SM Pw170es-6k-962
SM Pw170es-6k-962
SM Pw170es-6k-962
Shop
Manual
HYDRAULIC EXCAVATOR
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
10-I
STRUCTURE AND FUNCTION ENGINE RELATED PARTS
6 7 10 i4 8 9
D-D
A-A H-H
B-B c-c
1o-2
STRUCTURE AND FUNCTION RADIATOR. COOLER. AFTERCOOLER
/
6
1o-3
STRUCTURE AND FUNCTION POWER TRAIN
1 2 3 4 5 6
IO-4
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
1o-5
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
SPECIFICATIONS
1O-6
STRUCTURE AND FUNCTION SWING MACHINERY
OPERATION
From brake valve return
1) When swing brake solenoid valve is
deactivated
When the swing brake solenoid is deactivated,
the pressurized oil from the PPC pressure re-
ducing valve is shut off and port B is connected
to the tank circuit.
Because of this, brake piston (2) is pushed
down in the direction of the arrow by brake
spring (I), so disc (3) and plate (4) are pushed
together and the brake is applied.
2) When swing brake solenoid valve is excited From brake valve return
When the swing solenoid valve is excited, the
valve is switched, and the pressurized oil from
the PPC pressure reducing valve enters port B
and flows to brake chamber “a”.
The pressurized oil entering chamber “a” over-
comes the force of brake spring (I), and brake
piston (2) is pushed up in the direction of the
arrow. Because of this, disc (3) and plate (4)
separate, and the brake is released.
1. Brake spring
2. Brake piston
3. Disc
4. Plate
1o-7
STRUCTURE AND FUNCTION UNDERCARRIAGE
UNDERCARRIAGE
KW13OP6002 KW13OP6003
1. Undercarriage 6. Propshaft
2. Step 7. Travel motor
3. Wheel chock 8. Transmission
4. Front oscillating steering axle 9. Double wheel ass’y
5. Rear axle 10. Single wheel ass’y
1O-8
STRUCTURE AND FUNCTION TRANSMISSION
1o-9
STRUCTURE AND FUNCTION CLUTCH
STRUCTURE
TRANSMISSION
SWIVEL P --
Bar
FRONT REAR
TRAVEL TRAVEL
MOTOR TRANSMISSION MOTOR
1O-9A
STRUCTURE AND FUNCTION CLUTCH
FUNCTION
1O-9B
STRUCTURE AND FUNCTION AXLE
AXLE
OUTLINE
. Each axle consists of an axle housing support-
ing the chassis weight, a differential set in the
axle housing, a final drive, and a brake provided
at each and.
FRONT AXLE
Kw13OP6005
IO-IO
STRUCTURE AND FUNCTION AXLE
REAR AXLE
x KW13OP6006
IO-I 1
STRUCTURE AND FUNCTION AXLE
FRONT AXLE
Kw13OP6007
2
IO-12
STRUCTURE AND FUNCTION AXLE
REAR AXLE
IO-13
STRUCTURE AND FUNCTION SUSPENSION LOCK CYLINDER
KW13OP6009
1. Barrel Specifications
2. Plunger
Piston: 01 OOmm
Stroke: 155mm
Operating pressure: 40.0 MPa (408 Kg/cm’)
Pilot pressure: 3.0 MPa (30.6 Kg/cm”)
Max 5.0 MPa (51 .O Kg/cm*)
IO-14
SUSPENSION LOCK CYLINDER
CIRCUIT
Purpose Function
The undercarriage of wheeled hydraulic excavators The oscillating axle (3) is mounted in bearing (2) in
have one of the two driven axles oscillating the middle of the excavator. The two rams (1) which
mounted. This makes it possible to fully utilize the are full of hydraulic oil are connected through pipe-
excavator’s rimpull in rough terrain - all of the wheels lines to the oscillation lock solenoid valve (4).
being constantly in contact with the ground. When the excavator is being moved, the oscillation
An oscillating blocking ram is fitted on each side of lock solenoid valve should be de-energized so that
the undercarriage to block the axle during digging or the hydraulic oil in the ram can be returned to tank
lifting work. as the axle is oscillating up and down. Before com-
Blocking the axle increases the excavator’s stability. mencing excavating operations, the oscillation lock
solenoid valve should be energized to pressurize
1. Ram the oil in the rams. This will lock the axle in the posi-
2. Axle oscillating point tion it is in.
3. Oscillating axle
4. Oscillation lock solenoid valve
5. PPC pressure reducing valve
6. Hydraulic tank
7. Swivel joint
---
IO-15
STRUCTURE AND FUNCTION BRAKING TRAIN
BRAKING TRAIN
Brake valve
Priority valve
I
Gear pump
Engine
Accumulator
Diesel
P
Tank
Filter
\
Linkage
IO-16
STRUCTURE AND FUNCTION
BRAKE PEDAL
BRAKE PEDAL
KW13OP6012
IO-17
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
DS2
DSI P N
/ DS3
‘DS2
s2 DS2
DS2
Kw13OP6013
IO-18
STRUCTURE AND FUNCTION ACCUMULATOR FOR BRAKE SYSTEM
Specifications
IO-19
STRUCTURE AND FUNCTION STEERING TRAIN
‘EERING TRAIN
d
P
/-L.---L
L,s! q
-.
I
;
rr -IL :--
b
\ .._-- --
d‘ ‘i :
4 I’--
I
5 :\7--
- - i
1 O-20
STRUCTURE AND FUNCTION STEERING TRAIN
ITEM
POSITIONS
3. PRIORITY VALVE
CONTROL SPRING PRESSURE 7 bar
NORMAL
I= CYL.VOL = 748 cm3 = 3.8 TURNS
PUMPVOL 195 cm3
EMERGENCY
I= CYL.VOL = 748 cm3 = 10.7 TURNS
PUMP.VOL 70 cm3
IO-21
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Gaiter
4. Pedal
5. Hose
6. Orbitroll valve
7. Mounting bracket
1o-22
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
, I 4-OUTRIGGER
c------_
IJ J
1 1 I ’
I I
,qDR__:‘:_J I
REAR DOZER
,r - - - - - - J
I I
2-OUThGGER
Z-OUTRIGGER
-I-,DR'
i '
1O-23
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
Al
-
TI
a! _
----/<----
_ - - - ,‘OC
r02
ro2
- - - -
F-I-
_I
_ _ _p,q
1
I’
I
------ ------___
------ 5,0; - - - - - - _ , l-l ;i
A3
AA__----_/_------__h r02 II ,I
1’ I’ LL
!! II ,’
,_-_._.. I, L-_-e--I-d-----
;,A_ - ~ ro2
‘-S ; (Mlu vu*)
II
II
warl
& ’
T
~lo,Go,yD, _.I pq_
P,, - 1
_ I r - - - - - I-3 -+
r-
- 8
44
-‘mr’m I I
-lmmlpP, ,,
Il
II
~ ;I ~
; _
1 O-23A
STRUCTURE AND FUNCTION HYDRAULICTANK
HYDR AULICTANK
7 6 3
/, Fl
5
1. Hydraulic tank Specifications
2. Bypass valve Tank capacity:
3. Oil filter cap Amount of oil inside tank:
4. Sight gauge Pressure valve
5. Suction strainer Relief cracking pressure: 0.038 f 0.015 MPa
6. Filter element (0.39 f 0.15 kg/cm’)
7. Bypass strainer Suction cracking pressure: 0 - 0.0045 MPa
(0 - 0.046 kg/cm”)
Bypass valve set pressure: 0.103 f 0.02 MPa
(1.05 f 0.2 kg/cm’)
1O-24
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
,e
a b
1O-25
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
1. Operation of pump
1) cylinder block (7) rotates together with
shaft (l), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle a be-
tween center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle a is called the swash plate
angle.)
1 O-26
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PP
If swash plate angle a becomes larger, the dif- . Piston (14) moves in a reciprocal movement
ference in volumes E and F becomes larger and (t+) according to the command from the
discharge volume Q increases. TVC*LS valve and the spring force.
Swash plate angle a is changed by positioning . Main pump discharge pressure (self-pressure)
piston (12) and return piston (14). PP is always connected to the chamber receiv-
Servo piston (12) moves in a reciprocal move- ing the pressure on piston (12) end. (the self-
ment (-) according to the spring force and pressure is brought in).
pump output pressure. . Output pressure PEN of the LS valve is brought
This straight line movement is transmitted to the chamber receiving the pressure at piston
through rod (13) and (15) to rocker cam (4), and (14) end.
rocker cam (4), which is supported by the cylin- . The relationship between piston (12) and piston
drical surface to cradle (2), moves in a swinging (14) controls swash plate (4) angle.
movement on the cylindrical surface in (direc-
tion).
1 O-27
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1 O-28
STRUCTURE AND FUNCTION HYDRAULIC PUMP
1o-29
STRUCTURE AND FUNCTION HYDRAULIC PUMP
2. TVC. LS valve
I I \
: 654 ;A i
IO-30
STRUCTURE AND FUNCTION HYDRAULIC PUMP
FUNCTION
1. LS VALUE
. The LS valve detects the load and controls the a
E PSIG = 2.94 MPa (30 kg/m-+)
discharge amount. Lz
This valve controls main pump discharge s
amount Q according to differential pressure &
APLS (=PP - PLS) (the difference between ;
z
main pump pressure PP and control valve out- ::
5
let port pressure PLS) (called the LS differential
2
pressure). I? I ’
. Main pump pressure PP, pressure PLS (called 0.64 (6.5) 2.55 (26) UvlPa (kg/cm91
the LS pressure) coming from the control valve LS differential pressure PLS
output, and pressure PSIG (called the LS se-
lection pressure) from the proportional solenoid
vlve enter this valve. The reletionship between
discharge amount Q and differential pressure
APLS, (the difference between main pump
pressure PP and LS pressure PLS) (=PP -
PLS) changes as shown in the diagram on the
right according to LS selector pressure PSIG.
. When PSIG changes between 0 and 2.94 MPa
(0 and 30 kg/ cm”), the spool load changes ac-
cording to this, and the selector point for the
pump discharge amount changes at the rated
central value between 0.64 and 2.55 MPa (6.5
and 26 kg/cm”).
2. TUC VALUE
. When the pump discharge pressure PP
(selfpressure) is high, the TVC valve controls
the pump so that no more oil than the constant
flow (in accordance with the discharge pres-
sure) flows even if the stroke of the control valve
becomes larger. In this way it carries out equal
horsepower control so that the horsepower ab-
sorbed by the pump does not exceed the en-
gine horsepower.
. In other words, if the load during the operation
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount
from the pump; and if the pump discharge pres-
sure drops, it increases the discharge amount
from the pump. The relation between the pump Pump discharge pressure PP
discharge pressure PP and pump discharge
amount Q is shown on the right, with the current
given to the TVC valve solenoid shown as a pa-
rameter. However, in the heavy-duty operation
mode, there are cases where it is given the
function of sensing the actual speed of the en-
gine, and if the speed drops because of an in-
crease in the load, it reduces the pump dis-
charge amount to allow the speed to recover. In to the TVC valve solenoid from the controller in-
other words, when the load increases and the creases according to the drop in the engine
engine drops below the set value, the command speed to reduce the pump swash plate angle.
1o-31
STRUCTURE AND FUNCTION HYDRAULIC PUMP
OPERATION
! T-
,2
IO-31A
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PLS
Maximum direction
202FO6035
IO-31B
STRUCTURE AND FUNCTION HYDRAULIC PUMP
PLS PSIC
b. \
j
r--L
6
Minimum direction
202FO6036
lo-31c
STRUCTURE AND FUNCTION HYDRAULIC PUMP
NC valve
PLS
-%i 8
202FO6037
. Let us take the area receiving the pressure at At this point, the relationship between the area
the large piston diameter end as Al, the area receiving the pressure at both ends of piston (1)
receiving the pressure at the small diameter is AO:Al = 1:2, so the pressure applied to both
end as AO, and the pressure flowing into the ends of the piston when it is balanced becomes
large piston diameter end as Pen. If the main Pp: Pen = 2:l.
pump pressure Pp of the LS valve and the corn- The position where spool (4) is balanced and
bined force of force F of spring (3) and LS pres- stopped is the standard center, and the force of
sure PLs are balanced, and the relationship is spring (3) is adjusted so that it is determined
A0 x Pp = Al x Pen, servo piston (1) will stop in when Pp - PLs = 2.11 MPa (21.5 kg/cm’). How-
that position, and the swash plate will be kept at ever, if Psig (the output pressure of 0 - 2.94
an intermediate position. (It will stop at a posi- MPa (0 - 30 kg/cm’) of the EPC valve of the LS
tion where the opening from port b to port c and valve) is applied to port e, the balance stop po-
from port d to port c of spool (4) is approxi- sition will change in proportion to pressure Psig
mately the same.) between Pp - Pls = 2.11 t+ 0.637 MPa (21.5
t+ 6.5 kg/cm’).
IO-31D
STRUCTURE AND FUNCTION CIRCUIT DIAGRAM
202FO6038 202FO6139
2. TVC valve
1) When pump controller is normal
a. When the load on the actuator is small and l The size of command current X is determined
pump pressure Pp is low by the nature of the operation (lever operation),
(1) Movement of solenoid (1) the selection of the working mode, and the set
. The command current from the pump controller value and actual value for the engine speed.
flows to solenoid (1). This command current
changes the internal force pushing solenoid
push pin (11).
. On the opposite site to the force pushing this
solenoid push pin (11) is the spring set pres-
sure of springs (3) and (4) and pump pressure
Pp. Piston (2) stops at a position where the
combined force pushing piston (2) is balanced,
and the pressure (pressure of port c) output
from the TVC valve changes according to this
piston.
IO-31E
STRUCTURE AND FUNCTION CIRCUIT DIAGRAM
IO-31F
STRUCTURE AND FUNCTION CIRCUIT DIAGRAM
Minimum direction
I NC
202FO6039 202FO6139
b. When load on actuator is small and pump . If main pressure Pp increases further and pis-
discharge pressure is high ton (2) moves further to the left, main pump
. When the load is large and pump discharge pressure Pp flows to port c and acts to make
pressure Pp is high, the force pushing piston the discharge amount the minimum. When pis-
(2) to the left becomes larger and piston (2) ton (9) moves to the left, piston (5) is moved to
moves to the position shown in the diagram the right by cam (7) and lever (6). For this rea-
above. When this happens, as shown in the dia- son, springs 3 and 4 are compressed and push
gram above, part of the pressurized oil from back piston (2). Because of this force, piston (2)
port b flows out to port d and the pressure oil cuts off the connection from port b to port c,
flowing from port c to the LS valve becomes ap- and and port c and port d are connected. As a
proximately half of main pump pressure Pp. result, the pressure at port c (=f) drops, and pis-
. When port h and port e of the LS valve are con- ton (9) stops moving to the left. The position in
nected (see 1. LS valve), the pressure from port which piston (9) stops when this happens is fur-
f enters the large piston diameter end of servo ther to the left than the position when pump
piston (9), and servo piston (9) stops. pressure Pp is low.
lo-31G
STRUCTURE AND FUNCTION CIRCUIT DIAGRAM
202Fo6040
I
Pump discharge pressure PP
202FO6041
IO-31H
STRUCTURE AND FUNCTION CIRCUIT DIAGRAM
(Maximum direction)
202FO6042 202FO6139
2) When pump controller is abnormal and TVC . If main pump pressure Pp is low, the combined
prolix swiych is “ON” force of the pump pressure and the force of so-
a. When load on main pump is light lenoid (1) is weaker than the spring set force, so
. If there is a failure in the pump controller, turn piston (2) is balanced at a position to the rigft.
TVC prolix switch “ON” to switch to the resistor . At this point, port c is connected to the drain
side. In this case, the power source is taken di- pressure of port d, and the large piston diam-
rectly from the battery. But if the current is used eter end of servo piston (9) also becomes the
as it is, it is too large, so use the resistor to con- drain pressure Pt through the LS valve. When
trol the current flowing to solenoid (1). this happens, the pressure at the small piston
. When this is done, the current becomes con- diameter end is large, so servo piston (9)
stant, so the force pushing solenoid push pin moves in the direction to make the discharge
(11) is also constant. amount larger.
10-311
STRUCTURE AND FUNCTION CIRCUIT DIAGRAM
.,
tJhT
LS valve
A...
/b
-
(Minimum direction)
202FO6043 202FO6139
IO-31J
STRUCTURE AND FUNCTION PPC PUMPLESS SYSTEM
a I ves
35-$ba r A
A T P
- 7 4-.
4 b L -I
n
To orbitroll valve
-A N Sl s3
. .
Q
+ DS2
t-1’ 1
;-_ p _%&&--A III
I -
1
81’
1. Gear Pump.
2. Steering/Braking Priority Valve.
3. Power Brake Valve.
4. Pressure Reducing Valve.
FUNCTION
. The PPC Pumpless system discharges pressu-
rized oil to operate the PPC circuit and solenoid
valve assemblies.
IO-31K
STRUCTURE AND FUNCTION PPC PUMPLESS SYSTEM
OPERATION
. The PPC pumpless system utilises the return
line oil from the power brake valve. Oil is sup-
plied to the steering/braking circuits from a
gear pump driven by the engine. Oil flow is
prioritised to the steering circuit via a priority
valve with the remaining oil flow feeding the
power brake valve.
. The return line from the brake valve passes
through a pressure reducing valve where the oil
pressure is maintained at 35-O/3 bar.This pres-
sure is utilised to charge the PPC circuit.
IO-31L
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
Outline
The following control valve is standard: Pf. Port P6 (from travel REVERSE PPC valve)
. 8-spool valve (includes 2 service valves) Pg. Port P7 (from boom lift cylinder RAISE PPC
valve)
The cross sections shown are for the 6-spool valve Ph. Port P8 (from boom lift cylinder LOWER PPC
(sub assembly) valve)
* The cross-sectional structure of the service Pi. Port P9 (from arm OUT PPC valve)
valve is the same as the structure for the bucket Pj. Port PlO (from arm IN PPC valve)
valve, so refer to the bucket valve for details. Pk. Port Pll (from bucket DUMP PPC valve)
PI. Port P12 (from bucket CURL PPC valve)
General locations and names of ports (common Pm. Port P-l (from boom adjust EXTEND PPC
for each external view diagram) valve)
1. 6-spool valve sub assembly Pn. Port P-2 (from boom adjust RETRACT PPC
2. Cover A (main relief valve) valve)
3. Cover B (unload valve) PO. Port P-3 (from service PPC valve)
4. Arm counterbalance valve Pp. Port P-4 (from service PPC valve)
5. No. 1 service valve
6. No. 2 service valve
1 O-32
STRUCTURE AND FUNCTION CONTROL VALVE
EXTERNAL VIEW
PP PO
Pm
pk
Pi
Pi
Pj
Pg
Ph
Pe
Pf PC
Pd P*
pb bb
a
1
4
ee
6
1o-33
STRUCTURE AND FUNCTION CONTROL VALVE
Cross-sectional drawing
* The cross section is given only for the 6-spool valve (STANDARD). The cross-sectional structure of the
service valves in an 8-spool valve is the same as the structure of the bucket valve, so refer to the bucket
valve for details.
(1 Mark)
(1 Mark)
(2 Marks)
(4 Marks)
Side by Side
(1 Mark)
(4 Marks)
(2 Marks) (2 Marks)
Separated Seoarated
(1 Mark)
(1 Mark)
(3 Marks)
(3 Marks)
A-A Kw13OP6018
1. Pressure compensation valve (swing left) 7. Pressure compensation valve (bucket CURL)
2. Pressure compensation valve 8. Pressure compensation valve (arm IN)
(stabilizer EXTEND) 9. Pressure compensation valve (boom LOWER)
3. Pressure compensation valve 10. Pressure compensation valve
(travel FORWARD) (travel REVERSE)
4. Pressure compensation valve (boom RAISE) 11. Pressure compensation valve
5. Pressure compensation valve (arm OUT) (stabilizer RETRACT)
6. Pressure compensation valve (bucket DUMP) 12. Pressure compensation valve (swing RIGHT)
1o-34
STRUCTURE AND FUNCTION CONTROL VALVE
10
B-B
202rn6051
1 O-34A
STRUCTURE AND FUNCTION CONTROL VALVE
202FO6052
1 O-34B
CONTROL VALVE
STRUCTURE AND FUNCTION
(1 Mark)
(1 Mark)
(1 Mark)
(3 Marks)
(1 Mark)
202FO6053
IO-35
STRUCTURE AND FUNCTION CONTROL VALVE
E-E
F-F 8
12 Kw13OP6019
1 O-36
STRUCTURE AND FUNCTION CONTROL VALVE
6’ H-H ‘5 ‘4
16’ K-K
\
18
\
17
202FO6055
1 O-36A
STRUCTURE AND FUNCTION CONTROL VALVE
202F06056
1 O-36B
STRUCTURE AND FUNCTION CONTROL VALVE
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve
8. Sleeve
9. Adjustment screw
IO. Locknut
202FO6057
SPECIFICATIONS
1o-37
STRUCTURE AND FUNCTION CLSS
CLSS
OUTLINE OF CLSS
Actuators
r------!‘j Contrr
NC valve
Y ! I
I
Return
piston
_
I
I
Tank
Features Structure
. CLSS stands for Closed center Load Sensing l The CLSS consists of a main pump control
System, and has the following features. valve, and actuators for the work equipment.
. The main pump body consists of the pump it-
1) Fine control not influenced by load. self, the TVC valve and the LS valve.
2) Control enabling digging even with fine control.
3) Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations. Energy saving
using variable pump control.
1 O-38
STRUCTURE AND FUNCTION CLSS
BASIC PRINCIPLE
1) Control of pump swash plate angle
. The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS
is constant. LS differential pressure APLS, which is the differential pressure between pump discharge
pressure PP and LS pressure PLS (actuator load pressure) at the outlet port of the control valve (LS
differential pressure APLS = Pump discharge pressure PP - LS pressure PLS).
. If LS differential pressure APLS becomes lower than the set differential pressure of the LS valve, the pump
swash plate angle becomes greater, and if it becomes higher, the pump swash plate angle becomes
smaller.
Actuator
APLS I 1
P 1
I .---- L--- :I
I I pressure
I , small(Low) !1
Small current + 1Large current :1
II
T T
I ’ I- Y" I I
llil
TVC valve -I 11 I I
I I I I
I I I I
I I I I
._c I I
I I
,, ,‘-
I I
II--
---I I I
I I I I
II I I
II I I
II I I
I I
Q max. Q min.
7+qy7-~~~?J
Piston
positioning
1o-39
STRUCTURE AND FUNCTION CLSS
Load
1O-40
STRUCTURE AND FUNCTION CLSS
I
1
: wo2 Ps
I _ <-_____ _
_a-__P,
to2 __L
1 ’
1 :
A
V
IO-41
STRUCTURE AND FUNCTION CLSS
1. Unload valve
(LS pressure + 3.92 MPa (40 kg/cm’))
2. Safety-suction valve
(33.77 MPa (365 kg/cm’) - Arm,
Bucket, Second Boom)
(33.32 MPa (340 kg/cm’) - Boom)
3. Pressure compensation valve
4. LS shuttle valve
5. Suction valve
6. Main relief valve
(normal: 31.85 MPa (325 kg/cm’),
When pressure rises:
34.79 MPa (355 kg/cm’))
7. Lift check valve
8. Bypass check valve
9. LS select valve
1 O-42
STRUCTURE AND FUNCTION CLSS
1) Unload valve
Function
1. When the control valve is at neutral, pump discharge amount Q discharged by the minimum swash plate
angle is eleased to the tank circuit. When this happens, pump discharge pressure Pp is set at 3.92 MPa (40
kg/cm’) by spring (3) inside the valve. (LS pressure PLS: 0 MPa (0 kg/cm”).
PLS
202FOf3.363
Operation
1o-43
STRUCTURE AND FUNCTION CLSS
2. During fine control of the control valve, when the demand flow for the actuator is within the amount dis-
charged by the minimum swash plate angle of the pump, pump discharge pressure Pp is set to LS pressure
Pls + 3.92 MPa (40 kg/cm”). When the differential pressure between pump discharge pressure Pp and LS
pressure Pls reaches the load of spring (3) 3.92 MPa (40 kg/cm’), the unload valve opens, so LS differential
pressure APls becomes 3.92 MPa (40 kg/cm”).
PLS
\
pp.
202FO6064
Operation
1o-44
STRUCTURE AND FUNCTION CLSS
3. When the control valve is being operated and the demand flow for the actuator becomes greater than the
pump discharge from the minimum swash plate angle, the flow of the oil out to tank circuit T is cut off, and
all of pump discharge Q flows to the actuator circuit.
PLS.
PP.
202FO6065
Operation
1o-45
STRUCTURE AND FUNCTION CLSS
2) Introduction of LS pressure
+ The diagram shows the condition for arm IN.
7.
SLPOO210
Operation
. When spool (2) is operated, the pump pressure
passes through introduction hole a, enters port
and is taken to the LS circuit. When the pump
pressure rises and reaches the load pressure
of port B, ball valve (5) opens.
1 O-46
STRUCTURE AND FUNCTION CLSS
3) LS bypass plug
Outline
1. This releases the residual pressure of LS pressure Pk.
2. This make the speed of the rise in pressure of LS pressure Pls more gentle. In addition, with this discarded
throttled flow, it creates a pressure loss in the throttled amount of the spool or shuttle valve, and increases
the stability by lowering the effective LS differential pressure.
202FO6067
Operation
. The pressurized oil for LS circuit Pls passes 1. LS bypass plug
from clearance filter a (formed by the clearance
between LS bypass plug (1) and the valve Pls: LS circuit (pressure)
body) through through orifice b and flows to the T: Tank circuit (pressure)
tank circuit.
1o-47
STRUCTURE AND FUNCTION CLSS
.6
/
SLPOO212
1 O-48
STRUCTURE AND FUNCTION CLSS
- 6
.B
1o-49
STRUCTURE AND FUNCTION CLSS
3C4 B
SLPOOZ14
1O-50
STRUCTURE AND FUNCTION CLSS
SLPOO215
<For travel>
. No holding pressure is generated at port A in
the travel circuit, so a pressure compensation
valve without a shuttle valve is used.
SBPOO216
LS pressure
1o-51
STRUCTURE AND FUNCTION CLSS
Function
. The pressure compensation valve determines the compensation characteristics by carrying out fine adjust-
ment of the area ratio (A2/Al) between area A2 of piston (3) and area Al of valve (4) to match the charac-
teristics of each actuator.
202FO6076
IO-52
STRUCTURE AND FUNCTION CLSS
/ \
48 8 4A
SLPOO220
1o-53
CLSS
STRUCTURE AND FUNCTION
s LPOO221
1o-54
STRUCTURE AND FUNCTION CLSS
38
11 t
4B-
205FO6O60
1o-55
STRUCTURE AND FUNCTION CLSS
10
d i
205FO6061
Operation
. The cylinder bottom pressure enters port F and
pushes piston (6) to the left. Spool (7) moves
fully to the left and interconnects port C of re-
generation circuit (11) and tank drain circuit
(10). As a result, the pressure loss in the drain
circuit is reduced.
1 O-56
STRUCTURE AND FUNCTION CLSS
cylinder bonom
205FO6062
1. Piston Operation
2. Spool . During arm IN operations, if the actuating pres-
3. Spring sure at the arm cylinder bottom rises, the pres-
4. Check valve sure at port A also rises. When the force re-
5. Regeneration circuit ceived by piston (1) from the pressure at port A
6. Tank drain circuit becomes greater than the force of spring (3),
piston (1) moves to the left.
. Spool (2) is pushed by piston (1) and also
moves to the left, so ports B and C are intercon-
nected. When this happens, the pressurized oil
from the cylinder head passes through ports B
and C, and flows directly to drain circuit (6).
(The pressure loss is removed when draining.)
. When this happens, check valve (4) is closed by
the pressure at port A, so it shuts off regenera-
tion circuit (5), and prevents the oil from flowing
back from the cylinder bottom to the head end.
1o-57
STRUCTURE AND FUNCTION CLSS
Function
. When the swing + boom RAISE, or swing + travel are operated together, this valva prevents the high
pressure which is generated when driving the swing, and prevents swing LS pressure a from flowing into LS
circuit Pls.
202FO6081
1 O-58
STRUCTURE AND FUNCTION CLSS
202FO6082
1o-59
STRUCTURE AND FUNCTION CLSS
Function
. This function uses the TVC valve, pump controller, and pump pressure sensor, and if pump discharge
pressure Pp exceeds the set pressure, it makes pump discharge amount Q the minimum.
ctuator
-E&O
Control valvf
LS passage
/
Pump passage
Mir
l+q--j ============b
Piston
positioning
A: Cut off
B: Cut off cancel
1 O-60
STRUCTURE AND FUNCTION CLSS
1. Valve Function
2. Spring . It is possible to adjust the division of the oil flow
3. Sleeve to the service valve when the service valve (for
4. Poppet attachment) is operated together with the main
5. Spring control valve (boom RAISE, etc.). (Variable in
6. Screw proportion to surface area).
7. Locknut . The pump pressure leaving the service valve
8. Plastic cap spool acts on the left end of valve (I), and at the
same time passes through throttle a and enters
chamber g.
