clearance between 2nd boom
+0.145 +0.335
4 and 3rd bracket mounting pin ø80 0.125 - 0.276 1.0
+0.059 +0.270
and bushing
Clearance between 3rd
-0.025 +0.142
5 bracket and sub-link mounting ø50 0.105 - 0.206 1.0
-0.064 +0.080 Replace
pin and bushing
pin and
Clearance between 3rd bushing
-0.025 +0.142
6 bracket and arm mounting pin ø50 0.105 - 0.206 1.0
-0.064 +0.080
and bushing
Clearance between arm and -0.170 -0.012
7 ø45 0.105 - 0.218 1.0
link mounting pin and bushing -0.230 -0.065
Clearance between link and -0.170 -0.012
8 ø45 0.105 - 0.218 1.0
link mounting pin and bushing -0.230 -0.065
Clearance between link and
-0.170 -0.012
9 bucket mounting pin and ø45 0.105 - 0.218 1.0
-0.230 -0.065
bushing
Clearance between arm and
-0.170 -0.012
10 bucket mounting pin and ø45 0.105 - 0.218 1.0
-0.230 -0.065
bushing
Clearance between blade and
-0.025 +0.142
11 track frame mounting pin and ø35 0.105 - 0.229 1.0
-0.087 +0.080
bushing
PC58UU-3 10-101
12
DIMENSION OF WORK EQUIPMENT
1. Arm
10-102 PC58UU-3
(5)
12
Unit: mm
PC58UU-3
No. Tolerance
Standard
Measuring position
size
Shaft Hole
-0.025 -0.100
1 — ø50
-0.064 0
+2
Arm side 66.5
0
2
0
Cylinder head side 60
-0.5
-0.025 +0.100
3 — ø50
-0.064 0
-0.5
Boom side 186
-1.0
4
-0.5
Arm side 180
-1.0
5 — 143 ±1
+1
6 — 185.9
0
+1
7 — 323
0
8 — 1,620 —
+2
9 — 1,932.3
0
10 — 1,393.4 ±1
11 — 202.2 ±1
12 — 16.7 ±1
13 — 330 ±0.5
14 — 303 ±0.5
15 — 247 —
16 — 905.5 —
-0.170 -0.050
17 — ø45
-0.230 -0.089
+0.7
Link side 168
+0.2
18
+2
Bucket side 170
0
-0.170 -0.050
19 — ø45
-0.230 -0.089
+0.7
Arm side 168
+0.2
20
+2
Bucket side 170
0
Min. 900 ±1.5
21
Max. 1,480 —
PC58UU-3 10-103
12
2. Bucket
Unit: mm
PC58UU-3
No.
Measuring position Standard size Tolerance
1 — 246.9 ±0.5
2 — 5.7 ±0.5
3 — 736.3 —
4 — 55 —
5 — 55 —
6 — 30° —
7 — 30° —
8 — 13.5 —
9 — 170 +2
0
10 — 60 —
11 — 42 —
12 — 258 ±1
13 — ø85 —
14 — ø85 —
15 — ø45 -0.050
-0.089
10-104 PC58UU-3
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONING PIPING
12
AIR CONDITIONING PIPING
1. Hot water take-off piping

2. Hot water return piping
3. Refrigerant piping
4. Receiver dryer
5. Condenser
6. Air conditioner compressor
7. Air conditioner unit
8. Duct
A: Inner air circulation hole

B: Hot air/cold air spurting hole
PC58UU-3 10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
12
ENGINE CONTROL
1. Battery
2. Starter switch
3. Fuse box
4. Engine stop solenoid
5. Safety lock lever
6. PPC lock switch
7. Neutral engine start relay (for starter circuit)
8. Safety relay
9. Starter
10. Deceleration controller
11. Fuel adjust dial
12. Fuel adjust motor
13. One-touch deceleration switch
14. One-touch deceleration pilot lamp
15. Fuel adjust motor relay (for drive)
16. Fuel adjust motor relay (for acceleration)
17. Fuel adjust motor relay (for deceleration)
10-106 PC58UU-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
12
STARTING ENGINE
• When the starter switch (2) is shifted to the
ON position, the engine stop solenoid (4)
drives the governor stop lever to the OPERA-
TION position. Should an error develop in the
electric system, this arrangement stops the
engine operation that functions as a fail-safe
mechanism.
• If the starter switch (2) is shifted to the START
position with the safety lock lever (5) at the
LOCK position, the starting signal flows in the
starter (9) and the engine starts. If the safety
lock lever (5) is at the FREE position, the start-
ing signal to the starter (9) is cut off and the
engine cannot start.
• Since the fuel adjust lever (11) is linked with
the fuel adjust motor (12), the engine is
driven at the speed set on the fuel adjust lever
(11).
ENGINE STOP
• If you shift the starter switch (2) to the OFF
position, the engine stop solenoid (4) drives
the governor stop lever to the STOP position
to stop the engine.
PC58UU-3 10-107
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRICAL CONTROL SYSTEM
12
ELECTRICAL CONTROL SYSTEM
OVERALL SYSTEM DIAGRAM
10-108 PC58UU-3
(5)
12
1. Battery
3. Starter switch
4. Fuse box
5. Emergency Pump driving switch
6. Emergency Pump driving resistor
7. Travel acceleration pedal
9. PPC lock switch
10. Neutral engine start relay (for PPC lock)
11. Emergency work equipment operation switch
12. Work equipment operation resistor
13. Monitor panel
14. Alarm buzzer
15. TVC-EPC valve
16. 2nd travel speed selector solenoid valve
21. R.H. PPC valve
22. Travel PPC valve
23. L.H. PPC valve
24. Offset PPC valve
25. Travel motor
26. Boom potentiometer
27. Offset potentiometer
28. Arm potentiometer
29. Reset terminal
30. Engine
31. Engine speed sensor
32. Main pump
32a.Servo valve
32b.LS valve
32c.PC valve
33. Control valve
33a.Merged valve
34. Travel PPC oil pressure switch
35. Travel alarm
PC58UU-3 10-109
12
PUMP CONTROL FUNCTION
Input/output signal
1. Battery a. Controller power supply
2. Controller b. Solenoid power supply
3. Starter switch c. Engine speed signal
4. Fuse box d. EPC valve driving signal
5. Emergency pump driving switch
6. Resistor
7. TVC-EPC valve
8. Main pump
8a. Servo valve
8b. LS valve
8c. PC valve
9. Engine speed sensor
10. Engine
11. Control valve
11a.Work equipment control valve
11b.Merged valve
11c.Travel control valve
10-110 PC58UU-3
(5)
12
Function
• The controller sets up a pump absrobtion

torque corresponding to the engine speed.
As the engine speed goes high, it enhances
the pump operating performance by increas-
ing its absrobtion torque. When the engine
speed goes low, the controller reduces the
pump absorbtion torque to prevent the
engine from stopping.
A: Pump obsorbtion torque
B: Engine torque
P: Engine rated flywheel horsepower
(29.4 kW/2,400 rpm) {40 HP/2,400 rpm}
Emergency pump drive
• If normal operation of the pump becomes

unavailable due to failure of the controller, fix
the situation temporarily and resume opera-
tion by operating the emergency pump drive
switch.
(1) In normal operation.
(2) When a failure occurs.
PC58UU-3 10-111
MAINTENANCE STANDARD ELECTRICAL CONTROL SYSTEM
TRAVEL CONTROL FUNCTION
1. Battery Function
2. Controller Travel speed selection
3. Starter switch Travel speed is switched according to changes in the
4. Fuse box motor capacity, which is controlled by the travel
5. Accelerator pedal accelerator pedal.
6. 2nd travel speed selector solenoid valve
Relieve Step on
7. L.H. travel motor Accelerator pedal
(Low) (High)
8. R.H. travel motor
9. Control valve 2nd travel speed selector
OFF ON
solenoid valve
10. Engine
11. Main pump Motor capacity (cm3/rev) 26.4 15.3
12. Travel PPC valve Travel speed (km/h) 2.5 4.2
13. Travel PPC oil pressure Travel motor angle of
14. Travel alarm Max. Min.
inclination
Input/output signal
a. Controller power supply Travel alarm
b. Solenoid power supply • When the travel lever is operated, the travel PPC
c. 2nd travel speed selection signal oil pressure switch (13) goes ON and the signal
d. Solenoid valve driving signal is sent to the controller (2).
e. Travel PPC oil pressure switch signal • The controller senses that the travel lever is
f. Travel alarm actuation signal operated and then sends the signal to the travel
alarm to sound.
10-112 PC58UU-3
(5)
12
PPC LOCK FUNCTION
1. Battery Function
2. Controller • The PPC lock switch is linked with the safety
3. Starter switch lock lever. Shifting the safety lock lever to the
4. Fuse box LOCK position turns the PPC lock switch to
5. Safety lock lever the OFF position.
6. PPC lock switch • As the PPC lock switch is turned OFF, current
7. Neutral engine start relay to the PPC lock solenoid valve is shut down,
8. PPC lock solenoid valve thereby making it inoperative from the work
9. L.H. PPC valve equipment operation lever.
10. R.H. PPC valve
13. Engine
14. Main pump
Input/output signal
a. Controller power supply
b. Solenoid power supply
c. Solenoid valve driving signal
PC58UU-3 10-113
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRICAL SYSTEM
12
ELECTRICAL SYSTEM
• The electrical system is intended to ensure
work safety and to facilitate operating perfor-
mance. It consists of the following sub-
systems; Interference Prevention System,
Depth Measurement System, and the Auto-
matic Boom/Arm Stop System.
CONTROL FUNCTIONS
Reduction function
Stop/alarm function
Interference prevention system Emergency stop/alarm function
Cancelling function
Reset function
Depth-from-ground-surface display function
Depth measurement system
Electrical system Depth-from-datum-plane display function
Automatic boom/arm stop system Height setup function
Boom end cushioning
Arm end cushioning
Error code display/alarm function
Self-test function
Error code memory function
PC58UU-3 10-115
(5)
12
SYSTEM DIAGRAM
10-116 PC58UU-3
(5)
12
Input/output signal
1. Battery
a. Controller power supply
b. Epc valve, solenoid valve power supply
3. Starter switch
c. Power supply
4. Fuse box
d. Solenoid valve driving signal
5. Emergency work equipment operation switch
e. EPC valve driving signal
6. Work equipment operation resistor
f. EPC valve driving signal
g. Arm angle signal
h. Offset angle signal
j. Boom angle signal
10. Boom potentiometer
k. Mode signal
11. Offset potentiometer
l. Depth signal
12. Arm potentiometer
m. Electrical system signal
13. Monitor panel
n. Alarm buzzer signal
14. Alarm buzzer
p. Error code signal
15. R.H. PPC valve
r. Mode selection signal
s. Mode selection signal
17. L.H. PPC valve
t. Reset signal
u. Reset power supply
19. Reset terminal
v. Reset power supply
w. Reset power supply
21. PPC lock switch
x. Reset signal (side)
22. Neutral engine start relay (for PPC lock)
y. Reset signal (forward)
24. Engine
25. Main pump
26. Control valve
26a.Merged valve
PC58UU-3 10-117
12
INTERFERENCE PREVENTION SYSTEM
• Structure of the machine’s work equipment can introduce interference of the bucket against the canopy
or cab when you turn on the left offset operation or operation of the work equipment.This interference
potentially occurs at the front side and right side of the canopy or the cab.
• The interference prevention system constantly monitors the bucket position in order to automatically
stop movement of the work equipment and sound the alarm buzzer if the bucket approaches any of
these interfering zones.
Drawing dimension: A: 200 - 250 mm
B: 150 - 200 mm
• This function ensures work safety and operating performance in the left offset area.
• The controller constantly calculates X, Y and

Z coordinates of point A referencing output
signal from the potentiometer on rotation
angle of the boom (1), arm (3) or offset (2).
The potentiometer is provided for the boom,
the arm, and the offset.
• If point A approaches the interfering zone
(namely, if it enters reduction zone), the sys-
tem reduces moving speed of the work equip-
ment
• If the controller or one of the potentiometers
fails, the system stops movement of the work
equipment by stopping supply of power to
respective solenoid valves. In this case, work
equipment, swing and travel operation can be
resumed by turning on the emergency work
equipment operation switch.
10-118 PC58UU-3
(5)
12
Overall operation diagram

★ The bucket position in the diagram is somewhat modified from that in actual operations to facilitate
descriptions of the system function.
A. Interference
B. Emergency stop/alarm point
B1: 50 mm
B2: 50 mm
C. Stop/alarm point
C1: 200 mm
C2: 150 mm
D. Reduction start point
D1: 700 mm
E. Emergency stop zone
F. Stop zone
G. Reduction zone
H. Safety zone
PC58UU-3 10-119
12
1. Reduction function
• Speed of the bucket is reduced when it passes
through the safety zone (A) and enters the
reduction zone (B). The system ensures
smooth reduction of the bucket without intro-
ducing the "boom up" and "arm retract"
speeds.
• In order to reduce the speed, EPC valve
reduces output pressure from PPC valve to
the operation valve.
★ No speed reduction zone or function is pro-
vided for the offset.
A. Safety zone
B. Reduction zone
C. Interference zone
2. Stop/alarm function Boom RAISE
Reduction operation
• If the bucket passes through the reduction Arm IN
zone (B) and enters the interference zone (C)
its movement is automatically stopped and
the alarm buzzer is turned on.
★ The solenoid and EPC valves cut off output
Boom RAISE
pressure from the PPC valve to the operation
Stop operation Arm IN
valve to stop bucket movement.
Offset left
★ Resume bucket movement by driving the
bucket out of the stop zone using the opera- Delayed sounding
tion not currently disabled. Alarm buzzer intervals
(once every 0.8 seconds)
3. Emergency stop/alarm function
• If the bucket does not stop at the predeter-
mined stop point due to failures of the sole-
noid or EPC valves, and enters the emergency
stop zone, the system stops action of work
equipment, swing, travel, and sounds the Boom, Arm, Bucket
alarm buzzer. Stop operation
Swing, Offset, Travel
• When this function is turned on, failure must
be present on any of the equipment. In this Quick sounding interval
Alarm buzzer
case, the system notifies the operator of the (once every 0.4 seconds)
trouble by flashing the monitor panel elec-
Electronic system Quick flashing
tronic system caution lamp and displaying
caution system (once every 0.4 seconds)
"61" on the indicator.
• Using the solenoid valve, the system cuts off Depth indicator Error "61" is displayed
the source pressure from the control pump to
the PPC valve. Thus, every operation using
the PPC circuit will be disabled.
★ When this function has been turned on, you
need to resort to the cancel function for the
recovery. See the "Cancel Function" in Section
4.
10-120 PC58UU-3
12
4. Cancel function
• If the emergency stop function is turned on,
or if the controller or any of the potentiome-
ters fails, the controller will stop action of the
work equipment, swing, and travel by cutting
off signal current to the solenoid and EPC
valves.
• This situation requires your immediate check-
ups. In case the machine must be moved to a
safe place before starting the checkups, use
the emergency work equipment operation
switch (S) situated under the operator seat.
Turning this switch on allows you to move the
work equipment to any desired location.
(1) Normal position
(2) In emergency Stop cancel oper- Boom, Arm, Bucket
• As soon as the emergency work equipment ation Swing, Offset, Travel
operation switch (S) is turned on, "In emer-
Alarm buzzer Sounded for 7 seconds
gency (2)", the alarm buzzer will start sound-
ing and the electronic system caution lamp Electronic system Delayed flashing intervals
will also start flashing to notify the operator caution lamp (once every 0.8 seconds)
that the cancel function has been turned on.
★ If any failure is present in the electric system
of the solenoid or EPC valves, this cancel
function is not available.
When the error code "Failure in Solenoid Sys-
tem" is displayed on the monitor panel depth
indicator, you must not turn the emergency
work equipment switch (S) to the "In emer-
gency (2)" position.
★ When turning the emergency work equip-
ment operation switch (S) to the "emergency
(2)" position, be careful to operate the work
equipment because the interference preven-
tion function of the controller does not work.
★ The emergency work equipment operation
switch (S) is an auto-return type. Namely, if
you move your hand off the switch in the "In
emergency (2)" position, it will automatically
return to the "Normal (1)" position.
PC58UU-3 10-121
12
5. Reset function • For the correction, stop the bucket in the

1) Input signal (potentiometer mount specified position, then enter the auto-
angle) reset function matic left-and-right stop position reset
• If a potentiometer is mounted at an inap- signal. With this function, it will reference
propriate angle in its replacement or the actual output voltage from respective
replacement of work equipment, error in potentiometers, will calculate the differ-
input signal can result due to an error in ence (calculation error) between the com-
the mounting angle. puted value (A) and the standard value (B)
This reset function allows you to correct and stores it in memory as the "compen-
the error through a single switch opera- sation value (C)".
tion without measuring the output volt-
age level or resorting to fine adjustment
of the potentiometer.
• For the correction, enter the input reset
signal while maintaining the boom up,
arm retract and offset right at the stroke
end. The computer will determine the dif-
ference between the angle (A) computed
based upon actual output voltage from
respective potentiometers and the speci-
fied angle (B) on the computer (mounting
error). The difference will be stored in
memory as the "compensation value (C)".
2) Automatic fore-and-aft stop position

reset function
• When an error has resulted in the auto-
matic canopy or cab fore stop position
from errors in measuring the work equip-
ment size (used in the bucket position cal-
culation) or computer calculation error,
this function allows you to correct it in a
single switch operation.
• For the correction, stop the bucket in the
specified position, then enter the auto-
matic fore-and-aft stop position reset sig-
nal. With this function, it will reference the
actual output voltage from respective
potentiometers, will calculate the differ-
ence (calculation error) between the com-
puted value (A) and the standard value (B)
and stores it in memory as the "compen-
sation value (C)".
3) Automatic left-and-right stop posi-

tion reset function
• When an error has resulted in the auto-
matic side stop position of the cab from
errors in measuring the work equipment
size (used in the bucket position calcula-
tion) or computer calculation error, this
function allows you to correct it in a single
switch operation.
• This function can also be used for correct-
ing the stop position when an optional
narrower or wider bucket is used.
10-122 PC58UU-3
12
4) Depth indication reset function

• When an error has resulted in the depth
indication from errors in measuring the
work equipment size (used in the bucket
position calculation) or computer calcula-
tion error, this function allows you to cor-
rect it in a single switch operation.
• For the correction, place the bucket on the
ground surface at points a and then b,
then enter the depth indication reset sig-
nal when the bucket is at a as well as at b.
This function will determine the differ-
ence (calculation error) between the
actual depth (A) and the depth (B) calcu-
lated based upon the output voltage from
respective potentiometers and stores it in
memory as the "compensation value (C)".
★ A compensation value once stored will
remain undeleted if you turn off the
starter switch.
★ If the work equipment positioned signifi-
cantly away from the specified position,
the compensation value becomes 0 (zero).
In this case, the position control is turned
on without a compensation value.
The system will display an application
error code on the depth indicator to urge
the operator to retry the reset function.
★ For detailed procedures for resetting,
refer to the "Checkups and Adjustment"
section.
PC58UU-3 10-123
12
DEPTH MEASUREMENT SYSTEM

• This system facilitates your operations by dis-
playing a current digging depth or depth of a
target of measurement on the monitor panel.
• Two depth indication approaches are avail-
able from the depth measurement system.
One is a measurement from the ground level
(G. L.) and the other is that from the datum
plane.
★ When the starter switch is turned on, a mea-
surement from the ground level is automati-
cally turned on.
1. Depth-from-Ground-Level display func-

tion
• The depth (C) of the measurement level (B)
from the ground level (G.L.) is kept displayed
on the monitor panel depth indicator during
the operation.
[Setup procedure]
• Turn the starter switch on and this function
will be automatically started.
[Display method]
• Depth under the ground level is displayed in
0.1 mm steps.
★ Fractions are rounded off at two decimal
places.
• A height above the ground level is preceded
by the indication "UP".
★ You must stretch the bucket straight when
setting the zero point in this display system. If
the bucket is in any other position, discrep-
ancy (E) can result from the displayed and
actual depth.
★ If you select the Depth-from-Datum-Plane Dis-
play Function, this function will be cancelled.
10-124 PC58UU-3
(5)
12
2. Depth-from-Datum-Plane display func-

tion [Depth 0 set mode]
• This function displays a depth from any
datum plane you set on the monitor panel
depth indicator as long as your operation is
continued.
★ If you select this function, the Depth-from-
Ground-Level display Function is automati-
cally cancelled.
[Setup procedures]
• Turn the mode select switch to the [Depth Dis-
play 0 Set] position.
• Move the bucket to the datum plane (A).
• Shift the setup switch to the SET position,
then make sure that "0.0" is displayed on the
depth indicator.
★ Set the bucket in the same position when the
datum plane (A) is set and when the bucket is
placed on the measurement level (B).
[Display method]
• Depth below the datum plane (A) is indicated
in 0.1 mm steps.
★ Fractions are rounded off at two decimal
places.
• A depth above the datum plane (A) will be
preceded by the indication "UP".
[Canceling procedures]
• Turn the mode select switch to the [Depth Dis-
play 0 Set] position.
• Turn the setup switch to the CLEAR position.
★ If you cancel this function, the "Depth-from-
Ground-Level Display Function" will be
restored on the depth indicator.
• Explanatory notes on the depth measurement

C = Yc - Ya
D = Yc - Yb
C : Depth from the ground level (G.L.)
D : Depth from the datum plane.
Ya : Depth from the boom foot to the ground
level (constant)
Yb : Depth from the boom foot to any datum
plane selected
Yc : Depth from the boom foot to the
measurement level
PC58UU-3 10-125
12
AUTOMATIC HEIGHT STOP SYSTEM

• Automatic height stop function is capable of
stopping movement of the boom when it
reaches the predetermined height during
operation.
• These functions are helpful in ensuring work
safety and efficiency when working in job
sites where obstacles such as electric wires
are present.
1. Height setup function [height mode]

• You can stop movement of the boom during
operation at any height (A) you have previ-
ously set.
• You can limit the height of the work equip-
ment by setting the limit on the boom lift
height.
• This function reduces speed of the boom
prior to the forced stop to minimize resulting
shocks or impacts.
★ Note that this function is not usable for limit-
ing the bucket height.
[Setup procedures]
• Shift the mode select switch to the "Height".
• Lift the boom up to the height where you
want to set the limit.
• Turn the setup switch to the "SET" position to
make sure that the buzzer is sounded two
times and the indicator lamp comes on.
[Operation]
• When the above setting is complete, lower
the boom once. Now, whenever the boom
reaches the specified height during operation,
its movement will be stopped there.
• This stop is caused by reducing and then
shutting down the output pressure from the
PPC valve to the boom operation valve (UP
side) at the EPC valve.
A: Setup position
B: Setup angle
C: Operation possible zone
D: Operation impossible zone
• Shift the mode switch to the “Height”.

• Turn the setup switch to the “CLEAR” posi-
tion, then make sure that the indicator lamp is
turned off.
10-126 PC58UU-3
(5)
12
BOOM END CUSHIONING FUNCTION
• In the boom up move, this function reduces
speed of the boom before it reaches the
stroke end to lighten resulting impacts and,
thus, to prevent spillage of dirt or dust as well
as lighten load to the machine body and cyl-
inder.
[Operation]
• A cushioning zone is provided before the
boom-up stroke end (approximately 35°).
• This function reduces move speed of the
boom in this zone by reducing output pres-
sure from the boom PPC valve to the boom
operation valve (UP move) at the EPC valve.
• This arrangement helps reducing undesirable
impacts at the stroke end.
ARM END CUSHIONING FUNCTION
• In the arm retract move, this function reduces
speed of the arm before it reaches the stroke
to lighten resulting impacts and, thus, to pre-
vent spillage of dirt or dust as well as lighten
load to the machine body and cylinder.
[Operation]
• A cushioning zone is provided before the arm
retract stroke end (approximately 20°.
• This function reduces move speed of the arm
in this zone by reducing output pressure from
the arm PPC valve to the arm operation valve
(RETRACT move) at the EPC valve.
• This arrangement helps reduce undesirable
impacts at the stroke end.
SELF-TEST FUNCTION
1. Error code indication and alarm function
• The controller constantly monitors electronic
equipment consisting the system for normal
operation. These components include the
controller itself, potentiometers to generate
input signals, and solenoid valves and EPC
valves to receive output signals.
• If any of the electric equipment fails, the con-
troller diagnoses the symptom and notifies
the results to the operator by displaying a
corresponding error code on the monitor
panel. At the same time, it alerts the operator
attention by flashing the electric system cau-
tion lamp and sounding the alarm buzzer.
• For further information on the display and
remedial actions, refer to the "Checkups and
Adjustment" section.
2. Error code memory function
• If the advanced system has any trouble, it
executes the self-diagnosis and stores the
error code.
• For further information on the display, reset,
etc., refer to the "Checkups and Adjustment"
section.
PC58UU-3 10-127
(5)
12
SYSTEM COMPONENTS
ENGINE SPEED SENSOR
Function
• The engine speed sensor is installed on the

cover of the engine flywheel. It electrically 1. Connector
counts the number of gear teeth that pass its 2. Sensor
front side and sends the counting to the con-
troller.
Remarks: Number of ring gear teeth is 116.
PPC OIL PRESSURE SWITCH
1. Plug 3. Connector
2. Switch
Specifications
Contact: Normally open
Turning ON pressure: 490±98.1 kPa {5.0±1.0 kg/cm²}
Turning OFF pressure: 294±49.0 kPa {3.0±0.5 kg/cm²}
Operation
• Five switches of this type are attached to the operation valves.
These switches sense accuation of respective accuators by the
pressure of the PPC valve, and send the signal to the controller.
10-128 PC58UU-3
(5)
12
CONTROLLER
Model selection table Set/clear selection table

CN-G2, 37P CN-G2, 27P CN-G2, 7P CN-G2, 16P CN-G2, 2P CN-G2, 38P
PC58UU-3 X X X O Set O X
Clear X O
Attachment selection table

CN-G1, 17P CN-G1, 11P CN-G2, 17P
Standard arm O X O Deceleration motor installation signal
Long arm X O X CN-G2, 6P
Standard arm Motor less X

O X O
X-counter weight Motor installation O
Long arm
X O O
X-counter weight
Slide arm X X X
Arm crane installation signal
Multiple changer arm O O X
CN-G2, 28P
Standard specification X
Mode selection table
Crane specification O
CN-G2, 13P CN-G2, 3P
Depth display 0 set X X
Height setup O X
★ 1 X O
★ 2 O O
PC58UU-3 10-129
(5)
12
Input/output signals
DEUTSCH-24P [CN-G1]
Pin No. Signal name I/O signal Pin No. Signal name I/O signal
1 NC — 13 NC —
2 Boom cylinder bottom pressure sensor Input 14 Offset angle Input
3 Boom angle Input 15 NC —
4 GND signal — 16 NC —
5 2nd speed travel selection switch Input 17 Attachment 1 Input
6 NC — 18 Travel pressure switch Input
7 NC — 19 Boom cylinder head pressure sensor Input
8 Slide capacity Input 20 Arm angle Input
9 NC — 21 GND Analog —
10 GND signal — 22 Sensor power (+5 V) Output
11 Attachment 2 Input 23 NC —
12 NC — 24 NC —
DEUTSCH-40P [CN-G2]
1 NC — 21 S-NET Input/output
2 Set Input 22 CAN0-L Input/output
3 Mode select 2 Input 23 CAN1-L Input/output
4 232C_RxD Input 24 Prevention signal for writing in flash memory Input
5 NC — 25 NC —
6 Deceleration motor installation signal Input 26 Reset 2 Input
7 UU/US selection signal Input 27 Mode selection 2 Input
8 Electrical system Output 28 Arm crane installation signal Input
9 Data Output 29 GND pulse —
10 NC — 30 NC —
11 NC — 31 GND (S-NET) —
12 CAN shield — 32 CAN0-H Input/output
13 Mode selection 1 Input 33 CAN1-H Input/output
14 232C_RxD Output 34 GND (232C) —
15 Back-up light signal Input 35 Cancel signal for arm angle alarm Input
16 Main monitor selection signal Input 36 Reset 1 Input
17 Mode selection 3 Input 37 Mode selection 1 Input
18 Strobe Output 38 Clear Input
19 Clock Output 39 GND pulse —
20 Slide arm limit switch Input 40 Engine speed sensor (+) Input
DEUTSCH-40P (2) [CN-G3]

1 Controller power Input 21 GND controller —
2 Solenoid power Input 22 Solenoid power Input
3 GND solenoid — 23 GND solenoid —
4 NC — 24 Key signal Input
5 Arm IN EPC valve Output 25 Governor motor relay (for acceleration) Output
6 NC — 26 Boom RAISE EPC valve Output
7 NC — 27 2nd speed travel selector solenoid valve Output
8 One-touch deceleration pilot lamp Output 28 NC —
9 One-touch deceleration switch Input 29 Deceleration signal Input
10 Air compressor signal Input 30 Emergency work equipment operation switch Input
11 Controller power Input 31 GND controller —
12 Solenoid power Input 32 GND controller —
13 GND solenoid — 33 GND controller —
14 Key signal Input 34 NC —
15 Offset left stop solenoid Output 35 Governor motor relay (for deceleration) Output
16 TVC solenoid valve Output 36 NC —
17 Swing and travel alarm Output 37 Arm crane relay Output
18 Governor motor relay (for drive) Output 38 PPC lock solenoid valve Output
19 Acceleration signal Input 39 Auto-deceleration signal Input
20 NC — 40 NC —
10-130 PC58UU-3
12
POTENTIOMETER
1. Shaft 4. Brush
2. Housing 5. Resistor
3. Bearing 6. Connector
Functions
• A potentiometer is installed on each of the

boom feet, arm foot and second boom top to
detect the angle of the boom, arm and offset
work equipment.
• Using the resistance value of the variable
resistor, potentiometers send angle data to
the controller by converting the supply volt-
age (5V) into signal voltage according to the
angle of the work equipment.
PC58UU-3 10-131
(5)
12
RESISTOR
1. Resistor
2. Connector
Specification
System Resistance Value (Ω)
For boom RAISE stop EPC valve

3
For arm IN EPC valve
For main pump TVC-EPC valve 10
Function
• This resistor supplies a proper current to each

EPC valve according to the condition when
the emergency work equipment operation
switch or the emergency pump drive switch is
turned "ON".
Boom RAISE stop EPC valve

Arm IN stop EPC valve
Offset left stop solenoid valve
PPC lock solenoid valve
2nd speed travel selector solenoid valve
★ (See the "(EPC) solenoid valve".)
★ "See the Monitor panel".
10-132 PC58UU-3
(5)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
12
MONITOR SYSTEM
• This system monitors the machine status

using sensors installed on various parts of the
machine, processes the monitoring data and
displays the current machine status on the
panel for the operator to view.
PC58UU-3 10-133
12
MONITOR PANEL
Overview
• The monitor panel is provided with the moni- • If there is any abnormality in the monitor
tor display function, gauge display function, panel, controller, or wiring between the moni-
service meter function and advanced system tor panel and controller, the monitor does not
display function. display normally.
• It is also equipped with a CPU, which is used
to process, display and output the data.
Input/output signal
AMP040-16P [CN-F27]
1 Power supply (12 V) — 9 Engine oil pressure Input

2 Strobe Input 10 Charge volume Input
3 GND — 11 Electric system signal Input
4 GND (CWT.) — 12 Serial lock Input
5 Start signal Input 13 Preheat Input
6 Coolant temperature Input 14 Caution Input
7 Fuel level Input 15 Alarm buzzer Output
8 Serial data Input 16 Nighttime lighting Input
10-134 PC58UU-3
(5)
12
OPERATION
Display Display
No. Display item Display range Display method Remarks
section color
Time is measured while engine is running (alternator is gen- Time is
1 Service meter 0 - 99999.9 h —
erating power). displayed
While service
2 Service meter indicator meter is Flashes while service meter is operating. Green Lamp
operating
Setting of When boom
! Indicator work equip- rising distance
Lights up when boom rising distance is set to ""Height"" of
3 mode selection switch."
ment height is set
Only 1 corresponding segment lights up.
Coolant
4 [Segment flashes and buzzer sounds only when temperature Blue LCD
temperature
See above is in top level (above 105°C).]
Gauge
figure. Segment of corresponding level and all segments below it
5 Fuel level light up.
[Segments flash only when level is in lowest level (Empty).]
When Lights up (for about 18 seconds) when starting switch is
6 Pilot Preheating pre-heater is turned to HEAT position, then goes off to show that preheat- Green Lamp
turned on ing is finished.
• Displays depth of bucket from ground level.
0 - 9.9 m
! Depth Depth error
2 alpha numer-
• Displays "UP" when bucket is above ground level.
Blue LCD
7 indication code • Displays depth from datum plane in depth 0 set mode.
ics
• Displays 2-figure number if advanced system has trouble.
Lights up when starting switch is turned to ON position and
goes off after engine starts.
When advanced
! Electric
system has
Meaning of display is as follows.
8 system When normal: Goes off.
trouble
When abnormal: Lights up or flashes, and buzzer
sounds.
When charging
is abnormal
Caution Lights up when starting switch is turned to ON position and Red Lamp
9 Charge level (Charge volt-
age < Battery goes off after engine starts.
voltage) Meaning of display is as follows.
When normal: Goes off.
When below
When abnormal: Lights up.
specified
Engine oil (If trouble occurs while engine is running, buzzer
10 pressure
pressure sounds.)
49 kPa
(0.5 kg/cm²)
! For display and operation method marked with !, see "Advanced system" section.
PC58UU-3 10-135
(5)
12`
SENSORS
• Signal from a sensor is directly entered into • One end of a contact type sensor is connected
the panel. to the ground on the machine body.
• There are two types of sensors, contact type
and resistance type.
Display class Sensor type Sensing approach When normal When failed
Caution Engine oil pressure Contact OFF (open) ON (closed)
Coolant temperature Resistance — —

Gauge
Fuel level Resistance — —
ENGINE OIL PRESSURE SENSOR
1. Plug 3. Contact 5. Spring

2. Contact ring 4. Diaphragm 6. Terminal
Function specified level, the switch is turned on and a
• The engine oil pressure sensor is installed to signal is sent to the monitor panel.
the engine cylinder block. If the oil pressure
sensed by the diaphragm (4) is below the
COOLANT TEMPERATURE SENSOR
1. Connector
2. Plug
3. Thermistor
Function
• The coolant temperature sensor is installed to
the engine cylinder block. It senses the tem-
perature change as a resistor change of the
thermistor (3) and sends a temperature signal
to the monitor panel.
10-136 PC58UU-3
(5)
12
FUEL LEVEL SENSOR
1. Float 4. Variable resistor

2. Arm 5. Contact
3. Connector 6. Body
Function
• The fuel level sensor is installed to the fuel

tank. The float (1) moves up and down
according to the fuel level. The float (1) oper-
ates the variable resistor (4) through the arm
(2) and sends a signal to the monitor panel.
PC58UU-3 10-137
(5)
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE

Standard value table for engine . . . . . . . . . . . 20-2
Standard value table for chassis . . . . . . . . . . . 20-3
Standard value table for electrical parts . . . . 20-12
TESTING AND ADJUSTING . . . . . . . . . . . . . . 20-101
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 20-201
★ Note the following when making judgements using the standard value tables for testing, adjust-
ing, or troubleshooting.
1. The standard value for a new machine given in the table is the value used when shipping the
machine from the factory and is given for reference. It is used as a guideline for judging the
progress of wear after operating the machine, and as a reference value when performing
repairs.
2. The service limit value given in the tables is the estimated value for the shipped machine based
on the results of various tests. It is used for reference together with the state of repair and the
history of operation to judge if there is a failure.
3. These standard values are not the standards used in dealing with claims.
When carrying out testing, adjusting, or troubleshooting, park the machine on level
ground, insert the safety pins, and use blocks to prevent the machine from moving.
When carrying out work together with other workers, always use signals and do not let
unauthorized people near the machine.
When checking the engine coolant level, always wait for the water to cool down. If the
radiator cap is removed when the water is still hot, the water will spurt out and causes
burns.
Be careful not to get caught in the fan, fan belt, or other rotating parts.
PC58UU-3 20-1
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE

Serial No.: 20001 – 22000
Applicable model PC58UU-3

Engine 4D88E-3GB
Standard value for new
Item Measurement conditions Unit Service limit value
machine
High idling rpm 2,550 ± 50 —
Engine Speed Low idling rpm 1,150 ± 25 —
Rated speed rpm 2,400 —
At sudden acceleration Bosch Max. 3.0 Max. 5.0
Exhaust gas color
At high idling index Max. 1.5 Max. 2.5
Valve clearance Intake valve 0.2 —
mm
(normal temperature) Exhaust valve 0.2 —
Oil temperature:
Compression pressure 40 - 60°C MPa 3.43 ± 0.1 0.28 ± 0.1
(SAE 30 oil)
(engine speed: 250 rpm) {kg/cm²} {35 ± 1} {28 ± 1}
(Water temperature:
Blow-by pressure Operating range) Pa
— —
(SAE 30 oil) {mm H2O}
At high idling
(Water temperature:
Operating range)
At high idling (SAE 30) MPa 0.32 - 0.47 {3.3 - 4.8} Min. 0.2 {2.1}
Oil pressure
At high idling (SAE 10W) {kg/cm²} 0.32 - 0.47 {3.3 - 4.8} Min. 0.2 {2.1}
At low idling (SAE 30) Min. 0.15 {1.5} Min. 0.1 {1.0}
At low idling (SAE 10W) Min. 0.15 {1.5} Min. 0.1 {1.0}
Whole speed range
Oil temperature °C Max. 120 Max. 120
(inside oil pan)
Fuel injection timing Before top dead center deg 14 ± 1 —
Deflection when pressed
Fan belt tension with finger force of approx. mm 5-6 —
58.8 N {6 kg}
20-2 PC58UU-3
(6)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Applicable model PC58UU-3

Engine 4D88E-5XBB
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idling rpm 2,590 ± 50 —
Engine Speed Low idling rpm 1,200 ± 25 —
Rated speed rpm 2,400 —
At sudden acceleration Bosch Max. 4.0 Max. 5.0
Exhaust gas color
At high idling index Max. 1.0 Max. 2.5
Valve clearance Intake valve 0.2 —
mm
(normal temperature) Exhaust valve 0.2 —
Oil temperature:
Compression pressure 40 – 60°C MPa 3.43 ± 0.1 0.28 ± 0.1
(SAE 30 oil) {kg/cm²}
(engine speed: 250 rpm) {35 ± 1} {28 ± 1}
(Water temperature:
Blow-by pressure Operating range) Pa
— —
(SAE 30 oil) {mm H2O}
At high idling
(Water temperature:
Operating range)
At rated apred MPa
Oil pressure 0.39 – 0.54 {4.0 – 5.5} Min. 0.2 {2.1}
(Oil temp.: 80°C) {kg/cm²}
At low idling (SAE 30) Min. 0.15 {1.5} Min. 0.1 {1.0}
At low idling (SAE 10W) Min. 0.15 {1.5} Min. 0.1 {1.0}
Whole speed range
Oil temperature °C Max. 120 Max. 120
(inside oil pan)
Fuel injection timing Before top dead center deg 15.5 ± 1 —
Deflection when pressed
Fan belt tension with finger force of approx. mm 8 – 10 —
58.8 N {6 kg}
PC58UU-3 20-2-1
(6)
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS

Applicable Model PC58UU-3
Cate- Standard value Service limit
gory Item Measurement Conditions Unit for new machine value
• Hydraulic oil temperature: 45 - 55°C
Engine Speed
At 1-pump relief Min. 2,400 Min. 2,400

• Engine water temperature:
Within operating range rpm
• Engine oil temperature: Normal
At 2-pumps relief Min. 2,100 Min. 2,100
• 1-pump relief ---------Bucket relief
Boom control valve l a b l a b
Arm control valve
Bucket control valve
Offset control valve

30 6 6 30 6 6
Swing control valve
Spool stroke
L.H. travel control

valve mm
R.H. travel control
valve
Blade control valve 20 6 6 20 6 6
Boom control lever • Center of lever knob N! RAISE, LOWER

Arm control lever • Tip of pedal N! IN, OUT
Bucket control lever • Read max. value to N! CURL, DUMP 80 ± 10 80 ± 10
end of travel
Travel of control lever
Swing control lever • Engine stopped N! LEFT, RIGHT
Offset control lever N! LEFT, RIGHT 25 ± 5 25 ± 5

Blade control lever N! RAISE, LOWER mm 50 ± 5 50 ± 5
Travel control lever N! FORWARD, REVERSE 120 ± 15 120 ± 15
Boom, arm, bucket, Max. 5 Max. 5
swing control lever
Play of control lever Travel control lever Max. 20 Max. 20

Blade control lever Max. 15 Max. 15
Offset control lever Max. 4 Max. 4
PC58UU-3 20-3
1

Operating effort of control lever and pedal
15.7 ± 2.94 15.7 ± 2.94

Boom control lever {1.6 ± 0.3} {1.6 ± 0.3}
15.7 ± 2.94 15.7 ± 2.94
Arm control lever {1.6 ± 0.3} {1.6 ± 0.3}
• Engine at full throttle
15.7 ± 2.94 15.7 ± 2.94
Bucket control lever • Hydraulic oil temperature: 45 - 55°C {1.6 ± 0.3} {1.6 ± 0.3}
• Fit push-pull scale to center of control lever
15.7 ± 2.94 15.7 ± 2.94
Swing control lever knob to measure N {kg} {1.6 ± 0.3} {1.6 ± 0.3}
• Fit push-pull scale to tip of control pedal to 78.4 ± 15.7 78.4 ± 15.7
Offset control lever measure {8.0 ± 1.6} {8.0 ± 1.6}
• Measure max. value to end of travel 29.4 ± 5.9 29.4 ± 5.9
Blade control lever {3.0 ± 0.6} {3.0 ± 0.6}
19.6 ± 3.92 19.6 ± 3.92
Travel control lever {2.0 ± 0.4} {2.0 ± 0.4}
Unload pressure • All control levers at HOLD 2.9 ± 0.5 2.9 ± 0.5
{30 ± 5} {30 ± 5}
Boom
Arm 26.0 +1.0
-0.5 26.0 +1.0
-0.5
Bucket {265 +10
-5 } {265 +10
-5 }
Offset
20.6 +1.5
-0.5 20.6 +1.5
-0.5
Swing • Hydraulic oil temperature: 45 - 55°C
{210 +15
-5 } {210 +15
-5 }
• Relief pressure at engine full
Hydraulic pressure
(Relieve only circuit to be measured) +1.5

21.6 -0.5 21.6 +1.5
-0.5
Blade • Pump outlet port pressure
{220 +15
-5 } {220 +15
-5 }
MPa
{kg/cm²} 26.0 +1.0
-0.5 26.0 +1.0
-0.5
Travel
{265 +10
-5 } {265 +10
-5 }
2.94 +0.5
-0.1 2.94 +0.5
-0.1
Control
+5 }
{30 -1 +5 }
{30 -1
• Hydraulic oil temper-
All control levers at 3.2 ± 0.49 3.2 ± 0.49
ature: 45 - 55°C HOLD {33 ± 5} {33 ± 5}
★ LS differential pres-
LS differential sure = Pump outlet
pressure port pressure - LS
pressure
★ Measure on PP pres- At operating bucket 1.57 ± 0.1 1.57 ± 0.1
sure detection port, CURL with empty {16 ± 1} {16 ± 1}
LS3 pressure detec-
tion port
20-4 PC58UU-3
1

Overrun when stop- Deg. 30 ± 5 Max. 40

ping swing
• Stop after swinging one turn and measure dis-
tance that swing circle moves
90° 2.9 ± 0.2 Max. 3.4
Time taken to start

swing Sec.

180° — —
• Time taken to swing 90° and 180° from
Swing
Time taken to swing Sec. 30 ± 3 Max. 36

• Swing one turn, and measure time taken to
swing next 5 turns
• Posture when measuring: Max. reach, bucket at
rated load or full of soil (rated load: 3.53 kN
{360 kg}.)
Hydraulic drift of Deg. 0 0

swing {mm} (0) (0)
• Engine stopped
• Set machine on 15° slope, and set upper struc-
ture at an uphill angle of 45°.
• Make match marks on swing circle outer race
and track frame.
• Measure distance that match marks move
apart after 15 minutes.
Leakage from swing • Hydraulic oil temperature: 45 - 55°C cc/min. — —
motor
• Relieve swing circuit.
PC58UU-3 20-5
1

28.8 ± 2 28.8 ± 4
Lo (26.7 ± 2) (26.7 ± 4)
Travel speed Sec.

• Hydraulic oil temperature: 45 - 55°C Hi 17.1± 2 17.1 ± 4
(16 ± 2) (16 ± 4)
• Run up for at least 10 m, and measure time
taken to travel next 20 m on flat ground.

Travel deviation • Run up for at least 10 m, and measure devia- mm Max. 300 Max. 330
(At Hi or Lo) (At Hi or Lo)
tion when traveling next 20 m on flat ground.
★ Use a hard horizontal surface.
Travel
★ Measure dimension x
Hydraulic drift of mm 0 0
travel
• Engine stopped
• Stop machine on 30° slope with sprocket fac-
ing straight up the slope.
• Measure the distance the machine moves in 5
minutes.
Leakage from travel • Hydraulic oil temperature: 45 - 55°C
motor
l/min. — —
• Lock shoes and relieve travel circuit
20-6 PC58UU-3
1

Total work
equipment
(hydraulic drift Max. 300 Max. 450
at tip of bucket
teeth)
Boom cylinder
Hydraulic drift of work equipment
(amount of
retraction of cyl- Max. 10 Max. 15
inder) • Place in above posture and measure extension
or retraction of each cylinder and downward
Arm cylinder movement at tip of bucket teeth.
(amount of • Horizontal, flat ground
extension of cyl- Max. 30 Max. 45
mm
inder) • Bucket: Rated load 3,530 N {360 kg}
• Levers at HOLD
Bucket cylinder • Engine stopped
(amount of • Hydraulic oil temperature: 45 - 55°C Max. 15 Max. 22
retraction of cyl-
inder) • Start measuring immediately after setting.
• Measure hydraulic drift every 5 minutes, and
• Engine stopped
Blade • Hydraulic oil temperature: 45 - 55°C
(hydraulic drift • Set blade at maximum lifting height and mea- Max. 30 Max. 45
at tip of blade) sure downward movement at edge of blade for
15 minutes.
Work equipment
RAISE
Boom
Bucket teeth in 3.0 ± 0.3 Max. 3.6
contact with
ground
↕
LOWER
Cylinder fully • Engine at full throttle

3.3 ± 0.3 Max. 3.9
extended • Hydraulic oil temperature: 45 - 55°C
• Automatic control for second boom: ON
Work equipment speed
IN
3.3 ± 0.3 Max. 3.9

Arm cylinder
fully retracted
↕ Sec.
Fully extended
OUT
3.1 ± 0.3 Max. 3.7

CURL
3.3 ± 0.3 Max. 3.9

Bucket cylinder
fully retracted
↕
DUMP
Fully extended
2.2 ± 0.3 Max. 2.8
PC58UU-3 20-7
1

Left offset
3.7 ± 0.4 Max. 4.3
Offset cylinder
fully retracted
↕
Right offset
Work equipment speed
Fully extended
3.7 ± 0.4 Max. 4.3
RAISE
Blade 1.1 ± 0.2 Max. 1.8
Blade in contact
with ground
↕
LOWER
Blade fully
raised • Engine at full throttle 1.2 ± 0.2 Max. 1.9

Work equipment
Sec.
Boom Max. 2 Max. 3.9

• Engine at low idling
• Fully retract arm and bucket cylinders, then
lower boom from maximum height and mea-
sure time taken from point where bucket con-
Time lag
tacts ground to point where chassis rises from

ground.
Arm 0 Max. 1
• Set top of surface of boom horizontal, retract
bucket cylinder fully, the extend arm cylinder
and measure time taken for arm to start mov-
ing again after stopping at bottom.
20-8 PC58UU-3
1

Bucket 0 Max. 1

• Set top of surface of boom horizontal, retract
arm cylinder fully, then extend bucket cylinder
and measure time taken for bucket to start
Time lag
moving again after stopping at bottom.

Sec.
Work equipment
Blade Max. 1 Max. 2

• Lower blade from maximum height and mea-
sure time taken from point where blade con-
tacts ground to point where chassis rises from
ground.
Internal leakage

Cylinders ml/min. Max. 2.5 Max. 10
• Relieve circuit to be measured
PC58UU-3 20-9
1


Gear pump • Engine at rated speed l/min 33.0 27.1
• At relief pressure
Piston pump discharge amount [gear pump 2.9 MPa {30 kg/cm²}]
• STD mode
Hydraulic pump discharge amount
Hydraulic pump performance
• Rated speed of pump: 2,400 rpm

Test pump discharge Standard value for Judgement
Check point pressure Average pressure discharge amount standard value
MPa {kg/cm²} MPa {kg/cm²} (l/min) Q {kg/cm²}
As desired P1 P1 See graph See graph
★ The error is large near the point where the graph curves, so avoid measuring at this point.
20-10 PC58UU-3
1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
System Component name Connector Inspection Criteria Measurement

No. Method conditions
If the condition is within the range shown in the 1) Turn starting
table below, it is normal. switch OFF.
2) Insert
Power supply
G3
Measure Between b, 1! ~ d, 2# T-adapter
voltage voltage 10 ~ 16V 3) Turn starting
Between c, 1@, 2@ ~ d, 1#, 2# switch ON.
1) Turn starting
If the condition is within the range shown in the switch OFF.
table below, it is normal.
2) Insert
Power supply Measure T-adapter
for sensors G1 voltage Between 2@ ~ 2! 4.9 ~ 5.1V
3) Turn starting
switch ON.

2) Insert
Model Selec- Measure Selected pins 0 ~ 1V T-adapter
tion G1 voltage 3) Turn starting
Pins other than above 8 ~ 16V switch ON.
Electric system

Controller
table below, it is normal. switch ON.

2) Monitoring
Crane code [01] is
Work Standard Crane +
Work equip- Monitoring Measure equipment displayed.
Counterweight
ment selection code [1] voltage
STD 00 A0 C0
Long arm 01 A1 C1

2) Insert
When input Between 2^ ~ chassis 0 ~ 1V T-adapter
Measure signal is reset Between 3^ ~ chassis 10 ~ 16V 3) Turn starting
Reset signal G2 voltage switch ON.
When output Between 2^ ~ chassis 10 ~ 16V
signal is reset Between 3^ ~ chassis 0 ~ 1V
1) Turn starting
2) Insert
T-adapter
Boom potenti- Measure Between 2@ ~ 2! 4.9 ~ 5.1V
G1 3) Turn starting
ometer voltage
switch ON.
Between d ~ 2! 0.5 ~ 0.9V
4) Raise boom
to stroke end.
PC58UU-3 20-11
1
Connector Inspection Measurement

System Component name No. Method Criteria conditions
1) Turn starting
2) Insert
T-adapter
Arm potenti- Measure Between 2@ ~ 2! 4.9 ~ 5.1V
ometer G1 voltage 3) Turn starting
switch ON.
Between 2) ~ 2! 0.6 ~ 1.0V
4) Move arm in
to stroke end.
1) Turn starting
Controller
2) Insert
T-adapter
Offset potenti- Measure Between 2@ ~ 2! 4.9 ~ 5.1V 3) Turn starting
ometer G1 voltage switch ON.
Between 1$ ~ 2! 1.3 ~ 1.9V 4) Move right
offset to
stroke end.

2) Insert
Left offset stop Measure When operated 10 ~ 16V T-adapter
solenoid valve K1 voltage Between
15 ~ chassis 3) Turn starting
When not operated 0 ~ 3V switch ON.

Electric system
2) Disconnect
Between 0.2 ~ 7kΩ connector.
Boom M14 Measure
potentiometer resistance Between 0.2 ~ 7kΩ
Between 4 ~ 6kΩ

2) Disconnect
Arm Measure
potentiometer W4 resistance Between 0.2 ~ 7kΩ
Between 4 ~ 6kΩ

2) Disconnect
Offset W3 Measure
potentiometer resistance Between 0.2 ~ 7kΩ
Between 4 ~ 6kΩ

2) Disconnect
Boom RAISE stop F11 Measure Between F11(male) ~ F11(female) 3 ~ 15Ω connector.
EPC valve resistance
Between F11 ~ chassis Min. 1MΩ
20-12 PC58UU-3
1

2) Disconnect
Arm IN stop EPC F10 Measure Between F10(male) ~ F10(female) 3 ~ 15Ω connector.
valve resistance

2) Disconnect
Left offset stop F9 Measure Between F9(male) ~ F9(female) 5 ~ 25Ω connector.
solenoid valve resistance

2) Disconnect
PPC lock solenoid
F7
Measure Between F7(male) ~ F7(female) 5 ~ 25Ω connector.
valve resistance

2) Disconnect
Electric system
Pump TVC Measure Between M11(male) ~ M11(female) 3 ~ 15Ω connector.

solenoid valve M11 resistance
Between M11 ~ chassis Min. 1MΩ

2) Disconnect
Engine speed
M9
Measure Between male b ~ c 2,100 ~ 2,500Ω connector.
sensor resistance
Between male c ~ chassis Min. 1MΩ
★ At normal temperature (25°C)

2) Disconnect
Travel speed rais-
F8
Measure Between F8(male) ~ F8(female) 5 ~ 25Ω connector.
ing solenoid valve resistance

2) Disconnect
When pedal is in
(Male) neutral Min. 1MΩ connector.
Travel speed rais- Measure b~c When pedal is

ing switch
M9
resistance pressed Max. 1Ω
(Male)
— Min. 1MΩ
b, c ~ chassis
PC58UU-3 20-13
1

If the condition is within the range shown in the table below, it is normal. 1) Connect
T-adapter.
Table 1 (Check and caution section)
Monitor item Measurement Sensor input
Machine monitor system
Indication
(Input connector) condition signal
Engine oil pressure Lamp ON Max. 1V
Monitor panel
Start engine.
F27 j Lamp OFF 10 ~15V
Check and cau-
tion section Charge level Lamp ON Max. 5V
Start engine.
F27 1) Lamp OFF 10 ~15V
Preheating Lamp ON 10 ~15V
Stop engine.
F27 1# Lamp OFF Max. 1V
Electric system Lamp ON 8 ~15V
—
F27 1! Lamp OFF Max. 1V
20-14 PC58UU-3
1

Table 2 (Gauge section) 1) Turn starting
switch OFF
Display level for resistance and insert
Gauge display position (Monitor panel input sensor dummy resis-
Turn starting switch ON. Turn starting switch OFF. tance or
measure
Min. ~ Max. resistance of
(kΩ) sensor.
Measure Right side All lamps OFF 0 ~ 0.34
2) Turn starting
resistance 7 0.05 ~ 3.40 ON and check
of coolant display.
tempera-
# 6 3.19 ~ 3.67
ture gauge 5 3.46 ~ 4.19 3) Connect
Display socket.
F27(female) position
Monitor panel
4 3.95 ~ 6.75
between
g~d 3 6.36 ~ 10.05
Gauge section $
2 9.47 ~ 15.1
Left side 1 13.75 ~ Disconnection
Min. ~ Max.
(kΩ)
Right side 7 0 ~ 15.7

Measure
resistance 6 12.6 ~ 24.0
of fuel level # 5 20.5 ~ 30.6
gauge
Machine monitor system
Display 4 26.7 ~ 39.6

F27(female)
position 3 35.2 ~ 51.6
between
h~d 2 46.5 ~ 78.0
$
1 71.2 ~ 800
Left side All lamps OFF 500 ~ Disconnection
If the condition is within the range shown in the 1) Start engine.
table below, it is normal. 2) Disconnect
terminal.
Between sensor Min. 0.7 kg/cm² Min. 1MΩ
Engine oil pressure M5 Measure
sensor resistance
terminal ~ chassis Max. 0.3 kg/cm² Max. 1Ω

2) Disconnect
Normal temper- Approx. connector.
Coolant tempera- Measure ature (25°C) 37 ~ 50kΩ
ture sensor M10 resistance Between b ~ c
100°C Approx.
3.5 ~ 4.0kΩ

2) Disconnect
Fuel level sensor M1 Measure Full 9.5 ~ 11.0 Ω connector.
resistance Between
M1(male) ~ M1(female)
Empty 82 ~ 92 Ω
Between While engine is running (½ throttle or higher) ! 1) Start engine.

alternator L 13.5 ~ 14.5V
Alternator Measure #If battery is deteriorated or machine is used in
terminal ~ voltage cold district, voltage may not rise for a while
chassis after engine is started.
PC58UU-3 20-15
1
Tools for testing, adjusting, and troubleshooting ......................................................................................... 20-102

Measuring engine speed............................................................................................................................. 20-103
Measuring engine oil pressure .................................................................................................................... 20-103
Measuring compression pressure ............................................................................................................... 20-104
Adjusting valve clearance ........................................................................................................................... 20-105
Testing and adjusting fuel injection timing................................................................................................... 20-106
Testing and adjusting alternator belt tension............................................................................................... 20-107
Adjusting fuel control linkage ................................................................................................................... 20-107-1
Measuring exhaust color ............................................................................................................................. 20-108
Testing clearance of swing circle bearing ................................................................................................ 20-108-1
Checking wear of sprocket.......................................................................................................................... 20-109
Testing and adjusting track shoe tension .....................................................................................................20-110
Adjusting brade control lever .......................................................................................................................20-111
Testing and adjusting hydraulic pressure in work equipment, swing, and travel circuits..............................20-112
Testing and adjusting LS differential pressure .............................................................................................20-114
Adjusting PC valve .......................................................................................................................................20-115
Testing and adjusting hydraulic pressure in control pump circuit .................................................................20-116
Measuring solenoid valve output pressure ..................................................................................................20-117
Measuring PPC valve output pressure ........................................................................................................20-119
Adjusting PPC valve ................................................................................................................................... 20-121
Testing swing holding brake inlet pressure ................................................................................................. 20-121
Testing and adjusting travel deviation ......................................................................................................... 20-122
Measuring oil leakage from work equipment cylinder ................................................................................. 20-124
Bleeding air from each part ......................................................................................................................... 20-126
Releasing residual pressure from hydraulic circuit ..................................................................................... 20-128
Releasing residual pressure from hydraulic tank ........................................................................................ 20-128
Pressurizing hydraulic tank ......................................................................................................................... 20-128
Resetting procedure of electric system and check of its operation ............................................................. 20-129
Procedure for replacing potentiometer........................................................................................................ 20-142
Procedure for testing diode ......................................................................................................................... 20-143
PC58UU-3 20-101
(6)
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING

Checks or Measurement item Symbol Part No. Part name Remarks
1 799-203-9000 Multi-tachometer Digital display L: 60 – 2,000 rpm
Engine speed A H: 60 – 19,999 rpm
2 .799-203-8901 .Clamp-set
Coolant and oil temperature B 799-101-1502 Digital temperature gauge - 99.9 ~ + 1,299 °C
799-101-5002 Hydraulic tester Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
1 {25, 60, 400, 600 kg/cm²}
799-261-1203 Digital hydraulic tester
799-101-5160 Nipple PT1/8
2 799-101-5220 Nipple
10 x 1.25
07002-11023 O-Ring
799-401-2910 Nipple Both male and female 9/16-18 UNF

(female PT1/8)
Oil pressure C 07043-00108 Plug PT1/8 (for 799-401-2910)
02896-11008 O-Ring (for 799-401-2910)
3
799-401-2920 Nipple Both male and female 11/16-16 UNF
(female PT1/8)
07043-00108 Plug PT1/8 (for 799-401-2920)
02896-11009 O-ring (for 799-401-2920)
4 799-401-2320 Hydraulic gauge 1.0 MPa {10 kg/cm²}
5 799-401-2701 Differential
gauge
pressure
1 795-502-1905 Compression gauge

0 – 6.9 MPa {0 – 70 kg/cm²}
Compression pressure D 2 795-111-1110 Adapter
3 •795-101-1571 Joint —
Commercially
Valve clearance E available Feeler gauge
1 790-201-9000 Handy smoke checker Discoloration 0 – 70% (with standard
Exhaust color F Commercially
color)
2 available Smoke meter (Discoloration x 1/10 = Bosch index)
Commercially
Operating effort G available Push-pull scale
Commercially
Stroke, hydraulic drift H available Scale —
Commercially
Work equipment speed J available Stop watch —
Measuring voltage and resis- K Commercially
Tester —
tance values available
1 790-601-8000 T-adapter assembly

2 799-601-7360 Adapter For relay with 5P
3 799-601-7400 T-adapter assembly
799-601-9320 Box
4
799-601-9310 Plater for T-adapter
799-601-9200 Adapter assembly for DT

series connector
Troubleshooting of wiring L •799-601-9020 For DT2
harness and sensors
•799-601-9030 For DT3
5 •799-601-9040 For DT4

•799-601-9050 Adapter For DT6
•799-601-9010 For DTM2
•799-601-9170 For DT8B
•799-601-9120 For DT12B
6 799-601-9350 Adapter For DRC23-40
Measuring wear of sprocket M •796-127-1140 Wear gauge
20-102 PC58UU-3
(6)
MEASURING ENGINE SPEED,
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE SPEED MEASURING ENGINE OIL

a Measure the engine speed under the following
PRESSURE
condition. a Measure the engine oil pressure under the fol-
• Coolant temperature: In green range of cool- lowing condition.
ant water temperature gauge • Coolant temperature: In green range of cool-
• Hydraulic oil temperature: 45 – 55°C ant water temperature gauge
a When checking by the monitoring code, select
monitoring code [10] and read the engine speed. 1. Remove oil pressure switch (1) and install the
nipple of oil pressure gauge kit C1.
1. Remove the clamp from the injection pipe to Serial No.: 20001 – 22000
which you are installing the sensor.
2. Install sensor A-2 of multi-tachometer A to injec-

tion pipe (1) and connect it to multi-tachometer A
3. Run the engine under the measuring condition

and measure its speed.
1) Measuring low and high idling speeds:
Measure the engine speed with the fuel con-
trol lever at the low idling and high idling
positions.
2) Measuring engine speed when pump is
relieved:
Run the engine at full throttle and relieve
each pump and measure the engine speed.
a For the pumps to be relieved, see the STAN-
DARD VALUES TABLE. 2. Install oil pressure gauge C1 (2.5 MPa {25 kg/
cm2}.
3. Run the engine and measure the oil pressure at
low idling and high idling.
PC58UU-3 20-103
(6)
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION 5. Disconnect connector (M12) (1) of the engine

stop solenoid and crank the engine with the start-
PRESSURE ing motor and measure the compression pres-
k Take extreme care not to get burned with the

sure.
a Read the compression pressure after the pointer
exhaust manifold or caught in the fan belt of the compression gauge is stabilized.
while you are measuring the compression a After measuring the compression pressure,
pressure. install the nozzle holder assembly.
1. Adjust the valve clearance normally. For details, 3 Nozzle holder mounting nut:
see ADJUSTING VALVE CLEARANCE. 7.84 ± 0.98 Nm {0.8 ± 0.1 kgm}
2. Warm up the engine until the oil temperature Serial No.: 20001 – 22000
reaches 40 – 60°C.
3. Remove the nozzle holder assembly of the cylin-

der, the compression of which you are measur-
ing. For details. see DISSASSEMBLY AND
ASSEMBLY, Removal of nozzle holder assem-
bly.
4. Install adapter D2 to the nozzle holder mounting

part and connect compression gauge D1.
20-104 PC58UU-3
(6)
ADJUSTING VALVE CLEARANCE
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
ADJUSTING VALVE CLEAR-

ANCE
1. Remove the cylinder head cover.
2. Rotate the crankshaft forward to bring

"stamped line 1.4" (2) on the flywheel to the
center of the housing hole, watching the air
intake valve of cylinder No. 4.
★ Cylinder No. 1 is on the flywheel side.
3. Bring cylinder No. 1 to the compression top

dead center and adjust it, then rotate the crank-
shaft by 180° and adjust valve clearance a of
each cylinder in firing order.
• Firing order: 1 — 3 — 4 — 2
(Cylinder No. 1 is on the flywheel side, how-
ever.)
4. Insert tool E between rocker lever (2) and valve

stem (3) and turn adjustment screw (4) to the
degree that tool E will be move lightly, then
tighten locknut (5).
Locknut:
25.48 ± 2.94Nm{2.6 ± 0.3kgm}
★ After tightening the locknut, check valve clear-

ance a again.
PC58UU-3 20-105
b
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING

FUEL INJECTION TIMING
Serial No.: 20001 – 22000
TESTING
Adjust the injection timing of the fuel injection pump
according to the following procedure.
1. Disconnect fuel injection tube (1) of cylinder No.

1.
a Cylinder No. 1 is on the flywheel side.
2) If stamped injection timing mark (2) is above

timing mark (3).
• Since the injection timing is later than the
standard, loosen injection pump mount-
ing nuts (4) and lean the pump away
from the engine.
2. Using the crank pulley, rotate the crankshaft for-

ward and stop when the oil surface at the end of
delivery valve spring holder starts swelling.
3. Watch through the inspection hole of the fly-

wheel housing and check that injection timing
mark (2) stamped on the flywheel is matched to
the timing mark (3) on the flywheel housing.
a For the injection timing, see the STANDARD
VALUES.
ADJUSTING
If the injection timing is out of standard, adjust with
following procedure.
1) If stamped injection timing mark (2) is below
timing mark (3).
• Since the injection timing is earlier than
the standard, loosen injection pump
mounting nuts (4) and lean the pump
toward the engine.
a Adjust until the timing mark is matched to the

given injection timing mark.
20-106 PC58UU-3
(6)
Serial No.: 22001 and up 2. Accurately record the relative positions of

stamped line (5) of the fuel injection pump body
TESTING
and stamped line (6) of the gear case with mark-
Check mounting nut (1) of the fuel injection pump for
off lines (7), etc.
looseness.
a The fuel injection timing does not change as long
as the mounting nut is not loosened. Accordingly,
when removing and installing or replacing the
fuel injection pump, refer to the following adjust-
ing procedure.
3. Stick injection angle adjustment seal (8) to the

gear case, matching its center line to stamped
line (5) of the fuel injection pump body.
4. Remove the fuel injection pump and read the

"injection angle" recorded on it.
a See REMOVAL AND INSTALLATION of fuel
ADJUSTING
injection pump.
a The injection timing or the MP-type fuel injection
pump used engine cannot be measured like the
former models. Accordingly, adjust the injection
angle instead of measuring the injection timing.
1. Befor romoving fuel injection pump (2), remove
the cover in front of the timing gear case and
make match marks on the meshing parts of
pump drive gear (3) and idle gear (4).
PC58UU-3 20-106-1
(6)
5. Read the "injection angle" recorded on the fuel

injection pump to be installed and calculate the
difference between it and the "injection angle" of
the removed fuel injection pump.
a When the same fuel injection pump is
installed again, the angle difference is 0.
a Injection angle difference (cam angle) =
(injection angle of fuel injection pump to be
installed) – (injection angle of removed fuel
injection pump)
CAUTION
If the injection angle of the fuel injection pump is diffi-
cult to read, notify YAMMAR of the fuel injection
pump No. and ask the injection angle.
6. Install the fuel injection pump temporarily and

tighten the nut at the shaft end.
a See REMOVAL AND INSTALLATION of fuel
injection pump.
7. Read the injection angle difference calculated in

step 5 above by the scale of the adjustment seal
(Minimum division: 0.5° of cam angle) and adjust
the installed angle of the fuel injection pump.
a If the injection angle difference is +1°, lean
the fuel injection pump away from the cylin-
der block by 1°. If the injection angle differ-
ence is –1°, lean the fuel injection pump
toward the cylinder block by 1°.
REFERENCE
8. Tighten the fuel injection pump mounting nut. Standard installed angle of fuel injection pump :
12°.
REMARK
Injection angle i (cam angle) is the difference
between the angle at which injection is started and
the angle at which the plunger lift of the fuel injection
pump is 2.5 mm while the fuel injection pump unit is
driven with a motor.
Actual injection angle i is measured for each fuel
injection pump and recorded on the pump body.
20-106-2 PC58UU-3
(6)
TESTING AND ADJUSTING TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING Serial No.: 22001 and up

ALTERNATOR BELT TENSION TESTING
1. Remove covers (2 pieces) on the rear of boom.
Serial No.: 20001 – 22000
2. Press the intermediate point between fan pulley
TESTING and alternator pulley with force of about 58.8 N
1. Remove covers (2 pieces) on the rear of boom. {about 6 kg} and measure deflection of the belt.
• Deflection of belt: 10 – 15 mm
2. Press the intermediate point between fan pulley
and alternator pulley with force of about 58.8 N
{about 6 kg} and measure deflection of the belt.
• Deflection of belt: 5 – 6 mm
ADJUSTING
a If the deflection is abnormal, adjust it according
to the following procedure.
ADJUSTING 1. Remove covers (2 pieces) on the rear of boom.

a If the deflection is abnormal, adjust it according
to the following procedure. 2. Loosen alternator mounting nut (1) and belt ten-
sion adjustment bolt (2).
1. Remove covers (2 pieces) on the rear of boom.
3. Using a bar, etc., move alternator outward to
2. Loosen alternator mounting nut (1) and belt ten- adjust the belt tension.
sion adjustment bolt (2).
4. Tighten adjustment bolt (2) and alternator mount-
3. Using a bar, etc., move alternator outward to ing bolt (1) in order.
adjust the belt tension.
4. Tighten adjustment bolt (2) and alternator mount-

ing bolt (1) in order.
PC58UU-3 20-107
(6)
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL

LINKAGE
a If the fuel injection pump and cable were
replaced or if the engine speed is out of the stan-
dard range, adjust the fuel control linkage
according to the following procedure.
1. Adjust control linkage

1) If any part was replaced, connect the cable
to the fuel injection pump governor lever
securely.
2) Turn the starting switch to the ON position
and set the fuel control lever to the high
idling position.
3) Bring fuel injection pump governor lever (1)
in contact with stopper (6) on the FULL side.
4) Under this condition, secure cable (2) to
bracket (5) with nuts (3) and (4) temporarily.
a At this time, check that the cable mount-
ing pin has no play.
5) Return nut (3) at least 4 turns and tighten nut
(4) by 4 turns and pull loose spring (7) in the
direction of the arrow, then press and set
lever (1) against stopper (6) on the FULL
side.
6) Retighten nuts (3) and (4).
7) Start the engine and check that it runs at the
specified speed.
Serial No.: 20001 – 22000
Serial No.: 22001 –
20-107-1 PC58UU-3
(6)
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST
COLOR 4) Loosen the cap nut of the suction pump,
then fit the filter paper.
• When measuring in the field when there is no ★ Fit the filter paper securely so that the
air or electric power supply, use smoke checker exhaust gas does not leak.
F1. When recording official data, use smoke
5) Turn the power switch of smoke meter F2
meter F2.
ON.
★ Raise the coolant temperature to the operating
range before measuring. 6) Accelerate the engine suddenly, and at the
same time, depress the accelerator pedal of
smoke meter F2 and catch the exhaust gas
When removing or installing the color on the filter paper.
measuring equipment, be careful
not to touch any high temperature 7) Lay the filter paper used to catch the
exhaust gas color on top of unused filter
part.
papers (10 sheets or more) inside the filter
paper holder, and read the indicated value.
1. Measuring with handy smoke checker F1
1) Fit filter paper in tool F1.
2) Insert the exhaust gas intake port of the tool
F1 into the exhaust pipe.
3) Accelerate the engine suddenly, and at the
same time operate the handle of tool F1 to
catch the exhaust gas on the filter paper.
4) Remove the filter paper and compare it with
the scale provided to judge the condition.
2. Measuring with smoke meter F2

1) Insert probe of smoke meter F2 into the out-
let port of the exhaust pipe, then tighten the
clip to secure it to the exhaust pipe.
2) Connect the probe hose, accelerator switch
plug, and air hose to smoke meter F2.
★ The pressure of the air supply should be
less than 1.47 MPa {15 kg/cm²}.
3) Connect the power cord to the AC socket.
★ When connecting the cord, check that
the power switch of the smoke meter is
OFF.
20-108 PC58UU-3
(6)
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF 4. Set the arm at about right angles to the ground
and lower the boom until the front part of the
SWING CIRCLE BEARING undercarriage floats.
At this time, the front part of the upper structure
Method of testing clearance of swing circle bear- rises and the rear part lowers.
ing on machine
1. Fix dial gauge with magnet (1) to the swing circle 5. Read the dial gauge. The indicated value is the
outer ring (2) (or inner ring) (3) and apply the clearance of the swing circle bearing.
k WARNING! Do not put your hand or foot under
probe to the end face of the inner ring (or outer
ring). Set the dial gauge to the front or rear part.
the undercarriage during measurement.
2. Extend the work equipment to the maximum

reach and set the bucket tip to the height of the 6. Set the machine in the position explained in 2
underside of the revolving frame. above again and check that the dial gauge indi-
At this time, the front part of the upper structure cates zero. If the dial gauge does not indicate
lowers and the rear part rises. zero, repeat Steps 2 – 5.
3. Set the dial gauge to the zero point.
PC58UU-3 20-108-1
(6)
TESTING AND ADJUSTING CHECKING WEAR OF SPROCKET
CHECKING WEAR OF
SPROCKET
1. Remove the track shoe assembly.
★ For details, see DISASSEMBLY AND
ASSEMBLY, REMOVAL OF TRACK SHOE
ASSEMBLY.
2. Align wear gauge M with the sprocket.

★ Align the datum line, then align the wave
shape of the wear gauge.
3. Judge the sprocket wear.

★ If the wave shape of the sprocket is above
the wear limit line:
It is possible to continue to use the
sprocket.
★ If the wave shape of the sprocket has
reached the wear limit line:
Replace the sprocket with a new part.
PC58UU-3 20-109
b
TESTING AND ADJUSTING TRACK SHOE TENSION

TRACK SHOE TENSION
Testing Adjusting
1. Run the engine at low idling and move the ★ If the standard track shoe tension is abnormal,
machine forward by the length of track on the adjust according to the following procedure.
ground and stop slowly.
1. When tension is too high
2. Place straight-edge (3) over idler (1) and carrier
1) Loosen valve (1) gradually to discharge
roller (2). grease.
3. Measure the maximum distance between the Do not loosen the valve more
top of the track and the underside of the than 1 turn since the internal
straight-edge. high-pressure grease may spout
• If the standard slack (a) is in the following out.
range, the shoe tension is normal.
★ If the grease is not discharged sufficiently,
Specification Standard slack
(a) move the machine slowly forward and in
reverse.
Road liner, steel shoe 10 ~ 30 mm
Rubber shoe 1 ~ 3 mm 2) To check that the track shoe tension is nor-
mal, run the engine at low idling and move
the machine forward by the length of track
on the ground and stop slowly.
3) Test the track shoe tension again. If it is still
abnormal, adjust it again.
2. When tension is too low

1) Supply grease through grease fitting (2).
★ If the track shoe tension is not tensed
well, move the machine slowly forward
and in reverse.
Grease fitting: Grease (G2-LI)
2) To check that the track shoe tension is nor-

mal, run the engine at low idling and move
the machine forward by the length of track
on the ground and stop slowly.
3) Test the track shoe tension again. If it is still
abnormal, adjust again.
20-110 PC58UU-3
b
TESTING AND ADJUSTING ADJUSTING BLADE CONTROL LEVER
ADJUSTING BLADE
CONTROL LEVER
1. Adjust front and rear stopper bolts (1) to dimen-
sion e and set blade control lever (2) to the cen-
ter and tighten the locknut temporarily.
• Temporary installation dimension e: 7.0 mm
2. Adjust the yoke of cable (3) to dimension f.

• Installation dimension f: 132.8 mm
3. Adjust the yoke on the valve side of cable (3) to

dimension g.
• Installation dimension g: 119.2 mm
4. Loosen and retract stopper bolts (1) to the end.
5. Move blade control lever (2) to the front and rear

stroke ends and adjust stopper bolts (3) so that
they will come in contact with blade control lever
at each stroke end, then tighten the locknuts.
PC58UU-3 20-111
(6)
HYDRAULIC PRESSURE IN WORK EQUIPMENT,
TESTING AND ADJUSTING SWING, AND TRAVEL CIRCUITS

2. Measuring work equipment relief pressure
HYDRAULIC PRESSURE IN
1) Remove oil pressure pickup plug (1) (10
WORK EQUIPMENT, SWING, mm, P = 1.25) and install oil pressure gauge
C1 (39.2 MPa {400 kg/cm²}).
AND TRAVEL CIRCUITS
2) Run the engine at full throttle and relieve
Measuring each actuator and measure the oil pressure
at this time.
★ Oil temperature for measurement: 45 - 55 °C
Move each cylinder to the
Before removing the oil pressure stroke end.
pickup plug, release the residual
pressure from hydraulic tank. 3. Measuring travel circuit relief pressure
After installing the oil pressure 1) Remove oil pressure pickup plug (1) and (2)
gauge, pressurize the hydraulic (10 mm, P = 1.25) and install oil pressure
gauge C1 (39.2 MPa {400 kg/cm²}).
tank. For details, see Pressuriz-
ing hydraulic tank.
1. Measuring unload oil pressure

mm, P = 1.25) and install oil pressure gauge
C1 (39.2 MPa {400 kg/cm²}).
2) Run the engine at full throttle and set all
control levers in neutral and measure the
oil pressure.

the travel pump and measure the oil pres-
sure at this time.
Put block b against the

grouser of the track shoe or
put block c between the
sprocket and frame to lock
the track shoe.
20-112 PC58UU-3
b
HYDRAULIC PRESSURE IN WORK EQUIPMENT,
TESTING AND ADJUSTING SWING, AND TRAVEL CIRCUITS
4. Measuring swing circuit and blade circuit relief

pressure
mm, P = 1.25).
2) Install oil pressure gauge C1 (39.2 MPa {400

kg/cm²}).
the swing circuit and blade circuit and mea-
sure the oil pressure at this time.
Stop swinging securely by

using the work equipment.
Move the blade cylinder to

the stroke end.
PC58UU-3 20-113
b
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING 4) Run the engine at full throttle and measure
LS DIFFERENTIAL PRES- the pump discharge pressure under the
condition in above.
SURE ★ Read the gauge pointer correctly from
its front side.
Measuring
5) Calculate the LS differential pressure from
the pump discharge pressure and LS pres-
1. Measuring with differential pressure gauge sure.
1) Remove pump pressure pickup plug (1) of
the control valve and LS pressure pickup
plug (2).
2) Install differential pressure gauge C5.
★ Connect pump discharge pressure side
(port PP) (1) to the high pressure side of
the differential pressure gauge and con-
nect the LS pressure side (port LS3) (2)
to the low pressure side.
3) Run the engine at full throttle and measure
the LS differential pressure under the fol-
lowing condition.
• LS differential pressure during digging
operation of bucket with no load:
1.57 ± 0.1 MPa {16 ± 1 kg/cm²}
2. Measure with oil pressure gauge

★ Since the differential pressure does not
exceed 1.96 MPa {20 kg/cm²}, measure it
with the same pressure gauge.
1) Remove pump pressure pickup plug (1) of
the control valve and LS pressure pickup
plug (2).
2) Install oil pressure gauge C1.

★ Use and oil pressure gauge having the
minimum division of 0.98 MPa {10 kg/
cm²}.
3) Run the engine at full throttle and measure
the pump discharge pressure under the
condition in above.
★ Read the gauge pointer correctly from
its front side.
20-114 PC58UU-3
b
TESTING AND ADJUSTING LS DIFFERENTIAL PRESSURE
Adjusting ADJUSTING PC VALVE

★ When the load is increased, [the engine speed
1. Adjusting LS valve
may lower] or [the engine speed may be nor-
★ If the LS differential pressure is abnormal, mal and working speed may lower]. If this trou-
adjust the LS valve according to the follow- ble occurs and the pump discharge and LS
ing procedure. differential pressure are normal, adjust the
1) Loosen locknut (3) and rotate adjustment pump PC valve according to the following pro-
screw (4). cedure.
★ As the adjustment screw is ★ In which direction the adjustment screw should
• rotated clockwise, the pressure is be rotated to increase the torque is unknown.
heightened, and if it is Accordingly, monitor the engine speed when
• rotated counterclockwise, the pres- rotating the adjustment screw.
sure is lowered.
1. Loosen locknut (1) and rotate adjustment screw
★ Quantity of adjustment per turn of
adjustment screw: (2).
1.27 MPa {13 kg/cm²} If [the work equipment speed is low], turn
adjustment screw (2) to the [counterclockwise]
2) After adjusting, tighten locknut (3).
(to increase the pump absorption torque). If
[the engine speed lowers], turn adjustment
Locknut:
screw (2) to the [clockwise] (to reduce the pump
27.4 ~ 34.3 Nm {2.8 ~ 3.5 kgm}
absorption torque). Limit the adjustment range
★ After adjusting, measure the LS differ- to ± 180° from the position for shipping.
ential pressure, referring to Measuring ★ Since the position for shipping is not
described above. punched, make match marks (a) before
★ When loosening or tightening the lock- adjusting.
nut, secure adjustment screw (4) with a
spanner so that it will not be dragged.
2. After adjusting, tighten locknut (1).
Locknut:
27.4 ~ 34.3 Nm {2.8 ~ 3.5 kgm}
PC58UU-3 20-115
b
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN CONTROL PUMP CIRCUIT
TESTING AND ADJUSTING Adjusting

HYDRAULIC PRESSURE IN ★ If the control circuit pressure is abnormal,
CONTROL PUMP CIRCUIT adjust the control relief valve installed to the 5-
spool solenoid valve assembly according to the
Testing following procedure
★ Oil temperature for measurement: 45 - 55°C
1. Loosen locknut (2) and rotate adjustment screw
(3).
1. Remove oil pressure pickup plug (1) form the
★ As the adjustment screw is
solenoid valve assembly.
• rotated clockwise, the pressure is
heightened, and if it is
• rotated counterclockwise, the pres-
sure is lowered.
★ Quantity of adjustment per turn of
adjustment screw:
343 kPa {3.5 kg/cm²}
2. After adjusting, tighten locknut (2).
Locknut: 9.8 Nm {1.0 kgm}
★ After adjusting, check the oil pressure

according to the procedure shown above.
2. Install nipple C2 and oil pressure gauge C1 (5.9

MPa {60 kg.cm²}).
3. Run the engine at full throttle and set the con-

trol lever in neutral and measure the oil pres-
sure.
20-116 PC58UU-3
b
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING SOLENOID ★ The pressure in hose (3) can also be mea-

sured with the hoses disconnected from the
VALVE OUTPUT PRESSURE above ports of the main control valve.
★ Oil temperature for measurement: 45 - 55°C Item Measuring port
• Measure the output pressure of each solenoid PPC lock Solenoid valve outlet
valve at the port shown in the table. Travel speed Hi Travel motor inlet
Main valve inlet
1. Disconnect outlet hoses (1), (2), and (3) of the Offset LEFT stop (Offset LEFT spool)
solenoid valve, the output pressure of which
Main valve inlet
you are measuring. Arm IN stop (Arm IN spool)
• (1) : PPC lock solenoid valve Main valve inlet
Boom RAISE stop (Boom RAISE spool)
• (2) : Travel speed Hi solenoid valve
• (3) : Offset LEFT
: Arm IN 2. Install nipple C4 (including the O-ring and plug)
: Boom RAISE and C3 (including O-ring) to the place from
which each hose was disconnected, then install
oil pressure gauge C1 (5.9 MPa {60 kg.cm²})
★ The pressure in hose (2) can also be mea-

sured on the travel motor side.
★ If the output pressure is measured when the
boom is raised or the arm is moved IN to
the stroke end, it is lower than the normal
value.
PC58UU-3 20-117
b
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
3. Run the engine at full throttle and measure the

output pressure under the following condition.
1) PPC lock solenoid valve: Set the safety lever
to the FREE position.
2) Travel speed Hi solenoid valve: Press the
travel speed Hi pedal.
3) Offset LEFT stop solenoid valve: Perform
the LEFT offset operation.
4) Arm IN stop EPC valve: Perform the arm IN
operation.
5) Boom RAISE stop EPC valve: Perform the
boom RAISE operation.
★ Perform the offset LEFT stop, arm IN
stop, and boom RAISE stop operations
in the safety region where the interfer-
ence prevention function does not
work.
20-118 PC58UU-3
b
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE

3. Run the engine at full throttle and operate the
OUTPUT PRESSURE control lever of the objective circuit of measure-
ment and measure the output pressure.
★ Oil temperature for measurement: 45 - 55°C
★ The standard values are the same as those
1. Disconnect PPC hose (1) of the circuit which you in the control circuit (when the control lever
are measuring, from the solenoid valve assem- is moved to the stroke end).
bly or main control valve assembly.
★ For the hose to be disconnected, see
hydraulic circuit diagram on the next page.
2. Install nipple C4 (including the O-ring and plug)

and C3 (including O-ring), then install oil pres-
sure gauge C1 (5.9 MPa {60 kg/cm²}).
PC58UU-3 20-119
b
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING ADJUSTING PC VALVE
PPC VALVE AND SWING HOLDING BRAKE CIRCUIT
20-120 PC58UU-3
b
TESTING AND ADJUSTING ADJUSTING PPC VALVE
ADJUSTING PPC VALVE TESTING SWING HOLDING

★ If the work equipment control lever or swing BRAKE INLET PRESSURE
lever has excessive play, adjust it according to
the following procedure.
1. Disconnect hose (1).
Lower the work equipment to the
ground and stop the engine. Then,
loosen the oil filler cap slowly to
release the internal pressure of
the hydraulic tank. Set the safety
lock lever to the LOCK position.
1. Remove the PPC valve.
2. Remove boot (1).
3. Loosen locknut (2) and tighten disc (3) until it

comes in contact with the heads of 4 pistons
(4).
★ Do not move the pistons at this time. 2. Install nipple C4 (including O-ring and plug) and
C3 (including the O-ring), then install oil pres-
4. Fix disc (3) and tighten locknut (2) to the speci- sure gauge C1 (5.9 MPa {60 kg/cm²}.
fied torque.
Locknut: 107.9 ± 9.8 Nm {11 ± 1

kgm}
5. Install boot (1).

★ The clearance between disc (3) and piston
(4) is eliminated by the above adjustment.
3. Run the engine at full throttle and perform the

[LEFT swing] and [RIGHT swing] operations and
measure the inlet pressure.
★ The standard values are the same as those
in the control circuit (when the control lever
is moved to the stroke end).
PC58UU-3 20-121
b
TESTING AND ADJUSTING TRAVEL DEVIATION

TRAVEL DEVIATION
Measuring when traveling on level ground
1) Set the machine in the travel posture.

★ When setting the machine in the travel
posture, extend the bucket and arm cyl-
inder rods fully, and hold the boom at
an angle of 45°.
2) Travel for 10m, then measure dimension a
for the next 20m when traveling with the
engine at full throttle.
★ Measure at full throttle.
★ Install an oil pressure gauge and mea-
sure the pump discharge pressure at the
same time.
20-122 PC58UU-3
b
TRAVEL DEVIATION
Adjusting ★ Loosen the locknut with the hexagonal

wrench in position.
★ Travel deviation can be corrected by draining a
part of the amount of oil discharged from the • Loosening angle of locknut:
pump which discharges more oil with the Approx. 90 ~ 180°
adjustment plugs.
If the travel deviation is corrected by this
method, however, the travel speed, work equip-
ment speed in the compound operation, and
relief pressure lower since the pump discharge
is reduced.
★ The following is the method of correcting devia-
tion when the machine deviates to the right
(left) in both travel directions.
★ Travel deviation can be corrected by the follow-
ing method only when it is 200 mm or less.
If the adjustment plug is loosened

more than the adjustment limit,
high-pressure oil spouts out. Use
4. Correct the travel deviation by loosening
extreme caution.
adjustment plug (1) or (2).
Lower the work equipment to the • Quantity of correction of travel deviation
ground and stop the engine. Then, per turn of adjustment plug:
loosen the hydraulic oil filler cap 150 mm (For reference)
slowly to release the internal pres- ★ When the machine is shipped, the adjust-
sure of the hydraulic tank. ment plugs are tightened fully. Adjust the
correction angle by the loosening angle of
1. Check the position of each adjustment plug of the adjustment plugs.
the main pump. ★ If the adjustment plug is dragged when the
• When the machine deviates to the right: locknut is loosened, tighten it again.
Loosen the adjustment plug (1). ★ The adjustable range of each adjustment
• When the machine deviates to the left: plug is 2 turns (720°) from the tightened
Loosen adjustment plug (2). position.
★ Loosen only either plug. Do not loosen both
5. Tighten locknut (3).
plugs at the same time.
Locknut:
2.94 ~ 4.9 Nm {0.3 ~ 0.5 kgm}
6. Check for travel deviation again. If the machine

still deviates, adjust again according to the
above procedure.
★ Do not loosen the adjustment plugs more
than the adjustable range [2 turns (720°)].
2. Insert hexagonal wrench (Width across flats: 4

mm) in adjustment plug (1) or (2).
★ Insert hexagonal wrench securely.
3. Loosen locknut (3) with the hexagonal wrench

inserted.
★ Before adjusting, mark the position of the
locknut with paint.
PC58UU-3 20-123
b
MEASURING OIL LEAKAGE FROM WORK
TESTING AND ADJUSTING EQUIPMENT CYLINDER
MEASURING OIL LEAKAGE CYLINDERS
FROM WORK EQUIPMENT

CYLINDER
★ Oil temperature for measurement: 45 ~ 55°C
★ If the hydraulic drift exceeds the standard value,
measure the leakage in the cylinder to see if the
cause of the hydraulic drift is on the control
valve side.
• If the leakage is below the standard value, the
cause of hydraulic drift is on the control valve
side.
• If the leakage is above the standard value, the
cause of hydraulic drift is on the cylinder side.
1. Fully extract the rod of the cylinder to be

checked and stop the engine.
2. Disconnect the hose from the cylinder head and

plug it.
• Boom cylinder: Hose (1)
• Arm cylinder: Hose (2)
• Bucket cylinder: Hose (3)
• Offset cylinder: Hose (4)
Take care not to disconnect the

hose from the cylinder bottom.
MEASURING POSITION OF BOOM CYLINDER
MEASURING POSITION OF ARM AND BUCKET
20-124 PC58UU-3
b
MEASURING OIL LEAKAGE FROM WORK
TESTING AND ADJUSTING EQUIPMENT CYLINDER
3. Run the engine at full throttle and apply relief

pressure to the bottom side of the cylinder.
★ Boom cylinder: RAISE operation
Arm cylinder: IN operation
Bucket cylinder: CURL operation
Offset cylinder: LEFT offset operation
4. After 30 seconds, measure the quantity of oil

leaking in 1 minute.
PC58UU-3 20-125
b
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
BLEEDING AIR FROM EACH PART
Air bleeding item Air bleeding procedures

1 2 3 4 5 6 7
Bleed air Start Bleed air Bleed air Bleed air Pressurize Start
from engine from from from Hydraulic operation
Contents of work pump cylinder swing travel tank
motor motor
• Replacing hydraulic oil ! ! ! ! ! ! !
• Cleaning strainer (Note) (Note)
• Replacing return filter element ! ! !

• Replacing/Repairing pump
• Removing suction piping ! ! ! ! !
• Replacing/Repairing control valve ! ! ! !
• Replacing/Repairing cylinder
• Removing cylinder piping ! ! ! !
• Replacing/Repairing swing motor
• Removing swing motor piping ! ! ! !
• Replacing/Repairing travel motor and
swivel
• Removing travel motor and swivel pip- ! ! ! !
ing
Note: Bleed the air from the swing and travel motors only when the oil inside the motor case has been
drained.
1. Bleeding the air from pump

1) Loosen air bleeder (1) to bleed air through
itself.
★ If oil containing no air flows out, stop
bleeding.
2) Tighten air bleeder (1).
Bleeder:
8.8 ± 1 Nm {0.9 ± 0.1 kg/cm²}
★ Caution for starting engine

After the above work, run the engine at
low idling for about 10 minutes. After
that, keep engine speed at middle range
or below for about 1 hour.
20-126 PC58UU-3
b
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
2. Bleeding air from cylinder 4. Bleeding air from travel motor

1) Start and run the engine at low idling for 1) Run the engine at slow speed and raise the
about 5 minutes. left track shoe by using the work equip-
ment.
2) Raise and lower the boom 4 ~ 5 times with
the engine speed low. 2) Run the engine at slow speed and drive the
★ Move the piston rod to about 100 mm left track shoe idle for about 30 seconds.
before the stroke end and never relieve 3) Drive the right track shoe idle according to
the oil.
steps 1) and 2) above.
3) Perform the operation of 2) above with the
engine at full throttle. Then, run the engine
at low speed and move the piston rod to the
stroke end to relieve the oil.
4) Bleed air from each of the arm, bucket, off-
set, swing, and blade cylinders by perform-
ing above operations of 2) and 3).
5. Pressurizing hydraulic tank

1) Before pressurizing the hydraulic tank,
check the hydraulic oil level again.
2) Pressurize the hydraulic tank. For details,
see Pressurizing Hydraulic Tank.
3. Bleeding air from swing motor
1) Run the engine at slow speed and swing to
the left 3 times.
2) Swing to the right 3 times.
PC58UU-3 20-127
b
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC CIR-
RELEASING RESIDUAL PRESSURE FROM HYDRAULIC
TESTING AND ADJUSTING PRESSURIZING HYDRAULIC TANK
RELEASING RESIDUAL PRESSURIZING HYDRAULIC

PRESSURE FROM HYDRAU- TANK
LIC CIRCUIT ★ If the oil filler cap of the hydraulic tank was
removed, pressurize the hydraulic tank accord-
Since an accumulator is not installed, ing to the following procedure.
the residual pressure in the piping
between the main control valve and 1. Run the engine at slow speed and set the work
each hydraulic cylinder or swing equipment in the pressurizing position (extend
motor cannot be released even if con- the boom, arm, and bucket cylinders fully).
trol levers are operated.
1. Run the engine at slow speed and lower the

work equipment to the ground, taking care not
to relieve the cylinder at the stroke end, then
stop the engine.
★ If the hydraulic cylinder is relieved at the
stroke end before the engine is stopped, do
not perform the following work for 5 ~ 10
minutes.
2. When moving the piping, loosen the sleeve nut

of the piping gradually to release the residual
pressure from the piping until oil does not
come out any more, then remove the piping. 2. Stop the engine and open the oil filler cap of the
hydraulic tank and tighten it again.
3. Run the engine and lower the work equipment

to the ground to pressurize the hydraulic tank.
★ If the hydraulic tank is not pressurized, the
RELEASING RESIDUAL pumps will suck air which has bad effects
PRESSURE FROM HYDRAU- on the devices.
LIC TANK
The hydraulic tank is enclosed and
pressurized. When removing a hose,
plug, etc. connected to the hydraulic
tank, release the residual pressure in
the hydraulic tank according to the
following procedure.
1. Lower the work equipment to the ground and

stop the engine.
2. Loosen the oil filler cap or oil filler plug of the

hydraulic tank gradually to release the residual
pressure from the tank.
20-128 PC58UU-3
b
RESETTING PROCEDURE OF ELECTRIC SYSTEM
TESTING AND ADJUSTING AND CHECK OF ITS OPERATION
RESETTING PROCEDURE OF
ELECTRIC SYSTEM AND
CHECK OF ITS OPERATION
• When any of the following works is performed • Reset the potentiometer mounting angle first,
or when any error code is displayed, reset the then reset the front stop position, depth display,
electric system according to the flow chart and side stop.
shown below.
1) When the work equipment is removed and
installed for repair.
2) When the work equipment is replaced with
a long arm.
3) When the controller is replaced.
4) When a potentiometer is removed,
installed, or replaced.
5) When an error code of the reset signal sys-
tem is displayed.
• Flow chart of resetting of electric system

★ The number in the square shows the number of the item for resetting procedure written on pages
20-130 to 20-140.
1
Reset
potentiometer Error
input signal
2
3 4 Check 9
Check Correct
following in
automatic stop forward and
indication of
in left offset backward
depth
directions
1) Automatic
stop 10 Check
2) Stopping
length automatic
work equip-
ment control
function
Automatic Automatic
Automatic stop position stop position
stop position is in specified is outside of
is closer than range the specified
specified value value
5 Reset 6 Reset
automatic
automatic stop Error Error
stop output
output signal
7 signal 7
Automatic Automatic
stop position stop position
is in specified is in specified
range range
8 Move bucket to right and left to check automatic stop position
OK OK OK
PC58UU-3 20-129
b
TABLE OF PROCEDURES FOR RESETTING ELECTRIC SYSTEM
Order 1 2 3
Reset Item Prevention of interference
Initial setting at stroke end of cylinder Setting of displayed depth to 0
Step Front — Side
Engine Running — — Running — — Running — —
(Position 1) Caution: When (Position 2) Set bucket Set the bucket (Position 1) (Position 1)
• Set boom to setting "Position • Set offset to auto- to automatic • Set bucket • Set arm to
RAISE end. 1", turn ON boom to matic stop stop position to DUMP IN position
• Set offset emergency work LEFT end. position (Side) (Includ- position (Set bucket
Position of boom to equpipment • Set arm to (Front) ing operation (Set bucket top verti-
work equip- operation (Including of emer-
ment RIGHT end. switch. OUT end. operation of gency work top vertically)
• Set arm to IN ! Boom may emergency equipment cally)
end. be at any work equip- operation
position. ment opera- switch
tion switch)
Engine
Running Running Running Running Running Running
Starting switch
Mode selector Set displayed Set displayed ✩1 ✩1 ✩2 ✩2
switch position depth to 0 depth to 0
Connection of
connectors b+c b+d b+c b+d b+c b+d
After 2 sec- After 2 sec-
After 2 sec- After 2 sec- After 2 sec-
After 2 seconds, electric
onds, elec- onds, electric onds, electric
onds, elec-
onds, electric system cau-
tric system system cau- system cau-
tric system
Method of dis- system caution tion lamp ([--]
caution tion lamp ([--] tion lamp ([--]
caution lamp
playing and lamp ([--] at at center of
lamp ([--] at at center of at center of
([--] at cen-
resetting mon- center of [88]) [88]) starts
center of [88]) starts [88]) starts
ter of [88])
itor panel starts blinking blinking at
[88]) starts blinking at blinking at
starts blink-
at intervals of intervals of 0.8
blinking at intervals of intervals of
ing at inter-
0.8 seconds. seconds.
intervals of 0.8 seconds. 0.8 seconds.
vals of 0.8
1 second. seconds.
Disconnection
of connectors b+c b+d b+c b+d b+c b+d
Starting switch — — OFF — — OFF — — OFF
ON ON ON
Starting switch — — Resetting is — — Resetting is — — Resetting is
completed completed completed
• Electronic cushion • Run the engine at full throttle and stop • Lower bucket to ground with its top to
1) Movement of boom to RAISE end work equipment automatically and perpendicular to ground and check that
Method of 2) Movement of arm to IN end measure stopping distance (front, side). "00" is displayed as depth.
checking reset- 3) Movement of offset to LEFT end • Push up machine body with work equip-
ting
ment and check that displayed depth
changes.
Wiring
Connector Connector No. Tape color Type of plug
harness color
b: Power Without color
source F30 Red Female
tape
(12V)
c: Resetting 1 Without color

F32 Yellow/White Male
tape
d: Resetting 2 F31 Yellow Green/White Male
20-130 PC58UU-3
b
1. Resetting potentiometer input signal

1) Set the work equipment in the following
position.
i) Boom: RAISE stroke end
ii) Arm: IN stroke end
iii) Offset: RIGHT offset stroke end
★ With emergency work equipment
operation switch (4) turned ON
(reset), bring each cylinder to the
stroke end.
★ Do not stop the engine.
3) Check that the electric system caution lamp

on the monitor panel starts blinking at inter-
vals of 1 second 2 seconds later.
★ If the input signal (voltage) of the poten-
tiometer is out of the standard range at
this time, an error code in the range
from 10 to 19 is displayed on the moni-
tor panel.
4) If an error code is not displayed, disconnect
terminals (1) and (2) from each other and
turn the starting switch to the OFF position.
★ If the starting switch is turned to the
OFF position and turned to the ON posi-
tion again without disconnecting the
terminals, the electric system caution
2) Set the mode selector switch to [Set the dis- lamp blinks.
played depth to 0] and connect reset power 5) Turn the starting switch to the ON position
source terminal (1) and reset terminal (2) to again, and resetting operation is finished.
each other.
★ The reset terminal is taped to the wiring 6) After resetting, tape the reset terminals
harness at the rear of the panel. again as before.
★ The reset power source terminal (1) is a
female plug (red wiring harness) and
the input reset terminal (2) is a male
plug (yellow/white wiring harness with-
out tape).
PC58UU-3 20-131
b
1) Standard values of potentiometer input sig-

2. Actions to take against error codes dis- nals (When normal)
played during step 1 above (Resetting i) Boom: 0.69 ~ 4.31 V
potentiometer input signal) Arm: 0.82 ~ 4.18 V
• When the machine is set in the position Offset: 1.73 ~ 3.57 V
shown in step 1 above, if the potentiometer
i) Boom: Between M14 c ~ b
input signal (voltage) is out of the range in
the following table, an error code is dis- Arm: Between V4 c ~ d
played during the resetting operation and Offset: Between V3 c ~ b
resetting cannot be completed.
2) Contents of display
Group Repro- One of the error codes shown in the table at
name Code Contents of display duction left is displayed, depending on the contents
of the error
11 (!) Boom angle reset error " i) When only 1 system has error (Codes
12 (!) Arm angle reset error " marked !): 11, 12, 14, 18, 01, or 02 is dis-
Boom angle + Arm angle played
13 reset error "
i) When 2 or more systems have error
14 (!) Offset angle reset error " (Codes other than ones marked !): The
total of the first figures to the left is dis-
Boom angle + Offset angle
15 reset error " played.
Arm angle + Offset angle ★ For explanation of " in the Repro-
16 reset error code " duction column, see Displayed
Boom angle + Arm angle + method of monitor panel and con-
17 Offset angle reset error " troller.
Front stop position reset ★ When resetting is erroneous, if the
18 (!) error "
reset power source terminal and
Boom angle + Front stop input reset terminal are discon-
19 position reset error "
nected, the error code and electric
Arm angle + Front stop system caution lamp blink at inter-
1A position reset error "
vals of 0.6 seconds and buzzer
Resetting
Boom angle + Arm angle + sounds at the same intervals.