The maximum LS pressure passes through
throttle d and enters chamber e. At the same
time, the cylinder port pressure passes through
passage c and throttle f, and goes to chamber
h.
In addition, the force of spring (2) acts on valve
(l), and the force spring (5) acts on poppet (4).
The force of spring (5) can be adjusted with
screw (6).
IO-61
STRUCTURE AND FUNCTION CLSS
Operation
r
and the oil flows to the cylinder port. When this
happens, a differential pressure is formed be- r%l
tween the upstream and downstream sides of tP
Vroa rervice CrliaOr _
throttle a, and the pressure in chamber g goes velre SDODI Dart
down, so the force pushing valve (1) to the left is SDPOI I33
reduced. In other words, the area ratio be-
comes smaller, so valve (1) moves to the right
and increases the flow from the pump to the
cylinder.
1 O-62
STRUCTURE AND FUNCTION CLSS
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor
IO-63
STRUCTURE AND FUNCTION CLSS
1
f I I I
1
r KW13OP6021
1 O-64
CLSS
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor
1 O-65
STRUCTURE CLSS
AND FUNCTION
I
c
PLS
KW13DP6022
1O-66
STRUCTURE AND FUNCTION CLSS
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor
1 O-67
STRUCTURE AND FUNCTION CLSS
I-
-
18
KW13OP6023
I I
1O-68
When boom and arm are operated simulta- 1. Hydraulic tank
neously
Hydraulic pump
If boom spool (A9) is operated to the RAISE
2. Main pump
position and arm spool (8A) is operated to the
3. TVC valve
OUT position, pump discharge amount Q flows
4. LS valve
to cylinders (20) and (19).
When this happens, the load pressure of boom Control valve
cylinder (20) is greater than the load pressure 5. LS bypass plug
of arm cylinder (19), where the load pressure is 6. Unload valve
lower. However, the pressure at the down- 7. Bucket valve
stream side of arm spool (8A) is compensated 7A. Spool
by pressure compensation valve (7B), which 7B. Pressure compensation valve (DUMP)
receives the load pressure (=max. LS pressure 7c. Pressure compensation valve (CURL)
Pls) of the boom. 7D. LS shuttle valve
As a result, the upstream pressure and down- 8. Arm valve
stream pressure of boom spool (9A) and arm 8A. Spool
spool (8A) become equal, so the oil flow from 8B. Pressure compensation valve (OUT)
main pump (2) is divided in proportion to the 8C. Pressure compensation valve (IN)
area of opening of each spool. 8D. LS shuttle valve
In the same way as when the boom is operated 9. Boom valve
independently, the area of the opening of boom 9A. Spool
spool (9A) is a large oversize opening, so the 9B. Pressure compensation valve (RAISE)
difference between pump discharge pressure 8C. Pressure compensation valve (LOWER)
Pp and LS pressure Pls (LS differential pres- 9D. LS shuttle valve
sure PLS) becomes smaller. 9E. Check valve
This LS differential pressure PLS is lower than IO. Travel valve
the LS pressure of LS valve (4), so main pump 10A. Spool
(2) is held at the maximum swash plate angle. 1 OB. Pressure compensation valve
(FORWARD)
1 OC. Pressure compensation valve
(REVERSE)
1 OD. LS shuttle valve
11. Stabilizer valve
11A. Spool
11B. Pressure compensation valve
(EXTRACT)
11c. Pressure compensation valve
(RETRACT)
11 D. LS shuttle valve
12. Swing valve
12A. Spool
12B. Pressure compensation valve (LEFT)
12C. Pressure compensation valve (RIGHT
13. LS select valve
14. LS bypass plug
15. Main relief valve
16. Cooler bypass valve
17. Lift check valve
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor
1O-69
STRUCTURE AND FUNCTION CLSS
1
I a
KW13OP6024
::: I
I 1 1
1O-70
STRUCTURE AND FUNCTION CLSS
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor
IO-71
STRUCTURE AND FUNCTION CLSS
I I
PLS
I
KW13OP6025
,:.:
I
I
i.
I I
1 O-72
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
RIGHT SWING
-------
1
1o-73
STRUCTURE AND FUNCTION SWING MOTOR
SUCTION-SAFETY VALVE
Function
When the swing is stopped, the outlet port cir-
cuit of the motor is closed by the control valve,
but the motor continues to be turned by the iner-
tia of the swing. As a result, the pressure at the
outlet port of the motor becomes abnormally
high and there is danger that the motor will be
damaged.
The safety valve is installed to prevent this
problem. It acts to release the abnormally high
pressure oil from the outlet port of the motor to
port G and also functions as a swing brake.
The suction valve supplies an amount of oil
equivalent to the amount of oil released by the
safety valve. It sends this oil from port G to the
inlet port of the motor to prevent any cavitation.
Operation
When starting swing
If the swing control lever is operated to swing to
the right, the pressurized oil from the pump
passes through the control valve and it supplies
to port MA.
When this happens, the pressure at port MA
rises and the starting force is generated in the
motor, so the motor starts to turn.
The oil from the outlet port of the motor flows
from port MB through the control valve and re-
turns to the tank.
When stopping swing
When the swing control lever is returned to the
neutral position, no more pressurized oil is sup-
plied from the pump to port MA.
At the same time, the oil from the outlet port of
the motor returns from the control valve to the
tank, and the circuit is closed.
The pressure at port MB rises, and rotating re-
sistance to the motor is generated, so the brake
starts to take effect.
If the pressure at port MB rises to the set pres-
sure of safety valve (l), safety valve (1) opens
and releases the pressurized oil at port MB to
port G.
No pressurized oil is supplied at port MA, but
the swing continues, so negative force is gener-
ated.
When this negative pressure to the set pres-
sure of suction valve (2), suction valve (2)
opens and oil is supplied fromport G to prevent
cavitation.
1 O-73A
STRUCTURE AND FUNCTION SWING MOTOR
1. Barrel housing
2. Valve plate
3. Cylinder barrel
6. Roller bearings
7. Bearing housing
8. Shaft seal
9. Output/input shaft
/ 13
12
/
Section C-C
Section B-B
IO-74
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
To tank
From steering
orbitrol valve R
From control
valve 83
From steering
orbitrol valve L
From control /
valve AZ bA
_ From brake
From suspensoin valve BI
lock solenoid
valve ass’y AI
From travel
speed solenoid
valve ass’y A2
From brake -
valve 83
n
To travel
A-A
~W13OP6026
1. Cover
3
L. Housing
3. Sealing ring
4. Lip seal
5. Rotor
1o-75
STRUCTURE AND FUNCTION FRONTTRAVEL MOTOR
d h
\
-J,
C ~\i --
b
F---l a
MA GT
1 O-76
STRUCTURE AND FUNCTION REAR TRAVEL MOTOR
SPECIFICATON
1o-77
STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
2OUFO2032
1 O-78
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
A-A
D-D
B-B
E-E 2OUFO2033
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)
1o-79
WORK EQUIPMENT l SWING PPC VALVE
OPERATION
1. At neutral
Ports A and B of the control valve and ports Pl
and P2 of the PPC valve are connected to drain
chamber D through fine control hole “f” in spool
(I). (Fig 1)
PPC
l-l
Pressure
Reducing
Valve
1 O-80
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
4. At full stroke
When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (l), fine control
hole “f” is shut off from drain chamber D, and is
connected with pump pressure chamber Pp.
Therefore, the pilot pressure oil from the control
pump passes through fine control hole “f” and
flows to chamber A from port Pl, and pushes
the control valve spool. 9
The oil returning from chamber B passes from
port P2 through fine control hole “f” and flows to f. 77 ii
drain chamber D. (Fig. 4)
IPPC I I
1Reducingl I
IO-81
STRUCTURE AND FUNCTION TRAVEL PPC PEDAL
0 @> 0 0
0 B
SPECIFICATIONS
Kw13OP6031
Inlet pressure: 50 bar (max).
1 O-82
SERVICE PPC VALVE
STRUCTURE AND FUNCTION
1
?\
\
2
4
-
\
\
1. Pin
2. Cam
3. Ball
4. Piston
5. Cover
6. Sleeve
7. Centering spring
8. Metering spring
9. Spool
10. Body
1 O-83
STRUCTURE AND FUNCTION SERVICE PPC VALVE
OPERATION
At neutral
. The pressurized oil from the control pump en-
ters from port P and is blocked by spool (9).
. Port A and B of the control valve and port “a”
and “b” of the PPC valve are connected to drain
port T through fine control hole X of spool (9).
When operated
. When cam (2) is moved, metering spring (8) is
pushed by ball (3), piston (4) and sleeve (6),
and spool (9) is also pushed down by this.
. As a result, fine control hole X is shut off from
the drain circuit. At almost the same time, fine
control portion Y is connected with port “a”, and
the pressurized oil from port P flows from port
“a” to port A of the control valve.
1 O-84
STRUCTURE AND FUNCTION SERVICE PPC VALVE
1 O-85
STRUCTURE AND FUNCTION SAFETY LOCKVALVE PPC ACCUMULATOR
2 $
F205CXI I8
PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATIONS
Gas capacity: 400 cc
1O-86
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE
Pi2 P22
P42
P62
A2
A2
P62
P62
AP
PO2
P72 A4
P62
PA2
Pa2
Kw13OP6032
Function
This sends the PPC valve output pressure to the
control valve. It is provided with a mount port for the
pressure switch for detecting the pilot pressure.
1 O-87
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE
1O-88
PPC SHUTTLE VALVE
STRUCTURE AND FUNCTION
1
,2
2
F-F A-A
G-G B-B
N-N
L- -4
K-K D-D
(ZPLACES) M-M
L-L E-E
1O-89
STRUCTURE AND FUNCTION EPC, SOLENOID VALVE
i h g f e
1o-91
STRUCTURE AND FUNCTION EPC. SOLENOID VALVE
A-A
202FO6124
1o-92
STRUCTURE AND FUNCTION EPC, SOLENOID VALVE
Function
. 2.94_
The EPC valve consists of the proportional so- (30)
lenoid portion and the hydraulic valve portion.
. When it receivers signal current i from the pump Z 2.45_
controller, it generates EPC output pressure P E (251
eIYJ
in proportion to the size of the signal, and out- Y
puts it to the control valve. m X96_
2 (20)
a
E 1.47_
i (15)
h
2 0.98
,a (101
5
0.49_
(5)
I I
I I I 1 I 1 I I
Current i (mA)
202FO6113
Operation
1. When signal current is 0 (coil deactivated)
. There is no signal current flowing from the con-
troller to coil (5), coil (5) is deactivated.
. For this reason, spool (2) is pushed to the right
in the direction of the arrow by spring (3).
. As a result, port P closes and the pressurized
oil from the control pump does not flow to the
LS valve.
At the same time, the pressurized oil from the
LS valve passes from port C through port T and
is drained to the tank.
1o-93
STRUCTURE AND FUNCTION EPC. SOLENOID VALVE
c73
cited) LSvalve
. When a very small signal current flows to coil
(5), coil (5) is excited, and a propulsion force is
generated, which pushes plunger (6) to the left
in the direction of the arrow.
. Push pin (4) pushes spool (2) to the left in the
direction of the arrow and pressurized oil flows
from port P to port C.
. When the pressure at port C rises and the load
of spring (3) + the force acting on surface a of
spool (2) becomes greater than the proportion
force of plunger (6), spool (2) is pushed to the
right in the direction of the arrow. The circuit
between port P and port C is shut off, and at the
same time, port C and port T are connected.
. As a result, spool (2) is moved tot the left or
right until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pressure
of port C.
. Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in pro-
portion to the size of the signal current.
1o-94
STRUCTURE AND FUNCTION EPC, SOLENOID VALVE
A-A
202FO6124
1o-95
STRUCTURE AND FUNCTION EPC. SOLENOID VALVE
Function
2.94_
. The EPC valve consists of the proportional so- (30)
lenoid portion and the hydraulic valve portion.
. When it receivers signal current i from the
pump controller, it generates EPC output pres- $ :;“:-
sure P in proportion to the size of the signal, g
m 1.96_
and outputs it to the control valve. 2 (20)
a
!J 1.47
$ (151
h
5 0.98
,a (10)
S
I , , ; , , , , , , ,
Current i (mA)
202FO6113
Operation
1. When signal current is 0 (coil deactivated)
. There is no signal current flowing from the con-
troller to coil (5), coil (5) is deactivated.
. For this reason, spool (2) is pushed to the right
in the direction of the arrow by spring (3).
. As a result, port P closes and the pressurized
oil from the control pump does not flow to the
travel pedal PPC valve.
At the same time, the pressurized oil from the
travel pedal PPC valve passes from port C
through port T and is drained to the tank.
PPC Pressure
Reducing Valve
1O-96
STRUCTURE AND FUNCTION EPC, SOLENOID VALVE
1o-97
STRUCTURE AND FUNCTION EPC. SOLENOID VALVE
Nut
Plunger
Coil
Connector
1 II 5. Push pin
6. Spring
7. Spool
8. Block
202FO6131
Operation
When solenoid is deactiviated f4
. The signal current does not flow from the con-
troller, so coil (3) is deactivated.
. For this reason, spool (7) is pushed to the left in
the direction of the arrow by spring (6).
. As a result, port A closes the pressurized oil
from the control pump does not flow to the ac-
tuator.
At the same time, the pressurized oil from the
actuator flows from port B to port C, and is then
PPC Pressure
drained to the tank.
1O-98
STRUCTURE AND FUNCTION TRAVEL/BOOM/STABILISER SOLENOID VALVE
k I In
1O-99A
STRUCTURE AND FUNCTION BOOM SAFETY VALVE
To tank (T port)
Overload caution
signal I I
To cylinder port
0 port)
IO-106A
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
OPERATION
BOOM RAISE
. During boom raising the pilot signal from wrist V port
control operates control valve spool to direct
high pressure oil to port V of hose burst valve.
. This pressure lifts check valve (4) from seat &
high pressure oil flows in the bottom of the cyl-
inder raising the room.
Cylinder
BOOM LOWER
. During boom lowering the pilot signal reverses
T port
the flow through the control valve spool. High
pressure oil flows to the head side of the cylin- /
der. Oil in the bottom side of the cylinder flows
2e To tank
through the port Cy of the valve but cannot flow
past the check valve. The pilot signal also
opens the spool (2) of the hose burst valve and
allows oil to flow back to tank.
1Reducing Valve1
IO-106B
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
IO-106C
STRUCTURE AND FUNCTION HYDRAULIC CYLINDERS (Boom & Arm)
ARM CYLINDER
7 e 9 IO 12 13 14 I5
BUCKET CYLINDER
P
f
IO-107
STRUCTURE AND FUNCTION HYDRAULIC CYLINDERS
FK203P5021
Specifications
Unit: mm
1 O-l 08
STRUCTURE AND FUNCTION OUTRIGGER CYLINDER
OUTRIGGER CYLINDER
Cylinder head (4) guides the piston rod (2) which is Important
sealed by seal (9). Seal (9) is protected against dirt Depressurizing the cylinder
by wiper (8). The check valve built into the cylinder prevents any
cylinder movement due to oil leakage within the con-
When oil flows through port I tot he piston side of the trol block or sudden loss of hydraulic pressure due
cylinder the piston rod (2) extends out of the cylinder to a hose burst.
(1). The built in check valve also holds hydraulic pres-
sure within the cylinder when the hydraulic hoses
The piston is guided in the cylinder (1) by the piston are removed from the cylinder.
guide ring (7). It is sealed by the piston ring (14).The
cylinder head is sealed against the cylinder by O- a Depressurize the cylinder before opening
ring (13).
To depressurize the cylinder, loosen the plug (23)
When oil fows through port II to the rod side of the carefully using an Allen key and wait until the pres-
cylinder the piston rod retracts. sure has been released. To be absolutely sure the
plug can be completely removed.
IO-109
STRUCTURE AND FUNCTION DOZER BLADE CYLINDER
25-l_
tl--
1
I
I-
+--; i
‘7 ,8
1 27 i- I I
29 30
Cylinder head (4) guides the piston rod (2) which is Important
sealed by seal (11). Seal (11) is protected against Depressurizing the cylinder
dirt by wiper (10). The check valve built into the cylinder prevents any
cylinder movement due to oil leakage within the con-
When oil flows through port I tot he piston side of the trol block or sudden loss of hydraulic pressure due
cylinder the piston rod (2) extends out of the cylinder to a hose burst.
(1). The built in check valve also holds hydraulic pres-
sure within the cylinder when the hydraulic hoses
The piston is guided in the cylinder (1) by the piston are removed from the cylinder.
guide ring (18). It is sealed by the piston ring (16).
The cylinder head is sealed against the cylinder by A Depressurize the cylinder before opening
O-ring (20).
To depressurize the cylinder, loosen the plug (8)
When oil fows through port II to the rod side of the carefully using an Allen key and wait until the pres-
cylinder the piston rod retracts. sure has been released. To be absolutely sure the
plug can be completely removed.
10-110
STRUCTURE AND FUNCTION
1. Arm
2. Bucket cylinder
3. Arm cylinder
4. Boom
5. Boom cylinder
6. Bucket
7. Boom lift cylinder
a. First boom
9. Second boom
10. Boom adjust cylinder
10-111
0
“A*AK I “L” TYPE.
DOBO56-XXXXX
m
7*,?*1(1
"X" i"'"E.
D00055-XXXXX
PYIIO-6 CONNECT AK
LENOIO
cam cmlRMa PLV cmI?aL‘II
1 O-l 12A
J \
\ * /
RH WRIST CONTROL LH WRIST CONTROL
LEVER SWITCHES LEVER SWITCHES 10-I 12B
iiG
$
___
j;
--
--
--
--
--
li’
f
~1
10-I 12c
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
202Foe148
IO-113
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
1. OPERATION OF SYSTEM
Stat*ting engine
. When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start the
engine.
When this happens, the engine throttle control-
ler checks the signal from the fuel control dial
and sets the engine speed to the speed set by
the fuel control dial.
Stopping engine
. When the starting switch is placed at the OFF
position, the shut off valve is closed so the sup-
ply of fuel to the engine is shut off and the en-
gine stops.
IO-114
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
2. COMPONENTS OF SYSTEM
HIGH 1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
Front of-machine
6. Connector
A-A
3a3
z,‘, w
B
Composition
u
:
of circuit
205FO5 I I3
FUNCTION (%I *,
. 100
The fuel control dial is installed at the bottom of
the monitor panel. A potentiometer is installed
2
under the knob, and when the knob is turned, it
rotates the potentiometer shaft. ?z
b
When the shaft rotates, the resistance of the ;;i
variable resistor inside the potentiometer $
Z
changes, and the desired throttle signal is sent
2
to the engine throttle controller.
The shaded area in the graph on the right is the 0 0.25 1 4 4.75 5 Voltage
IO-115
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
2. GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
-.
L
Composition of circuit
I I
202FO6149
FUNCTION OPERATION
. The motor is rotated and the governor lever of Motor stationary
the fuel injection pump is controlled by the drive . Both A phase and B phase of the motor a con-
signal from the engine throttle controller. tinuous, and a holding torque is generated in
. A stepping motor is used for the motor which the motor.
provides the motive power. Motor rotating
. In addition, a potentiometer for giving feedback . A pulse current is applied to the A phase and B
is installed to allow observation of the operation phase from the engine throttle controller to geve
of the motor. synchronous rotation with the pulse.
The rotation of the motor is transmitted to the
potentiometer through a gear.
IO-116
STRUCTURE AND FUNCTION ENGINE CONTROL
CN3 CN5
CNI CN2
IO-117
STRUCTURE AND FUNCTION ENGINE CONTROL
CN-1 CN-3
‘in. Input/ ‘in. Input/
Name of signal Name of signal
I
VO. output 10. I 0uttJut I
1 Battery relay drive output output
2 NC
I ii
Boom LOWER pressure
switch
IArm OUT pressure switch
I
Input
I
I Input I
19 Travel EPC solenoid (-) output
20 NC
I I
12 S-NET(+)
I Input,
output I
21 PGND Input I 13 IModel selection 2 I InputI
I 14 IModel selection 4 I InputI
I 15 ISpeed select I InputI
I 16 ISwing lock switch I InputI
IO-118
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
I
I 2
I I I
Pump and valve control function
I 3
I I I
Power maximizing function
I 3
I
I 6
I I I
Swing control function
I 8
I I I
Components of system
IO-119
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Travel pedal
Y&
Hydraulic
switch
Fuel control 1
dial s s-
Hi 5 .s
(Travel pedal signal)
(Network signal)
FUNCTION
There are five modes available for selection l The pump controller detects the actual engine
with the working mode switch on the monitor speed and the speed set by the engine gover-
panel. These modes are the heavy-duty opera- nor through the fuel control dial matches the
tion (H/O) mode, general operation (G/O) pump absorption torque set for each mode, and
mode, lifting operation (L/O) mode, and the carries out control so that the pump absorbs all
breaker operation (B/O) mode. It is possible to of the torque at each output point of the engine.
select the most suitable engine torque and
pump absorption torque to match the nature of
the work
H/O (Travel)
UO B/O
P
I I . ,
HI0 (Travel) v) t
z
0
E
a
b
;
fj
t
I I Ill 2
Engine speed N Engine speed N Pump discharge amount 0.
IO-120
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1. Control method in each mode Heavy-duty travel operation (H/O) travel mode
. Matching point in heavy-duty operation mode: Rated output point
. When the load on the pump rises and the pressure rises, the engine speed goes down.
When this happens, the pump dischrge amount is reduced, and the engine speed is controlled so that it
becomes the rated speed. Just the cut-off at relief is cancelled and the oil flow at relief is increased.
. If the reverse happens and the pressure goes down, the system is controlled so that the pump discharge
amount is increased until the engine speed reaches the rated speed.
by repeating this control, the engine can always be used at near the rated output point
iU”l/(’
Engine speed N Engme speed N ump discharge amount (1
. Matching point in general operation and finishing operation modes: 75 % partial output point.
. When the load on the pump rises and the pressure rises, the engine speed goes down. When this happens,
mutual control of the engine and pump is used to control the system so that the pump absorption torque
follows the equal horsepower curve of the engine,1 and the engine speed is lowered while keeping the
torque constant.
. In this way, the engine is used in a range which provides good fuel efficiency.
IO-121
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
I-
--w
2
o-
?
\
5 \
I
.-e \
F
w \
I
\
Engine speed N Pump discharge amount 0
Engine speed N
Breaker operation (B/O) mode Breaker operation (B/O) 160kW (82 PS) 1,910 rpm
Matching point in lifting operation mode: 70 %
partial output point
The pump absorption torque in the breaker op-
eration mode is the same as for the general op-
eration and finishing operation modes, and is
controlled to become an even lower speed.
As a result, the pump absorption torque needed
to ensure the breaker drive is ensured, and
theengine is used in a range that provides a
much better fuel comsumption ration than for
the general operation mode or finishing mode.
202FO6166 202FO6166
202FO6167
IO-122
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
IO-124
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
I I I I
Engine speed N
202FO6169
202FO6170
202FO6171
202FO6172
IO-125
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
r----1
j ’
$I
31
JJ
>I
Control Valve ?j j
r------
I ‘1 !=II
‘5
r Hi
!-stage relief I_______________,L____________--A
Engine
Electric
Fuel injection governor
Hi -- ---I
I
LS
i___ control
EPC
valve
TVC valve A
FUNCTION
IO-126
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Swing
Working mode switch Knob switch
lock
IO-127
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
5. Fine control mode function . Relationship between working mode and pump
. When the finishing operation (F/O) mode is discharge amount (for independent operation)
selected from the-working mode, the pump (%)-
LS valve is controlled, and the pump dis-
charge amount is reduced to improve the
ease of fine control and the precision when
finishing.
Arm
T
-E bucket Swing
Actuator RAISE LOWER OUT
Heavy-duty
operation
(H/O)
100 50 100 50 50
General
operation
(G/O)
Finlshlng
operation 80 40 60 80 40 40
(F/O)
Lifting
operation 100 50 100 100 50 50
mode (L/O)
6. LS bypass function Breaker
. When the travel is operated at the same operation 100 50 100 100 50 50
IO-128
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Control valve
Work
equipement
lever knob
switch
FUNCTION
IO-129
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Actuated
Heavy-duty working Automatically canceled
Canceled (31.85 34.79 MPa)
operation (H/O work) after 8.5 set
(325 355 kg/cm’)
I Working mode
I
Actuating time
IO-130
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
4) Auto-deceleration function
Boom Bucket
n n
Engine
Fuel injection
Main pump , I
ww (
M
@
Monitor panel
‘F
Governor,
pump controller
Function
. If all the control levers are at neutral when wait-
ing for work or waiting for a dump truck, the en-
gine speed is automatically recuded to a
midrange speed to reduce fuel consumption
and noise.
. If any lever is operated, the engine speed re-
turns immediately to the set speed.
IO-131
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Operation
Control levers at neutral When control lever is operated
If the engine is running at above the decelera- l If any control lever is-operated when the engine
tion actuation speed (approx. 1,400 rpm), and speed is at No. 2 deceleration, the engine
all the control levers are returned to neutral, the speed will immediately rise to the speed set by
engine speed drops immediately to approx. 100 the fuel control dial.
rpm below the set speed to the No. 1 decelera-
tion position.
If another 4 seconds pass, the engine speed is
reduced to the No. 2 deceleration position
(approx. 1,400 rpm), and is kept at that speed
until a lever is operated.
speed (rpm)
No. 1 deceleration
Time (set)
Levers at neutral
Lever operated
IO-132
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
I Control valve
Governor,
pump controller
FUNCTION
. If the coolant temperature is low, this automati-
cally raises the engine speed to warm up the
engine after it is started. (Automatic warming up
function).
In addition, if the coolant temperature rises too
high during operations, it reduces the load of
the pump to prevent overheating. (Engine over-
heat prevention function).
IO-133
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
IO-134
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Normal operation
(coolant temperture below 102°C)
Actuation condition
Coolant tempera-
ture: Below 102%
7 i!
(Coolant tempera-
ture gauge:
Green ranae)
-0
1 st stage (Coolant temperature between 102°C and 105%) u
IO-137
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Swing motor
i
I
I Swing brake
1solenoid valve
Control valve
Engine e
.i OiiT;rre
Monitor panel
il Pump controller
Function
. The system is provided with a swing lock and
swing holding brake function.
IO-138
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1. Swing lock, swing holding brake function . Swing lock switch and swing lock, holding brake
. The swing lock (manual) can be locked at any
desired positon, and the swing holding brake
(automatic) is interconnected with the swing, so
Operation
it prevents any hydraulic drift after the swing is
stopped. When swing lever is placed at
neutral, swing brake is applied
after approx. 4 set; when swing
lever is operated, brake is
canceled and swing can be
operated freely.
Swing lock is actuated and swing
is held in position. Even when
Swing
ON
I I
ON
lock
swing lever is operated, swing
lock is not canceld and swing
does not move.
202FO6182
IO-139
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
Travel
Motor
Control valve
Pump pressure
sensor
Monitor panel
Q
c4
t
t
Engine throttle
controller
Function
IO-140
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
If the travel speed switch is set to Lo, Mi or Hi, Pump flow (%) 30 100 100
the pump controller controls the pump flow and Motor volume Max. Max. Min.
motor volume at each speed range as follows to Travel speed (km/h) 2.7 1.o 30
switch the travel speed.
IO-141
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
8) Components of system
0
gtz-p
Composition of circuit
202FO6185
1. Wire Function
2. Magnet . The engine speed sensor is installed to the ring
3. Terminal gear portion of the engine flywheel. It counts
4. Housing electrically the number of gear teeth that pass
5. Connector in front of the sensor, and sends the result to
the pump controller.
. This detection is carried out by a magnet, and
an electric current is generated every time the
gear tooth passes in front of the magnet.
1. Plut
2. Switch
3. Connector
1 2 3
SPECIFICATONS
Composition of points: N.O. points
Actuation (ON) pressure:
___ 0.49 f 0.1 MPa (5.0 f 1 .O kb/cm’)
_-_
Reset (OFF) pressure:
k!I+ 0.29 f 0.05 MPa (3.0 f 0.5 kg/cm’)
Function
. There are 8 switches installed to the PPC shut-
tle valve.The operating condition of each actua-
tor is detected from the PPC pressure, and this
is sent to the pump controller.
@q---J PzjzJ
Composition of circuit
202FO6186
IO-142
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
1. Plug
2. Sensor
3. Connector
ffJ=pqJ
Composition of circuit
202FO6187
Function
. This sensor is installed to the inlet port circuit of
the control valve. It converts the pump dis- Insulation layer
charge pressure to a voltage and sends this to
the controller.
Operation
When the pressurized oil entering from the
pressure introduction portion pressurized the
diaphragm of the pressure detection portion,
the diaphragm deflects and changes shape.
A gauge layer is installed to the face opposite
the diaphragm, and the resistance of the gauge
layer converts the deflection of the diaphragm
into an output voltage and sends it to the amp
(voltage amplifier).
the voltage is further amplified by the amplifier
and is sent to the pump controller.