1B Front stop position reset " ★ All the error codes in the reset group
error
are shown in the table at left.
Offset angle + Front stop
1C position reset error "
Boom angle + Offset angle
1D + Front stop position reset "
error
Arm angle + Offset angle +
1E Front stop position reset "
error
Boom angle + Arm angle +
1F Offset angle + Front stop "
position reset error
01 (!) Side stop position reset

error "
02 (!) Depth display correction

error "
Side stop position reset
03 error + Depth display cor- "
rection error
★ If an error code is displayed during the resetting
operation and the starting switch is turned to
the OFF position with the error code left dis-
played and the starting switch is turned to the
ON position again, the currently saved input
signal is deleted.
Accordingly, remove the all factors of the error
code, then reset securely.
20-132 PC58UU-3
b
i) Set the work equipment in the position

3) Actions to take when error code is dis-
played for resetting and check again to see if
★ Check that the rod is free from bend, the error code is displayed.
scuffing, etc. • Boom: RAISE stroke end
• Boom potentiometer (1) • Arm: IN stroke end
Check the position of the work equip- • Offset: RIGHT offset stroke end
ment for resetting. If it is normal and the
★ The action to take for the arm poten-
error code is still displayed, replace the
potentiometer and case assembly. tiometer is shown below as an exam-
ple.
i) Remove joint bolt (4).
ii) Loosen locknut (5) and adjust joint (6)
iii) Tighten locknut (5).
• Arm potentiometer (2) and offset poten-

tiometer (3)
iv) Check that the potentiometer case input

signal (voltage) is in the standard range.
★ For standard range, see 1) above.
★ The boom potentiometer cannot be
adjusted with the rod. They must be
controlled with the controller.
PC58UU-3 20-133
b
3. Checking automatic stop in left offset 4. Checking automatic stop and stopping
• When the reset operation for the potenti- distance in front direction
ometer input signal in Item 1 is completed, (Use the arm IN operation to check)
keep the work equipment in the same pos- 1) Check automatic stop
ture, and check the automatic stop in the
i) Set the work equipment to the following
left offset direction.
posture.
★ Standard value (A): 150 ~ 200 mm
• Boom: Rear face perpendicular
1) With the engine at low idling and the pedal • Bucket: Horizontal (when stopped)
fully depressed, operate from the end of the
right offset stroke in the left direction and • Offset: Align center of bucket with
check that it automatically stops. right edge of cab
i) With the engine at low idling, operate to
2) Run the engine at full throttle to check the
above operation. the end of the arm IN stroke, and check
that it automatically stops
ii) Run the engine at full throttle to check
the above operation.
2) Check stopping distance

• Run the engine at full throttle, carry out
the automatic stop operation as
explained above, and check that dis-
tance L between the tip of the bucket
teeth and the cab is within specified
range.
★ Specified value: 260 -- 300 mm
★ After carrying out the automatic stop, if
the bucket is not horizontal, make it hor-
izontal, then carry out the measure-
ment.
20-134 PC58UU-3
4) Set the mode selection switch to DEPTH

5. Automatic stop position is closer than
SET 0, then connect reset power supply ter-
specified value minal (1) and reset terminal (2).
★ Even if the value is slightly closer than the ★ Reset power supply terminal (1) is a
specified value, there is no problem in female 1-pin connector (red wiring har-
actual operations, so except in special cases ness).
Reset terminal (2) is a male 1-pin con-
(for example, a request from the user), do nector (yellow/white wiring harness
not carry out the resetting (adjustment) without tape).
operation unnecessarily.
• Carry out the resetting (adjustment) opera-
tion as follows.
1) Operate the arm in the OUT direction and
move the bucket about 400 mm away from
the cab.
2) Set cancel switch (4) to the ON (automatic

return) position, operate the arm slowly in
the IN direction, and set distance L between
the tip of the bucket teeth and the cab to
260 -- 300 mm.
★ Because of inertia when stopping, the
work equipment will move about 50
mm closer than the set position, so
allow a margin when setting.
5) Check that the electrical system caution
lamp on the monitor panel starts to flash 2
seconds later in a 1-second cycle.
6) Disconnect terminals (1) and (2), then turn
the starting switch OFF.
7) When the starting switch is turned ON
again, the resetting operation is completed.
8) After finishing the operation, tape the reset
terminals to their original positions.
3) Turn the starting switch OFF and stop the

engine, then turn the starting switch ON
again.
PC58UU-3 20-135
4) Set the mode selection switch to ✩ 1, then

6. Automatic stop position is outside of the
connect reset power supply terminal (1) and
specified value. reset terminal (2).
★ Even if the value is slightly outside the ★ Reset power supply terminal (1) is a
specified value, there is no problem in female 1-pin connector (red wiring har-
actual operations, so except in special cases ness).
(for example, a request from the user), do nector (yellow/white wiring harness
not carry out the resetting (adjustment) without tape).
operation unnecessarily.
• Carry out the resetting (adjustment) opera-
tion as follows.
1) Operate the arm in the OUT direction and
move the bucket about 400 mm away from
the cab.
2) Set cancel switch (4) to the ON position,

operate the arm slowly in the IN direction,
and set distance L between the tip of the
bucket teeth and the cab to 260 mm.
★ Because of inertia, when stopping, the

3) Turn the starting switch OFF and stop the

engine, then turn the starting switch ON
again.
20-136 PC58UU-3
7. Action to be taken when an abnormality 8. Move position of bucket to left and right and
display (error code) is given for Items 5 or check automatic stop position
6 (resetting automatic stop position) • If the automatic stopping distance has been
★ For details of the abnormality, see Item 2, reset in Item 5 or Item 6, move the bucket to
Table 1. the maximum left offset and the center of
• The adjustment range for the automatic the cab, carry out the automatic stop, and
stop position is 300 mm to the front and check that there is no extreme difference
rear of the automatic stop position, so with between the distance set previously and the
the normal reset, there is no reset error, but actual distance from the tip of the bucket
if an abnormality display is given, carry out teeth to the cab.
the resetting stop position into the range
1) Set the bucket to maximum left offset posi-
that does not give any abnormality display. tion (1) and carry out the automatic stop.
★ Adjustment range:
2) Set the bucket in line with cab center (2) and
Automatic stop position ± 300 mm carry out the automatic stop.
★ When measuring after stopping, set the
bucket in a horizontal position.
★ If the above resetting operation causes any

problem with normal operations, carry out
the resetting operation again from "1. Reset
potentiometer input signal".
★ If an abnormality display appears during
the resetting operation, remove all the
causes, then reset the system properly.
PC58UU-3 20-137
b
9. Compensation resetting for depth display

1) Set the work equipment in the following
posture.
Set the bucket to the end of the DUMP
stroke, operate the arm so that the top of
the bucket is perpendicular to the ground,
then lower the boom to set the bucket teeth
in contact with the ground.

★ If abnormality display code [02] is
given, carry out the operation again
from "1. Reset potentiometer input sig-
nal".
5) Disconnect terminals (1) and (2).
6) Set the mode selector switch to ✩ 2.
2) Set the mode selection switch to HEIGHT.
7) Connect reset power supply terminal (1)
and reset terminal (2).
★ Reset power supply terminal (1) is a
female 1-pin connector (red wiring har-
ness).
nector (yellow/white wiring harness
without tape).
3) Connect reset power supply terminal (1)

and reset terminal (2).
★ Reset power supply terminal (1) is a
female 1-pin connector (red wiring har-
ness).
nector (yellow/white wiring harness
without tape).
8) Repeat Steps 3) to 5).
9) Turn the starting switch OFF, the ON again
to complete the resetting operation.
20-138 PC58UU-3
b
3) Depth mode (function for setting depth)

10. Check automatic control for work equip-
i) Raise the bucket so that the tip of the
ment
teeth is 0.5 m above the ground.
★ Carry out the operation on a surface that is
as horizontal as possible.
1) Depth display (function for displaying depth
from ground level)
i) Set the bucket vertical and in contact
with the ground, and check that the
depth display shows [0.0].
i) Set the mode selection switch to DEPTH

SET 0 and turn the setting switch to the
SET position.
★ When this is done, the buzzer will
sound twice and the indicator will
light up.
ii) Raise the boom, then run the engine at
i) Use the work equipment to raise the full throttle and operate the lever fully to
chassis and check that the depth display lower the boom, and check that it stops
changes. at the original position.
2) DEPTH SET 0 mode (function for displaying iii) Turn the setting switch to the CLEAR
depth from standard surface) position to cancel the setting.
i) Raise the bucket to a point 1 m above
the ground and check that the depth dis-
play shows UP.
i) In the above posture, set the mode

selection switch to DEPTH SET 0 and
turn the setting switch to the SET posi-
tion. Check that the depth display
changes to [0.0] when this is done.
ii) Lower the bucket to the ground and
check that the depth display changes to
[1.0].
iii) Turn the setting switch to the CLEAR
position to cancel the setting.
PC58UU-3 20-139
b
4) Height mode (function for setting height)

11. Compensation resetting of for side stop
★ This is not set for the single boom spec-
ification. position
i) Set the work equipment arm in the max- • When the bucket is replaced with one hav-
imum DUMP position and raise the ing different width and the distance
boom to about 1 m above the ground. between the new bucket and cab is nar-
rowed
1) Move the offset slowly to the left to adjust
distance L between the bucket and cab to
260 mm.
★ Because of inertia when stopping, the
i) Set the mode selection switch to

HEIGHT and turn the setting switch to
SET position.
2) Set the mode selection switch to ✩ 1.

ii) Lower the boom, then run the engine at

full throttle and operate the lever fully to
raise the boom, and check that it stops
at the original position.
iii) Turn the setting switch to the CLEAR
position to cancel the setting.
20-140 PC58UU-3
b
3) Connect the power supply terminal (1) and

left and right reset terminal (3). If the bucket has been replaced with a bucket of
★ The mode selection switch can be in any a different width and clearance between the
position. bucket and the cab has become larger:
★ Reset power supply terminal (1) is a 8) As a basic rule, it is prohibited to reset the
female 1-pin connector (red wiring har- compensation when a narrow bucket has
ness). been installed. If the controller has been
Left and right reset terminal (3) is a replaced and it is necessary to reset the
male 1-pin connector (green/white wir- compensation, set distance L.
ing harness with yellow tape).
L = 260 + B-A
2 (mm)
A: Width of narrow bucket

B: Width of standard bucket

★ If abnormality display code [01] is given
carry out the operation again from "1.
Reset potentiometer input signal". 9) Perform the above procedure from 2) to 7).
★ Run the engine at full throttle, carry out
the automatic stop and check stopping
distance L.
terminals to their original position.
PC58UU-3 20-141
b
TESTING AND ADJUSTING PROCEDURE FOR REPLACING POTENTIOMETER
PROCEDURE FOR REPLAC- ★ After replacing the potentiometers, set the

work equipment in the position for resetting
ING POTENTIOMETER and check to see if any error code is dis-
played. If any error code is displayed, reset
1. Remove potentiometers (1), (2), and (3) from the potentiometers, referring to "Procedure
the work equipment and install new ones. for resetting input and output signals of
• Boom potentiometer: (1) electric system".
• Arm potentiometer: (2)
• Offset potentiometer: (3)
20-142 PC58UU-3
b
TESTING AND ADJUSTING PROCEDURE FOR TESTING DIODE
PROCEDURE FOR TESTING

DIODE
• Use the following procedure to check the diode
as individual part and the wiring harness
including the diode.
• Use a digital tester with a range for measuring
diodes.
1. Put the red (+) end of the test pin in contact with
the anode (P) of the diode, and the black (-) end
in contact with the cathode (N).
★ There is a mark showing the direction of
continuity on the surface of the diode.
2. If a normal tester is switched to the diode

range, the voltage of the internal battery is dis-
played.
The value indicates the following.
• No change: No continuity
• Changes: There is continuity (normal)
(Note).
• The value is 0 or near 0: Short circuit inside
diode.
Note) If the diode is a silicon diode, the tester
indicates a value between 400 and 600.
Testers of certain kinds indicate 0.4 - 0.6.
PC58UU-3 20-143
b
TROUBLESHOOTING
TROUBLESHOOTING POINTS TO REMEMBER...................................................................................... 20-202

SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN PERFORMING MAINTENANCE .......................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CONNECTOR TYPES AND MOUNTING LOCATIONS ............................................................................. 20-214
CONNECTOR ARRANGEMENT DIAGRAM .............................................................................................. 20-216
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-219
T-ADAPTER - BOXES AND T-ADAPTER TABLE ................................................................................... 20-241-1
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRICAL SYSTEM ............................................ 20-242
METHOD OF USING JUDGEMENT TABLE............................................................................................... 20-258
METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-259
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................. 20-301
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (F-MODE)................................... 20-401
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H-MODE).......................................... 20-501
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M-MODE)............................................................ 20-601
PC58UU-3 20-201
(6)
TROUBLESHOOTING TROUBLESHOOTING POINTS TO REMEMBER
TROUBLESHOOTING POINTS TO REMEMBER
Stop the machine at a level place, and check that the safety pin, blocks, and parking
brake are securely fitted
When performing an operation with two or more workers, keep to the agreed signals
and do not allow any unauthorized person near the machine.
Removing the radiator cap when the engine is hot may cause hot water to spurt out,
causing burns. Thus, wait for the engine to cool down before removing the radiator
cap to troubleshoot the cooling system.
Do not touch any hot parts or get caught in any rotating parts.
Always disconnect the negative (-) battery terminal before disconnecting any wiring.
When removing a cap or plug from a location that is under pressure from oil, water,
or air, always release the internal pressure first.
The purpose of troubleshooting is to pinpoint the cause of the failure so that repairs can be made, and to
prevent reoccurence of the failure.
1. When troubleshooting, do not hurry to disas- 3) Check the travel of the control levers.
semble the parts. Disassembling the parts
4) Check the stroke of the control valve spool.
immediately may cause:
• Needless parts replacement. 5) Other maintenance items can be checked
externally, so check any item that is consid-
• Difficulty with diagnosis . ered to be necessary.
• A waste of manhours and parts.
• Loss of operator confidence. 4. Confirming failure.
Determine if the failure is due to a failed part or
a problem with the method of operation.
Thus, it is necessary to troubleshoot in accor-
dance with the established procedure. ★ When operating the machine to re-enact the
symptoms, do not perform any trouble-
2. Points to ask the operator. shooting or measurement that may make
matters worse.
1) Have any other problems occured beside
the reported problem? 5. Troubleshooting
2) Did the machine act "strange" just before Use the results of the investigation, items 2 thru
the failure occured? 4, to narrow the cause of failure. Then, use the
troubleshooting flowchart to locate the exact
3) Did the failure occur suddenly or were there
prior problems? cause of the failure.
★ The basic troubleshooting procedure is as
4) Under what conditions did the failure
occur? follows.
i) Start from the simple points.
5) Had any repairs been made just prior to the
failure? If so, what repairs? ii) Start from the most likely points.
iii) Investigate other related parts or infor-
6) Has the same kind of failure occured previ-
ously? mation.
6. Measures to remove the cause of failure.

3. Checks before troubleshooting.
• If the failure is repaired and the cause of the
1) Check the oil level. failure is not determined, the same failure
2) Check for andy external oil leakage from the may reoccur. To prevent a repeat failure,
piping or hydraulic equipment. always investigate why the problem
occurred and then remove or repair the
cause.
20-202 PC58UU-3
1
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PC58UU-3 20-203
(6)
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic
equipment" (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric

equipment
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

(1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or oxi-
dization of the contact surfaces.
(2) Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
are in contact at the crimped terminal or sol-
dered portion, but if there is excessive force
brought to bear on the wiring, the plating at
the joint will peel and cause improper con-
nection or breakage.
20-204 PC58UU-3
(6)
(3) Disconnections in wiring

If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering
may be damaged, or the wiring may be bro-
ken.
(4) High-pressure water entering connector

The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the connec-
tor, depending on the direction of the water
jet.
As already said, the connector is designed to
prevent water from entering, but at the same
time, if water does enter, it is difficult for it to
be drained. Therefore, if water should get
into the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take other
appropriate action before passing electricity
through it.
(5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector and
an oil film is formed on the mating surface be-
tween the male and female pins, the oil will
not let the electricity pass, so there will be de-
fective contact.
If there is oil or grease stuck to the connector,
wipe it off with a dry cloth or blow it dry with
compressed air and spray it with a contact re-
storer.
When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
PC58UU-3 20-205
(6)
2) Removing, installing, and drying connectors

and wiring harnesses
(1) Disconnecting connectors

• Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connectors
held by a screw, loosen the screw fully, then
hold the male and female connectors in each
hand and pull apart. For connectors which
have a lock stopper, press down the stopper
with your thumb and pull the connectors
apart.
Never pull with one hand.
• When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
If the connector is twisted up and down
or to the left or right, the housing may
break.
• Action to take after removing connectors

After removing any connector, cover it with a
vinyl bag to prevent any dust, dirt, oil, or wa-
ter from getting in the connector portion.
If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
20-206 PC58UU-3
(6)
(2) Connecting connectors

• Check the connector visually.
Check that there is no oil, dirt, or water stuck
to the connector pins (mating portion).
Check that there is no deformation, defective
contact, corrosion, or damage to the connec-
tor pins.
Check that there is no damage or breakage
to the outside of the connector.
If there is any oil, water, or dirt stuck to
the connector, wipe it off with a dry cloth.
If any water has got inside the connector,
warm the inside of the wiring with a dryer,
but be careful not to make it too hot as
this will cause short circuits.
If there is any damage or breakage, re-
place the connector.
• Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in the
connector until the stopper clicks into posi-
tion.
• Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is out
of position, adjust it to its correct position.
If the connector cannot be corrected eas-
ily, remove the clamp and adjust the po-
sition.
• If the connector clamp has been removed, be

sure to return it to its original position. Check
also that there are no loose clamps.
(3) Connecting connectors (DT type connector)

Since the DT 8-pole and 12-pole DT type con-
nectors have 2 latches respectively, push them
in until they click 2 times.
1. Male connector, 2. Female connector
• Normal locking state (Horizontal): a, b, d
• Incomplete locking state (Diagonal): c
PC58UU-3 20-207
(6)
(4) Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure water
or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-

lows.
• Disconnect the connector and wipe off the
water with a dry cloth.
If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
• Dry the inside of the connector with a dryer.

If water gets inside the connector, use a
dryer to dry the connector.
Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
• Carry out a continuity test on the connector.

After drying, leave the wiring harness discon-
nected and carry out a continuity test to
check for any short circuits between pins
caused by water.
After completely drying the connector,
blow it with contact restorer and reas-
semble.
20-208 PC58UU-3
(6)
3) Handling control box

(1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
(2) Do not open the cover of the control box un-
less necessary.
(3) Do not place objects on top of the control

box.
(4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
(5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to rain.
(6) Do not place the control box on oil, water, or

soil, or in any hot place, even for a short time.
(Place it on a suitable dry stand).
(7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc weld-
ing ground close to the welding point.
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays
will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current),
move the related wiring and connectors several times and check that there is no change in the reading
of the tester.
If there is any change, there is probably defective contact in that circuit.
PC58UU-3 20-209
(6)
3. Points to remember when handling hydraulic

equipment
With the increase in pressure and precision of

hydraulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling or
assembling hydraulic equipment, it is necessary to
be particularly careful.
1) Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt or dust get in during refill-

ing operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil cleaning
device is used, it is possible to filter out the dirt
that has collected during storage, so this is an
even more effective method.
20-210 PC58UU-3
(6)
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-
taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or
contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
PC58UU-3 20-211
(6)
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
Item Judgement Remedy

standard
1. Check fuel level, type of fuel — Add fuel
2. Check for impurities in fuel — Clean, drain
Lubricating oil, coolant
3. Check hydraulic oil level — Add oil

4. Check hydraulic strainer — Clean, drain
5. Check hydraulic filter (Torque converter, transmission oil) — Replace
6. Check brake oil level — Add oil
7. Check engine oil level — Add oil
8. Check coolant level — Add coolant
9. Check dust indicator for clogging — Clean or replace
10. Check for looseness, corrosion of battery terminal, wiring — Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wir-
equipment
Electrical
— Tighten or replace
ing
12. Check for looseness, corrosion of starting motor terminal,
— Repair or replace
wiring
13. Check operation of instruments — Repair or replace
14. Check for abnormal noise, smell — Repair
mechanical
equipment
Hydraulic,
15. Check for oil leakage — Repair

16. Carry out air bleeding — Bleed air
17. Check effect of parking brake, wheel brake Adjust, repair or
—
replace
18. Check battery voltage (engine stopped) 10 - 15 V Repair or replace
19. Check battery electrolyte level — Add or replace
20. Check for discolored, burnt, exposed wiring — Repair or replace
Electrical equipment
21. Check for missing wiring clamps, hanging wire — Repair

22. Check for water leaking on wiring (pay particular attention Disconnect
to water leaking on connectors or terminals) — connector and dry
23. Check for blown, corroded fuses Replace

24. Check alternator voltage (engine running at 1/2 throttle or After running for
several minutes: Check, repair or
above) (If the battery charge is low, the voltage may be 13.5 - 14.5 V replace
approximately. 25V immediately after charging)
25. Sound of actuation of battery relay (when starting switch
— Replace
is turned ON/OFF)
20-212 PC58UU-3
1
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR TYPES AND MOUNTING LOCATIONS

a The addresses in the address column are used in the connector arrangement drawing (3-dimensional draw-
ing).
Serial No.: 20001 – 22000

Con- Type of No. Con- Type of No.
nector connec- of Connector Add- nector connec- of Connector Add-
No. tor pins ress No. tor pins ress
A1 DT 3 Junction connector X-6 F11 DT 2 Boom stop EPC valve T-2

Air conditiner unit (Cab specification,
A2 SWP 6 optional) — F12 DT 2 —
Compressor (Cab specification,

A3 X 1 — F13 X 2 PPC lock switch X-4
optional)
B3 M 3 Junction connector W-2 F14 M 2 Alarm buzzer X-3
AM/FM car radio (Cab specification,
B4 — 9 — F15 KES1 4 Heater switch X-5
optional)
B5 KES1 2 Speaker (Left) — F16 KES1 4 Working lamp switch X-5
B6 KES1 2 Speaker (Right) — F17 KES1 6 Wiper switch X-4
B7 M 4 Junction connector W-2 F18 M 2 X-4
B8 Yazaki 4 Wiper motor — F19 X 2 Travel speed raising switch W-2
B9 M 2 Room lamp — F19 DT 4 Equipment signal connector —
B10 M 2 Junction connector X-2 F20 KES1 2 Heater X-6
D1 SWP 2 Diode (TVC) S-4 F21 DT 2 Power source for inside options X-6
D2 SWP 2 Diode (TVC) S-5 F22 SWP 6 FUel governor motor T-7
D3 SWP 2 Diode (PPC) S-5 F23 DT 2 T-7
D4 SWP 2 Diode (Offset) S-5 F24 DT 4 Attachment selection connector X-6
Emergency work equipment opera-
D5 SWP 2 Diode (Arm) T-1 F25 X 2 S-6
tion switch
D6 SWP 2 Diode (Boom) V-1 F26 M 2 Horn switch T-7
D7 SWP 2 Diode (PPC) T-1 F27 AMP040 16 Monitor panel U-7
D8 SWP 2 Diode (Offset) U-1 F28 KES1 3 Set/Clear switch U-7
D9 SWP 2 Diode (Arm) U-1 F29 KES1 4 Mode selector switch U-8
D10 SWP 2 Diode (Boom) U-1 F30 Terminal 1 Reset terminal power source X-7
Potentiometer stop position reset ter- W-7
D11 SWP 2 Diode K-8 F31 Terminal 1
minal (Side)
Potentiometer stop position reset ter- W-7
E1 SWP 8 Junction connector S-6 F32 Terminal 1
minal (Front)
F1 X 4 Junction connector S-3 FB1 — — Fuse box W-8
F2 Yazaki 2 Junction connector S-4 G1 DRC-23 24 (CR700) controller —
F3 SWP 12 Junction connector S-3 G2 DRC-23 40 (CR700) controller —
F5 DT 2 For driving pump TVC in emergency T-1 M1 DT 2 Fuel level sensor —
F6 DT 2 For driving work equipment in emer- T-2 M2 DT 2 Outside optional power source G-1
gency
F7 DT 2 PPC lock solenoid S-2 M3 KES0 2 Washer tank —
F8 DT 2 Travel speed solenoid S-2 M4 Yazaki 2 Horn J-1
F9 DT 2 LEFT offset stop solenoid S-2 M5 M 2 Fusible link H-1
F10 DT 2 Arm IN stop EPC valve S-2 M6 KES1 2 Alternator H-9
20-214 PC58UU-3
(6)
Con- Type of No. Con- Type of No.

Add- Add-
nector connec- of Connector nector connec- of Connector
No. tor pins ress No. tor pins ress
M7 M 1 Alternator J-9 (T-)M4 Terminal 1 Alternator (B) I-9

M8 X 1 Junction connector K-8 (T-)M5 Terminal 1 Engine oil pressure switch K-3
M9 DT 2 Engine speed sensor K-6 (T-)M6 Terminal 1 Air heater K-7
M10 DT 2 Coolant temperature sensor I-10 (T-)F7 Terminal 1 Pump drive switch in emergency —
M11 DT 2 TVC solenoid K-5 (T-)F8 Terminal 1 Pump drive switch in emergency —
M12 X 12 Engine stop solenoid K-7 W1 SWP 12 Junction connector H-9
M13 Terminal 1 Safety relay K-6 W3 DT 3 Offset potentiometer G-9
M13 X 2 Fuel pump K-1 W4 DT 3 Arm potentiometer B-6
M14 Terminal 1 Safety relay H-1 W5 DT 3 Working lamp (Left) G-9
M14 DT 3 Boom potentiometer H-1 W6 DT 3 Working lamp (Right) F-9
M15 X 4 Safety relay L-1 T1 X 2 Travel pressure switch I-2
M15 DT 3 Junction connector — T2 DT 2 Travel alarm I-2
M16 KES1 4 Timer L-2
M31 DT 4 Junction connector J-2
M32 X 4 Junction connector J-2
Neutral engine start relay (Starting
R1 — 5 V-1
motor circuit)
R1 Yazaki 2 Engine stop solenoid relay K-3
Neutral engine start relay (For PPC
R2 — 5 lock circuit) V-1
R3 — 5 Fuel governor motor relay (For V-1

deceleration)
Fuel governor motor relay (For accel-
R4 — 5 eration) V-1
R5 — 5 Fuel governor motor relay (For driv- V-1

ing)
R6 — 5 Crane changeover relay —
(T-)F1 Terminal 1 Starting switch T-9
(T-)F2 Terminal 1 Starting switch S-8
(T-)M1 Terminal 1 Battery (+) G-1
(T-)M2 Terminal 1 Starting motor (B) J-2
(T-)M3 Terminal 1 Starting motor (S) K-3
PC58UU-3 20-215
(6)

Con- Type of No. Add- Con- Type of No. Add-
ress ress
No. tor pins No. tor pins
A1 DT 3 Junction connector X-6 F11 DT 2 Boom stop EPC valve T-2
Air conditiner unit (Cab specification,
A2 SWP 6 — F12 DT 2 —
optional)
Compressor (Cab specification,
A3 X 1 — F13 X 2 PPC lock switch X-4
optional)
B3 M 3 Junction connector W-2 F14 M 2 Alarm buzzer X-3
B4 — 9 AM/FM car radio (Cab specification, — F15 KES1 4 Heater switch X-5
optional)
B5 KES1 2 Speaker (Left) — F16 KES1 4 Working lamp switch X-5
B6 KES1 2 Speaker (Right) — F17 KES1 6 Wiper switch X-4
B7 M 4 Junction connector W-2 F18 M 2 X-4
B8 Yazaki 4 Wiper motor — F19 X 2 Travel speed raising switch W-2
B9 M 2 Room lamp — F19 DT 4 Equipment signal connector —
B10 M 2 Junction connector X-2 F20 KES1 2 Heater X-6
D1 SWP 2 Diode (TVC) S-4 F21 DT 2 Power source for inside options X-6
D2 SWP 2 Diode (TVC) S-5 F22 SWP 6 Fuel governor motor T-7
D3 SWP 2 Diode (PPC) S-5 F23 DT 2 T-7
D4 SWP 2 Diode (Offset) S-5 F24 DT 4 Attachment selection connector X-6
Emergency work equipment operation S-6
D5 SWP 2 Diode (Arm) T-1 F25 X 2
switch
D6 SWP 2 Diode (Boom) V-1 F26 M 2 Horn switch T-7
D7 SWP 2 Diode (PPC) T-1 F27 AMP040 16 Monitor panel U-7
D8 SWP 2 Diode (Offset) U-1 F28 KES1 3 Set/Clear switch U-7
D9 SWP 2 Diode (Arm) U-1 F29 KES1 4 Mode selector switch U-8
D10 SWP 2 Diode (Boom) U-1 F30 Terminal 1 Reset terminal power source X-7
D11 SWP 2 Diode K-8 F31 Terminal 1 Potentiometer stop position reset ter- W-7
minal (Side)
E1 SWP 8 Junction connector S-6 F32 Terminal 1 Potentiometer stop position reset ter- W-7
minal (Front)
F1 X 4 Junction connector S-3 FB1 — — Fuse box W-8
F2 Yazaki 2 Junction connector S-4 G1 DRC-23 24 (CR700) controller —
F5 DT 2 For driving pump TVC in emergency T-1 M1 DT 2 Fuel level sensor —
F6 DT 2 For driving work equipment in emer- T-2 M2 DT 2 Outside optional power source G-1
gency
F7 DT 2 PPC lock solenoid S-2 M3 KES0 2 Washer tank —
F8 DT 2 Travel speed solenoid S-2 M4 Yazaki 2 Horn J-1
F9 DT 2 LEFT offset stop solenoid S-2 M5 M 2 Fusible link H-1
F10 DT 2 Arm IN stop EPC valve S-2 M6 SUMI 3 Alternator H-9

TOMO
20-215-1 PC58UU-3
(6)
Con- Type of No. Add- Con- Type of No. Add-

ress ress
No. tor pins No. tor pins
M8 X 1 Junction connector K-8 (T-)F8 Terminal 1 Pump drive switch in emergency —
M9 DT 2 Engine speed sensor K-6 W1 SWP 12 Junction connector H-9
M10 DT 2 Coolant temperature sensor I-10 W3 DT 3 Offset potentiometer G-9
M11 DT 2 TVC solenoid K-5 W4 DT 3 Arm potentiometer B-6
M12 X 3 Engine stop solenoid K-7 W5 DT 3 Working lamp (Left) G-9
M13 X 2 Fuel pump K-1 W6 DT 3 Working lamp (Right) F-9
M16 KES 4 Timer L-2 T1 X 2 Travel pressure switch I-2
SUMI
M34 2 Safety relay K-1 T2 DT 2 Travel alarm I-2
TOMO
SUMI
M35 TOMO 6 Safety relay K-1
Neutral engine start relay (Starting

R1 — 5 V-1
motor circuit)
Neutral engine start relay (For PPC
R2 — 5 V-1
lock circuit)
Fuel governor motor relay (For
R3 — 5 deceleration) V-1
R4 — 5 Fuel governor motor relay (For accel- V-1

eration)
R5 — 5 Fuel governor motor relay (For driv- V-1

ing)
R6 — 5 Crane changeover relay —
T1 DT 2 Pressure switch (for travel alarm)
T2 DT 2 Travel alarm
(T-)M1 Terminal 1 Battery (+) G-1
(T-)M2 Terminal 1 Starting motor (B) J-2
(T-)M3 Terminal 1 Starting motor (S) K-3
(T-)M4 Terminal 1 Alternator (B) I-9
(T-)M5 Terminal 1 Engine oil pressure switch K-3
(T-)M6 Terminal 1 Air heater K-7
(T-)F7 Terminal 1 Pump drive switch in emergency —
PC58UU-3 20-215-2
(6)
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
CONNECTOR ARRANGEMENT DIAGRAM

Serial No.: 20001 — 22000
20-216 PC58UU-3
(6)
PC58UU-3 20-217
1
20-218 PC58UU-3
1
20-218-2 PC58UU-3
(6)
PC58UU-3 20-218-3
(6)
20-218-4 PC58UU-3
(6)
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
the mating portion of the housing.
No. X-type connector

of T-adapter
pins Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part no.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491

• Terminal part no.: 79A-222-3370 • Terminal part no.: 79A-222-3390
• Electric wire size: 0.85 • Electric wire size: 0.85
— —
• Grommet: black • Grommet: black
• Quantity: 20 • Quantity: 20
• Terminal part no.: 79A-222-3380 • Terminal part no.: 79A-222-3410
— —
• Grommet: red • Grommet: red
PC58UU-3 20-219
1
No. SWP-type connector

of T-adapter
Part No.
6 799-601-7050
Part No.: 08055- 10681 Part No.: Part No.: 08055- 10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055- 10891
12 799-601-7310
Part No.: 08055- 11281 Part No.: 08055- 11291
14 799-601-7070
Part No.: 08055- 11481 Part No.: 08055-11491
20-220 PC58UU-3
1
No. SWP-type connector

of T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691

• Terminal part no.: • Terminal part no.:
— —
• Grommet: black • Grommet: black
• Terminal part no.: • Terminal part no.:
— —
• Grommet: red • Grommet: red
PC58UU-3 20-221
1
No. M-type connector

of T-adapter
Part No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
Part No.: 08056-00671 Part No.: 08056-00681
8 799-601-7340
Part No.: 08056-00871 Part No.: 08056-00881
20-222 PC58UU-3
(6)
S-type connector
No.
of pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
799-601-7150
(white)
Part No.: 08056-11071 Part No.: 08056-11081
12
799-601-7350
(white)
Part No.: 08056-11271 Part No.: 08056-11281
16
799-601-7330
(white)
Part No.: 08056-11671 Part No.: 08056-11681
PC58UU-3 20-223
1
No. S-type connector

of T-adapter
Part No.
10
—
(blue)
— —
12
799-601-7160
(blue)
Part No.: 08056-11272 Part No.: 08056-11282
16
799-601-7170
(blue)
Part No.: 08056-11672 Part No.: 08056-11682
20-224 PC58UU-3
1
MIC type connector

No.
of pins T-adapter
Part No.
Housing part No.: 79A-222-2640 Housing part No.: 79A-222-2630
7 —
Qty.: 5 Qty.: 5
11 —
Qty.: 5 Qty.: 5
5 799-601-2710

Qty.: 5 Qty.: 5
9 799-601-2950

Qty.: 5 Qty.: 5
13 799-601-2720

Qty.: 2 Qty.: 2
PC58UU-3 20-225
(6)
MIC type connector

No. of
pins T-adapter
Part No.
17 799-601-2730

Qty.: 2 Qty.: 2
21 799-601-2740

Qty.: 2 Qty.: 2
—
Qty.: 50 Qty.: 50
20-226 PC58UU-3
1
AMP040-type connector
No. of
pins T-adapter
Part No.
8 799-601-7180
Housing part No.: 79A-222-3430

—
Qty.: 5
12 799-601-7190

—
Qty.: 5
16 799-601-7210

—
Qty.: 5
20 799-601-7220

—
Qty.: 5
★Terminal part No.: 79A-222-3470 (no relation with number of pins)
PC58UU-3 20-227
1
AMPO70-type connector
No. of
pins T-adapter
Part No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
20 799-601-7550
— Part No.: 08195-20210
20-228 PC58UU-3
1
L type connector
No. of
pins T-adapter
Part No.
—
2
— — —
PA type connector
No. of
pins T-adapter
Part No.
— —
Bendix MS connector
No. of
pins T-adapter
Part No.
10 799-601-3460
— —
PC58UU-3 20-229
1
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
2 —
Part No.: 08027-10210 (natural color) Part No.: 08027-10260 (natural color)
08027-10220 (black) 08027-10270 (black)
3 —
Part No.: 08027-10310 Part No.: 08027-10360
4 —
08027-10420 (black) 08027-10470 (black)
6 —
08027-10620 (black) 08027-10670 (black)
20-230 PC58UU-3
1
KES 1 (Automobile) connector

No. of
pins T-adapter
Part No.
8 —
08027-10820 (black) 08027-10870 (black)
PC58UU-3 20-231
1
Connector for relay (socket type)

No. of
pins T-adapter
Part No.
5 799-601-7360
— —
6 799-601-7370
— —
20-232 PC58UU-3
1
F-type connector
No. of
pins T-adapter
Part No.
4 —
— —
PC58UU-3 20-233
1
Type HD30 series connector

(shell size T-adapter
code) Body (plug) Body (receptacle)
Part No.
Pin (male terminal) Pin (female terminal)
Part No.: 08191-11201, 08191-11202, Part No.: 08191-14101, 08191-14102,

18-8 08191-11205, 08191-11206 08191-14105, 08191-14106
799-601-9210
(1) Pin (female terminal) Pin (male terminal)
Part No.: 08191-12201, 08191-12202, Part No.: 08191-13101, 08191-13102,

08191-12205, 08191-12206 08191-13105, 08191-13106
Part No.: 08191-21201, 08191-12202, Part No.: 08191-24101, 08191-24102

18-14 08191-21205, 08191-12206 08191-24105, 08191-24106
799-601-9220
Part No.: 08191-22201, 08191-22202, Part No.: 08191-23101, 08191-23102,

08191-22205, 08191-22206 08191-23105, 08191-23106
20-234 PC58UU-3
1

Part No.
18-20 Part No.: 08191-31201, 08191-31202 Part No.: 08191-34101, 08191-34102

799-601-9230
Part No.: 08191-32201, 08191-32202 Part No.: 08191-33101, 08191-33102

18-21 Part No.: 08191-41201, 08191-42202 Part No.: 08191-44101, 08191-44102

799-601-9240
Part No.: 08191-42201, 08191-42202 Part No.: 08191-43101, 08191-43102
PC58UU-3 20-235
1

Part No.
24-9 Part No.: 08191-51201, 08191-51202 Part No.: 08191-54101, 08191-54102

799-601-9250
Part No.: 08191-52201, 08191-52202 Part No.: 08191-53101, 08191-53102

Part No.: 08191-61201, 08191-62202 Part No.: 08191-64101, 08191-64102

24-16 08191-61205, 08191-62206 08191-64105, 08191-64106
799-601-9260
Part No.: 08191-62201, 08191-62202, Part No.: 08191-63101, 08191-63102,

08191-62205, 08191-62206 08191-63105, 08191-63106
20-236 PC58UU-3
1

Part No.
Part No.: 08191-71201, 08191-71202, Part No.: 08191-74101, 08191-74102,

24-21 08191-71205, 08191-71206 08191-74105, 08191-74106
799-601-9270
Part No.: 08191-72201, 08191-72202, Part No.: 08191-73101, 08191-73102,

08191-72205, 08191-72206 08191-73105, 08191-73106
Part No.: 08191-81201, 08191-81202, 08191- Part No.: 08191-84101, 08191-84102, 08191-
81203, 08191-81204, 08191-81205, 08191- 84103, 08191-84104, 08191-84105, 08191-
24-22 81206 84106
799-601-9280
Part No.: 08191-82201, 08191-82202, 08191- Part No.: 08191-83101, 08191-83102, 08191-
82203, 08191-82204, 08191-82205, 08191- 83103, 08191-83104, 08191-83105, 08191-
82206 83106
PC58UU-3 20-237
(6)

Part No.
Part No.: 08191-91203, 08191-91204, Part No.: 08191-94103, 08191-94104,

24-31 08191-91205, 08191-91206 08191-94105, 08191-94106
799-601-9290
Part No.: 08191-92203, 08191-92204, Part No.: 08191-93103, 08191-93104,

08191-92205, 08191-92206 08191-93105, 08191-93106
20-238 PC58UU-3
1
DT series connector
No. of
pins T-adapter
Body (plug) Body (receptacle)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
4 799-601-9040
6 799-601-9050
PC58UU-3 20-239
1
DT series connector
No. of
pins T-adapter
Part No.
8Gr: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8Br: 799-601-9080
Part No.: 08192-1820! (normal type) Part No.: 08192-1810!(normal type)

08192-2820! (fine wire type) 08192-2810!(fine wire type)
12Gr: 799-601-9110
12B: 799-601-9120
12 12G: 799-601-9130
12Br: 799-601-9140
Part No.: 08192-1920! (normal type) Part No.: 08192-1910!(normal type)

08192-2920! (fine wire type) 08192-2910! (fine wire type)
20-240 PC58UU-3
(6)
DTM series connector

No. of
pins T-adapter
Part No.
2 799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
DTHD series connector

No. of
pins T-adapter
Part No.
Part No.: 08192 - 31200 (contact size #12) Part No.: 08192 - 31100 (contact size #12)
08192 - 41200 (contact size #8) 08192 - 41100 (contact size #8)
08192 - 51200 (contact size #4) 08192 - 51100 (contact size #4)
PC58UU-3 20-241
(6)
TROUBLESHOOTING T-ADAPTER - BOXES AND T-ADAPTER TABLE
T-ADAPTER - BOXES AND T-ADAPTER TABLE

The part Nos. of the T-adapter boxes and T-adapters are shown in the columns and those of the wiring har-
ness checker assemblies are shown in the lines.
KIT Part No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
Part No. Type of connector No. of pins
799-601-2600 Box for measurement Econo-21P Q Q Q Q Q Q

799-601-3100 Box for measurement MS-37P Q
799-601-3200 Box for measurement MS-37P Q
799-601-3300 Box for measurement Econo-24P Q
799-601-3360 Plate For MS box
799-601-3410 BENDIX(MS) 24P Q Q
799-601-3420 BENDIX(MS) 24P Q Q
799-601-3430 BENDIX(MS) 17P Q Q
799-601-3440 BENDIX(MS) 17P Q Q
799-601-3450 BENDIX(MS) 5P Q Q
799-601-3460 BENDIX(MS) 10P Q Q
799-601-3510 BENDIX(MS) 5P Q Q
799-601-3520 BENDIX(MS) 14P Q Q
799-601-3530 BENDIX(MS) 19P Q Q
799-601-2910 BENDIX(MS) 14P Q Q
799-601-3470 Case Q
799-601-2710 MIC 5P Q Q Q Q
799-601-2720 MIC 13P Q Q Q Q
799-601-2730 MIC 17P Q Q Q Q Q Q Q
799-601-2740 MIC 21P Q Q Q Q Q Q Q
799-601-2950 MIC 9P Q Q Q Q
799-601-2750 ECONO 2P Q Q
799-601-2760 ECONO 3P Q Q
799-601-2770 ECONO 4P Q Q
799-601-2780 ECONO 8P Q Q
799-601-2790 ECONO 12P Q Q
799-601-2810 DLI 8P Q Q
799-601-2820 DLI 12P Q Q
799-601-2830 DLI 16P Q Q
799-601-2840 Extension cable Q Q Q
799-601-2850 Case Q
799-601-7010 X 1P Q Q
799-601-7020 X 2P Q Q Q Q
799-601-7030 X 3P Q Q Q Q
799-601-7040 X 4P Q Q Q Q
799-601-7050 SWP 6P Q Q Q
799-601-7060 SWP 8P Q Q Q
799-601-7310 SWP 12P Q
799-601-7070 SWP 14P Q Q
20-241-1 PC58UU-3
(6)
KIT Part No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-7320 SWP 16P Q

799-601-7080 M 1P Q Q
799-601-7090 M 2P Q Q Q Q
799-601-7110 M 3P Q Q Q Q
799-601-7120 M 4P Q Q Q Q
799-601-7130 M 6P Q Q Q Q
799-601-7340 M 8P Q
799-601-7140 S 8P Q Q Q Q
799-601-7150 S 10P-White Q Q Q Q
799-601-7160 S 12P-Blue Q Q Q
799-601-7170 S 16P-Blue Q Q Q Q
799-601-7330 S 16P-White Q
799-601-7350 S 12P-White Q
799-601-7180 AMP040 8P Q
799-601-7190 AMP040 12P Q Q
799-601-7210 AMP040 16P Q Q Q Q
799-601-7220 AMP040 20P Q Q Q Q
799-601-7230 Short connector X-2 Q Q Q Q
799-601-7240 Case Q Q
799-601-7270 Case Q
799-601-7510 070 10P Q
799-601-7520 070 12P Q
799-601-7530 070 14P Q
799-601-7540 070 18P Q
799-601-7550 070 20P Q
799-601-7360 Relay connector 5P Q
799-601-7370 Relay connector 6P Q
799-601-7380 JFC connector 2P Q
799-601-9010 DTM 2P Q Q
799-601-9020 DT 2P Q Q
799-601-9030 DT 3P Q Q
799-601-9040 DT 4P Q Q
799-601-9050 DT 6P Q Q
799-601-9060 DT 8P-Gray Q Q
799-601-9070 DT 8P-Black Q Q
799-601-9080 DT 8P-Green Q Q
799-601-9090 DT 8P-Brown Q Q
799-601-9110 DT 12P-Gray Q Q
799-601-9120 DT 12P-Black Q Q
799-601-9130 DT 12P-Green Q Q
799-601-9140 DT 12P-Brown Q Q
799-601-9210 HD30 18-8 Q Q
799-601-9220 HD30 18-14 Q Q
799-601-9230 HD30 18-20 Q Q
PC58UU-3 20-241-2
(6)
KIT Part No.
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
—
799-601-9240 HD30 18-21 Q Q

799-601-9250 HD24 24-9 Q Q
799-601-9260 HD30 24-16 Q Q
799-601-9270 HD30 24-21 Q Q
799-601-9280 HD30 24-23 Q Q
799-601-9290 HD30 24-31 Q Q
799-601-9310 Plate For HD30 Q Q Q
799-601-9320 Box for measurement For DT, HD Q Q Q
799-601-9330 Case Q
799-601-9340 Case Q
799-601-9350 DEUTSCH 40P Q
799-601-9360 DEUTSCH 24P Q
799-601-9410 For NE, G sensor 2P Q
For fuel, boost
799-601-9420 3P Q
pressure
799-601-9430 PVC socket 2P Q
20-241-3 PC58UU-3
(6)
EXPLANATIONS OF CONTROL MECHANISM OF
TROUBLESHOOTING ELECTRICAL SYSTEM
EXPLANATIONS OF CONTROL MECHANISM OF ELECTRI-

CAL SYSTEM
This section gives the necessary knowledge for trouble shooting of the electrical system, and explains the
functions and nature of checks for the monitor panel and controller.
1. Explantion of functions
The control mechanism of the electrical system consists of the monitor panel and controller. It carries
out various controls such as stopping the work equipment in the interference area, setting the working
area (height, depth, offset), displaying the depth, and one-touch deceleration.
The monitor panel and controller each input the necessary signals, and at the same time, together with
the signals selected and set by the moitor panel, the controller inputs and outputs the necessary signals
to control the stopping of the work equipment, the setting of the working area (height, depth, offset),
displaying of the depth, and one-touch deceleration.
• Input/Output signal system for monitor and controller
20-242 PC58UU-3
1
PRECAUTIONS FOR TROUBLESHOOTING

The controller has a self-diagnosis function of troubleshooting itself as long as possible.
During troubleshooting, error codes are displayed in the depth display section of the monitor panel and in
the display section of the controller.
At the same time, the controller blinks the caution lamp of the electric system and sounds the alarm buzzer
intermittently to notify the operator for the trouble mode and takes the following actions.
• Display of troubled systems and actions taken for them
When work equipment solenoid valve systems (E, F, G) are troubled (Error codes: 5!, 5@, 4@)
• Stops operations of E, F, and G (Work equipment cannot move in interfering directions).
When PPC main pressure lock solenoid valve system (I) is troubled (Error code: 41)
• When error code is 41: Stop operation of H (Since PPC main pressure is too low,
machine cannot operate work equipment, travel, or swing at all).
When interference prevention system is troubled (When work equipment enters into interference
area because spool does not close) (Error code: 61)
• Stops operation of I (Since PPC main pressure is too low, machine cannot operate
work equipment, travel, swing, or blade at all).
When resetting switch systems (J, 1)) are troubled (Error codes: 01 - 18)
• Sets values to zero of indication of potentiometer angle, bucket front and side stop
positions, and depth. Machine can operate normally, however.
When pump control systems (1!, 1#) are troubled (Error codes: 54, 24)
• Operates machine with 1! at certain value, or stops the machine.
★ Once a trouble other than error code [61] is diagnosed, trouble is kept as it is. If the trouble of error
code [61] is diagnosed and reset, the controller is set in the normal mode and the error code display
goes off.
Even if there is any abnormality in the other than monitored inputs, error code is not displayed. Some
input and output signals are checked with the [monitoring function].
PC58UU-3 20-243
1
CHECK OF OPERATION OF ELECTRIC SYSTEM