Relationship between P (kg/cm’) and output
voltage (v)
V = 0.008 x P + 1 .O
+ 1 kg/cm2 = 0.098 MPa
0
100 400 500
Pressure P (kg/crrS)
202FO6163
IO-143
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
202FO6216
1. Resistor Function
2. Connector . This resistor acts to allow a suitable current to
flow to the TVC solenoid when the TVC prolix
SPECIFICATION switch is ON.
Resistance: 30 !A . No currect flows when the TVC prolix switch is
OFF
7. TVC valve
+ See HYDRAULIC PUMP
IO-144
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
Switch signal
Caution. water
temperature, fuel
level signal Governor,
pump controller
I
Sensor signal
SWlSOrS
w
BUZZW
signal
I
Buzzer
IO-145
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
1. Monitor panel
CN-PO2
CN-PO1
IO-146
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
DISPLAY MONITOR
1. Clock (displays error code when error occurs)
2. Service meter
3. Coolant temperature gauge
4. Fuel gauge
5. Engine oil level caution lamp
3 4
6. Preheating pilot lamp
7. Swing holding brake pilot lamp
13 14
8. Charge level caution lamp
9. air cleaner clogging caution lamp
5
10. Overload caution lamp
11
11. Coolant level caution lamp
10 6
12. Engine oil pressure caution lamp
13. Fuel level caution lamp
12 9 8 15 7 14. Coolant temperature caution lamp
Content of display 15. Oil maintenance caution lamp
When engine is
Symbol Display item Display range When engine is running
stopped
Flashes and buzzer
fG Coolant level Below low level Flashes when abnormal
SAP00519 sounds when abnormal
Below 1,500 rpm:
Lights up when normal
Engine oil below 0.05 MPa (0.5 kg/cm’) Flashes and buzzer
(goes out when engine
pressure Above 1,500 rpm: sounds when abnormal
SAW0520 starts)
below 0.15 MPa (1.5 kg/cm’)
Air cleaner
When clogged OFF Flashes when abnormal
clogging
04
SAP00523
Engine oil
level
Below low level Flashes when abnormal OFF
!.s Over load Above high level OFF Flashes when abnormal
SDPOO688
Oil
maintenance
IO-147
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
(II m II 1.
2.
Working mode switch
Auto deceleration switch
3. Travel speed switch
4. Power max./Swift slow-down switch
d” SDP00695
AUTO DECEL ON - OFF
aa 69SDP00696
TRAVEL SPEED Hi ++ Mi ++ Lo
IO-148
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
2. Sensors
. The signals from the sensor are input directly to
the monitor panel.
The contact type sensors are always con-
nected at one end to the chassis GND.
Engine oil
Contact type
pressure
Coolant
Resistance type
temperature
1. Sub-tank
2. Float
3. Sensor
4. Connector
SAP00375
IO-149
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
1. Connector
2. Bracket
3. Float
4. Switch
Composition of
circuit
SSPOO376
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
1 2 3 4 5 6
5. Spring
6. Terminal
0 69 @ Composition of circuit
?.SP00379
Composition of circuit
swoo379
IO-150
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
1. Float
2. Connector
FULL 3. Cover
4. Variable resistor
EMPTY
Composition of circuit
f!L
Composition of circuit
IO-151
AND FUNCTION OVERLOAD WARNING DEVICE
STRUCTURE
Function
. This device is installed to prevent the machine
from tipping over when it lifts an excessive
weight while being used as a crane.
Structure
. When an excessive weight is lifted, the oil pres-
sure goes up at the bottom side of the boom
cylinders. When this happens, the pressure
switch senses the rising pressure, turns the
pressure switch on, and lights the monitor lamp
to warn the operator. When the monitor lamp
lights, immediately lower the weight to the
ground or bring the arm closer in the operator to
prevent the machine from tipping over.
Overload warning
monitor lamp
.
IO-152
STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE
2) OPERATION
IO-153
STRUCTURE AND FUNCTION BREAKER MODE HYDRAULIC PERFORMANCE
Main
valve
Attachment
Bypass
valve
Max. back
pressure
29.5 bar
Flow lLitras/minutel
IO-154
STRUCTURE AND FUNCTION BREAKER MODE HYDRAULIC PERFORMANCE
Max. back
pressure
50 bar
flow ~Litrdminutel
20 TESTING AND ADJUSTING
Table of judgement standard value 20- 2 Testing and adjusting PPC pressure 20- 33
Standard value table for electrical parts . . . ....20- 12 Testing EPC valve, solenoid valve output
Checking and adjusting belt tension for pressure 20- 35
air conditioner compression 20- 20 Measuring PPC valve output pressure
Adjusting engine speed sensor 20- 21 and testing PPC shuttle valve 20- 37
Testing and adjusting governor motor Adjusting work equipment
lever strong 20- 22 l swing PPC valve 20- 39
Testing clearance of swing circle bearing .. ...20 -24 Testing locations causing hydraulic
Testing and adjusting hydraulic pressure drift of working equipment 20- 40
in work equipment, swing, travel circuit . . . . ....20- 25 Measuring oil leakage 20- 42
Testing and adjusting TVC valve output Releasing remaining pressure in
pressure (servo piston input pressure).........20- 28 hydraulic circuit 20- 43
Testing and adjusting LS valve output Bleeding air 20- 44
pressure (servo piston input pressure) and Accumulators 20- 46
LS differential 20- 30 Troubleshooting 20- 50
a When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
a When checking the water level, always wait for the water to cool down. If the radiator cap is removed
when the water is still hot, the water will spurt out and cause burns.
a Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-I
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Engine SA4Dl02E
20-2
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
. FOR CHASSIS
+ The standard values and permissible values shown in this table are all values for H/O (heavy-duty opera-
tion) mode.
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
Hydraulic oil temperature
At pump relief (LS relief) Min. 2,100 2,100 * 50
45 - 55°C
Coolant temperature:
At pump relief (power whithin operating range
max)
rpm Min. 2,100 2,100 * 50
Pump relief: Arm relief
Speed when auto Fuel control dial at MAX.
1,400 * 200 1,400 * 200
deceleration is operated Control lever at neutral
Service valve
w KW13OP6012
20-3
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Machine model
T PWI 70-6k
Kw13OP6044
31.85kl.47 31.85k2.45
Normal
(325?15) (325?25)
RAISE
Power 34.79k1.47 34.79k2.45
t max. (355ki 5) (355*25)
soom
31.85kl.47 31.85k2.45
(325?15) (325?25)
33.8kl.47 33.8lk2.45
(345?15) (345?25)
31.85?1.47 31.85k2.45
Normal
(325*15) (325*25)
Power 34.79kl.47 34.79k2.45
max. (355ki 5) (355*25)
) Hydraulic oil temperature 31.85kl.47 31.85k2.45
45 _550c Normal (325?15) (325?25)
3ucket ) Relief pressure with engine at ~
MPa
Power kg/cm2) 34.79k1.47 34.79k2.45
high idling (Relieve only circuit
max. (355k15) (355*25)
) to be measured)
) In H/O mode 31.85?1.47 31.85k2.45
swing
(325*15) (325*25)
-ravel
34.79k0.98 34.79k1.96
(355ki 0) (355*20)
;tabiliser
Levers at neutral
.S differential pressure ) Hydraulic oil Controllevers at
temperature neutral 3.9*1 .o 3.0*1 .o
45 - 55°C
(4Oki 0) (4Oki 0)
rvc valve output pressure ) Engine at high idling
servo piston input ) In H/O mode
jressure)
20-4
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Machine model
T PWI70-6k
20-5
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Machine model
T PWI 70-6k
KW13OP6048
Lo 36 30-42
sec.
KW13OP6049
Mi
Travel speed l Engine at high idling 18 15-21
l Hydraulic oil temperature:
45 - 55°C
l In H/O mode !O kph
l Run up for at least 200 m, set 9 8.6 - 9.4
and measure time taken to Hi
travel next 50 m on flat 10 kph
ground. set 6 5.8 - 6.2
mm 0 0
Hydraulic drift of
travel
l Engine stopped
l Hydraulic oil temperature:
45 - 55°C
l Stop machine on 12” slope
l Apply park brake
l Measure the distance the
machine moves in 5 minutes
20-6
?-
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
m
Applicable model
- 1 PWI70-6k
/mil 30
Leakage of travel
motor(s)
Boom cylinder
(amount of
Max. 5 Max. 7.5
retraction of
cylinder)
Place in above posture and
2nd Boom measure extension or retraction of
cylinder (amount each cylinder and downward
movement at tip of bucket teeth nm Max. 5 Max. 7.5
of extension of
cylinder) Bucket: Rated load
Horizontal, flat ground
Arm cylinder Levers at neutral
(amount of Engine stopped
Hydraulic oil temperature: Max. 30 Max. 45
extension of
45 - 55°C
cylinder)
Start measuring immediately after
Bucket cylinder setting
(amount of Measure hydraulic drift every 5
minutes, and judge from results for 0 0
retraction of
cylinder) 15 minutes _
Bucket teeth in
contact with KW13OP6053
;ec.
ground
Cylinder fully
l Engine at high idling 2.8kO.3 Max. 3.2
extended
l Hydraulic oil temperature:
45 - 55°C
-
20-7
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Cate
T
Applicable model
Permissible value
gorl
Z
- 3.7kO.4 Max. 4.6
Arm cylinder fully
retracted
1
fully extended
Kw13OP6054
& Kw13OP6055
fully extended
l Engine at high idling 2.2kO.3 Max. 2.6
l Hydraulic oil temperature:
45 - 55°C
set
!a
Kw13OP6056/
Max. 2.0 Max. 3.0
l Lower boom and measrue time
taken from point where bucket
contact ground to point where
chassis rises from ground
l Engine at low idling
l Hydraulic oil temperature:
45 - 55°C
Arm
Kw13OP6057 Max. 1 .O Max. 2.6
20-8
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Cate
T
Applicable model
Permissible value
Item
gorl
Bucket
Cylinders
Center swivel joint
sec. Max. 2.0 Max. 3.0
Kw13OP6058
l Stop bucket and measure time taken
for bucket to stop at bottom and then
start again
l Engine at low idling
l Hydraulic oil temperature:
45 - 55°C
20-9
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
Cate
PWI 70-6K (H.0 WORK TRAVEL)
gory
I I I
I
I
-------- .---
-r-------- 1-- -
I
I
I
I
I
.___;----.---_I_____
I I
Pump Q (I/min)
As far as possible, bring pump discharge pressures P as close as possible to the average pres-
sure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
When measuring with the pump mounted on the machine, if it is impossible to set the engine
speed to the specified speed with the fuel control dial, take the pump discharge amount and the
engine speed at the point of measurement, and use them as a base for calculating the pump
discharge amount at the specified speed.
20-I 0
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
20-I 1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
E05 (male)
I Between (3) - (4) 1 2.5 - 7.5 n I
I Between (1) - (3) 1 No continuity I
Between (1) - chassis No continuity
Between (3) - chassis No continuity
sensor
Measure with AC range 1) Start engine.
2) Insert T-adapter.
1 Between (l)-(2) 1 0.5 - 3.0 V
20-I 2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
ispectior
SYS Name of Connector Judgement table Measurement
method
ten- component No. conditions
Swing holding If the condition is within the range shown in 1) Turn starting
brake solenoid the table below, it is normal switch OFF
valve vo4 2) Disconnect
1 Between (I) - (2) I 20 -60 f-l
(male) connector
I Between (I), (2) - chassls
I Min. 1 M.Q V06
20-13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
II
I
-r
bower source)
2
b If the condition is as shown in the table be- 1) Turn starting
E
low, it is normal switch OFF
9
s Coolant PO7
Normal temperature
(25”Cl
Aprrox. 37 - 50 kfl
2) Disconnect
connector
temperature (male) 100°C Aprrox. 3.5 - 4.0 k.Q PO7
sensor 3) Insert T -
adapter into
connector at
sensor end.
20-I 4
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Name of
component T
Connector
No.
ispectiol
method
Judgement table Measurement
conditions
1) Start engine.
f the condition is as shown in the table be-
ow, it is normal 2) Turn swing
lock switch
When either swing or OFF.
work equipment control 3) Turn swing
lever is operated o-3v lock prolix
Swing holding (solenoid ON, swing switch OFF.
xake sole- co1 holding brake canceled) 4) Insert T -
Between
ioid adapter.
Approx. 5 set after (3) -
swing lever and work + The lever can
(6h (12) be operated
equipment control
levers are placed at 20 - 30 v slightly
neutral (solenoid OFF, (without
swing holding brake moving the
applied) equipment).
:-I
2) IsertT-
When swing lock switch
adapter.
is OFF, and swing +
+ The lever can
travel levers are opera-
o-3v be operated
Suspension co1 ted simultaneously Between slightly
ock (solenoid ON, LS not
(2) - (without
divided)
(6h (12) moving the
When sing lock switch equipment).
is ON (solenoid OFF, 20 - 30 v
LS not divided)
20-15
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
-
sys Name of Connector lspectiol Judgement table Measurement
ten component No. method conditions
20-I 6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
-
SYS Name of Connector lspectiot Judgement table Measurement
method
ten component No. conditions
-
If the condition is within the range shown in 1) Turn starting
the table below, it is switch OFF
3) Disconnect
!_
Between (1) - (2) 500- iooon
connector.
1Between (2) - chassis 1 Min. 1 M.Q
20-17
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
H
contact
a between
sensor
A Cl
terminals
A & C.
20-I 8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
I 8.502 - 10.774 I
r Level 1 flashes.
20-I 9
CHECKING AND ADJUSTING BELTTENSION FOR AIR
TESTING AND ADJUSTING CONDITONER COMPRESSOR
ADJUSTING
1. Loosen two nuts and bolts 0.
2. Carefully lever compressor housing as shown to
tighten belt to tightness criteria. Tighten lower bolt to
hold in position.
3. Tighten upper bolt.
4. Check each pulley for damage, wear of the V-groove
and wear of the V-belt. In particular, be sure to check
the V-belt is not touching the bottom of the V-groove.
5. Replace belt if it has streched, leaving no allowance
for adjustment, or if there is a cut or crack on belt.
6. Refit belt guard.
7. When the new belt is set, readjust it after operating for
one hour.
20-20
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
20-21
TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
ADJUSTMENT
20-22
TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
20-23
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF
Revolving framel
SWING CIRCLE BEARING
Method of testing clearance of swing circle bearing
when mounted on machine
Kw130P6060
20-24
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING,TRAVEL CIRCUIT
A Lower the work equipment to the ground and stop the 202FO6339
20-25
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
TESTING AND ADJUSTING EQUIPMENT, SWING, TRAVEL CIRCUIT
20-26
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING,TRAVEL CIRCUIT
ADJUSTING
$B Locknut:
58.8 f 4.9 Nm (6 f 0.5 kgm)
cm Locknut:
44.1 f 4.9 Nm (4.5 f 0.5 kgm)
20-27
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
[Reference]
If there is any abnormality in the LS valve or servo
piston, the servo piston input pressure will be almost
the same or 0 of the pump discharge pressure.
202FO6340
20-28
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
ADJUSTING
+ If the load becomes larger, the engine speed will drop.
Or if the engine speed remains normal, the work
equipment speed will drop. In such cases, if the pump
discharge pressure and LS differential pressure are
normal, adjust the TVC valve as follows.
1. Loosen locknut (3), and if the speed is slow, turn
screw (4) to the left; if the engine speed drops, turn the
screw to the right.
+ If the screw is turned to clockwise the pump ab-
sorption torque will be increased, and if it is
turned to anticlockwise pump absorption torque
will be reduced.
2. After completing the adjustment, tighten thr locknut.
CW Locknut:Nm (kgm)
20-29
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO
TESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
MEASURING
1. Measuring LS valve output pressure (servo piston in-
put pressure).
1) Remove pressure measurements plugs (1) and
(2) and install oil pressure gauge Cl.
* Install a 39.2 MPa (400 kg/cm’) gauge to the
servo end, and a 58.8 (600 kg/cm’)
gauge to the pump outlet port end.
. Oil pressure when travel is rotating under no load
(wheels OFF the ground).
i) Set the working mode tp H/O mode, and turn the
travel speed switch to HI.
ii) Use the work equipment and/or undercarriage at-
tachment to raise the wheels OFF the ground.
iii) Measure the oil pressure with the engine at high
idling and the travel pedal operated to the end of
its stroke to rotate the wheels under no load. Run
the engine at high idling, operate the travel pedal
to the end of its stroke, and measure the oil pres-
sure when the working mode and travel speed
are switched as shown in Table 1.
Table 1
202FO6340
20-30
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO
TESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
Table 2
// 202FO6354
20-31
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO
TESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
ADJUSTING
1. Adjusting LS valve
When the differential pressure is measured under the
conditions above, and the results show that the differ-
ential pressure is not within the standard value, adjust
as follows.
1) Loosen locknut (4) and turn screw (5) to adjust
the differential pressure.
+ Turn the screw to adjust the differential pressure
as follows.
. To INCREASE pressure, turn CLOCKWISE
. To DECREASE pressure, turn COUNTER-
CLOCKWISE
2) After adjusting, tighten locknut (4)
cm Locknut:
29.4 f 4.9 Nm (3.0 f 0.5kgm)
20-32
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE
Solenoid valve
202F06358A-K
20-33
TESTING AND ADJUSTING TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE
Table 1
output
Engine (Reference)
Operation pressure
speed (rpm) Current (A)
MPa (kg/cm2)
2.5
Min. 1100 800 * 80
(2’3
0.2 * 0.2
Max. 1900 0
(2 * 2)
20-35
TESTING AND ADJUSTING TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE
Table 2
Cl 202FO6362
20-36
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND TESTING PPC SHUTTLE VALVE
PPC
/
c5
Blind pl& 202F06366
20-37
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND TESTING PPC SHUTTLE VALVE
Swing
Bucket DUMP (SO8)
‘(507)
w&t CURL
Arm IN
(505)
Boom LOWER
(SO41
Arm OUT
(503)
Boom RAISE
2-Piece boom (502)
stabiI\ser
(G66)
Control valve
0 Bucket DUMP
b
------A
0 Arm
_----~
-,---(*
(Swing RIGHT)
---_1-
L. H. PPC valvel
---
(Extend) KWKiOP6062
1. Swing PPC shuttle valve 4. Stabiliser / 2 piece boom PPC shuttle valve
2. PPC shuttle valve for LS select 5. 2 Piece boom PPC shuttle valve
3. Stabiliser PPC shuttle valve
20-38
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
20-39
TESTING LOCATIONS CAUSING HYDRAULIC
TESTING AND ADJUSTING DRIFT OF WORK EQUIPMENT
[Reference]
If the cause of the hydraulic drift is in the packing, and
the above operation is carried out, the downward
movement becomes faster for the following reasons.
1) If the work equipment is set to the above posture 3) When the pressure is balanced, the down-
(holding pressure applied to the bottom end), the ward movement becomes slower. If the lever
oil at the bottom end leaks to the head end. How- is then operated according to the procedure
ever, the volume at the head end is smaller than given above, the circuit at the head end is
the volume at the bottom end by the volume of the opened to the drain circuit (the bottom end is
rod, so the internal pressure at the head end in- closed by the check valve), so the oil at the
creases because of the oil flowing in from the bot- head end flows to the drain circuit and the
tom end. downward movement becomes faster.
2) When the internal pressure at the head end in-
creases, the pressure at the bottom end also rises
in proportion to this. the balance is maintained at a
certain pressure (this differs according to the
amount of leakage) by repeating this procedure.
20-40
TESTING LOCATIONS CAUSING HYDRAULIC
TESTING AND ADJUSTING DRIFT OF WORK EQUIPMENT
20-41
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
Disconnect hose
End of stroke &pd
I F201 C6006
Arm cylinder
I 202FO6376 I 202FO6375 1
20-42
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
2. Swing motor
1) Disconnect drain hose (1) from the swing motor,
then fit a blind plug at the tank end.
2) Turn the swing lock switch ON.
3) Start the engine and operate the swing relief with
the engine at high idling.
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one minute.
+ After measuring, swing 180” and measure
again.
3. Travel motor
1) Disconnect drain hose (2) from the travel motor,
then fit a blind plug at the tank end.
2) Apply park brakes
3) Start the engine and operate the travel relief with
the engine at high idling.
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
* No accumulator is installed, so the pressure remain-
ing in the piping between the control valve and the
hydralic cylinder or swing motor cannot be released by
operating the control levers. Therefore, when remov-
ing the above piping, be careful of the following points.
20-43
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
l Replace cylinder
0 -+ 0 ’ 0
l Remove cylinder piping
l Replace swing motor
0 ’ 0 ’ 0
l Remove swing motor piping
l Replace travel motor
0 ’ 0 0
l Remove travel motor, swivel piping
Note 1: Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained.
20-44
TESTING AND ADJUSTING BLEEDING AIR
20-45
TESTING AND ADJUSTING ACCUMULATORS
ACCUMULATORS
CHARACTERISTIC DETAILS
1. Model code
Charging hose 1 _
with cap screw Gl
(fem. thread W 24.32 x l/14” - DIN 477) suitable for
direct connection with nitrogen bottles in Germany,
Netherlands, Switzerland, Sweden, Finnland, Russia,
Belgium (see point 4.3).
Case I
Accessories
full details required when ordering
Gas safety valve with intermediate piece (see point 4.5)
Pressure release valve with connector (see point 4.5)
Adapter for cap screw D (see point 4.1)
2. Weight
2.2 kg with case
1 .O kg without case
3. Mounting position
Optional
20-46
TESTING AND ADJUSTING ACCUMULATORS
OPERATING INSTRUCTIONS
20E-60-K1150
Max. working pressure (~2) = 210 bar
Gas pre-charge (PO) = 50 bar
po, to = pO.t2 z
3. PREPARATION
Prior to each testing, charging or topping-up of
nitorgen, the accumulator has to be separated from
the pressurised system by means of the shut-off valve
and the fluid has to be released. The protective cap S
has to be unscrewed. Slightly loosen the int.hex.
screw by means of an Allen key GW 0, DIN 911
(approx l/2 turn). Screw cap nut D by hand onto accu-
mulator gas valve. Turn charging unit to a position
where the gauge can be easily read.
4. TESTING
Valve V is opened by loosening the int.hex. screw with
spindle A. After the pointer of the gauge begins to
deflect unscrew the spindle by a further full turn.
The gauge now shows the charging pressure in de ac-
cumulator. The check valve prevents any escape of ni- Piston and diaphragm accumulators
trogen. (gas valve)
5. PRESSURERELEASE
By carefully opening relief valve B, the nitrogen es-
capes into the atmosphere.
20-47
TESTING AND ADJUSTING ACCUMULATORS
20-48
TESTING AND ADJUSTING ACCUMULATORS
20-49
TROUBLESHOOTING
20-50
TROUBLESHOOTING POINTSTO REMEMBER WHEN TROUBLESHOOTING
A When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, an important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible cusses of the failure that would produce the reported symptoms.
1. When carrying out thoubleshooting, do not 5) Other maintenance items can be checked
hurry to disassemble the components. If com- externally, so check any item that is consid-
ponents are disassembled immediately any fail- ered to be necessary.
ure occurs: 4. Confirming failure
. Parts that have no connection with the fail- . Confirm the extent of the failure yourself,
ure or other unnecessary parts will be dis- and judge whether to handle it as a real
assembled. failure or as a problem with the method of
. It will become impossible to find the cause operation etc.
of the failure. + When operating the machine to
It will also cause a waste of manhours, parts, or reenact the troubleshooting symp-
oil or grease, and at the same time, will also toms, do not carry out any investiga-
loose the confidence of the user or operator. tion or measurement that may make
For this reason, when carrying out trouble- the problem worse.
shooting, it is necessary to carry out thorough 5. Troubleshooting
priorinvestigation and to carry out troubleshoot- . Use the results of the investigation and in-
ing in accordance with the fixed procedure. spection in items 2-4 to narrow down the
2. Points to ask user or operator causes of failure, then use the trouble-
1) Have any other problems occurred apart shooting flowchart to locate the position of
from the problem that has been reported? the failure exactly.
2) Was there anything strange about the ma- + The basic procedure for troubleshoot-
chine before the failure occurred? ing is as follows.
3) Did the failure occur suddenly, or were 1) Start from the simple points
there problems with the machine condition 2) Start from the most likely points
before this? 3) Investigate other related parts or
4) Under what conditions did the failure oc- information.
cur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before . Even if the failure is repaired, if the root
the failure? cause of the failure is not repaired, the
When were these repairs carried out? same failure will occur again.
6) Has the same kind of failure occurred be- To prevent this, always investigate why the
fore? problem occurred. Then, remove the root
3. Check before troubleshooting cause.
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers
4) Check the stroke of the control valve spool
20-51
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
Step 1
IExamination, confirmation of symptoms1 _
_
l) When a request for repairs is received,
\r-
first ask the following points.
. Name of customer
. Type, serial numer of machine
. Details of lobsite, etc.
2) Ask questions to gain an outline of the
problem.
. Condition of failure
. Work being carried out at the time
of the failure
. Operating environment TEW00182
. Past history, details of marnte-
nance. etc.
\
TEW00183
Step 2
Determining probable location of cause
TEW00184
i
Step 3
I
1Preparation of troubleshooting tools 1 zzzr TEW00185
w \
firm
really
the condition
a failure.
and judge if there IS
TEWOOl88
Step 4
IGo Ask operator questions to confirm details
20-52
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS 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 sec-
tion deals particularly with correct repair procedures for
mechatronics and is aimed at improving the quality of re-
pairs. For this purpose, it gives sections on “Handling elec-
tric equipment” and “Handling hydraulic equipment” (par-
ticularly hydraulic oil).
I TEW00192
20-53
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
20-54
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
when removing
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 an pull apart. For connectors which
have a lock stopper, press down the stopper with
your thumb and pull the connectors apart. v TEW00197
Connecting connectors
(1) Check the connector visually
a. Check that there is no oil, dirt or water stuck to the
connector pins (mating portion).
b. Check that there is no deformation, defective con-
tact, corrosion, or damage to the connector pins.
c. 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 con- TEW00199
20-55
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
II TEWOOlSS
TEW00202
20-56
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
T-adapter
I1 TEW00206
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
3) Sealing openings
After any piping or equipment is removed, the open-
ings should be sealed with caps, tapes, or vinyl bags
to prevent any dirt or dust from entering. 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, collect it and ask the customer
to dispose of it, or take it back with you for disposal.
I TEW00209
20-58
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
6) Flushing operations
After disassembling and assembling the equipment,
or changing the oil, use flushing oil to remove the con-
taminants, sludge and old oil from the hydraulic circuit.
Normally flushing is carried out twice: primary flushing
is carried out with flushing oil, and secondary 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 TEWOO210
cleaning toi remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3 u) particles that the filter built into the
hydraulic equipment cannot remove, so it is an ex-
tremely effective device.
I TEW00211
20-59
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
6. Check engine oil level (Level of oil in oil pan) Add oil
20-60
TROUBLESHOOTING CONNECTOR TYPES
CONNECTORTYPES
17 Pump controller
20 Pump controller
16 Pump controller
IO TVC prolix switch
2 TVC prolix resistor
3 Pump pressure sensor
2 I LS control EPC solenoid valve
2 Pump TVC solenoid valve
3 Governor potentiometer
4 Governor motor
3 Fuel control dial
2 Engine speed sensor
14 Intermediate connector
SIMPLE
Eli L 1 Heater relay G51 CONN- 1 ENG room lamp
ECTOR
El2 1 3 ALTERNATOR G52 KESO 4 Lower wiper
El3 I 2 STARTER G53 HELLA 6 Flasher unit
SIMPLE
FOI X 2 Travel alarm G54 CONN- 1 SUS lock switch
ECTOR
TROUBLESHOOTING CONNECTOR TYPES
G62 ForwarcVreversesol
G63 EPC flow
G68 2 PC boom/stabiliser switch
G69 M 2 Lower wiper
G70 M 4 LH wrist control
G71 M 4 RH wrist control
G72 X 2 Service sol
G75 X 2 Travel switch
Simple
G76 tonne- 1 Sidelight
%ctor
Simple
G77 tonne- 1 Sidelight Travel (Park brake buzzer)
ctor
Simple
G90 tonne- 1 Park brake switch
ctor
Simple
G91 tonne- 1 Brake light switch SUS lock switch
ctor
G92 Britax 1 5 Roadlights switch
G94 AMP 1 1
G95 Britax 1 9 Hazard switch
G96 Britax 1 6 SUS lock switch
G97 _ I 3 Indicator switch
G98 Britax I 6 Outriggers UR switch
G99 Britax I 9 Park brake switch
GIOO Britax I 2 Worklights pilot
G101 Britax I 2 Indicators pilot
G102 Britax I 2 Low brake press pilot
G103 Britax I 2 Main beam pilot
G104
20-62
TROUBLESHOOTING CONNECTOR TYPES
No. of
Electrical component Electrical component
pins
M30 l - Ill Work lights (option) SO6 X Bucket CURL oil pressure switch
Electromagnetic clutch for air
M34 1 M so7 x Bucket DUMP oil pressure switch
conditioner compressor
M38 1 M 3 I Light switch t SO8 X Swing oil pressure switch
20-63
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
pins
r Male (female housing)
X type connector
205FO53 IO
205FO5309
205FO5.3 I I 205FO53 I2
2 2
205FO53 I3 205FO53 I4
1 3
\
4 2
205FO53 I5 205FO53 I6
20-64
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T M type connector
205FO53 I7 205FO53 I8
1
1
205FO53 I9
205FO5320
2
\ ;3
-
3
,2&F
1
20560532 I 205FO5322
1 3
\ I
!
2 4
205FO5323 205FO5324
20-65
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
4 1
ES
/ \
3 s 6 3
205FO5325 205FO5326
20-66
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T S type connector
5 1
8 4 8 4
205FO5327 205FO5329
1 6 6 1
/
IO
/ \
10 5
205FO5329 205FO5330
8 1
16
8 i
16 7
205FO5333 205FO5334
20-67
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
r AMP040 type connector
16
1 9
205FO5335
10 20 20 10
/
‘\
\ i
20
205FO5337
1 11 ri 1 205FO5338
20-68
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T AMP070 type connector
14
205FO6364 205FO6365
18
k.4
205FO6366 205FO6367
20-69
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Y
3
a 3
1
205FO6366
205FO6369
20-70
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T SWP type connector
118 4 1
/
14
/ I \ \
14 10 7 3
3 7 10 14
F56103067 F56103086
20-71
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
17
I I
142F414 142F415
11
1
21 12
21
142F416 - 142F417
20-72
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
6 5 6
No.
of Ring connector
pins
20-73
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
r L type connector
2OTFOl 150
20TF01149
205FO6370 205FO637 I
20-74
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T Automobile conector (KESI)
E3
205FO6373
205FO6372
20-75
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
PE 423F350
423F349
I 1
B
I I 1
2 3 3 2
I
423F351 423F 352
423F354
423F353
20-76
TROUBLESHOOTING EXPLANATION OF CONTROL MACHANISM FOR ELECTRICAL SYSTEM
_ Star-signal 0
20-77
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
OFF OFF
WVM/-v
OFF OFF User code OFF OFF OFF
EKP00077
20-78
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Working
mode _
function
Operation Display
1. To set to the trouble data display mode. 1. On the tme display and service meter display, the service
Keep the TIME switch + L.H. travel code and number of hours (service meter hours) that
speed switch pressed for 2.5 seconds. have elapsed since the occurrense of the abnormality are
Note: It is possible to call it up at the fol- displayed.
lowing times. . Example of display : When E212 has occured 12
1) In the normal mode hours before (service meter)
2) In the user code display mode 1) Display of service code 2) Display of elapsed time
3) In the machine data monitoring
mode
4) In the time adjustment mode
20-79
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Operation I Display
4. To finish with the trouble data display 4. If there is no abnormality code in memory
mode, keep the TIME switch + L.H.
travel speed switch pressed for 2.5 sec-
onds. OFF OFF
5. To erase the memory, keep the time
switch pressed, turn the starting switch
from OFF to ON, and keep the time
switch pressed for 5 seconds.
wwh-Jwv
OFF - is displayed OFF - is displayed OFF
Time display
meter
Til
switch
\
Travel speed e
switch \ e
Operation Display
1. To set the machine data monitoring 1. On the time display and service meter display, the moni-
mode, do as follows. toring code and data are displayed.
Keep the time switch + knob button func- . Example of display
tion switch pressed for 2.5 seconds. 1) When engine speed is monitoring (monitoring code
Note: this is possible at the following 10)
times.
OFF OFF
1) During the normal code
2) During the user code display
3) During the time adjustment mode
4) During the trouble data display
mode v-- uvvw-v-v
OFF OFF Monitoring OFF OFF Monitoring OFF OFF
code code data
(example of 1950 rpm)
BKP00083
20-80
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Operation Display
20 Governor, pump controller PPC oil pressure switch input signal (1) B Governor, pump controller
21 Governor, pump controller PPC oil pressure switch input signal (2) B Governor, pump controller
22 Governor, pump controller PPC oil pressure switch input signal (3) B Governor, pump controller
24 Input condition of sensor for governor, pump controller monitor warning 1 B Governor, pump controller
25 Input condition of sensor for governor, pump controller monitor warning 2 B Governor, pump controller
20-81
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
+ For detalis of the B in the Unit column, see the bit pattern chart in the next section.
20-82
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
OFF OFF
BKPO0085
(3)
08 Connection of S-NET components
(4)
(5)
(6)
(1) Swing switch ON
(1)
(2) Overload sensor Open
20-83
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
(1)
(2)
Input condition of governor, pump (3)
36
controller (4)
(5) Starting switch ON
(6)
(1) Battery relay: Actuated
(2)
Output condition of governor, pump (3)
37
controller (4)
(5)
(6)
(1)
(2) Alarm buzzer: when operated machine
(3)
47 Monitor panel output condition 1 (4)
(5)
(6)
(1) KEY ON SW OFF
-(6)
20-84
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
Operation Display
4
1. To set the governor motor adjustment I.
OFF
mode, press the time switch + R.H. OFF
working mode switch.
---J-w-v
OFF Displays “g-SET” OFF OFF OFF
BKP00086
2. To return to the time display mode use 2. Buzzer sounds once a second
the same procedure as in step 1.
Operation Display
1. To set the time adjustment mode, keep 1. The time mark portion flashes
the time switch depressed for 2.5
seconds.
OFF OFF
20-85
TROUBLESHOOTING METHOD OF USING JUDGEMENTTABLE
[Judgement]
1) If a service code is being displayed on the monitor panel.. .go to troubleshooting [E3:00 ] for the governor,
pump controller (governor control system).
2) If no service code is displayed on the monitor panel, and the engine does not start:
20-86
TROUBLESHOOTING METHOD OF USING JUDGEMENTTABLE
2. When using judgement table for governor, pump controller (governor control sustem) and hydraulic related
parts.
. If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of the
judgement table (C-00).
(A l mark is put at the places where the failure mode and service code match.)
. If a problem has appeared but no service code is displayed on the monitor panel, go to the point where
the failure mode matches the input signal, and check the display for the input signal (the display at the
place with a mark).
. If it is displayed normally, go to the troubleshooting code on the right of the judgement table
(H-00).
. If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (F-00).
Procedure: check if the service code is being displayed on the monitor panel.
[Judgement]
1) If a service code is being displayed on the monitor panel...go to troubleshooting [E2: ] for the governor,
pump controller (pump controller system).
2) If no service code is displayed on the monitor panel, and the upper structure does not swing:
There is no signal
Go to troubleshooting
mechanical system
Go to troubleshooting
of governor,
H-25 of
F-00
pump controller
input signal system (F mode
for applicable system)
20-87
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-88
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
(1) M-9 When starting switch is turned ON (engine stopped), check item for previous trouble-
shooting flashes
(4) + Before carrying out troubleshooting, check that all the related connectors are properly in-
serted.
* Always connect any disconnected connectors before going on the next step.
* Check that the coolant is at the specifies level before carrying out troubleshooting.
Cause
Table
Connected I Yes I
Disconnected No
I
20-89
TROUBLESHOOTING DETAILS OFTROUBLESHOOTING ANDTROUBLESHOOTING PROCEDURE
The procedure for carrying out check items No. 3 and 4 in the flow chart below is given on the following pages.
E
E02 (TVC system)
YE
E03 (Swing holding brake system)
Go to Item 2
E05 (Governor motor system) I
Engine system
1
2 5
Is problem in engine
IS Selvlce code YE system of hydraulic NO chart ior
displayed on monitor * Go to flow chart for Ilems where
(mechanical)
panel? sectlo” where there IS ,,,ere ,s ,,o
system? dIsp,ayj (El 1
no abnormality display
on judgment table E15)
. Operate and check * After adlustIng 011
1Hydraulic Carry out trouble-
Selvlce code. pressure, judge from
(mechani- shooting for hydraulic
engine speed. ^
YE controller Input and tial) system (mechanical) system
* Is all workequlpment
(H mode)
slow and does
engine speed drop
* Check wng under heavy load?
1
3 monitoring code.
. Governor controller:
-Carry out troubleshooting for
30,31,33,34 IO
NC Input slgnal system (F mode).
Are monitor codes * Pump controller.
02, 03, 06 normal? 10-24
* Valve controller.
50 69
* Check ConnectIon - Carry out troubleshootlng
condltlon of S-NET I” NO for communication
monitoring codes abnormality system
02,03,08 (N comde).
+ For details, see governor, pump controller (governor control system) (pump control system) in the JUDGE-
MENT TABLE.
20-90
TROUBLESHOOTING DETAILS OFTROUBLESHOOTING ANDTROUBLESHOOTING PROCEDURE
If there is no abnormality display in the communications system transmitted in S-NET, it can be taken that the
output signal from the monitor panel has been transmitted. However, even if there is no abnormality display, if the
operation is defective, use the following procedure when checking directly. If any abnormality occurs in the S-
NET system, the system is automatically switched to the following default mode, so be careful when carrying out
troubleshooting.
Default Mode when communications cannot be carried out for the monitor and governor, pump controller
2. Checking working mode signal (check No. 2 throttle signal monitoring code 16) at the same time)
1) Set to the monitoring mode and display monitoring code 10.
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
Table 1
0% 1 Swing Lock ON
20-91
TROUBLESHOOTING DETAILS OFTROUBLESHOOTING ANDTROUBLESHOOTING PROCEDURE
20-92
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
20-93
TROUBLESHOOTING DETAILS OFTROUBLESHOOTING ANDTROUBLESHOOTING PROCEDURE
20-94
TROUBLESHOOTING SERVICE CODE TABLE
El01 Abnormality in error history data El12 Short circuit in relay drive R
20-95
TROUBLESHOOTING OF COMMUNICATION
ABNORMALITY SYSTEM
(N MODE)
20-97
TROUBLESHOOTING N-l
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the service code E is not displayed, the problem has been removed.
* If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that
the service code displays E. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related
connectors are properly inserted. Remedy
* Always connect any disconnected connectors before going on
the next step.
4 YES
Is monitoring code Defective monitor panel Repair
02,03 display normal?
- See Table 2
YES Defective governor, pump Replace
* Turn starting switch
ON. controller
Is voltage between
Cl7 (4) (12) and
chassis normal? Defevtive monitor panel Replace
Is reslstance between
- Turn starting PO1(4), (11) andC17
switch ON.
. Mln 75V Disconnection in wiring
* Disconnect Cl7 harnees between PO1(4), Replace
and measure (11) and Cl7 (4) (12)
voltage at c17.
harnees end. * Max. 10
Table 1
When each controller is connected to the
” ” is displayed. If the correct
1rable 2
. Light up when connected . Note: Checks can be carried out with code 08 only
(1) Governor, pump controller when there is a disconnection. The display does not
(2) Governor, pump controller change when there is a short circuit.
Therefore, checks when there is a short circuit
should be carried out basically using Table 1
20-98
TROUBLESHOOTING N-l
S-NET(+)
\
C17(04016)
20-99
TROUBLESHOOTING OF GOVERNOR,
PUMP CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
Points to remember when carrying out troubleshooting of governor, pump controller system.. ............... 20-101
Action taken by controller and condition of machine when abnormality occurs ....................................... 20-I 02
Judgement table for governor, pump controller (governor control system)
and engine related parts .......................................................................................................................... 20-l 06
Electrical circuit diagram of governor, pump controller (governor control system). .................................. 20-l 08
E- 1 Abnormality in governor, pump controller power sosurce (controller LED is OFF). ............ 20-I IO
E-2 [E308] Abnormality in fuel control dial input value is displayed.. ........................................ 20-l 11
E-3 [E317] Abnormality (disconnection) in governor motor drive system is displayed .............. 20-l 12
E-4 [E318] Abnormality (short circuit) in governor motor drive system is displayed ................. 20-I 13
E-5 [E306] Abnormality in feedback potentiometer system is displayed.. ................................. 20-I 14
E-6 [E315] Abnormality (short circuit) in battery relay output system is displayed.. .................. 20-l 15
E-7 [E316] Abnormality (step-out) in motor is displayed.. ......................................................... 20-l 16
E-8 Engine does not start.. ........................................................................................................ 20-I 18
E-9 Engine speed is irregular.. .................................................................................................. 20-120
a) Idling speed is irregular.. .............................................................................................. 20-120
b) There is hunting.. ......................................................................................................... 20-122
E-l 0 Lack of output (engine high idling speed is to low). ............................................................ 20-124
E-l 1 Engine does not stop.. ........................................................................................................ 20-l 26
E-12 Defective operation of battery relay system (engine does not stop). .................................. 20-l 28
20-I 00
POINTSTO REMEMBER WHEN CARRYING OUTTROUBLESHOOTING OF
TROUBLESHOOTING GOVERNOR, PUMP CONTROLLER SYSTEM
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting flow
chart for the mechanidal system or electrical system. For details of the procedure for adjusting the linkage,
see TESTING AND ADJUSTING.
20-I 01
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PRO-BLEMS ON MACHINE
20-I 02
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
1. If during operation
1) Set to low idling
2) Engine does not stop
20-103
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Abnormality (short circuit) If excess current flows between CO3 (1) and battery relay
E315 in battery relay output + This occurs only when turning starting switch to OFF and
system stopping engine
20-I 04
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
20-105
JUDGEMENTTABLE FOR GOVERNOR, PUMP GOVERNOR
TROUBLESHOOTING fGOVERNOR CONTROL SYSTEM) AAND ENGINE RELATED PARTS
s
x
_ _
Failure mode _ _
301 31!
_ _
1 1Enaine does not start easilv
_ _
2 Engine does not start
3 Engine speed stays at low idling, and does not follow accelerator; or engine pickup is poor 5
- 5
-
4 Engine stops during operation
- -
5 Engine rotation is irregular
When idling speed is irregular
-
When there is huntino
-
6 Lack of output (engine high idling speed is too low) _
7 1Auto-deceleration does not work
8 1Enaine does not stoo 5
_
9 1Warming-up operation is defective
_
10 1Exhaust gas is black
- -
11 1Oil consumotion is excessive. or exhaust aas is blue
- -
12 1Oil becomes dirty prematurely
- -
13 1Fuel consumption is excessive, or exhaust qas is blue
- -
14 Oil is mixed in coolant
- -
15 1Engine oil pressure caution lamp lights up _ _
16 I Oil level rises
_ _
17 Coolant temperature rises too high (overheating)
_ _
18 IAbnormal noise is generated
_ _
19 1There is excessive vibration
- -
20 Engine speed does not change even when working mode is switched
- -
- -
Troubleshooting code when service code is displayed i_-
- i_!
-
5 I
20-I 06
JUDGEMENTTABLE FOR GOVERNOR, PUMP GOVERNOR
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM) AAND ENGINE RELATED PARTS
Checking mon,tor,ng,
check items
7
z
0
5
a,
2
6
mz
5
2
a,
s
n
_
xutorlng code
-s.
- S-l
- s-2
_ s-3
_ s-4
_ E-9A), S-5
_ E-9A), S-5
_ E-l 0, S-6
E-3. E-4
=Y
-’
-
-
_
_
_
_
_
-
-
-
-
_
_
_
-1;
_
20407
FUEL I
PW70-6 CDNNECT
PNlM-6 DlmNNECl
.5El+&
CN-Gl53
20-I 08
TROUBLESHOOTING
-f-o
OArrm
4
408 -
40R
/
r--_-_--_- --__,I
20- 109
TROUBLESHOOTING E-l
Cause Remedy
Is voltage between
CO1 (7) (13) and CO2 _
Defective contact, or
(111 1211 normal? 2 YES disconnection in wiring Repair or
harness between fuse 1 and replace
Is voltage between CO1 (female) (7) (13)
. Turn starting swtch
fuse 1 and chassis
ON.
. 20.30V Defective contact, or
* Turn starting switch
disconnection in wiring Repair or
NO
ON. harness between fuse I- replace
. 20.30V HI5 (2)-Ml4 (2) (I)-battery
relay M
04 0
0 @ M14(L2)
C02(MIC21)
Battery
I/-lj BKPOWS6
20-I IO
TROUBLESHOOTING E-2
~
Defective wiring harness in
system with defective Replace
resistance
+ If E306 also occurs at the same time, check the wiring harness below.
. Wiring harness between CO3 (female) (7) - E04 (female) (1) short circuiting with groud, or contact with
other wiring harness
Table 1
Resistance
CO3 (female) E04 (male)
value
1 (7)-(4) 1 (l)-(2) 1 0.25-7kC
1 (4) - (17) 1 (2) - (3) 1 0.25 - 7kC
CO3(04020) Kil
Fuel control
Throttle
dial
command
Throttle power
source (+I Governor
potentiometer
Feedback
Throttle power
source (-1 BKPOOO97
20-I 11
TROUBLESHOOTING E-3
Cause Remedy
(female), or between
,. ,,
Defective wiring harness in Replace
system with defective
(male), or between * Turn starting switch No
resistance
each p,n and chassis OFF
as shown ,n Table I? * Disconnect ~02.
. Turn starting swtch
OFF. Defective governor motor Replace
NO
. Disconnect E05.
Table 1
20-I 12
TROUBLESHOOTING E-4
Cause Remedy
Table 1
Resistance
E05 (male) CO2 (female)
value
Between Between
chassis and chassis and
pins (1) (2) (3) pins (2) (3) (4) Min’ ’ Mn
(4) (5)
20-I 13
TROUBLESHOOTING E-5
Cause Remedy
+ If E308 also occurs at the same time, check the wiring harness below.
. Wiring harness between CO3 (female) (7) - x07 (6) - E06 (female) (1) short circuiting with ground, or
contact with other wiring harness
Table 1
Resistance
CO3 (female) E04 (male)
value
Throttle
command
Throttle power
source (+I
Feedback
Throttle power
source (-1
20-I 14
TROUBLESHOOTING E-6
Cause Remedy
Is resistance
between CO1
(female) (1) and
2 YES
chassis normal? Defective battery relay Replace
~ Is WSlStance between
co, (female) (1) and bat-
* Between co1
NE tery relay telmlnal BR. - Contact between other
(female) (1) and and between w,r,ng har-
chassis.Approx. ne** and chassis normal? wiring harness and wiring
lion harness between CO1 (fe- Replace
* Turn starting switch * Between CO1 NO
male) (I)-battery
OFF (female) (1) and
* Disconnect COl. battery relay BR: relay BR.
Max ln When light is connected
. Between Waring
harness and chassis.
Min. 1 MO
* Turn starting swtch
OFF.
* Disconnect CO1 and
battery relay BR.
/ gz$i;;Nitch &
CO3(04020)
20-I 15
TROUBLESHOOTING E-7
I Cause Remedy
20-I 16
TROUBLESHOOTING E-8
YES
El-
N
. Approx24” NO
YEiS
YE
, ‘“, ,YES
L
NO
E-8 Related electric circuit diagram
MOZ(X2)
Safety relay
4
S B
n Fusible link -
Starting motor
C
Shut-off vdve
E09
20-I 18
L L
TROUBLESHOOTING E-9
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
2 4 YES
VI -- ”
Is controller model YE ~
code as shown I”
. Turn starting switch
ON.
Table 1?
Fuel control dial 5
I
Is voltage between
ON. NO
CO3 (4) and (17)
- Set to monltorlng
normal and stable?
code03or02.
Table 1
20-I 20
TROUBLESHOOTING E-9
I Cause Remedy
See N mode
See E-5
See E-2
See C-14
H08(M6)
I I I
Governor
Feedback potentiometer
20-I 21
TROUBLESHOOTING E-9
b) There is hunting
2 4 YES
I
I
become normal?
lr
connected and motor
lever IS placed at po- CO3 (8) and chassis
Potentiometer
NO sItIon engine low
idling?
I normal and stable?
Is controller model YE
code as shown in
* Turn starting switch NO
ON.
Table 17
* Turn fuel control dial
Fuel control dial 5 I I
from MIN to MAX
. At MIN
* Turn starting switch and stop also at
:2.9 3.3v
ON. midway position. NO
. At MAX
* Set to monitoring
code 03 or 02 NO :0.5 - 0.9v
. At MIN
: -
4.0 4.75v NO
. At MAX
:0.25 -
1 .OV
Table 1
20-I 22
TROUBLESHOOTING E-9
I Cause Remedy
See N mode
See E-5
See E-2
See C-14
P5
Fuse
14
1
Fuel control dia
E04(X3)
rnr0ttlepowerSOURCE
(+) Q)
Governor
Feedback @ a potentiometer
Throttle
powerSOUICB
f-)
20-123
TROUBLESHOOTING E-l 0
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted
* Always connect any disconnected connectors before going on the next step.
YIIS
YE Is E218
dIsplayed?
‘I
Does injection pump normal and stable?
lever contact FULL
Fuel control dial
NO stopper?
. At MIN
,2 9 3.3v
I
* Start engine. . At MAX
NO
- Set fuel control dial normal and stable?
,05-09v
to MAX
* H/O mode.
4 . At MIN
ll
* Turn starting switch
ON. 4 0 4.75v
Is adjustment of . At MAX
* Set to monitoring
llnkage between ‘025. l.OV
code 03 0102
NO governor motor and
pump normal? 8 YES
NO
- See TESTING AND
ADJUSTING.
Table 1
20-I 24
TROUBLESHOOTING E-l 0
I Cause Remedy
See N mode
See E-5
See E-2
Defective adjustment of
governor motor linkage
See C-14
HOS(M6)
Starting switch
Governor
potentiometer
20-125
TROUBLESHOOTING E-l 1
a Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION
position).
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before goning on the next step.
* Read the precautions given in TESTING AND ADJUSTING, “Adjusting travel of governor motor lever”
before carrying out the troubleshooting.
”
lever contact STOP
3
Turn starting switch
Potentiometer 6 YES
ON-OFF
. When llnkage IS
When starting switch
YES ISOFF, ISVOltage
condition become
Relay drwe slgnal 5 - between CO3 (14) -
~ and (17) normal?
* Does loose spring When starting swtch
YES is OFF, does voltage ~ -
. When engine IS NO
Is controller model - between CO1 (1) and -
(6) (12) change as stopped
code as shown in . See TESTING AND Starting motor signal 4
~ shown in Table 2? * 29.33v
Table 17 ADJUSTING.
When stating swtch ~
t * 20 3ov
is OFF, is voltage
: between CO3 (8) and - NO
* Turn starting switch N0
chassis normal?
ON.
* Set to monitoring
* Max.lV
code 03 or 02
NO
Table 1
~~
Table 2
Note 1: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is always
flowing from starting switch BR, so if the voltage is measured at CO1 (I), there is a voltage of 20 -30V
20-I 26
TROUBLESHOOTING E-l 1
I Cause Remedy
See E-5
Battery relaydrive
CO1(MIC13)
20-127
TROUBLESHOOTING E-12
E-12 Defective operation of battery relay system (engine does not stop)
This only occurs when the engine is stopped and the starting switch is turned OFF.
2L Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION
** position).
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
See E-6
Table 1
OFF
Voltage output from controller when starting swirch is OFF
See Note 1
1When ON
(Approx. 24V)
Condition of actuation
of controller circuit OFF I; j _ Min, 4,0z;anerv re’av (BR)
co1 (1)
Drive time Max. 7sec. (when it is impossible to set to
NO IINJECTION because of failure in motor)
ElKP00206
Note 1: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is always
from starting switch BR, so if the voltage is measured at CO1 (l), there is a voltage of 20 - 30V.
20-I 28
TROUBLESHOOTING OF
ENGINE SYSTEM (S MODE)
20-I 29
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections @ + @ in the chart on the right corresponds
to the items where answers can be obtained from the
user. The items in @ are items that can be obtained
from the user, depending on the user’s level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under 0 in the chart
on the right correspond to this.
The serviceman narrows down the causes from infor-
mation @ that he has obtained from the user and the
results of 0 that he has obtained from his own inspec-
tion.
[Troubleshooting]
Troubleshooting is carried out in the order of probabil-
ity, starting with the causes that have been marked as
having the highest probability from information gained
from [Questions] and [Check items].
20-I 30
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20431
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-I 32
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Five causes
Step 1
Three symptoms
t ’ ’
II Step 2
Step 3
20-133
TROUBLESHOOTING S-l
\ Charging1 1 1 1 1
Amb\rate 1 100% 1 90% 1 80% 1 75% 1 70%
. The specific gravity should exceed the value for the charging rate of
70% in the above table.
. In cold areas the specific gravety must exceed the value for the
chargi ing rate of 75% in the above table.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
a : Possible causes due to length of use (used for a long period)
nut is loosened
2) Little fuel comes out even when fuel filter air bleed
20-I 34
TROUBLESHOOTING s-2
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
A: Possible causes due to length of use (used for a long period)
0: Items to confirm the cause. d
!
1 Confirm recent repair history
-
Degree of use of machine 1Operated for long period
Found to be chipped
I-L Remedy -
20-I 35
TROUBLESHOOTING s-2
+ check that the monitor panel does not display any ab-
normality in the governor control system.
General causes why engine turns but no exhaust smoke
comes out.
. Supply of fuel impossible
. Supply of fuel is extremely small
. Improper selection of fuel (particulary in winter)
Diesel fuel
Legen
P 2) No fuel comes out even when fuel filter air bleed plug is loosened 0 00 0
6 3) No fuel spurts out even when injection pipe sleeve nut is loosened 0 0 0
20-I 36
TROUBLESHOOTING s-2
20-137
TROUBLESHOOTING s-3
20-I 38
TROUBLESHOOTING S-A
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
n : Possible causes due to length of use (used for a long period)
Condition when
engine stopped
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Chedc items)
A: Possible causes due to length of use (used for a long period)
Condition of hunting
en tnjectton pump Is
20-140
TROUBLESHOOTING S-6
Legend
0 : Possible causes (judging from Questions and check items)
Q : Mostprobable causes (judging from Questions and Check items)
A : Possible causes due to length of use fused for a long period)
l : Items to confirm the cause.
r
When fuel filter, strainer are inspected directly, they are found to be clogged
.-z When feed pump strainer is inspected directly, it is found to be clogged 1 1 1 1 10 1 1
A I
Speed does not change when oparation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy, or does not return
Whenvalve clearanceis checkeddirsctly, it is found to bs outside standardvalue
I I When lever is olaced at FULL position, it does not contact stopper I I I I I Il l I I
20-141
TROUBLESHOOTING s-7
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
1 Confirm recent repair history I I I I I I I I I I I
/ Degree of use of machine 1 Operated for long period I lalnlnl I I I I Inl
-
When turbocharger is rotated by hand, it is found to be heavy
When cheek is made using delivery method, injection timing is found to be incorrect
Remedy
20-I 42
TROUBLESHOOTING S-8
20-143
TROUBLESHOOTING s-9
Causes
be catching or broken I
20-I 44
TROUBLESHOOTING S-l 0
Condition of fuel
Exhaust smoke
$ pt;g’;‘;u
Remedy $_ * B .z L E 2 3
% :;a
Pna”%Soua
I
20-145
TROUBLESHOOTING S-l 1
20-I 46
TROUBLESHOOTING S-l 2
Ambient temperature
Diesel fuel
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
a : Possible causes due to length of use (used for a long period)
a : hems to confirm the cause.
-
Non-soecified oil is beina used
-
t-
Condition when oil
P
._ 1
.a
5 Remove oil pan and inspect directly
e Oil pump rotation is heavy, there is play $
$
o
.g
There is catching of relief valve or regulator valve, spring or B
a P
; valve guide is broken %
B
When oil pressure is measured, it is found to be within 1a
standard value s
Remedy -
i
20-147
TROUBLESHOOTING s-13
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
A: Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Confirm recent repair histon/
f
20-I 48
TROUBLESHOOTING S-l 4
Condition of overheating
I-
r~-----~
Water is leaking because of cracks in hose or loose clamps
Remedy
20- 149
TROUBLESHOOTING s-15
20-I 50
TROUBLESHOOTING S-l 6
I Causes I
Legend
0: Possible causes (judging from Questions and check items)
0: Most probable causes (judgingfrom Questions and Check items)
A: Possible causes due to length of use (used for a long period1
l : Items to confirm the cause.