★ The boom (RAISE) end cushion and arm (IN) end cushion functions are not checked.
When the following operations are executed according to the given procedure, if the monitor panel and
controller operate as shown below, the input and output signals, monitor panel, and controller are nor-
mal.
Check item (When normal)
Operation procedure and condition of machine
Monitor panel Controller
B Turn OFF starting switch. • All segments go OFF. • All segments go OFF.
• All segments light up for about 3
ON ! 3 sec sec.
• Buzzer sounds for about 1 sec.
Turn ON starting • Engine oil pressure and charge • [0.0] is displayed in self-diagno-
C switch. 3 sec ! 5 sec level lamps light up. sis display section.
• If bucket is above ground, [UP]
After 5 sec is displayed. If below ground,
[depth] is displayed.
• Work equipment can be oper-
D Run engine (at slow speed). • All caution lamps go OFF. ated.
• Buzzer does not sound.
• Work equipment stops at speci-
Bring bucket from front and side to near fied position.
E cab (canopy). • Buzzer sounds at intervals of
about 1 sec.
• Work equipment can be moved
away from cab (Arm DUMP,
RIGHT offset).
F Move bucket away from cab (canopy). • Buzzer sounds continuously
until work equipment is moved
away sufficiently, then sound
stops.
Turn ON emergency work equipment • Electric system lamp blinks at
operation switch. • Buzzer sounds for about 7 sec.
intervals of about 1 sec.
#
• Work equipment can be oper-
G Perform E and F above. • Electric system lamp blinks at
ated (It does not stop automati-
# intervals of about 1 sec
cally, however).
Turn OFF emergency work equipment • Electric system lamp goes off.
operation switch.
Raise work equipment to 1 m above • Height mode indicator lights up. • Buzzer sounds twice.
ground and set mode selector switch to
[HEIGHT] and turn setting switch to SET. • Work equipment stops near set
H
# position.
• Buzzer sounds twice.
Lower boom once, then raise it.
Set boom to LEFT offset and mode selec- • Offset mode indicator lights up. • Buzzer sounds twice.
tor switch to OFFSET, then turn setting
switch to SET. • Work equipment stops near set
I
# position.
• Buzzer sounds twice.
Offset arm to right once, then to left.
• Depth indicator displays [0.0]
•
Push up machine body with work equip- (ground level).
J ment. • Displayed depth increases from
[0.1].
1) Turn OFF starting switch. • All segments go OFF. • All segments go OFF.
20-244 PC58UU-3
1
POSITIONS OF WORK EQUIPMENT

• Operation steps E and F (Front of operator's • Operation step h
cab)
• Operation steps E and F (Side of operator's

cab)
PC58UU-3 20-245
1
DISPLAY METHOD OF MONITOR PANEL AND CONTROLLER

1. Monitor panel.
1) Machine monitor
After the starting switch is turned ON, all the mon-
itor and gauge segments light up for about 3 sec-
onds and the buzzer sounds for about 1 second
and monitor performs self-diagnosis
2) The mode indicator lights up in the height mode.
★ If the starting switch is turned OFF, setting is
cleared.
3) Depth display section
i) Display of depth (Normal display)
The depth from the ground level or from the
datum plane is displayed as shown below.
• If the bucket is below the ground level or
datum plane, a [figure] is displayed.
• If the bucket is above the ground level or
datum plane, [UP] is displayed.
• Example of depth of 2.5 m

Display of depth Display of depth
from ground level from datum plane Display
Above ground level Above datum plane UP

Ground level Datum plane 0.0
Below ground level Below datum plane 2.5
20-246 PC58UU-3
1
ii) Display of self-diagnosis (Abnormal display)

If the controller has a trouble in itself or
detects a trouble in the input signal system or
output signal system, it displays the corre-
sponding error code in the height display sec-
tion.
At this time, electric system caution lamp (1)

blinks. The alarm buzzer sounds, depending
on the degree of the trouble.
★ The self-diagnosis result is displayed prior to
the depth.
★ If there is a trouble in communication
between the monitor panel and controller, the
error code [EE] is displayed in the height dis-
play section but the electric system caution
lamp and the alarm buzzer are not turned on.
In this case, since communication between
the controller and monitor is erroneous,
machine condition cannot be monitored.
★ For the displayed error codes, see "2. Control-
ler".
4) Function of displaying saved error codes
The error codes detected by the controller are
saved in the controller and can be displayed by
the following operation.
• The error codes detected in the past can be dis-
played at any time by the following procedures.
★ Once an error code is detected (saved), it is kept
saved until it is deleted. Accordingly, delete it
after checking it.
1) Turn the starting switch to the ON position (or
start the engine).
• The buzzer sounds for about 1 second and
the monitor and gauge segments light up
for about 3 seconds, then all the segments,
except the engine oil pressure and battery
charge level, go off.
PC58UU-3 20-247
1
2) Set mode selector switch (1) of the monitor

panel to [Depth to 0] and turn SET/CLEAR
switch (2) to the [CLEAR] position and hold it
for at least 20 seconds.
i) If there is any trouble record, the error
code (2-digit number) is displayed (The
latest one is displayed).
Example of display: 2 Boom potentiome-
ter trouble
ii) If there is not a trouble record, [——]is dis-
played.
iii) If the trouble is still being detected, the
[HEIGHT] indicator of the mode indicator
lights up.
3) While the code is displayed, advance (return)
to the code you want to check by setting the
SET/CLEAR switch to the [SET] ([CLEAR])
position.
• While the data is displayed, if the SET/
CLEAR switch is set to the [SET] (or
[CLEAR]) position, the code is displayed.
• For the contents of display, see [Error
codes list].
4) To turn off the function of displaying saved
error codes, perform the operation of 2)
above again or turn the starting switch to the
OFF position.
20-248 PC58UU-3
1
5) To delete error codes

With the SET/CLEAR switch at the [CLEAR] posi-
tion, turn the starting switch from the OFF position
to the ON position and hold it for at least 5 seconds
(The error code is deleted under this condition).
Check that the error codes are deleted by the
method above. (If [——] is displayed, the error
codes were deleted.) After checking, finish by the
method in 4) above.
★ If a trouble occurs in communication between
the monitor panel and controller, the monitor
displays the error code of [EE] on itself.
Accordingly, while communication is troubled,

even if the controller detects a trouble and out-
puts an error code, it is not displayed on the
monitor. This state is dangerous. In this case,
do not operate the machine until the communi-
cation trouble is repaired.
Note that although the [monitoring function] is
not available for the above reason, the control-
ler does not have a trouble.
2. Controller
1) Normal display: The green lamp in the side win-
dow lights up.
2) Side window: Green lamp blinks.
PC58UU-3 20-249
1
3. Display in monitoring mode

• Enter the monitoring mode according to the fol-
lowing procedure.
1) Turn the starting switch to the ON position (or
start the engine if you want to check the operating
condition).
• The buzzer sounds for about 1 second and the
monitor and gauge segments light up for
about 3 seconds, then all the segments,
except the engine oil pressure and battery
charge level, go off.
2) Set mode selector switch (1) of the monitor panel

to [Depth to 0] and turn SET/CLEAR switch (2) to
the SET position and hold it for at least 20 sec-
onds."
• The monitoring code is displayed in the
height display section (error code display sec-
tion). After 2.5 seconds, the data of each code
are displayed.
• While the code is displayed, the [central] indi-
cator lamp keeps lighted up.
• While the data are displayed, the [central] and
[right] indicator lamps keep lighted up.
• The figure at right is an example of display of
arm potentiometer voltage, where the code of
[32] and voltage of [2.8 V] are displayed.
3) While the code is displayed, advance (return) to
the code you want to check by setting the SET/
CLEAR switch (2) to the [SET] ([CLEAR]) position.
• While the data is displayed, if the SET/CLEAR
switch is set to the [SET] (or [CLEAR]) posi-
tion, the code is displayed.
• For the contents of display, see the following
page.
• While the code of [00] is displayed, if the
switch is set to the [CLEAR] position, [60] is
displayed again.
4) To go out of the monitoring mode, perform the
operation of 2) above again or turn the starting
switch to the OFF position.
20-250 PC58UU-3
1
CONTENTS OF DISPLAY IN MONITORING MODE

You can select a code with the SET/CLEAR switch and see its contents. You can also check the inputting,
outputting, and connecting conditions of the ON/OFF inputs and outputs by operating switches and con-
necting plugs.
Type of display (A: Numeral, B: Bit)
Monitoring mode table
Displayed Contents Unit Type of Example of display
code display
00 Software version No. — A If [1.0] is displayed, version No. of controller is

1.0.
01 Selection of attachment 00 :Standard arm
01 :Long arm
A0: Standard arm of arm crane specification
A1: Long arm of arm crane specification
— A C0: Standard arm of arm crane specification +
X-counterweight
C1: Long arm of arm crane specification +
X-counterweight
— : No setting
10 Engine speed When left indicator is turned off, it denotes that
number of thousands in rpm is 1. If [53] is dis-
rpm A played, engine speed is 1,530 rpm.
When left indicator is turned on, it denotes that
number of thousands in rpm is 2. If [03] is dis-
played, engine speed is 2,030 rpm.
20 ON/OFF input/output 1 — B
23 ON/OFF input/output 4 — B See [Bit map table].
30 Work equipment angle sensor V A

voltage for 1st boom

voltage for offset
If [24] is displayed, input voltage is 2.4 V.
voltage for arm

voltage for slide
40 Boom bottom pressure MPa A If [24] is displayed, input pressure is 24 MPa.
50 EPC output current for TVC x 10mA A
51 EPC output current for 1st boom x 10mA A If [55] is displayed, current is 550 mA. [F.F] is dis-
RAISE played when current is 1 A, however.
52 EPC output current for arm IN x 10mA A
60 ON/OFF output — B See [Bit map table].
80 Distance of work equipment edge cm A

from front of cab
If [21] is displayed, distance is 21 cm. If [F.F] is
81 Height of work equipment edge cm A displayed, distance is longer than 100 cm.
82 Distance of work equipment edge cm A
from side of cab
PC58UU-3 20-251
1
BIT MAP TABLE
Displayed codes 20 ~ 25 and 60 are bit codes used to check ON/OFF input and output.
Bit e Bit b
Displayed Contents Bit f Bit c
code
Bit g Bit d
ATT1 ATT1
(When GND is connected) (When GND is connected) "1
20 ON/OFF Model selection 2 ATT2
input/output 1 (When GND is connected) (When GND is connected) "1
UU/US selection ATT3
(When GND is connected) (When GND is connected)
Compressor signal Main monitor selection

(When power source is connected)
21 ON/OFF Deceleration motor
input/output 2
(When power source is connected)
Installation of arm crane
Mode 1 " 2 Reset 1
(When GND is connected) (When plug is connected) " 3
Mode 2 " 2 Reset 2
22 ON/OFF (When GND is connected) (When plug is connected) " 3
input/output 3
Deceleration LED Monitor back light
(When one-touch deceleration is turned
ON) (When lighting up)
23 ON/OFF
input/output 4
Motor drive relay Acceleration signal
(When relay changeover is turned ON) (When signal is input)
ON/OFF Motor relay (+) Deceleration signal
24 input/output 5 (When relay changeover is turned ON) (When signal is input)
Motor relay (-) Automatic deceleration switch
(When relay changeover is turned ON) (When signal is input)
Arm-ground angle alarm Display selection switch

ON/OFF (Crane monitor)
25 input/output 6 Bucket dump prohibition solenoid + Crane mode switch
Rotary lamp (Crane monitor)
Emergency work equipment operation
switch
ON/OFF
26 input/output 7 Deceleration switch
Slide arm limit switch Travel speed raising switch
LEFT offset stop solenoid PPC main pressure lock solenoid
ON/OFF (When LEFT offset is stopped) (When main pressure lock is reset)
60
input/output Travel speed raising solenoid
(When travel speed is raised)
" 1 ~ " 3 , see the following page.
20-252 PC58UU-3
1
" 1: Connections of the attachment selection wires are shown below.
(Bits of GND section are displayed during normal operation.)

Attachment Attachment selection (1) Attachment selection (2) Attachment selection (3)
Standard arm GND OPEN OPEN
Long arm OPEN GND OPEN
Crane, standard GND OPEN OPEN
Crane, standard X GND OPEN GND
Crane, long OPEN GND OPEN
Crane, long X OPEN GND GND
No setting Other than above combinations of OPEN and GND
" 2: Connections of the mode setting switches are shown below.
(Bits of GND section are displayed during normal operation.)

Position of switch Mode (1) switch Mode (2) switch
Set displayed depth to 0 OPEN OPEN
Height GND OPEN
★ 1 OPEN GND
★ 2 GND GND
" 3: Connections of the stroke end switches and reset switches are shown below.
(Bits are displayed when connected to power source terminal (CN-F30) during normal operation.)
Set Connection when bits are displayed Tape
Stroke end set (1) CN-F32 Not wound
Stroke end set (2) CN-F31 Wound
Front stop CN-F30 CN-F32 Not wound
Side stop (Power source) CN-F31 Wound
Depth reset (1) CN-F32 Not wound
Depth reset (2) CN-F31 Wound
★ In this monitoring mode, the [SET] and [CLEAR] positions of the SET/CLEAR switch are used to change
the display of data to the display of code. Accordingly, you cannot check that they are working nor-
mally. When they can change the display of data to the display of code, however, they are judged nor-
mal.
PC58UU-3 20-253
1
ERROR CODES LIST

Method of reproduction # : Turn the starting switch to the ON position.
$ : Run the engine and set the work equipment in the reset position and
connect the reset terminal.
" : Run the engine and bring the bucket into the interference area.
★ The error codes other than [01] ~ [1F] and [SINGLE] are not saved.
Error Method
Single/ of Method
Group Troubled system repro- Group Error Troubled system Single/ of repro-
code mutiple duction code mutiple duction
Front stop position reset

01 trouble Single $ 11 Boom angle reset trouble Single $
Side stop position reset
02
trouble
Single $ 12 Arm angle reset trouble Single $
Front stop position reset + Boom angle reset + Arm
03 Side stop position reset 01 + 02 $ 13
angle reset trouble
11 + 12 $
trouble
14 Offset angle reset trouble Single $
Boom angle reset + Offset
15
angle reset trouble
11 + 14 $
Arm angle reset + Offset
16 angle reset trouble 12 + 14 $
Boom angle reset + Arm 11 + 12 +
17 angle reset + Offset angle
14 $
reset trouble
Front stop position boom
18 angle reset trouble Single $
Boom angle reset + Front
19 stop position boom angle 11 + 18 $
Reset
Reset
reset trouble
Arm angle reset + Front stop
1A position boom angle reset 12 + 18 $
trouble
Boom angle reset + Arm
angle reset + Front stop 11 + 12 +
1b position boom angle reset 18 $
trouble
Offset angle reset + Front
1C stop position boom angle 14 + 18 $
reset trouble
Boom angle reset + Offset
1d position boom angle reset 18 $
trouble
Arm angle reset + Offset
1E
position boom angle reset 18 $
trouble
Boom angle reset + Arm
angle reset + Offset angle 11 + 12
1F reset + Front stop position +14 + 18 $
boom angle reset trouble
Front stop position reset trouble/Side stop position Reset trouble: When the actual angle is out of the
reset trouble set angle range
: When the stop position is out of the set reset Boom = At RAISE stroke end, angle is ± 5°.
width
Reset width: ± 300 mm Arm = At IN stroke end, angle is ± 14°.
Depth display correction trouble Offset boom = At RIGHT end, angle is ± 20°.
: When the displayed depth is out of the
correction width for zero setting
Correction width: ± 500 mm
★ The items in the thick frames are displayed singly.

★ If an error code in the range from 01 ~ 1F is displayed, reset the system referring to [Procedure for reset-
ting electric system and checking its operation].
20-254 PC58UU-3
1
Error Method
Single/ of Method
Sensor
24 Rotation sensor # 41 PPC lock solenoid trouble Single #

42 LEFT offset solenoid trouble Single #
Boom angle sensor system PPC lock solenoid + LEFT
31 trouble Single # 43 offset solenoid trouble 41 + 42 #
ON/OFF solenoid
Arm angle sensor system Traveling accelerator sole-
32 trouble Single # 48 noid trouble Single #
Boom angle sensor system PPC lock solenoid + Travel-
33 + Arm angle sensor system 31 + 32 # 49 ing accelerator solenoid 41 + 48 #
trouble trouble
LEFT offset solenoid + Trav-
Potentiometer
Offset angle sensor system

34 troubl Single # 4A eling accelerator solenoid 42 + 48 #
trouble
Boom angle sensor system
35 trouble + Offset angle sen- 31 + 34 #
sor system trouble
Arm angle sensor system
36 trouble + Offset angle sen- 32 + 34 # 51 Boom RAISE EPC trouble Single #
sor system trouble
Boom angle sensor system
+ Arm angle sensor system 31 + 32
37 # 52 Arm IN EPC trouble Single #
+ Offset angle sensor sys-
tem trouble
+ 34
Proportional solenoid
Boom RAISE EPC + Arm IN
53
EPC trouble
51 + 52 #
54 Pump TVC trouble Single #
Boom RAISE EPC + Pump
55 TVC trouble 51 + 54 #
Arm IN EPC + Pump TVC
56
trouble
52 + 54 #
Boom RAISE EPC + Arm IN 51 + 52
57 EPC + Pump TVC trouble + 54 #
Sensor
• When rotation sensor wire to controller is disconnected/shorted
Potentiometer
• Setting range of output voltage (Standard arm)
Boom: 0.69 - 4.31 V
Arm : 0.82 - 4.18 V
Offset: 1.73 - 3.57 V
PC58UU-3 20-255
1
Error Method
Single/ of Method
Accelerator motor relay (+)

61 Valve open trouble Single # 71 trouble Single #
Accelerator motor relay (-)
62 Source voltage trouble Single # 72
trouble
Single #
Accelerator motor relay (+) +
Valve open + Source volt-
63 age trouble 61 + 62 # 73 Accelerator motor relay (-) 71 + 72 #
trouble
Power source
Sensor source voltage trou- Accelerator motor drive

64 ble Single # 74 relay trouble Single #
Relay
Valve open + Sensor source Accelerator motor relay (+) +
65
voltage trouble
61 + 64 # 75 Accelerator motor drive 71 + 74 #
relay trouble
Accelerator motor relay (-) +
66 62 + 64 # 76 Accelerator motor drive 72 + 74 #
relay trouble
Valve open + Source volt- Accelerator motor relay (+) +

61 + 62 Accelerator motor relay (-) + 71 + 72
67 age + Sensor source volt- + 64 # 77 Accelerator motor drive + 74 #
age trouble relay trouble
Valve open: When work equipment enters in emergency stop area

Source voltage over-range: Above 17.68 V, below 8.58 V
Sensor source voltage over-range: Above 5.45 V, below 4.78 V
20-256 PC58UU-3
1
3. Operation patterns table of monitor panel, controller, electric system caution lamp, and alarm buzzer
Item Monitor panel Controller Electric system caution Alarm buzzer

lamp
When interference prevention — — — Sounds (at intervals of
system works (Automatic stop) 1 sec)
When emergency stop system Error code [61] is dis- Blinks Blinks (at intervals of Sounds (at intervals of
works played. 0.4 sec) 0.4 sec)
When reset switch is turned ON If trouble occurs, error Blinks (at intervals of
When trouble is detected Normal operation
Blinks Sound (for only 7 sec)

code is displayed 0.8 sec)
When automatic control mode When displayed depth Sounds (twice at inter-
is set is set to 0, [0.0] is dis- — — val of 0.4 sec).
played. (Does not sound in
When automatic control mode depth display set
— — — mode.)
works (Automatic stop)
When trouble occurs Error code is displayed Blinks Blinks (at intervals of Sounds (at intervals of
1.6 sec) 1.6 sec)
When controller power source Error code [62] is dis- Goes off — —
system is troubled played
Communication circuit system Error code [EE] is dis- — — —
trouble played
Electric system signal system

trouble — — Lights up —
★ Each device operates and displays normally in the areas which are not displayed in the above table.
• Monitor panel: Displays depth.
• Controller: Turns on LED (Green) lamp when normal code is displayed.
• Electric system caution lamp: Goes off.
• Alarm buzzer: Does not sound.
★ The display by the controller indicates the condition of the LED (Green) lamp on the side window.
PC58UU-3 20-257
1
TROUBLESHOOTING METHOD OF USING JUDGEMENT TABLE
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in
the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then
used to decide which troubleshooting table (E-$$, H-$$) matches the symptoms. The judgement table is
designed so that it is easy to determine from the user code and service code which troubleshooting table to
go to.
★ The abnormality display, warning, given by the monitor panel leads directly to troubleshooting of the
machine monitor (M-$$).
(See contents for troubleshooting of the machine monitor system.)
[Method of using judgement table]
• A • mark is put at the places where the failure mode and self diagnostic display match, so check if that
abnormality display is being given, and proceed as follows.
• If the abnormality diaplay is given, go to troubleshooting code
at the bottom of the judgement table (%)......................................................... Go to E-$$.
• If the problem has appeared but no abnormality display is given,
go to the troubleshooting code on the right of the judgement table (&)....... Go to H-$$.
• For failure modes not marked with •, go directly to the troubleshooting code on the right side (&).
Example Failure mode "offset can not be used"
Procedure: Check if the self-diagnostic error code is being displayed on the depth
display portion (side face of controller) of the monitor panel.
Judgement: If error code 41 is being displayed

.............. go to troubleshooting E-5 of electrical system
If no error code is displayed, and the offset mode cannot be used
.............. go to troubleshooting H-14 of hydraulic system
20-258 PC58UU-3
1
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
E- OO Troubleshooting of electrical system
F- OO Troubleshooting of controller input system
H- OO Troubleshooting of hydraulic and mechanical system
M- OO Troubleshooting of machine monitor system
2. Using the troubleshooting flow chart

1) Troubleshooting code number and problem (for (1) - (4), see the example on the next page.)
The title at the top of the troubleshooting chart gives the troubleshooting code and failure mode
(problem with the machine).
2) Distinguishing conditions
Even with the same failure mode (problem) the method of troubleshooting may differ according to
the model, component, or problem. In such cases, the failure mode (problem) is further divided into
sections marked with small letters, for example a, so go to the appropriate section to carry out trou-
bleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check
item in the failure mode.
3) Method of following troubleshooting chart
• Check or measure the item inside , and according to the answer, follow either the YES or
the NO line to go to the next . (Note: The number written at the top right corner of the 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
finally to the Cause column. Check the cause and take the action given in the Remedy column
on the right.
• Below the there are the methods for inspection or measurement, and the judgement values.
If the judgement values below the are correct or the answer to the question inside the is
YES, follow the YES line; if the judgement value is not correct, or the answer to the question is
NO, follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling
is mistaken, 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, and start the work in order from Item 1.
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with ★ .
The precautions marked ★ are not given in the , but must always be followed when carrying out
the check inside the .
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details,
see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number
connection. When carrying out troubleshooting, see this chart for details of the connector pin num-
ber and location for inspection and measurement of the wiring connector CNOO appearing in the
troubleshooting flow chart for each failure mode (problem).
PC58UU-3 20-259
1
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
b E-1 Error code [24] (Engine speed sensor system trouble) is displayed
Cause Remedy
• Turn starting switch 1
OFF.
• Disconnect M9. Is resistance between M9 (male) No Defective engine speed
b ~ c normal? sensor (Internal disconnec- Replace
• 2,100 ~ 2,500 Ω tion, defective contact,
short circuit with chassis
Yes ground)
2
• Turn starting switch Disconnection, defective
OFF. contact, or short circuit
with chassis ground in wir-
• Disconnect G2. Is resistance between G2 No ing harness between G2 Repair or
(female) 3( ~ 4) normal? (female) 4) ~ M9 (female) replace
• 2,100 ~ 2,500 Ω
c or between G2 (female)
3( ~ M9 (female) b
Yes Defective controller Replace
E-1 Related electrical circuit diagram
20-260 PC58UU-3
1
TROUBLESHOOTING OF
CONTROLLER AND ELECTRIC SYSTEM
(E-MODE)
Actions of self-diagnosis function and problems in machine ...................................................................... 20-302

Judgment table for machine control ............................................................................................................ 20-308
E-mode related electrical circuit diagram .................................................................................................... 20-310
Pump controller ............................................................................................................................................20-311
Engine controller ......................................................................................................................................... 20-312
Precautions for troubleshooting controller system ...................................................................................... 20-313
Precautions for using system reset switch after a trouble is displayed and work equipment stops ............ 20-315
E- 1 Error code [24] (Trouble in engine speed sensor system) is displayed ............................................ 20-316
E- 2 Error code [31] (Trouble in boom potentiometer system) is displayed.............................................. 20-317
E- 3 Error code [32] (Trouble in arm potentiometer system) is displayed ................................................ 20-318
E- 4 Error code [34] (Trouble in offset potentiometer system) is displayed .............................................. 20-319
E- 5 Error code [41] (Trouble in PPC lock solenoid system) is displayed ................................................ 20-320
E- 6 Error code [42] (Trouble in LEFT offset stop solenoid system) is displayed ..................................... 20-321
E- 7 Error code [48] (Trouble in traveling accelerator solenoid system) is displayed............................... 20-322
E- 8 Error code [51] (Trouble in boom RAISE stop solenoid system) is displayed................................... 20-323
E- 9 Error code [52] (Trouble in arm IN stop solenoid system) is displayed............................................. 20-324
E-10 Error code [54] (Trouble in TVC-EPC solenoid system) is displayed ............................................... 20-325
E-11 Error code [62] (Trouble in controller power source system) is displayed ........................................ 20-326
E-12 Error code [64] (Trouble in sensor power source system) is displayed ............................................ 20-327
E-13 Error code [71] (Motor drive relay (accelerator)) is displayed ........................................................... 20-328
E-14 Error code [72] (Motor drive relay (decelerator)) is displayed........................................................... 20-329
E-15 Error code [74] (Motor drive relay (decelerator)) is displayed........................................................... 20-330
E-16 Error code [78] (Abnormality in motor stall system) is displayed ...................................................... 20-331
E-17 Error code [EE] (Fault in controller) is displayed .............................................................................. 20-333
a) When controller has fault in it....................................................................................................... 20-333
b) When communication system between controller and monitor panel is troubled ........................ 20-334
E-18 Defective engine control system ....................................................................................................... 20-335
a) Engine control system does not operate at all or it operates for a moment and does not
operate any more ......................................................................................................................... 20-335
b) Engine control system does not operate at all or it operates for a moment and does not
operate any more
(Abnormal speed or insufficient stroke of cable) .......................................................................... 20-337
c) One-touch decelerator does not operate ..................................................................................... 20-338
d) Engine control system operates near idling speed but does not operate to FULL
(high-load range).......................................................................................................................... 20-338
E-19 When starting switch is turned to START position, engine does not start......................................... 20-339
a) Starting system............................................................................................................................. 20-339
b) Engine stop solenoid system ....................................................................................................... 20-345
E-20 When starting switch is turned to OFF position, engine does not stop ............................................. 20-347
E-21 When traveling accelerator pedal is pressed, travel speed does not rise......................................... 20-349
E-22 When traveling accelerator pedal is released, travel speed does not lower from raised level.......... 20-350
E-23 When work equipment lock lever is set to FREE position, work equipment does not move............. 20-351
E-24 After work equipment lock lever is locked, work equipment still moves............................................ 20-353
E-25 System cannot be initialized ............................................................................................................. 20-354
E-26 Depth cannot be set to 0 or height cannot be set ............................................................................. 20-356
a Before carrying out troubleshooting, check that all the related connectors are properly inserted.
a Always connect any disconnected connectors before going on to the next step.
PC58UU-3 20-301
(6)
TROUBLESHOOTING E-MODE
ACTIONS OF SELF-DIAGNOSIS FUNCTION AND PROBLEMS IN

MACHINE
Displayed
code Troubled system Contents of trouble
1) Disconnection in wiring harness

2) Defective rotation sensor or improper installation of it
24 Engine speed sensor system 3) Defective controller
1) Disconnection in wiring harness (1 of 3)

31 Boom potentiometer system 2) Short circuit between wiring harnesses (2 of 3)
3) Short circuit with chassis ground in wiring harness
32 Arm potentiometer system 4) Defective potentiometer
5) Defective controller
34 Offset potentiometer system
1) Short circuit of (+) side of solenoid with chassis ground

2) Short circuit in solenoid
41 PPC hydraulic lock solenoid system 3) Contact of (+) side of solenoid with wiring harness on ground side
4) Defective relay R2
2) Disconnection in (+) side of solenoid
(When internal resistance of solenoid is lowered extremely)
4) Disconnection in solenoid
5) Contact of (+) side of solenoid with wiring harness on ground side
42 LEFT offset stop solenoid system

2) Disconnection in (+) side of solenoid
48 Traveling accelerator solenoid system (When internal resistance of solenoid is lowered extremely)
5) Contact of (+) side of solenoid with wiring harness on ground side
2) Short circuit in solenoid or short circuit of solenoid with chassis ground
51 Boom RAISE stop EPC solenoid system 3) Disconnection of wiring harness on (+) side of solenoid or short circuit of it with
chassis ground
1) Short circuit of (+) side (K24) of solenoid with chassis ground

52 Arm IN stop EPC solenoid system 3) Disconnection of wiring harness or short circuit of it with chassis ground
54 TVC-EPC solenoid system 3) Disconnection of wiring harness on (+) side of solenoid
1) Bucket edge entered emergency stop area (actually) or controller recognized

61 Valve open system by mistake that bucket edge entered emergency stop area.
1) When power is not input to controller

62 Controller power source 2) When source voltage of controller is above 17.68 V or below 8.58 V
1) Short circuit of sensor power source output

2) If sensor power source voltage is above 4.79 V, voltage is above 5.44 V.
64 Sensor power source system 3) Defective controller
1) Short circuit of (+) side of relay coil with chassis

2) Disconnection in (+) side of relay coil
71 Motor drive relay (accelerator) system
3) Disconnection in relay coil or short circuit of it
20-302 PC58UU-3
(6)
Normal condition Action taken by controller when Problem that appears on machine when
(Voltage, current, resistance) abnormality is detected there is abnormality
1) Resistance between G2 (40) – (39): 1) Sets output to TVC-EPC solenoid to 0.6A. 1) If load is increased, engine speed low-
2,100 – 2,500 z 2) Recognizes engine speed as partial output. ers remarkably.
2) Voltage between G2 (40) – (39)
(M9 (1) – (2)): 0.5 – 3 V)
* Use AC range.
Voltage between G1 (3) – (21) 1) Turns off output to boom RAISE stop solenoid, 1) Machine cannot perform boom
(M14 (B) – (A)): 0.3 – 4.7 V arm IN stop solenoid, and LEFT offset stop sole- RAISE, arm IN, and LEFT offset oper-
noid (Lowers voltage for them to 0A). ations.
Voltage between G1 (3) – (21) a Trouble is kept displayed even after troubled
(W4 (B) – (A)): 0.3 – 4.7 V part is repaired (Operation is kept stopped, too).
Voltage between G1 (14) – (21)
(W3 (B) – (A)): 0.3 – 4.7 V
Voltage between G1 (22) – (21)

(Source voltage): 0.3 – 4.7 V
1) Turns off output to boom RAISE stop solenoid, 1) Machine cannot operate work equip-
arm IN stop solenoid, LEFT offset stop solenoid, ment, travel, and swing at all.
and PPC hydraulic lock solenoid (Lowers volt-
age for them to 0A).
a This system does not self-diagnose disconnec-
tion (Bucket stops without displaying error code)
1) Resistance of solenoid: 5 – 25 z
1) Turns off output to boom RAISE stop solenoid, 1) Machine cannot perform boom
arm IN stop solenoid, and LEFT offset stop sole- RAISE, arm IN, and LEFT offset oper-
noid (Lowers voltage for them to 0A). ations.
a Even if wire is disconnected during operation,
offset boom stops without displaying error code.
1) Turns off output to traveling accelerator sole- 1) Travel speed is not raised.
noid.
Resistance of solenoid: 20 – 60 z
1) Resistance of solenoid: 5 – 25 z 1) Turns off output to boom RAISE stop solenoid, 1) Machine cannot perform boom
2) Voltage between G3 (26) – (23): arm IN stop solenoid, and LEFT offset stop sole- RAISE, arm IN, and LEFT offset oper-
0.75 – 1.0 V (In bucket safety area) noid. ations.
a Trouble is kept displayed even after troubled
part is repaired (Operation is kept stopped, too).
1) Resistance of solenoid: 5 – 25 z 1) Turns off output to boom RAISE stop solenoid, 1) Machine cannot perform boom
2) Voltage between G3 (5) – (23): arm IN stop solenoid, and LEFT offset stop sole- RAISE, arm IN, and LEFT offset oper-
0.75 – 1.0 V (In bucket safetyarea) noid (Lowers voltage for them to 0A). ations.
a Trouble is kept displayed even after troubled
1) Resistance of solenoid: 5 – 7.5 z 1) Turns off output to TVC-EPC solenoid (Lowers 1) If load is increased, engine speed low-
2) Voltage between G3 (16) – (23): voltage for it to 0A). ers remarkably.
0.4 – 0.6 V, 0.3 – 0.9 V a Trouble is kept displayed even after troubled
* Electric system cannot be measured. 1) Turns off output to PPC lock solenoid (Lowers All operations are stopped.
current for it to 0A).
a If troubled part is repaired, error code goes off
and operation becomes normal.
1) Voltage between G3 (1), (11) – (21), 1) Stops all functions but restarts normal operation Machine cannot operate work equip-
(31),(32), (33): 24 – 30 V when source voltage becomes normal. ment, travel, and swing at all (can operate
a Error code goes off. blade, however).
Turns OFF output to boom RAISE stop solenoid, 1) Machine cannot perform boom
Voltage between G1(22) – (21): arm IN stop solenoid, and LEFT offset stop sole- RAISE, arm IN, and LEFT offset oper-
4.9 – 5.1 V noid. ations.
1) Turns off output to motor drive relay, accelerator Engine cannot be controlled (cannot be
Resistance of relay coil: 80 – 120 z relay, decelerator and relay. accelerated or decelerated).
a Trouble is detected only while power is turned
on.
PC58UU-3 20-303
(6)
Displayed
code Troubled system Contents of trouble

72 Motor drive relay (decelerator) system 3) Disconnection in relay coil or short circuit of it
74 Motor drive relay system
3) Disconnection in relay coil or short circuit of it
1) Fixing of motor or disconnection in internal wiring harness
2) Defective motor drive relay (Disconnection)
3) Disconnection in motor drive relay wiring harness
78 Motor stall system (When motor burn pre-
vention function operates)
1) Disconnection in one of wiring harnesses (Clock, Data, Strobe) between moni-

tor and controller
2) No output in one of wiring harnesses (Clock, Data, Strobe) between monitor
and controller
3) Defective controller (Broken completely)
EE Monitor communication system
20-304 PC58UU-3
(6)
Normal condition Action taken by controller when Problem that appears on machine when
(Voltage, current, resistance) abnormality is detected there is abnormality
relay, decelerator and relay. accelerated or decelerated).
Resistance of relay coil: 80 – 120 z a Trouble is detected only while power is turned
on.
Resistance of relay coil: 80 – 1200 z relay, decelerator and relay. accelerated or decelerated).
a Trouble is detected only while power is turned
on.
1) Resistance of relay coil: 260 – 320 z If accelerator, decelerator, or one-touch decelerator • When signal system is abnormal
2) Motor starts and stops with in 2 sec- operates continuously for 10 seconds, "Motor drive Motor starts but stalls. Then, motor
onds from slow to full and from full to relay output", "Motor drive (accelerator) relay out- does not start any more even if dial is
slow. put, and "Motor drive (decelerator) relay output" are operated.
stopped. • When motor is abnormal
Motor stalls from first. Then, motor
does not start any more even if dial is
operated.
1) Resistance of following sections: 1) When communication system is troubled: Con- 1) Machine can operate normally but
Max. 10 z troller does not react particularly. cannot perform the following.
(1) Any code other than EE is not dis-
played.
(2) Buzzer does not sound.
3) When controller is troubled: Controller stops out- 3) All work equipment, swing, and travel
3) Turns ON LED on the side of the con- putting signals to all electronic devices which the operations are impossible (Blade
troller controller controls. operates normally, however).
PC58UU-3 20-305
(6)
Self-diagnostic display (Abnormal display)
Controller power source system
Sensor power source system
Boom positioner system

Communication system
Arm positioner system

Trouble mode
Error code EE 62 64 31 32
Boom does not raise q q q q
Boom does not lower
Arm does not move in q q q q
Offset boom does not move to left q q q q
Boom does not stop rising auto- All operations stop just before interference
matically at normal position Work equipment interferes
Operations of work equipment
Arm does not stop moving in auto- All operations stop just before interference
matically at normal position Work equipment interferes
Offset boom does not stop auto- All operations stop just before interference
matically at normal position after
moving to left Work equipment interferes
Machine cannot use height mode
Automatic stop distance is short (During operation)
Automatic stop distance is long (During operation)
Depth mode stop is abnormal Work equipment overruns, then stops

(after setting, during operation) Work equipment stops before set depth
Height mode stop is abnormal Work equipment overruns, then stops

(after setting, during operation) Work equipment stops before set height
Offset mode stop is abnormal Work equipment overruns, then stops

(after setting, during operation) Work equipment stops before set position
When machine stops automatically q
When reset switch is turned ON q
Buzzer does not sound When mode is set or machine stops q
During self-diagnostic display (Display is nor-
mal) q
While reset switch is not turned on, buzzer sounds for 7 seconds and electric system
lamp blinks
Electric system caution lamp keeps blinking
Boom RAISE, arm IN, and LEFT offset All operations stop just before interference
operations do not stop automatically a2 Work equipment interferes
System cannot be initialized

Depth cannot be set to 0
While work equipment lock lever is set to LOCK position, work equipment moves
Troubleshooting code when abnormal display is given E-19 E-11 E-12 E-2 E-3
a1: [EE] is displayed on monitor panel but display unit of controller is turned off.
a2: When error code [61] is not displayed
20-306 PC58UU-3
(6)
Offset potentiometer system
q
q
q
34
E-4
PC58UU-3
PPC hydraulic lock solenoid
q
q
q
41
E-5
system
LEFT offset stop solenoid
q
q
q
42
E-6
system
TROUBLESHOOTING
Boom RAISE stop solenoid
q
q
q
q
q
q
51
E-8
system
Arm IN stop solenoid system
q
q
q
q
q
52
E-9
Self-diagnostic display (Abnormal display)
Valve open system
—
q
q
q
q
q
q
q
q
q
61
Troubleshooting code when
—
—
—
—
—
—
—
—
—
abnormal display is not given
H-11
E-24
E-26
E-25
H-41
H-41
H-41
H-13
H-10
M-11
M-15
(6)
20-307
E-MODE
JUDGMENT TABLE FOR MACHINE CONTROL

Self-diagnostic display
(Abnormal display)
Communication system
Arm positioner system

Sensor power source
Traveling accelerator
Offset potentiometer
PPC hydraulic lock
Boom raising EPC

Controller power
LEFT offset stop

Boom positioner
solenoid system
solenoid system
solenoid system
solenoid system
source system
system
system
system
Error code 62 64 24 31 32 34 41 42 48 51
Trouble mode Monitor code —

All work equipment, travel, and swing speed or power is low
All work equipment,
travel, and swing
Engine speed lowers extremely or engine stalls q q q

Machine cannot operate work equipment, travel, and swing at all q q q
Abnormal sound comes out (from around pump)
One-touch decelerator does not operate q
Fine controllability or response is low q q q
Boom speed or power is low
Arm speed or power is low
Bucket speed or power is low
Work equipment
Offset boom speed or power is low

Boom does not move q q q q q q q q
Arm does not move q q q q q q q q
Bucket does not move q q
Offset boom does not move q q q q q q q q
Hydraulic drift is large
Time lag is large (Engine speed is low)
Compound
operation
Part loaded more moves slower in compound operation of work equipment
Travel deviation is large

Travel deviation Travel deviation is large
Travel system
when starting
Travel speed is low
Machine cannot be steered sharply or steering force is insufficient q
Travel speed does not change or is higher than set speed
Machine does not travel q q
in both directions q q
Machine cannot swing
in either direction
in both directions
Swing acceleration is low
Swing system
in either direction
in both directions
Overrun of swing is large
in either direction
Large shock is made when machine stops swinging (in either direction)
Large abnormal sound is made when machine stops swinging
when brake is turned ON
Swing hydraulic drift is large
when brake is turned OFF
Engine cannot be controlled (cannot be accelerated or decelerated).
Blade speed or power is low
Hydraulic drift of blade is large
Troubleshooting code when abnormal display is given E-11 E-12 E-1 E-2 E-3 E-4 E-5 E-6 E-7 E-8
20-308 PC58UU-3
(6)
Self-diagnostic display Items checked in

(Abnormal display) monitoring mode
Arm IN EPC solenoid
Traveling accelerator
code when abnormal

display is not given
TVC-EPC solenoid
Valve open system
Decelerator switch
Motor stall system
Motor drive relay
Motor drive relay
Motor drive relay
Troubleshooting
(decelerator)
(accelerator)
system
system
52 54 61 71 72 74 78 —
— UP Hi
q H-1
q H-2
q H-3
H-4
q q q q q E-15
H-6
H-7
H-8
H-9
H-10
q q
q q
H-11
q
q q
H-12
H-13
operation
pound
Com-
H-14
H-15
H-16
H-17
q H-18
H-19
q
H-20
q
H-21
q
H-22
H-23
H-24
H-25
E-17
H-26
H-27
E-9 E-10 — E-13 E-14 E-15 E-16 F-1 F-2 —
PC58UU-3 20-309
(6)
E-MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
20-310 PC58UU-3
1
PUMP CONTROLLER
PC58UU-3 20-311
1
ENGINE CONTROLLER
Serial No.: 20001 – 22000
20-312 PC58UU-3
(6)
PC58UU-3 20-312-1
(6)
PRECAUTIONS FOR TROUBLESHOOTING CONTROLLER SYSTEM

• Since the controller mounted on this machine for preventing interference has unique functions of stop-
ping the bucket automatically or decelerating it before stopping automatically.
Accordingly, some phenomena which have not occurred in the conventional machines may occur in
this machine.
• The following phenomena are not troubles. Accordingly, check the working condition carefully before
starting troubleshooting.
1. After the bucket stops automatically, even if it is

returned forward or to the right by about 50 - 100 mm,
the operator cannot perform the boom RAISE, arm IN,
and LEFT offset operations (An example of returning
forward is shown in the figure).
★ The bucket is still in the interference area by about
50 ~ 100 mm. If it is returned further, it can be
operated.
2. After the bucket stops automatically, even if it is

returned forward or by less than 500 mm, the boom
RAISE and arm IN operation speed is low.
★ The bucket is still in the deceleration area. If it is
returned further, it can be operated at the normal
speed.
3. After the bucket stops automatically during the LEFT

offset operation, if it is moved forward to avoid inter-
ference by operating the arm and then returned to the
original position, it stops automatically again.
★ The bucket is still in the interference area in the
LEFT offset direction. If it is offset by about 50 mm
to the right, it can be operated.
PC58UU-3 20-313
1
4. After the bucket stops automatically, if it is moved

toward the canopy (cab) further and the reset switch is
turned off, the self-diagnosis function displays error
code [61] and the machine cannot move the work
equipment or swing at all.
★ If the reset switch is turned on and the bucket is
moved away from the canopy (cab), the machine
operates normally and the error code goes off.
5. When each potentiometer is removed and installed

again, the automatic stop position changes.
★ If the potentiometer input signal is reset according
to TESTING AND ADJUSTING, the automatic stop
position becomes normal.
6. When the interference prevention function or auto-

matic control function is turned on in a cold district,
the automatic stop position changes.
★ Error code [61] may be displayed. It goes off, how-
ever, after the oil temperature rises.
Precautions for cases where detected trouble is

reset by itself
1) A detected trouble is repaired by itself.