20-151
TROUBLESHOOTING OF GOVERNOR,
PUMP CONTROLLER
(PUMP CONTROL SYSTEM) (C MODE)
Points to remember when carrying out troubleshooting of pump controller system 20-l 53
Action taken by controller and condition of machine when abnormality occurs 20-l 54
Judgement table for governor, pump controller and hydraulic related parts.. 20-I 60
Electrical circuit diagram of C mode systems 20-l 62
c- 1 Abnormality in controller power source (controller LED is OFF). .............................................. 20-164
c- 2 [E232] Short circuit in pump TVC solenoid system is displayed ............................................... 20-I 65
c- 3 [E233] Disconnection pump TVC solenoid system is displayed ............................................... 20-I 67
c- 8 [E203] Short circuit in swing holding brake solenoid system is displayed.. ............................... 20-169
c- 9 [E213] Disconnection in swing holding brake solenoid system is displayed ............................. 20-l 71
c-10 [E205] Short circuit in 2-stage relief solenoid system is displayed ........................................... 20-I 73
C-l 1 [E215] Disconnection in 2-stage relief solenoid system is displayed ........................................ 20-l 74
c-12 [E206] Short circuit in travel speed solenoid system is displayed ............................................. 20-l 75
c-13 [E216] Disconnection in travel speed solenoid system is displayed ......................................... 20-I 76
c-14 [E217] Model selection input error is displayed ........................................................................ 20-I 77
c-15 [E222] Short circuit in LS-EPc solenoid system is displayed .................................................... 20-178
C-16 [E223] Disconnection in LS-EPc solenoid system is displayed ................................................ 20-l 79
c-17 [E224] Abnormality in pump pressure sensor system is displayed ........................................... 20-I 80
c-19 [E226] Abnormality in pressure sensor power source is displayed ........................................... 20-I 81
c-20 [E227] Abnormality in engine speed sensor system is displayed ............................................. 20-l 82
20-I 52
POINTS TO REMEMBER WHEN TROUBLESKOOTING PUMP
TROUBLESHOOTING CONTROLLER SYSTEM
20- 153
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
1. Short circuit with ground, short circuit inside pump TVC solenoid
2. Short circuit with power source, short circuit with ground in wiring
harness between controller CO2 (8) and TVC solenoid Cl3 (1) ((+)
E232 Short circuit in pump side)
TVC solenoid system 3. Short circuit with power source in wiring harness between control-
ler CO2 (18) and TVC solenoid Cl 3 (2) ((-) side)
4. Defective governor, pump controller
E02
1. Disconnection, defective contact inside pump TVC solenoid
2. Disconnection, defective contact in wiring harness between con-
troller CO2 (8) and TVC solenoid Cl 3 (1) ((+) side)
Disconnection in 3. Disconnection, defective contact, short circuit with ground in wiring
E233 pump TVC solenoid harness between controllerC02 (18) and TVC solenoidC13 (2) ((-)
sytem side)
4. Defective governor, pump controller
1. Short circuit with ground, short circuit inside swing holding brake
solenoid
Short circuit in swing 2. Short circuit with ground in wiring harness between controller CO1
E203 holding brake sole- (3) and solenoid V04 (2) ((+) side)
noid system 3. Defective governor, pump controller
E03
1. Disconnection, defective contact inside swing holding brake sole-
noid
Disconnection in 2. Disconnection, defective contact, short circuit with power source in
E213 swing holding brake wiring harness between controller CO1 (3) and solenoid V04 (2)
solenoid system ((+) side)
3. Disconnection, defective contact in wiring harness between sole-
noid V04 (1) and chassis ground ((-) side)
4. Defective governor, pump controller
20-I 54
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when abnormality ‘roblem that appears on machine
(voltage, current, resistance) is detected when there is abnormality
The current stops flowing to the TVC 1. In the case of 1, it is the same
solenoid, so no particular action is as E232.
. Resistance of solenoid: taken. 2. In the case of 2, the current
IO-22D If there is a short circuit with the (min. 1A) continues to flow to
. Current: 1000 mA (H/O ground at the (-) end, the current (min. the pump TVC solenoid, so the
mode, auto-deceleration IA) continues to flow to the TVC sole- output of the pump TVC valve
ON, levers at neutral, fuel noid. increases and the overall
control dial at MAX.) It displayes user code E02 on the speed becomes slower.
monitor panel.
If the abnormality is restored by the
vibration of the machine, it resets the
power source to restore to the proper
condition. (However, the service code
display does not go out.)
20- 155
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Short circuit in LS 1. Short circuit with ground, short circuit inside LS bypass solenoid
E201 bypass solenoid 2. Short circuit with ground in wiring harness between controller co1
system (2) and solenoid V05 (2) ((+) side)
3. Defective governor, pump controller
Short circuit in 2- 1. Short circuit with ground, short circuit inside 2-stage relief solenoid
stage relief solenoid 2. Short circuit with ground in wiring harness between controller ~01
E205 system (IO) and solenoid V05 (2) ((+) side)
3. Defective governor, pump controller
1. Short circuit with ground, short circuit inside travel speed solenoid
Short circuit in travel 2. Short circuit with ground in wiring harness between controller CO1
E206 speed solenoid (9) and solenoid V06 (2) ((+) side)
system 3. Defective governor, pump controller
E217 Model selection input 1. Disconnection, defective contact, short circuit with ground in model
error selection wiring harness Cl7 (5) (6) (7) (13) (14)
2. Defective governor, pump controller
20-I 56
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when abnormality Problem that appears on machine
(voltage, current, resistance) is detected when there is abnormality
1. The current stops flowing to the sole- Same content as display for E201
noid, so no particular action is taken.
+ If the abnormality is restored by the
l Resistance of solenoid: vibration of the machine, it resets the
20 - 60R power source to restore to the proper
condition. (However, the service code
display does not go out.)
1. The current stops flowing to the sole- Same content as display for E205
noid, so no particular action is taken.
l Resistance of solenoid: + If the abnormality is restored by the
20 - 60 R vibration of the machine, it resets the
power source to restore to the proper
condition. (However, the service code
display does not go out.)
1. The current stops flowing to the sole- Same content as display for E206
noid, so no particular action is taken.
l Resistance of solenoid: * If the abnormality is restored by the
20 - 60 D vibration of the machine, it resets the
power source to restore to the proper
condition. (However, the service code
display does not go out.)
20- 157
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Abnormality in 1. Short circuit, short circuit with ground inside pump pressure sensor
E226 pressure sensor 2. Short circuit, short circuit with ground in wiring harness between
power source system controller CO3 (6) and fron pressure sensor CO8 (2)
3. Defective governor, pump controller
20-I 58
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when abnormality Problem that appears on machine
(voltage, current, resistance) is detected when there is abnormality
1. The current stops flowing to the LS-EPC In the case of 1, it is the same as
solenoid, so no particular action is taken. E222
2. If there is a short circuit with the ground at In the case of 2, electric current
Current: Approx. 705 mA (Le- the (-) end, the current (min. 1A) conti- (min. 1A) continues to flow to the
vers at neutral, low idling) nues to flow to the LS-EPC solenoid. LS-EPC solenoid, so the work
t If the abnormality is restored by the vibra- equipment, travel, and swing
tion of the machine, it resets the power speeds are slow
source to restore to the proper condition.
(However, the service code display does
not go out.)
_
Between CO3 (3) and (16): 0.5 - 1 Takes pump pressure as 0 MPa (0 kg/ The travel speed does not auto-
4.5 V cm2)when actuating. matically shift (it does not change
Between CO3 (6) and (16): 18 - * If the abnormality is restored by the vibra- from Hi to Lo).
28V tion of the machine, it resets the power + If the button is operated
Between CO3 (female) (3) and source to restore to the proper condition. manually, the panel display is
(16), (3) and chassis (However, the service code display does switched.
Resistance: Min. 1 MG (Discon- not go out.)
nect connectors CO3 and C08.)
1. Takes front pump and rear pump pressure 1. The travel speed dos not auto-
as 0 MPa (0 kg/cm”) when actuating. matically shift (it does not change
l Voltage between CO3 (6) and 2. When abnormality is detected, it switches form Hi to Lo).
(16): 18 - 28V the output OFF, and when all levers are t If the button is operated
returned to neutral, it outputs again. manually, the panel display is
* This automatic resetting is repeated up to switched.
3 times.
l Resistance: 500 - 1000 CI 1. It functions in the equivalent of the G/O It operated about the same as G/O
l Voltage (AC range) : 0.5 - 3.0 V mode (the speed rises) mode (prolix) (the power is slightly
(engine started) lower)
20-I 59
JUDGEMENTTABLE FOR GOVERNOR, PUMP CONTROLLER
TROUBLESHOOTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
Failure mode
20-I 60
JUDGEMENTTABLE FOR GOVERNOR, PUMP CONTROLLER
TROUBLESHOOTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
* If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode.
Go”elnOl
pump
cmltrder
(E2
xx Check items in monitoring mode
4yzlem)
20-161
TROUBLESHOOTING
a I I I
II
_
_
_
r
20-I 62
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE 2/2
J
5
-
_
_
-
_
_
_
20-I 63
TROUBLESHOOTING C-l
Cause Remedy
YES
1 , Defective governor, pump controller Replace
Isvoltage between
CO1 (7) (13) and ~02 - Defective contact or disconnection in Repair or
(11) (21) normal? 2 YES wwng harness between fuse and 1 replace
CO1 (female) (7) (13)
~ Is voltage between
* Turn starting swtch
_ fuse 1 and chassis _
ON.
No normal?
. 20.30V Defective contact, or disconnection in
I I I
wwng harness between fuse 1 Hi5
* Turn StartlnC] swtch NO (2) Ml4 (2) (1) battery relay M
ON.
* 20 - 3ov
1
gI a-
PGND
f-l Fusible link
12
C02(MIC21)
II-II
-!3 M14iL2)
20-I 64
TROUBLESHOOTING c-2
Cause Remedy
1L-
bet-
YES ween CO2 (female)
- (8) and (18), (8) and
2
~ chassis as shown in
Is rexstance Table l?
between Cl3 (male) ~ GotoA
* Turn starting swtch NO
(1) and (2), (1) and -
OFF.
chassis as shown in
* Disconnect CO2
Table l?
* Turn starting switch
OFF NO
* Disconnect Cl3
I
Defective TVC prolix switch (Internal
* Turn Starting swtch NO short circuit with ground or short Replace
A- OFF. :ircuit with power source)
* Disconnect CO5
. Turn TVC prolix Short c,rcu,t with ground or short
* Turn starting wtch switch OFF. :,rcu,t with power source ,n w,r,ng
wness between CO5 (female) (3) Repalr or
OFF.
* Disconnect C05.
IO -112 ,
(3) Cl3 (female) (1) orshort replace
:ircuit with power sow% in wiring
wness between CO5 (female) (4)
ii2 (4) -Cl3 (female) (2)
Table 1
1Between Cl3 (male) (1) - (2) 1Between CO2 (female) (8) - (18) 1Between CO5 (female) (3) - (4) 1 IO-22f-l I
Between Cl3 (male) (1) - chassis Between CO2 (female) (8) - chassis Between CO5 (female) (3) - chassis Min. 1 MCI I
Table 2
20-I 65
TROUBLESHOOTING c-2
20-I 66
TROUBLESHOOTING c-3
Cause Remedy
3 YFS
Defective governor, pump controller Replace
IS resistance
l-
YES between ~02
- (female) (8) and (1 S),
2
~ (18) and chassis as
Is rexstance shown in Table l?
between Cl3 (male) ~ GotoA
* Turn starting switch NO
(1) and (Z), (2) and -
OFF.
chassis as shown in
* Disconnect ~02.
Table l?
* Turn starting switch
OFF.
NO
* Disconnect C13.
A r
I- between CO5
(female) (3) and
(4),(4) and chassis
as shown m Table 17
Iurn starting wtcn
OFF.
* Disconnect C05.
NO
Defective TVC prolix switch (internal
jlsconnectlon, defective contact, or
short c,rcu,t with ground)
Repair or
replace
jlsconnectlon in wwng harness
,etween CO5 (female) (4) Hi2 (4)
313 (female) (2)
Table 1
Between Cl3 (male) (1) - (2) Between CO2 (female) (8) - (18) Between CO5 (female) (3) - (4) IO-220
Between Cl3 (male) (2) - chassis Between CO2 (female) (18) - chassis Between CO5 (female) (4) - chassis Min. 1 MCI
Table 2
20-167
TROUBLESHOOTING c-3
m&-- da---
l!f!_k
I
I’
I I -
5
-
7
C13(X2)
L-kg-1
20-I 68
TROUBLESHOOTING C-8
Cause Remedy
3 YES
Defective governor, pump controller Replace
YI
2 /zjzzq.,,,,
H
II (3).A26(1)(2)-H13(1)-X01 (7). replace
Is resistance between
X05 (male) (3)
* Disconnect X05.
- 20 60 0
* Turn starting switch
Defective swing lock sitch (internal Replace
OFF
NO short c,rcu,t with ground)
- Disconnect X05
* Turn swing lock
swtch OFF
. Mln 1 MO
Table 1
20- 169
TROUBLESHOOTING C-8
Fuse
I I
A26
Governor, pump controller
CO1(MlC13)
H13(S16) X01 (MIC21) X05(M4)
brake solenoid
VO4(X2)
A05
@ Swing holding
I- brake solenoid
valve
20-170
TROUBLESHOOTING c-9
Cause Remedy
3 YES
YI ~~-‘GotoA
2
Replace
Is resistance
* Turn starting switch NO
yES_ between V04 (male)
ON.
(1) and (2) normal?
1 * Disconnect 601.
I
Interchange
. Turn starting switch
connector wth other AC=
solenoid. Is [E213]
* Disconnect V04 NO
dIsplayed?
Table 1
Between CO1 (male) Between X05 (male) Between V04 (male) 0 - 3V 5 seconds after all levers are returned to neutral
(3) - chassis (3) - chassis (2) - chassis 20 - 30V Swing lever operated
20-171
TROUBLESHOOTING c-9
Fuse
I I
brake solenoid
rE
-
VO4(X2)
A05
g Swing holding
l- brake solenoid
@ valve
TTT
20-I 72
TROUBLESHOOTING C-l 0
Cause Remedy
3 YES
Defective governor, pump controller Replace
IS resistance
YES between CO1
2 (female) (10) and
Short c,rcu,t with chassis ground I” Repalr or
~ Is resistance chassis normal?
wwng harness between CO1 (female x replace
YES between V25 (male) *~ Turn starting swtch ~NO IO) and V25 (female) (2)
- (1) and (2)> (2) and - OFF.
1 chassis as shown in * Disconnect CO1
~ Table l? * 20 - 60n
Interchange * Turn starting switch
connector with other
OFF
solenoid. Is [E205] - NO
* Disconnect V25
dlsplayed?
Table 1
20-I 73
TROUBLESHOOTING C-l 1
Cause Remedy
4 YEE
Defective contact or dIsconnectIon m
awng harness between V25 (female)
(1) and chassis ground
chassis as shown in
Short circuit with power source,
defective contact, or dlsconnectlon in Repair or
awng harness between CO1 (female) replace
(10) -V25 (female) (2)
* Disconnect V25
chaws as shown m
displayed? . . . 20 - 60 n
* Turn starting switch Defective Z-stage relief solenoid
OFF. I (Internal dIsconnectIon or short wcut
* Interchange V25 with NO alth power source)
other connector
- Turn starting swtch
ON.
Table 1
Troubleshooting No. 3 I Troubleshooting No. 4 1 Voltage 1 Measurement condition
Between CO1 (male) (10) - Between V25 (female) (2) - 0 - 3V All levers at neutral
chassis chassis 20 - 30V 1Travel operated independently
A04
, II I
20-I 74
TROUBLESHOOTING c-12
Cause Remedy
3 YES
Replace
IS resistance
YES between CO1
2 (female) (9) and
Short circuit with chassis ground in Repair or
~ chassis normal?
Is resistance wwng harness between CO1 (female) replace
YES between V04 (male) *~ Turn starting switch ~NO (8) and V04 (female) (2)
- (1) and (21, (2) and - OFF.
1 chassis as shown in * Disconnect 601.
~ ~Table l? * 20-6on
Interchange * Turn starting wtch
connector with other OFF.
solenoid Is [E206] - NO
* Disconnect V04
displayed?
Table 1
Travel speed
solenoid valve
I
20-175
TROUBLESHOOTING c-13
Cause Remedy
4 YE
Defective contact or disconnection in Repair or
wwng harness between VO6 (female) replace
YE (1) and chassis ground
F[
Table 1
Troubleshooting No. 3 I Troubleshooting No. 4 1 Voltage 1 Measurement condition I
0 - 3v Travel speed switch at Lo
Between CO1 (male) (10) - Between V06 (female) (2) - Travel speed switch at Mi or Hi
chassis chassis
2o - 3ov Operate the lever slightly not enough to move the
machine
Travel speed
solenoid valve
20-I 76
TROUBLESHOOTING C-l 6
Cause Remedy
2 YES
Defective governor, pump controller Replace
IS resistance
between CO2 Defect contact or short circuit with
(female) (7) and (17), Ii chassis ground in wiring harness
1
11171 and chassis as 11 between CO2 (female) (7) and Cl0
IS resistance shown in Table 17 (female) (I), or defective contact, Repalr or
between Cl0 (male) * Turn starting switch NO short c,rcu,t with ground, or replace
(1) and (2), (2) and -.
OFF dIsconnectIon in wwng harness
chassis as shown in * Disconnect C02. between CO2 (female) (17) Cl 0
Table l? (female) (2)
- Turn startlnq wtch
OFF. Defective LS-EPS solenoid (Internal
NO dIsconnectIon, defective contact, or Replace
- Disconnect Cl0
short circuit with ground)
Table 1
20- 179
TROUBLESHOOTING c-17
Cause Remedy
2 YES
17
Defective governor, pump controller Replace
- 1
H’
defective contact,‘or dIsconnectIon in RepaIr or
Is voltage
between wwng harness between CO3 (female)
CO8 (2) and (1)
Engine at high ldllng NO (3) CO8 (female) (3)
replace
* Operate repeatedly
normal?
arm IN relief H
Short clrcut with ground, defective
contact, or dlsconnctlon I” w,r,ng RepaIr or
harness between CO3 (female) (6) replace
and CO8 (female) (1)
20-I 80
TROUBLESHOOTING c-19
Cause Remedy
2 YES
iJefect1ve front pump pressure sensor Replace
(Internal short c,rcu,t or short c,rcu,t
Is voltage between
with ground)
YES CO3 (6) and (16)
* Disconnect 608.
normal? . 18.28V
. Turn starting switch Short c,rcu,t or short c,rcu,t with Repalr or
OFF. ground in wwng harness of system replace
. Disconnect C03, and where resistance value is defective
cot3
. Mln 1 MO
)$=J+i
Pump pressure sensor
H
1
~EzT~,,, 2
Pump pressure
sensor
3
1 I 1 1 I I I
20-I 81
TROUBLESHOOTING c-20
Cause Remedy
2 YES
Defective govenror, pump controller Replace
IS resistance
YES between Cl6 Short circuit with ground, defective
1 contact, 01 disconnection in wiring
(female) (1) and (2)
harness between Cl6 (female) (1) RepaIr or
nC#tllal?
E08 (10) E07 replace
Is resistance (female) (2), or between Cl6
* Turn starting switch NO
between E07 (male) - (female) (2) E08 (9) E07
OFF.
(1) and (2) normal? (female) (1)
* Disconnect 616.
* 500. iooon
* Turn starting swtch Defective englne speed sensor
OFF. (Internal dIsconnectIon, defective Replace
NO contact, or short circuit with ground)
. Disconnect E07.
-
* 500 1ooon
B-- - a Engine
speed
f3 Q sensor
(SIG \Y I” I I
BKPOO255
20-I 82
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER
(INPUT SIGNAL SYSTEM) (F MODE)
20-I 83
TROUBLESHOOTING
_.
r--
Slyi RmlmAlx sl.
PUP REDUNDANCYCIRCUIT SWITCH
CU-FRE E 1
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE l/2 RESISTER
I
I -
r -
I
I
I
r-
k-
I
t:r
20-184
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE 2/2
20-I 85
TROUBLESHOOTING F-l
F-l Bit pattern 2041) Swing oil pressure switch does not
light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT_adapter, or when removing theT_adapter and returning the connector
to its original position, if the monitor code display returns to normal, the problem has been re-
moved.
Turn the swing lock switch ON before operating the swing lever.
If there is no display when the lever is operated on one side, the PPC shuttle valve is defective. (See H-5)
(When measuring with the engine stopped, charge the accumulator first.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective governor, pump controller Replace
1 I
Defective contact or dIsconnectIon m RepaIr or
Is voltage between 3 YES wiring harness between SO8 (female) replace
Cl6 (5) and chassis Is resistance between (1) and chassis ground
Klrtllal? YES C16 (female) (5) and
_ SO8 (female) (2) nor- _
v Start engine. 2 mal, and IS c,rcu,t ,nsu- Defective contact, short clrcut with
’ Swig lever at Is reskance between lated from chassis? ground, or dlsconnectlon in wlrlng RepaIr or
neutral .20- 30 v - SO8 (male) (1) and * Turn starting switch NO
harness between C16 (female) (5) replace
) Swing lever N
’
(2) normal,and IS - OFF.
and SO8 (female) (2)
operated circuit insulated from * Disconnect Cl6 and SO8.
:
Max. 1V chassU * Between Cl6 and 508: Max. 1 0 Defective swung 011pressure wtch (If
* Disconnect SO8. * Between wirinq harness and chassis: Min. 1 Mn the condition does not return to Replace
* Start enalne ..^ normal even when the switch is
NV
* Swing lever at replaced, go the H-5
neutral: Min. 1 MfI
* Swing lever
operated: Max 10
* See Note 1.
20-I 86
TROUBLESHOOTING F-2
Cause Remedy
Governor, pumpcontroller
. I
:16(MIC17)
20-I 87
TROUBLESHOOTING F-3
Cause Remedy
TTT
BKPOO259
20-I 88
TROUBLESHOOTING F-4
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does
not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT-adapter, or when removing theT-adapter and returning the connector
to its original position, if the monitor code display returns to normal, the problem has been re-
moved.
When measuring with the engine running, operate the lever slightly and make sure that the work equipment
does not move.
(When measuring with the engine stopped, charge the accumulator first.)
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
Cause Remedy
n-T
20- 189
TROUBLESHOOTING F-5
F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not
light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT_adapter, or when removing theT_adapter and returning the connector
to its original position, if the monitor code display returns to normal, the problem has been re-
moved.
When measuring with the engine running, operate the lever slightly and make sure that the work equipment
does not move.
(When measuring with the engine stopped, charge the accumulator first.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
20-I 90
TROUBLESHOOTING F-7
F-6 Bit pattern 20-6 Arm Out oil pressure switch does not
light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT-adapter, or when removing theT-adapter and returning the connector
to its original position, if the monitor code display returns to normal, the problem has been re-
moved.
A When measuring with the engine running, operate the lever slightly and make sure that the work equipment
does not move.
(When measuring with the engine stopped, charge the accumulator first.)
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
Cause Remedy
BKW0262
20-I 91
TROUBLESHOOTING F-7
F-7 Bit pattern 2141) Bucket CURL oil pressure switch does
not light up
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT_adapter, or when removing theT_adapter and returning the connector
to its original position, if the monitor code display returns to normal, the problem has been re-
a moved.
When measuring with the engine running, operate the lever slightly and make sure that the work equipment
does not move.
(When measuring with the engine stopped, charge the accumulator first.)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.
Cause Remedy
YES
Defective governor, pump controller Replace
11
BKPW263
20-I 92
TROUBLESHOOTING F-8
F-8 Bit pattern 2142) Bucket DUMP oil pressure switch does
not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT-adapter, or when removing theT-adapter and returning the connector
to its original position, if the monitor code display returns to normal, the problem has been re-
moved.
When measuring with the engine running, operate the lever slightly and make sure that the work equipment
does not move.
(When measuring with the engine stopped, charge the accumulator first.)
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
Cause Remedy
20- 193
TROUBLESHOOTING F-9
F-9 Bit pattern 21-(3) Swing lock switch does not light up
+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT_adapter, or when removing theT_adapter and returning the connector
to its original position, if the monitor code display returns to normal, the problem has been re-
moved.
+ If the panel display is normal. (If the swing lock lamp does not light up, go to M-21 .)
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
Cause Remedy
20-I 94
TROUBLESHOOTING F-l 1
F-II Bit pattern 22-(6) L.H. knob switch does not light up
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT-adapter, or when removing theT-adapter and returning the connector
to its original position, if the monitor code display returns to normal, the problem has been re-
moved.
When fuse No. 5 is not blown.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
Cause Remedy
H12(S16)
@ @ >I I+-
Y
20- 195
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM (H MODE)
20- 197
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
s t E
T 5 8 2
ii
9 I” ‘n
P iiL lil
Failure mode
(
2 z [2E
9 8 E E E 5E
i- -Y - WI
-
s- ij- 2 n
- -
Speeds of all work equipment, swing, travel are slow or lack power 0
- -
0
- -
0
-
0
- - -
There is excessive drop in engine speed, or engine stalls 0
_
0
_ _ _ _
No work equipment, travel, swing move _
0
_
0
_ _0 _
Abnormal noise generated (around pump) - - -
0
- -
0
- - -
Auto-deceleration does not work - - - - - - - -
Fine control ability is poor or response is poor _
0 0 0
_ _ _ _
Boom is slow or lacks power _ _ _ _ 0
_
Arm is slow or lacks power - - - - - - - -
0
+ In the failure modes, modes for compound operations are used when inde
20-I 98
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
- - - - - - -
Control
-
valve
- T
L I”
9 1” 9
s
.- F E
-5 L g
3
E
2 s a, %I
I” x s Y 3
9 1” 9 9 _c lil
E
5
z
1” E
2 E a,
m
5
E z
0
75 s
8
5 9 t!? C Ea, 5 C E L E 5 0 ‘5
_o E .- 6
a,
P 2 5a
.E s
a, a :
3 5 E z7 9
2
z ,x
iz
‘5
a
.E
5
2
Troubleshooting
code
: 2 2
r”
- -3 -ct 2- -Y -2 2- -< - a
- -a $
a - -c?l15
-
-
0
- - - - -
-
0
- - - - - - - H-i
0 H-2
0 H-3
- - - - - - - - - - - - H-4
-
- -
- - - - - - - - - -
C
- - - H-5
0 H-6
0 0 0 H-7
0
- -
0
- - 0
- -
0
- - - - - H-8
-
- - -
- - -
0
- - - - - -
0
- - - - H-9
0
0 H-10
- - - - - -
0
- - - - -
-
- - -
- - -
0
- - - - - - - - - - H-i 1
0 H-12
0 H-13
- - - - - - - - - - - - H-14
-
- -
-
0
- - - - - - - - - - - - H-15
H-16
0 C H-17
- - - -
0
- - - -
c
- -- - H-18
--
- -
H-19
- - - - - - - - - -
--
- -
H-21
- - -
0
- -
0
- - - -
0
-
C
- -
H-23
- - - - - - - - - -- - H-25
--
- -
- - - - - - - - -
0
- - -
C
H-26
0 0 <
H-27
- - - - - - - - -
0
- - -
0
- -
- - - - - - - - -
0
- - -
0
- - H-28
H-29
- - - - - - - - - - - - - - H-30
- - -
0
- - - - - - - - - - -
H-31
20-I 99
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
22 5
a
9 $ L9
2 5
F
5 0 P .- 5
5
2 ,” 4 &2
Failure mode
W 5 .-F 5is .I!?
5
\ 5 &I 2 c cz
; Speeds of all work equipment, swing, travel are slow or lack power 0 0
6
E F There is excessive drop in engine speed, or engine stalls - - - - -
%2
P Y
No work equipment, travel, swing move - - - - -
L>
a, Abnormal noise generated (around pump) - - - - -
g 2 Auto-deceleration does not work
i Fine control ability is poor or response is poor
Boom is slow or lacks power - - - - -
Arm is slow or lacks power
Bucket OS slow or lacks power
2 Boom does not move
Arm does not move - - - - -
Bucket does not move
- - - - -
Excessive hydraulic drift
Escessive time lag (engine at low idling) 0
* In the failure modes, modes for compound operations are used when independ
20-200
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
-
Travel motor
- - -
s
ST
.G
lil
Pressure switch
- T
73
.- _c
a
2
9 E
I” i .-F
9 5 L
5 b 9 5
g a, u
1”
c $ .G
3 9
s
.- d
L E I” 2 Y 5 9
9 9 .-9 .o s .-5
I) Troubleshooting code
lil ti 6 7 F
,x F 5a, 5 3 u
e E 5 -0 a,
$2 5 5
2 2 i 8 5
2
- -0 -6 -c - -I’ -m -* -I -+
H-l
- - - - - - - - - -
H-2
H-3
- - - - - - - - - - - H-4
- - - - - - - - - - 0000000
-
0 H-5
H-6
0 0 H-7
- - - - - -
0
- - - - -
H-8
- - - - - -
0
- - - - -
H-9
H-10
- - - - - - - - - - -
- - - - - -
0
-
0
- - - -
H-i 1
H-12
H-13
- - - - - - - - - - -
H-14
- - - - - - - - - - -
H-15
H-16
H-17
- - - - - - - - - - -
H-18
- - - - - - - - - - -
H-19
H-21
- - - - - - - - -0 - -
0 H-23
- - - - - - - - - -
0
-
- - - - - - - - - - -
- - - - - - - - - - -
- - - - - - - - - - -
0
- - - - - - - - - -
0
-
- - - - - - - - - - -
20-20 1
TROUBLESHOOTING H-l
3 YES
- 0 2? 0.2 MPa NO
(2 f 2 kg/cm2)
- Eqne at high ldllng
2 * Arm relief
I
NI3
20-202
TROUBLESHOOTING H-l
I Cause Remedy
20-203
TROUBLESHOOTING H-2
Cause Remedy
Is throttle inside
sewo clogged?