2) When a connector is disconnected and a T-adapter
is inserted for troubleshooting or when the T-
adapter is removed and the connector is connected
again, the service code is not displayed or the
monitor displays normally again.
20-314 PC58UU-3
1
PRECAUTIONS FOR OPERATING SYSTEM RESET SWITCH WHEN

ERROR CODE IS DISPLAYED AND WORK EQUIPMENT STOPS
• If the solenoid system has a trouble and the error code [42], [51], and [52] are displayed and the work
equipment stops, do not turn ON the emergency work equipment operation switch. If the emergency
work equipment operation switch is turned ON and fuse 3 is broken, inspect the related diodes as well
as the solenoid system having the trouble.
<Reference>
When the cause of the trouble in the solenoid system is a short circuit in the solenoid or short circuit
with the chassis ground in the wiring harness between the controller and solenoid, if the emergency
work equipment operation switch is turned on, an overcurrent flows and the internal resistance of the
diodes may become 0 before the fuse is broken.
★ The PPC lock solenoid system is checked for only [short circuit in the solenoid and short circuit with the
chassis ground in the positive (+) wiring harness]. Accordingly, if error code [41] is displayed, never
turn on the reset switch but perform troubleshooting first.
• Diodes related to each solenoid

Related diodes
Error code Troubled system
D3 D4 D5 D6 D7 D8 D9 D10
41 PPC lock solenoid ● ●
42 LEFT offset stop solenoid ● ●
51 Boom RAISE EPC solenoid ● ●
52 Arm IN EPC solenoid ● ●
PC58UU-3 20-315
1
TROUBLESHOOTING E-1
E-1 Error code [24] (Trouble in engine speed sensor system) is displayed
Cause Remedy
1
Defective engine speed sen-
• Turn starting switch OFF. Is resistance between M9 (male) (1) – NO sor (Internal disconnection,
• Disconnect M9. defective contact, short cir-
Replace
• 2,100 – 2,500 z (2) normal?
cuit with chassis ground)
YES
2 Disconnection, defective con-

tact, or short circuit with
• Turn starting switch OFF. Is resistance between G2 (female) (39) NO chassis ground in wiring har- Repair or
• Disconnect G2. – (40) normal? ness between G2 (female) replace
• 2,100 – 2,500 z (40) – M9 (female) (2) or
YES between G2 (female) (39) –
M9 (female) (1)
Defective controller Replace
20-316 PC58UU-3
(6)
TROUBLESHOOTING E-2
E-2 Error code [31] (Trouble in boom potentiometer system) is displayed
Cause Remedy
1
• 0.3 – 4.7 V Is voltage between G1 (3) – (22) nor- NO
• Turn starting switch ON mal?
YES
2
Is [31] displayed under measuring con- NO
• Turn starting switch ON Has been reset —
dition in 1 above?
YES
3
Is resistance between M14 (male) NO
• Turn starting switch OFF Defective boom RAISE
(A) – (C) and between (B) – (A) as Replace
• Disconnect M14 shown in Table 1? potentiometer
YES
• Resistance of wiring harness: 4

Max. 10 z Disconnection, defective con-
Is resistance between G1 (female) (3)
• Resistance between wiring – M14 (male) (B) normal and is wiring NO tact, or short circuit with
Repair or
harness and chassis ground: harness insulated from chassis
chassis ground in wiring har-
replace
Min. 1 Mz ness between G1 (female)
ground?
• Turn starting switch OFF (21) – M14 (female) (B)
• Disconnect G1 and M14 YES
Disconnection, defective con-

chassis ground in wiring har- Repair or
ness between G1 (female) replace
(21), (22) – M14 (female) (A),
Table 1 (C)
M14 (male) Resistance

Between 4 – 6 kz
(A) – (C)
Between
(B) – (A) 0.2 – 7 kz
PC58UU-3 20-317
(6)
TROUBLESHOOTING E-3
E-3 Error code [32] (Trouble in arm potentiometer system) is displayed
Cause Remedy
1
YES
2
dition in 1 above?
YES
3
Is resistance between W4 (male) NO
• Turn starting switch OFF
(A) – (C) and between (B) – (A) as Defective arm potentiometer Replace
• Disconnect W4 shown in Table 1?
YES

Is resistance between G1 (female) (20)
• Resistance between wiring – W4 (male) (B) normal and is wiring NO tact, or short circuit with
Repair or
harness and chassis ground: harness insulated from chassis
Min. 1 Mz ness between G1 (female) replace
• Turn starting switch OFF ground? (20) – W4 (female) (B)
• Disconnect G1 and W4 YES

(21), (22) – W4 (female) (A),
Table 1 (C)
W4 (male) Resistance
Between 4 – 6 kz
(A) – (C)
Between
(B) – (A) 0.2 – 7 kz
20-318 PC58UU-3
(6)
TROUBLESHOOTING E-4
E-4 Error code [34] (Trouble in offset potentiometer system) is displayed
Cause Remedy
1
YES
2
dition in 1 above?
YES
3
Is resistance between W3 (male) NO
(A) – (C) and between (B) – (A) as Defective arm potentiometer Replace
• Disconnect W3 shown in Table 1?
YES

Is resistance between G1 (female)
• Resistance between wiring (14) – W4 (male) (B) normal and is wir- NO
Repair or
harness and chassis ground: ing harness insulated from chassis
Min. 1 Mz ness between G1 (female) replace
• Turn starting switch OFF ground? (14) – W3 (female) (B)
• Disconnect G1 and W3 YES

(21), (22) – W3 (female) (A),
Table 1 (C)
W3 (male) Resistance
Between 4 – 6 kz
(A) – (C)
Between
(B) – (A) 0.2 – 7 kz
PC58UU-3 20-319
(6)
TROUBLESHOOTING E-5
E-5 Error code [41] (Trouble in PPC lock solenoid system) is displayed
a Only a short circuit with the chassis ground in the wiring harness between the controller and solenoid or a
short circuit between the wiring harness lines is detected.
a If the machine does not work with no error codes displayed, see E-21.
Cause Remedy
• 5 – 25z 1
• Between F7 (2) – chassis Is resistance between F7 (male) (1) – NO Defective PPC main pres-
ground: Min. 1 Mz (2) normal and is wiring harness insu- Replace
• Turn starting switch OFF lated from chassis ground? sure lock solenoid valve
• Disconnect F7
YES
2
When R3 is replaced, is condition nor- NO
• Replace R3 with normal relay.
mal?
Defective relay R3 Replace

YES
3
Short circuit with chassis
• Turn starting switch OFF Is there continuity between G3 (female) ground in wiring harness
• Disconnect G3, F7, and R2 (38) – R2 (female) (3) and between R3 NO between G3 (female) (38) – Repair or
• Measure on G3 (female) side (female) (5) – F7 (female) (2) and are replace
wiring harnesses insulated from chas- R2 (female) (3) or between
in diode range (Note) sis ground? R2 (female) (5) – F3 (female)
(2)
YES
Note: If an ordinary tester is set in the diode range, the voltage of the battery in itself is indicated. When a har-
ness containing a diode is checked with this tester, [if this voltage does not change, there is not continu-
ity], and [if this voltage changes, there is continuity].
20-320 PC58UU-3
(6)
TROUBLESHOOTING E-6
E-6 Error code [42] (Trouble in LEFT offset stop solenoid system) is
displayed
a If the wiring harness between the controller and solenoid is shorted to the chassis ground, it is displayed
during operation. If the wiring harness is disconnected, however, the work equipment stops without display-
ing the error code.
In this case, turn the starting switch to the OFF position and to the ON position again, and the error code is
displayed.
Cause Remedy
• 5 – 25z 1
• Between F9 (2) – chassis Is resistance between F9 (male) (1) – NO Defective LEFT offset sole-
• Turn starting switch OFF lated from chassis ground? noid
• Disconnect F9
YES
2
• Turn starting switch OFF Disconnection or defective
• Disconnect G3 and F9 Is there continuity between G3 (female) NO contact in wiring harness Repair or
• Measure on G3 (female) side (15) – F9 (female) (2) and is wiring har- between G3 (female) (15) –
ness insulated from chassis ground? replace
in diode range (Note) F9 (female) (2)
YES

• Max. 10 W NO tact, or short circuit with
Is resistance between F9 (female) (1) Repair or
• Turn starting switch OFF chassis ground in wiring har-
• Disconnect F9
and G3 (3) normal? ness between F9 (female) (1) replace
– G3 (3)
YES
PC58UU-3 20-321
(6)
TROUBLESHOOTING E-7
E-7 Error code [48] (Trouble in traveling accelerator solenoid system) is

displayed
Cause Remedy
• 5 – 25z 1 Defective traveling accelera-

• Between F8 (2) – chassis Is resistance between F8 (male) (2) – NO tor solenoid (Internal discon-
ground: Min. 1 Mz (1) normal and is wiring harness insu- nection, defective contact, Replace
• Turn starting switch OFF lated from chassis ground? short circuit with chassis
• Disconnect F8 ground)
YES

ground or defective contact in
• Turn starting switch OFF 2 wiring harness between G3
• Between G3 (27) – chassis Is resistance between G3 (female) (27) NO (female) (27) – F8 (female) Repair or
ground: Min. 1 Mz – (3) normal and is wiring harness insu- (2) or disconnection, defec- replace
• Turn starting switch OFF lated from chassis ground? tive contact, or short circuit
• Disconnect G3 with chassis ground in wiring
YES harness between G3
(female) (3) – F8 (female) (1)
20-322 PC58UU-3
(6)
TROUBLESHOOTING E-8
E-8 Error code [51] (Trouble in boom RAISE stop solenoid system) is
displayed
Cause Remedy
• 3 – 15z 1
• Between F11 (2) – chassis Is resistance between F11 (male) (1) – NO Defective boom RAISE sole-
• Turn starting switch OFF lated from chassis ground? noid valve
• Disconnect F11
YES

• Turn starting switch OFF Is there continuity between G3 (female) NO tact, or short circuit with
• Disconnect G3 and F11 Repair or
• Measure on G3 (female) side (26) – F11 (female) (2) and is wiring chassis ground in wiring har- replace
harness insulated from chassis ground? ness between G3 (female)
in diode range (Note) (26) – F11 (female) (2)
YES
3
• Between wiring harness Max. Disconnection, defective con-
10 z Is resistance between G3 (female) (23)
• Between wiring harness and and F11 (female) (1) normal, and is wir- NO Repair or
chassis ground in wiring har- replace
chassis ground: Min. 1Mz ing harness insulated from chassis
ness between G3 (female)
• Turn starting switch OFF ground?
(23) – F11 (female) (1)
• Disconnect G3 and F11
YES
PC58UU-3 20-323
(6)
TROUBLESHOOTING E-9
E-9 Error code [52] (Trouble in arm IN stop solenoid system) is displayed
Cause Remedy
• 3 – 15z 1
• Between F10 (2) – chassis Is resistance between F10 (male) (1) – NO Defective arm IN solenoid
• Turn starting switch OFF lated from chassis ground? valve
• Disconnect F10
YES

• Turn starting switch OFF Is there continuity between G1 (female) NO tact, or short circuit with
• Disconnect G1 and F10 Repair or
(5) – F10 (female) (2) and is wiring har- chassis ground in wiring har-
• Measure on G1 (female) side ness insulated from chassis ground? ness between G1 (female) replace
in diode range (Note) (5) – F10 (female) (2)
YES
3
10 z Is resistance between G1 (female) (23) tact, or short circuit with
• Between wiring harness and and F10 (female) (1) normal, and is wir- NO Repair or
chassis ground: Min. 1Mz ing harness insulated from chassis ness between G1 (female) replace
• Turn starting switch OFF ground? (23) – F10 (female) (1)
• Disconnect G1 and F10
YES
ity], and[if this voltage changes, there is continuity].
20-324 PC58UU-3
(6)
TROUBLESHOOTING E-10
E-10 Error code [54] (Trouble in TVC-EPC solenoid system) is displayed
Cause Remedy
• 3 – 15z 1
• Between M11 (1), (2) – chas- Is resistance between F11 (female) (1) NO
sis ground: Min. 1 Mz – (2) normal and is wiring harness insu- Defective TVC-EPC solenoid Replace
• Turn starting switch OFF lated from chassis ground?
• Disconnect F11
YES
• Max. 1z 2 Disconnection, defective con-

• Between G3 (female) (18) – Is resistance between G3 (female) (18) NO tact, or short circuit with
Repair or
chassis ground: Min. 1 Mz – M11 (female) (1) normal and is wiring chassis ground in wiring har-
• Turn starting switch OFF harness insulated from chassis ground? ness between G3 (female) replace
• Disconnect G3 and M11 (18) – M11 (female) (1)
YES
3
1z Is resistance between G3 (female) (23) tact, or short circuit with
• Between G3 (female) (23) – and M11 (female) (2) normal and is wir- NO Repair or
chassis ground: Min. 1Mz ing harness insulated from chassis ness between G3 (female) replace
• Turn starting switch OFF ground? (23) – M11 (female) (2)
• Disconnect G3 and M11
YES
PC58UU-3 20-325
(6)
E-11 Error code [62] (Trouble in controller power source system) is

displayed
a Check that fuse (F04) is not blown.
Cause Remedy
1
• 10 – 16 V Is voltage between G3 (2), (12), (22) NO
• Turn starting switch ON and (23) and chassis ground normal?
YES
Disconnection or defective
contact in wiring harness
Repair or
between G3 (female) (2),
replace
(12), (22) – fuse (5) – starting
switch
20-326 PC58UU-3
(6)
E-12 Error code [64] (Trouble in sensor power source system) is

displayed
a Check that fuse 5 is not blown.
Cause Remedy
1
YES
2
• 20 – 30 V Is voltage between G3 (1), (11) and NO contact in wiring harness Repair or
• Turn starting switch ON chassis ground normal? between G3 (1), (11) – bat- replace
tery
YES
between G1 (female) (22) – Replace
M14 (female) (C), W4
(female) (A), W3 (female) (C)
PC58UU-3 20-327
(6)
E-13 Error code [71] (Motor drive relay (accelerator)) is displayed
Cause Remedy
• Turn starting switch OFF. 1

• Replace relay R4 with another When relay R4 is replaced with same NO Defective accelerator relay
relay. Replace
• Turn starting switch ON. relay, is [71] displayed? (R4)
• Depress accelerator pedal.
YES
2
• Max. 1 z Is resistance between G3 (female) (13) NO contact in wiring harness Repair or
• Turn starting switch OFF.
• Disconnect G3 and R4. – R4 (female) (2) normal? between G3 (female) (13) – replace
R4 (female) (2)
YES
• Between G3 (female) (25) – 3 Disconnection, defective con-

R4 (female) (1): Max. 1 z Is resistance between G3 (female) (25) NO tact, or short circuit with
• Between G3 (female) (25) – Repair or
– R4 (female) (1) or between G3 chassis in wiring harness
chassis: Min. 1 M z (female) (25) – chassis normal? between G3 (female) (25) –
replace
• Turn starting switch OFF. R4 (female) (1)
• Disconnect G3 and R4. YES
20-328 PC58UU-3
(6)
E-14 Error code [72] (Motor drive relay (decelerator)) is displayed
Cause Remedy

• Replace relay R3 with another When relay R3 is replaced with same NO Defective decelerator relay
relay. Replace
• Turn starting switch ON. relay, is [72] displayed? (R3)
• Depress accelerator pedal.
YES
2
• Disconnect G3 and R3. - R3 (female) (2) normal? between G3 (female) (13) – replace
R3 (female) (2)
YES

- R3 (female) (1) or between G3 chassis in wiring harness
chassis: Min. 1 Mz (female) (35) – chassis normal? between G3 (female) (35) –
replace
PC58UU-3 20-329
(6)
E-15 Error code [74] (Motor drive relay (decelerator)) is displayed
Cause Remedy
• Replace relay R5 with another
relay. When relay R5 is replaced with same NO Defective decelerator relay
• Turn starting switch ON. Replace
relay, is [72] displayed? (R5)
• Depress accelerator pedal or
decelerator pedal. YES
2
• Disconnect G3 and R5. – R5 (female) (2) normal? between G3 (female) (18) – replace
R5 (female) (2)
YES

- R5 (female) (1) or between G3 chassis in wiring harness
chassis: Min. 1 Mz (female) (18) - chassis normal? between G3 (female) (18) –
replace
20-330 PC58UU-3
(6)
E-16 Error code [78] (Abnormality in motor stall system) is displayed

a Abnormality in the motor stall system is displayed if the motor does not follow up 10 seconds after the dial is
operated. In the meantime, check that the input signal and relay output are normal with the monitoring func-
tion.
Cause Remedy
1
For condition of bit, see actions
of controller taken when trouble NO
Is monitored value normal?
occurs and phenomena of
machine.
YES
• Turn starting switch ON. 2
• Current must be below 4 A
when normal. Is current between F22 (female) (1) NO
When dial is increased: (Motor (+)) and (4) (Motor (–)) normal?
(1) side (+), (4) side (–)
When dial is decreased:
(1) side (–), (4) side (+) YES
Development motor
Replace motor
(drive system)
• Resistance between (1) and

(2) of each relay: 96 z ± 10%
• Operation of each relay
(When starting switch is 3
turned ON)
Do relays R5, R4, and R3 operate nor- NO
When in neutral, (3) and (6) Defective relay Replace
are connected to each other. mally?
When dial is increased, R5 YES Disconnection or defective
and R4 (3), (5) are connected contact in wiring harness
to each other. between F22 (female) (1), (4) Repair or
When dial is decreased, R5 replace
– R3 (female) (3), R4
and R3 (3), (5) are connected (female) (3)
to each other.
4
• Disconnect G3 and F22. Is resistance between G3 (female) (19) Disconnection or defective
• Resistance between pins: – F22 (female) (5), G3 (female) (29) – contact in wiring harness
NO (having defective resistance) Repair or
Max. 1 z F22 (female) (6), G3 (female) (39) –
between G3 (female) (19), replace
• Resistance between each pin F22 (female) (3) and between each wir- (29), (39) – F22 (female) (5),
– chassis: Min. 1 Mz ing harness – chassis normal? (6), (3)
YES
• Turn starting switch ON.
5
• When dial is increased:
Between G3 (19), (39) – (23): When dial is operated, is each input NO Defective motor (signal sys-
10 - 16 V Replace
signal normal? tem)
• When dial is decreased:
Between G3 (29) – (23): YES
10 – 16 V
PC58UU-3 20-331
(6)
20-332 PC58UU-3
(6)
E-17 Error code [EE] (Fault in controller) is displayed

a) When controller has fault in it
a The monitor panel displays [EE] and the work equipment/swing/travel system does not operate.
a The LED on the side of the controller does not light up.
Cause Remedy
• Turn starting switch ON. 1
• Constant power supply line Defective wiring harness
Voltage between CN-G3 (1), Is voltage of each power supply line of NO • Defective constant power
(11) – chassis: 10 – 16 V controller normal? supply line
• Ordinary power supply line Disconnection or defective
Voltage between CN-G3 (2), YES contact in wiring harness
(12), (22) – chassis: 10 –16 V between CN-F2 (1) – FU4 – Repair or
CN-G3 (1), (11) replace wiring
• Defective ordinary power harness
supply line
between fuse No. 5 – CN-
G3 (1), (11), (22)
Broken fuse FU4 Replace fuse
Replace con-
Defective controller
troller
E-17 a) Related electrical circuit diagram (Fault in controller)
PC58UU-3 20-333
(6)
b) When communication system between controller and monitor panel is troubled

a [EE] is displayed on the monitor panel and the work equipment, swing, and travel operations are impos-
sible.
a The LED on the side face of the controller does not light up.
Cause Remedy
• Turn starting switch ON 1

• Disconnect G2. Does controller output communication NO Replace con-
• Voltage between G2 (9), (18), Defective controller troller
(19) – chassis ground: signals normally?
6 – 10 V
YES
• Turn starting switch ON. 2 Defective wiring harness

Defective communication
• Disconnect CN-F27. Does monitor input communication sig- NO line: Disconnection or defec-
Repair or
• Voltage between F27 (2), (8), replace wiring
tive contact in wiring harness harness
(12) (wiring harness side) – nal normally?
between CN-F27 (2), (8),
chassis: 6 – 10 V (12) - CN-G2 (9), (18), (19)
YES
Defective monitor panel Replace moni-

tor panel
E-17 b) Related electrical circuit diagram (Fault in controller)
20-334 PC58UU-3
(6)
E-18 Defective engine control system

a Check that the fuel control cable is not damaged or bent extremely sharply.
a Check that the decelerator indicator lamp is turned OFF.
a Carry out the following troubleshooting when none of error codes [71], [72], and [73] is displayed.
a Check that fuse F04 and (3) are not broken.
a) Engine control system does not operate at all or it operates for a moment and does not operate any
more
Cause Remedy
1
When cable is disconnected from NO
accelerator motor, does engine control
system operate normally?
YES
Defective fuel control linkage Replace
2
• 10 – 15 V Is resistance between G3 (female) (1), NO contact in wiring harness Repair or
• Turn starting switch ON. (11) – chassis ground normal? between fuse FU4 – G3 replace
(female) (1), (11)
YES
3
• Replace R3, R4, or R5 with When R3, R4, or R5 is replaced, does NO
engine control system operate nor- Defective relay R3, R4, or R5 Replace
normal relay. mally?
4 Disconnection or defective
• Max. 1 z Is resistance between R3 (female) (4) – NO contact in wiring harness
• Turn starting switch OFF. chassis ground or R4 (female) (4) – between R3 (female) (4) – Repair or
replace
• Disconnect R3 and R4. chassis ground normal? chassis ground, R4 (female)
(4) – chassis ground
YES
• Turn starting switch OFF. R4 (female) (5) – R5 (female) (5) nor- between R3 (female) (5) – Repair or
• Disconnect R3, R4, and R5. mal? R4 (female) (5) – R5 (female) replace
(5)
YES
• Max. 1 z Is resistance between F22 (female) (4) contact in wiring harness
• Turn starting switch OFF. – R3 (female) (3), F22 (female) (1) – R4 NO between F22 (female) (4) – Repair or
• Disconnect F22, R3, R4, and (female) (3), or F22 (female) (2) – R5 R3 (female) (3), F22 (female) replace
R5. (female) (3) normal? (1) – R4 (female) (3) or F22
(female) (2) – R5 (female) (3)
YES
7 Short circuit with chassis

• Min. 1 Mz ground in wiring harness
Is resistance between F22 (female) (4), NO
• Turn starting switch OFF. F22 (female) (1), F22 (female) (2) –
between F22 (female) (4) – Repair or
• Disconnect F22, R3, R4, and chassis ground normal?
R3 (female) (3), F22 (female) replace
R5. (1) – R4 (female) (3), or F22
YES (female) (2) – R5 (female) (3)
• Between wiring harnesses: 8 Disconnection, defective con-

Max. 1 z Is resistance between F22 (female) (5) tact, or short circuit with
• Between F22 (female) (5), F22 - G3 (female) (19), F22 (female) (6) – NO chassis ground in wiring har-
Repair or
(female) (6) – chassis: G3 (female) (29), or F22 (female) (5), ness between F22 (female)
Min. 1 Mz F22 (female) (6) – chassis ground nor- (5) – G3 (female) (19) or F22 replace
• Turn starting switch OFF. mal? (female) (6) – G3 (female)
• Disconnect F22 and G3. (29)
YES
9
Is voltage between each terminal of NO
accelerator motor and chassis as Defective accelerator motor Replace
shown in Table 1?
YES
PC58UU-3 20-335
(6)
Table 1
Connector Contents of operation Voltage Condition
Between F22 (1) – chassis Accelerate engine. 10 – 16V Turn starting switch ON.
Insert T-adapter.
Turn starting switch ON.
Decelerate engine. Max. 1 V Insert T-adapter.
Between F22 (2) – chassis Turn starting switch ON. 10 – 16V Turn starting switch ON.
Insert T-adapter.
Turn starting switch OFF. Max. 1 V Insert T-adapter.
Between F22 (3) – chassis Turn starting switch ON.
Accelerate engine. 10 – 16V Insert T-adapter.
Decelerate engine. Max. 1 V Turn starting switch ON.
Insert T-adapter.
Accelerate engine. Max. 1 V Insert T-adapter.
Decelerate engine. 10 – 16V Insert T-adapter.
Between F22 (5) – chassis Accelerate engine. 10 – 16V Turn starting switch ON.
Insert T-adapter.
Decelerate engine. Max. 1 V Insert T-adapter.
Accelerate engine. Max. 1 V Insert T-adapter.
Decelerate engine. 10 – 16V Turn starting switch ON.
Insert T-adapter.
20-336 PC58UU-3
(6)
b) Engine control system does not operate at all or it operates for a moment and does not operate any
more
(Abnormal speed or insufficient stroke of cable)
Cause Remedy
1
Bending or interference of
• Disconnect cable from motor Does fuel control system move NO fuel control linkage or defec- Replace
and rotate it with hand. smoothly? tive operation of governor
lever
YES
2
• 10 – 15 V Is resistance between G3 (1), (11) – NO contact in wiring harness Repair or
• Turn starting switch ON. chassis ground normal? between fuse FU4 – G3 replace
(female) (1), (11)
YES
3
• Replace R3, R4, or R5 with When R3, R4, or R5 is replaced, does NO
engine control system operate nor- Defective relay R3, R4, or R5 Replace
normal relay. mally?
• Turn starting switch OFF. chassis ground or R4 (female) (4) chas- between R3 (female) (4) – Repair or
replace
• Disconnect R3 and R4. sis ground normal? chassis ground or R4
(female) (4) – chassis ground
YES
• Turn starting switch OFF. R4 (female) (5) – R5 (female) (5) nor- between R3 (female) (5) – Repair or
• Disconnect R3, R4, and R5. mal? R4 (female) (5) – R5 (female) replace
(5)
YES
• Max. 1 z Is resistance between F22 (female) (4) contact in wiring harness
• Turn starting switch OFF. – R3 (female) (3), F22 (female) (1) – R4 NO between F22 (female) (4) – Repair or
• Disconnect F22, R3, R4, and (female) (3), or F22 (female) (2) – R5 R3 (female) (3), F22 (female) replace
R5. (female) (3) normal? (1) – R4 (female) (3), or F22
(female) (2) – R5 (female) (3)
YES
7 Short circuit with chassis

• Min. 1 Mz ground in wiring harness
Is resistance between F22 (female) (4), NO
• Turn starting switch OFF. F22 (female) (1), F22 (female) (2) –
• Disconnect F22, R3, R4, and chassis ground normal?
R3 (female) (3), F22 (female) replace
R5. (1) – R4 (female) (3), or F22
YES (female) (2) – R5 (female) (3)
• Between wiring harnesses: 8 Disconnection, defective con-

Max. 1 z Is resistance between F22 (female) (5)
• Between F22 (female) (5), F22 – G3 (female) (19), F22 (female) (6) – NO
(female) (6) – chassis: ness between F22 (female) Repair or
G3 (female) (29), or F22 (female) (5), (5) – G3 (female) (19) or F22 replace
Min. 1 Mz F22 (female) (6) – chassis normal?
• Turn starting switch OFF. (female) (6) – G3 (female)
• Disconnect F22 and G3. (29)
9
accelerator motor and chassis as Defective accelerator motor Replace
shown in Table 1?
PC58UU-3 20-337
(6)
c) One-touch decelerator does not operate
a Carry out the following troubleshooting when the results of a) and b) are normal.
Cause Remedy
1
• Turn one-touch decelerator
switch ON: Max. 1 z Is resistance of one-touch decelerator NO Defective one-touch deceler-
Replace
• Turn starting switch OFF. switch normal? ator switch
• Disconnect F18.
YES
2
• 10 – 15 V Is voltage between F18 (female) (2) – NO contact in wiring harness Repair or
• Turn starting switch ON. chassis ground normal? between fuse (3) – F18 replace
(female) (2)
YES
• 10 – 15 V 3
• Turn starting switch ON. Disconnection or defective
• Turn one-touch decelerator Is voltage between G3 (female) (9) – NO contact in wiring harness Repair or
switch ON. chassis ground normal? between F18 (female) (1) – replace
• Set fuel control dial to FULL G3 (female) (9)
position. YES
4
accelerator motor - chassis as shown in Defective controller Replace
Table 1?
YES
Defective accelerator motor Replace
d) Engine control system operates near idling speed but does not operate to FULL (high-load range)
a Carry out the following troubleshooting when the results of a) and b) are normal.
Cause Remedy
1
Bending or interference of
* Disconnect cable from motor Does fuel control cable move NO fuel control cable linkage or Repair or
and rotate it with hand. smoothly? defective operation of gover- replace
nor lever
YES
Insufficient accelerator motor

Replace
torque
20-338 PC58UU-3
(6)
E-19 When starting switch is turned to START position, engine does not
start
Serial No.: 20001 – 22000
a When performing the following troubleshooting, set the safety lock lever to LOCK (upper) position.
a) Starting system
Cause Remedy
1
• Voltage: Min. 12 V Are voltage and specific gravity of bat- NO Charge or
Defective battery
• Specific gravity: Min. 1.26 tery normal? replace
YES
2
Is voltage between safety relay terminal NO
• 10 – 15 V
B and chassis ground normal?
YES
3
• Starting switch Is voltage between M15 (1) and chassis NO
ON: 10 – 15 V
OFF: Max. 1 V ground normal?
YES
4
• When locked: Max. 1z
• When free: Min. 1 Mz Is resistance of PPC lock switch nor- NO
Defective PPC lock switch Replace
• Turn starting switch OFF mal?
• Disconnect F13
YES
5
• 10 – 15 V Is voltage between F13 (female) (2) NO contact in wiring harness Repair or
• Turn starting switch ON and chassis ground normal? between F13 (female) (2) replace
and chassis ground
YES
6
• Replace R2 with normal relay Defective relay R2 Replace
mal?
YES
7
• Max. 1 z Is voltage between R2 (female) (2) and NO contact in wiring harness Repair or
chassis ground normal? between R2 (female) (2) – replace
• Disconnect R2 chassis ground
YES
8
• Starting switch
• START: 10 – 15 V Is voltage between M15 (2) and chassis NO
• Starting switch ground normal?
• ON or OFF: Max. 1 V
YES
9
• Starting switch START: Is voltage between safety relay terminal NO
10 – 15 V B and chassis ground normal?
YES
To 13 on next page To 11 on next page
To 14 on next page To 10 on next page To 12 on next page
PC58UU-3 20-339
(6)
From 8 on previous page From 3 on previous page Cause Remedy

From 9 on From 2 on
previous page previous page
From 9 on
previous page 10
• Starting switch START: Is voltage between safety relay terminal NO contact in wiring harness Repair or
10 – 15 V S and chassis ground normal? between safety relay terminal replace
S – starting motor terminal S
YES
Repair or
Defective starting motor
replace
11
Is voltage between starting switch ter- NO contact in wiring harness Repair or
• 10 – 15 V between starting switch ter-
minal B and chassis ground normal? replace
minal B – battery
YES
contact in wiring harness Repair or
between safety relay terminal replace
B – starting switch terminal B
12
Is voltage between starting switch ter- NO Defective starting switch
• Starting switch ON: 10 – 15 V Replace
minal ACC and chassis ground normal? (between B – ACC)
YES Disconnection or defective

between starting switch ter- replace
minal ACC - M15 (female) (1)
13
• Starting switch START: Is voltage between starting switch ter- NO Defective starting switch Replace
10 – 15 V minal C and chassis ground normal? (between B – C)

between starting switch ter- Repair or
minal C – R2 (female) (3) or replace
between R2 (female) (4) –
M15 (female) (2)
14
• Max. 1z Is voltage between M15 (female) (4) NO contact in wiring harness Repair or
• Disconnect R1 between M15 (female) (4) – replace
• Turn starting switch OFF and chassis ground normal?
chassis ground
YES
Defective safety relay Replace
20-340 PC58UU-3
(6)
E-19 a) Related electrical circuit diagram
PC58UU-3 20-341
(6)

a When performing the following troubleshooting, set the safety lock lever to LOCK (upper) position.
a) Starting system
Cause Remedy
1
• Voltage: Min. 12 V Are voltage and specific gravity of bat- NO Charge or
Defective battery
• Specific gravity: Min. 1.26 tery normal? replace
YES
2
Is voltage between safety relay terminal NO
• 10 – 15 V
B and chassis ground normal?
YES
3
• Starting switch Is voltage between M35 (3) and chassis NO
ON: 10 – 15 V
OFF: Max. 1 V ground normal?
YES
4
• When locked: Max. 1z
• When free: Min. 1 Mz Is resistance of PPC lock switch nor- NO
• Turn starting switch OFF mal?
• Disconnect F13
YES
5
• 10 – 15 V Is voltage between F13 (female) (2) NO contact in wiring harness Repair or
• Turn starting switch ON and chassis ground normal? between F13 (female) (2) replace
and chassis ground
YES
6
• Replace R1 with normal relay Defective relay R1 Replace
mal?
YES
7
• Max. 1 z Is voltage between R1 (female) (2) and NO contact in wiring harness Repair or
chassis ground normal? between R1 (female) (2) – replace
• Disconnect R1 chassis ground
YES
8
• Starting switch
• START: 10 – 15 V Is voltage between M35 (1) and chassis NO
• Starting switch ground normal?
• ON or OFF: Max. 1 V
YES
9
• Starting switch START: Is voltage between safety relay terminal NO
10 – 15 V B and chassis ground normal?
YES
To 13 on next page To 11 on next page
To 14 on next page To 10 on next page To 12 on next page
20-342 PC58UU-3
(6)
From 8 on previous page From 3 on previous page Cause Remedy

From 9 on From 2 on
previous page previous page
From 9 on
previous page 10
• Starting switch START: Is voltage between safety relay terminal NO contact in wiring harness Repair or
10 – 15 V S and chassis ground normal? between safety relay terminal replace
S – starting motor terminal S
YES
Repair or
Defective starting motor
replace
11
Is voltage between starting switch ter- NO contact in wiring harness Repair or
• 10 – 15 V between starting switch ter-
minal B and chassis ground normal? replace
minal B – battery
YES
between safety relay terminal replace
B – starting switch terminal B
12
Is voltage between starting switch ter- NO Defective starting switch
• Starting switch ON: 10 – 15 V Replace
minal ACC and chassis ground normal? (between B – ACC)

minal ACC – M35 (female)
13 (3)
• Starting switch START: Is voltage between starting switch ter- NO Defective starting switch
Replace
10 – 15 V minal C and chassis ground normal? (between B – C)

between starting switch ter- Repair or
minal C – R1 (female) (3) or replace
between R1 (female) (4) –
M35 (female) (3)
14
• Max. 1z Is voltage between M35 (female) (5) NO contact in wiring harness Repair or
• Disconnect R1 between M35 (female) (5) – replace
• Turn starting switch OFF and chassis ground normal?
chassis ground
YES
Defective safety relay Replace
PC58UU-3 20-343
(6)
E-19 a) Related electrical circuit diagram
20-344 PC58UU-3
(6)
b) Engine stop solenoid system

a Perform the following troubleshooting when the starting motor operates normally.
Cause Remedy
1
Is voltage between M12 (1) and chassis NO
ground as shown in table?
YES
2
Is voltage between M12 (2) and chassis NO
YES
3
• Max. 1z Is resistance between M12 (female) (3) NO contact in wiring harness Repair or
• Turn starting switch OFF between M12 (female) (3) – replace
• Disconnect M12 and chassis ground normal? chassis ground
YES Defective stop solenoid or Repair or
fuel injection pump (gover-
nor) replace
4
• 10 – 15 V Is voltage between fuse 1 and chassis NO contact in wiring harness Repair or
• Turn starting switch ON ground as shown in table? minal BR – fuse 1
between fuse 1 – M12 replace
(female) (1)
5
Is voltage between R3 (female) and NO Disconnection or defective
Repair or
chassis ground as shown in table? between R3 (female) – fuse 1 replace
YES
6
Is voltage between M16 (1) and (2) as NO
shown in table?
YES
7
Is voltage between R4 and chassis NO
Defective stop solenoid relay Replace

between R4 (female) – M12
(female) (2)
8
Is voltage between M16 (4) and chassis NO contact in wiring harness Repair or
ground as shown in table? between M16 (female) (4) – replace
fuse 1
YES
To 9 on next page
Table
START
Starting switch ON
OFF
Between M12 (1) Between R4 – Between M16 (1) –

12V PULL coil
Between R1 (1) – (2) 1.0 ± 0.5 sec.
– chassis ground chassis ground (2)
0V
Between M12 (2) Between R3(female) Between M16 (4) –

12V HOLD coil
—
– chassis ground – chassis ground chassis ground
0V
PC58UU-3 20-345
(6)
Cause Remedy
1
• Max. 1 z Is resistance between M16 (female) (3) NO contact in wiring harness Repair or
• Disconnect M16
• Turn starting switch OFF and chassis ground normal? between M16 (female) (3) – replace
chassis ground
YES
2
Is voltage between M16 (1) – (2) as NO
Defective timer Replace
shown in table?

between R1 (female) (1), (2) replace
– M16 (female) (1), (2)
E-19 b) Related electrical circuit diagram
20-346 PC58UU-3
(6)
E-20 When starting switch is turned to OFF position, engine does not
stop
Serial No.: 20001 – 22000
a Before disconnecting the wiring harness from starting switch terminal B, be sure to disconnect the cable
from the negative (–) terminal of the battery.
Cause Remedy
1
• When starting switch is turned Is voltage between M13 (2) and chassis NO
Defective starting switch Replace
OFF: 0 V ground normal?
YES
2
* Remove solenoid and turn in NO
Does stop solenoid operate normally? Defective stop solenoid Replace
ON and OFF repeatedly
YES
Defective governor Repair or

replace
PC58UU-3 20-347
(6)
a Before disconnecting the wiring harness from starting switch terminal B, be sure to disconnect the cable
from the negative (–) terminal of the battery.
Cause Remedy
1
• When starting switch is turned Is voltage between M13 (2) and chassis NO
Defective starting switch Replace
OFF: 0 V ground normal?
YES
2
* Remove solenoid and turn NO
Does stop solenoid operate normally? Defective stop solenoid Replace
in ON and OFF repeatedly
YES
Defective governor Repair or

replace
20-348 PC58UU-3
(6)
E-21 When traveling accelerator pedal is pressed, travel speed does not
rise
Cause Remedy
• Approx. 12 V 1
• Turn traveling accelerator When traveling accelerator switch is NO
switch to OFF (low speed) turned off, is voltage between F19 (2)
position and chassis ground normal?
• Turn starting switch ON
YES
• When switch is turned ON: 2

Max. 1 z
• When switch is turned OFF: Is continuity of traveling accelerator NO Defective traveling accelera-
Min. 1 Mz Replace
switch normal? tor switch
• Disconnect switch terminal YES
3
• Max. 1 z Is resistance between F19 (female) (1) NO contact in wiring harness Repair or
• Turn starting switch OFF between G1 (female) (5) – replace
• Disconnect F19 and chassis ground normal?
F19 (female) (2)
YES
Trouble in hydraulic system —
4
• 15 – 25 z NO
Is resistance of traveling accelerator
• Turn starting switch OFF solenoid normal? Defective controller Replace
• Disconnect F8
YES
between travel speed accel- Repair or
replace
eration switch – F19 (1) –
chassis ground
PC58UU-3 20-349
(6)
E-22 When traveling accelerator pedal is released, travel speed does not
lower from raised level
Cause Remedy
• When traveling accelerator 1
switch is turned ON:
Approx. 0 V Is voltage between F19 (2) and chassis NO
• When traveling accelerator ground normal?
switch is turned OFF:
Approx. 12 V YES
Trouble in hydraulic system —
• When switch is turned ON: 2

Max. 1 z
• When switch is turned OFF: Is continuity of traveling accelerator NO Defective traveling accelera-
Min. 1 Mz tor switch Replace
switch normal?
• Disconnect switch terminal YES Short circuit with power
source in wiring harness
between G3 (female) (27) – Repair or
F8 (female) (2) replace
20-350 PC58UU-3
(6)
E-23 When work equipment lock lever is set to FREE position, work
equipment does not move
a Perform the following troubleshooting when error code [61] (Valve open) is not displayed.
a This system does not self-diagnose disconnection.
a If fuse (3) is broken, inspect from fuse (3) to relay (R2) (1) for PPC lock circuit.
Cause Remedy
• When lever is at LOCK: 1

10 – 15 V
• When lever is at FREE: Is voltage between F13 (1) and (2) nor- NO
Max. 1 V mal?
• Turn starting switch ON
YES —
See H-3

Min. 1 Mz
• When lever is at FREE: Is resistance between PPC lock switch NO
Max. 1 z F13 (male) (1) and (2) normal?
YES
3
• 5 – 25 z
• Turn starting switch OFF. Is resistance between F7 (male) (1) and NO
Defective PPC lock solenoid Replace
• Disconnect F7 (2) normal?
YES
4
When R2 is replaced, is condition nor- NO Defective relay (R2) for PPC
• Replace R2 with normal relay. Replace
mal? lock circuit
YES
5
• Max. 1z Disconnection or defective
• Turn starting switch OFF Is resistance between fuse (13) and F13 NO contact in wiring harness
Replace
• Disconnect F13 (female) (2) normal? between fuse (13) – F13
(female) (2)
YES
6
• Min. 1Mz NO
• Turn starting switch OFF Is resistance between G3 (female) (5) contact in wiring harness
Repair or replace
• Disconnect G3 and F13 and VF13 (female) (1) normal? between G3 (female) (5) –
F13 (female) (1)
YES
7
• Min. 1Mz NO
Is resistance between R2 (female) (2) contact in wiring harness
• Turn starting switch OFF Repair or replace
• Disconnect R2 and chassis ground normal? between R2 (female) (2) –
chassis ground
YES
8
• Min. 1Mz Disconnection or defective
Is resistance between R2 (female) (5) NO contact in wiring harness
• Disconnect R2 and F7 and F7 (female) (2) normal? between R2 (female) (5) – F7 Repair or replace
(female) (2)
YES
• Max. 1 z 9 Defective diode (D7) or dis-

• Turn starting switch OFF. connection or defective con-
• Disconnect G3 and R2. Is resistance between G3 (female) (38) NO
tact in wiring harness Repair or replace
• Measure on G3 side in diode and R2 (female) (3) normal? between R2 (female) (38) –
range R2 (female) (3)
Yes
To 10 on next page
PC58UU-3 20-351
(6)
From 9 on previous page Cause Remedy

1
• Max. 1z Is resistance between R2 (female) (5) NO contact in wiring harness Repair or
• Disconnect R2 and F7 and F7 (female) (2) normal? between R2 (female) (5) – F7 replace
(female) (2)
YES
20-352 PC58UU-3
(6)
E-24 After work equipment lock lever is locked, work equipment still
moves
a Perform the following troubleshooting when error code [61] (Valve open) is not displayed.
a This system does not self-diagnose disconnection.
Cause Remedy

Min. 1 Mz
• When lever is at FREE: Is voltage between PPC lock switch NO
F13 (1) and (2) normal? Defective PPC lock switch Replace
Max. 1z
YES
2
• 5 – 25 z
• Turn starting switch OFF. Is resistance between F7 (male) (1) and NO
Defective PPC lock solenoid Replace
(2) normal?
• Disconnect F7
YES
3
When R2 is replaced, is condition nor- NO Defective relay (R2) for PPC
• Replace R2 with normal relay Replace
mal? lock circuit
YES
• Max. 1 V 4
• Turn starting switch OFF Short circuit with power
• Disconnect G3 and F13 Is voltage between G3 (female) (5) and NO source in wiring harness Repair or
• Turn switch ON chassis ground normal? between G3 (female) (5) – replace
F13 (female) (1)
• Set PPC lock switch to FREE YES
• Max. 1 V 5
Is voltage between F7 (female) (2) and NO
• Disconnect G3 and F7 Turn Defective controller Replace
chassis ground normal?
switch ON
• Set PPC lock switch to FREE YES Short circuit with power
source in wiring harness Repair or
between G3 (female) (38) – replace
F7 (female) (2)
E-24 Related Electrical Circuit Diagram
PC58UU-3 20-353
(6)
E-25 System cannot be initialized

a Carry out the following troubleshooting when the angle sensors of the boom, arm, and offset are normal and
the work equipment is set normally according to them.
Cause Remedy
1
When mode selector switch is operated NO
• Turn starting switch ON. and reset terminals (F30 – F32, F30 –
• Check in monitoring mode F31) are connected, is bit displayed as
(Code: 22).
shown in Table 1?
YES
2
• Between G2 (female) (3) – Is resistance between G2 (female) (3) – tact, or short circuit with
F29 (female) (2), G2 (female) F29 (female) (2), G2 (female) (3) – chassis ground in wiring har-
(13) – F29 (female) (1), (4), G2 chassis, G2 (female) (13) – F29 ness between G2 (female)
(female) (26) – F31 (male), (female) (1), (4), or G2 (female) (13) – (3) – F29 (female) (2), G2
and G2 (female) (36) – F32 chassis normal? Is resistance between NO (female) (13) – F29 (female) Repair or
(male): Max. 1 z F29 (female) (3) and chassis normal? (1), (4), G2 (female) (26) – replace
Between each terminal – Is resistance between G2 (female) (26) F31, or G2 (female) (36) –
chassis Min. 1Mz – F31 (male one-pin connector) or G2 F32, or disconnection or
• Between F29 (female) (3) – (female) (36) – F32 (male one-pin con- defective contact in wiring
chassis: Max. 1 z nector) normal? harness between F29
(female) (3) – T2
YES
3
Is voltage between F30 (female one-pin Disconnection or defective Repair or
• Turn starting switch ON. contact in wiring harness replace
connector) – chassis ground normal? between F30 – fuse 1
YES
4
• Turn starting switch OFF. NO Defective mode selector
Is fuse (1) broken? switch Replace
• Check fuse (1).

ground in wiring harness Repair or
between F30 – fuse (1) replace
(Defective fuse (1))
Table 1
The connections of the mode selector switch are shown below.
(When the operation is normal, the bit at the GND part is displayed)
Switch position Mode (1) switch Mode (2) switch
Depth display 0 set 0 OPEN OPEN
Height 1 GND OPEN
A 1 (Reset 1) 2 OPEN GND
A 2 (Reset 2) 3 GND GND
a In this monitoring mode, SET and CLEAR of the set switch are used to change the data display to the code
display. Accordingly, the normal operation cannot be judged by the bit. Instead, judge that the operation is
normal when the code is displayed.
20-354 PC58UU-3
(6)
PC58UU-3 20-355
(6)
E-26 Depth cannot be set to 0 or height cannot be set
Cause Remedy
1
NO
• Turn starting switch ON. When mode selector switch and set
• Check in monitoring mode (SET/CLEAR) switch are operated, is
(Code: 22). bit displayed as shown in Table 1?
YES
2
Disconnection or short circuit
• Between (female) (2) – F28
with chassis ground in wiring
(female) (3), G2 (female) (3) – Is resistance between G2 (female) (2) – harness between G2
F29 (female) (2), G2 (female) F28 (female) (3), G2 (female) (2) – (female) (2) – F28 (female)
(13) – F29 (female) (1), (4), chassis, G2 (female) (3) – F29 (female)
(3), G2 (female) (3) – F29
and G2 (female) (38) – F28 (2), G2 (female) (3) – chassis, G2 NO (female) (2), G2 (female) (13)
(female) (2): Max. 1 z (female) (13) – F29 (female) (1), (4), G2 – F29 (female) (1), (4), or G2 Repair or
Between each terminal – (female) (13) – chassis, G2 (female) replace
(female) (38) – F28 (female)
chassis: Min. 1 Mz (38) – F28 (female) (2), or G2 (female) (2), or disconnection or
• Between F29 (female) (3) – (38) – chassis normal? Is resistance defective contact in wiring
chassis: Max. 1 z between F28 (female) (1) – chassis or
harness between F28
• Turn starting switch OFF. F29 (female) (3) – chassis normal? (female) (1) – M1 (female) (2)
• Disconnect G2, F28, and F29. – T2 or F29 (female) (3) – T2
YES
Defective mode selector

switch or set (SET/CLEAR) Replace
switch
Table 1
The connections of the mode selector switch are shown below.
(When the operation is normal, the bit at the GND part is displayed)
Switch position Mode (1) switch Mode (2) switch
Depth display 0 set 0 OPEN OPEN
Height 1 GND OPEN
A 1 (Reset 1) 2 OPEN GND
A 2 (Reset 2) 3 GND GND
a In this monitoring mode, SET and CLEAR of the set switch are used to change the data display to the code
display. Accordingly, the normal operation cannot be judged by the bit. Instead, judge that the operation is
normal when the code is displayed.
20-356 PC58UU-3
(6)
TROUBLESHOOTING FOR CONTROLLER
INPUT SIGNAL SYSTEM
(F-MODE)
F-1 Controller does not display [26 (2)] (One-touch deceleration) ............................................................. 20-402
F-2 Controller does not display [26 (3)] (Traveling accelerator switch)...................................................... 20-403
PC58UU-3 20-401
(6)
TROUBLESHOOTING F-1
F-1 Controller does not display [26 (2)] (One-touch deceleration)

a This code is displayed in only the display unit of the controller.
Cause Remedy
• Turn one-touch decelerator 1

switch ON: Max. 1 V Is voltage between G3 (9) – chassis NO
• Turn one-touch decelerator
normal?
switch OFF: 3 – 4 V
YES
• Turn one-touch decelerator 2

switch ON: Max. 1 z
• Turn one-touch decelerator Is resistance of one-touch decelerator NO Defective one-touch deceler-
Replace
switch OFF: Min. 1 Mz switch normal? ator switch
• Disconnect F18. YES
3
• Max. 1 z Is resistance between F18 (2) – chassis NO
• Turn starting switch OFF. Defective fuse (3) Replace
ground normal?
• Disconnect F18.
contact in wiring harness Replace wiring
between F18 (1) – G3 (9) harness
F-1 Related electrical circuit diagram
20-402 PC58UU-3
(6)
TROUBLESHOOTING F-2
F-2 Controller does not display [26 (3)] (Traveling accelerator switch)
a The error code is displayed only on the display unit of the controller.
Cause Remedy
• When traveling accelerator 1

switch is at HIGH: Max. 1 V Is voltage between G1 (5) and NO
• When traveling accelerator chassis ground normal?
switch is at LOW: Min. 4 V
YES
2
• At HIGH: Max. 1 z
• At LOW: Min. 1 Mz Is resistance of traveling accelerator NO Defective traveling accelera-
• Turn starting switch OFF. Replace
switch normal? tor switch
• Disconnect switch terminal.
YES
• Max. 1 z contact in wiring harness
Is resistance between traveling acceler- NO Replace wiring
• Turn starting switch OFF. between traveling accelerator harness
• Disconnect switch terminal. ator switch and chassis ground normal?
switch – chassis ground
contact in wiring harness Replace wiring
between traveling accelerator harness
switch – G1 (5)
F-2 Related electrical circuit diagram
PC58UU-3 20-403
(6)
TROUBLESHOOTING FOR
HYDRAULIC AND MECHANICAL SYSTEMS
(H-MODE)
H-MODE
TABLE OF FAILURE MODES AND CAUSES................................................................................................ 20-504
H-1 Speed or power of work equipment (including blade), travel, and swing systems is low.... 20-506
a) Speed or power of two or more of work equipment (boom, arm, and bucket),
travel, swing, and blade systems is low ............................................................................... 20-506
b) Speed or power of work equipment (excluding blade), travel, and swing systems
is low........................................................................................................................................ 20-507
c) Speed or power of work equipment (excluding blade) and travel systems is low ........... 20-507
d) Speed or power of swing and blade systems is low ........................................................... 20-508
e) Speed or power of travel and blade systems is low............................................................ 20-508
f) Speed or power of work equipment (excluding blade) is low ............................................ 20-509
g) Speed or power of travel and swing systems is low ........................................................... 20-509
H-2 There is excessive drop in engine speed or engine stalls........................................................ 20-510
H-3 Two or more of work equipment (boom, arm, bucket, and offset), travel, swing,
and blade systems do not move ................................................................................................ 20-512
a) Work equipment (including blade), travel, and swing systems do not move ................... 20-512
b) Work equipment (excluding blade), travel, and swing systems do not move .................. 20-513
c) Work equipment (excluding blade) and travel systems do not move ............................... 20-513
d) Swing and blade systems do not move ............................................................................... 20-513
e) Travel and blade systems do not move................................................................................ 20-514
f) Work equipment (excluding blade) system does not move ............................................... 20-514
H-4 Abnormal noise generated (from around pump)...................................................................... 20-515
H-5 Fine controllability is poor or response is low .......................................................................... 20-516
(Two or more systems have poor fine controllability or low response simultaneously) ...... 20-516
H-6 Boom speed or power is low (Other work equipment is normal) ........................................... 20-517
a) Boom RAISE speed or power is low ..................................................................................... 20-517
b) Boom LOWER speed or power is low ................................................................................... 20-518
H-7 Arm IN speed or power is low .................................................................................................... 20-519
a) Arm speed or power is low (Other work equipment is normal) ......................................... 20-519
b) Arm OUT speed or power is low ........................................................................................... 20-520
H-8 Bucket CURL speed or power is low .......................................................................................... 20-521
a) Bucket speed or power is low (Other work equipment is normal) .................................... 20-521
b) Bucket DUMP speed or power is low ................................................................................... 20-522
H-9 Offset LEFT speed or power is low............................................................................................. 20-523
a) Offset boom speed or power is low (Other work equipment is normal) ........................... 20-523
b) Offset RIGHT speed or power is low ..................................................................................... 20-524
H-10 Boom does not RAISE ................................................................................................................. 20-525
a) Boom does not move ............................................................................................................. 20-525
b) Boom does not LOWER.......................................................................................................... 20-526
H-11 Arm does not move in................................................................................................................. 20-527
a) Arm does not move................................................................................................................ 20-527
b)Arm does not move out ........................................................................................................... 20-528
H-12 Bucket does not curl .................................................................................................................... 20-529
a) Bucket does not move............................................................................................................ 20-529
b) Bucket does not dump ........................................................................................................... 20-530
H-13 Offset boom does not move to left ............................................................................................ 20-531
a) Offset boom does not move .................................................................................................. 20-531
b) Offset boom does not move to right..................................................................................... 20-532
H-14 Hydraulic drift of boom is large.................................................................................................. 20-533
H-15 Hydraulic drift of arm is large ..................................................................................................... 20-533
H-16 Hydraulic drift of bucket is large................................................................................................. 20-534
H-17 Hydraulic drift of offset boom is large ....................................................................................... 20-534
a) Hydraulic drift of offset boom to left is large ....................................................................... 20-534
b) Hydraulic drift of offset boom to right is large..................................................................... 20-534
H-18 Time lag is large (Engine speed is low) ..................................................................................... 20-535
PC58UU-3 20-501
1
TROUBLESHOOTING H-MODE
H-19 Part loaded more moves slower in compound operation of work equipment ...................... 20-535
H-20 Travel deviation is large .............................................................................................................. 20-536
a) Travel deviation is large during ordinary travel................................................................... 20-536
b) Travel deviation is large when machine starting (but normal during ordinary travel)..... 20-537
H-21 Travel speed or power is low (Work equipment, swing, and blade operations are normal) 20-538
H-22 Machine cannot be steered sharply or steering force is insufficient....................................... 20-539
H-23 Travel speed does not change.................................................................................................... 20-540
H-24 Machine does not travel.............................................................................................................. 20-541
H-25 Overrun of travel is large ............................................................................................................ 20-543
H-26 Travel hydraulic drift is large ...................................................................................................... 20-543
H-27 Fine controllability or response is low ....................................................................................... 20-544
H-28 Swing speed or power is low (Work equipment, travel, and blade operations are normal.. 20-545
a) Swing speed or power is low in both directions ................................................................. 20-545
b) Swing speed or power is low in either direction ................................................................. 20-547
H-29 Machine does not swing (Work equipment, travel, and blade operations are normal) ........ 20-548
a) Machine does not swing in either direction ......................................................................... 20-550
b) Machine does not swing in both directions ......................................................................... 20-550
H-30 Swing acceleration is low ........................................................................................................... 20-551
a) Swing acceleration is low in both directions ....................................................................... 20-551
b) Swing acceleration is low in either direction ....................................................................... 20-551
H-31 Overrun of swing is large............................................................................................................ 20-552
a) Overrun of swing is large in both directions ........................................................................ 20-552
b) Overrun of swing is large in either direction........................................................................ 20-552
H-32 Large shock is made when machine stops swinging ............................................................... 20-553
H-33 Large abnormal sound is made when machine stops swinging ............................................. 20-553
H-34 Swing hydraulic drift is large...................................................................................................... 20-553
H-35 Fine controllability or response of swing is low ....................................................................... 20-554
H-36 Blade speed or power is low (Work equipment, travel, and swing operations are normal). 20-555
H-37 Blade does not move (Work equipment, travel, and swing operations are normal) ............. 20-556
a) Blade does not raise ............................................................................................................... 20-556
b) Blade does not lower.............................................................................................................. 20-557
H-38 Hydraulic drift of blade is excessive........................................................................................... 20-558
H-39 Fine controllability is poor or response of blade is low ........................................................... 20-558
H-40 Monitor panel displays error code [61] and boom RAISE, arm IN, and LEFT offset
operations stop just before interference.................................................................................... 20-559
H-41 Machine does not stop boom RAISE, arm IN, and LEFT offset operations
automatically but interferes ........................................................................................................ 20-559
20-502 PC58UU-3
1
TROUBLESHOOTING H-MODE
H-MODE
TABLE OF FAILURE MODES AND CAUSES
Tank Hydraulic pump Control valve
Parts causing failure
Pressure compensation valve

LS bypass check valve
Failure mode
LS bypass throttle
Engine system
LS line throttle
Control pump
Unload valve
Piston pump
Servo piston
Hydraulic oil
Gear pump
EPC valve
PC valve
LS valve
Strainer
Damper
Orifice
Spool
Cap
Speed of all work equipment, swing, travel, are slow or lack power ● ● ● ● ● ● ●
Work equip- There is excessive drop in engine speed, or engine stalls ● ● ● ● ● ●

ment, travel,
Two or more of work equipment, travel, swing, or blade do not move ● ● ● ● ● ● ●
swing, and
blade Abnormal noise generated (around pump) ● ● ● ● ● ●
Fine controllability is poor or response is low ● ● ● ● ● ●
Boom ● ●
Arm ● ●
Speed is slow or lacks power
Bucket ● ●
Offset ● ●
Boom ● ●
Work equipment does not Arm ● ●

move Bucket ● ●
Work equip-
ment Offset ● ●
Boom ●
Arm ●
Excessive hydraulic drift
Bucket ●
Offset ●
Excessive time lag (Engine speed is low)
In compound operations, work equipment with larger load is slow ●
Excessive travel deviation ● ● ●
Travel speed is slow or lacks power ● ● ●
Machine cannot be steered sharply or steering force is insufficient ● ● ●
Travel speed does not change
Travel
Machine does not travel ● ● ●
Excessive overrun of travel ●
Excessive travel hydraulic drift
Fine controllability is poor or response is low ● ● ●
Swing speed is slow or lacks power ●
Machine does not swing ●
Swing acceleration is poor ●
Excessive overrun of swing
Swing
Excessive shock is made when machine stops swinging ●
Excessive abnormal noise is made when machine stops swinging
Excessive hydraulic drift of swing
Fine controllability of swing is poor or response is low ●
Blade speed is slow or lacks power ●
Blade does not move ●
Blade
Excessive hydraulic drift of blade ●
Fine controllability of blade is poor or response is low ●
Monitor panel displays error code [61] and all operations stop just before
Prevention of interference
interference Machine does not stop boom RAISE, arm IN, and LEFT offset operations auto-
matically but interferes
20-504 PC58UU-3
1
●
●
●
Main relief valve
Main relief circuit check valve TAB
H-MODE
Merging valve
● ●
● ● ●
● ● ●
Logic valve
PC58UU-3
●
● ● ●
●
●
PPC circuit check valve
Travel junction throttle
Centralized safety valve
● ●
● ●
● ●
● ●
●
●
●
●
●
●
● ●
● ●
Suction valve
● ●
●
Boom lock valve
Control Valve
● ● ● ●
Boom assist valve
TROUBLESHOOTING
●
●
● ●
Gear pump circuit relief valve
●
Swing PPC circuit throttle
● ●
● ●
● ●
● ●
●
●
Swing brake circuit check valve
●
●
●
●
Blade safety valve
●
●
●
●
Back pressure valve
●
●
Swing PPC slow return valve
● ●
Swing PPC line throttle
● ● ●
● ● ●
● ● ●
● ● ●
Swing brake reset line throttle
●
●
●
●
PPC valve (Right lever)
●
●
●
●
●
●
●
●
PPC valve (Left lever)
●
●
●
●
●
●
PPC valve (Travel lever)
●
●
PPC valve (Offset pedal)
Control relief valve
●
●
● ●
PPC main pressure lock solenoid valve

LE OF FAILURE MODES AND CAUSES
Traveling accelerator solenoid valve
●
●
Boom RAISE EPC valve
●
●
Arm IN EPC valve

Solenoid valve
● ● ●
● ● ●
●
● Offset LEFT solenoid valve
Piston motor
●
Safety valve
Check valve
● ● ●
● ● ● ●
Suction valve
● ● ● ● ●
● ● ● ● ●
● ● ● ● ●
● ● ● ● ●
Parking brake
Swing motor
● ●
Parking brake hydraulic timer
●
●
Swing machinery
●
●
●
●
●
●
●
Center swivel joint
●
Piston motor
● ●
●
Counterbalance valve
● ● ●
● ● ●
● ● ● ●
● ● ● ●
Check valve
●
2nd gear speed changeover valve and piston
Parking brake
Travel motor
● ●
● ●
Parking brake valve
● ● ●
● ● ●
● ● ● Final drive
●
●
●
●
●
●
●
●
●
●
●
●
Hydraulic cylinder
● ●
● ●
● ●
● ●
Control linkage
Trouble mode
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-10
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-41
H-40
H-39
H-38
H-37
H-36
H-35
H-34
H-33
H-32
H-31
H-30
H-29
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-MODE
20-505
1
TROUBLESHOOTING H-1
H-1 Speed or power of two or more of work equipment (boom,

arm, bucket, and offset), travel, swing, and blade systems is
low
★ Before carrying out troubleshooting, check that oil level in the tank is proper.
★ If the engine speed lowers, carry out H-2 first.
★ If [Individual factor] is indicated, a trouble which occurs less frequently than the detected trouble may
have occurred or several troubles may be combined. Accordingly, carry out troubleshooting for each of
those troubles.
★ Select a combination of systems which have low speed or power from Table 1 before going to the next
troubleshooting.
★ If the combination of the detected troubles is not in Table 1, carry out troubleshooting for the actuators
of each system [which has low speed or power] (H-6 ~ H-9).
Table 1 !: Normal ✕: Speed is slow or lacks power

Troubleshooting
Work equipment Travel Swing Blade item
✕ ✕ ✕ ✕ a Go to a
✕ ✕ ✕ ! b Go to a
✕ ✕ ! ! c Go to a
! ! ✕ ✕ d Go to a
! ✕ ! ✕ e Go to a
✕ ! ! ! f Go to a
! ✕ ✕ ! g Go to a
a) Speed or power of work equipment (including blade), travel, and swing systems is low
Cause Remedy
1
No Go to related troubleshoot- —
Is suction strainer clogged?
ing in H-6 ~ 9, 21, 28, and 36
Yes Clogged of suction strainer Clean or replace

(Suction trouble of pump)
20-506 PC58UU-3
1
TROUBLESHOOTING H-1
b) Speed or power of work equipment (excluding blade), travel, and swing systems is low
Cause Remedy
1
• 2.94 +- 0.5
0.1 MPa Is output pressure of PPC main pres-
No
{30 +- 51 kg/cm²} sure lock solenoid valve normal?
Yes Go to related troubleshoot-

ing in H-6 ~ 9, 21, and 28 —
When control relief valve is adjusted, No

is trouble repaired?
Yes Improper adjustment of

control relief valve Adjust
3
When PPC main pressure lock sole- No
noid valve is replaced, is trouble Defective control pump Repair or
replace
repaired?
Yes Defective PPC main pres- Repair or
sure lock solenoid valve replace
c) Speed or power of work equipment (excluding blade) and travel systems is low
Cause Remedy
1
• Bucket IN
26.0 +1
- 0.5 MPa Is work equipment relief pressure No
{265 +10
-5 kg/cm²} normal?
• Run engine at full throttle Yes
2
No Go to related troubleshoot- —
Is travel relief pressure normal? ing in H-6 ~ 9 and 21
Yes
3
When blade is raised until its circuit is No Defective variable-capacity
relieved, are work equipment and pump (Lowering of effi- Repair or
replace
travel speeds heightened? ciency)
Yes Defective boom assist Repair or
valve replace
4
• 26.0 +1
- 0.5 MPa No
{265 +10
-5 kg/cm²} Is travel relief pressure normal?
• Run engine at full throttle
ing in H-6 ~ 9 and 21 —
5
When travel relief pressure is No
adjusted or relief valve is replaced, is
trouble repaired?
Yes
Defective main relief valve Adjust or
replace
6
No Adjust or
Does unload valve move smoothly? Defective unload valve replace
Yes
Go to troubleshooting No. 3
PC58UU-3 20-507
1
TROUBLESHOOTING H-1
d) Speed or power of swing and blade systems is low
Cause Remedy
1
• Blade RAISE
21.6 +1.5 MPa No
-0.5 Is gear pump relief pressure normal?
{220 +15
-5 kg/cm²}
• Run engine at full throttle Yes Go to related troubleshoot- —
ing in H-28 and 36
2
When gear pump circuit relief valve No Repair or
is adjusted or replaced, is trouble Defective gear pump replace
repaired?
Yes Defective gear pump rota-
tion relief pressure Adjust or repair
e) Speed or power of travel and blade systems is low
Cause Remedy
1
• 26.0 +1
- 0.5 MPa No
{265 +10
-5 kg/cm²} Is travel relief pressure normal?
ing in H-21 and 36 —
2
• Blade RAISE
21.6 +1.5 MPa No
-0.5 Is blade relief pressure normal?
{220 +15
-5 kg/cm²}
• Run engine at full throttle Yes Go to related troubleshoot- —
ing in H-21 and 36
3
When hose is disconnected from No Go to related troubleshoot- —
valve outlet and plug is installed ing in H-21 and 36
instead, is relief pressure normal?
Yes Repair or
Defective swivel joint replace
20-508 PC58UU-3
1
TROUBLESHOOTING H-1
f) Speed or power of work equipment (excluding blade) is low
Cause Remedy
1
• 2.45 MPa {25 kg/cm²} Is all PPC pressure normal (at PPC No
• Run engine at full throttle pressure inlet of control valve)?
Yes
2
• 1.57 ± 0.1 MPa No
{16 ± 1 kg/cm²} Is LS differential pressure normal? Improper adjustment of Adjust
pump LS valve
Yes Go to related troubleshoot- —
ing in H-6 ~ 9
3
Is PPC pressure normal at only 1 part No Go to related troubleshoot- —

(in single operation)? ing in H-6 ~ 9
Yes Defective PPC circuit check

valve at part where PPC Replace
pressure is normal
g) Speed or power of travel and swing systems is low

Carry out troubleshooting in b) above.
★ If the PPC main pressure is lower than in b) above, this trouble can occur.
PC58UU-3 20-509
1
TROUBLESHOOTING H-2
H-2 There is excessive drop in engine speed or engine stalls

Cause Remedy
1
• Oil temperature: 50°C When bucket is curled and blade is
• Is full throttle engine speed raised simultaneously until their cir- No
kept higher than 2,100 rpm? cuit is relieved, does engine speed
(If not, go to [NO] side.) lower excessively?
Yes
2
• Oil temperature: 50°C When blade is raised or bucket is
• Is full throttle engine speed swung until its circuit is relieved and No
kept higher than 2,100 rpm? other work equipment is moved
(If not, go to [NO] side.) without relieving its circuit, does
engine speed lower excessively?
Yes Carry out troubleshooting
No. 4
3
• 26.0 +1
- 0.5 MPa No
Is bucket CURL relief pressure nor-
{265 +10
-5 kg/cm²} mal?
Yes
4
• 21.6 +1.5
-0.5 MPa No
Is blade RAISE relief pressure nor-
{220 +15
-5 kg/cm²} mal?
Yes
5
When gear pump circuit relief valve is No
adjusted, repaired, or replaced, is
trouble repaired?
Yes Defective gear pump circuit Adjust or
relief valve replace
6
When main relief valve is adjusted or No

replaced, is trouble repaired?
Yes Defective main relief valve Repair or

replace
7
Does monitor display error code [54] No

to indicate defective TVC?
Yes
8
No
Is TVC connector connected? Defective connection Repair
Yes Defective TVC-EPC valve Replace

(Solenoid valve)
9
When engine speed changes, does No Repair or

TVC current change? Defective controller replace
Yes
To next page
20-510 PC58UU-3
1
TROUBLESHOOTING H-2
From previous page Cause Remedy
10
When TVC connector is discon- No
nected, does engine speed lower
more?
Yes
11
When PC valve is adjusted, is trouble No
repaired?
Yes Adjust or
Defective PC valve
replace
12
When orifice of servo is cleaned, is No
trouble repaired?
Yes
Clogged orifice
13
When EPC valve TVC is replaced, is No Carry out troubleshooting —
trouble repaired? No. 11
Yes Repair or
Defective EPC valve replace
14
When pump assembly is replaced, is No Defective engine system —
trouble repaired?
Yes Repair or
Defective pump or servo replace
PC58UU-3 20-511
1
TROUBLESHOOTING H-3
H-3 Two or more of work equipment (boom, arm, bucket, and off-
set), travel, swing, and blade systems do not move
★ Before carrying out troubleshooting, check that oil level in the tank is proper.
Select a combination of systems which do not move from Table 1 before going to the next trouble-
shooting.
If the combination of the detected troubles is not in Table 1, carry out troubleshooting for the actuators
of each system [which does not move] (H-10 ~ H-13).
Table 1 Combination table of troubled systems and troubleshooting items

!: Normal ✕: Does not move
Troubleshooting
Work equipment Travel Swing Blade item
✕ ✕ ✕ ✕ a Go to a
✕ ✕ ✕ ! b Go to a
✕ ✕ ! ! c Go to a
! ! ✕ ✕ d Go to a
! ✕ ! ✕ e Go to a
✕ ! ! ! f Go to a
! ✕ ✕ ! g Go to a
a) Work equipment (including blade), travel, and swing systems do not move
Cause Remedy
1
When engine is cranked, does oil
flow out of pump?
When oil does not flow out of any of

following pump
• Main pump
• Gear pump
• Pilot pump
2
No
Is suction strainer clogged?
Yes
Clogging of suction strainer Clean or replace
3
No
Is damper or spline damaged? Defective main pump shaft Replace
Yes
Defective damper or spline Replace
• When oil flows out of main pump

but does not flow out of gear pump
and pilot pump
4
Coupling or spline between main No
pump and gear pump is damaged. Defective gear pump Replace
Yes
Defective coupling or spline Replace
20-512 PC58UU-3
1
TROUBLESHOOTING H-3
b) Work equipment (excluding blade), travel, and swing systems do not move
Cause Remedy
1
When engine is cranked, does oil No Repair or
flow out of control pump? Defective control pump replace
Yes
1
• 2.94 +- 0.5
0.1 MPa No Defective PPC main pres-
{30 +- 51 kg/cm²}
Is output pressure of PPC main pres-
sure lock solenoid valve normal? sure lock solenoid valve or Repair or
defective electric system replace
ing in H-10 ~ 13, 24, and 29
c) Work equipment (excluding blade) and travel systems do not move
Cause Remedy
1
flow out of main pump? Defective main pump
replace
Yes
2
• 2.94 +- 0.5
0.1 MPa No
+ 5 When main relief valve is adjusted or
{30 - 1 kg/cm²} replaced, is travel repaired?
replace
3
No Repair or
Does unload valve move smoothly? Defective unload valve replace
Yes
Defective main relief valve Repair
replace
or
d) Swing and blade systems do not move
Cause Remedy
1
flow out of gear pump? Defective gear pump replace
Yes
1
When gear pump circuit relief valve No Go to related troubleshoot- —
is adjusted or replaced, is travel
repaired? ing in H-29 and 37
Yes Defective gear pump circuit Adjust or
relief valve replace
PC58UU-3 20-513
1
TROUBLESHOOTING H-3
e) Travel and blade systems do not move
Cause Remedy
1
• 26.0 +1
- 0.5 MPa
No Repair or
{265 +10
-5 kg/cm²} Is travel relief pressure normal? replace
ing in H-24 and 37
2
• 21.6 +1.5
-0.5 MPa
+15 When main relief valve is adjusted or No
{220 - 5 kg/cm²} replaced, is travel repaired?
replace
3
No Repair or
Does unload valve move smoothly? Defective unload valve
replace
Yes
Defective main relief valve Repair or
replace
f) Work equipment (excluding blade) system does not move
Cause Remedy
1
• 2.45 MPa {25 kg/cm²} Is all PPC pressure normal (at PPC No
• Run engine at full throttle pressure inlet of connection)?
ing in H-10 ~ 137
1
Is PPC pressure normal at only 1 No Go to related troubleshoot- —
part? ing in H-10 ~ 13
Yes Defective PPC circuit check

valve at part where pres- Replace
sure is normal
20-514 PC58UU-3
1
TROUBLESHOOTING H-4
H-4 Abnormal noise generated (from around pump)
Cause Remedy
1
No
Is oil level in hydraulic tank normal? Improper hydraulic oil level Add
oil
hydraulic
Yes
2
No
Are there bubbles in hydraulic tank?
Yes
3
When engine is stopped, do bubbles No
disappear? Improper hydraulic oil level —
Yes Go to troubleshooting No.

4
4
Is suction strainer clogged with for- No

" Foreign matter: Cloth, etc eign matter?
Yes Clogging of suction strainer
with foreign matter (cloth, Remove
etc.)
5
Is suction strainer clogged with No
metallic matter or metallic dust?
Yes Repair or
Defective inside of pump replace
6
No Operate and check condi- Check again
Is hydraulic tank cap clogged? tion for a while (as condition
changes)
Yes Negative pressure in tank Clean or replace
caused by clogging of cap cap
PC58UU-3 20-515
1
TROUBLESHOOTING H-5
H-5 Fine controllability is poor or response is low

(Two or more systems have poor fine controllability or
low response simultaneously)
★ The following troubleshooting is not applicable to travel, swing, and blade systems
Cause Remedy
1
• See TESTING AND No
ADJUSTING Is LS differential pressure normal?
Yes
2
No
Is orifice of unload valve clogged?
Yes Clogging of orifice of

unload valve Clean
3
No Defective PC valve or servo Repair or
Is orifice of piston pump clogged? replace
piston
Yes Clogging of orifice of pis-
ton pump Clean
When LS valve is adjusted, is trouble No Defective LS valve Repair or

repaired? replace
Yes Improper adjustment of LS Adjust
valve
20-516 PC58UU-3
1
TROUBLESHOOTING H-6
H-6 Boom speed or power is low (Other work equipment is nor-

mal)
a) Boom RAISE speed or power is low
★ When measuring the boom RAISE relief pressure, reset the interference prevention system.
★ When the boom speed is low, if the result of troubleshooting No. 1 is [NO], take actions against the
relief pressure and carry out troubleshooting No. 2.
Cause Remedy
1
• 26.5 +1.0
-0.5 MPa
No
{265 +10
-5 kg/cm²} Is boom relief pressure normal?
Yes
2
• 2.45 MPa {25 kg/cm²} Is EPC valve output pressure normal No
(at PPC pressure inlet of control
• Run engine at full throttle valve?
Yes
3
Does control valve spool move No Defective operation of con- Repair or
smoothly? trol valve spool replace
Yes
4
Does pressure compensation valve No Defective pressure compen- Repair or
move smoothly? sation valve replace
Yes
5
• 26.5 +1.0
-0.5 MPa
Is boom LOWER relief pressure nor- No Defective centralized safety
{265 +10
-5 kg/cm²} mal? valve Replace
Yes
Defective suction valve Repair or
(Boom RAISE side) replace
6
When pilot hose of boom assist valve No Defective boom cylinder Repair or
is disconnected, is speed increased? packing replace
Yes
Defective seat of check valve Repair or
of boom assist valve replace
7
When PPC hose of control valve is No
(Move arm IN and RAISE replaced with arm IN hose, is trouble
boom) repaired? (Return hose immediately Go to troubleshooting No. 3 —
after checking.)
Yes
• 2.94 +- 0.1
0.5 MPa 8
+ 5
{30 - 1 kg/cm²} No Defective boom RAISE PPC Repair or
• Run engine at full throttle Is PPC valve output pressure normal?
valve replace
• Measure at solenoid valve
inlet Yes
Defective boom RAISE EPC Repair or
valve replace
PC58UU-3 20-517
1
TROUBLESHOOTING H-6
b) Boom LOWER speed or power is low

★ When the boom speed is low, if the result of troubleshooting No. 1 is [NO], take actions against the
Cause Remedy
1
• 26.5 +1.0
-0.5 MPa
Is boom LOWER relief pressure nor- No
{265 +10
-5 kg/cm²} mal?
Yes
2
• 2.94 +- 0.5
0.1 MPa Is PPC valve output pressure normal No
{30 +- 51 kg/cm²} (at PPC pressure inlet of control
valve?
Yes
3
smoothly? trol valve spool or EPC valve replace
spool
Yes
4
Do poppet and pilot piston of boom No
lock valve move smoothly and is ori- Defective operation of lock Repair, clean,
fice free of clogging? valve or replace
Yes
Defective operation of spool Check 3 again
5
• 26.5 +1.0
-0.5 MPa
Is boom RAISE relief pressure nor- No Defective centralized safety
{265 +10
Yes
(Boom LOWER side) replace
6
When PPC hose of control valve is
(Move arm OUT and LOWER replaced with arm OUT hose, is trou- No
boom) ble repaired? (Return hose immedi- Go to troubleshooting No. 3 —
ately after checking.)
Yes
Defective boom LOWER PPC Repair or
valve replace
20-518 PC58UU-3
1
TROUBLESHOOTING H-7
H-7 Arm speed or power is low (Other work equipment is normal)
a) Arm IN speed or power is low
★ When measuring the arm IN relief pressure, reset the interference prevention system.
★ When the arm speed is low, if the result of troubleshooting No. 1 is [NO], take actions against the relief
pressure and carry out troubleshooting No. 2.
Cause Remedy
1
• 26.5 +1.0
-0.5 MPa
No
{265 +10
-5 kg/cm²} Is arm IN relief pressure normal?
Yes
2
• 2.45 MPa {25 kg/cm²} Is EPC valve output pressure normal No
(at PPC pressure inlet of control
• Run engine at full throttle valve?
Yes
3
Yes
4
Yes Defective arm cylinder pack- Repair or
ing replace
5
• 26.5 +1.0
-0.5 MPa
No Defective centralized safety
{265 +10
-5 kg/cm²} Is arm OUT relief pressure normal? valve Replace
Yes
Defective suction valve (Arm Repair or
IN side) replace
6
When PPC hose of control valve is No
(RAISE boom and move arm replaced with boom RAISE hose, is
IN) trouble repaired? (Return hose imme-
diately after checking.)
Yes
When arm is moved in while swing- No

ing, is condition normal? Go to troubleshooting No. 3 —
Yes Defective seats of swing Repair or

brake circuit check valve and replace
swing PPC slow return valve
8
• 2.94 +- 0.5
0.1 MPa Are PPC pressure inlet of solenoid No Repair or
{30 +- 51 kg/cm²} valve and PPC valve output pressure Defective arm IN PPC valve
replace
• Run engine at full throttle normal?
Yes
Defective arm IN EPC valve Repair or
replace
PC58UU-3 20-519
1
TROUBLESHOOTING H-7
b) Arm OUT speed or power is low
★ When the arm speed is low, if the result of troubleshooting No. 1 is [NO], take actions against the relief
pressure and carry out troubleshooting No. 2.
Cause Remedy
1
• 26.5 +1.0
-0.5 MPa
No
{265 +10
-5 kg/cm²} Is arm OUT relief pressure normal?
Yes
2
• 2.94 +- 0.5
valve?
Yes
3
Yes
4
Yes Defective arm cylinder pack- Repair or
ing replace
5
• 26.5 +1.0
-0.5 MPa
No Defective centralized safety
{265 +10
-5 kg/cm²} Is arm IN relief pressure normal? valve Replace
Yes
Defective suction valve (Arm Repair or
OUT side) replace
6
(LOWER boom and move arm replaced with boom LOWER hose, is No
OUT) trouble repaired? (Return hose imme- Go to troubleshooting No. 3 —
Yes
Defective arm OUT PPC Repair or
valve replace
20-520 PC58UU-3
1
TROUBLESHOOTING H-8
H-8 Bucket speed or power is low (Other work equipment is nor-

mal)
a) Bucket CURL speed or power is low
★ When the bucket speed is low, if the result of troubleshooting No. 1 is [NO], take actions against the
Cause Remedy
1
• 26.5 +1.0
-0.5 MPa
Is bucket CURL relief pressure nor- No
+10
{265 - 5 kg/cm²} mal?
Yes
2
• 2.94 +- 0.5
valve?
Yes
3
Yes
4
Yes Defective bucket cylinder Repair or
packing replace
5
• 26.5 +1.0
-0.5 MPa
Is bucket DUMP relief pressure nor- No Defective centralized safety
+10
{265 - 5 kg/cm²} Replace
mal? valve
Yes
(Bucket DUMP side) replace
6
(Move arm IN and CURL replaced with arm IN hose, is trouble No
bucket) repaired? (Return hose immediately Go to troubleshooting No. 3 —
after checking.)
Yes
Defective bucket CURL PPC Repair or
valve replace
PC58UU-3 20-521
1
TROUBLESHOOTING H-8
b) Bucket DUMP speed or power is low
Cause Remedy
1
• 26.5 +1.0
-0.5 MPa
Is bucket DUMP relief pressure nor- No
{265 +10
-5 kg/cm²} mal?
Yes
2
• 2.94 +- 0.5
valve?
Yes
3
Yes
4
Yes Defective bucket cylinder Repair or
packing replace
5
• 26.5 +1.0
-0.5 MPa
Is bucket CURL relief pressure nor- No Defective centralized safety
{265 +10
Yes
(Bucket DUMP side) replace
6
(Move arm OUT and DUMP replaced with arm OUT hose, is trou- No
bucket) ble repaired? (Return hose immedi- Go to troubleshooting No. 3 —
ately after checking.)
Yes
Defective bucket DUMP PPC Repair or
valve replace
20-522 PC58UU-3
1
TROUBLESHOOTING H-9
H-9 Offset boom speed or power is low (Other work equipment is

normal)
a) Offset LEFT speed or power is low
★ Relieve the offset LEFT cylinder in a position where the interference prevention function does not work
★ When the offset boom speed is low, if the result of troubleshooting No. 1 is [NO], take actions against
the relief pressure and carry out troubleshooting No. 2.
Cause Remedy
1
• 26.5 +1.0
-0.5 MPa
No
{265 +10
-5 kg/cm²} Is offset LEFT relief pressure normal?
Yes
2
• 2.94 +- 0.5
0.1 MPa Is output pressure of solenoid valve No
+ 5
{30 - 1 kg/cm²} normal (at PPC pressure inlet of con-
trol valve)?
Yes
3
Yes
4
Yes Defective offset cylinder Repair or
packing replace
5
• 26.5 +1.0
-0.5 MPa
Is offset RIGHT relief pressure nor- No Defective operation of pres- Repair or
{265 +10
-5 kg/cm²} mal? sure compensation valve replace
Yes Defective packing seal near Repair or
extraction end of offset cylin- replace
der
6
(CURL bucket and move off- replaced with bucket CURL hose, is No
set LEFT cylinder) trouble repaired? (Return hose imme- Go to troubleshooting No. 3 —
Yes
Defective bucket DUMP PPC Repair or
valve replace
7
No Defective offset LEFT PPC Repair or
Is PPC valve output pressure normal?
valve replace
Yes Defective offset LEFT sole- Repair or

noid valve replace
PC58UU-3 20-523
1
TROUBLESHOOTING H-9
b) Offset RIGHT speed or power is low
Cause Remedy
1
• 26.5 +1.0
-0.5 MPa
Is offset RIGHT relief pressure nor- No
{265 +10
-5 kg/cm²} mal?
Yes
2
• 2.94 +- 0.5
0.1 MPa Is output pressure of solenoid valve No
{30 +- 51 kg/cm²} normal (at PPC pressure inlet of con-
trol valve)?
Yes
3
Yes
4
Yes Defective offset cylinder Repair or
packing replace
5
• 26.5 +1.0
-0.5 MPa
No Defective pressure compen- Repair or
{265 +10
-5 kg/cm²} Is offset LEFT relief pressure normal? sation valve replace
Yes
Defective suction valve (Off- Repair or
set RIGHT side) replace
6
(DUMP bucket and move replaced with bucket DUMP hose, is No
RIGHT offset cylinder) trouble repaired? (Return hose imme- Go to troubleshooting No. 3 —
Yes
Defective offset RIGHT PPC Repair or
valve replace
20-524 PC58UU-3
1
TROUBLESHOOTING H-10
H-10 Boom does not move
★ Perform the following troubleshooting when the boom does not move when it is operated singularly
(and the other work equipment is normal).
a) Boom does not RAISE
Cause Remedy
1
• 2.94 +- 0.5
0.1 MPa Is EPC valve output pressure normal No
{30 +- 51 kg/cm² (at PPC pressure inlet of control
valve)?
Yes
2
No Defective operation of con- Repair or
Does boom LOWER? trol valve spool or seizure of replace
poppet of lock valve
Yes
3
• 26.5 +1.0
-0.5 MPa
When boom is RAISED, is pump relief No
{265 +10
-5 kg/cm²} pressure normal?
Yes Deformation of cylinder or Repair or
work equipment (It does not replace
move from deformed point)
4
No Defective raising operation Repair or
Does spool move smoothly?
of spool replace
Yes Defective pressure compen- Repair or
sation valve replace
5
(DUMP bucket and move replaced with arm IN hose, is trouble No
RIGHT offset cylinder) repaired? (Return hose immediately Go to troubleshooting No. 2 —
after checking.)
Yes
6
No Defective boom RAISE PPC Repair or
Is PPC valve output pressure normal?
valve replace
Yes Defective boom RAISE sole- Repair or
noid valve replace
PC58UU-3 20-525
1
b) Boom does not LOWER
Cause Remedy
1
• 2.94 +- 0.5
{30 +- 51 kg/cm² (at PPC pressure inlet of control
valve)?
Yes
2
No Defective operation of con- Repair or
Does boom RAISE? trol valve spool or seizure of replace
poppet of lock valve
Yes
3
• 26.5 +1.0
-0.5 MPa
When boom is LOWERED, is pump No
{265 +10
-5 kg/cm²} relief pressure normal?
Yes
Defective operation of lock Repair or
valve replace
4
No Defective lowering opera- Repair or
tion of spool replace
Yes Defective pressure compen- Repair or
sation valve replace
5
(Move arm OUT and LOWER replaced with arm IN hose, is trouble No
boom) repaired? (Return hose immediately Go to troubleshooting No. 2 —
after checking.)
Yes Defective boom LOWER PPC
valve
20-526 PC58UU-3
1
H-11 Arm does not move
★ Perform the following troubleshooting when the arm does not move when it is operated singly (and the
other work equipment is normal).
a) Arm does not move in
Cause Remedy
1
• 2.45 MPa {25 kg/cm²} Is EPC valve output pressure NO
normal (at PPC pressure inlet
• Run engine at full throttle. of control valve)?
YES
2
NO Defective operation Repair or
Does arm move out? of control valve spool replace
YES
3
• 26.5+1.0 +10 kg/cm²}
-0.5 MPa {265 -5 When arm is moved in, is NO
• Run engine at full throttle. pump relief pressure normal?
Deformation of cylin-
YES der or work equip- Repair or
ment (It does not replace
move from deformed
point)
4
NO Defective arm IN Repair or
Does spool move smoothly? operation of spool replace
YES Defective pressure Repair or
compensation valve replace
When PPC hose of control

(Raise boom and move arm valve is replaced with boom NO
out) RAISE hose, is trouble
repaired? (Return hose
immediately after checking.)
6
When arm is moved in while NO Go to troubleshoot- Repair or
bucket is swinging, does it ing No. 2 replace
move?
YES Defective seats of
swing brake circuit Repair or
check valve and replace
swing PPC slow
7 return valve
• 2.94+0.5 {30+5 Are PPC pressure inlet of sole- NO
-0.1 MPa -1 kg/cm²} noid valve and PPC valve out- Defective arm IN PPC Repair or
• Run engine at full throttle. put pressure normal? valve replace
YES Defective arm IN EPC Repair or
valve replace
PC58UU-3 20-527
1
b) Arm does not move out
Cause Remedy
1
• 2.94+0.5 +5 kg/cm²}
-0.1 MPa {30 -1
Is PPC valve output pressure NO
YES
2
Does arm move out? of control valve spool replace
YES
3
• 26.5+1.0 +10 kg/cm²}
-0.5 MPa {265 -5 When arm is moved out, is NO
• Run engine at full throttle. pump relief pressure normal?
move from deformed
point)
4
NO Defective arm OUT Repair or
Does spool move smoothly? operation of spool replace

(Lower boom and move arm valve is replaced with boom NO Defective arm OUT Repair or
out) LOWER hose, is trouble PPC valve replace
YES Go to troubleshoot-
ing No. 2 —
20-528 PC58UU-3
1
H-12 Bucket does not move
★ Perform the following troubleshooting when the bucket does not move when it is operated singly (and
the other work equipment is normal).
a) Bucket does not curl
Cause Remedy
1
• 2.94+0.5 +5 kg/cm²
-0.1 MPa {30 -1
YES
2
Does bucket dump? of control valve spool replace
YES
3
• 26.5+1.0 +10 kg/cm²
-0.5 MPa {265 -5 When bucket curls, is pump NO
• Run engine at full throttle. relief pressure normal?
move from deformed
point)
4
NO Defective bucket Repair or
Does spool move smoothly? CURL operation of replace
spool
5
(Move arm in and curl bucket) When PPC hose of control

When arm is moved in, normal valve is replaced with arm IN NO Go to troubleshoot-
PPC pressure at PCC pressure hose, is trouble repaired? ing No. 2 —
inlet of control valve is above (Return hose
2.45 MPa {25 kg/cm²}. immediately after checking.)
YES Defective bucket Repair or

CURL PPC valve replace
PC58UU-3 20-529
1
b) Bucket does not dump
Cause Remedy
1
• 2.94+0.5 +5 kg/cm
-0.1 MPa {30 -1
YES
2
Does bucket curl? of control valve spool replace
YES
3
• 26.5+1.0 +10 kg/cm²
-0.5 MPa {265 -5 When bucket dumps, is pump NO
• Run engine at full throttle. relief pressure normal?
move from deformed
point)
4
Does spool move smoothly? DUMP operation of replace
spool

(Move arm out and dump valve is replaced with arm OUT NO Go to troubleshoot-
bucket) hose, is trouble repaired? ing No. 2 —
(Return hose
YES Defective bucket Repair or

DUMP PPC valve replace
20-530 PC58UU-3
1
H-13 Offset boom does not move
★ Perform the following troubleshooting when the offset boom does not move when it is operated singly
(and the other work equipment is normal).
a) Offset boom does not move to left
Cause Remedy
1
• 2.94+0.5 +5 kg/cm
-0.1 MPa {30 -1
YES
2
Does offset boom move to the NO Defective operation Repair or
right? of control valve spool replace
YES
3
• 26.5+1.0 +10 kg/cm
-0.5 MPa {265 -5
When offset boom is moved to NO
the left, is pump relief pressure
• Run engine at full throttle. normal?
move from deformed
point)
4
spool

(Curl bucket and move offset valve is replaced with bucket NO Go to troubleshoot-
boom to left) CURL hose, is trouble ing No. 2 —
YES
6
Is PPC valve output pressure NO Defective offset LEFT Repair or
normal? PPC valve replace
YES Defective offset LEFT Repair or
solenoid valve replace
PC58UU-3 20-531
1
b) Offset boom does not move to right
Cause Remedy
1
• 2.94+0.5 +5 kg/cm²}
-0.1 MPa {30 -1
YES
2
Does offset boom move to the NO Defective operation Repair or
left? of control valve spool replace
YES
3
• 26.5+1.0 +10 kg/cm²}
-0.5 MPa {265 -5
When offset boom is moved to NO
the right, is pump relief pres-
• Run engine at full throttle. sure normal?
move from deformed
point)
4
spool

(Dump bucket and move offset valve is replaced with bucket NO Go to troubleshoot-
boom to right) DUMP hose, is trouble ing No. 2 —
YES Defective offset Repair or

RIGHT PPC valve replace
20-532 PC58UU-3
1
TROUBLESHOOTING H-14, H-15
H-14, H-15
H-14 Hydraulic drift of boom is large
Cause Remedy
1
Is leakage from hydraulic cylin- NO Defective cylinder Repair or
der normal? piston packing replace
YES
2
When centralized safety valve NO Defective boom lock Repair or
is replaced, is trouble repaired? valve replace
YES Defective centralized Replace
safety valve
H15 Hydraulic drift of arm is large
Cause Remedy
1
YES
2
NO
When centralized safety valve
is replaced, is trouble repaired?

safety valve
3
If suction valve is replaced with NO Defective oiltight-
ness of control valve Repair or
blind plug, is travel repaired? spool replace
YES Defective suction Repair or
valve replace
PC58UU-3 20-533
1
H-16, H-17
H-16 Hydraulic drift of bucket is large
Cause Remedy
1
YES
2
NO
When centralized safety valve
is replaced, is trouble repaired?

safety valve
3
YES Defective suction Repair or
valve replace
H-17 Hydraulic drift of offset boom is large

a) Hydraulic drift of offset boom to left is large
Cause Remedy
1
YES
2
YES Defective suction
valve Replace
b) Hydraulic drift of offset boom to right is large
Cause Remedy
1
YES Defective oiltight-
ness of control valve Repair
replace
or
spool
20-534 PC58UU-3
1
H-18, H-19
H-18 Time lag is large (Engine speed is low)
★ Perform the following troubleshooting when the work equipment speed is normal.
Cause Remedy
1
When puppet and spring of NO Defective suction Repair or
back pressure valve are valve replace
YES Defective back pres- Repair or
sure valve replace
H-19 Part loaded more moves slower in compound operation of

work equipment
Cause Remedy
Defective pressure
compensation valve Replace
on lighter load side
Compound operation Heavier load side Lighter load side

1 Boom RAISE + Arm IN Boom RAISE Arm IN
2 Boom RAISE + Arm OUT Arm OUT Boom RAISE
3 Boom RAISE + Bucket CURL Arm OUT Bucket CURL
4 Arm OUT + Bucket DUMP Arm OUT Bucket CURL
5 Boom LOWER + Arm OUT Arm OUT Boom LOWER
PC58UU-3 20-535
1
H-20 Travel deviation is large

a) Travel deviation is large during ordinary travel
• Is shoe tension same on Cause Remedy
1
both sides?
• Are rollers free from revo- NO
Does undercarriage have any trou-
lution trouble? ble?
• Are tracks free from defor-
mation and damage? YES
Repair or
Defective undercarriage replace
2
• 2.45 MPa {25 kg.cm²} NO
• Run engine at full throttle. Is PPC pressure normal on both
• Set lever to stroke end. sides?
YES
3
When both hoses at pump outlet NO
are replaced with each other, does
deviation direction change?
YES Improper adjustment of Adjust,
pump or defective repair, or
pump replace
4
When both hoses between control NO
valve and swivel joint are replaced
with each other, does deviation
direction change?
YES
Is pressure at PP oil pressure

When only travel section is pickup port at top of control valve NO
operated
equal to pump pressure?
YES
6
Does merging valve spool move NO Adjust,
smoothly and is drilled hole free of Defective operation of repair, or
clogging? merging valve
replace
YES Check,
Defective operation of
logic valve clean,
repair, or
7 replace
Are PPC pressure inlet of solenoid NO

valve and PPC valve output pres-
sure normal?
YES Adjust,
Defective arm IN EPC repair, or
valve
replace
8
Defective operation of Adjust,
Does unload valve move smoothly NO unload valve (Clogging repair, or
and is drilled hole free of clogging?
of drilled hole, etc.) replace
YES 9
Defective operation of Adjust,
Does pressure compensation valve NO pressure compensation repair, or
move smoothly?
valve replace
YES
To next To next page To next
page page
20-536 PC58UU-3
1
From From
previous From previous page previous Cause Remedy
page page
10
NO
Does travel spool move smoothly? Defective operation of Repair or
spool replace
YES
Go to troubleshooting
No. 11
11
Defective travel motor Check,
When both hoses between swivel NO (Motor unit, counterbal- repair, or
joint and travel motor are replaced ance valve, final drive) replace
with each other, does deviation
direction change?
YES
Repair or
12
When both PPC hoses are replaced NO Defective PPC circuit Repair or
with each other, does deviation check valve of control replace
direction change? valve
YES Improper adjustment of Repair or
pump or defective replace
pump
13
NO Repair or
Does lever interferes with floor? Defective PPC valve replace
YES Defective PPC pressure

output caused by inter- Adjust
ference
b) Travel deviation is large when machine starting (but normal during ordinary travel)
Cause Remedy
1
Does brake dragging sound

come out of travel motor on NO
the deviation side at start?
YES
Defective swivel joint
Repair or
replace
Does travel motor counterbal- NO Defective counterbal- Repair or

ance valve operate smoothly? ance valve replace
YES
Go to troubleshoot-
ing No. 5 in (a) above —
PC58UU-3 20-537
1
H-21 Travel speed or power is low (Work equipment, swing, and

blade operations are normal)
★ If there is any other trouble in the work equipment, see H-1.
Cause Remedy
1
• 26.0 +1.0
-0.5 MPa NO
+10
265 -5 kg/cm² Is relief pressure normal?
• Run engine at full throttle.
YES
2
Is pressure at PP oil pressure NO
pickup port at top of control valve
equal to port pressure?
YES
Does merging valve spool move NO

smoothly and is drilled hole free of Defective operation of Repair or
merging valve replace
clogging?
YES
Defective operation of Repair or
logic valve replace
4
• When pump pressure is NO Large resistance of
below 12.7 MPa {130 kg/ Repair or
travel motor and under- replace
cm²} while traveling on flat Is pump pressure normal during carriage
concrete with engine at full travel?
throttle
YES Large leakage from
travel motor or swivel Repair or
joint replace
• Above 2.45 MPa {25 kg/cm²} Is PPC pressure normal (at PPC
• Run engine at full throttle. NO Defective centralized
pressure inlet of control valve)? Replace
safety valve
YES Defective suction valve

6
NO
Does spool move smoothly? Defective operation of Repair or
spool replace
YES
Does pressure compensation valve NO Defective pressure com- Repair or

move smoothly? pensation valve replace
YES
8
Does unload valve move NO Repair or

Defective unload valve
smoothly? replace
YES Large leakage from Repair or

travel motor or swivel
joint replace
When PPC circuit check valve is NO Repair or

Defective PPC valve
replaced, is travel speed normal? replace
YES
Defective PPC circuit Replace
check valve
20-538 PC58UU-3
1
H-22 Machine cannot be steered sharply or steering force is insuf-

ficient
Cause Remedy
1
Does engine speed lower? NO
(Does engine speed lower
extremely only when machine
is steered during travel?)
YES
Defective pump Repair or
servo replace
2
pickup port at top of control
valve equal to port pressure?
YES
3
Does merging valve spool NO
Defective operation Repair or
move smoothly and is drilled of merging valve replace
hole free of clogging?
YES Defective operation Repair or
of logic valve replace
4
Is drive pump pressure of
inside motor normal? (When NO
machine is steered along curve
about 5 m in radius on flat con-
crete, is inside pump pressure
below about 10 MPa {100 kg/
cm²})?
YES
5
Is PPC pressure on the steered NO Repair or
side low? Defective PPC replace
YES
6
Does spool move smoothly? of spool replace
YES Defective unload Repair or
valve replace
7
When check valve of main NO Defective counterbal-
relief circuit is replaced, is trou- ance valve of travel Repair or
motor or defective replace
ble repaired? swivel joint
YES Defective check valve Repair or
of main relief circuit replace
PC58UU-3 20-539
1
H-23 Travel speed does not change
Cause Remedy
1
• Traveling accelerator pedal NO
Defective traveling Repair or
ON: Min. 2.45 MPa {25 kg/cm²} Is output of traveling accelera- accelerator solenoid
OFF: 0 MPa {0 kg/cm²} tor solenoid valve normal? replace
valve or trouble in elec-
• Run engine at full throttle tric system caused by
defective traveling
YES accelerator switch
Defective travel motor Repair or

or piston of 2nd gear
speed changeover valve replace
20-540 PC58UU-3
1
H-24 Machine does not travel
Cause Remedy
1
• 26.0 +1.0
-0.5 MPa
NO
+10
265 -5 kg/cm² Does pump pressure rise to relief
pressure?
YES
Is foreign matter drained from final NO

drive?
YES
Defective final drive Repair or
replace
3
NO
Does travel motor counterbalance Defective counterbal- Repair or
valve operate smoothly? ance valve replace
YES
Is undercarriage deformed or dam- NO Repair or

aged? Defective undercarriage replace
YES Defective travel motor

(motor unit, parking Repair or
brake system) replace
" See Note 1 5

• Above 2.45 MPa {25 kg/cm²} NO
• Run engine at full throttle. Is PPC pressure normal (at PPC
pressure inlet of control valve)?
• Set lever to stroke end.
YES
6
" Note 1 NO
Defective operation of Repair or
Does travel spool move smoothly? spool replace
If engine runs at full throttle
and pump pressure is above
10 MPa {100 kg/cm²} on flat YES
concrete but machine does
not travel, carry out trouble- 7
shooting 2.
Does pressure compensation valve NO Defective pressure com- Repair or
move smoothly? pensation valve replace
YES
8
Does unload valve move NO Repair or

smoothly? Defective unload valve replace
YES Defective travel motor Repair or

or swivel joint replace
9
• Try to move machine with
boom PPC pressure When PPC hose is replaced with NO Defective PPC circuit Repair or
boom hose on control valve side, check valve replace
(Restore original state does PPC pressure rise?
immediately after checking).
YES
Repair or
Defective PPC valve replace
PC58UU-3 20-541
1
H-24 Supplement
Relationship between PPC circuit check valves and "Machine does not travel"
PPC circuit check valves b - e are arranged to take out signal pressure for changing merging valve from the
travel PPC pressure. If the checking function of check valves b - e is lost, the machine may not travel.
Example: When checking function of b is lost

• Normal operations: "Left forward", "Left forward + Right forward", "Left forward + Right reverse"
• Operations which may be abnormal: "Left reverse", "Right forward", "Right reverse", "Left reverse +
Right forward", "Left reverse + Right reverse"
20-542 PC58UU-3
1
H-25 Overrun of travel is large
Cause Remedy
1
When lever is returned, does PPC NO
pressure lower quickly (at PPC Defective PPC Repair or
pressure inlet of control valve)? replace
YES
2
NO Defective operation of Repair or
Does spool move smoothly? spool replace
YES
3
NO
When suction valve is replaced, is
trouble repaired?
YES
replace
4
NO
When back pressure valve is
YES
Defective back pressure Repair or
valve replace
Does travel motor counterbalance NO

valve move smoothly? Defective counterbal- Repair or
ance valve replace
YES
6
NO
Does travel motor check valve Defective check valve Repair or
move smoothly? replace
YES
Defective travel motor Repair or
(motor unit) replace
H-26 Travel hydraulic drift is large
Cause Remedy
Defective parking
brake of travel motor Repair or
or defective parking replace
brake valve
PC58UU-3 20-543
1
H-27 Fine controllability or response is low
Cause Remedy
When air is bled from PPC circuit, NO

YES Air remaining in PPC cir- Bleed air

cuit
2
pickup port at top of control valve
equal to port pressure?
YES
3
Does merging valve spool move NO
smoothly and is drilled hole free of Defective operation of Repair or
merging valve replace
clogging?
YES Defective operation of Repair or
logic valve replace
Does unload valve move smoothly NO Defective operation of Repair or

and is drilled hole free of clogging? unload valve replace
YES
5
Does pressure compensation valve NO Defective operation of

pressure compensation Repair or
move smoothly? valve replace
YES
6
spool replace
YES
7
When PPC valve is replaced, is NO Repair or

Defective travel motor
trouble repaired? replace
YES
Defective PPC Repair or

replace
20-544 PC58UU-3
1
H-28 Swing speed or power is low

(Work equipment, travel, and blade operations are normal)
★ If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
a) Swing speed or power is low in both directions
Cause Remedy
1
• 26.0 +1.0
-0.5 MPa NO
Is swing relief pressure normal?
265 +10
-5 kg/cm²
• Run engine at full throttle. YES
2
• 2.45 MPa {25 kg.cm²} Does pressure rises to near relief NO
• Run engine at full throttle. pressure during ordinary swing?
YES
3
NO
Is switch brake dragging sound
heard?
YES
4
When throttle of swing brake reset swing brake (Defective replace
line is cleaned, is trouble repaired? reset)
YES
Clogging of throttle Clean
5
Does check valve in spool move check valve in spool replace
smoothly?
YES Defective motor unit, Check,

brake, swing machin- repair, or
ery, or circle replace
6
• 2.45 MPa {25 kg/cm²} Is PPC pressure normal (at PPC NO
• Run engine at full throttle. pressure inlet of control valve)?
YES
7
When swing PPC slow return valve NO
and swing PPC circuit throttle are
cleaned, is trouble repaired?
YES Clogging of throttle or Clean,
defective operation of repair, or
slow return valve replace
8
YES
Repair or
Defective swing motor replace
9
When swing PPC line throttle is NO
YES
To next To next
page page
PC58UU-3 20-545
1
Cause Remedy
From From
previous previous
page page
10
When spring case on IN side of NO
arm valve is replaced, is trouble Defective PPC valve Repair or
replace
repaired?
YES Defective arm valve or
check valve of swing Replace
brake circuit
11
NO
When safety valve of swing motor
is adjusted or replaced, is trouble
repaired?
YES
Defective safety valves Adjust or
replace
12
When check valve and suction NO —
valve of swing motor are replaced, Go to troubleshooting
is trouble repaired? No. 6
YES
Defective check valve Repair or
and suction valve replace
20-546 PC58UU-3
1
b) Swing speed or power is low in either direction
Cause Remedy
1
+1.0 NO
• 20.6 -0.5 MPa
{210 +10
-5 kg/cm²}
• Run engine at full throttle. YES
2
Does pressure rises to near relief NO
pressure during ordinary swing?
YES
3
Is switch brake dragging sound NO Defective operation of Repair or

heard? check valve in spool replace
YES Go to troubleshooting —
No. 4
4
Replace both PPC hoses at opera-
tion pattern change point in inspec- When both PPC hoses are replaced NO
tion window of left deck (Restore with each other, does condition
original state immediately after change?
checking).
YES
5
When swing PPC line throttle is NO Repair or