2 YES
Defective piston pump Assy Replace
Is engine speed at
NC arm IN relief normal? -
Note 1:
* Engine speed (reference) at arm IN relief when engine and pump are normal
20-204
TROUBLESHOOTING H-3,H-4
I Cause Remedy
Cause Remedy
3 YES
I I Goto
IS suction strainer
Is hydraulic tank oil
- clogged by external -
level normal? 5 YES
NO oblect? Defect inside pump Repair or
Is suction strainer
~
. External oblect, clogged with metal replace
Cloth, etc. _ particles or are metal -
NO particles stuck to Operate for a short time and Inspect agai
drain plug?
watch for any change in (depending
NC)
symptoms on changes
in symptoms
20-205
TROUBLESHOOTING H-5. H-6
Cause Remedy
1 YES
Defective pressure switch Replace
Does condition
become normal when
pressure switch is
E!plLX6d?
Defective operation of PPC Repair OI
shuttle valve in applicable replace
NO system (swing or travel)
I Cause Remedy
1 YES
Cloggd throttle in LS circuit Clean
Replace
20-206
TROUBLESHOOTING H-7
YES
YE
valve move
smoothly?
n
YES
Is relief pressure of
pump normal when
Check LS shuttle for
arm and bucket
‘L
NO
boom RAISE circuit
IS relieved?
I
- 31 4 34 8 MPa
-
(320 355 kg/cm2) L
- Engine at high ldllng NO
8 YES
4
r 1
Is operating pressure
IS pressure normal when boom
IES
compensation valve for
boom normal, or does I F~0 LOWER is being
operated?
- 4 9? 2.9 MPa NO
* It is also possible to (50 ? 30 kg/cm2)
mterchange wth - Engine at high ldllng
Does control valve
IES other compensation
spool for boom move
valve I
smoothly?
. See Note 2. N0
IS outputpressure of
PPCvalve normal?
NO
1:
H
I
Is pressure switch for
boom RAISE,
LOWER normal?
* See Judgement
Table. (Bit pattern 20
(3) (4))
I
. Mln 30MPa
(31 kg/cm2)
- Eqne at high ldllng j
* Operate boom.
N(
. See Note 1. NO
Note 1: If auto-deceleration is canceled when boom RAISE or boom LOWER is operated, system is normal.
Note 2: After inspection, do not forget to return the interchanged valves to the original position.
20-208
TROUBLESHOOTING H-7
I Cause
I
Remedy
7 YES
Defective operation of boom Correct or
lock valve replace
Replace
20-209
TROUBLESHOOTING H-8
r
YES
YES
Interchange wth
other compensation NO
valve.
. See Note 2.
- Mln 30MPa
Is pressure switch for
(31 kg/cm*)
arm IN. OUT r.:.. _I L.-L ._I,..
normal? g NO
I
* see Judgement
Table. (Bit pattern 20
(5)z (‘31) NO
- See Table 1
Note 1: If the auto-decleration is canceled when arm IN or arm OUT is operated, the system is normal.
Note 2: After inspection, do not forget to return the interchanged valves to the original position.
20-210
TROUBLESHOOTING H-8
I Cause Remedy
7 YES
Defective operation of arm Correct or
regeneration valve or arm replace
_ Is leakage from arm _ counterbalance valve.
cylinder normal?
20-211
TROUBLESHOOTING H-9
Cause Remedy
H
3 v ‘ES
I\
GotoA
.
ri
control valve spool for replace
YE3 bucket
Note 1: If the auto-deceleration is canceled when bucket CURL or bucket DUMP is operated, the system is
normal.
Note 2: After inspection, do not forget to return the interchanged valves to the original position.
20-212
TROUBLESHOOTING H-l 0, H-l 1
1 YES
Defective control valve spool Correct or
replace
Is output pressure of
PPC valve normal?
1 YES
Defective hydraulic cylinder Replace
Does speed of piston packing
downward movement
become faster when
lever IS operated? 2 YES
Defective operation of Replace
- See TESTING AND Does condition satety-suction valve
ADJUSTING. become normal when
* It IS alsopowble to NO safety-suction valve
measure leakage of IS Interchanged?
cylinder. Defective operation of boom Correct or
* Max. 20 cclmin NO lock valve replace
- At relief
* Engine at high idling
1
Does speed of
downward movement
become faster when YES Defective operation of Replace
lever IS operated? safety-suction valve
Note 1: After inspection, do not forget to return the interchanged valves to the original position.
20-213
TROUBLESHOOTING H-12, H-13
Cause Remedy
1
compensation valve I Bucket
YES valve
_ normal, or does
pressure compensation
1
~ piston move smoothly?
Defective operation of Correct or
IS output pressure of . It IS also powble to pressure compensation replace
LS-EPC solenoid - interchange with NO valve or pressure compen-
valve normal? other compensation sation piston
valve.
* See Note 1. - See Note 2
Defective operation of LS- Correct or
NO EPC sloenoid valve replace
Cause Remedy
Defective operation of
pressure compensation
valve slipper seal (The
slipper seal in the pressure Replace
compensation valve of the
circuit that moved is
defective.)
20-214
TROUBLESHOOTING H-14, H-15, H-16
1 YES
II
Defective LS valve Correct or
replace
IS output pressure of
LS-EPC solenoid
2 YES
I Defective main relief valve Replace
20-215
TROUBLESHOOTING H-17. H-18. H-19
Cause Remedy
1 YES
Defective operation of LS Correct or
select valve replace
IS output pressure of
LS select solenoid -
valve normal?
Defective operation of PPC Correct or
* Min. 3.0 MPa NO shuttle valve for LS select replace
(31 kg/cm2)
* Operate boom
circuit
RAISE (operate lever
slightly)
‘I I smoothly?
_
* Engine at high idling
* Operate travel lever
Defective operation of LS Repair or
IS pressure of LS fully.
bypass solenoid
NO bypass valve replace
valve clrwt normal?
H
Cause Remedy
1 YES
Defective operation of LS Repair or
II bypass valve replace
Is pressure of LS
bypass solenoid -
valve circuit normal?
Defective operation of LS Repair or
* 0.2 f 0.2 MPa NO bypass solenoid valve
(2 ? 2 kg/cm2)
* Engine at high idling
* Operate boom
RAISE and travel
simultaneously
20-216
TROUBLESHOOTING H-21
3 YES
II
YES IS output pressure of
LS control EPC
solenoid valve
2, r
Is traveloilpressure L n0rtXl?
wtch normal? NO
. See Table 1
,H
FOkWARD and Note:
H
REVERSE, or is it If auto-deceleration IS NO
slow I” one dIrectIon canceled when travel is
only? operated, system IS
normal. (When travel
PPC shuttle IS normal).
Lo Mi Hi
20-218
TROUBLESHOOTING H-21
Cause Remedy
Go to H-20
20-219
TROUBLESHOOTING H-23. H-24
switch: Mi, Hi
- See Table 1.
- Turn travel wtch ON. Defective operation of LS- Correct or
Is travel pressure
wtch normal?
NO EPC solenoid valve replace
* See Judgement
Table. Defective travel pressure Replace
(Bit pattern 20 (2)) hln switch
* If autodeceleratlon IS ‘.-
canceled when travel
IS operated, system
IS normal.
Travel speed
I
2.0 f 0.2 2.2 f 0.2 0.2 f 0.2
LS-EPC output pressure (20.0 f 2.0) (22.7 f 2.0) (2.0 f 2.0)
l Engine at high idling
Remarks
l Operate travel lever slightly (auto-deceleration cancel position)
Cause Remedy
- Max :
30 //mln
* Engine at high idling ho Defective travel motor Replace
- At travel relief
20-220
TROUBLESHOOTING H-25
Cause Remedy
3 YES
Defective swing machinery Repair or
replace
equipment lever).
- See Judgement Defective swing pressure Replace
Table. (Bit pattern 20 i
switch
NO
(1))
* If autodeceleration is
canceled when swng
is operated, system
IS normal
Cause Remedy
>
Defective operation of Correct or
control valve spool for swing replace
20-22 1
TROUBLESHOOTING H-26
4 YES
1
YES
I 1 ,
2 * Travel operated
mdependengly NO
Both left and Does LS shuttle * Min. 2.7 MPa
right Both valve move (28 kg/cm*)
dIrectIon smoothly?
1-I
1
- LS shuttle for boom, NO
arm, bucket, R.H.
travel, L H. travel
YES
1 8
I IS pressure compen-
IS svmlg acceleration
sation valve normal, or
poor in both
does pressure
dIrectIons or I” one compensationvalve
direction only? o~ston move smoothlv?
I I
- It IS also possible to
YE Does control valve interchange with other
-
NO
compensation valve
:
* Note After inspection,
do not forget to return
to the orIgInal posltlon.
5
I I
- Same condltlons as
One dIrectIon Is output pressure of for Item 5
only - RemOVe PPC shuttle NO
PPC valve normal?
block inlet hose, fit
1-I t
adapter, and block
- Mln 3 0 MPa tip. (Note).
(31 kg/cm*)
* Engine at high idling IO
. Turn sw,ng lock
switch ON (lock).
Note: If the adapter for blocking the circuit is not availabel, interchange PPC hose of swing with one of bucket
(CURL, DUMP), boom (LOWER), or arm (IN).
20-222
TROUBLESHOOTING H-26
I Cause Remedy
20-223
TROUBLESHOOTING H-27
I Cause Remedy
Correct or
replace
b) Both directions
I Cause I Remedy I
1 Defective swing motor 1 Repair or replace
20-224
TROUBLESHOOTING H-28, H-29
1 YES
Defective swing PPC slow Correct or
Does condltlon be-
come normal when left return valve (check valve) replace
and right swing PPC -
slow return valves are
Interchanged?
Defective PPC valve Replace
NO
Cause Remedy
Does
3 Defective operation of swing Clean
motor safety-suction valve
1
1
condltlon be-
come normal when Defective swing motor Replace
swing motor safety- YES
suction valve is 2 safety-suction valve
cleaned?
Does condlbon
become normal when
swing motor safety- -
N 3 YES
suction valve is Defective swing machinery Repair or
replaced?
Is foreign material replace
- found I” swng
NO machinery?
20-225
TROUBLESHOOTING H-30
I Cause Remedy
H
7 I
‘I
I Cause Remedy
1 YES
Defective operation of swing Repair of
Is output pressure of
holding brake replace
swrngholdmg brake
solenoid valve
normal?
Defective operation of swing Correct or
. 0.2 f 0.2 MPa NO
(2 ? 2 kg/cm2) holding brake solenoid valve replace
. When 5 seconds
have passed after all
swing and work
equipment control
levers have been
returned to neutral
20-226
TROUBLESHOOTING H-31
I Cause Remedy
1 YES
Defective operation of LS Replace
Is outputpressureof valve servo
LS-EPC solenoid - assembly
valve normal?
Defective LS-EPC solenoid Correct or
. See Table 1. NO
replace
20-227
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM (M MODE)
Action taken by panel and condition of machine when abnormality occurs... 20-230
Electrical circuit diagram for monitor system 20-232
M- 1 [El011 Abnormality in error data is displayed [El021 Error in clock data is displayed ............. 20-234
M- 2 [El031 Short circuit in buzzer output or contact of 24 V wiring harness with buzzer
drive harness is displayed.. ...................................................................................................... 20-235
M- 3 [El 041 Air cleaner clogging detected is displayed ................................................................... 20-236
M- 4 [El 061 Drop in engine oil pressure Hi detected is displayed .................................................... 20-236
M- 5 [El 081 Engine water temperature 105°C detected is displayed ............................................... 20-237
M- 6 When starting switch is turned ON, none of lamps on monitor panel light up
for three seconds ..................................................................................................................... 20-238
M- 7 When starting switch is turned ON, monitor panel lamps all stay lighted up
and do not go out.. ................................................................................................................... 20-240
M- 8 When starting switch is turned ON, items lighted up on monitor panel are different
from actual machine (model) ................................................................................................... 20-240
M- 9 When starting switch is turned ON (engine stopped), basic check items flash ....................... 20-241
M- 10 Preheating is not being used but preheating monitor lights up ................................................ 20-243
M- 11 When starting switch is turned ON and engine is started, basic check items flash.. ............... 20-244
M- 12 When starting switch is turned ON (engine stopped), caution items,
emergency stop items flash ..................................................................................................... 20-246
M- 13 When starting switch is turned ON and engine is started, caution items,
emergency stop items flash ..................................................................................................... 20-248
M- 14 When starting switch is turned ON (engine stopped), buzzer does
not sound for 1 second. Caution item flashes but buzzer does not sound ............................... 20-251
M- 15 No abnormality is displayed on monitor but buzzer sounds ..................................................... 20-251
M- 16 Night lighting on monitor panel does not light up (liquid crystal display is normal ................... 20-252
M- 17 Coolant temperature gauge does not rise ............................................................................... 20-253
M- 18 Coolant temperature gauge does not give any display ............................................................ 20-253
M- 19 Fuel level gauge always displays FULL ................................................................................... 20-254
M- 20 Fuel level gauge does not give any display ............................................................................. 20-254
M- 21 Swing lock switch is turned ON (LOCK) but swing lock monitor does not light up.. ................. 20-255
M- 22 Swing prolix switch is turned ON (prolix), but swing lock monitor does not flash.. ................... 20-255
M- 23 Service meter does not advance while engine is running.. ...................................................... 20-256
M- 24 When starting switch is at OFF and time switch is pressed, time and
service meter are not displayed ............................................................................................... 20-256
M- 25 Defective fuel level sensor system ........................................................................................... 20-257
M- 26 Defective coolant temperature sensor system ......................................................................... 20-258
M- 27 Defective engine oil level sensor system ................................................................................. 20-259
M- 28 Defective coolant level sensor system ..................................................................................... 20-260
M- 30 Wiper does not work or switch is not being used but wiper is actuated ................................... 20-261
20-229
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
El 04 Air cleaner clogging 1. Air cleaner clogging sensor has detected clogging
detected is displayed
20-230
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
20-231
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE 112
20-232
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE 2/2
20-233
TROUBLESHOOTING M-l
Cause Remedy
2 YES
Defective monitor panel Replace
Power source
(g 8. @
(+24V)
GND (3J @ g
Power source
(+24V) 63 Fusible link
20-234
TROUBLESHOOTING M-2
Cause Remedy
YES
Defective monitor panel Replace
Table
P04(M2)
-Ii=@= Buzzer
All
20-235
TROUBLESHOOTING M-3.4
Cause Remedy
IS a,r cleanerclogging
caution lamp on
monitor flashing? 2 YES
Defective monltor panel Replace
Note 1: The monitor panel display has returned to normal, but the air cleaner clogging sensor has detected
symptoms of clogging in the past, so carry out troubleshooting of the engine to remove the problem
Cause Remedy
Note 1: The monitor panel display has returned to normal, but the engine oil pressure sensor has detected
symptoms of a drop in the oil pressure in the past, so carry out throubleshooting of the engine to
remove the problem.
20-236
TROUBLESHOOTING M-5
Note 1: The monitor panel display has returned to normal, but the coolant temperature sensor has detected
symptoms of the coolant temperature reaching 105°C in the past, so carry out troubleshooting of the
engine to remove the problem.
20-237
TROUBLESHOOTING M-6
YES
Defective monitor panel Replace
2
.CN:e[i
- Turn starting swtch Disconnection, defective contact,
short c,rcu,t with ground I” w,r,ng
harness between PO2 (female) (8)
(14)andfuseNo.i3
. 20.30V
Cause Remedy
20-238
TROUBLESHOOTING M-6
Starting switch ON
H14(M6) Mll(L2)
GND
Power source (. a a
GND
Power source
PO2(04016)
mP @
Battery relay
20-239
TROUBLESHOOTING M-7, M-8
Cause Remedy
Cause Remedy
1 YES
Defective monitor panel Replace
Is display of
monltorlng code 01 -
as shown in table?
Go to troubleshooting for C
. Turn starting swtch NO
ON.
* Set to monltorlng
code 01.
Table
20-240
TROUBLESHOOTING M-9
+ Check that the coolant is at the specified level before carrying out troubleshooting.
Cause Remedy
4 YES
-r
Table
@
I Coolant
level sensor
BKP00277
20-241
TROUBLESHOOTING M-9
Cause Remedy
41
I
3 YES
Defective governor, pump controller
when PO5 (female)
(1) is connected to Is bit (4) of
chassis ground? YES monltormg code 24
2 lighted up?
. Disconnect P05.
* Turn starting switch Is continuity between
Defective mon~tor panel
ON. Cl6 (female) (16) NO
_ - Turn starting
NO and chassis as
switch ON.
shown in table?
- Set to monltormg
* Turn starting code 24.
Defective contact, or dIsconnectIon in
wwng harness between Cl6 (female)
. k%%?e%l6,PO5. No (16) E08 (5) PO5 (female) (1)
* Connect-dwxnnect short connector to
PO5 (female) (1).
Table
Network 3
20-242
TROUBLESHOOTING M-10
Cause Remedy
Starting switch
Fuse H08(M6)
A- @. BR
I I
Monitor panel
PO1 (04020)
H13(S16)
20-243
TROUBLESHOOTING M-11
a) Alternator system
Cause Remedy
Battery
Network
charge
20-244
TROUBLESHOOTING M-l 1
Cause Remedy
1
1
When engine IS running
at low idling and wiring Contact of chassis ground with Repair or
harness of oil pressure YES wiring harness between Cl 6 rep&e
sensor IS removed.
Does display go out?
2 I (female) (15) E08 (8) Pi0 (c)
or Pi0 (A) E08 (11) CO3 (16)
* Engine at low idling
20-245
TROUBLESHOOTING M-12
a) Alternator system
Cause Remedy
Battery
Network
charge
20-246
TROUBLESHOOTING M-12
I Cause Remedy
20-247
TROUBLESHOOTING M-13
* Check that the engine oil pressure is normal before Cause Remedy
carrying out troubleshooting.
See M-l 1 b)
See M-9 a)
Cause Remedy
See M-l 1 a)
20-248
TROUBLESHOOTING M-13
d) u -
SAP00527
(coolant
.
temperature) flashes
I
Remedy
+ Check that the coolant temperature is normal before
carrying out troubleshooting
YES Defective coolant tempera-
2 ture sensor system (see M-
When PO7 IS d~scon- 26)
netted, does only
YE
level 1 (left end) of -
3 YES Defective governor, pump Replace
gauge display light
up? Is resistance controller
* Start engine. between CO3
No- -
(female) (1) (16) - - Short circuit of Waring harness
chassis normal? between, CO3 (female) (A) - E08 Repair or
(6) - PO7 (female) (1) and wiring
Is coolant tempera- * Turn starting swtch NO replace
ture in red range? harness between CO3 (female)
OFF.
(16) E08 (11) PO7 (female)
t * Disconnect CO3 and
I
PO7. (B)
Start engine and run
. Max. 1 Mn
at ml&range or Replace
Defective monitor panel
above NO
BKPOO284
r
Defective contact or
disconnection in wiring Repair or
level may vary, so the 1 I I
H
Is fuel gauge in red
display IS given a * Connect PO6 (female) N~ harness between CO3 replace
range? (female) (2) and PO6
time delay.) (1) to chassis ground.
* Turn starting switch ON. (feamle) (1)
* Max 03V
* Start engine.
Defective monitor panel Replace
NO
EKPOOZ85
20-249
TROUBLESHOOTING M-13
s+
f1 c--4 a
SAP00521
(air cleaner clogging) flashes
BKP00266
20-250
TROUBLESHOOTING M-14, M-15
~1~~~~
Repair or
replace
Replace
P04(M2)
Monitor panel POl(O4020)
a
Buzzer
Buzzer a a.
I
20-251
TROUBLESHOOTING M-16
Cause Remedy
L Gjj$5--1-
ON. _
- Setto monltorlng NO Defective contact, or disconnec- Repair or
tion in wiring hanress between replace
code 49.
PO1 (female) (8) -X01 (1) M38
* Turn starting switch NO
(female) (1)
ON.
* Turn light switch ON.
* 20.3ov
Light @ @ 3
@- 3
@ .a
Fuse
I
I
‘I
20-252
TROUBLESHOOTING M-17
1 3 YES
Defective monitor panel Replace
When short connector Does momtonng
is connected to PO7 YES code 41 show a
(female), do level - value of less than -
lamps on guage go up
,n turn and then all 50? Defective governor, pump
lamps go out?
2 Replace
controller
~ Is there continuity bet- . Connect ~hortc~nnector NO
* Disconnect P07. ween CO3 (female) (1) to PO7 (female).
* Turn starting switch _ and (1s) when short _ . Turn starting swtch ON
ON. NO connector IS connected . set to monltorlng code Defective contact, or d~sconnec- Repair or
to PO7 (female)?
YES tion in wiring harness between replace
1
. Turn starting swtch CO3 (female) (16) - E08 (11) -
OFF. PO7 (female) (6)
between CO3
* Disconnect CO3 and II
Y
PO7. Defective contact or disconnec-
Repair or
tion in wiring harness between
replace
* Turn starting switch NO CO3 (female) (1) E08 (6) PO7
OFF. (female) (A)
* Disconnect CO3 and
PO7
1
When PO7 IS d~scon-
Contact of chassis ground with Repair or
netted, does coolant
YES wiring harness between CO3 replace
temperature gauge n (female) (1) E08 (6) PO7
display appear?
(female) (A)
* Disconnect P07.
* Turn starting wtch ,
ON. Defective governor, pump Replace
controller
* Turn starting switch code 41 show a
* Disconnect C03,
PO7. Defective monitor panel Replace
* Turn starting switch NO
ON.
* Set to monitoring
code 41.
BKPW284
20-253
TROUBLESHOOTING M-19, M-20
- Disconnect F
. Turn starting Defective monitor panel Replace
ON. NO
Defective contact, or
disconnection in wiring Repair or
harness between CO3 replace
OFF. NO
* Disconnect C03, PO6 (female) (2) and PO6
(female) (1)
BKP00285
20-254
TROUBLESHOOTING M-21. M-22
Table
0
M-22 Swing prolix switch is turned ON (prolix), but
(swing lock monitor) does not flash SA%OO98
+ Carry out this troubleshooting only if the swing prolix is actually beir actuated.
* Before carrying out troubleshooting, check that all the related
Cause Remedy
connectors are properly inserted.
* Always connect any disconnected connectors before going
on the next step.
2 YES
Defective monitor panel Replace
Is bit (6) of
yES_ monltorlng code 21 _
1 lighted up?
Defective governor, pump Replace
Is voltage between
- Turn starting swtch NO controller
Cl7 (8) and chassis _
as shown in table? UP.
* Set to monitoring Defective contact or
code 21
disconnection in wiring Repair or
* Turn starting switch
ON. harness between Cl7 replace
NO
(female) (8) and prolix
switch (4)
20-255
TROUBLESHOOTING M-23, M-24
Cause Remedy
YES
1 I See M-13 d)
Cause Remedy
2 YES
I I Defective monitor panel Replace
When starting switch
.
IS ON, IS panel
display normal?
See M-6
Turnstarting swtch NO
ON.
20-256
TROUBLESHOOTING M-25
Cause Remedy
Table
Bottom (EMPTY)
BLPOO290
Note 1: Difference between fuel level an gauge display. For gaugedisplay position 14 (FULL), the amount of
fuel is 78-l 00%; and for display position 1 (EMPTY) it is below 145%. If the chassis is at an angle, the
displayed amount of fuel will be different from the actual amount. Therefore when checking, stop the
machine at a horizontal place and wait for at least 2 minutes before checking the gauge. (The display is
given a time delay so that the gauge can deal with sudden changes in the fuel level).
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so be
carefyul when installing
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
20-257
TROUBLESHOOTING M-26
I
ES
Cause
Defective contact of
I
Remedy
Zlean con-
iector or re-
1 connector (See Note 1)
Aace sensor
between temperature
sensor connector Disconnection in wiring Replace
(male) (1) and (2) as 2 YES harness (See Note 2) sensor
show in table? (defective clamp)
Check wiring harness
_ visually (external force applied)
Is it broken?
Table
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check
the connector and wiring harness at the chassis end.
Note 2: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
20-258
TROUBLESHOOTING M-27
Cause Remedy
Is any foreign
YE material (dirt) stuck Replace
to mwng part of 3 YES Resonance of mount (See Note sensor (See
float?
2) Note 4)
Is ther any large
- crack, chip, or
When float is moved No damage to float? Clean
up and down,is resis- Defective contact of connector connector or
tance betweenconnec- NO (See Note 2) replace
tor (I) and flanqe as
Table
BLPoo292
Note 1: Variations in oil level. The oil level may change according to the angle of the machine, the engine
speed, or the temperature of the oil, so if there is any display, check the oil level again with the machine
at a horizontal place.
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check
the connector and wiring harness at the chassis end.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again,
check for vibration at the connector mount, and if there is excessive vibration, take the appropriate
action.
20-259
TROUBLESHOOTING M-28
I Cause Remedy
4 YES
Disconnection in wiring Replace
I I harness (Se Note 3) sensor
1Check Waring harness 11 1 (defective clamp) (external
Replace
Table
Note 1: Variations in coolant level. The coolant level may change according to the angle of the machine, or the
swaying of the machine, so if there is any display, check the coolant level again with the machine at a
horizontal place.
Note 2: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check
the connector and wiring harness at the chassis end.
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again,
check for vibration at the connector mount, and if there is excessive vibration, take the appropriate
action.
20-260
TROUBLESHOOTING M-30
M-30 Wiper does not work or switch is not being used but
wiper is actuated
a) Wiper does not work
* Check that fuse No. 7 is normal. Cause Remedy
4 YEE
GotoA
Is resistancebet-
YES wean Ml 8 (female)
3 (1) (4 (1) (4) as
~ shown in Table l? Defective wiper washer Replace
YES Is voltage between * Turn starting switch NC switch
- M46 (2) and (1) - OFF.
2 normal? * Disconnect Ml& Defective contact, or discon- Replace
I I nection in winng harness bet- wiring
. 20.30V ween fuse (7) and W08 (female)
YES between WlO (male) harness
* Turn starting swtch NO (5), or WOE (female) (l), (8) and
(3) (4) WO8
(4) (18) ON.
GND
1
* Max. 1 CI
Defective contact, or disconnec-
Replace
* Turn starting swtch tion in wiring harness between
between WlO wiring
(female) (3) and (4) OFF. NO Ml0 (male) (3) (4) and WOE
* Disconnect WlO, (male) (3) (4) and W08 (female) harness
WOK (4) (8)
* Front window closed l Replace
position. Min. 1 M 0 i l Defective rear limit switch
l Set window
* Turn starting wtch Ni0 l Front window is open
OFF.
in posistion
* Disconnect WlO. correctly.
FromA-m
W04 (male) W08
ON. N Contact between wiring Replace
(female) as shown m
harnesses of system with wiring
* Turn starting switch NC defective resistance harness
ON.
* Turn starting switch * Disconnect W04,
Short circuit in wiring Replace
OFF. W08.
* Disconnect M18, harness between Ml8 wiring
W08. NO (male) (1) (2) (4) -X01 (21) harness
(11) (20) - W08 (female) (12)
(14) (15)
Table 1 Table 2
Actuation mode Ml8 (female) W08 (female) Between W04 (female) (1) W08 (female) (7)
Between (1) (2) Between (12) Between W04 (female) (6) -WOE
(female) (10)
OFF mode Between (1) (4) Between (12) Between ~04 (female) (1) (3) (4) (5) (6) GND Min. 1MCI
Between (2) (4) Between (14)
Max. 1 0
ON mode w
Max. 1 MCI
20-261
TROUBLESHOOTING M-30
Table 3
Set time
1.5 set
I Item
I
Symbol
I
Set time
1
Safety circuit during operation of
W04(M6) H15(L2)
Connector for
Rear lock
20-262
TROUBLESHOOTING M-30
Cause Remedy
3 YES
YEIS
!
Defective wiper washer Replace
Is resistance NO switch
YE
between Ml8 (male)
(3) and (4) normal?
Defective contact. or
1
disconnection in wiring Replace
Is resistance . Max. 1 Mn
harness between Ml0 wiring
between WlO * Turn startino switch
(female) (3) and (4) OFF. _I NIO (male) (3) (4) - W08 (female) harness
normal? * Disconnect WlO, (4) (18)
WO8.
. Front window closed
l Defective rear limit switch l Replace
posistion: Min. 1 MO
. Turn starting switch NO l Front window is open l Set window
OFF. in position
. Disconnect WlO. correctly.