Defective PPC valve
cleaned, is trouble repaired? replace
YES
6
7
spool replace
YES Defective check valve of

swing brake circuit Replace
8
When check valve and suction NO
valve of swing motor are replaced, Go to troubleshooting —
No. 4
PC58UU-3 20-547
1
H-29 Machine does not swing (Work equipment, travel, and blade
operations are normal)
★ If there is any other trouble in the work equipment, travel system, or blade system, see H-1.
1
Cause Remedy
+1.0
• 20.6 -0.5 MPa NO
{210 +10
-5 kg/cm²}
• Set PPC lever to stroke end. YES
2
• Min. 1 MPa {Min. 10 kg/cm²} Is swing brake reset pressure nor- NO
• Set PPC lever to stroke end. mal (at motor inlet)?
YES
3
a) Machine does not swing in Does check valve in spool move NO Defective operation of Repair or
either direction smoothly? check valve in spool replace
YES Defective motor unit, Check,

brake, swing machinery, repair, or
or circle replace
4
When throttle of swing brake reset NO
line is cleaned, is trouble repaired?
YES Clogging of throttle of

swing brake reset line Clean
5
When throttle of swing brake reset NO
line is removed, does bucket
swing?
YES Large leakage from Repair or
swing brake replace
6
• 2.45 MPa {25 kg/cm²} Is PPC pressure normal (at PPC NO
• Run engine at full throttle. pressure inlet of control valve)?
YES
7
(Perform on both sides.) and swing PPC circuit throttle are
8
YES Repair or
Defective swing motor replace
9
When swing PPC line throttle is NO
YES
To next To next
page page
20-548 PC58UU-3
1
Cause Remedy
From From
previous previous
page page
10
When spring case on IN side of NO
arm valve is replaced, is trouble Defective PPC valve Repair or
repaired? replace
YES Defective arm valve or

check valve of swing Replace
brake circuit
11
NO
Does swing motor rotate (Check by
sound)?
YES
Damage of motor shaft Adjust or
or swing machinery replace
12
When safety valve of swing motor NO
is adjusted or replaced, is trouble
repaired?
YES
Defective safety valve Adjust or
replace
13
No. 6
YES
Defective check valve Repair or
PC58UU-3 20-549
1
a)
b) Machine does not swing in both directions
Cause Remedy
1
+1.0
• 20.6 -0.5 MPa NO
{210 +10
-5 kg/cm²}
• Set PPC lever to stroke end. YES
Is swing brake reset pressure nor- NO

• Min. 1 MPa {Min. 10 kg/cm²}
mal (at motor inlet)?
YES Defective operation of Repair or

check valve in spool replace
3
Replace both PPC hoses at opera-
tion pattern change point in inspec- When both PPC hoses are replaced NO
tion window of left deck (Restore with each other, does condition
original state immediately after change?
checking). Go to troubleshooting
YES No. 4 —
When swing PPC line throttle is NO Repair or

Defective PPC valve
cleaned, is trouble repaired? replace
YES
5
6
spool replace
YES Defective check valve of

swing brake circuit Replace
7
No. 3
20-550 PC58UU-3
1
H-30 Swing acceleration is low
a) Swing acceleration is low in both directions
Cause Remedy
1
NO
IWhen swing motor safety Carry out troubleshoot-
valve is replaced, is trouble ing in H-28 and H-35
repaired?
YES
Defective swing motor Replace

safety valve
b) Swing acceleration is low in either direction
Cause Remedy
Carry out trouble-

shooting in H-28 (b)
and H-35
PC58UU-3 20-551
1
H-31 Overrun of swing is large
a) Overrun of swing is large in both directions
Cause Remedy
• 20.6 +1.47
-0.49
MPa When swing motor is relieved, is NO Defective swing motor Replace
pump relief pressure normal? safety valve
{210 +15
-5 kg/cm²}
• Run engine at full throttle. YES Defective swing motor Repair or
unit replace
b) Overrun of swing is large in either direction
Cause Remedy
Does control valve spool move NO Defective operation of Repair or

smoothly? control valve spool replace
YES
When swing motor suction valve is NO

YES Defective swing motor Repair or

suction valve replace
When swing motor check valve is NO


check valve replace
When swing PPC slow return NO Repair or

valve, swing PPC line throttle, and Defective PPC valve
replace
swing PPC circuit throttle are
YES Clogging of swing PPC

slow return valve, swing Repair or
PPC line throttle, and replace
swing PPC circuit throttle
20-552 PC58UU-3
1
TROUBLESHOOTING H-32, H-33, H-34
H-32, H-33, H-34

H-32 Large shock is made when machine stops swinging
Cause Remedy
Does control valve spool move NO Defective operation of Repair or

smoothly? control valve spool replace
YES
When swing motor safety valve is NO Defective swing motor

replaced, is trouble repaired? safety valve Replace
YES Repair or
H-33 Large abnormal sound is made when machine stops swinging
Cause Remedy
When safety valve is replaced, is NO

trouble repaired?
YES Defective swing motor

safety valve Replace
When suction valve is replaced, is NO

trouble repaired?

suction valve replace
Is foreign matter drained from NO Defective back pressure Repair or

swing machinery? valve of control valve replace
YES Defective swing Repair or

machinery replace
H-34 Swing hydraulic drift is large
Cause Remedy
Defective swing parking Repair or

brake (Clogging of
hydraulic timer) replace
PC58UU-3 20-553
1
H-35 Fine controllability or response of swing is low
Cause Remedy
When air is bled from PPC circuit, is NO

trouble repaired?
YES Air remaining in PPC cir- Bleed air

cuit
"1 2
Do spool and check valve in it move NO Defective operation of Repair or

smoothly? spool replace
YES
"2 3
When each throttle is cleaned, is NO

trouble repaired?
YES Clogging of each throt-

tle Clean
When both PPC hoses are replaced NO

with each other, is trouble repaired?
YES Repair or
5 Defective motor
motor unit
When spring case sub-assembly on NO safety valve Repair or
port B side of arm valve is replaced, check valve replace
suction valve
YES brake
Defective check valve of
swing brake circuit of Repair or
replace
arm valve
"1 Each throttle in troubleshooting 3 denotes the following.
• Swing PPC circuit throttle (inside spring case of control valve)
• Swing slow return valve (Adapter of PPC pressure inlet of control valve)
• Swing PPC line throttle
• Swing brake reset line throttle
"2 Replace the hoses at operation pattern change point in inspection window of left
deck (Restore original state immediately after checking).
20-554 PC58UU-3
1
H-36 Blade speed or power is low (Work equipment, travel, and

swing operations are normal)
★ If there is any other trouble in the work equipment, travel system, or swing system, see H-1.
Cause Remedy
1
• See standard values table for No Improper adjustment or Adjust,
machine body. Is stroke of spool normal? trouble of linkage and repair, or
• From neutral to full stroke of 6 cable replace
mm Yes
2
• 21.6 +1.0
-0.5 MPa
No Go to troubleshooting
{210 +10
-5
kg/cm²} Is blade relief pressure normal? No. 5 —
Yes
Does pump pressure rise to relief No

pressure during operation?
Yes
4
Is any hose between control valve Defective operation of
No check valve in spool or Repair or
and cylinder flattened or clogging of drilled hole replace
deformed? of spool
Yes
Flattened or deformed Replace
hose
5
Carry out troubleshoot-
No ing in H-38 (Hydraulic
• Max. 45 mm/15 min Is hydraulic drift normal? —
drift of blade is exces-
sive)
Yes Leakage inside control
valve (through clear- Repair or
ance between swing replace
valve and blade valve)
PC58UU-3 20-555
1
H-37 Blade does not move (Work equipment, travel, and swing
operations are normal)
★ If there is any other trouble in the work equipment, travel system, or swing system, see H-3.
a) Blade does not raise
Cause Remedy
• From neutral to full stroke 1

of 6 mm No Improper adjustment or trou- Adjust, repair,
Is stroke of spool normal?
• See standard values table ble of linkage and cable or replace
for machine body Yes
2
No
Is blade relief pressure normal?
Yes
3
Is cylinder or work equipment No
deformed?
Yes Deformed cylinder or work Repair or
equipment replace
4
No Defective operation of check Repair or
Is any hose flattened or deformed? valve in spool or clogging of replace
drilled hole of spool
Yes
Flattened or deformed hose Replace
5
Carry out H-38 (Hydraulic drift of
blade is excessive)
Yes
If trouble is not repaired by H-38 Leakage inside control valve Repair or
(through clearance between
swing valve and blade valve) replace
20-556 PC58UU-3
1
b) Blade does not lower
Cause Remedy
1
Blade cannot be lowered from float- No
ing position?
Yes
2
No Improper adjustment or trou- Adjust, repair,
Is stroke of spool normal?
ble of linkage and cable or replace
Yes
3
Is cylinder or work equipment No
deformed?
Yes Deformed cylinder or work Repair or
equipment replace
4
Is any hose flattened or deformed? valve in spool or clogging of replace
Yes
Flattened or deformed hose Replace
5
Blade cannot be lowered below
ground level to lift machine body
Yes Carry out troubleshooting in Repair or
H-36 (Blade speed or power replace
is low)
PC58UU-3 20-557
1
TROUBLESHOOTING H-38,H-39
H-38,H-39
H-38 Hydraulic drift of blade is excessive
Cause Remedy
1
No Defective cylinder piston Repair or
Is leakage from cylinder normal?
packing replace
Yes
2
When hose is disconnected from No
valve outlet and plug is installed
instead, is hydraulic drift excessive?
Yes Repair or
3
• Hydraulic drift of blade from No
When centralized safety valve is
floating position is exces- replaced, is trouble repaired?
sive
Yes Defective centralized safety
valve Replace
4
When suction valve is replaced with No Defective oiltightness of Repair or
blind plug, is trouble repaired? spool replace
Yes Defective safety suction Repair or
valve replace
5
• Hydraulic drift of blade is
When blade safety valve is replaced, No Defective oiltightness of Repair or
excessive when it is used to is trouble repaired? spool replace
lift up machine body
Yes Repair or
Defective blade safety valve replace
H-39 Fine controllability is poor or response of blade is low
Cause Remedy
1
No
Is play of lever large in neutral?
Yes
2
Does spool move within play range No Improper adjustment or trou- Adjust, repair,
of lever in neutral? ble of linkage and cable or replace
Yes Looseness of fitting parts of Repair or
spool spring replace
3
Is hydraulic drift excessive? valve in spool or clogging of replace
Yes Carry out troubleshooting in
H-38 (Hydraulic drift of blade
is excessive)
20-558 PC58UU-3
1
H-40, H-41
H-40 Monitor panel displays error code [61] and boom RAISE, arm
IN, and LEFT offset operations stop just before interference
★ Monitor panel displays error code [61] and boom RAISE, arm IN, and LEFT offset operations stop just
before interference
Cause Remedy
Defective solenoid valve Repair or

replace
H-41 Machine does not stop boom RAISE, arm IN, and LEFT offset
operations automatically but interferes
★ If this trouble occurs, the trouble in h-39 occurs, too.
Cause Remedy
1
Does PPC lock solenoid valve move No Defective operation of PPC Repair or
smoothly? lock solenoid valve (It does replace
not return)
Yes
PC58UU-3 20-559
1
TROUBLE SHOOTING FOR
MACHINE MONITOR SYSTEM
(M-MODE)
Electric circuit diagram of machine monitor system .................................................................................... 20-602
M-1 When starting switch is turned to the ON position, nothing is displayed
(Segments do not light up for 3 seconds)......................................................................................... 20-603
M-2 When starting switch is turned to ON position, all segments light up but do not
go off after 3 seconds ....................................................................................................................... 20-603
M-3 When starting switch is turned to ON position, some items do not light up for all
segment light-up period of 3 seconds............................................................................................... 20-604
a) Gauges do not light up ................................................................................................................ 20-604
b) Electric system caution lamp does not light up ........................................................................... 20-604
c) Charge level caution lamp does not light up ............................................................................... 20-604
d) Engine oil pressure caution lamp does not light up..................................................................... 20-604
M-4 When starting switch is turned to ON position (with engine stopped), charge level
caution lamp does not light up.......................................................................................................... 20-605
M-5 When starting switch is turned to ON position (with engine stopped), engine oil
pressure caution lamp does not light up........................................................................................... 20-606
M-6 Engine preheating pilot lamp does not light up while engine is preheated....................................... 20-607
M-7 Engine oil pressure caution lamp lights up while engine is running
(Engine oil pressure is normal)......................................................................................................... 20-607
M-8 Charge level caution lamp lights up while engine is running ............................................................ 20-608
M-9 Engine water temperature gauge (Coolant temperature gauge) indicates abnormally ................. 20-608-2
a) After engine is started, temperature does not rise at all from lowest level ............................... 20-608-2
b) After engine is started, temperature rises immediatelyTemperature reaches
red range while engine is not overheated ................................................................................... 20-609
c) Water temperature gauge goes off.............................................................................................. 20-609
M-10 Fuel level gauge indicates abnormally ............................................................................................. 20-610
a) All segments of fuel level gauge go off........................................................................................ 20-610
b) Fuel level gauge keeps indicating full while fuel is consumed .................................................... 20-610
c) Fuel level gauge does not indicate full while fuel tank is full ........................................................20-611
M-11 Alarm buzzer operates abnormally................................................................................................... 20-612
a) Buzzer does not sound................................................................................................................ 20-612
b) Buzzer keeps sounding ............................................................................................................... 20-612
M-12 Alarm buzzer sounds for 7 seconds and electric system caution lamp blinks
while emergency work equipment operation switch is not turned on ............................................... 20-613
M-13 Service meter does not operate while engine is running.................................................................. 20-614
a) When charge level caution lamp does not light up...................................................................... 20-614
b) When charge level caution lamp lights up................................................................................... 20-614
M-14 Lamps for night work do not light up................................................................................................. 20-615
a) Lamp for coolant temperature gauge, fuel level gauge, and depth indicator
does not light up .......................................................................................................................... 20-615
b) Lamp for service meter does not light up .................................................................................... 20-615
M-15 Electric system caution lamp does not go off (Controller does not display any
error code and operation is normal) ................................................................................................. 20-616
M-16 Heater does not operate................................................................................................................... 20-617
a) Heater does not operate at both Lo and Hi levels ....................................................................... 20-617
b) Heater does not operate at only Lo level..................................................................................... 20-617
c) Heater does not operate at only Hi level ..................................................................................... 20-617
M-17 Travel alarm does not sound or does not stop sounding.................................................................. 20-619
a) Travel alarm does not sound ....................................................................................................... 20-619
b) When machine stops, alarm does not stop ................................................................................. 20-619
PC58UU-3 20-601
(6)
TROUBLESHOOTING M-MODE
Electric circuit diagram of machine monitor system

Serial No.: 20001 – 22000
20-602 PC58UU-3
(6)
TROUBLESHOOTING M-MODE
PC58UU-3 20-602-1
(6)
TROUBLESHOOTING M-1, M-2
M-1 When starting switch is turned to the ON position, nothing is

displayed (Segments do not light up for 3 seconds)
a Before carrying out troubleshooting, check fuse 5.
Cause Remedy
1
• 10 – 15 V Is voltage between F27 (female) (1) NO
• Turn starting switch ON. and (3), (4) normal?
YES
Defective monitor panel Replace
2
Check for cause
NO of breakage of
Is fuse 5 normal (free of breakage)? Broken fuse 5 fuse and
replace fuse
YES Disconnection or defective Repair or
contact in wiring harness replace wiring
between F27 (female) (1) – harness
fuse 5
M-1 Related electrical circuit diagram
M-2 When starting switch is turned to ON position, all segments light up

but do not go off after 3 seconds
Cause Remedy
PC58UU-3 20-603
(6)
TROUBLESHOOTING M-3
M-3 When starting switch is turned to ON position, some items do not light
up for all segment light-up period of 3 seconds
a) Gauges do not light up
Engine preheating pilot lamp does not light up
Cause Remedy
b) Electric system caution lamp does not light up

1 Cause Remedy
• Check bulb visually for Is any wire in the lamp, which No

breakage. Defective monitor panel Replace
does not light, broken?
Yes
Broken bulb Replace
c) Charge level caution lamp does not light up

1 Cause Remedy
• Check bulb visually for No

breakage. Is any wire in the lamp broken? Go to M-4 —
Yes
Broken bulb Replace
d) Engine oil pressure caution lamp does not light up

1 Cause Remedy
• Check bulb visually for No

breakage. Is any wire in the lamp broken? Go to M-5 —
Yes
Broken bulb Replace
20-604 PC58UU-3
1
TROUBLESHOOTING M-4
M-4 When starting switch is turned to ON position (with engine stopped),

charge level caution lamp does not light up
a Before carrying out troubleshooting, check the bulb for breakage.
Cause Remedy
1
• Start engine Is voltage between F27 (female) (10) NO
• 13.5 – 14.5 V and (3), (4) normal?
YES
2
• Start engine Is voltage between alternator terminal L NO
Defective alternator Replace
• 13.5 – 14.5 V and chassis ground normal?
YES Disconnection in wiring har- Repair or

ness between F27 (female) replace wiring
(10) – alternator terminal L harness

Serial No.: 20001 – 22000
PC58UU-3 20-605
(6)
TROUBLESHOOTING M-5
M-5 When starting switch is turned to ON position (with engine stopped),

engine oil pressure caution lamp does not light up
a Before carrying out troubleshooting, check the bulb for breakage.
Cause Remedy
1
• Max. 0.5 z
• Turn starting switch OFF. Is continuity between sensor terminal NO Defective engine oil pres-
Replace
• Disconnect (+) terminal (T-M5) and chassis ground normal? sure switch
(T-M5) of sensor
YES
2
Disconnection in wiring har-
• Max. 0.5 z Is continuity between F27 (female) (9) NO ness between F27 (female) Repair or
• Turn starting switch OFF. (9) – T-M5 replace wiring
• Disconnect F27. and (3), (4) normal? harness
(wiring harness side)
YES
20-606 PC58UU-3
(6)
TROUBLESHOOTING M-6, M-7
M-6 Engine preheating pilot lamp does not light up while engine is
preheated
a If the lamp does not light up for 3 seconds after the starting switch is turned to the ON position, carry out M-2.
Cause Remedy
1
Disconnection in wiring har-
• Turn the starting switch to Is voltage between F27 (13) and (3), (4) NO ness between F27 (female) Repair or
HEAT position. (13) – starting switch R1 or replace
• 10 – 15 V. normal?
defective starting switch
YES
M-7 Engine oil pressure caution lamp lights up while engine is running
(Engine oil pressure is normal)
Cause Remedy
1
• Start engine. Does engine oil pressure caution lamp NO
• Disconnect T-M5. go off?
YES
Defective engine oil pres- Replace
sure switch
2
• Min. 1.0 Mz Is F27 (female) (9) insulated from chas- NO Contact with chassis ground Repair or
• Turn starting switch OFF. in wiring harness between replace wiring
• Disconnect F27 and T-M5. sis ground? F27 (female) (9) – T-M5 harness
YES
PC58UU-3 20-607
(6)
TROUBLESHOOTING M-8
M-8 Charge level caution lamp lights up while engine is running

Serial No.: 20001 – 22000
Cause Remedy
• Start engine. 1
• Measure voltage between NO
Is voltage at alternator terminal L nor-
alternator terminal L and chas-
mal?
sis ground.
• 13.5 – 14.5 V YES
Defective generation by alter-
Replace
nator
2
Contact with chassis ground Repair or
• Start engine. Is voltage between F27 (female) (10) NO in wiring harness between replace wiring
• 13.5 – 14.5 V and (3), (4) normal? F27 (female) – alternator harness
terminal L
YES
20-608 PC58UU-3
(6)
TROUBLESHOOTING M-8
Cause Remedy
• Start engine. 1
• Measure voltage between
Is voltage at alternator terminal L nor- NO
alternator terminal L and chas-
mal?
sis ground.
• 13.5 – 14.5 V YES
Defective generation by alter-
Replace
nator
2
Contact with chassis ground Repair or
• Start engine. Is voltage between F27 (female) (10) NO in wiring harness between
• 13.5 – 14.5 V replace wiring
and (3), (4) normal? F27 (female) – alternator harness
terminal L
YES
PC58UU-3 20-608-1
(6)
TROUBLESHOOTING M-9
M-9 Engine water temperature gauge (Coolant temperature gauge)

indicates abnormally
a) After engine is started, temperature does not rise at all from lowest level
Cause Remedy
1
• Connect short connector to Does gauge rise 1 level by 1 and go off NO
M10. at last?
• See Note 1).
YES
Defective coolant tempera-
Replace
ture sensor
• Turn starting switch ON. Does gauge rise 1 level by 1 and go off NO between F27 (female) (6) – Repair or
• Short F27 (6) to (3) and (4). M10 (female) (1) or between replace wiring
• See Note 1). at last? M10 (female) (2) – chassis harness
ground
YES
Note 1) If normal, gauge rises 1
level by 1 at intervals of about 2
seconds.
20-608-2 PC58UU-3
(6)
TROUBLESHOOTING M-9
b) After engine is started, temperature rises immediately

Temperature reaches red range while engine is not overheated
Cause Remedy
1
• Start engine. Is voltage between F27b (3), (4) and NO contact in wiring harness Repair or
• Max. 0.1 V chassis ground normal? between F27 (female) (3), (4) replace wiring
harness
– chassis ground
YES
2
• Start engine Is resistance between M10 (male) (1) NO Defective engine water tem-
• Min. 4 kz. Replace
• Disconnect M10. and (2) normal? perature sensor
YES
c) Water temperature gauge goes off
Cause Remedy
1
• Start engine. NO
Does lowest level segment light up?
• Disconnect M10.
YES
Defective engine water tem-
Replace
perature sensor
2
Contact with chassis ground
• Disconnect F27. Is resistance between F27 (female) (6) NO in wiring harness between Repair or
• Resistance Min. 1 kz. and (3), (4) normal? F27 (female) (6) – M10 replace
(female) (1)
YES
M-9 a), b), and c) Related electrical circuit diagram
PC58UU-3 20-609
(6)
TROUBLESHOOTING M-10
M-10 Fuel level gauge indicates abnormally

a) All segments of fuel level gauge go off
Cause Remedy
1
• Connect short connector to M1 Does fuel level gauge indicate full (do NO
• Turn starting switch to ON.
• Wait for about 1 minute. all segments light up)?
YES
Defective fuel level sensor
Replace
(internal disconnection)
2
• Short F27 (7) to (3), (4). NO
• Turn starting switch ON. Does fuel level gauge indicate full? Defective monitor panel Replace
• Wait for about 1 minute.
M1 (female) (1) or between replace
M1 (female) (2) – chassis
ground
b) Fuel level gauge keeps indicating full while fuel is consumed
Cause Remedy
1
• Start engine. Is voltage between F27 (3), (4) and NO Repair or
• Max. 0.1 V. chassis normal? between F27 (female) (3), (4) harness
– chassis ground
YES
• Remove sensor.
• Move float with hand and mea- 2
sure resistance between M1 Is resistance of fuel level sensor nor- NO
(male) (1) and (2). Defective fuel level sensor Replace
• F position: Max. 10 z mal?
• E position: Min. 85 z
• Disconnect M1 YES
3
• Disconnect M1 Do all segments of fuel level gauge go NO ground in wiring harness Repair or
• Turn the starting switch ON. between F27 (female) (7) – replace wiring
• Wait for 1 minute off? harness
M1 (female) (1)
YES
20-610 PC58UU-3
(6)
c) Fuel level gauge does not indicate full while fuel tank is full
Cause Remedy
• Remove sensor. 1
• Move float with hand and mea-
sure resistance between M1 Is resistance of fuel level sensor nor- NO
(male) (1) and (2). Defective fuel level sensor Replace
mal?
• F position: Max. 10 z.
• Disconnect M1. YES
2
• Start engine Is voltage between F27 (3), (4) and NO contact in wiring harness Repair or
• Max. 0.1 V chassis ground normal? between F27 (female) (3), (4) replace wiring
– chassis ground harness
YES
PC58UU-3 20-611
(6)
M-11 Alarm buzzer operates abnormally

a) Buzzer does not sound
Cause Remedy
1
• Connect F27 (female) (15) to When F27 (female) (15) is connected to NO
(3).
• Turn starting switch ON. (3), does buzzer sound?
YES
2
Broken fuse or disconnec-
• 10 – 15 V Is voltage between F14 (female) (2) NO tion or defective contact in Repair or
• Turn starting switch ON. and chassis ground normal? wiring harness between fuse replace
(2) – F14 (female) (2)
YES
between F14 (female) (1) – replace
F27 (female) (15) or defec-
tive buzzer
b) Buzzer keeps sounding
Cause Remedy
1
• Turn the starting switch ON. When F27 is disconnected, does NO in wiring harness between Repair or
• Disconnect F27. buzzer stop sounding? F27 (female) (15) – F14 replace
(female) (1)
YES
M-11 a) and b) Related electrical circuit diagram
20-612 PC58UU-3
(6)
M-12 Alarm buzzer sounds for 7 seconds and electric system cau-
tion lamp blinks while emergency work equipment operation
switch is not turned on
1 Cause Remedy
• Emergency work equip- No

ment operation switch Is voltage between G3 (30) and
OFF: Max. 1 V chassis ground normal?
ON: 10 - 15 V
• Turn starting switch ON. YES
• When normal: 0 - 15 V No
When abnormal: Max. 1 V Is voltage between G3 (8) and
chassis ground normal? Defective controller Replace
YES
No
• Turn starting switch OFF. Is continuity between F25 (male)
(1) and (2) as shown in Table 1? Defective reset switch Replace
YES Contact with power

source wiring harness in Repair or
wiring harness between replace
G3 (female) (30) - F25
(female) (1)
Table 1
Emergency work equipment operation switch 1 2 3
ON (RAISE) O O
OFF (LOWER) O O
M-12 Related Electrical Circuit Diagram
PC58UU-3 20-613
(6)
M-13 Service meter does not operate while engine is running

Serial No.: 20001 – 22000
a) When charge level caution lamp does not light up
Cause Remedy
1
• Start engine. Is voltage between F27 (10) and (3), (4) NO in wiring harness between Repair or
F27 (female) (10) – M6 replace wiring
• 10 – 15 V. normal? harness
(female) (1)
YES
b) When charge level caution lamp lights up

a Judge by carrying out M-8.
Cause Remedy
• Start engine. 1
• Measure voltage between Is voltage at alternator terminal L nor- NO Defective generation by alter-
alternator terminal L and chas- Replace
sis ground. mal? nator
• 13.5 – 14.5 V
YES
2
• Start engine Is voltage between F27 (female) (10) NO in wiring harness between Repair or
• 13.5 – 14.5 V and (3), (4) normal? F27 (female) (10) – alternator replace
terminal L
YES
M-13 a), b) Related electrical circuit diagram
20-614 PC58UU-3
(6)
a) When charge level caution lamp does not light up
Cause Remedy
1
• Start engine. Is voltage between F27 (10) and (3), (4) NO in wiring harness between Repair or
F27 (female) (10) – M6 replace wiring
• 10 – 15 V. normal? harness
(female) (1)
YES
b) When charge level caution lamp lights up

a Judge by carrying out M-8.
Cause Remedy
• Start engine. 1
• Measure voltage between Is voltage at alternator terminal L nor- NO Defective generation by alter-
alternator terminal L and chas- Replace
sis ground. mal? nator
• 13.5 – 14.5 V
YES
2
• Start engine Is voltage between F27 (female) (10) NO in wiring harness between Repair or
• 13.5 – 14.5 V and (3), (4) normal? F27 (female) (10) – alternator replace
terminal L
YES
PC58UU-3 20-614-1
(6)
M-14 Lamps for night work do not light up

a) Lamp for coolant temperature gauge, fuel level gauge, and depth indicator does not light up
Cause Remedy
1
• Disconnect F27. Disconnection or defective
• Turn starting switch ON. Is voltage between F27 (female) (16) NO Repair or
• Turn light switch ON. and (3), (4) normal? between F27 (female) (16) – harness
• 10 – 15 V F16 (female) (3)
YES
Breakage of bulb for night Replace
work (inside monitor panel)
b) Lamp for service meter does not light up

Cause Remedy
PC58UU-3 20-615
(6)
M-15 Electric system caution lamp does not go off (Controller does not
display any error code and operation is normal)
Cause Remedy
1
• Max. 1 V Is voltage between F27 (11) and (3), (4) NO
• Turn starting switch ON. normal?
YES
2
When G2 (female) (8) is connected to Disconnection or defective Repair or
NO contact in wiring harness
• Turn starting switch ON. chassis ground, does caution lamp go replace wiring
off? between F27 (female) (11) – harness
G2 (female) (8)
YES
20-616 PC58UU-3
(6)
M-16 Heater does not operate

a) Heater does not operate at both Lo and Hi levels
Cause Remedy
1
• Turn starting switch OFF. Is continuity of heater switch (between NO
Defective heater switch Replace
• Disconnect F15. F15 male terminals) as shown in Table 1?
YES
2
Is there continuity between F15 NO contact in wiring harness Repair or
• Turn starting switch OFF. replace
(female) (4) and chassis ground? between F15 (female) (4) –
chassis ground
YES
See troubleshooting for —
heater
Table 1
Switch position Terminals that must have continuity
Lo Between (3) – (4)
Hi Between (2) – (3) – (4)
b) Heater does not operate at only Lo level
Cause Remedy
1
• Turn starting switch OFF. Is there continuity between F15 (male) NO
• Disconnect F15. Defective heater switch Replace
• Set heater switch to Lo. (3) and (4)?
YES
2
• Turn starting switch OFF. Is there continuity between F15 (male) NO contact in wiring harness Repair or
• Disconnect F20. between F15 (female) (3) – replace
• Set heater switch to Lo. (2) and chassis ground?
F20 (female) (2)
YES
heater
c) Heater does not operate at only Hi level
Cause Remedy
1
• Turn starting switch OFF. Is continuity of heater switch between NO
• Disconnect F15. Defective heater switch Replace
• Set heater switch to Hi. F15 (male) (2) and (4)
YES
2
• Turn starting switch OFF. Disconnection or defective
Is there continuity between F15 (male) NO contact in wiring harness Repair or
• Disconnect F20. replace
• Set heater switch to Hi. (3) and chassis ground? between F15 (female) (3) –
F20 (female) (2)
YES
heater
PC58UU-3 20-617
(6)
20-618 PC58UU-3
1
M-17 Travel alarm does not sound or does not stop sounding
a Before carrying out the following troubleshooting, check that fuse (4) is not broken.
a When measuring voltage, turn the starting switch ON. When measuring resistance, turn the starting switch
OFF.
a Before carrying out the following troubleshooting, check that there is not a person around the machine since
the machine is moved for the troubleshooting.
a) Travel alarm does not sound
Cause Remedy
1
• 10 – 15 V
• Start engine. Is voltage between T2 (1) – chassis NO
• Move machine forward or in ground normal?
reverse.
YES
2
• Max. 1 z Is voltage between T2 (female) (2) – NO contact in wiring harness
• Turn starting switch OFF. Repair or
chassis ground normal? between T2 (female) (2) – replace
• Disconnect T2. chassis ground
YES
Defective travel alarm Replace
3
• 10 – 15 V
• Start engine. Is voltage between T1 (2) and chassis NO
• Move machine forward or in ground normal?
reverse.
between T1 (female) (1) – T2 replace
(female) (1)
4
• 10 – 15 V Is voltage between T1 (1) and chassis NO contact in wiring harness Repair or
• Turn starting switch ON. ground normal? between fuse (4) - T1 replace
(female) (2)
YES
Defective pressure switch Replace
b) When machine stops, alarm does not stop
Cause Remedy
1
Short circuit with power
• Turn starting switch ON. When connector T1 is disconnected, NO source in wiring harness Repair or
• Set travel lever in neutral. does alarm stop? between T1 (female) (1) – T2 replace
(female) (2)
YES
Defective pressure switch Replace
PC58UU-3 20-619
(6)
20-620 PC58UU-3
(6)
30 DISASSEMBLY AND ASSEMBLY
12
METHOD OF USING MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-2
PRECAUTIONS WHEN PERFORMING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-7
ENGINE AND WORK EQUIPMENT PUMP ASSEMBLY
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
CENTER SWIVEL JOINT ASSEMBLY
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
SWING MOTOR AND SWING MACHINERY ASSEMBLY
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-28
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
REVOLVING FRAME ASSEMBLY
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-34
SWING CIRCLE ASSEMBLY
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-38
RUBBER SHOE ASSEMBLY
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-39
ROAD LINER, IRON SHOE ASSEMBLY
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
SWING MACHINERY ASSEMBLY
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-42
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
CENTER SWIVEL JOINT ASSEMBLY
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-48
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-49
IDLER CUSHION ASSEMBLY
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51
INSTALLATION OF IDLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-52
INSTALLATION OF TRACK ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-54
INSTALLATION OF CARRIER ROLLER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-55
INSTALLATION OF HYDRAULIC CYLINDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-56
ASSEMBLY OF WORK EQUIPMENT VALVE (NOTES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
PC58UU-3 30-1
2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
12
METHOD OF USING MANUAL
1. When removing or installing unit assemblies
1 When removing or installing a unit assembly, the order of work and techniques used are given for
the removal operation; the order of work for the installation operation is not given.
2 Any special techniques applying only to the installation procedure are marked , and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the instal-
lation procedure it applies to.
(Example)
REMOVAL OF OOOO ASSEMBLY................................ Title of operation
........................................................................................ Precaution related to safety when performing
operation
1. XXXX(1) .................................................................... Step in operation
★ ............................................................................. Technique or important point to remember
when removing XXXX (1).
2. ∆ ∆ ∆ ∆ (2):.................................................................. Indicates that a technique is listed for
use during installation
3. ❒ ❒ ❒ ❒ assembly (3)
....................................................................... Quantity of oil or water drained

INSTALLATION OF OOOO ASSEMBLY ........................ Title of operation
• Perform installation in reverse order to removal
....................................................................... Technique used during installation
★ ............................................................................. Technique or important point to remember
when installing ∆ ∆ ∆ ∆ (2).
• Adding water, oil ................................................. Step in operation
★ ..................................................................... Point to remember when adding water or oil
............................................................... Quantity when filling with oil or water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are
given together as PRECAUTIONS WHEN PERFORMING OPERATION, so be sure to follow these precau-
tions when performing out the operation.
3. Listing of special tools

1 For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the
operation procedure, see the SPECIAL TOOL LIST later in this section.
30-2 PC58UU-3
2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
12
PRECAUTIONS WHEN PERFORMING OPERATION
Be sure to follow the general precautions given below when performing removal or installation (disassem-
bly or assembly) of units.
1.Precautions when performing removal work
• If the engine coolant water contains antifreeze, dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from enter-
ing.
• 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
places before removal to prevent any mistake when assembling.
• To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force
to the wiring, always hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify and show their installation position and help prevent any
mistakes when re-installing.
• Count and check the number and thickness of the shims, and keep in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and
safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
• Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
★ Precautions when handling piping during disassembling
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
A. Hoses and tubes using sleeve nuts

Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
B. Split flange type hoses and tubes

C. If the part is not under hydraulic pressure, the following corks can be used:
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
PC58UU-3 30-3
2
12
2. Precautions when carrying out installation work
• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with two or three drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After 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 eye bolts, check that there is no deformation or deterioration, screw them fully, and align
the direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
3. Precautions when completing the operations
• If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the spec-
ified level. Run the engine to circulate the coolant water through the system. Then check the coolant
water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, have been removed for repair, Always bleed the air from the sys-
tem after reassembling the parts.
★ For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related
parts.
4. Other precautions
• To maintain the performance of the machine and to prevent failures, it is particularly important to pay
attention to the degree of cleanliness of the oil in the hydraulic circuits. When adding oil or changing
the oil, or when replacing the filters, check that the oil container and area around the filler of the hydrau-
lic tank are clean.
• To keep the hydraulic circuits clean and to protect the hydraulic equipment, br careful of the following
when disassembling or assembling.
• Before disassembling, wash the machine. Be particularly careful to completely clean the area that is
to be disassembled.
• Do not let dirt or dust get into the hydraulic circuits when when disassembling or assembling.
• Carru out thorough flushing of the parts, and be particularly careful to do this thoroughly for the cir-
cuits or parts that have failed.
• When disassembling or after flushing, always mask the openings of the piping or hydraulic equip-
ment completely.
• Do not use seal tape for the thread of the plug mounts or connections.
• If any internal part of the hydraulic equipment breaks, disassemble and clean all hydraulic equipment
and circuits to remove any dirt or pieces from the circuit. If any parts of the hydraulic circuits are disas-
sembled and assembled, also carry out thorough flushing of the hydraulic circuits.
• When changing the oil in the hydraulic tank, or when removing the piston pump or piston pump piping,
always bleed the air before starting the engine to prevent seizure of the pump.
For details, see TESTING AND ADJUSTING, Bleeding air from piston pump.
30-4 PC58UU-3
2
★ After replacing or flushing the hydraulic tank oil, filter element, or strainer, or when removing and
installing any hydraulic cylinder, hydraulic pump or any other hydraulic equipment or work equipment
piping, always bleed the air as follows after completion of the installation.
1. Run the engine at low idle, and extend and retract the steering, bucket, and lift arm cylinders 4 - 5
times without going to the end of the strike. (Stop approx. 100 mm before the end of the stroke.
2. Operate the steering, bucket, and lift arm cylinders 3 - 4 times to the end of the stroke, then stop the
engine and bleed the air from the plugs at the top of the hydraulic tank filler.
3. Raise the engine speed and repeat Step 2. to bleed the air. Repeat this procedure until no more air
comes out from the plugs.
4. After completing bleeding the air, tighten the plugs.
Plug: 11.3 ± 1.5 Nm {1.15 ± 0.15 kgm}
★ If the engine is run at high speed from the start, or the cylinders are operated to the end of the
stroke, the air inside the cylinder will cause damage to the piston packing.
★ After repair or long storage, follow the same procedure.
PC58UU-3 30-5
2
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

a Tools with part number 79OT-OOO-OOOO cannot be supplied
(they are items to be locally manufactured).
a Necessity: t: Cannot be substituted, should always be installed (used).
q: Extremely useful if available, can be substituted with commercially available part.
New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: Tools already available for other models, used without any modification.
a Tools marked O in the Sketch column are tools introduced in the sketches of the special tools
(See SKETCHES OF SPECIAL TOOLS).
Neces- New/
Component Symbol Part Number. Part Name Qty. Sketch Nature of work, remarks
sity remodeled
790-101-5201 Push tool KIT (B) q 1
• 790-101-5241 Plate 1
1 Installation of oil seal
• 790-101-5221 Grip 1
• 01010-51225 Bolt 1
790-101-5201 Push tool KIT (B) q 1
• 790-101-5281 Plate 1
2 Press fit of sub-bearing outer race
Disassembly, • 790-101-5221 Grip 1
assembly of • 01010-51225 Bolt 1
swing motor
F 790-101-5201 Push tool KIT (B) q 1
and swing
machinery • 790-101-5311 Plate 1
assembly 3 Press fitting of main bearing outer
• 790-101-5221 Grip 1 races
• 01010-51225 Bolt 1
4 796-465-1120 Push tool t 1 Press fit of main bearing inner race
5 791-463-1120 Push tool q 1 Press fit of sub-bearing inner race
Wrench
796-720-2300
assembly t 1
6 Measurement of shaft starting torque
795-630-1803 Torque wrench t 1
790-101-5001 Push tool KIT (A) q 1
• 790-101-5081 Plate 1
1 Press fit of idler bushing
• 790-101-5021 Grip 1
Disassembly • 01010-50816 Bolt 1
and
re-assembly 2 791-430-3230 Installer t 1 Installation of idler floating seal
of idler and 790-101-5001 Push tool KIT (A) q 1
track roller
assembly • 790-101-5081 Plate 1
3 Press fit of track roller bushing
• 790-101-5021 Grip 1
• 01010-50816 Bolt 1
4 790-430-3230 Installer t 1 Installation of track roller floating seal
790-101-5001 Push tool KIT (A) q 1
L
• 790-101-5081 Plate 1
5 Press fit of carrier roller bearing
• 790-101-5021 Grip 1
• 01010-50816 Bolt 1
Disassembly 790-101-5001 Push tool KIT (A) q 1

and • 790-101-5111 Plate 1
re-assembly 6 Press fit of carrier roller oil seal
of carrier roller • 790-101-5021 Grip 1
assembly • 01010-50816 Bolt 1
790-101-5001 Push tool KIT (A) q 1
• 790-101-5081 Plate 1
7 Press fit of carrier roller cap
• 790-101-5021 Grip 1
• 01010-50816 Bolt 1
PC58UU-3 30-7
(6)
Neces- Qty. New/

Component Symbol Part Number. Part Name Sketch Nature of work, remarks
sity remodeled
Removal and
installation of M 792-371-1400 Sleeve t 1 Removal and installation of spring
recoil spring
Remover and
791-615-7001 installer t 1
Disassembly Remover and

791-616-1020
installer t 1
and
R Removal and installation of track pin
re-assembly 796-126-1120 Guide t 1
of track link
790-101-1102 Hydraulic pump t 1
790-105-1100 Cylinder (30-ton) t 1
790-101-2501 Push tool KIT q 1
• 790-101-2510 Block 1
• 790-101-2520 Screw 1
Disassembly
• 791-112-1180 Nut 1
and
Disconnection of swivel shaft and
re-assembly of T • 790-101-2540 Washer 1
rotor
center swivel
• 790-101-2630 Leg 2
joint assembly
• 790-101-2570 Washer 4
• 790-101-2560 Nut 2
• 790-101-2660 Adapter 2
790-502-1003 Unit repair stand t 1 Disassembly and re-assembly of
1
790-101-1102 Unit repair stand t 1 hydraulic cylinder
Wrench Removal and installation of cylinder

2 790-330-1100 assembly t 1
head
790-302-1280 Socket wrench t 1 55 mm: Bucket, offset and blade
3 790-302-1290 Socket wrench t 1 60 mm: Arm
790-102-1320 Socket wrench t 1 70 mm: 2nd boom
790-201-1702 Push tool KIT q 1 Press fit of cylinder head bushing
• 790-101-5021 Grip 1
• 01010-50816 Bolt 1
4
790-201-1771 Push tool 1 1st boom cylinder
790-201-1761 Push tool 2 Bucket, offset and blade cylinder
Disassembly 790-201-1781 Push tool 4 2nd boom cylinder
and
re-assembly
790-201-1500 Push tool KIT t 2 Press fit of cylinder head dust seal
U
of hydraulic • 790-101-5021 Grip 2
cylinder
• 01010-50816 Bolt 1
assembly 5
790-201-1570 Plate 1 Bucket, offset and blade cylinder
790-201-1580 Plate 1 1st boom cylinder
790-201-1590 Plate 1 2nd boom cylinder
6 790-720-1000 Expander q 1
Installation of piston ring
796-720-1660 Band q 1
1st boom and blade cylinder
7
07281-01159 Clamp q 1
796-720-1670 Band q 1
8 2nd boom cylinder
07281-01279 Clamp q 1
796-720-1650 Band q 1
9 Arm and offset cylinder
07281-01029 Clamp q 1
796-720-1640 Band q 1
10 Bucket cylinder
07281-00909 Clamp q 1
30-8 PC58UU-3
(6)
Neces- Qty. New/

Component Symbol Part Number. Part Name Sketch Nature of work, remarks
sity remodeled
790-441-1802 Remover t 1
• 790-441-1810 Sleeve 1
• 792-900-1530 Screw 1
• 796-270-1110 Adapter 1
1 Removal of boom foot pin
• 01803-13034 Nut 1
• 01643-33080 Washer 1
790-101-4000 Puller (50-ton) 1
790-101-1102 Hydraulic pump 1
791-735-1123 Sleeve t 1
791-520-4140 Screw 1
Removal and 791-101-2420 Adapter 1

installation Removal of 2nd boom pin and offset
2 790-101-2540 Washer 1
of work V pin
equipment 791-112-1180 Nut 1
assembly 790-101-2102 Puller (30-ton) 1
790-101-1102 Hydraulic pump 1
790-201-2840 Spacer t 1
792-900-1420 Plate t 1
791-520-4140 Screw t 1
790-101-2420 Adapter t 1
Removal of arm cylinder trunnion pin
3 790-101-2450 Adapter t 1
(Arm cylinder)(Offset cylinder)
790-101-2540 Washer t 1
791-112-1180 Nut t 1
790-101-2102 Puller (30-ton) t 1
790-101-1102 Hydraulic pump t 1
799-703-1200 Service tool KIT t 1
799-703-1100 Vacuum pump t 1 (100V)
Fill of air
conditioner gas
X 799-703-1110 Vacuum pump t 1 (220V) For overseas market
799-703-1120 Vacuum pump t 1 (240V) For overseas market
799-703-1400 Leak tester t 1
PC58UU-3 30-9
(6)
DISASSEMBLY AND ASSEMBLY ENGINE AND WORK EQUIPMENT PUMP ASSEMBLY
REMOVAL OF ENGINE AND 3. Attach the eyebolts to the auxiliary counter-

weight (4). Temporarily support and lift it with a
WORK EQUIPMENT PUMP lifting tool enough to remove the hood catch and
ASSEMBLY the two mounting bolts from behind the auxiliary
counterweight. The auxiliary counterweight (4)
a The shapes of the water separator and fuel filter can now be removed.
4 Auxiliary weight: 170 kg
of a machine, Serial No. 22001 or higher, are dif-
ferent from those of a machine of a lower Serial
No. The removal procedure for the engine and
work equipment pump assembly is the same,
however.
1. Open the engine hood (1), remove the mounting

bracket bolts (2), and remove the hood.
4. Remove the four mounting nuts from the exhaust

muffler (5). Remove the shield. Loosen the tail
pipe clamp (6) nut from U-bolt (7) and remove
the muffler and the tail pipe.
2. Loosen the rear cover (3) mounting bolt. Loosen

the fuel air bleed hose clamp inside the cover
and remove the hose. Remove the fuel tank cap
and remove the cover (3).
30-10 PC58UU-3
(6)
12
5. Attach the eyebolts b to the counterweight
(8). Lift it with the lifting tool. Remove the 3
mounting bolts and lift the counterweight (8)
to remove it.
Counterweight Approx.: 750 kg
7. Disconnect hoses (12), (13), (14), (15) and (16)

from the hydraulic pump (11). Then, remove
the accelerator cable clamp (17).
★ Place male or female plugs into the
removed hoses and the elbow.
★ To remove the hydraulic oil drain, the

radiator coolant drain, and the suction
tube from the hydraulic pump, turn the
machine about 90 degrees counterclock-
wise from its normal parked position.
Lower the work equipment completely to
the ground and stop the engine.
★ Remove the cable from the negative (-)
terminal of the battery.
★ Loosen the cap on the hydraulic tank to
release any pressure.
6. Loosen the drain plug (9) on the lower surface 8. Remove the 4 mounting bolts from the suc-
of the hydraulic tank and drain the hydraulic tion tube (18) on the lower surface of the
oil in a container. hydraulic pump and remove the suction tube.
Loosen the drain plug (10) on the radiator
lower tank and drain the coolant in a con- ★ Mask the removed suction tube in order
tainer. to prevent foreign matters from entering
★ When antifreeze is used in the coolant, the tube.
handle it as a hazardous liquid in accor-
dance with all local laws and safety regu-
lations.
Hydraulic oil: Approx. 56 l
Coolant: Approx. 8 l
PC58UU-3 30-11
2
12
9. Remove the clamps from the electrical har- 11. Loosen the upper radiator hose (25) and the
ness (19). Loosen the clamps on the air intake lower radiator hose (26) clamps from the radi-
hoses (20) and (21) and disconnect the hoses. ator on the engine side and disconnect the
Remove the air cleaner (54) and remove hoses. Remove the intermediate clamp (27)
brackets (55) and (56). of the lower hose.
10. Remove the radiator reservoir tank (22) with 12. Loosen the ground cable (28) mounting bolt
its bracket. Remove the fan guard (23) mount- from the engine and disconnect it.
ing bolt and remove the guard. Remove the
fan (24) mounting bolt and remove the fan.
13. Disconnect the electrical harness and remove

the connectors and harnesses from the work
equipment pump solenoid (29), the engine
speed sensor (30), the fuel pump, the stop
motor, the air heater, the oil pressure gauge,
etc.
30-12 PC58UU-3
2
12
14. Remove the alternator inspection cover (31). 17. Remove the controller cover (39) (behind the
Remove the divider panel (32) mounting bolt operator’s seat). Remove four mounting bolts
from the hydraulic tank and remove the from the controller and remove the controller.
divider panel from the canopy mounting Then, move the harness to a place where it is
frame (33). easy to work without removing it. Remove
the 11 mounting bolts and temporarily lift the
canopy (40).
15. Remove the accelerator control cable rod (34)

mounting nut and remove the rod. Loosen 18. Wind a lifting sling around the right side of
the nut on the cable bracket (35), disconnect the canopy assembly (40) and remove the
the cable and remove the clamp (36). assembly by lifting it.
★ Before loosening the nut on the bracket ★ Use a lifting sling.
(35), record the number between the rod- ★ Remove the rear view mirror.
side nuts and the mounting nuts.
Canopy assembly: 164 kg
16. Remove the clamp and fuel hose (37). Discon-

nect the hose below the fuel pump (38).
19. Remove the Left side cover (41).
PC58UU-3 30-13
2
12
20. Remove the left handrail (42) with cover (43), 23. Disconnect each harness from the alternator
from the floor and the canopy mounting (47). Loosen adjuster (48) and move the alter-
frame (33). nator (47) toward the engine. Remove the
connector (50) from the water temperature
sensor (49).
21. Remove the fuel oil filler port mounting

bracket (44) and the cover mounting bracket
(45) from the canopy mounting frame (33). 24. Lift the canopy mounting frame (33) momen-
tarily to remove the 4 bolts, then lift the frame
away.
Frame: 60 kg
22. Disconnect each harness from the starting

motor (46).
25. Use the eyebolts and lift the engine pump

assembly (51) to remove the 4 nuts of the
mount (52), then lift the engine pump assem-
bly away.
Engine pump assembly: 230 kg
30-14 PC58UU-3
2
INSTALLATION OF ENGINE 3. Connect the electrical harness and install each

connector and harness of the work equipment
AND WORK EQUIPMENT pump solenoid (29), the engine speed sensor
PUMP ASSEMBLY (30), the fuel pump, etc. to the engine pump
assembly.
a The shapes of the water separator and fuel filter
however.
1. Use the two eyebolts on the engine and lift the

engine pump assembly (51). Bring the bolt of
the revolving frame mount (52) to the hole of the
engine-side bracket, lower the engine pump
assembly, attach the mounting bolt and nut to the
bracket and tighten the nut to the specified
torque.
3 Mounting nut: 59 – 74 Nm {6 – 7.5 kgm} 4. Connect each harness of the starting motor (40)
and alternator (47). Install the connector (50) of
the water temperature sensor (49) to the engine
and pump assembly.
2. Connect the hose of the fuel pump (38) and the

fuel filter hose (37) to the engine pump assembly
and clamp the two hoses to the engine block.
5. Lift the canopy mounting frame (33) and set it in
position. Attach it with 4 bolts and tighten the
bolts to the specified torque.
4 Frame : 60 kg
PC58UU-3 30-15
(6)
12
6. Install the panel (32) to the canopy mounting 9. Pull the alternator (47) toward you to adjust
frame of (33). the fan belt (53). Tighten the adjuster (48) to
secure the belt adjustment.
7. Connect the accelerator control cable rod (34)

to the engine pump assembly, connect the 10. Install the fan guard (23) and connect the
cable to the cable adjustment and locking lower hose (26) to the engine pump assem-
bracket (35), adjust the cable and tighten the bly. Tighten the clamp to the specified torque.
nut. Install the cable clamp (36) to the engine Install the intermediate hose clamp (27) to the
pump assembly. engine pump assembly.
8. Place the fan belt (53) on the alternator pulley 11. Install the radiator reservoir tank (22) bracket.
and the fan pulley. Install the fan (24) with the Install the tank and connect the reservoir hose
4 bolts (Be careful not to drop the spacers.). and the engine ground cable (28) to the
Connect the upper hose (25) to the engine engine pump assembly.
pump assembly and tighten the clamp to the
specified torque.
30-16 PC58UU-3
2
12
12. Install the fuel oil filler port mounting bracket 15. Connect the air cleaner air intake hose (21).
(44) and the cover mounting bracket (45) to Install the air intake manifold (20). Clamp the
the canopy mounting frame (33). electrical harness (19) to the engine pump
assembly by applying the specified torque.
Hose clamp: 8.8 ± 0.5 Nm

(90 ± 5 kgcm)
13. Install the exhaust muffler (5) to the exhaust

manifold and tighten the 4 nuts to the speci-
fied torque.
★ The tail pipe will be connected later, with
the counterweight,
16. Install the cover (41) on the left side of the
machine. Install the left handrail (42) and the
cover (43) to the floor and to the canopy
mounting frame (33).
14. Install the air cleaner brackets (55) and (56)

and then install the air cleaner (54) to the
engine pump assembly.
17. Install the controller (39), its cover (57) and

the alternator cover (31) onto the engine
pump assembly.
PC58UU-3 30-17
2
12
18. Connect hoses (12), (13), (14), (15) and (16) of 20. Insert the tail pipe (58) into the exhaust muf-
hydraulic pump (11) to the engine pump fler (5) and tighten the clamp (6) and the U-
assembly. Install the accelerator cable clamp bolt (7) lightly.
(17) on the engine pump assembly.
21. Attach the eyebolts B to the counterweight

19. Tighten the radiator drain plug (10) and fill (8). Lift the counterweight to align the tail
the radiator with coolant. Tighten the hydrau- pipe (58) of the exhaust muffler to the hole in
lic oil drain plug (9) and fill it with hydraulic the counterweight. Place the weight in its
oil. specified position. Attach the bolt to the tail
pipe and tighten the bolt to the specified
Coolant: 8 l torque
Hydraulic oil: 56 l
★ Connect the negative (-) battery cable to

its terminal.
★ Add coolant up to the specified level.
Start the engine to raise the temperature
of the coolant so the thermostat opens
and coolant circulates. Check the coolant
level again.
★ Add hydraulic oil up to the oil level. Start
the engine. Place the machine in the posi-
tion to check the oil level and check it. Set 22. Attach the eyebolts B to the auxiliary weight
the work equipment in the minimum turn- (4). Lift the weight to align the tail pipe (58) of
ing position. Stop the engine. Remove the the exhaust muffler to the hole in the auxil-
tank cap and tighten it again so that pres- iary weight. Place the weight in its specified
sure is applied inside the tank. position. Attach the bolt to the tail pipe and
tighten the bolt to the specified torque.
★ Start the engine. Turn the work equip-

ment to the right. Lower the bucket com-
pletely to the ground in front of the blade
and stop the engine.
30-18 PC58UU-3
2
23. Secure the tail pipe (58), on which the 26. Install the canopy assembly (40) on the
exhaust muffler (5) was mounted. Use clamp engine pump assembly by lifting the right
(6) and the U-bolt (7). end with a lifting sling. Tighten the 11 bolts to
the specified torque. Install the rear-view mir-
ror. Install the floor mat.
24. Position engine hood (1) and install the right

and left mounting brackets (2). Install the
hood latch (59) on the engine pump assem-
bly.
25. Remove the fuel cap. Place the left rear cover
(3) onto the engine pump assembly. Connect
the air bleed hose inside the cover which is
used when adding oil. Install the clamp on the
engine pump assembly. Install the tank cap
and attach the cover (3) with the bolt to the
engine pump assembly.
PC58UU-3 30-19
2
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT ASSEMBLY
REMOVAL OF CENTER 4. Remove the controller cover behind the opera-

tor’s seat (5). Remove the controller (6) and
SWIVEL JOINT ASSEMBLY remove the operator’s seat (5).

however.
k WARNING! Stop the machine on level ground
and lower the work equipment and the blade
completely to the ground.
1. Loosen the cap on the hydraulic tank and

release any pressure inside the tank.
2. Disconnect the negative (–) cable (2) from the 5. Remove the front cover (7) under which the work
battery (1) terminal. equipment solenoid, resistor, etc. are stored.
3. Remove the floor mat (3). Temporarily lift the a Before removing the floor assembly, identify the
right side of the canopy (4) with a sling, remove parts mounted on the floor and the parts to be left
the 11 mounting bolts and then lower the canopy. because they are mounted on the revolving
4 Canopy assembly: 164 kg frame.
30-20 PC58UU-3
(6)
12
6. Disconnect 2 connectors (9) and remove 8. Disconnect 4 pilot hoses (16) from the PPC
resistor (8) with its mounting bracket (10). valve (15) (traveling). Disconnect the hose
Remove the diode box (11) together with its (17) from the solenoid valve on the travel
bracket. valve side. Disconnect the hose (marked with
2 white bands) from behind the offset valve
(18) on the block side.
★ Install male or female plugs on the
removed hoses and nipples.
7. Remove the connectors (13) from the 5-spool

solenoid valves (12), remove 4 connectors
(14) from the upper part of the solenoid valve
and pull the harness assembly with the diode
box above the floor. 9. Open the left side cover (19) from the control
★ Mask the male and female screws of the pattern selector valve and disconnect each
removed connectors. pilot hose (20) from the right and left PPC
valves used for operating the work equip-
ment (the quick coupler).
WARNING! Be careful. Avoid injury from

the cutting edges of the color bands
wound around the hoses.
PC58UU-3 30-21
2
12
10. Disconnect the blade control cable (21). Pull 12. Remove the cover (28). Remove the handrail
out the beta pin and the roll pin from the turn- (29) with the cover (30) from the floor.
buckle (22). Remove them from the blade
control lever. Loosen the lock nut on the cable
mounting bracket (23). Disconnect the cable
and pull it down through the floor hole.
13. Loosen the 4 bolts around the floor mount

(31) and remove the floor mount.
11. Disconnect the accelerator control cable (24).