Table 1
OFF mode Between (1) (4) Between (12) (15) Max 1MD
Between (2) (4) Between (14) (15)
20-263
TROUBLESHOOTING M-30
Table 3
INTSWO ;pF 1
Switch
wsw @ ;F”F
,,:
R. limit Switch@ ,“,“,
W04(M6) H15(L2)
Connector for I
troubleshooting
M46(M3)
Wiper motor
controller
WO8(07(
Wl O(M4)
Rear lock
20-264
30 DISASSEMBLY AND ASSEMBLY
30-I
LS CONTROL EPC VALVE ASSEMBLY ARM ASSEMBLY
Removal and installation ...................... .30-52 Removal ............................................... .30-73
EPC SOLENOID VALVE ASSEMBLY Installation ............................................ .30-73
Removal and Installation ...................... .30-53 BUCKET, ARM ASSEMBLY
PPC SHUTTLE VALVE ASSEMBLY Removal ............................................... .30-75
Removal ............................................... .30-54 Installation ............................................ .30-75
Installation ............................................ .30-55 BOOM ASSEMBLY
Disassembly.. ....................................... .30-56 Removal ............................................... .30-77
Assembly ............................................. .30-57 Installation ............................................ .30-78
WORK EQUIPMENT PPC VALVE ASSEMBLY OPERATOR’S CAB ASSEMBLY
Removal and Installation ...................... .30-58 Removal ............................................... .30-79
TRAVEL PPC VALVE ASSEMBLY Installation ............................................ .30-81
Removal and Installation ...................... .30-59 COUNTERWEIGHT ASSEMBLY
Disassembly.. ....................................... .30-59 Removal and Installation ...................... .30-82
Assembly ............................................. .30-59 GOVERNOR, PUMP CONTROLLER ASSEMBLY
BOOM CYLINDER ASSEMBLY Removal and Installation ...................... .30-83
Removal ............................................... .30-60 MONITOR PANEL ASSEMBLY
Installation ............................................ .30-61 Removal and Installation ...................... .30-84
ARM CYLINDER ASSEMBLY SWING MACHINERY ASSEMBLY
Removal ............................................... .30-62 Disassembly.. ....................................... .30-85
lnstalltion .............................................. .30-63 Assembly ............................................. .30-l 01
BUCKET CYLINDER ASSEMBLY (Special tools) ..................................... ..30-12 1
Removal ............................................... .30-64 TRANSMISSION ........................................ ..30-12 3
Installation ............................................ .30-65 FRONT AXLE.. ............................................ .30-l 30
HYDRAULIC CYLINDER ASSEMBLY REAR AXLE ................................................ .30-l 48
Disassembly.. ....................................... .30-66 BUCKET ADAPTOR
Assembly ............................................. .30-68 Welding instructions ................................... ..30-16 2
WORK EQUIPMENT ASSEMBLY OUTRIGGER + BLADE
Removal ............................................... .30-71 Cyl ............................................................. .30-l 65
Installation ............................................ .30-72
BUCKET ASSEMBLY
Removal ............................................... .30-73
Installation ............................................ .30-73
30-2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
(Example)
REMOVAL OF 0 0 0 0 ASSEMBLY . . . . . ..Title of operation
a Precautions related to safety when carrying out the operation
1. XXXX(1) Step in operation
+ Technique or important point to remember when removing
xxxx (1).
2. A A A A (2): m Indicates that a technique is listed for use during instal-
lation
3. 0 0 0 0 assembly (3)
:
u Quantity of oil or water drained
30-3
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
mm mm kgm Nm
6 IO 1.35 f 0.15 13.2 f 1.4
8 13 3.2 f 0.3 31.4 f 2.9
IO 17 6.7 f 0.7 65.7 f 6.8
12 19 11.5 f 1 .o 112 f 9.8
14 22 18.0 f 2.0 177 f 19
16 24 28.5 f 3 279 f 29
18 27 39 f 4 383 f 39
20 30 56 f 6 549 f 58
22 32 76 f 8 745 f 78
24 36 94.5 f 10 927 f 98
27 41 135 f 15 1320 f 140
30 46 175f20 1720 f 190
33 50 225 f 25 2210 f 240
36 55 280 f 30 2750 f 290
39 60 335 f 35 3280 f 340
,Sealing surface
30-4
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 0737650210 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)
Nominal number I Flange (hose end) 1 Sleeve head (tube end) 1 Split flange
04 07379-00400 07378-I 0400 07371-30400
05 07379-00500 07378-i 0500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D 1 d 1 L
06 1 07049-00608
DEW00401
30-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
* When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the
cylinder 100 mm form the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
* When using the machine for the first time after repair or long storage, follow the same procedure.
30-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
l Revolving frame
30-7
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
-
Nature of work Symbol Part No. Part Name a’ty Remarks
Cylinder repair
790-502-l 003 1
stand
1
790-l 01-l 102 Pump 1
Socket
790-l 02-l 330 (wdth across flats: 1
75 mm)
2
7
Socket
790-302-l 430 (width across flats: 1
Disassembly, assembly of
0 85 mm)
hydraulic cylinder
3 790-720-I 000 Expander 1 Expansion of piston ring
4
07281-01279
796-720-l
07281-01159
660
Clamp
Ring
Clamp
-
1
1
I
30-8
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
30-9
DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY
a. Drsconnect the cable from the negative (-) terminal of
the battery.
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY
. Carry out installation in the reverse order to removal.
Ig
+ Adjust the rod. For details, see TESTING AND
ADJUSTING, Testing and adjusting of governor
motor lever stroke.
30-I 0
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
& kg
1
Hydraulic oil cooler assembly: 60 kg
INSTALLATION OF HYDRAULIC 6
30-I 1
DISASSEMBLY AND ASSEMBLY RADIATOR l HYDRAULIC OIL COOLER
REMOVAL OF RADIATOR l
-
HYDRAULIC OIL COOLER
ASSEMBLY
a Lower the work equipment completely to the ground
and stop the engine. Then loosen the oil filler cap
slowly to release the pressure inside the hydraulic
tank.
. Remove the hydraulic tank strainer, and using tool B,
stop the oil.
. When not using tool B, remove the drain plug,
and drain the oil from the hydraulic tank and in-
side the system.
:
u Hydraulic tank: Approx. 120 B
. Drain engine coolant.
205FO6458
30-I 2
DISASSEMBLY AND ASSEMBLY RADIATOR l HYDRAULIC OIL COOLER
INSTALLATION OF RADIATOR l
30-I 3
DISASSEMBLY AND ASSEMBLY ENGINE l HYDRAULIC PUMP
REMOVAL OF ENGINE l
HYDRAULIC PUMP ASSEMBLY
a. Disconnect the cable from the negative (-) terminal of
the battery.
30-I 4
DISASSEMBLY AND ASSEMBLY ENGINE l HYDRAULIC PUMP
30-I 5
DISASSEMBLY AND ASSEMBLY ENGINE l HYDRAULIC PUMP
31. Remove mount bolt, then lift off engine and hydraulic
pump assembly (36) slowly. m
* When removing the engine and hydraulic pump
asembly, check that all wiring and piping has
been disconnected, and be careful not to hit any
part when removing.
30-16
DISASSEMBLY AND ASSEMBLY ENGINE l HYDRAULIC PUMP
INSTALLATION OF ENGINE l
HYDRAULIC PUMP ASSEMBLY
. Carry out installation in the reverse order to removal.
m
* Adjust the fan belt tension.
For details, see TESTING AND ADJUSTING,
Testing and adjusting fan belt tension.
m
+ Check that the O-ring is not damaged or deterio-
rated, then connect the hoses.
Run the engine to circulate the water through the (Mount at fan end)
202FO6610
system. Then check the water level again.
Bleeding air
* Bleed the air from the hydraulic pump.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-I 7
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Remove main pump assembly. For details, see RE-
MOVAL OF MAIN PUMP ASSEMBLY.
INSTALLATION OF DAMPER
ASSEMBLY
. Carry out installation in the reverse order to removal.
30-I 8
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUELTANK
ASSEMBLY
Ah Drsconnect the cable from the negative (-) terminal of
the battery.
2. Disconnect fuel supply hose (2) and return hose (3). 205FO6484
I 202FO6473
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
. Carry out installation in the reverse order to removal.
. Bleeding air
* Bleed the air from the travel motor.
For details, see TESTING AND ADJUSTING,
Bleeding air.
KW13OP6094
30-20
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING
MOTOR ASSEMBLY
a Lower the work equipment completely to the ground
and stop the engine. Loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank. Then
set the safety lock lever to the LOCK position.
1. Disconnect hoses (l), (2), (3), and (4), and tubes (5)
and (6), then remove filter and bracket assembly.
+ Machines equipped with additional attachment
circuit
INSTALLATION OF SWING
MOTOR ASSEMBLY
. Carry out installation in the reverse order to removal.
REMOVAL OF SWING
MACHINERY ASSEMBLY
1. Remove swing motor assembly. For details, see RE-
MOVAL OF SWING MOTOR ASSEMBLY.
INSTALLATION OF SWING
MACHINERY ASSEMBLY
Carry out installation in the reverse order to removal.
h
SmSwing machinery mounting bolt:
548.8 f 49 Nm (56 f 5 kgm)
. Bleeding air
+ Bleed the air from the swing motor. For details,
see TESTING AND ADJUSTING, Bleeding air.
30-22
DISASSEMBLY AND ASSEMBLY SWING MOTOR
a) Clean the mating surfaces from oils or paint and fit the
gearbox to the undercarriage.
30-23
DISASSEMBLY AND ASSEMBLY SWING MOTOR
1 F12 NmflO 1
60
6o ‘\ 60 11 138.0 13894185
I I I
\
mm
30-24
DISASSEMBLY AND ASSEMBLY SWING MOTOR
Dissasem bly
30-26
DISASSEMBLY AND ASSEMBLY SWING MOTOR
Thread specification:
F12 Thread Tool
60 M24x1.5 3793077
Assembly
30-27
DISASSEMBLY AND ASSEMBLY SWING MOTOR
30-28
DISASSEMBLY AND ASSEMBLY SWING MOTOR
Item Title
221 O-RING
225 O-RING
229 O-RING
231 SEAL CARRIER
233 SHAFT SEAL
488 SHIM
491 HEX SOCKET SCREW
30-29
DISASSEMBLY AND ASSEMBLY SWING MOTOR
37
135 ;
r 36
__-7
,452
30-30
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
A Disconnect the cable from the negative (-) terminal of
the battery.
:
u Hydraulic tank: Approx. 120 B
30-3 1
REVOLVING FRAME
DISASSEMBLY AND ASSEMBLY
30-32
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
INSTALLATION OF REVOLVING
FRAME ASSEMBLY
. Carry out installation in the reverse order to removal.
. Bleeding air
* Bleed the air. For details, see TESTING AND
ADJUSTING, Bleeding air.
30-33
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
2OSFO6557
30-34
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
INSTALLATION OF SWING
CIRCLE ASSEMBLY
. Carry out installation in the reverse order to removal.
m
+ Set the soft zone S mark on the inside ring of the
inner race facing the right side as shown in the
diagram, then install to the track frame.
30-35
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
1. Drain oil from hydraulic tank.
b
& Hydraulic tank: Approx. 120 G
30-36
10. Disconnect hydraulic tank inlet hose (16).
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
. Carry out installation in the reverse order to removal.
m
&&Thread of hydraulic tank mounting bolt:
Thread tightnener (LT-2)
Bleeding air
* Bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-37
REMOVAL OF MAIN PUMP
ASSEMBLY
a Disconnect he cable from the negative (-) terminal of
the battery.
L
I I
30-38
DISASSEMBLY AND ASSEMBLY
la]
. Bleeding air
Sr Bleed the air from main pump.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-39
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL
VALVE ASSEMBLY
a Release the remaiing pressure in the hydraulic
circuit.
For details, see TESTING AND ADJUSTING, Re-
leasing pressure in hydraulic circuit.
30-40
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
INSTALLATION OF CONTROL
VALVE ASSEMBLY
Carry out installation in the reverse order to removal.
Bleeding air
* Bleed the air from the circuit between the valve
and the hydraulic cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air.
30-4 1
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-42
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-44
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
30-45
DISASSEMBLY AND ASSEMBLY LS SELECT VALVE
DISASSEMBLY OF LS SELECT
VALVE
202FO6542
2. Remove O-rings (4) and (5), and seal (6) from sleeve
(1).
ASSEMBLY OF LS SELECT
VALVE
. Before assembling coat the sliding surface with
engine oil.
4. Install O-rings (4) and (5), and seal (6) to sleeve (1).
30-46
DISASSEMBLY AND ASSEMBLY LS SHUTTLE VALVE
(6 Places)
(1 Place)
TypeA
2. Remove ball (5) from plug (l), then remove O-rings
(6) and (7), and ring (8).
+ After disassembling, if there is any abnormality
in plug (l), seat (2), or ball (5), replace the
whole LS shuttle valve assembly.
ASSEMBLY OF LS SHUTTLE
VALVE
. Before assembling coat the sliding surface with
engine oil.
1. Install ring (8) and O-rings (7) and (6) to plug (1)
2. Fit ring (4) and O-ring (3) to seat (2), then assemble
ball (5) to plug (l), and install seat (2).
INDENTIFICATION OF LS
TypeB
SHUTTLE VALVE
Shuttle valves are identified by markings on the valve
assembly.
Type A - 1 mark
Type B - 3 marks
30-47
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
30-48
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
30-49
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
202FO6646
30-50
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
202FO6645
. Before assembling coat the sliding surface with sm Nut: 58.8f4.9 Nm (6f0.5 kgm)
engine oil.
8. Tighten nut (4) to specified torque.
1. Install O-ring (17) and ring (16) to seat (15), and
assemble sleeve (11). cm Nut: 44.1f4.9 Nm (4.5f0.5 kgm)
2. Assemble sleeve (14) to sleeve (11). * After installing to the control valve assembly,
adjust the pressure.
3. Install nut (7) and O-ring (10) to holder (8), then For details, see TESTING AND ADJUST-
assemble retainer (9), poppet (13), and spring ING, Testing and adjusting oil pressure of
(12), and install to sleeve (11). work equipment, swing, travel circuits.
* Set contact surface of seat (15) and poppet
(13) in position securely.
30-5 1
DISASSEMBLY AND ASSEMBLY LS CONTROL EPC VALVE
INSTALLATION OF LS CONTROL
EPC VALVE ASSEMBLY
. Carry out installation in the reverse order to removal.
m
30-52
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
2. Remove
PPC pumpless
valve bracket
valve
(1).
El Kw13OP6135
INSTALLATION OF SOLENOID
VALVE ASSEMBLY
. Carry out installation in the reverse order to removal.
m
202FO6628
30-53
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
2 3
30-54
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
INSTALLATION OF PPC
SHUTTLE VALVE ASSEMBLY
. Carry out installation in the reverse order to removal.
m
. Check that the quick joint does not come out when
the hose is pulled.
30-55
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
1. Disconnection of valve
Remove mounting bolts (I), and disconnect shuttle
valve assembly (2), EPCklamshell sol. valve and
plate (4).
30-56
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
30-57
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT l SWING PPC VALVE
REMOVAL OF WORK
EQUIPMENT l SWING PPC
VALVE ASSEMBLY
a Lower the work equipment completely to the ground
and stop the engine.‘Then loosen the-oil filler-cap
solwly to release the pressure inside the hydraulic
tank.
INSTALLATION OF WORK
EQUIPMENT l SWING PPC
VALVE ASSEMBLY
. Carry out installation in the reverse order to removal.
m
cm Hose mounting joint bolt:
29.4f4.9 Nm (3.0f0.5 kgm)
m
30-58
DISASSEMBLY AND ASSEMBLY TRAVEL PPC PEDAL
screws (1) m
3. Remove
30-59
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
202055 I201
30-60
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
. Carry out installation in the reverse order to removal.
m
+ When tightening the locknut, tighten so that the
clearance between the plate and nut is 0.5 - 1.5
mm.
0.5-1,5mm
ZOSFWSS
&& Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
Bleeding air
+ Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinder.
30-6 1
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
30-62
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
INSTALLATION OF ARM
CYLINDER ASSEMBLY
. Carry out installation in the reverse order to removal.
m
a Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
Bleeding air
* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinder.
30-63
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
a Extend the bucket cylinder piston rod approx. 200
mm, lower the work equipment completely to the
ground, then set the safety lock lever to the LOCK
position.
30-64
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
. Carry out installation in the reverse order to removal.
m
+ When tightening the locknut, tighten so that the
clearance between the plate and nut is 0.5 - 1.5
mm.
m
2OSF6065
0
Refilling with oil (hydraulic tank)
* Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
Bleeding air
F20505
L
* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinder.
30-65
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts, and disconnect head
assembly (1).
3) Pull out piston rod assembly (2).
+ Place a container to catch the oil under the
cylinder.
202FO548 I
Unit: mm
PWI 70-6 1 75 1 85 1 75
205FCO5162
202F0550 I -K
30-66
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
I 202FO5485
202F05486
30-67
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
* Be careful not to damage the packings, dust seals,
and O-rings.
* Do not try to force the backup ring into position.
Warm it in warm water (50 - 60°C) before fitting it.
202FO5486
202F05487D 202FOS467C
202FO5485
L
30-68
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
205FCO5162
c= Nut:
202FO5462
202FO5469
30-69
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
m Mounting bolt:
Boom
Arm 330flO Nm (33.7fl .O kgm)
Bucket
30-70
DISASSEMBLY AND ASSEMBLY
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
A Extend the arm and the bucket fully and lower the
work equipment completely to the ground, then
operate the control levers 2 to 3 times.
the pin.
600kg
/I 1’
20X05492-1
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
. Carry out installation in the reverse order to removal.
m
+ When tightening the locknut, tighten so that the
clearance between the plate and nut is 0.5 - 1.5
mm.
A-
m 0.5-1.5mm
2OSFW65
&I&, Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
. Bleeding air
* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinder.
30-72
A Start the engine, and retract the arm
REMOVAL OF BUCKET
cylrnder rod, then tie the rod with wire to
ASSEMBLY prevent it from coming out.
g Set the back of the bucket facing down, \AdRelease the remaining pressure in the
lower the work equipment completeley to t circuit. For details, see TESTING AND
the ground, and operate the control levers ADJUSTING, Releasing pressure in
2 of 3 times. hydraulic circuit for machines with PPC
1. Remove lock bolt (1). (See Fl) m valve.
2. Remove plate (2). (See Fl) m
3. Remove pin (3). (See Fl) m 4. Disconnect hoses (2). (See F4)
4. Remove lock bolt (4). (See Fl) m
5. Remove pin (5). (See Fl) 5. Remove pin (3). (See F4)
6. Remove bucket assembly (6). (See Fl)
+ Raise the work equipment and disconnect 6. Remove arm assembly (4). (See F4)
the arm from the bucket. * Raise the boom and disconnect the boom
from the arm.
& kg 600 kg
See Weight Table.
INSTALLATION OF BUCKET
INSTALLATION OF ARM
ASSEMBLY
ASSEMBLY
. Carry out installation in the reverse order to
removal. . Carry out installation in the reverse order to
removal.
mm m
+ Tighten with the locknut so that the
clearance between the bucket boss and A When aligning the position of the pin hole,
run the engine at low idling, and align
nut is 0.5 - 1.5mm. (See F2)
m slowly.
+ Adjust the shim thickness so that the Never insert your fingers in the pin hole.
clearance between bucket boss (7) and
spacer (8) is 2mm. (See F3)
. Bleeding air
m * Bleed the air from the cylinder.
+ When aligning the position of the pin hole, For details, see TESTING AND ADJUST-
run the engine at low idling, and align ING, Bleeding air from hydraulic cylinder.
slowly. * After bleeding the air from the cylinder,
Never insert your fingers in the pin hole. check the level of the oil in the hydraulic
tank.
REMOVAL OF ARM
ASSEMBLY
1. Bucket assembly
For details, see REMOVAL OF BUCKET
ASSEMBLY.
30-73
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
F4 Fl
F2
0.5-1.5mm ZOSI
%065A
F3
30-74
REMOVAL OF ARM, BUCKET
ASSEMBLY
Extend the arm and bucket fully, lower the work
equipment completely to the ground, and operate the
control levers 2 or 3 times.
INSTALLATION OF ARM,
BUCKET ASSEMBLY
. Carry out installation in the reverse order to removal.
. Bleeding air
* Bleed the air from the cylinder.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
* After bleeding the air from the cylinder, check
the level of the oil in the hydraulic tank.
30-75
DISASSEMBLY AND ASSEMBLY
Fl
I
F20505339
F2
I
F20106128
30-76
Fl
REMOVAL OF BOOM ASSEMBLY
1. Arm and bucket assembly
For details, see REMOVAL OF ARM, BUCKET
ASSEMBLY.
205FO5601
F4
I F20109129
DISASSEMBLY AND ASSEMBLY BOOM
INSTALLATION OF BOOM
ASSEMBLY
. Carry out installation in the reverse order to removal.
m
+ When tightening the locknut, tighten so that the
clearance between the plate and nut is 0.5 - 1.5
mm.
I 0.5 - 1.5 mm
2OSFSOSS
& Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
. Bleeding air
* Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinder.
30-78
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
REMOVAL OF OPERATOR’S
CAB ASSEMBLY
a Drsconnect the table from the negative (-) terminal of
the battery.
4. Remove 4 caps (4) and clip (5), then remove middle i632
panel (6).
LL-
202FO6634
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
30-80
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
205FO6662
06590
INSTALLATION OF OPERATOR’S
CAB ASSEMBLY
. Carry out installation in the reverse order to removal
30-8 1
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
ASSEMBLY
1. Set lifting hook chains of counterweight assembly in
position, and sling.
2. Remove mounting bolts (2) and (3). m
+ Be careful not to lose the shims when removing.
3. Lift off counterweight (1) horizontally with wire or
chain block.
~-kiFv6..,
11
+ Be careful not to hit the engine, radiator and
cooler assembly. ,A --
INSTALLATION OF
COUNTERWEIGHT ASSEMBLY
.
m
Carry out installation in the reverse order to removal.
---r
a
E
In
+I
I
” -
/
l
, Counterweight
-1Of4mm
30-82
DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
INSTALLATION OF GOVERNOR,
PUMP CONTROLLER ASSEMBLY
. Carry out installation in the reverse order to removal.
m
. Check the performance of the work equipment,
travel, and swing For details, see TESTING AND
ADJUSTING.
30-83
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
INSTALLATION OF MONITOR
PANEL ASSEMBLY
. Carry out installation in the reverse order to removal.
m
. Check the mode setting and display function.
For details, see TESTING, AND ADJUSTING, AND
TROUBLESHOOTING.
30-84
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
Mark the
assembly position
a Note
STEP 1
Unscrew the draining plug Ml 8x1,5 (pos. 9) and its washer
(pos. 8) from the gearbox housing (pos. 7) and drain the oil
from the gearbox.
30-86
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 2
Remove the extentions (pos. IO), the elbow (pos. 11) and
the washer (pos. 8) from the gearbox housing (pos. 7).
STEP 3
Unscrew the plug G1/4 (pos. 47) from the motor adaptor
(pos. 50)
STEP 4
Unscrew the elbow (pos. 46) from the motor adaptor (pos.
50).
30-87
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 5
Unscrew the dipstick for oil filling and level kit (pos. 52).
STEP 6
Unscrew the 8 socket head screws MlOx30 (pos. 48)
grade 8.8, fixing the motor adaptor (pos. 50) to the brake
housing (pos. 32).
STEP 7
Remove the 8 socket head screws (pos. 48), the bracket of
oil filling and level kit (pos. 52) and remove the motor adap-
tor (~0s. 50).
30-88
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 8
Remove the O-ring (pos. 44) from its seat in the motor
adaptor (pos. 50).
STEP 9
Unscrew the 11 socket head screws Ml 0x70 (pos. 33)
grade 8.8 and remove the brake assembly.
STEP 10
Overturn the brake assembly and remove the O-ring (pos.
24) from its seat in the break housing (pos. 33).
30-89
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 11
Remove the brake shaft (pos. 35).
STEP 12
Remove the toothed ring (pos. 25).
STEP 13
Remove the 1st stage sun gear (pos. 27).
30-90
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 14
Remove th 1st reduction assembly (pos. 26).
STEP 15
Remove the O-ring (pos. 24) from its seat in the cover (pos.
21).
STEP 16
Using pliers remove the elbow and the extension of the oil
filling and level kit (pos. 52) from the cover (pos. 21) and all
plugs and washers present in the gearbox too.
30-9 1
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 17
Unscrew the 4 socket head screws MlZx80 (pos
grade 12.9, and the 12 socket head screws M12x90
23), grade 12.9, and remove the cover (pos. 21).
STEP 18
Remove the O-ring (pos. 12) from its seat in the end (:over
(pos. 21).
STEP 19
Remove the 2nd stage sun gear (pos. 19).
30-92
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 20
Remove the 2nd reduction assembly (pos. 17).
STEP 21
Remove the toothed ring (pos. 18).
STEP 22
Remove the O-ring (pc3s. 12) from its seaIt in the g earbox
housing (pos. 7).
30-93
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
a Note
STEP 23
By means of a punch, remove the caulking in the edge of
the nut (pos. 15).
STEP 24
Using the tool AT709CO6, unscrew the nut M75x2 (pos.
15).
30-94
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 25
Overturn the output assembly (pos. 16), unscrew and re-
move the 8 socket head screws M8x20 (pos. 4), grade 8.8,
from the front cover (pos. 5)
STEP 26
Place the gearbox housing (pos. 7) on three spacers and
through a press push on the pinion shaft (pos. 1) and re-
move it from the gearbox housing (pos. 7).
STEP 27
Place the pinion shaft (pos. l), front cover (pos. 5) and
bearing (pos. 6) group on a spacer.
Through a press push on the pinion shaft (pos. 1) and ex-
tract the bearing (pos. 6).
30-95
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 28
Remove the front cover (pos. 5).
STEP 29
Use a screwdriver to remove the ringseals (pos. 3) from
their grove in the front cover (pos. 5)
STEP 30
Use a rubber hammer a metal stopper to remove the bear-
ing (pos. 14) from the the gearbox housing (pos. 7).
30-96
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 31
Use a rubber hammer a metal stopper to remove the seal
ring (pos. 13). from the the gearbox housing (pos. 7).
A Important
STEP 32
Through a press and a metal stopper, push on the spring
retainer (pos. 42), thus removing the force of the springs
/;os. 41) on the circlip (pos. 43) and through pliers remove
STEP 33
Remove the springs retainer (pos. 42).
30-97
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 34
Remove the springs (pos. 41) from their groves in the
brake piston (pos. 40).
STEP 35
Remove the brake piston (pos. 40).
To get it easier, pumping compressed air into the brake
port hole (max. 0,2 bar), taking care the piston (pos. 40)
doesn’t jump out the brake housing (pos. 32).
STEP 36
Remove the 1 st O-rings (pos. 34) from its seat in the brake
housing (pos. 32).
30-98
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 37
Remove spacer (pos. 38) and remove the 2nd O-rings
(pos. 34) from its grove in the brake housing (pas. 32).
STEP 38
Remove the O-ring 39) from its seat in the spacer
(pos. 38).
STEP 39
Remove brake discs pack (pos. 36-37).
30-99
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 40
Through pliers remove the circlip (pos. 29) from its grove in
the brake housing (pos. 32).
STEP 41
Remove the discs retainer (pos. 30)
a Note
The gearbox disassembling ends with the above operation:
all items are now available for the necessary inspections.
30-I 00
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
4. ASSEMBLY
STEP 42
Place correctly the spacer (pos. 2) on th pinion shaft (pos.
1).
STEP 43
Through a press and a metal stopper push the spacer
(pos. 2) against the shoulder on the pinion shaft (pos. 1)
until1 assembling is complete.
30-I 01
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 44
Mount the seal ring (pos. 3) into its grove in the front cover
(pos. 5).
STEP 45
Mount the front cover (pos. 5) on the pinion shaft (pos. 1).
STEP 46
Apply on the bearing (pos. 6) a coat of grease type NGLI 2
with EP characteristics.
30-I 02
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 47
Place the bearing (pos. 6) on the pinion shaft (pos. 1).
Through a press and a metal stopper, push the bearing
(pos. 6) against the spacer shoulder (pos. 2).
STEP 48
Pace the seal ring (pos. 13) inside the gearbox housing
(pos. 7).
STEP 49
Through a press and the proper metal stopper AT709C14,
push the seal ring (pos. 13) against the shoulder on the
gearbox housing (pos. 7).
30-I 03
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 50
Overturn the gearbox housing (pos. 7) and fill with grease
type NGLI 2 with EP characteristics the upper chamber
placed between the seal ring (pos. 13) and the bearing
(pos. 6).
STEP 51
Place the pinion shaft (pos. 1) -spacer (pos. 2) -front cover
(pos. 5) -bearing (pos. 6) group in the gearbox housing
(pos. 7).
STEP 52
Usa a press and a proper metal stopper to push the pinion
shaft (pos. 1) against the shoulder on the gearbox housing
(pos. 7 until assembling of the unit is complete.
30-I 04
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 53
Tighten the 6 socket head screws M8x20 (pos. 4), grade
8.8, by a torque wrench at a torque of 2,5 daNm.
STEP 54
Overturn the gearbox (pos. 7) and place inside it the bear-
ing (~0s. 14).
STEP 55
Use a press and the metal stopper to push the bearing
(pos. 14) against the shoulder in the gearbox housing (pos.
7).
30-I 05
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 56
Place a new ring nut (pos. 15) on the pinion shaft (pos. 1).
Never use the nut disassembled because already de-
formed.
STEP 57
Use the tool AT709CO6 to tighten the ring nut M75x2 (pos.
15), by a torque wrech, at a torque of 11 O-l 20 daNm.
STEP 58
Caulk the ring nut (pos. 13) next to 3 spaces placed at 120”
of the pinion shaft spline (pos. 1).
30-106
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
STEP 60
Assemble the 2nd reduction assembly (pos. 17).
STEP 61
Insert the 2nd stage sun gear (pos. 19).
30-I 07
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 62
Assemble the toothed ring (pos. 18).
STEP 63
Apply in the O-ring’s seat in the cover (pos. 21) a coat of
grease.
Mount the 2nd O-ring (pos. 12).
STEP 64
Place the cover (pos. 21) on the toothed ring (pos. 18) and
fix it through 4 socket head screws M12x80 (pos. 22),
grade 8.8, and through 12 socket head screws M12x90
(pos. 23), grade 8.8, tightened by a torque wrench at 12
daNm torque.
30-108
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
DISASSEMBLING
STEP 65
Apply in the O-ring’s seat in the cove!r (P OS. 17) a coat of
grease.
Mount the 1st O-ring (pos. 2 4).
STEP 66
Assemble the 1st reduction assembly (pos. 26).
STEP 67
Insert the 1st stage sun gear (pos. 27).
30- 109
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 68
Assemble the toothed ring (pos. 25).
STEP 69
Apply in the internal seal’s groves of the brake housing
(pos. 32) a coat of grease, and insert the O-rings (pos. 34).
STEP 70
Apply in the inside surface of the spacer (pos. 38) a coat of
grease.
Fit the O-ring (pos. 39) into its seat in the spacer (pos. 38).
30-I IO
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 71
Assemble corectly the spacer (pos. 38) to the brake piston
(pos. 40), paying attention not to damage the O-ring (pos.
39) already fitted.
STEP 72
Insert the brake piston-spacer group (pos. 40-38) inside
the brake housing (pos. 32), paying attention not to dam-
age the seals already fitted.
STEP 73
Insert the springs (pos. 41) into the holes in the brake pis-
ton (pos. 40), according the picture arangement.
30-I 11
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 74
Insert the springs retainer (pos. 42).
STEP 75
Through a press and a metal stopper, push on the springs
retainer (pos. 42), in lowering it in order to permit the as-
sembly of the circlip (pos. 43) in its grove in the brake hous-
ing (pos. 32).
STEP 76
Overturn the brake housing (pos. 32) and assemble the
brake discs package according to the following order:
firstly insert an external toothed sintered bronze disc (pos.
37).
30-I 12
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 77
Then insert, an internal toothed steel disc (pos. 36).
Repete the operation until1 reaching the number of 6
sintered bronze and 5 stell discs.
STEP 78
Assemble the brake shaft (pos. 35) and insert oil at a pres-
sure of 20 bar from the brake pilot port (see installation
drawing ref. 4) in order to permit the assembling of the last
sintered bronze disc (pos. 37) and the discs retainer (pos.
30).
STEP 79
Assemble correctly the discs retainer (pos. 30) in the brake
housing (pos. 32).
30-I 13
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 80
Through pliers, assemble the circlip (pos. 29) into its grove.
Then remove the compressed air from the brake assembly
and dismount the brake shaft (pos. 35).
STEP 81
Apply in the O-ring’s seat in the brake housing (pos. 32) a
coat of grease.
Mount the 2nd O-ring (pos. 24).
STEP 82
Assemble the brake shaft (pos. 35).
30-I 14
DISASSEMBLY AND ASSEMBLY
SWING MACHINERY
ASSEMBLING
STEP 83
Assemble the brake assembly.
STEP 84
Tighten the 11 socket head screws MlOx70 (pos. 33),
grade 8.8, by a torque wrench at 5 daNm torque.
Sl-EP 85
Mclunt the O-ring (pas. 44) ilnto its seaIt in the mo ltor flan
ge
(PI3s. 50).
30-115
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 86
Place the motor flange (pos. 50) on the brake housing (pos.
32) and insert the 8 socket head screws Ml 0x30 (pos. 48)
grade 8.8.
Contemporary assemble the flask of the filling and oil level
kit (pos. 52).
STEP 87
Tighten the 8 socket head screws Ml 0x30 (pos. 48), grade
8.8, by a torque wrench at 5 daNm torque.
STEP 88
Using pliers, screw the washer (pos. 8), the elbow and the
extension of the filling and oil level kit (pos. 52) in the cover
(pos. 21).
30416
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 89
Mount and tighten the dipstick of the filling and oil level kit
(pos. 52).
STEP 90
Insert and screw all plugs M18x1,5 (pos. 9) and washers
(pos. 8) in the gearbox.
STEP 91
Assemble the angle (pos. 46) in the motor flange (pos. 50).
30-I 17
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 92
Assemble the breather plug G l/4 (pos. 47).
STEP 93
Asemble the extensions (pos. lo), the angle (pos. 11) and
the washer (pos. 8) in the gea rbox housing (:pos. 7‘).
STEP 94
Assemble the plug Ml 8x1,5 (pos. 9).
30-118
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
ASSEMBLING
STEP 95
A Important
After mounting the hydraulic motor, verify, through a depth
slide gauge, the axial dimension of the gearbox measured
by input side of the motor adaptor (pos. 50) to the brake
shaft (pos. 35).
Axial dimension = 93-945 mm.
STEP 96
After having reassebled the gearbox, fit the hydraulic motor
(taking care to include the O-ring pos. 51), throurgh 2 fixing
screws M16x40 (pos. 49), grade 8.8 tightened at a torque
of 21,5 daNm. Fill the gearbox with the lubricant oil as
shown in section 4.2.
30-I 19
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
5. BRAKE CHECK
\
i
_--
/ 0 100
I:
-\..
~ -1
Dwg. - Correct brake assembly, chec
30-120
SWING MACHINERY
DISASSEMBLY AND ASSEMBLY
+ CHANFER 2x45’
I
R 5 iu
I
-
_.
_-------I
D 7
I
I
----_-
I
1
CHANi=ER 1x45’
I- i
12.5
d
30-121
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
I
1_
r 1 \\
30-I 22
DISASSEMBLY AND ASSEMBLY TRANSMISSION
Oil drain
TRANSMISSION Before intervening on transfer box you have to drain
oil (refer to page A)
DISASSEMBLING, SETTING OP-
ERATIONS AND REASSEMBLING Warning: The exhaust oil disposal must be car-
ried out according to the laws in force.
Clean the shaft and ensure the seal area of the Check the oil level and, if necessary, re-fill.
same is not damaged, fitted or grooved.
Carry out the braking system bleeding.
Place the sealing lips towards the oil side.
O-ring
Ensure adequate lubrication of these seals before
inserting them in their seats to avoid twisting during
shaft assembly.
Shims
For each adjustment select the correct shims by indi-
vidual measurements. Do not trust pack measure-
ments or the thickness indicated on the shim.
Bearings
For a correct assembly it is suggested to warm them
in a furnace from 80C to 9OC before installation in
their respective shafts or to cool them before insert-
ing in their respective seats woth outer housing.
Sealing
Use LOCTITE 510 or types following the
sepcifications. Ensure that both sides to be sealed
are clean, dry and totally free from grease and oil.
30- 123
DISASSEMBLY AND ASSEMBLY TRANSMISSION
EMERGENCY BRAKE
(Refer to page 30-49)
. Keep the brake piston (20) and the seal rings (16-17-
18-l 9); replace if necessary.
. Keep the three trust pins (6) and the O-rings; replace if
necessary
. Do not operate on the screws (5) and the nuts (4), but
only in the event of brake release manual intervention.
In this case carry out theadjustment setting the screws
in touch with the pins (6), then unscrew 1 turn and lock
with the counternut (4).
. Check the brake drum (13) and the reaction plate (14)
are not worn out.
SPECIAL TOOLS
. Driver for oil seal (9): ref. 119038
. Interchangeable handle: ref. 119033
30-I 24
DISASSEMBLY AND ASSEMBLY TRANSMISSION
7
6
6
Kw130P6101
30-125
DISASSEMBLY AND ASSEMBLY TRANSMISSION
. Unscrew the screw (6) and extract the fork control le-
ver (8).
. Remove the stop ring (13), then axtract the fork (g),
shaft (15) and sleeve (11) group.
30-I 26
DISASSEMBLY AND ASSEMBLY TRANSMISSION
9-
10-
ll-, 1
15\- (i
Kw13OP6102
30-127
DISASSEMBLY AND ASSEMBLY TRANSMISSION
FLANGE POSITIONING
TIGHTENING TORQUES
(Refer to page 53)
Thread 1 Nm
Screw-fork to shaft 32
Screw-output flanges M 12x25 139
Brake release nut-screw M 10x20 50
Front cover-screw M 10x90 50
Rear cover-screw M 10x30 50
Fork control screw-lever M 10x20 50
Half-housing fastening screw M 10x65 50
Breather Ml0 10
Oil drain, filling and level plug M22 60
Kw13OP6103
30-I 28
DISASSEMBLY AND ASSEMBLY TRANSMISSION
_-_ __
KW13OP6104
30-I 29
DISASSEMBLY AND ASSEMBLY FRONT AXLE
Sealing compound
FRONT AXLE Use LOCTITE 510 or types following the specifica-
tions. Ensure that both sides to be sealed are clean,
DISASSEMBLING, SETTING OP- dry and totally free from grease and oil.
ERATIONS AND REASSEMBLING
Disassembling - Reassembling
The overhauling of epicycloidal group and wheel
FOREWARD hubs can be completed without removing the axle
from the vehicle.
Oil seals for rotating shafts
For correct installation of oil seals adhere to the fol- Oil drain
lowing recommendations: Before intervening on axle you have to drain oil from
the final drives and from the axle box (refer to page
Befopre installation soak the seal for half an C.)
hour in the same oil that will be used in the axle
to be sealed. Warning: The exhaust oil disposal must be car-
ried out according to the laws in force.
Clean the shaft and ensure the seal area of the
same is not damaged, fitter or grooved. Removal an dinstallation of the axle
In order to remove the axle, support adequately the
Place the sealing lips towards the oil side. vehicle to get a certain safety.
Lubricate the seal lip (oil is better than grease) Unscrew the fastening nuts and remove the wheels
and fill with grease the space between oil lip and from the hubs.
dust lip of dual lip seals.
Disconnect the controlling brakes pipings, then in-
lnstal the oil seal using a suitable seal driver. stall some protection plugs.
Avoid hammering directly on the seal.
Loose al lthe remaining connections between frame
To avoid damages to the seal lip caused by the and axle, then seperate the axle from the frame
shaft; adequatly protect the same during shaft structure.
assembly procedure.
Installing the axle reverse the order; check for even-
O-ring tual leakes of oil.
Ensure adequate lubricatoin of these seals before
inserting them in their seats to avoid twisting during Check the oil level and, if necessary, re-fill.
shaft assembly.
Carry out the braking system bleeding.
Shims
For each adjustment select the correct shims by indi-
vidual measurements. Do not trust pack measure-
ments or the thickness indicated on the shim.
Bearings
For a correct assembly it is suggested to warm them
in a furnace from 80C to 9OC before installing in their
respective shafts or to cool them before inserting in
their respective seats with outer housing.
Elastic plugs
During the plug assembly and with turbo off, ensure
that their notch has oriented towards the stress
which is subjecting the thrust.
30-I 30
DISASSEMBLY AND ASSEMBLY FRONT AXLE
FINAL DRIVES
. Turn the wheel hub and position the plug (1) to the
upper point. Fill it with specified oil.
30-I 31
DISASSEMBLY AND ASSEMBLY FRONT AXLE
. Remove the ring (I), the reaction plate (2), the brake
disc (3) and the reaction plate (4).
. Check the reaction plates (2) and (4) do not show any
signs of excessive wear o grooves exceeding 0.20
mm.
30-I 32
DISASSEMBLY AND ASSEMBLY FRONT AXLE
Kw13OP6107
A = 51.95 to 52.00
B = 114.175 to 114.225
c = 29.00 to 29.15
D = 3.95 to 4.00
30-I 33
DISASSEMBLY AND ASSEMBLY FRONT AXLE
SWIVEL HOUSING
KW13OP6108
30-I 34
DISASSEMBLY AND ASSEMBLY FRONT AXLE
Kw13OP6109
30-I 35
DISASSEMBLY AND ASSEMBLY FRONT AXLE
DRIVE SHAFTS
Kw13OP611(
30-I 36
DISASSEMBLY AND ASSEMBLY FRONT AXLE
Kw130P6111
Steering cylinder . Check for the distance (M) is the same both
. Inspect the steering cylinder rod (1) and its pis- side.
ton for wear or damages.
. When the final adjustment is reached, lock the
. Inspect the ball joints assy (2) and (3) for wear nuts (4) and (5) to 300 Nm.
or damages.
Toe-in
. The toe-in value has to be of +l to -1 mm.
30-I 37
DISASSEMBLY AND ASSEMBLY FRONT AXLE
KW13OP6112
. Unscrew the screw (1) and the bolts (10) to dis- . Check the oil seal (8) conditions, best replace it.
assemble the complete differential and to be When reassembling, fill with grease the oil seal.
able to work on bench.
The operations to carry out on this group are the fol-
. Check the conditions of the bevel pinion bear- lowing ones:
ings (2) and of the differential bearings (3);
repplace them, if necessary. PINION POSITIONING
PINION BEARINGS PRE-LOAD
. If you change the bevel gear and the pinion set, PINION-CROWN TEETH BACKLASH
you have to replace the ring nut (4), the washers DIFFERENTIAL BEARINGS PRE-LOAD
(5) and (6) and the collapsible spacer (7). ADJUSTMENT FLANGE ON PINION
30-138
DISASSEMBLY AND ASSEMBLY FRONT AXLE
PINION POSITIONING
Kw130P6113
Bevel distance
Install the pinion bearings in their seat in the differen-
tial end plate and put them in contact using the tool (1);
it must be possible turn the conical bearings by hand,
never close tight.
30- 139
DISASSEMBLY AND ASSEMBLY FRONT AXLE
Kw13OP6114
30-I 40
DISASSEMBLY AND ASSEMBLY FRONT AXLE
Turn the other ring nut clockwise, and at the same time
use a plastice hammer in order to eliminate any bear-
ing backlash. You can get such a condition when the
ring nut rotation becomes difficult.
DIFFERENTIAL BEARINGS
PRE-LOAD
T = (P + 29) to (P + 44) N
30-I 41
DISASSEMBLY AND ASSEMBLY FRONT AXLE
KW13OP6115
30-I 42
DISASSEMBLY AND ASSEMBLY FRONT AXLE
DIFFERENTIAL
3
cd
Kw13OP6116
30-I 43
DISASSEMBLY AND ASSEMBLY FRONT AXLE
AXLE BEAM
'13OP6117
. Inspect the drive shaft bushing (3) for wear and dam-
ages; replace, if necessary.
30-I 44
DISASSEMBLY AND ASSEMBLY FRONT AXLE
Kw13OP6118
30-I 46
DISASSEMBLY AND ASSEMBLY FRONT AXLE
TIGHTENING TORQUES
Thread Nm
14 Greaser MlOxl 10
17 Oil plug 60
30-I 47
DISASSEMBLY AND ASSEMBLY REAR AXLE
Sealing compound
REAR AXLE Use LOCTITE 510 or types following the specifica-
tions. Ensure that both sides to be sealed are clean,
DISASSEMBLING, SETTING OP- dry and totally free from grease and oil.
ERATIONS AND REASSEMBLING
Disassembling - Reassembling
The overhauling of epicycloidal group and wheel
FOREWARD hubs can be completed without removing the axle
from the vehicle.
Oils seals for rotating shafts
For correct installation of oil seals adhere to the fol- Oil drain
lowing recommendations: Before intervening on axle you have to drain oil from
Before installation soak the seal for half an hour the final drives, from the central gear and from the
in the same oil that will be used in the axle to be reduction gear (refer to page 71)
sealed.
Warning: The exhaust oil disposal must be car-
Clean the shaft and ensure teh seal area of the ried out according to the laws in force.
same is not damaged, fitted or grooved.
Removal and Installation of the axle
Place the sealing lips towards the oil side. In order to remove the axle, support adequately the
vehicle to get a certain safety.
Lubricate the seal lip (oil is better than grease)
and fill with grease the space between oil lip and Unscrew the fastening nuts and remove the wheels
dust lip of dual lip seals. from the hubs.
Install the oil seal using a suitable seal driver. Disconnect the controlling brakes pipings, then in-
Avoid hammering directly on the seal.
stall some protection plugs.
To avoid damages to the seal lip caused by the Loose all the remaining connections between frame
saft: adequately protect the same during shaft and axle, then separate the axle from the frame
assembly procedure. structure.
O-ring Installing the axle reverse the order; check for even-
Ensure adequate lubrication of these seals before tual leakages of oil.
inserting them in their seats to avoid twisting during
shaft assembly. Check the oil level and, if necessary, re-fill.
Bearings
For a correct assembly it is suggested to warm them
in a furnace from 80°C to 90°C before installation in
their respective shafts or to cool them before insert-
ing in ther respective seats with outer housing.
Elastic plugs
During the plug assembly and with turbo off ensure
that their notch has oriented towards the stress with
is subjecting the trust.
30-I 48
DISASSEMBLY AND ASSEMBLY REAR AXLE
FINAL DRIVES
Kw13OP6119
. Turn the wheel hub and position the plug (1) to the
upper point. Fill it with specified oil.
30- 149
DISASSEMBLY AND ASSEMBLY REAR AXLE
WHEEL HUBS
KW13OP6120
30-I 50
DISASSEMBLY AND ASSEMBLY REAR AXLE
KW13OP6121
A = 68.95 to 69.00
B = 132.175 to 132.225
c = 29.00 to 29.15
D = 4.95 to 5.00
30-I 51
DISASSEMBLY AND ASSEMBLY REAR AXLE
BRAKES
KW13OP6122
Check the brake piston (4) and the reaction plate (5)
do not show and signs of excessive wear o grooves
exceeding 0.20 mm.
30-I 52
DISASSEMBLY AND ASSEMBLY REAR AXLE
KW13OP6123
. Unscrew the screw (1) and the bolts (10) to dis- . Check the oil seal (8) conditions, best replace it.
assemble the complete differential and to be When reassembling, fill with grease the oil seal.
able to work on bench. The operations to carry out on this group are the
following ones;
. Check the conditions of the bevel pinion bear-
ings (2) and of the differential bearings (3); re- PINION POSITIONING
place them, if necessary. PINION BEARINGS PRE-LOAD
PINION - CROWN TEETH BACKLASH
. If you change the bevel gear and the pinion DIFFERENTIAL BEARINGS PRE-LOAD
bearings (2) and of the differential bearings (3); ADJUSTMENT FLANGE ON PINION
replace them, if necessary.
30- 153
DISASSEMBLY AND ASSEMBLY REAR AXLE
PINION POSITIONING
Bevel distance
Install the pinion bearings in their seat in the differen-
tial end plate and put them in contact using the tool (1);
it must be possible turn the conical bearings by hand,
never close tight.
30-I 54
DISASSEMBLY AND ASSEMBLY REAR AXLE
Kw13OP6125
30- 155
DISASSEMBLY AND ASSEMBLY REAR AXLE
Turn the other ring nut clockwise, and at the same time
use a plastic hammer in order to eliminate any bearing
backlash.You can get such a condition when the ring
nut rotation becomes difficult.
T = (P+29) to (P+44) N
30-I 56
DISASSEMBLY AND ASSEMBLY REAR AXLE
KW13OP6126
30- 157
DISASSEMBLY AND ASSEMBLY REAR AXLE
DIFFERENTIAL
KW13OP6127
30-I 58
DISASSEMBLY AND ASSEMBLY REAR AXLE
AXLE BEAM
KW13OP6128
30-I 59
DISASSEMBLY AND ASSEMBLY REAR AXLE
0
-
1
K-T
W
-
d3
I
KW13OP6129
30-160
DISASSEMBLY AND ASSEMBLY REAR AXLE
TIGHTENING TORQUES
Thread Nm
DIFFERENTIAL CASE
Ring nut - bevel pinion M45x1.5 pre-load
30-161
DISASSEMBLY AND ASSEMBLY ADAPTER WELDING INSTRUCTION - ELECTRODE WELDING
ADAPTER WELDING
INSTRUCTION - ELECTRODE
WELDING
BE SAFE!
When performing the procedures described in this
catalog, you should WEAR OSHA-approved hard hat,
safety glasses, work gloves and safety shoes.
IMPORTANT!
ESCO weld-on Helilok adapters are hardened typically to
415BHN. In order to eliminate cracking commonly associ-
ated with welding steel at these hardness levels, follow
these procedures carefully and employ good welding tech-
niques and practices.
30-I 62
DISASSEMBLY AND ASSEMBLY ADAPTER WELDING INSTRUCTION - ELECTRODE WELDING
Fillet weld
Cone
across adapter
Grinder
---___
, Fill caviry
opening
/
I
_----
B;;;:
radius
30-163
DISASSEMBLY AND ASSEMBLY ADAPTER WELDING INSTRUCTION - ELECTRODE WELDING
Bucket Side
P/aleBevel
’ lip of lip
Angle ofcutto march
&-
* x30”
angle of side p/ate \ chamter
leading edge bevel
\ /----;<
<’
-&-__ ‘0‘;_
‘.,_- --
/ \
lmagina( Extension Side’ Plate
ol Side f/ate
Edge of
‘side
cket
I Top of Lip
30-I 64
DISASSEMBLY AND ASSEMBLY OUT RIGGER CYLINDER
8) Remove cylinder.
30-165
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER
BLADE CYLINDER
7) Remove cylinder.
30-166
40 MAINTENANCE STANDARD
40-I
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
A-A
B-B c-c
Unit: mm
40-2
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
Standard Clearance limit Check measurement standard
Pos. Check item Component Check measurement limit (mm)
clearance (mm) (mm) (mm) 1
Measurement over pin 04mm
Motor Shaft: 34,144 -0,054 -0,120 Measurement over pin m4mm 33,90
1 Backlash between motor shaft 0,064- 0,155 0,33
and brake shaft Measurement over pin 03,5mm
Brake shaft: Measurement over pin m3,5mm 22,85
22,484 +0,171 +0,063
IGHTNING
TORQUE
490--608Nm
ARGET 549Nm
490--608Nm
549Nm
Unit: mm
I I I
Check item
I Remedy
40-5
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
c
q
40-6
MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
A-A
Pressure
compensation valve 74.5 N 55.9 N
3 16.9 15.5
adjuster spring (7.6 kg) - (5.7 kg)
service
40-7
MAINTENANCE STANDARD CONTROL VALVE
B-B
Unit: mm
40-8
MAINTENANCE STANDARD CONTROL VALVE
40-9
CONTROL VALVE
MAINTENANCE STANDARD
D-D
40-I 0
MAINTENANCE STANDARD CONTROL VALVE
E-E
17.2r2.5Mm
(1.75~0.25 kgm)
F-F
3 17.2&.5Nnl
(?.75+025kgm)
G-G 202FO6295
Unit: mm
40-I 1
MAINTENANCE STANDARD CONTROL VALVE
(A31 183)
H- H TRAVEL -
u J-J -
K-K
40-12
MAINTENANCE STANDARD CONTROL VALVE
N-N
P-P
40-I 3
MAINTENANCE STANDARD SUCTION-SAFETY VALVE
SUCTION-SAFETY VALVE
lZ.O-+i5kwm
/
Unit: mm
40-I 4
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
I I I \ \ \
I \
202FO6299
’ A
40-I 5
MAINTENANCE STANDARD WORK EQUIPMENT. SWING PPC VALVE
Unit: mm
40-16
MAINTENANCE STANDARD PPC SHUTTLE VALVE,TRAVEL JUNCTION VALVE
40-I 7
MAINTENANCE STANDARD EPC SOLENOID VALVE
11.3+1.5Nm
(1.15+0.15kgm)
\
Unit: mm
40-18
MAINTENANCE STANDARD CENTER SWIVEL JOINT
A’
i
Unit: mm
No.
I Check item
I Criteria Remedy
Clearance between
1
rotor and shaft
Clearance between
2
rotor + shaft
40-I 9
MAINTENANCE STANDARD ARM. BOOM SAFETY VALVE
Unit: mm
Check valve
3 spring. (Boom and
arm safety valve)
40-20
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
PW170ES6K
Unit: mm
Name of
cylinder
Standard
size
r Tolerance Standard
clearance
Zlearance
limit
Shaft Hole
40-21
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
PWI 70ES6K
Section D-D
Section A-A Section H-H
6-
Section J-J
Section E-E
Section B-B
Section C-C
202FO5665
40-22
MAINTENANCE STANDARD WORK EQUIPMENT - ONE PIECE BOOM
H-H
A-A
J-J
E-E
K-K
F-F
G-G
KW13OP6167
40-23
MAINTENANCE STANDARD WORK EQUIPMENT -TWO PIECE BOOM
D-D
H-H
A-A
2
B-B
J-J
E-E
N-N
K-K
F-F
G-G
Kw13OP6168
40-24
MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
40-25
MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT
1. ARM
16 18
SAP00446
40-26
MAINTENANCE STANDARD WORK EQUIPMENT
4 080 +0337
I-0.030 080 +0.337
I-0.030
+o 273 -0.icl4 +a273 -0.icl4
5
I 395.8 f 2
I
399.5 f 2
6 203.8 f 1 173.8f 1
I I
8 2995.3 3357.6 f 3
13 400.8 400.8
I I
14 (1348) (1348)
I I
15
16 311.5f 1 311.5 f 1
I I
17
18 Arm as individual
part 276 PO., 276 PO.,
40-27
MAINTENANCE STANDARD WORK EQUIPMENT
1. BUCKET
A-A SAP00447
40-28
MAINTENANCE STANDARD WORK EQUIPMENT
PW170ES-6k
3 103" 23'
5
I 1348
I 311.5 ;O.*
12 96
13 440 A'
I 0130
16 0130
17 440 '00-l
I R95
20 R95
21 311.5 +y
40-29
MAINTENANCE STANDARD DOZER BLADE AND OUTRIGGERS HYDRAULIC CYLINDERS
Unit: mm
Clearance 0.30 60
between piston
2
rod and shaft
0.30 60
support bushing
Clearance 0.30 60
between bottom
3
support shaft and
0.30 60
bushing
40-30
MAINTENANCE STANDARD OUTRIGGER BUSH PINS
\
\ 2
1 2
Unit: mm
40-3 1
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1. Oil filling m 60 f 6Nm (6.1 f 0.61 kgm)
2. Oil level w 60 f 6Nm (6.1 f 0.61 kgm)
3. Oil drain m 60 f 6Nm (6.1 f 0.61 kgm)
4. Oil brake connection port m 137 +_53Nm (14.0 +_6 kgm)
5. Oil breather m 10 f 1.5Nm (1 .O f 0.15 kgm)
_60f6Nrn
(6.1~0.61 kQm)
\ REAR VIEW
(6.1kO.61 kQm) \ -Z
#d&l 60*6Nm
w 10+1.5Nm (6.1f0.61 kgm) m 137f53 Nm
(l.Of0.15 kgm) (14;0*6kgm)
\
ENGAGED DISENGAGE0
FRONT VIEW
\
m 60*6Nm
(6.1kO.61 kgm) Kw13OP6157
LUBRICATION
Filling: use oil SAE 85W-140 that meets the specification SAE-J306C, API GL5
40-32
MAINTENANCE STANDARD FRONT AXLE
FRONT AXLE
1. Wheel hubs drain, filling and level plug m 60 f 6Nm (6.1 f 0.61 kgm)
2. Differential oil filling and level plug w 60 f 6Nm (6.1 f 0.61 kgm)
3. Differential drain plug m 60 f 6Nm (6.1 f 0.61 kgm)
4. Brake control fluid inlet port w 14 f 2Nm (1.4 f 0.15 kgm)
5. Brake circuit bleeding $XKl 14 f 2Nm (1.4 f 0.15 kgm)
6. Axle beam oil breather m 5 f 1 Nm (0.51 f 0.5 kgm)
7. Lubrication point m 10 f 1.5Nm (1 .O f 0.15 kgm)
8. Steering cylinder feeding m 240 f 30Nm (24.5 f 3.06 kgm)
52 kom 60i6Nm
(6.1 f 0.61 bm 1
LUBRICATION GREASING
Filling: use oil SAE 8OW-90 that meets the specifica- Use lithium gun grease with molybdenum bisuphide
tion SAE-J306C API GL5 Applications: every 250 hours.
40-33
MAINTENANCE STANDARD REAR AXLE
REAR AXLE
1. Wheel hubs drain, filling and level plug m 60 f 6Nm (6.1 f 0.61 kgm)
2. Differential oil filling and level plug w 60 f 6Nm (6.1 f 0.61 kgm)
3. Differential drain plug m 60 f 6Nm (3.1 f 0.4 kgm)
4. Brake control liquid inlet port w 14 f 2Nm (1.4 f 0.15 kgm)
5. Brake circuit bleeding m IO f 2Nm (0.98 f 0.2 kgm)
6. Axle beam oil breather m 5 f 1 Nm (0.51 f 0.1 kgm)
Kw13OP6159
40-34
MAINTENANCE STANDARD ARM ROTATION CIRCLE
Unit: mm
2 Clearance in bearing in
0.08 - 0.25
axial direction
40-35
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
PFMRl 081696