Remove the mounting nut at the tip of the rod
(25) from the lever. Loosen the cable lock nut
on the bracket (26) and remove the clamp
(27). Disconnect the cable from the engine
side. Remove the clamp on the hydraulic
pump by pulling it out toward the operator’s
seat.
14. Attach 2 eyebolts b to the operator’s seat

floor and also to the operator’s seat mounting
bracket and lift them with lifting tools. Pre-
pare a stable pedestal high enough so that
the parts on the lower surface of the floor and
below will not be damaged.
Floor assembly: 110 kg
30-22 PC58UU-3
2
12
15. Remove the cover from the lower surface of 17. Disconnect the hose (38) and 7 other hoses,
the center swivel joint and disconnect the one after the other, from the top of the center
hoses (32) and (33). swivel joint and remove the plate (39).
★ Attach male or female plugs to the ★ Before disconnecting the hoses, loosen
removed hoses and nipples. the 2 bolts on the plate (39) from the
swivel joint due to large torque.
★ Before disconnecting each hose, record or
tag the hose and its connection.
16. Disconnect the hoses (34) and (35). Discon-

nect the 4 hoses including (36) and (37) from
the travel motor and those on the opposite
side as well. 18. Remove 4 mounting bolts (41) from the cen-
ter swivel joint (40) and then remove the
swivel joint (40).
Swivel joint: 19.5 kg approx.
PC58UU-3 30-23
2
INSTALLATION OF CENTER 3. Connect the hoses (32) and (33) below the
swivel joint.
SWIVEL JOINT ASSEMBLY
however.
1. Install the swivel joint (40) onto the mounting

frame with the bolts (41). Tighten them to the
specified torque.
3 Swivel mounting bolt:
66 ± 7 Nm {6.7 ± 0.7 kgm}
4. Tighten the mounting bolt of the plate (39) above
the swivel joint by applying the specified torque.
Also, connect the 7 hoses including hose (38),
one after another from below and install the
lower cover of the swivel joint.
2. Connect the 4 hoses, first (37) and (36) and then

(34) and (35), between the travel motors from
below the swivel joint.
5. Lift and install the operator’s seat floor assembly.

Attach the eyebolts at two places each on the
front section of the floor and on the operator’s
seat mounting bracket. Lift them with the lifting
tools and install them at the specified positions.
4 Floor assembly: 110 kg
30-24 PC58UU-3
(6)
12
6. Attach 4 bolts to the floor mount (31) and 9. Open the left side cover (19) to access the
tighten them to the specified torque. control pattern selector valve. Connect each
pilot hose (20) to the right and left PPC valves.
WARNING! Be careful. Avoid injury

from the cutting edges of the color
bands wound around the hoses.
★ Make sure the hose coupler has been

firmly locked.
7. Pass the accelerator control cable (24)

through the hole below the canopy mounting
frame, install the tip of the rod (25) on the
pump lever and tighten the nut. Connect the
cable to the bracket (26) and tighten the lock
nut. Install the clamp (27).
10. Connect 4 pilot hoses (16) from the PPC valve

(15) for traveling. Connect the hose (17) to the
solenoid valve, and connect the hose (marked
with 2 white bands) between the rear block of
the offset valve (18) and the control valve.
8. Connect the blade control cable (21) to the

bracket (23) and tighten the nut. Install the
turnbuckle (22) on the control lever and install
the roll pin and the beta pin in the turnbuckle
by inserting them.
PC58UU-3 30-25
2
12
11. Move the harness assembly from the floor 14. Install the front cover (7) under which the
side to the front, install the connectors (13) to work equipment solenoid, resistor, etc. are
the 5-spool solenoid valve (12) and install the stored.
4 connectors (14) on the valve.
15. Install the controller (6) and the cover. Install

12. Install the resistor (8) with mounting bracket the operator seat (5).
(10) and connect 2 connectors (9). Install the
diode box (11).
16. Lift the right side of the canopy (4) with a lift-
ing strap. Place the canopy in position and
13. Install the cover (28) on which the fuel oil filler tighten the mounting bolt by applying the
port is provided. Install the left handrail (29) specified torque. Install the floor mat.
with the cover (30).
30-26 PC58UU-3
2
12
17. Connect the negative (-) cable (2) to the termi-
nal of the battery (1).
★ Start the engine and move the travel

blade slowly to check how it works.
★ Operate the work equipment, bring it to
the oil level measuring position and check
the oil level. If the oil level is low, open
the hydraulic tank cap (42) and add oil up
to the specified level.
★ Bring the work equipment to the mini-
mum turning position and stop the
engine. Loosen and tighten the hydraulic
tank cap (42) to release any existing pres-
sure so that pressure, with a full tank, will
be applied.
PC58UU-3 30-27
2
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY
12
REMOVAL OF SWING MOTOR AND SWING MACHINERY
ASSEMBLY ASSEMBLY
l 3. Remove 8 mounting bolts (6) from the swing
machinery (5).
WARNING! Stop the machine on level
ground. Lower the work equipment and
the blade completely to the ground.
★ Stop the work equipment so that the boom

back face inclines forward.
1. Remove the covers (1) and (2) behind the

boom foot.
4. Lift the swing motor and machinery assembly

(7) temporarily and pull out the machinery
from the dowel pin by using 2 forcing screws
b. Lift the swing motor and machinery
assembly (7) away and place it on a stable
pedestal.
Swing motor and machinery

assembly: 52 kg, approx.
2. Disconnect five hoses including the left right
swing hose (4) from above the swing motor
(3). Disconnect the hose from the front below
the boom foot.
★ Attach male or female plugs to the
removed hoses and nipples.
30-28 PC58UU-3
2
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY ASSEMBLY
12
INSTALLATION OF SWING MOTOR AND SWING MACHINERY

ASSEMBLY ASSEMBLY
1. Lift the swing motor and machinery assembly 3. Attach the covers (2) and (1) behind the boom
(7) and place it in the specified position. foot.
Adjust the position of the dowel pin by using
guide bolt c. Attach 8 bolts and tighten them
to the specified torque.
Machinery mounting bolt:

98 to 123 Nm (10 to 12.5 kgm)
★ Start the engine to supply oil to the swing

motor. During low idling of the engine,
repeatedly turn the machine for several
seconds.
★ Bring the work equipment to the oil level
measuring position and add oil up to the
specified level.
★ Bring the work equipment to the mini-
★ When installing the swing motor and mum turning position and stop the
machinery assembly, remove the swing engine. Loosen and tighten the hydraulic
motor if the position of the dowel pin tank cap to release any existing pressure
mounting bolt cannot be adjusted due to so that pressure, with a full tank, will be
relationship between the pinion gear and applied.
the circle gear of the machinery. Install
★ Start the engine and move each cylinder
the machinery by itself and then install
of the work equipment. Then, use the
the swing motor in the specified position.
swing operation lever in fine operation
★ After removing the swing motor, try to and in full operation to check if the swing
prevent foreign matter from entering the system is normal.
motor.
2. Connect the five hoses including the hoses (4)

from the swing motor (3).
PC58UU-3 30-29
2
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME ASSEMBLY
12
REMOVAL OF REVOLVING FRAME ASSEMBLY
2. Remove the front cover (4) (horn), cover (5)

WARNING! Stop the machine on level and the right side cover (6) in this order.
ground. Lower the work equipment and
the blade completely to the ground.
★ Stop the machine on level ground. Sit on the

operator seat, turn the blade backward and
direct the work equipment to the sprocket.
Then, bring the work equipment to the maxi-
mum digging posture and lower the bucket
completely to the ground.
★ Loosen the cap of the hydraulic tank and
relieve inner pressure of the tank.
★ Disconnect the negative (-) cable from the
negative (-) battery terminal.
3. Remove the hose cover (7) on the right side of
1. Remove the floor mat. Remove the handrail the boom, remove the right and left harness
(3) on the left side of the operator’s seat with connectors from the working lamp (8).
the cover. Temporarily lift the right side of the Remove the right working lamp (8) with its
canopy (2) with a lifting strap. Remove the 11 bracket.
bolts and lift the canopy away.
4. Remove the cover (9) below the boom foot,

the rear cover (10), the foot pin cover (11) and
2 grease nipples (12) in this order.
30-30 PC58UU-3
2
12
5. Remove the harness connector (13) (potentio- 7. Remove bracket (18) from the work equip-
sensor of the work equipment). Remove the ment. Disconnect each hose at the hose inter-
battery-side partition cover (14). Remove the mediate joint (19).
rubber seal and place it on the rear cover ★ Attach male and female plugs to each
side. removed hose.
★ Mask male and female screws of the ★ Before disconnecting each hose, record
removed connector. how it is connected.
6. Temporarily lift the boom cylinder (15). 8. Pull out the beta pin (23) from the joint pin
Remove the lock plate from the load pin (16) section of the lever (21) of the potentio-sensor
and pull out the pin. Place a stable pedestal, (20) and from the boom-side lever so that
on which the cylinder can be placed level, they can be separated.
below the cylinder and lower the cylinder Remove the bracket (24) from the work equip-
onto it. Cut off the binding bands holding the ment hose.
electrical harness (17). Remove the harness
from the bracket and move the harness
toward the boom top.
PC58UU-3 30-31
2
12
9. Disconnect the connector (25) from the poten- 12. Lift the work equipment assembly (29).
tio-harness (to which the lever is attached Remove it from the revolving frame and
with sealing tape to prevent the potentiome- lower it to a stable position.
ter from shifting), remove the 3 mounting ★ Before lifting the work equipment, fasten
bolts and remove the potentiometer (20). around the part (30) of the second boom,
the arm cylinder and the offset cylinder
rod together, using a lifting strap and
chain block, so that they do not offset
when the work equipment is lifted.
10. Remove the partition cover (26) (used for con-

necting the work equipment hose) and
remove the potentiometer mounting plate
(27) that is also used as a boom foot pin stop-
per. 13. Temporarily lift the boom cylinder assembly
(31). Disconnect 2 hoses (32), pull out the bot-
tom pin (33) and lift the cylinder assembly
away.
Cylinder assembly: 70 kg
11. Lift the work equipment assembly tempo-

rarily, install tool V1 to the boom foot pin (28)
and pull out the pin.
Work equipment assembly: 900 kg
30-32 PC58UU-3
2
12
14. Remove the floor assembly. When removing 17. Insert a pin in the boom foot mounting
the floor assembly, read the part about bracket of the revolving frame assembly (38)
Removal of the Floor Assembly in the para- and connect a lifting tool (strap or cable) to it.
graph for Removal of Center Swivel Joint Wind the lifting tool (strap or cable) around
Assembly. the lower part of the counterweight and lift
★ Remove the upper 8 hoses only from the the counterweight. Remove all mounting
center swivel joint. bolts from the swing circle on the lower face
of the revolving frame and from the outer
15. Disconnect the lubrication hose (34) from the race of the revolving frame. Lift the revolving
swing circle and remove the nipple (35). frame assembly away.
Revolving frame assembly:

2,200 kg approx.
16. Remove the right and left bolts from the

mounting bracket (37) and remove the engine
hood (36).
PC58UU-3 30-33
2
12
INSTALLATION OF REVOLVING FRAME ASSEMBLY

1. Insert the pin into the boom foot mounting 3. Install nipple (35) of oil hose (34) connected to
hole of the revolving frame assembly (38), the swing circle, and install the hose.
and install the lifting tool. Lift the tool from
the bottom of the counterweight intermediate
section. Align the mounting hole with the
dowel pin locating at the top of swing circle
outer race, and carefully lower the revolving
frame assembly.
4. Install the floor assembly. See the ""Installing

the Floor Assembly"" section of the CENTER
SWIVEL JOINT, INSTALLATION.
5. Lift boom cylinder assembly (31), install it on

the revolving frame, install bottom pin (33)
2. Install bolts on the revolving arm through and lock it using the mounting plate. Then,
swing circle outer race (39), and temporarily install the hoses (32).
secure all bolts.
Boom cylinder assembly: 70 kg
Mounting bolts: Grease the LT-2.
★ Tighten the bolts permanently when the

machine can be moved.
30-34 PC58UU-3
2
12
6. Lift the work equipment assembly (29), and 8. Install plate (27) that holds the boom foot pin
install it on the revolving frame. and mounts the potentiometer sensor. Then,
★ Before lifting the work equipment assem- install partition cover (26) for work equipment
bly, connect the second boom, arm cylin- hose mounting.
der, offset cylinder and others using belts
and chain blocks so that the equipment is
not offset. The section (30) must be fas-
tened together.
Work equipment assembly: 900 kg
9. Install potentiometer (20) on the plate, and

connector (25) of the potentiometer harness.
7. Align the boom foot pinhole with the revolv-

ing frame hole, and install the shim. Install
boom foot pin (28) on the revolving frame
using tool V1.
WARNING! Be very careful to keep

your fingers from going into the pin- 10. Install beta pin (23) of the joint pin section
hole when aligning it. that connects lever (21) of potentiometer sen-
sor (20) to boom lever (22). Then, install
★ Coat the pin sliding surface with LM-P bracket (24) for the work equipment hose.
during reassembly.
★ Use hyper white grease, and refill the
grease until the dust seals at both ends
are full.
★ Change the position of boom foot section,
and add the grease.
PC58UU-3 30-35
2
12
11. Connect the hoses at intermediate joint (19). 14. Install boom foot under cover (9), rear cover
Then, attach hose bracket (18) to the work (10), foot pin cover (11) and two grease nip-
equipment. ples (12).
12. Lift boom cylinder (15), install rod pin (16), 15. Install hose cover (7) at the boom right side.
and install the lock-plate. Secure electrical Install working lamp (8) and its bracket in
wiring harness (17) of the work equipment position, plug the right and left harness con-
using harness bands. nectors of working lamp (8) into their sockets,
★ Use the specified harness bands only. and install the right and left clamps.
They are double-structured special bands.
16. Install cover (5), front cover (4)(horn), and

13. Install separation cover (14) at the side of bat- right side cover (6).
tery, and install the rubber seals. Plug har-
ness connector (13) into its socket
(potentiometer sensor for the work equip-
ment).
30-36 PC58UU-3
2
12
17. Raise the right upper section of canopy (2) us, 20. Start the engine and drive it at a slow speed.
position the canopy, install and tighten 11 Sequentially operate all actuators by fine
bolts to the specified torque. Then, install left steering control. When the operation is sta-
handrail (3) and cover. Install floor mat (1). ble, change the equipment position and check
the oil level. Then, change the work equip-
ment to have the minimum turning radius
Canopy: 164 kg and stop its engine. Loosen oil cap (40) from
the hydraulic tank, and retighten it to apply
the internal pressure to the tank.
★ Tighten the mounting bolts of the swing
circle outer race and revolving frame to
the specified torque.
★ Turn the work equipment to allow easy
bolt tightening, and retighten bolts.
★ Start the engine, drive it at low, intermedi-
ate and high speed, and make sure that all
actuators of hydraulic and electrical sys-
tems operate normally.
18. Position the engine hood (36) and install bolts

of right and left bracket (37) to secure the
hood,
19. Remove cap (40) from the hydraulic tank,

check and fill the oil, as required.
Connect the negative (-) battery cable (41) to
the battery terminal.
PC58UU-3 30-37
2
DISASSEMBLY AND ASSEMBLY SWING CIRCLE ASSEMBLY
12
REMOVAL OF SWING CIRCLE INSTALLATION OF SWING
ASSEMBLY ASSEMBLY CIRCLE ASSEMBLY
1. Remove the revolving frame assembly (see 1. Lift the swing circle assembly, align the inner
the REVOLVING FRAME ASSEMBLY, ring soft zone position (the S marking posi-
REMOVAL). tion on the inner ring surface) with S marking
(2) which is 27 degrees shifted toward the left
2. Install 4 lifting bolts (having nuts) through the front position from the turning center line of
mounting bolt holes of the revolving frame of right and left inner rings. Place the swing cir-
swing circle assembly (1). Temporarily lift the cle assembly in the specific track frame posi-
swing circle assembly using the lifting tool. tion, and tighten 20 mounting bolts to the
Then, remove 20 mounting bolts from the specified torque.
track frame, and lift and remove the swing cir-
cle assembly. Threads of mounting bolts:
Grease the LT-2.
Swing circle assembly:
Approx. 72 kg Mounting bolt:
98 to 122.6 Nm (10 to 12.5 kgm)
★ Grease the internal gear with plenty of

G2-L1.
★ Point 3 is the machine body front side.
30-38 PC58UU-3
2
DISASSEMBLY AND ASSEMBLY RUBBER SHOE ASSEMBLY
12
REMOVAL OF RUBBER SHOE INSTALLATION OF RUBBER
ASSEMBLY ASSEMBLY SHOE ASSEMBLY
• Perform installation in the reverse order of
1. Lower the work equipment to the ground, removal.
then loosen lubricator (1) to loosen the track
shoe.
★ Adjust the track shoe tension. For details,
see TESTING AND ADJUSTING, Testing
and adjusting track shoe tension.
WARNING! Since the pressure in

the adjustment cylinder is very high,
do not loosen the lubricator more
than 1 turn. If the grease does not
come out, move the machine forward
and backward.
2. Swing the work equipment by 90 degrees and

raise the machine body a little.
3. Insert steel pipes in spaces between the rub-

ber shoes (2) and rollers, then rotate the
sprocket in the reverse direction. If the rubber
shoe is raised from the idler by the steel
pipes, slide the shoe off sideways.
Rubber shoe assembly: 222 kg
PC58UU-3 30-39
2
DISASSEMBLY AND ASSEMBLY ROAD LINER IRON SHOE ASSEMBLY
12
REMOVAL OF ROAD LINER IRON SHOE ASSEMBLY
1. Stop the machine in a place where the road 3. Remove the master pin using the tool R.
liner shoe assembly can be extended. Turn Place a small block in front of the shoe, and
the work equipment 90 degrees, and slightly slightly run the machine on the block. When
lift the machine body using the boom. Rotate the pin hole has enough clearance, remove
the shoe at the lifted body section so that tool R and remove the seal. Insert a crowbar
master pin (1) locates in the front upper posi- into the master pin hole, and lift the crowbar
tion of the idler gear. Then, move down the by holding its end section. Slightly move the
machine body and rotate the work equipment machine backward and expand road liner
to the machine front side. shoe (3).
2. Loosen lubricator (2) and release the tension

of road liner shoe (3).
WARNING! Never rotate the lubrica-

tor two or more turns because the
inner pressure of the adjustment cylin-
der is very high. If it is difficult to
release the road liner shoe (3), move
the machine forward and backward to
release the shoe.
30-40 PC58UU-3
2
DISASSEMBLY AND ASSEMBLY ROAD LINER IRON SHOE ASSEMBLY
12
INSTALLATION OF ROAD LINER IRON SHOE ASSEMBLY
★ When assembling the shoe, observe the shoe 3. Tighten lubricator (2), grease the required
from its upper position and determine that points, and adjust the tension of road liner
the section having the larger shoe bolt shoe (3).
mounting pitch is the idler section. ★ Adjust the tension of road liner shoe so
that the clearance between the center
1. Place the shoe assembly under the track roller tread and the link drive surface
frame, and move the sprocket until it reaches reaches 30 to 50 mm.
the shoe end position. Lift the shoe end sec-
tion at the idler side, and place block B so
that the front end of the shoe reaches the
height approximately half of the idler.
Insert a crowbar into the master pin hole at
the sprocket side, and place the sprocket in
front of the front shoe end. Slightly move the
machine forward while holding up the shoe
end, and align the master pin hole.
2. Install the seal, align the pin hole, and install

master pin (1) using tool R.
Dust seal and each end of master

pin: Grease the G2-LI.
PC58UU-3 30-41
2
DISASSEMBLY AND ASSEMBLY SWING MACHINERY ASSEMBLY
12
DISASSEMBLY OF SWING MACHINERY ASSEMBLY
★ Prepare an oil pan and drain the oil from the Disassemble No. 1 planetary gear carrier assem-
the swing machinery case before disassembly (3).
bly.
3. Using snap ring pliers. Remove 3 snaps (4), 3
Amount of oil in the case: 1.3 liters thrust washers (5), 3 planetary gears (6), 3
needle bearings and 3 thrust washers, and
thrust plate (7).
1. Place the swing motor and swing machinery
assembly on the block.
Remove 5 bolts from swing motor assembly
(1), and remove the motor assembly.
4. Use a hammer and insert the stopper pin into

the carrier of shaft (8), and remove 3 shafts
from carrier (3).
★ Remove shaft (8) first, then remove the
2. Remove No. 1 sun gear (2) and No. 1 plane- pin from the shaft.
tary gear carrier assembly (3).
30-42 PC58UU-3
2
12
5. Remove No. 2 sun gear (9), and remove the 7. Use a hammer and insert the stopper pin into
snap ring. Remove No. 2 planetary gear car- the carrier of shaft (18), and remove 3 shafts
rier assembly (10). Then, remove 2 mounting from carrier (19).
bolts (12) from ring gear (11), and remove the ★ Remove shaft (18) first, then remove the
ring gear. pin from the shaft.
6. Disassemble No. 2 planetary gear carrier 8. Remove 2 spacers (20).

assembly (10). Remove 3 snap rings (14)
using snap ring pliers. Then, remove 3 thrust 9. Remove output shaft assembly (21) using
washers (15), 3 needle bearings, 3 thrust push tool C.
washers, and thrust plate (17).
PC58UU-3 30-43
2
12
10. Remove bearing inner race (22) from shaft
(23), and remove seal (24).
11. Remove bearing inner race (25) from case

assembly (26).
12. Remove bearing outer race (27) from case

(28).
13. Remove bearing outer race (29), and remove

oil seal (30).
30-44 PC58UU-3
2
12
ASSEMBLY OF SWING MACHINERY ASSEMBLY
1. Press-fit oil seal (30) into case (28) using tool 2. Install seal (24) to shaft (23).
F2. ★ When installing, make lip side of seal face
★ Face the rubber face of oil seal down- to upper side.
ward, and face its metal surface upward Press-fit bearing inner race (22) to shaft
during press-fit. (23) by using tool F4.
★ Press-fitting force: 7.25 to 19.70 kN
Press-fit surface of oil seal: (0.74 to 2.01 tons)
Grease the LG-6.
★ Take care not to contact the seal lip and

shaft to the liquid gasket.
Space of oil seal lip section:

Fill the G2-L1 40% to 60%.
Using tools F2 and F3, press-fit bearing

outer races (29) and (27) into case (28).
★ Press-fitting force: 0 to 12.74 kN
(0 to 1.3 tons)
Press-fitting force: 0 to 10.29 kN
(0 to 1.05 tons) 3. Install case assembly (26) on shaft assembly
(21).
Coat approximately 60 g of G2-

L1 grease on the roller surface,
sliding surface and seal lip of the
bearing inner race.
Press-fit bearing inner race (25) using tool F5.

★ Press-fitting pressure: 5.0 to 13.33 kN
(0.51 to 1.36 tons)
★ Press-fit the bearing inner race gradually
by rotating the case.
PC58UU-3 30-45
2
12
4. Install spacer (20). 6. Reassemble the No. 2 planetary gear carrier.
★ After you have installed the spacer, install Install 3 shafts (18) on carrier (19), and use a
the case and output shaft assembly on the hammer and insert the stopper pin into shaft
block. (18) through the hole of carrier (19).
★ After pin insertion, crimp two outer edge
positions of the carrier pin.
5. Measure the starting torque of the output

shaft using tool F6.
★ Starting torque: 13.2 Nm or less (1.35 kgm 7. Install thrust plate (17). Install a thrust washer
or less) on each shaft (total 3 thrust washers), and
install needle bearing on each thrust washer
(15)(total 3 needle bearings). Using snap ring
pliers, install 3 snap rings (14) to complete
carrier assembly (10).
★ Use new snap rings only.
★ Do not open the opening more than 7 mm
when installing the snap ring.
30-46 PC58UU-3
2
12
8. Install ring gear (11), and tighten 2 mounting Install thrust plate (7) on carrier (3).
bolts (12) to the specified torque. Install No. 2 10. Install a thrust washer on each shaft (total 3
planetary gear carrier (10). Install the snap washers), and install a needle bearing on
ring on No. 2 sun gear (9), and install it by fac- each thrust washer (total 3 needle bearings).
ing its longer side (when measured from the Install 3 planetary gears (6), and 3 thrust
snap ring) downward. washers (5). Then, install 3 snap rings (4).
★ Use new snap rings only.
★ Do not open the opening more than 7 mm
Case alignment side:
when installing the snap ring.
Grease the LG-6.
Tightening torque of mounting

bolts:
98 to 123 Nm (10 to 12.5 kgm)
11. Install No. 1 planetary gear carrier assembly

(3). Install No. 1 sun gear (2).
9. Assemble the No. 1 planetary gear carrier.

Install 3 shafts (8) on carrier (3), and use a
hammer and insert the stopper pin into shaft
(8) through the hole of carrier (3).
★ After pin insertion, crimp two outer edge
positions of the carrier pin.
12.
Machinery case: 1.3 liters (E010-CD)
★ Refill the oil until it reaches the top sur-

face of No. 1 planetary gear snap ring.
13. Install swing motor assembly (1), and tighten
the 5 mounting bolts to the specified torque.
Tightening torque of bolts:
98 to 123 Nm (10 to 12.5 kgm)
PC58UU-3 30-47
2
DISASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY

1. Remove O-ring (2) from the bottom of center 4. Use tool T and pull out shaft (5) from rotor
swivel joint assembly (1). (7).
2. Remove snap ring (3) using snap ring pliers. 5. Remove shaft (5) from rotor (7), and remove
dust seal (8). Remove 15 nipples (9) from the
rotor and shaft.
★ Record the position and direction of each
nipple so that you can reassemble them
correctly.
3. Remove spacer (4), and remove 4 plugs (6)

from shaft (5). Also, remove one similar plug
from the head of shaft (5).
6. Remove one O-ring (10) and 8 slipper seals

(11) from the inside of rotor (7).
30-48 PC58UU-3
2
12
ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY
1. Install one O-ring (10) and 8 slipper seals (11) ★ After assembling the joint, seal the nip-
inside the rotor (7). ples and elbows by covering them with
★ Take care not to scratch the O-ring during polyethylene caps.
assembly.
★ Clean all parts carefully. Make sure all for-
eign matter is removed.
4. Install spacer (4) at the bottom of rotor (7).
2. Install 4 plugs (6) at the bottom of shaft (5),

and install 1 plug (12) at the top of the shaft.
Install dust seal (8) on shaft (5), and assemble
shaft (5) in rotor (7).
★ Wash, degrease and dry the plug and the
mounting section of the assembly.
Entire surface of plug screws:

Grease the LG-5.
Tightening torque:
32 ± 13 Nm (3.3 ± 1.3 kgm) for plug (6) 5. Use snap ring pliers and install snap ring (3)
16.7 ± 2.9 Nm (1.7 ± 0.3 kgm) for plug (12) at the bottom of rotor (7), and install O-ring
(2).
★ Coat G0-L1 or G2-L1 grease on the contact ★ Make sure that the snap ring has fallen
surface of the dust seal lip, the rotor and into the groove.
the shaft.
★ Use a plastic hammer or equivlent, and
slightly tap the shaft to insert it into the
rotor. Take care not to damage the O-
ring.
3. Install 15 nipples (9) on shaft (5) and rotor (7).
PC58UU-3 30-49
2
DISASSEMBLY AND ASSEMBLY IDLER CUSHION ASSEMBLY
12
DISASSEMBLY OF IDLER CUSHION ASSEMBLY
1. Remove valve (1), and remove piston rod (2). 3. Gradually release the hydraulic pressure to
expand the recoil spring, and remove bracket
(5) and spring (6) from cylinder (7).
★ Spring free length: 302 mm
2. Install tool M on the recoil spring. Compress

the spring by gradually increasing the
hydraulic pressure of the tool. Remove lock
bolt (3) and remove nut (4).
WARNING!Install tool M correctly on 4. Remove snap ring (8), spacer (9), dust seal
the recoil spring. The spring is (11), O-ring (12) and ring (13) from cylinder
compressed by a large force. This is a (10).
dangerous operation if the tool is set
incorrectly.
★ Compress the recoil spring until you can

loosen the nut.
★ Spring compression force:
26.9 kN (274.8 kg)
30-50 PC58UU-3
2
DISASSEMBLY AND ASSEMBLY IDLER CUSHION ASSEMBLY
12
ASSEMBLY OF IDLER CUSHION ASSEMBLY
1. Attach ring (13), O-ring (12), dust seal (11), 3. Slowly apply oil pressure using tool M and
spacer (9) and snap ring (8) to cylinder (10). tighten the spring, then attach nut (4) and
★ Make sure that the snap ring is securely in tighten lock bolt (3).
the groove.
WARNING! Make sure that it is
securely set because the installing
load of the spring is large.
Lock bolt: apply LT-2
★ Spring installation height (mm)
Rubber shoe Road liner, Iron shoe
202.2 238.2
2. Attach spring (6) and bracket (5) to the cylin- ★ Spring installation load (kN(kg))
der and set it on the press table.
Rubber shoe Road liner, Iron shoe
42.4 {4,326} 26.9 {2,748}
★ Assemble the cylinder so that the lock

bolt is fastened from above.
PC58UU-3 30-51
2
DISASSEMBLY AND ASSEMBLY INSTALLATION OF IDLER ASSEMBLY
12
4. After assembling the recoil spring to cylinder INSTALLATION OF IDLER
(7), confirm that the parallelism of surface a
of cylinder (7) and the surface b of bracket (5) ASSEMBLY
is 0.5 mm or less.
1. Press fit two bushings (10) onto idler (9) using
tool L1.
★ Clean the bushings thoroughly so that no
contaminants, chips or burrs remain.
5. Install valve (1).

★ Tighten the valve, then turn it back
approximately 2 turns in order to drain
grease out of grease drain hole c. Pour
approximately 120 cc of G2-L1 grease into
the cylinder. Insert piston rod (2) into the
cylinder. Insert the piston rod until the 2. Install two floating seals (8) to idler (9) using
grease comes out of c (so that no air tool L2.
remains in the cylinder). When the grease
★ Clean the O-ring and the contacting sur-
comes out, tighten valve (1).
face of the O-ring, and let them dry after
★ After tightening the valve, confirm that degreasing thoroughly.
the grease fitting faces the outer side of
★ Apply engine oil (EO30-CD) to the sliding
the machine body.
surface of the floating seal, making sure
that there are no contaminants.
30-52 PC58UU-3
2
DISASSEMBLY AND ASSEMBLY INSTALLATION OF IDLER ASSEMBLY
12
3. Install floating seal (7) to supports (3) and (6) 5. Install the support shaft assembly (4) onto the
using tool L2. idler (9). Pour engine oil into the idler.
face, and let them dry after degreasing Idler: approximately 20 cc (EO30-CD)
thoroughly. Attach support (3) to the shaft and
★ Apply engine oil (EO30-CD) to the sliding tighten it to the specified torque.
that there are no contaminants. Lock bolt: apply LT-2
Attach bracket (2).
4. Install the O-ring on shaft (5), then install it in
the support (6). Insert the lock bolt for the
shaft and tighten it to the specified torque. Mounting bolt: apply LT-2
Mounting bolt: apply LT-2 Mounting bolt:

90.8 Nm (10.0-12.5 kgm)
Install cover (1).
PC58UU-3 30-53
2
DISASSEMBLY AND ASSEMBLY INSTALLATION OF TRACK ROLLER ASSEMBLY
12
INSTALLATION OF TRACK ROLLER ASSEMBLY
1. Press fit two bushings (7) onto the roller (6) 4. Install the O-ring to shaft (3), and install it on
using tool L3. the roller. Install collar (2) to shaft (3) and fas-
★ Clean the bushing shaft thoroughly so ten it with a snap ring. Fill roller (6) with gear
that no contaminants, chips or burrs oil.
remain.
Inside the roller: 135 cc (GO140)
2. Install two floating seals (5) using tool L4.
★ Clean the O-ring and the contacting sur- Install collar (1) to shaft (3) and fasten it with a
face of the O-ring, and let them dry thor- snap ring.
oughly after degreasing.
★ Apply engine oil (EO30-CD) to the sliding
that there are no contaminants.
★ Make sure that the track roller assembly

with the track frame attached rotates at
163.5 Nm (16.7 kgm) or lower.
3. Install floating seal (4) to collars (1) and (2)

using tool L4.
face of the O-ring, and let them dry thor-
oughly after degreasing.
30-54 PC58UU-3
2
DISASSEMBLY AND ASSEMBLY INSTALLATION OF CARRIER ROLLER ASSEMBLY
12
INSTALLATION OF CARRIER ROLLER ASSEMBLY
★ Clean the insides of each part and the parts to 3. Install shaft (3) into roller (5). Attach snap
be installed so that no contaminants, chips or ring (2) to shaft (3) using snap ring pliers.
burrs remain. ★ Install the snap ring so that its interior
edge is attached to the tip of the shaft,
1. Press fit two ball bearings (6) in roller (5) and confirm that it is securely in the
using tool L5. groove.
Fill the ball section of bearing (6) with grease
(Albania EP-2 or equivalent). 4. Press fit cap (1) using tool L7.
★ Cap press fit depth a: 10 mm
2. Press fit dust seal (4) onto roller (6) using tool
L6. Fill roller (7) with grease.
Grease in the roller:

30 cc (Albania EP-2 or equivalent)
PC58UU-3 30-55
2
DISASSEMBLY AND ASSEMBLY INSTALLATION OF HYDRAULIC CYLINDER ASSEMBLY
12
INSTALLATION OF HYDRAULIC CYLINDER ASSEMBLY
★ Apply engine oil to the sliding surface of each 4. Set piston ring (8) on tool U6 and widen it by
part. Take care not to damage the packing, turning the handle 8 to 10 times.
dust seal or O-ring.
★ Do not forcibly insert the backup ring. Heat 5. Retract piston ring (8) using tool U7.
the backup ring in hot water approximately ★ Tool and cylinder combination
(50 to 60°C), then insert it. U7: boom/blade cylinder
U9: arm/offset cylinder
1. Press fit bushing (14) into the cylinder head U10: bucket cylinder
using tool U4. (U8: for second boom cylinder)
2. Install dust seal (12) using tool U5.
6. Install wear ring (7).

★ Take care not to widen the abutment joint
3. Secure dust seal (12) using snap ring (11). of the ring too much.
Install rod packing (13), then install O-ring
(10) and backup ring/O-ring (9).
30-56 PC58UU-3
2
DISASSEMBLY AND ASSEMBLY INSTALLATION OF HYDRAULIC CYLINDER ASSEMBLY
12
7. Install head assembly (2) and piston assem- 9. Set the cylinder on tool U1. Install piston rod
bly (6) to piston rod (5). assembly (3).
★ Press the piston rod in, fully.
8. Set piston rod assembly (3) on tool U1.

Tighten nylon nut (4) using tool U3. 10. Using either a hydraulic pump or a power
★ After cleaning and degreasing the nut and wrench, tighten head assembly (2) with tool
the screw of the piston rod, apply an U2.
adhesive compound to the piston rod
screw and tighten it. Piston nut: see below
Piston rod screw: Loctite N262

Loctite Japan product equivalent Cylinder name Nut tightening torque
Boom 735 ± 73.5 kNm {75 ± 7.5 kgm}

Piston nut: see below
Arm 764 ± 76.4 kNm {78 ± 7.8 kgm}
Tighten up to 863 kNm {88 kgm}
Cylinder name Nut tightening torque
Bucket Loosen up to 0 Nm {0 kgm}
Boom 1.67 ± 0.17 kNm {170 ± 17.0 kgm} Tighten up to 863 kNm {88 kgm}
Arm 1.67 ± 0.17 kNm {170 ± 17.0 kgm} Offset 676 ± 67.6 kNm {69 ± 6.9 kgm}
Bucket 1.42 ± 0.14 kNm {145 ± 14.5 kgm} Blade 863 ± 86.5kNm {88 ± 8.8 kgm}
Offset 1.42 ± 0.14 kNm {145 ± 14.5 kgm}
Blade 1.42 ± 0.14 kNm {145 ± 14.5 kgm}
★ Thoroughly bleed air during the first oper-

ation after assembling the cylinder. For
the first 3 to 5 strokes, do not relieve both
extending and retracting sides of the cyl-
inder at the strokes end.
PC58UU-3 30-57
2
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF WORK EQUIPMENT VALVE (NOTES)
12
ASSEMBLY OF WORK EQUIPMENT VALVE (NOTES)
★ Assemble and disassemble hydraulic preci-
sion parts in a clean environment.
WARNING! Take care not to injure your-

self on the edges of the machine parts.
★ Check the contacting surfaces of all parts. If

there are scratches or sharp edges, replace
them with new parts to avoid trouble. Also,
take precautionary measures to avoid dent or
damage caused by dropping or contact.
★ Clean all metal parts with solvent and let
them air dry. Do not use cloth or paper since
it may cause particles to enter the product
and contaminate the hydraulic system,
thereby causing trouble.
★ As a general rule, install new consumable
parts such as O-rings or seals. Also, apply a
small amount of clean grease to parts such as
O-rings.
1. Tighten the guide valve on the valve assem-

bly to the specified torque
(1) cover, (2) swing valve, (3) blade valve, (4)
offset valve, (5) bucket valve, (6) arm valve,
(7) boom valve, (8) pump merge-divider
valve, (9) R.H. travel valve, (10) L.H. travel
valve, (11) block, (12) centralized safety valve,
(13) suction safety valve, (14) main relief 2. Centralized safety valve details
valve, (15) suction valve. Nut (30), nut (31), spacer (32), O-ring (33),
spring (34), poppet (35), plug (36), O-ring (37),
Centralized safety valve (12): seal (38), seat (39), piston (40), spring (41),
137 - 157 Nm {14 - 16 kgm} poppet (42), seal (43), sleeve (44), O-ring (45),
ring (46), O-ring (47).
Main relief valve (14):
49 - 58.8 Nm {5 - 6 kgm}
Twelve suction safety valves (12)

and suction valves (15):
39.2 - 49 Nm {4 - 5 kgm}
30-58 PC58UU-3
2
12
3. Suction safety valve details 5. Suction valve details
Nut (48), nut (49), spacer (50), O-ring (51), Sleeve (82), O-ring (83), spring (84), seal (85),
spring (52), poppet (53), plug (54), O-ring (55), valve (86).
seal (56), spring (57), piston (58), seal (59),
poppet (60), sleeve (61), sleeve (62), O-ring
(63).
6. Apply one drop (approximately 0.02 g) of Loc-

tite to plugs (16) to (22) of the spool and
tighten them.
4. Main relief valve details Degrease the screws of the plug and the
Nut (64), nut (65), spacer (66), O-ring (67), spool thoroughly using Drysol or the like and
spring (68), poppet (69), plug (70), O-ring (71), let them dry.
seal (72), seat (73), piston (74), spring (75), ★ Do not apply pressure for at least two
poppet (76), seal (77), sleeve (78), O-ring (79), hours after tightening the plugs.
ring (80), O-ring (81). ★ Make sure that the spool is assembled in
the correct direction.
Plug screw: Loctite (No. 638)
Plug:
14.7 - 19.6 Nm {1.5 - 2.0 kgm}
PC58UU-3 30-59
2
12
7. Tighten the mounting bolt of spring case (23) 10. Always tighten or loosen the 9 mounting
and plate (24) to the specified torque. bolts (87) on each spool of the retainer of the
spool return spring with spool (88) in the
Mounting bolt: valve chest (89)(to avoid deformation).
9.8 - 12.7 Nm {1 - 1.3 kgm}
6.9 - 9.8 Nm {0.7 - 1.0 kgm}
8. Tighten plugs (25) and (26) of each valve to

the specified torque.
11. Apply one drop (0.02 g) of Loctite before
Plug: 47 - 58.8 Nm {4.8 - 6 kgm} installing plug (91) on the lower surface of
swing valve (90).
★ Degrease and dry the plugs and screws of
the valve chest thoroughly using Drysol
or similar products.
★ Do not apply pressure for at least two
hours after tightening the plugs.
Plug screw: Loctite No. 638
Nut:
1.3 - 1.7 Nm {0.13 - 0.17 kgm}
9. Tighten the mounting bolt of valve cover (27)

and stud bolt (29) and the nut to valve block
(28) to the specified torque.
Bolt and nut:

29.4 - 34.3 Nm {3 - 3.5 kgm}
30-60 PC58UU-3
2
90 OTHERS
HYDRAULIC CIRCUIT DIAGRAM ................... 90- 3

HYDRAULIC CIRCUIT DIAGRAM
(ADDITIONAL ATTACHMENT CIRCUIT)......... 90- 5
ELECTRICAL CIRCUIT DIAGRAM (1/2)
Serial No.: 20001 – 20423........................... 90- 7
Serial No.: 20001 – 20423........................... 90- 9
Serial No.: 20424 – 22000............................90-11
Serial No.: 20424 – 22000........................... 90-13
Serial No.: 22001 and up............................. 90-15
Serial No.: 22001 and up............................. 90-17
PC58UU-3 90-1
(5)
HYDRAULIC CIRCUIT DIAGRAM
1: For Serial No. 22001 and up
PC58UU-3 90-3
(7)
+<'5$8/,&&,5&8,7',$*5$0
)RU6HULDO1RDQGXS
$'',7,21$/$77$&+0(17&,5&8,7
3&88

(/(&75,&$/&,5&8,7',$*5$0
6HULDO1R±
3&88

(/(&75,&$/&,5&8,7',$*5$0
6HULDO1R±
3&88

(/(&75,&$/&,5&8,7',$*5$0
6HULDO1R±
3&88

(/(&75,&$/&,5&8,7',$*5$0
6HULDO1R±
3&88

(/(&75,&$/&,5&8,7',$*5$0
6HULDO1RDQGXS
3&88

(/(&75,&$/&,5&8,7',$*5$0
6HULDO1RDQGXS
3&88

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SEBM023907

MACHINE MODEL SERIAL NUMBER

PC58UU-3 20001 and up

• PC58UU-3 mounts the 4D88E-3G and 4D88E-5XBB engine.

10 STRUCTURE, FUNCTION AND MAINTENANCE

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

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

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

( ) Page to be deleted Discard

Pages having no marks are those previously revised

LIST OF REVISED PAGES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Slinging near the edge of the hook may cause

• If a part cannot be smoothly removed from the

★ The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

k Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

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

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

2) After inserting the hose in the mating adapter

• Used to prevent rubber gaskets, rub-

Holtz • Used as heat-resisting sealant for re-

• Features: Silicone type, heat resist-

LM-G 09940-00051 60 g Can • Used as lubricant for sliding portion

SYG2-400CA • Used for normal temperature, light

Molybdenum • Used for heavy load portion

SUNSTAR • Used as primer for cab side

SUNSTAR • "S" is used for high-tempera-

SUNSTAR • Used to seal joints of glass

STANDARD TIGHTENING TORQUE

6 10 11.8 – 14.7 1.2 – 1.5

16 24 235 – 285 23.5 – 29.5

27 41 1150 – 1440 118 – 147

6 10 5.9 – 9.8 0.6 – 1.0

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 ± 4.9 2.5 ± 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

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

02 14 35 – 63 {3.5 – 6.5} 44 {4.5}

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

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

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

TIGHTENING TORQUE FOR 102 ENGINE SERIES

ELECTRIC WIRE CODE

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal