parts manual - pc400
DESCRIPTION
KomatsuTRANSCRIPT
7/21/2019 Parts Manual - PC400
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SEBM033007
MACHINE MODEL SERIAL No.
PC400-7 50001 and up
PC400LC-7 50001 and up
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GENERAL
CONTENTS
No. of page
01 GENERAL............................................................................................................................ 01-1
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD............................................ 10-1
20 TESTING AND ADJUSTING ......................................................................... 20-1
30 DISASSEMBLY AND ASSEMBLY ..................................................... 30-1
90 OTHERS ................................................................................................................................ 90-1
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LIST OF REVISED PAGES
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following marks. It is requested that necessaryactions be taken to these pages according to the
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbolk is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual care-
fully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read
all the precautions given on the decals which are
fixed to the machine.
2. When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
• Always wear safety glasses when hitting
parts with a hammer.
• Always wear safety glasses when grinding
parts with a grinder, etc.
3. If welding repairs are needed, always have a
trained, experienced welder carry out the work.
When carrying out welding work, always wear
6. Decide a place in the repair workshop to keep
tools and removed parts. Always keep the tools
and parts in their correct places. Always keep
the work area clean and make sure that there is
no dirt or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while work-
ing.
PREPARATIONS FOR WORK
7. Before adding oil or making any repairs, park the
machine on hard, level ground, and block the
wheels or tracks to prevent the machine from
moving.
8. Before starting work, lower blade, ripper, bucket
or any other work equipment to the ground. If
this is not possible, insert the safety pin or use
blocks to prevent the work equipment from fall-
ing. In addition, be sure to lock all the control
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SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11.When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen
them slowly to prevent the oil from spurting out.
Before disconnecting or removing components
of the oil, water or air circuits, first remove the
pressure completely from the circuit.
12.The water and oil in the circuits are hot when the
engine is stopped, so be careful not to getburned.
Wait for the oil and water to cool before carry-
ing out any work on the oil or water circuits.
13.Before starting work, remove the leads from the
battery. Always remove the lead from the nega-
tive (–) terminal first.
14.When raising heavy components, use a hoist or
crane.
Check that the wire rope, chains and hooks are
free from damage.
Always use lifting equipment which has ample
capacity.
Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to pre-vent the component from hitting any other part.
Do not work with any part still raised by the hoist
or crane.
15.When removing covers which are under internal
pressure or under pressure from a spring,
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17 When removing piping stop the fuel or oil from
19.Be sure to assemble all parts again in their origi-
nal places.
Replace any damaged parts with new parts.
• When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is being
operated.
20.When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when install-ing tubes for high pressure circuits. Also, check
that connecting parts are correctly installed.
21.When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be par-
ticularly careful to check that they are installedcorrectly.
22.When aligning two holes, never insert your fin-
gers or hand. Be careful not to get your fingers
caught in a hole.
23.When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24.Take care when removing or installing the tracks
of track-type machines.
When removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
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FOREWORD GENERAL
FOREWORD
GENERALThis shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-ther divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLYThis section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
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FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMESShop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume:
Attachments volume:
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with
all repairs for any model , it is necessary that chas-
sis, engine, electrical and attachment volumes be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will besent to KOMATSU distributors. Get the most up-to-
date information before you start any work.
FILING METHOD
1. See the page number on the bottom of the page.
File the pages in correct order.
2. Following examples show how to read the page
number.
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for each
item.
Example 2 (Engine volume):
12 - 5
Unit number (1 Engine)
REVISED EDITION MARK
When a manual is revised, an edit ion mark((1)(2)(3)....) is recorded on the bottom of the pages.
REVISIONS
Revised pages are shown in the LIST OF REVISED
PAGES next to the CONTENTS page.
SYMBOLS
So that the shop manual can be of ample practical
use, important safety and quality portions are
marked with the following symbols.
Symbol Item Remarks
k Safety
Special safety precautions
are necessary when per-
forming the work.
a Caution
Special technical precau-
tions or other precautions
for preserving standards
are necessary when per-forming the work.
4 Weight
Weight of parts of sys-
tems. Caution necessary
when selecting hoisting
wire, or when working pos-
ture is important, etc.
3Tighteningtorque
Places that require special
attention for the tighteningtorque during assembly.
2 Coat
Places to be coated with
adhesives and lubricants,
etc.
Pl h il t
}·
Each issued as one
volume to cover all
models
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FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
k Heavy parts (25 kg or more) must be lifted
with a hoist, etc. In the DISASSEMBLY
AND ASSEMBLY section, every part
weighing 25 kg or more is indicated clearly
with the symbol
• If a part cannot be smoothly removed from the
machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interference with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below:
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing)
Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
a serious accident can result. Hooks have max-
imum strength at the middle portion.
3) Do not sling a heavy load with one rope alone,
but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
of the load during hoisting, untwisting of
the rope, or slipping of the rope from its
original winding position on the load, which
can result in a dangerous accident.
4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
when hoisting is made with two ropes, each of
which is allowed to sling up to 9.8 kN {1000 kg}
vertically, at various hanging angles.
When two ropes sling a load vertically, up to
19.6 kN {2000 kg} of total weight can be sus-pended. This weight becomes 9.8 kN {1000 kg}
when two ropes make a 120° hanging angle.
On the other hand, two ropes are subjected to
an excessive force as large as 39.2 kN {4000
kg} if they sling a 19.6 kN {2000 kg} load at a
Rope diameter Allowable load
mm kN tons
10
11.5
12.5
14
16
18
20
22.4
30
40
50
60
9.8
13.7
15.7
21.6
27.5
35.3
43.1
54.9
98.1
176.5
274.6
392 2
1.0
1.4
1.6
2.2
2.8
3.6
4.4
5.6
10.0
18.0
28.0
40 0
4
SAD00479
41%71%79%88%100%
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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
k Before carrying out the following work, releasethe residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.
k Even if the residual pressure is released from
the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
l ic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) intomating adapter (3). (See Fig. 1)
★ The adapter can be pushed in about 3.5
mm.
★ Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),
press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.
(See Fig. 3)
★ Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)★ Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter
perfectly, pull it back to check its connecting
condition. (See Fig. 5)
Type 1
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FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
D i s a s s e m b l y
1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn
lever (4) to the right (clockwise).
3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it.
1) Hold the mouthpiece of the tightening portionand push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of
the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and push
until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre
• Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre
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FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassemblyand assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
Adhesives
LT-1A 790-129-9030 150 g Tube• Used to prevent rubber gaskets, rubber
cushions, and cock plug from coming out.
LT-1B 790-129-9050 20 g(2 pcs.)
Polyethylenecontainer
• Used in places requiring an immediatelyeffective, strong adhesive.
Used for plastics (except polyethylene,polyprophylene, tetrafluoroethlene andvinyl chloride), rubber, metal and non-metal.
LT-2 09940-00030 50 gPolyethylene
container
• Features:Resistance to heat and chemicals
• Used for anti-loosening and sealantpurpose for bolts and plugs.
LT-3
790-129-9060(Set of adhesiveand hardening
agent)
Adhesive:1 kg
Hardeningagent:500 g
Can
• Used as adhesive or sealant for metal,glass and plastic.
LT-4 790-129-9040 250 gPolyethylene
container • Used as sealant for machined holes.
HoltzMH 705
790-126-9120 75 g Tube• Used as heat-resisting sealant for
repairing engine.
Three bond1735
790-129-9140 50 gPolyethylene
container
• Quick hardening type adhesive• Cure time: within 5 sec. to 3 min.• Used mainly for adhesion of metals,
rubbers, plastics and woods.
Aron-alpha201
790-129-9130 2 gPolyethylene
container
• Quick hardening type adhesive• Quick cure type
(max. strength after 30 minutes)• Used mainly for adhesion of rubbers,
plastics and metals.
Loctite648-50
79A-129-9110 50 ccPolyethylene
container
• Resistance to heat, chemicals• Used at joint portions subject to high
temperatures.
LG-1 790-129-9010 200 g Tube
• Used as adhesive or sealant for gaskets
and packing of power train case, etc.
LG-5 790-129-9080 1 kg Can
• Used as sealant for various threads, pipe joints, flanges.
• Used as sealant for tapered plugs,elbows, nipples of hydraulic piping.
• Features: Silicon based, resistance toheat, cold
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FOREWORD COATING MATERIALS
Molybdenumdisulphidelubricant
LM-G 09940-00051 60 g Can • Used as lubricant for sliding portion (toprevent from squeaking).
LM-P 09940-00040 200 g Tube
• Used to prevent seizure or scuffling of thethread when press fitting or shrink fitting.
• Used as lubricant for linkage, bearings,etc.
Grease
G2-LI
SYG2-400LISYG2-350LISYG2-400LI-ASYG2-160LI
SYGA-160CNLI
Various Various
• General purpose type
G2-CA
SYG2-400CASYG2-350CASYG2-400CA-ASYG2-160CASYGA-160CNCA
Various Various
• Used for normal temperature, light loadbearing at places in contact with water orsteam.
MolybdenumdisulphidegreaseLM-G (G2-M)
SYG2-400MSYG2-400M-ASYGA-16CNM
400 g × 10400 g × 20
16 kg
Bellows typeBellows type
Can
• Used for heavy load portion
Hyper WhiteGrease G2-TG0-T (*)*: For use in
cold district
SYG2-400T-ASYG2-16CNTSYG0-400T-A (*)SYG0-16CNT (*)
400 g16 kg
Bellows typeCan
• Seizure resistance and heat resistancehigher than molybdenum disulfide grease
• Since this grease is white, it does notstand out against machine body.
Biogrease G2BG2-BT (*)*: For high
temperatureand large load
SYG2-400BSYGA-16CNBSYG2-400BT (*)SYGA-16CNBT (*)
400 g16 kg
Bellows typeCan
• Since this grease is decomposed bybacteria in short period, it has less effectson microorganisms, animals, and plants.
Primer
SUNSTARPAINT PRIMER580 SUPER
417-926-3910
20 ml Glasscontainer
c a b g l a s s
• Used as primer for cab side(Using limit: 4 months)
SUNSTARGLASS PRIMER580 SUPER
20 mlGlass
container
• Used as primer for glass side(Using limit: 4 months)
SUNSTARPAINT PRIMER435-95
22M-54-27230 20 mlGlass
container
• Used as primer for painted surface oncab side(Using limit: 4 months)
SUNSTARGLASS PRIMER435-41
22M-54-27240 150 ml Can
• Used as primer for black ceramic-
coated surface on glass side and forhard polycarbonate-coated surface(Using limit: 4 months)
SUNSTARSASH PRIMERGP-402
22M-54-27250 20 mlGlass
container
• Used as primer for sash (Alumite).(Using limit: 4 months)
SUNSTAR Ecocart • Used as adhesive for glass.
Category Komatsu code Part No. Q’ty Container Main applications, features
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FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)★ In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS
Thread diameterof bolt
Width acrossflats
Tightening torque
mm mm Nm kgm
6
8
10
12
14
10
13
17
19
22
11.8 – 14.7
27 – 34
59 – 74
98 – 123
153 – 190
1.2 – 1.5
2.8 – 3.5
6 – 7.5
10 – 12.5
15.5 – 19.5
16
18
20
2224
24
27
30
3236
235 – 285
320 – 400
455 – 565
610 – 765785 – 980
23.5 – 29.5
33 – 41
46.5 – 58
62.5 – 7880 – 100
27
30
33
36
39
41
46
50
55
60
1150 – 1440
1520 – 1910
1960 – 2450
2450 – 3040
2890 – 3630
118 – 147
155 – 195
200 – 250
250 – 310
295 – 370
Thread diameterof bolt
Width acrossflats
Tightening torque
mm mm Nm kgm
6
8
10
12
10
13
14
27
5.9 – 9.8
13.7 – 23.5
34.3 – 46.1
74.5 – 90.2
0.6 – 1.0
1.4 – 2.4
3.5 – 4.7
7.6 – 9.2
Sealing surface
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FOREWORD STANDARD TIGHTENING TORQUE
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS
★ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS
★ Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS
★ Unless there are special instructions, tighten the O-ring boss plugs to the torque below.
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
10
12
16
14
17
22
59 – 74
98 – 123
235 – 285
6 – 7.5
10 – 12.5
23.5 – 29.5
Norminal No.
Thread diameter Width across flat Tightening torque (Nm {kgm})
mm mm Range Target
02
03, 04
05, 06
10, 12
14
14
20
24
33
42
Varies depending
on type of
connector.
35 – 63 {3.5 – 6.5}
84 – 132 {8.5 – 13.5}
128 – 186 {13.0 – 19.0}
363 – 480 {37.0 – 49.0}
746 – 1010 {76.0 – 103}
44 {4.5}
103 {10.5}
157 {16.0}
422 {43.0}
883 {90.0}
Norminal No.
Thread diameter Width across flat Tightening torque (Nm {kgm})
mm mm Range Target
08 08 14 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75}
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FOREWORD STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE FOR 102 AND 114 ENGINE SERIES
1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
2) EYE JOINTSUse these torques for eye joints (unit: mm) of Cummins Engine.
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Thread diameter Tightening torque
mm Nm kgm
6
8
10
12
10 0 2
24 0 4
43 0 6
77 0 12
1.02 0 0.20
2.45 0 0.41
4.38 0 0.61
7.85 0 1.22
Thread diameter Tightening torque
mm Nm kgm
6
8
10
12
14
8 0 2
10 0 2
12 0 2
24 0 4
36 0 5
0.81 0 0.20
1.02 0 0.20
1.22 0 0.20
2.45 0 0.41
3.67 0 0.51
Thread diameter Tightening torque
inch Nm kgm
1 / 16
1 / 8
1 / 43 / 8
1 / 2
3 / 4
1
3 0 1
8 0 2
12 0 215 0 2
24 0 4
36 0 5
60 0 9
0.31 0 0.10
0.81 0 0.20
1.22 0 0.201.53 0 0.20
2.45 0 0.41
3.67 0 0.51
6.12 0 0.92
Nominal sizeof hose
Width acrossflats
Tightening torque (Nm {kgm})Taper seal
typeFace seal type
Range TargetThread size
(mm)
Nominal threadsize - Threads perinch, Thread series
Root diameter(mm) (Reference)
34 54 {3 5 5 5} 44 {4 5} 14 39
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FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODEIn the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE
Norminalnumber
Copper wire
Cable O.D.(mm)
Currentrating
(A)
Applicable circuit
Number ofstrands
Dia. of
strands(mm2)
Cross
section(mm2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signaletc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
Priori-ty
Circuits
Classi-fication
Charging Ground Starting Lighting Instrument Signal Other
1Pri-
mary
Code W B B R Y G L
Color White Black Black Red Yellow Green Blue
2
Code WR — BW RW YR GW LW
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
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FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to theleft) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
0
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
0.079
0.472
0.866
1.260
1.654
2.047
2.441
2.835
3.228
0.118
0.512
0.906
1.299
1.693
2.087
2.480
2.874
3.268
0.157
0.551
0.945
1.339
1.732
2.126
2.520
2.913
3.307
0.197
0.591
0.984
1.378
1.772
2.165
2.559
2.953
3.346
0.236
0.630
1.024
1.417
1.811
2.205
2.598
2.992
3.386
0.276
0.669
1.063
1.457
1.850
2.244
2.638
3.032
3.425
0.315
0.709
1.102
1.496
1.890
2.283
2.677
3.071
3.465
0.354
0.748
1.142
1.536
1.929
2.323
2.717
3.110
3.504
(A)
(B)
(C)
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FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0
0.394
0.787
1.181
1.575
1.969
2.362
2.756
3.150
3.543
0.039
0.433
0.827
1.220
1.614
2.008
2.402
2.795
3.189
3.583
0.079
0.472
0.866
1.260
1.654
2.047
2.441
2.835
3.228
3.622
0.118
0.512
0.906
1.299
1.693
2.087
2.480
2.874
3.268
3.661
0.157
0.551
0.945
1.339
1.732
2.126
2.520
2.913
3.307
3.701
0.197
0.591
0.984
1.378
1.772
2.165
2.559
2.953
3.346
3.740
0.236
0.630
1.024
1.417
1.811
2.205
2.598
2.992
3.386
3.780
0.276
0.669
1.063
1.457
1.850
2.244
2.638
3.032
3.425
3.819
0.315
0.709
1.102
1.496
1.890
2.283
2.677
3.071
3.465
3.858
0.354
0.748
1.142
1.536
1.929
2.323
2.717
3.110
3.504
3.898
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
0
22.05
44.09
66.14
88.18
110.23
132.28
154.32
176 37
2.20
24.25
46.30
68.34
90.39
112.44
134.48
156.53
178 57
4.41
26.46
48.50
70.55
92.59
114.64
136.69
158.73
180 78
6.61
28.66
50.71
72.75
94.80
116.85
138.89
160.94
182 98
8.82
30.86
51.91
74.96
97.00
119.05
141.10
163.14
185 19
11.02
33.07
55.12
77.16
99.21
121.25
143.30
165.35
187 39
13.23
35.27
57.32
79.37
101.41
123.46
145.51
167.55
189 60
15.43
37.48
59.53
81.57
103.62
125.66
147.71
169.76
191 80
17.64
39.68
61.73
83.78
105.82
127.87
149.91
171.96
194 01
19.84
41.89
63.93
85.98
108.03
130.07
152.12
174.17
196 21
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FOREWORD CONVERSION TABLE
Liter to U.S. Gallon
1l = 0.2642 U.S. Gal
Liter to U.K. Gallon
1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
0
2.642
5.283
7.925
10.567
13.209
15.850
18.492
21.134
23.775
0.264
2.906
5.548
8.189
10.831
13.473
16.115
18.756
21.398
24.040
0.528
3.170
5.812
8.454
11.095
13.737
16.379
19.020
21.662
24.304
0.793
3.434
6.076
8.718
11.359
14.001
16.643
19.285
21.926
24.568
1.057
3.698
6.340
8.982
11.624
14.265
16.907
19.549
22.190
24.832
1.321
3.963
6.604
9.246
11.888
14.529
17.171
19.813
22.455
25.096
1.585
4.227
6.869
9.510
12.152
14.795
17.435
20.077
22.719
25.361
1.849
4.491
7.133
9.774
12.416
15.058
17.700
20.341
22.983
25.625
2.113
4.755
7.397
10.039
12.680
15.322
17.964
20.605
23.247
25.889
2.378
5.019
7.661
10.303
12.944
15.586
18.228
20.870
23.511
26.153
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
0
2.200
4.399
6.599
8.799
10.998
13.198
0.220
2.420
4.619
6.819
9.019
11.281
13.418
0.440
2.640
4.839
7.039
9.239
11.438
13.638
0.660
2.860
5.059
7.259
9.459
11.658
13.858
0.880
3.080
5.279
7.479
9.679
11.878
14.078
1.100
3.300
5.499
7.969
9.899
12.098
14.298
1.320
3.520
5.719
7.919
10.119
12.318
14.518
1.540
3.740
5.939
8.139
10.339
12.528
14.738
1.760
3.950
6.159
8.359
10.559
12.758
14.958
1.980
4.179
6.379
8.579
10.778
12.978
15.178
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FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
0
142.2
284.5
426.7
568.9
711.2
853.4
995.6
1138
1280
1422
1565
1707
1849
1991
2134
2276
2418
2560
2702
2845
2987
3129
32 1
14.2
156.5
298.7
440.9
583.2
725.4
867.6
1010
1152
1294
1437
1579
1721
1863
2005
2148
2290
2432
2574
2717
2859
3001
3143
3286
28.4
170.7
312.9
455.1
597.4
739.6
881.8
1024
1166
1309
1451
1593
1735
1877
2020
2162
2304
2446
2589
2731
2873
3015
3158
3300
42.7
184.9
327.1
469.4
611.6
753.8
896.1
1038
1181
1323
1465
1607
1749
1892
2034
2176
2318
2460
2603
2745
2887
3030
3172
3314
56.9
199.1
341.4
483.6
625.8
768.1
910.3
1053
1195
1337
1479
1621
1764
1906
2048
2190
2333
2475
2617
2759
2901
3044
3186
3328
71.1
213.4
355.6
497.8
640.1
782.3
924.5
1067
1209
1351
1493
1636
1778
1920
2062
2205
2347
2489
2631
2773
2916
3058
3200
3343
85.3
227.6
369.8
512.0
654.3
796.5
938.7
1081
1223
1365
1508
1650
1792
1934
2077
2219
2361
2503
2646
2788
2930
3072
3214
33
99.6
241.8
384.0
526.3
668.5
810.7
953.0
1095
1237
1380
1522
1664
1806
1949
2091
2233
2375
2518
2660
2802
2944
3086
3229
33 1
113.8
256.0
398.3
540.5
682.7
825.0
967.2
1109
1252
1394
1536
1678
1821
1963
2105
2247
2389
2532
2674
2816
2958
3101
3243
338
128.0
270.2
412.5
554.7
696.9
839.2
981.4
1124
1266
1408
1550
1693
1835
1977
2119
2262
2404
2546
2688
2830
2973
3115
3257
3399
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FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F
°C °F °C °F °C °F °C °F
–40.4
–37.2
–34.4
–31.7
–28.9
–28.3
–27.8
–27.2
–26.7
–26.1
–25.6
–25.0
–24.4
–23.9
–23.3
–22.8
–22.2
–21.7
–21.1
–20.6
–20.0
–19.4
–18.9
–18.3
–40
–35
–30
–25
–20
–19
–18
–17
–16
–15
–14
–13
–12
–11
–10
–9
–8
–7
–6
–5
–4
–3
–2
–1
–40.0
–31.0
–22.0
–13.0
–4.0
–2.2
–0.4
1.4
3.2
5.0
6.8
8.6
10.4
12.2
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
28.4
30.2
–11.7
–11.1
–10.6
–10.0
–9.4
–8.9
–8.3
–7.8
–7.2
–6.7
–6.1
–5.6
–5.0
–4.4
–3.9
–3.3
–2.8
–2.2
–1.7
–1.1
–0.6
0
0.6
1.1
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
51.8
53.6
55.4
57.2
59.0
60.8
62.6
64.4
66.2
68.0
69.8
71.6
73.4
75.2
77.0
78.8
80.6
82.4
84.2
86.0
87.8
89.6
91.4
93.2
7.8
8.3
8.9
9.4
10.0
10.6
11.1
11.7
12.2
12.8
13.3
13.9
14.4
15.0
15.6
16.1
16.7
17.2
17.8
18.3
18.9
19.4
20.0
20.6
46
47
48
49
50
51
52
53
54
55
56
57
58
59
0
61
62
63
64
65
66
67
68
69
114.8
116.6
118.4
120.2
122.0
123.8
125.6
127.4
129.2
131.0
132.8
134.6
136.4
138.2
140.0
141.8
143.6
145.4
147.2
149.0
150.8
152.6
154.4
156.2
27.2
27.8
28.3
28.9
29.4
30.0
30.6
31.1
31.7
32.2
32.8
33.3
33.9
34.4
35.0
35.6
36.1
36.7
37.2
37.8
40.6
43.3
46.1
48.9
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
105
110
115
120
117.8
179.6
181.4
183.2
185.0
186.8
188.6
190.4
192.2
194.0
195.8
197.6
199.4
201.2
203.0
204.8
206.6
208.4
210.2
212.0
221.0
230.0
239.0
248.0
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FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}kW/rpm {HP/rpm}
g/kWh {g/HPh}
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SPECIFICATION DRAWINGS......................................................................................................................01- 2
SPECIFICATIONS ........................................................................................................................................01- 4
WEIGHT TABLE............................................................................................................................................01- 8
FUEL, COOLANT AND LUBRICANTS .........................................................................................................01- 12
01 GENERAL
GENERAL SPECIFICATION DRAWINGS
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GENERAL SPECIFICATION DRAWINGS
SPECIFICATION DRAWINGS
DIMENSIONS
WORKING RANGES
GENERAL SPECIFICATION DRAWINGS
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GENERAL SPECIFICATION DRAWINGS
DIMENSIONS
Fixed gauge specification
Variable gauge specification
Item Unit PC400-7 PC400LC-7 PC450-7 PC450LC-7
A Overall length mm 11,940 11,940 12,040 12,040
B Overall height mm 3,635 3,635 3,660 3,660
C Overall width mm 3,340 3,440 3,340 3,340
D Track shoe width mm 600 700 600 600
E Height of machine cab mm 3,265 3,265 3,265 3,265
F Tail swing radius mm 3,645 3,645 3,645 3,645
G Track overall length mm 5,055 5,355 5,055 5,355
H Length of track on ground mm 4,020 4,350 4,020 4,350
Min. ground clearance mm 555 550 555 550
Item Unit PC400-7 PC400LC-7 PC450-7 PC450LC-7
A Overall length mm 11,940 11,940 12,040 12,040
B Overall height mm 3,635 3,635 3,660 3,660
C Overall width mm 3,490 3,490 3,490 3,490
D Track shoe width mm 600 600 600 600
E Height of machine cab mm 3,265 3,265 3,265 3,265
F Tail swing radius mm 3,645 3,645 3,645 3,645
G Track overall length mm 5,055 5,355 5,055 5,355
H Length of track on ground mm 4,020 4,350 4,020 4,350
Min. ground clearance mm 685 685 685 685
GENERAL SPECIFICATIONS
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G S C C O S
SPECIFICATIONS
PC400-7, PC400LC-7
Machine model
PC400-7 PC400LC-7
Fixed gauge
spec.
Variable
gauge spec.
Fixed gauge
spec.
Variable
gauge spec.
Serial Number 50001 and up
Bucket capacity m3 1.4 1.4
Weight of machine kg 41,200 42,400 42,200 43,500
P e r f o r m a n c e
W
o r k i n g r a n g e s
Max. digging depth
Max. vertical wall depth
Max. digging reach
Max. reach at ground level
Max. digging heightMax. dumping height
mm
mm
mm
mm
mmmm
7,820
6,870
12,025
11,820
10,9157,565
7,820
6,870
12,025
11,820
10,9157,565
Max. digging force
(using power max. function)
Swing speed
Swing max. slope angle
Travel speed
Gradeability
kN {kg}
kN {kg}
rpm
deg.
km/h
deg.
256.0 {26,100}
(274.6 {28,000})
9.1
20
Lo: 3.0, Mi: 4.4, Hi: 5.5
35
256.0 {26,100}
(274.6 {28,000})
9.1
20
Lo: 3.0, Mi: 4.4, Hi: 5.5
35
Ground pressure
[standard shoe width]
kPa {kg/cm2}
[mm]
77.7{0.79}
[600]
79.9 {0.82}
[600]
73.9 {0.75}
[700]
65.3 {0.67}
[700]
e n s i o n s
Overall length (for transport)
Overall width
Overall width of track
Overall width of track when extendedOverall height (for transport)
Overall height to top of machine
Ground clearance of upper structure
Min. ground clearance
mm
mm
mm
mmmm
mm
mm
mm
11,940
3,340
3,340
—3,635
3,265
1,320
555
11,940
3,490
2,990
3,4903,635
3,265
1,320
685
11,940
3,440
3,440
—3,635
3,265
1,320
555
11,940
3,490
2,990
3,4903,635
3,265
1,320
685
GENERAL SPECIFICATIONS
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Machine model PC400-7 PC400LC-7
Serial Number 50001 and up
E n g i n e
Model
Type
No. of cylinders – bore × stroke
Piston displacement
mm
l {cc}
SAA6D125E-3
4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler
6 – 125 × 150
11.045 {11,045}
P e r f o r m a n
c e Flywheel horsepower
Max. torqueMax. speed at no load
Min. speed at no load
Min. fuel consumption
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}rpm
rpm
g/kWh {g/HPh}
246.4/1,850 {330/1,850}
1,334/1,400 {136/1,400}1,930
1,000
203 {151}
Starting motor
Alternator
Battery
24V, 7.5 kW
24V, 35A
12V, 110 Ah × 2
Radiator core type ALW-4
U n d e r c a r r i a g e Carrier roller 2 on each side
Track roller 7 on each side 8 on each side
Track shoe Assembly-type triple grouser,
45 on each side
Assembly-type triple grouser,
48 on each side
y d r a u l i c s y s t e m
H y d r a u
l i c p u m p Type × No.
Delivery
Set pressure
l /min
MPa {kg/cm2}
HPV190+190, variable displacement, piston type x2
345 × 2
37.8 {380}
C o n t r o l v a l v e Type × No.
Control method
6-spool type + 1-spool type × 1
Hydraulic
H y d r a u l i c m o t o r Travel motor
Swing motor
KMV200ADT-2, Variable displacement, piston type
(with brake valve, parking brake): × 2
KMF230ABE-5, Fixed displacement piston type(with safety valve, holding brake, reverse rotation preventive valve): × 1
Boom Arm Bucket
GENERAL SPECIFICATIONS
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PC450-7, PC450LC-7
Machine model
PC450LC-7 PC450LC-7
Fixed gauge
spec.
Variable
gauge spec.
Fixed gauge
spec.
Variable
gauge spec.
Serial Number 20001 and up
Bucket capacity m3 1.4 1.4
Operating weight kg 42,700 44,000 43,700 44,600
P e r f o r m a n c e
W o r k i n g r a n g e s
Max. digging depth
Max. vertical wall depth
Max. digging reach
Max. reach at ground level
Max. digging height
Max. dumping height
mm
mm
mm
mm
mm
mm
7,790
6,600
12,005
11,800
10,925
7,625
7,790
6,600
12,005
11,800
10,925
7,625
Max. digging force
(using power max. function)
Swing speed
Swing max. slope angle
Travel speed
Gradeability
kN {kg}
rpm
deg.
km/h
deg.
258.9 {26,400}
(275.5 {28,300})
9.1
17
Lo: 3.0, Mi: 4.4, Hi: 5.5
35
258.9 {26,400}
(275.5 {28,300})
9.1
17
Lo: 3.0, Mi: 4.4, Hi: 5.5
35
Ground pressure[standard shoe width]
kPa {kg/cm2}[mm]
80.5 {0.82}[600]
82.9 {0.85}[600]
76.5 {0.78}[600]
78.1 {0.80}[600]
m e n s i o n s
Overall length (for transport)
Overall width
Overall width of track
Overall width of track when extended
Overall height (for transport)
Overall height to top of machine
Ground clearance of upper structure
Min. ground clearance
mm
mm
mm
mm
mm
mm
mm
12,040
3,340
3,340
—
3,660
3,265
1,320
555
12,040
3,490
2,990
3,490
3,660
3,265
1,320
685
12,040
3,340
3,340
—
3,660
3,265
1,320
555
12,040
3,490
2,990
3,490
3,660
3,265
1,320
685
GENERAL SPECIFICATIONS
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Machine model PC450-7 PC450LC-7
Serial Number 20001 and up
E n g i n e
Model
Type
No. of cylinders – bore × stroke
Piston displacement
mm
l {cc}
SAA6D125E-3
4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler
6 – 125 × 150
11.045 {11,045}
P e r f o r m a n c e Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption
kW/rpm {HP/rpm}
Nm/rpm {kgm/rpm}
rpm
rpm
g/kWh {g/HPh}
246.4/1,850 {330/1,850}
1,334/1,400 {136/1,400}
1,930
4,000
203 {151}
Starting motor
Alternator
Battery
24V, 7.5 kW
24 V, 35 A
12V, 110 Ah × 2
Radiator core type ALW-4
U n d e r c a r r i a g e Carrier roller 2 on each side
Track roller 7 on each side 8 on each side
Track shoe Assembly-type triple grouser,
45 on each side
Assembly-type triple grouser,
48 on each side
c s y s t e m
H y d r a u l i c p u m
p Type × No.
Delivery
Set pressure
l /min
MPa {kg/cm2}
HPV190+190, ariable displacement, piston type × 2
345 × 2
37.8 {380}
C o
n t r o l v a l v e Type × No.
Control method
6-spool type + 1-spool type × 1
Hydraulic
r a u l i c m o t o r Travel motor
Swing motor
KMV200ADT-2, Variable displacement, piston type
(with brake valve, parking brake): × 2
KMF230ABE-5, Fixed displacement piston type × 2
GENERAL WEIGHT TABLE
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WEIGHT TABLE
PC400-7, PC400LC-7
k This weight table is for use when handling components or when transporting the machine.
Unit: kg
Machine model PC400-7 PC400LC-7
Serial Number 50001 and up
Engine assembly
• Engine
• Damper
• Hydraulic pump
1,500
1,150
14.7
210
1,500
1,150
14.7
210
Radiator, oil cooler assembly 195 195
Hydraulic tank, filter assembly (excluding hydraulic oil) 198 198
Fuel tank (excluding fuel) 251 251
Revolving frame 3,297 3,297
Operator's cab 279 279
Operator's seat 35 35
Counterweight 9,220 9,500
Swing machinery (including swing motor) 526 526
Control valve (with service valve) 257 257
Swing motor 105 105
Travel motor 208 × 2 208 × 2
Center swivel joint 40 40
• Track frame assembly
• Track frame
• • Center frame
• • Crawler frame
• Swing circle
Fixed gauge
specification
Variable gauge
specification
Fixed gauge
specification
Variable gauge
specification
10,173 11,367 10,965 11,934
5,506 6,766 6,077 7,096
— 3,229 — 3,229
— 1,754 × 2 — 1,921 × 2
605 × 2 605 × 2
GENERAL WEIGHT TABLE
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Unit: kg
Machine model PC400-7 PC400LC-7
Serial Number 50001 and up
Track shoe assembly
• Standard triple grouser shoe (600 mm)
• Standard triple grouser shoe (700 mm)
• Wide triple grouser shoe (800 mm)
• Wide triple grouser shoe (900 mm)
4,470
4,890
5,320
—
4,760
5,210
5,670
6,130
Boom assembly 3,290 3,290
Arm assembly 1,374 1,374
Bucket assembly 1,366 1,366
Boom cylinder assembly 355 × 2 355 × 2
Arm cylinder assembly 510 510
Bucket cylinder assembly 280 280
Link assembly 258 258
Boom pin 92 + 20 × 2 + 73 + 27 + 54 92 + 20 × 2 + 73 + 27 + 54 Arm pin 17 + 23 17 + 23
Bucket pin 38 × 2 38 × 2
Link pin 34 × 2 34 × 2
GENERAL WEIGHT TABLE
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PC450-7, PC450LC-7
Unit: kg
Machine model PC450-7 PC450LC-7
Serial Number 20001 and up
Engine assembly
• Engine
• Damper
• Hydraulic pump
1,500
1,150
14.7
210
1,500
1,150
14.7
210
Radiator oil cooler assembly 195 195
Hydraulic tank, filter assembly (excluding hydraulic oil) 198 198
Fuel tank (excluding fuel) 251 251
Revolving frame 3,402 3,402
Operator’s cab 279 279
Operator’s seat 35 35
Counterweight 9,220 9,220
Swing machinery 526 526
Control valve 257 257
Swing motor 105 105
Travel motor 208 × 2 208 × 2
Center swivel joint 40 40
• Track frame assembly
• Track frame
• • Center frame
• • Crawler frame• Swing circle
• Idler
• Idler cushion
• Carrier roller
Fixed gauge
specification
Variable gauge
specification
Fixed gauge
specification
Variable gauge
specification
10,462 11,697 11,269 12,244
5,506 6,766 6,077 7,096
— 3,229 — 3,229
— 1,754 × 2 — 1,921 × 2
605
230 × 2
338 × 2
32 × 4
605
230 × 2
338 × 2
32 × 4
GENERAL WEIGHT TABLE
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Unit: kg
Machine model PC450-7 PC450LC-7
Serial Number 20001 and up
Track shoe assembly
• Standard triple grouser shoe (600 mm)
• Standard triple grouser shoe (700 mm)
• Wide triple grouser shoe (800 mm)
4,470
4,890
—
4,760
5,210
—
Boom assembly 3,380 3,380
Arm assembly 1,622 1,622
Bucket assembly 1,941 1,941
Boom cylinder assembly 355 × 2 355 × 2
Arm cylinder assembly 580 580
Bucket cylinder assembly 280 280
Link assembly 258 258
Boom pin 92 + 20 × 2 + 73 + 27 + 54 92 + 20 × 2 + 73 + 27 + 54
Arm pin 17 + 23 17 + 23
Bucket pin 38 × 2 38 × 2
Link pin 34 × 2 34 × 2
GENERAL FUEL, COOLANT AND LUBRICANTS
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FUEL, COOLANT AND LUBRICANTS
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ENGINE RELATED PARTS..................... 10- 2
RADIATOR • OIL COOLER •
AFTERCOOLER ................................ 10- 3
POWER TRAIN ....................................... 10- 4
FINAL DRIVE .......................................... 10- 6
SPROCKET............................................. 10- 7-1
SWING MACHINERY.............................. 10- 8
SWING CIRCLE ...................................... 10- 10TRACK FRAME AND RECOIL SPRING. 10- 12
IDLER...................................................... 10- 14
CARRIER ROLLER ................................. 10- 16
TRACK ROLLER..................................... 10- 17
TRACK SHOE ......................................... 10- 18
HYDRAULIC PIPING DRAWING ............ 10- 22
HYDRAULIC TANK.................................. 10- 24
HYDRAULIC PUMP ................................ 10- 26
LS(PC)-EPC VALVE ................................ 10- 44VARIABLE VOLUME VALVE .................. 10- 47
CONTROL VALVE ................................... 10- 50
MAIN RELIEF VALVE.............................. 10- 64
CLSS ....................................................... 10- 66
SELF PRESSURE REDUCING VALVE... 10- 69
SWING MOTOR...................................... 10- 72
CENTER SWIVEL JOINT........................ 10- 80
TRAVEL MOTOR..................................... 10- 82
TRAVEL JUNCTION VALVE.................... 10- 93
VALVE CONTROL................................... 10- 95
TRAVEL PPC SHUTTLE VALVE ............. 10- 96
WORK EQUIPMENT • SWING PPC
VALVE ................................................ 10-100
TRAVEL PPC VALVE 10 104
AIR CONDITIONER .................................10-144
ENGINE CONTROL.................................10-145
ELECTRONIC CONTROL SYSTEM........10-151
MONITOR SYSTEM.................................10-178
7-SEGMENT MONITOR SYSTEM........ 10-197-1
SENSOR ..................................................10-198
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE RELATED PARTS
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ENGINE RELATED PARTS
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RADIATOR • OIL COOLER • AFTERCOOLER
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RADIATOR • OIL COOLER • AFTERCOOLER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN
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POWER TRAIN
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
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FINAL DRIVE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE
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Unit: mm
No. Check item Criteria Remedy
14 Backlash between No. 1 sungear and No. 1 planetary gear
Standard clearance Clearance limit
0.15 – 0.54 1.10
15Backlash between No. 1
planetary gear and ring gear 0.18 – 0.66 1.30
Backlash between No 2
Specification
Reduction ratio:
– × = –68.600
1. Level plug
2. Drain plug3. No. 1 planetary gear (No. of teeth: 43)
4. No. 1 sun gear (No. of teeth: 10)
5. No. 2 sun gear (No. of teeth: 18)
6. No. 1 planetary carrier
7. No. 2 planetary carrier
8. Cover
9. Ring gear (No. of teeth: 98)
10. Sprocket
11. Floating seal12. Travel motor
13. No. 2 planetary gear (No. of teeth: 38)
10 + 98
10
18 + 98
18
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
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SPROCKET
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPROCKET
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SPROCKET TOOTH SHAPE OF REAL DIMENSION
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
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SWING MACHINERY
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MACHINERY
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Unit: mm
No. Check item Criteria Remedy
14Backlash between swing
motor shaft and No. 1 sun gear
Standard clearance Clearance limit
Replace
0.18 – 0.28 —
15
Backlash between No. 1 sun
gear and No. 1 planetary
gear
0.15 – 0.51 1.00
16
Backlash between No. 1
planetary gear and ring gear 0.17 – 0.60 1.10
17
Backlash between No. 1
planetary carrier and No. 2
sun gear
0.40 – 0.75 1.20
18Backlash between No. 2 sun
0 16 0 55 1 00
Specification
Reduction ratio:
× = 24.039
1. Swing pinion (No. of teeth: 13)
2. Cover 3. Case
4. No. 2 planetary gear
5. No. 2 sun gear
6. Ring gear
7. No. 1 sun gear
8. Swing motor
9. Oil level gauge
10. No. 1 planetary gear
11. No. 1 planetary carrier 12. No. 2 planetary carrier
13. Drain plug
19 + 6819 16 + 6816
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SWING CIRCLE
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
TRACK FRAME AND RECOIL SPRING
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TRACK FRAME AND RECOIL SPRING
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK FRAME AND RECOIL SPRING
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Standard shoe
Unit: mm
Model
ItemPC400-7 PC400LC-7 PC450-7 PC450LC-7
Shoe width 600 mm 700 mm 600 mm 600 mm
Link pitch 228 mm 228 mm 228 mm 228 mm
No. on track (one side) 46 (Pieces) 46 (Pieces) 49 (Pieces) 49 (Pieces)
No. Check item Criteria Remedy
Standard
sizeTolerance Repair limit
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD IDLER
IDLER
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IDLER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
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Unit: mm
No. Check item Criteria Remedy
1Outside diameter of protrud-
ing
Standard sizeRepair limit
Rebuild or
704 —
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
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CARRIER ROLLER
Unit: mm
No. Check item Criteria Remedy
1 Outside diameter of flangeStandard size Repair limit
175 —
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
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TRACK ROLLER
Unit: mm
No. Check item Criteria Remedy
1Outside diameter of outer
flange
Standard size Repair limit
Rebuild or
replace
240 —
2Outside diameter of inner flange
(double flange)237 —
3 Outside diameter of tread 200 188
4 Thickness of tread 56.2 50.2
5 Overall width 278 —
6 Width of treadSinge flange 54.6 —
Double flange 51.6 —
Width of outer Singe flange 32.6 —
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
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C S OTRACK SHOE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
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Unit: mm
No. Check item Criteria Remedy
1 Link pitchStandard size Repair limit
Reverse orreplace
228.9 231.9
2 Bushing outside diameter Standard size When turned
71.5 66.5
3 Thickness of bushing metal 12 7 Adjust or
replace
4 Link heightStandard size Repair limit
Repair or
replace
129 119
5 Thickness of link metal(bushing press-fitting portion)
34.5 24.5
6
Shoe bolt pitch
184
Replace7 144
8 76.2
9
Link
Inside
width106
Repair or
replace10
Overall
width51.6
11Tread
width44.8
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
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Unit: mm
No. Check item Criteria Remedy
20
Shoe bolt
a. Regular
link
Tightening torque
(Nm {kgm})
Additinal tightening
angle (deg.)
RetightenTriple shoe 393±39 {40±4} 120±10
b. Master
link
Tightening torque
(Nm {kgm})
Additinal tightening
angle (deg.)
Lower limit torque
(Nm {kgm})
— — —
No. of shoes (each side)PC400-7, PC450-7: 46
PC400LC-7, PC450LC-7: 49—
21 Interference betweenbushing and link
Standard sizeTolerance Standard
interference
Shaft Hole
71+0.494
+0.454
+0.074
00.380 – 0.494
22Interference between regular
pin and link47
+0.235
+0.085
–0.218
–0.2800.303 – 0.515
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRACK SHOE
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TRIPLE GROUSER SHOE
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING DRAWING
HYDRAULIC PIPING DRAWING
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1. Bucket cylinder
2. Arm cylinder
3. Boom cylinder
4. Swing motor
5. Control valve
6. Oil cooler
7. Hydraulic filter
8. Hydraulic pump
9. L.H. travel motor
10. Hydraulic tank11. Multi-pattern selector valve
12. L.H. PPC valve
13. Safety lever (electric type)
14. Center swivel joint
15. R.H. PPC valve
16. Travel PPC valve
17. Attachment circuit selector valve
18. Holding valve
19. Accumulator 20. Solenoid valve assembly
20A. PPC lock solenoid
20B. Travel junction solenoid
20C. Pump merge/divider solenoid
20D. Travel speed solenoid
20E. Swing brake solenoid
20F. Machine push-up solenoid
20G. 2-stage relief solenoid
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING DRAWING
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK
HYDRAULIC TANK
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1. Oil filler cap Specifications
Tank capacity: 335 l2 Breather
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
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HPV190+190
1. Front main pump
2. Rear main pump
3 LS valve
IM : PC mode selector current
ISIG : LS set selector current
PAF : Front pump delivery
PENR : Rear pump control
pressure detection port
PLSF : Front load pressure input
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
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Function
• The rotation and torque transmitted to the pump
shaft are converted into hydraulic energy, and
pressurized oil is discharged according to the
load.
• It is possible to change the discharge amount by
changing the swash plate angle.
Structure
• Cylinder block (7) is supported to shaft (1) by a
spline, and shaft (1) is supported by the front and
rear bearings.
• The tip of piston (6) is a concave ball, and shoe
(5) is caulked to it to form one unit. Piston (6) and
shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface A, and shoe (5) is
always pressed against this surface while sliding
in a circular movement.Rocker cam (4) brings high pressure oil at cylin-
der surface B with cradle (2), which is secured to
the case, and forms a static pressure bearing
when it slides.
Pi t (6) i t l ti t i th
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
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Operation
1) Operation of pump
i Cylinder block (7) rotates together with shaft
(1), and shoe (5) slides on flat surface A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle
between center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle is called the swash plate
angle.)ii Center line X of rocker cam (4) maintains
swash plate angle in relation to the axial
direction of cylinder block (7), and flat surface
A moves as a cam in relation to shoe (5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volumes E and F is created inside cylinder
block (7). The suction and discharge is car-ried out by this difference F – E.
In other words, when cylinder block (7)
rotates and the volume of chamber E
becomes smaller, the oil is discharged during
that stroke. On the other hand, the volume of
chamber F becomes larger, and as the vol-
ume becomes bigger, the oil is sucked in.
iii If center line X of rocker cam (4) is in line with
the axial direction of cylinder block (7) (swashplate angle = 0), the difference between vol-
umes E and F inside cylinder block (7)
becomes 0, so the pump does not carry out
any suction or discharge of oil.
(In actual fact, the swash plate angle never
becomes 0.)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
2) C t l f di h t
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2) Control of discharge amount
• If the swash plate angle becomes larger,the difference between volumes E and F be-
comes larger and discharge amount Q in-
creases.
• Swash plate angle is changed by servo
piston (12).
• Servo piston (12) moves in a reciprocal
movement ( ) according to the signal pres-
sure from the PC and LS valves. This
straight l ine movement is transmittedthrough rod (13) to rocker cam (4), and rock-
er cam (4), which is supported by the cylin-
drical surface to cradle (2), slides in a
rotating movement in direction of arrow.
• With servo piston (12), the area receiving the
pressure is different on the left and the right,
so main pump discharge pressure (self pres-
sure) PP is always brought to the chamber
receiving the pressure at the small diameter
piston end.
• Output pressure Pen of the LS valve is
brought to the chamber receiving the pres-
sure at the large diameter end. The relation-
ship in the size of pressure PP at the small
diameter piston end and pressure Pen at the
large diameter end, and the ratio between
the area receiving the pressure of the smalldiameter piston and the large diameter pis-
ton controls the movement of servo piston
(12).
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
LS VALVE
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PC VALVE
1. Plug PA : Pump port
2. Locknut PP : Pump port
3. Sleeve PDP : Drain port
4. Spring PLP : LS control pressure output port
5. Seat PLS : LS pressure input port6. Spool PPL : PC control pressure input port
7. Piston PSIG : LS mode selection pilot port
8. Sleeve
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
Function
(1) LS valve
The LS valve detects the load and controls the
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The LS valve detects the load and controls the
discharge amount.This valve controls main pump discharge
amount Q according to differential pressure
PLS (=PP – PLS) [called the LS differential
pressure] (the difference between main pump
pressure PP and control valve outlet port pres-
sure PLS).
Main pump pressure PP, pressure PLS {called
the LS pressure} coming from the control valve
output, and pressure PSIG {called the LS selec-
tor pressure} from the proportional solenoid
valve enter this valve. The relationship between
discharge amount Q and differential pressure
PLS, (the difference between main pump
pressure PP and LS pressure PLS) (= PP –
PLS) changes as shown in the diagram at the
right according to LS pressure selector current
PSIG of the LS-EPC valve.When PSIG changes between 0 and 1A, the set
pressure of the spring changes according to this,
and the selector point for the pump discharge
amount changes at the rated central valve
between 1.2 2.6 MPa {12 27 kg/cm2}.
(2) PC valve
When the pump discharge pressure PP1 (self-
pressure) and PP2 (other pump pressure) arehigh, the PC valve controls the pump so that no
more oil than the constant flow (in accordance
with the discharge pressure) flows even if the
stroke of the control valve becomes larger. In
this way, it carries out equal horsepower control
so that the horsepower absorbed by the pump
does not exceed the engine horsepower.
In other words, If the load during the operationbecomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount from
the pump; and if the pump discharge pressure
drops, it increases the discharge amount from
the pump The relationship between the average
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
OPERATION
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(1) LS valve
1) When control valve is at neutral position
• The LS valve is a three-way selector valve, with
pressure PLS (LS pressure) from the inlet port of
the control valve brought to spring chamber B,
and main pump discharge pressure PP brought
to port H of sleeve (8). The size of this LS pres-sure PLS + force Z of spring (4) and the main
pump pressure (self pressure) PP determines
the position of spool (6). However, the size of the
output pressure PSIG (the LS selection pres-
) f th EPC l f th LS l t i
of the piston, so the swash plate is moved to the
minimum angle by the difference in the area of
the piston (12).
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2) Operation in increase direction for pump
discharge amount
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3) Operation in decrease direction for
pump discharge amount
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
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(2) PC Valve
1) When pump controller is normal
a. When the load on the actuator is smalland pump pressures PP1 and PP2 are
low
i) Movement of PC-EPC solenoid (1)
• The command current from the pump con- • The size of command current X is deter-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
• Port C of the PC valve is connected to port E
of the LS valve (see (1) LS valve). Self pres-
sure PP1 enters port B and the small diame
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sure PP1 enters port B and the small diame-
ter end of servo piston (9), and other pump
pressure PP2 enters port A.
• When pump pressures PP1 and PP2 are
small, spool (3) is on the left. At this point,
port C and D are connected, and the pres-
sure entering the LS valve becomes drain
pressure PT. If port E and port G of the LS
valve are connected (see (1) LS valve), the
pressure entering the large diameter end of the piston from port J becomes drain pres-
sure PT, and servo piston (9) moves to the
left. In this way, the pump discharge amount
moves in the direction of increase.
• As servo piston (9) moves further, springs
(4) and (6) expand and the spring force be-
comes weaker. When the spring force be-
comes weaker, spool (3) moves to the right,
so the connection between port C and port Dis cut, and the pump discharge pressure
ports B and C are connected. As a result, the
pressure at port C rises, and the pressure at
the large diameter end of the piston also ris-
es, so the movement of piston (9) to the left
is stopped.
• In other words, the stop position for piston (9)
(= pump discharge amount) is decided at the
point where the force of springs (4) and (6)
and the pushing force from the PC-EPC
valve solenoid and the pushing force created
by the pressures PP1 and PP2 acting on the
spool (3) are in balance.
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b. When load on actuator is large and pump
discharge pressure is high
• When the load is large and pump discharge • If pump discharge pressure PP and PP2 in-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PUMP
• The relation of average pump pressure (PP1
+ PP2)/2 and the position of servo piston (9)
forms a bent line because of the double-
spring effect of springs (4) and (6). The rela-
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tionship between average pump pressure(PP1 + PP2)/2 and pump discharge amount
Q is shown in the figure at the right.
• If command voltage X sent to PC-EPC valve
solenoid (1) increases further, the relation-
ship between average pump pressure (PP1
+ PP2)/2, and pump discharge amount Q is
proportional to the pushing force of the PC-
EPC valve solenoid and moves in parallel. In
other words, the pushing force of PC-EPC
solenoid (1) is added to the force pushing tothe left because of the pump pressure ap-
plied to the spool (3), so the relationship be-
tween the average pump pressure (PP1 +
PP2)/2 and Q moves from to in accord-
ance with the increase in X.
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2) When pump controller is abnormal and
emergency pump drive switch is ON
a. When load on main pump is light
• If there is a failure in the pump controller turn
• At this point, port C is connected to the drain
pressure of port D, and the large diameter
end of the piston of servo piston (9) also be-
comes the drain pressure PT through the LS
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b. When main pump load is heavy
• In the same way as in the previous item,
when the emergency pump drive switch is
ON, the command current sent to PC-EPC
valve solenoid (1) becomes constant. For
this reason, the force of piston (2) pushing
l (3) i t t
the diagram for the valve of the current sent
to the PC-EPC valve solenoid through the
resistor.
The curve when the emergency pump drive
switch is ON is curve , which is to the left
f f h th t ll i
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LS(PC)-EPC VALVE
LS(PC)-EPC VALVE
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1. Body 5. Coil PSIG : To LS(PC) valve
2. Spool 6. Plunger PT : To tank
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LS(PC)-EPC VALVE
Function
• The EPC valve consists of the proportional sole-
noid portion and the hydraulic valve portion.
Wh it i i l t i f th
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• When it receives signal current i from the pumpcontroller, it generates the EPC output pressure
in proportion to the size of the signal, and outputs
it to the LS valve.
Operation
1. When signal current is 0 (coil de-energized)
• When there is no signal current flowing from the
controller to coil (5), coil (5) is de-energized.• For this reason, spool (2) is pushed to the left in
the direction of the arrow by spring (3).
• As a result, port PEPC closes and the pressu-
rized oil from the main pump does not flow to the
LS valve.
At the same time, the pressurized oil from the LS
valve passes from port PSIG(PM) through port
PT and is drained to the tank.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LS(PC)-EPC VALVE
2. When signal current is very small (coil ener-
gized)
• When a very small signal current flows to coil (5),
coil (5) is energized, and a propulsion force is
generated which pushes plunger (6) to the left
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generated which pushes plunger (6) to the left.• Push pin (4) pushes spool (2) to the left, and
pressurized oil flows from port PEPC to port
PSIG(PM).
• When the pressure at port PSIG(PM) rises and
the load of spring (3) + the force acting on sur-
face a of spool (2) becomes greater than the pro-
pulsion force of plunger (6), spool (2) is pushed
to the right. The circuit between port PEPC and
port PSIG(PM) is shut off, and at the same time,
port PSIG(PM) and port PT are connected.
• As a result, spool (2) is moved up or down until
the propulsion force of plunger (6) is balanced
with the load of spring (3) + pressure of port
PSIG(PM).
• Therefore, the circuit pressure between the EPC
valve and the LS valve is controlled in proportion
to the size of the signal current.
3. When signal current is maximum (coil ener-
gized)
• When the signal current flows to coil (5), coil (5)
is energized.
• When this happens, the signal current is at its
maximum, so the propulsion force of plunger (6)
is also at its maximum.
• For this reason, spool (2) is completely pushed to
the left by push pin (4).
• As a result, the maximum flow of pressurized oil
from port PEPC flows to port PSIG(PM), and the
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VARIABLE VOLUME VALVE
VARIABLE VOLUME VALVE
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1. Block PM : To PC valve
2. Plug PT : To tank
3. Spring PEPC:From self-reducing pressure valve
4. Piston
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VARIABLE VOLUME VALVE
Function
• This stabilizes the EPC output pressure.
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Operation
• The output pressure from EPC flows to port PM,
and when the propulsion force of piston (4) be-
comes larger than the load of spring (3), piston
(4) is pushed to the left and the volume at port
PM increases.
When the propulsion force of piston (4) becomes
less than the load on spring (3), piston (4) ispushed to the right and the volume at port PM
goes down.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
1. 6-spool valve
2. Cover 1
3. Cover 2
Outline
• This control valve consists of a 7-spool valve (6
spool valve + boom • arm Hi valve). A merge-di-
vider valve, back-pressure valve, boom hydraulic
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3 Co e
4. Pump merge-divider valve
5. Back pressure valve
6. Boom lock valve
7. Boom, arm Hi valve
8. Quick return valve
9. Boom Hi check valve
de a e, bac p essu e a e, boo yd au c
drift prevention valve, quick return valve, and Hi
valve check valve are installed to it.
• Since all the valves are assembled together with
connecting bolts and their passes are connected
to each other inside the assembly, the assembly
is small in size and easy to maintain.
• Since one spool of this control valve is used for
one work equipment unit, its structure is simple.
A1 : To bucket cylinder bottom P11 : From arm PPC valve
A2 : o left travel motor P12 : From arm PPC valve
A3 : To boom cylinder bottom BP1 : Boom RAISE PPC output pressure
A4 : To swing motor PB5 : From 2-stage safety valve solenoid valve
A5 : To right travel motor PLS1 : To rear pump control
A6 : To arm cylinder head PLS2 : To front pump control
A-1 : To boom cylinder bottom PP1 : To rear pump control
A-2 : To attachment PP2 : To front pump control
B1 : To bucket cylinder head PPS1 : From rear main pumpB3 : To bottom cylinder head PPS2 : From front main pump
B4 : To swing motor PR : To solenoid valve, PPC valve, EPC valve
B5 : To right travel motor PS : From pump merge-divider solenoid valve
B6 : To arm cylinder bottom PST : From travel junction valve
B-1 : To arm cylinder bottom PX1 : From 2-stage solenoid valve
P1 : From bucket PPC valve PX2 : From 2-stage solenoid valve
P2 : From bucket PPC valve SA : Pressure sensor fitting port
P3 : From left travel PPC valve SB : Pressure sensor fitting port
P4 : From left travel PPC valve T : To tank
P5 : From boom PPC valve T1 : To tank
P6 : From boom PPC valve TS : To tank
P7 : From swing PPC valve TSW : To swing motor
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
7-spool valve
(1/9)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
(2/9)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
(3/9)
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1. Unload valve 9. Pressure compensation valve (Arm IN)
2. Pressure compensation valve (Arm OUT) 10. Pressure compensation valve (Bucket DUMP)
3. Pressure compensation valve (Right travel re-
verse)
11. Pressure compensation valve (Left travel forward)
12. Pressure compensation valve (Boom LOWER)
4. Pressure compensation valve (Left swing) 13. Pressure compensation valve (Right swing)
5. Pressure compensation valve (Boom RAISE) 14. Pressure compensation valve (Right travel for-
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
(5/9)
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1. Safety-suction valve (Arm OUT) 9. Safety-suction valve (2-stage) (Boom LOWER)
2. Suction valve (Right travel reverse) 10. Suction valve (Right travel forward)
3. Suction valve (Boom RAISE) 11. Safety-suction valve (Arm IN)
4 S ti l (L ft t l ) 12 LS h ttl l (A i ht t l)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
(6/9)
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ARM CONTROL VALVE R. H. TRAVEL CONTROL VALVE
1. Unload valve 5. Safety-suction valve 12. Suction valve
2. Main relief valve 6. Spool 13. Spool
3. Safety valve (Boom RAISE) 7. Pressure compensation valve
(OUT)
14. Pressure compensation valve
(Reverse)4. Lift check valve
8. LS shuttle valve 15. LS shuttle valve
9. Pressure compensation valve 16. Pressure compensation valve
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limitFree length Installed Installed Free Installed
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18 Regeneration valve spring
If damaged or
deformed,
replace spring
Free length
× OD
Installed
length
Installed
load
Free
length
Installed
load
31.5 × 10.3 19.56.2 N
{0.6 kg}—
4.9 N
{0.5 kg}
19 Piston return spring 36.9 × 11.1 2829.4 N
{3 kg}—
23.5 N
{2.4 kg}
20 Piston return spring 36.9 × 11.1 2829.4 N
{3 kg} —23.5 N
{2.4 kg}
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
(7/9)
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SWING CONTROL VALVE
1. Spool2. Pressure compensation valve
(Left)
3. LS select valve
ARM CONTROL VALVE
5. Suction valve6. Spool
7. Pressure compensation valve
(RAISE)
L. H. TRAVEL CONTROL VALVE
13. Pump merge-divider valve(Travel junction valve)
14. Return spring
15. Suction valve
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limitFree length Installed Installed Free Installed
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21 Regeneration valve spring
If damaged or
deformed,
replace spring
× OD length load length load
31.5 × 10.3 19.56.2 N
{0.6 kg}—
4.9 N
{0.5 kg}
22 Piston return spring 48.1 × 10.8 2817.5 N
{1.8 kg}—
14.0 N
{1.4 kg}
23 Piston return spring 36.9 × 11.1 28
29.4 N
{3 kg} —
23.5 N
{2.4 kg}
24 Spool return spring 30.7 × 20.5 2350.0 N
{5.1 kg}—
40.0 N
{4.1 kg}
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
(8/9)
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BUCKET CONTROL VALVE
1. Safety-suction valve2. Spool
3. Pressure compensation valve (CURL)
4. LS shuttle valve
5 Pressure compensation valve (DUMP)
BOOM, ARM HI VALVE
7. Boom Hi spool8. Pressure compensation valve (Boom RAISE)
9. Boom Hi check valve
10. Quick-return valve
11 Pressure compensation valve (Arm IN)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
(9/9)
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1 Unload valve 9 LS bypass plug
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROL VALVE
Unit: mm
No. Check item Criteria Remedy
17 Check valve spring
Standard size Repair limit
Free length
× OD
Installed
length
Installed
load
Free
length
Installed
load
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17 Check valve spring
If damaged or
deformed,
replace spring
× OD length load length load
11.5 × 4.6 8.51.5 N
{0.15 kg}—
1.2 N
{0.12 kg}
18 Spool return spring 46.6 × 21.8 3.3156.8 N
{16.0 kg}—
125.5 N
{12.8 kg}
19 Spool return spring 64.5 × 32.3 63
177.5 N
{18.1 kg} —
142.0 N
{14.5 kg}
20 Sequence valve spring 70.9 × 18.0 59199.8 N
{20.4 kg}—
160.0 N
{16.3 kg}
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MAIN RELIEF VALVE
MAIN RELIEF VALVE
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Function
• The relief valve set pressure is set to 2 stages.
When power is needed, pilot pressure P is turned
ON and the pressure is set to high pressure.
Operation
• The relief valve set pressure is determined by the
installed load of spring (1). (First stage)
• It is unnecessary to set the first and second
stage individually.
The second stage is set when the first stage is
set.
1. When pilot pressure P is OFF: Low-pressure
setting
The set pressure is determined by the installed
load of spring (1).
1. Spring
2. Poppet
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
CLSS
OUTLINE OF CLSS
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Features Structure
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
Basic principle
1) Control of pump swash plate
• The pump swash plate angle (pump dischargeamount) is controlled so that LS differential pres-
sure PLS (the difference between pump pres-
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( p p p
sure PP and control valve outlet port LS pressure
PLS) (load pressure of actuator) is constant.
(LS pressure PLS = Pump discharge pressure
PP – LS pressure PLS)
• If LS differential pressure PLS becomes lower
than the set pressure of the LS valve (when the
actuator load pressure is high), the pump swashplate moves towards the maximum position; if it
becomes higher than the set pressure of the LS
valve (when the actuator load pressure is low),
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLSS
2) Pressure compensation
• A pressure compensation valve is installed to the
outlet port side of the control valve to balance the
load.• When two actuators are operated together, this
valve acts to make pressure difference P be-
In this way, the flow of oil from the pump is divid-
ed (compensated) in proportion to the area of
opening S1 and S2 of each valve.
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tween the upstream (inlet port) and downstream
(outlet port) of the spool of each valve the same
regardless of the size of the load (pressure).
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
SELF PRESSURE REDUCING VALVE
Function
• This value reduces the discharge pressure of themain pump and supplies it as control pressure for
the solenoid valves, PPC valves, etc.
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Operation
1. When engine is stopped
• Poppet (11) is pressed by spring (12) against the
seat and port PR is not connected to TS.• Valve (14) is pressed by spring (13) against the
left side and port P2 is connected to PR.
• Valve (7) is pressed by spring (8) against the left
side and port P2 is not connected to A2.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
2. When in neutral or load pressure P2 is low
(When the boom is lowered and arm is at the IN
position and they are moving down under their
own weight)Note: When load pressure A2 is lower than self-
pressure reducing valve output pressure
PR
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PR.
• Valve (7) receives the force of spring (8) and PR
pressure (which is 0 MPa {0 kg/cm2} when the
engine is stopped) in the direction to close the
circuit between ports P2 and A2. If the hydraulic
oil flows in port P2, the fdx P2 pressure becomesequal to the total force of spring (8) and the value
of area of ød × PR pressure, then the area of the
pass between ports P2 and A2 is adjusted so the
P2 pressure will be kept constant above the PR
pressure.
• If the PR pressure rises above the set level, pup-
pet (11) opens and the hydraulic oil flows from
the PR port through orifice “a” in spool (14) and
open part of poppet (11) to seal drain port TS. Accordingly, differential pressure is generated
between before and after orifice “a” in spool (14)
and then spool (14) moves to close the pass be-
tween port P2 and PR. The P2 pressure is con-
trolled constant (at the set pressure) by the area
of the oil pass at this time and supplied as the PR
pressure.
3. When load pressure P2 is high
• If load pressure A2 rises and the pump discharge
increases because of operation of the work
equipment, the fdx P2 pressure rises higher than
the total of the force of spring (8) and the value of
ød × PR pressure, and then valve (7) moves to
the right stroke end.
• As a result, the area of the pass between ports
P2 and A2 increases and the pass resistancelowers and the loss of the engine power is re-
duced.
• If the PR pressure rises above the set pressure,
t (11) d th h d li il fl
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SELF PRESSURE REDUCING VALVE
4. When abnormal high pressure is generated
• If the PR pressure on the self-pressure reducing
valve rises abnormally high, ball (16) separates
from the seat against the force of spring (15) andthe hydraulic oil flows from output port PR to TS.
Accordingly, the PR pressure lowers. By this op-
eration the hydraulic devices (PPC valves sole
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eration, the hydraulic devices (PPC valves, sole-
noid valves, etc.) are protected from abnormal
pressure.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
KMF230ABE-5
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
RELIEF VALVE
1. OutlineThe relief portion consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief
valve (1).
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2. Function
When the swing is stopped, the outlet port circuit
of the motor from the control valve is closed, but
the motor continues to rotate under inertia, so
the pressure at the output side of the motor becomes abnormally high, and this may dam-
age the motor.
To prevent this, the abnormal high pressure oil is
relieved to port S from the outlet port of the
motor (high-pressure side) to prevent any dam-
age.
3. Operation
1) When starting swing
• When the swing control lever is operated to
swing right, the pressure oil from the pump pass-
es through the control valve and is supplied to
port MA. As a result, the pressure at port MA ris-
es, the starting torque is generated in the motor,
and the motor starts to rotate. The oil from the
outlet port of the motor passes from port MA
through the control valve and returns to the tank.(Fig. 1)
2) When stopping swing
• When the swing control lever is returned to neu-
tral, the supply of pressure oil from the pump to
port MA is stopped. With the oil from the outlet
port of the motor, the return circuit to the tank is
closed by the control valve, so the pressure at
port MB rises. As a result, rotation resistance isgenerated in the motor, so the braking effect
starts.
• If the pressure at port MB becomes higher than
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
Operation of swing lock
1. When swing lock solenoid valve is deactivat-
edWhen the swing lock solenoid valve is deacti-
vated, the pressurized oil from the main pump is
shut off and port B is connected to the tank cir-
it
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cuit.
As a result, brake piston (7) is pushed down by
brake spring (1), discs (5) and plates (6) are
pushed together, and the brake is applied.
2. When swing lock solenoid valve is activated
When the swing lock solenoid valve is activated,the valve is switched and the pressure oil from
the main pump enters port B and flows to brake
chamber a.
The pressure oil entering chamber a overcomes
brake spring (1) and pushes brake piston (7) up.
As a result, discs (5) and plates (6) are sepa-
rated and the brake is released.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
REVERSAL PREVENTION VALVE
Outline diagram
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Explanation of effect
1. Valve body
2. Spool (MA side)
3. Spring (MA side)
4. Plug
5. Spool (MB side)
6. Spring (MB side)
7. Plug
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SWING MOTOR
Outline
This valve reduces the swing back generated in
the swing body by the inertia of the swing body,the backlash and rigidity of the machinery sys-
tem, and the compression of the hydraulic oil
when the swing is stopped. This is effective in
preventing spillage of the load and reducing the
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preventing spillage of the load and reducing the
cycle time when stopping the swing (the posi-
tioning ability is good and it is possible to move
swiftly to the next job.
Operation
1. When brake pressure is being generated at
port MB
• Pressure MB passes through the notch and goes
to chamber d, spool (5) pushes spring (6) ac-
cording to the difference in area D1 > D2, moves
to the left, and MB is connected to e.
When this happens, pressure MA is below the
set pressure of spring (3), so spool (2) does not
move. For this reason, the pressure oil is closed
by spool (2), and the braking force is ensured.
2. After motor stops• The motor is reversed by the closing pressure
generated at port MB. (1st reversal)
When this happens, reversal pressure is gener-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
TRAVEL MOTOR
KMV280ADT
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
Operation of moter
1) At low speed (motor swash plate angle at
maximumu)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
2) At high speed (motor swash plate angle at
minimum)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
PARKING BRAKE
1. When starting to travel
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Operation
• When the travel lever is operated, the pressu-
rized oil from the pump actuates counterbalance
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
2. When stopping travel
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Operation
• When the travel lever is placed in neutral, coun-
terbalance valve spool (13) returns to the neutral
valve (7) when the brake piston returns, and this
ensures that the brake is applied after the ma-
chine stops
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
Operation of brake valve
• The brake valve consists of a check valve (1),
counterbalance valve (2), and safety valve (3) in
a circuit as shown in the diagram on the right.
• The function and operation of each component is
as given below.
1) Counterbalance valve, check valve
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) ,
Function
• When traveling downhill, the weight of the ma-
chine makes it try to travel faster than the speedof the motor.
As a result, if the machine travels with the engine
at low speed, the motor will rotate without load
and the machine will run away, which is extreme-
ly dangerous.
To prevent this, these valves act to make the ma-
chine travel according to the engine speed
(pump discharge amount).
Operation when pressurized oil is supplied
• When the travel lever is operated, the pressu-
rized oil from the control valve is supplied to port
PA. It pushes open check valve (12a) and flows
from motor inlet port MA to motor outlet port MB.
However, the motor outlet port is closed by check
valve (12b) and spool (13), so the pressure at the
supply side rises.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
• The pressurized oil at the supply side flows from
orifice E1 in spool (13) and orifice E2 in the pis-
ton to chamber S1. When the pressure in cham-
ber S1 goes above the spool switching pressure,
spool (13) is pushed to the right.
As a result, port MB and port PB are connected,
the outlet port side of the motor is opened, and
the motor starts to rotate.
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Operation of brake when traveling downhill
• If the machine tries to run away when travelingdownhill, the motor will turn under no load, so the
pressure at the motor inlet port will drop, and the
pressure in chamber S1 through orifices E1 and
E2 will also drop.
When the pressure in chamber S1 drops below
the spool switching pressure, spool (13) is re-
turned to the left by spring (14), and outlet port
MB is throttled.
As a result, the pressure at the outlet port siderises, resistance is generated to the rotation of
the motor, and this prevents the machine from
running away.
In other words, the spool moves to a position
where the pressure at outlet port MB balances
the pressure at the inlet port and the force gener-
ated by the weight of the machine. It throttles the
outlet port circuit and controls the travel speed
according to the amount of oil discharged from
the pump.
2) S f t l (2 di ti ti 2 t
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
Operation in both directions
1) When pressure in chamber MB has become
high (when rotating clockwise)
• When the travel is stopped (or when traveling
downhill), chamber MB in the outlet port circuit is
closed by the check valve of the counterbalance
valve, but the pressure at the outlet port rises be-
cause of inertia.
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• If the pressure goes above the set pressure, the
force produced by the difference in area between
D1 and D2 [x/4 (D12 – D2) × pressure] overcomes
the force of the spring and moves the poppet tothe left, so the oil flows to chamber MA in the cir-
cuit on the opposite side.
2) When stopping travel (low-pressure setting)
• When the travel lever is placed at neutral, the
pressure in chamber PA drops and counterbal-
ance valve spool (13) returns to the neutral posi-
tion. While the counterbalance valve spool (13) is
returning to the neutral position, the pressurizedoil in chamber J passes through passage H, and
escapes to chamber PA from chamber G. The
piston moves to the left, and the set load be-
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL MOTOR
3) When pressure in chamber MA has become
high (when rotating counterclockwise)
• When the travel is stopped (or when traveling
downhill), chamber MA in the outlet port circuit is
closed by the check valve of the counterbalance
valve, but the pressure at the outlet port rises be-
cause of inertia.
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• If the pressure goes above the set pressure, the
force produced by the difference in area between
D1 and D3 [x/4 (D32 – D12) × pressure] over-comes the force of the spring and moves the
poppet to the left, so the oil flows to chamber MB
in the circuit on the opposite side.
Operation of mechanism for varying set
pressure
1) When starting travel (high-pressure setting)
• When the travel lever is operated, the pressu-
rized oil from the pump actuates counterbalance
valve spool (19), and opens the pilot circuit to the
safety valve. The oil passes from chamber G to
passage H and flows into chamber J, pushes thepiston to the right, and compresses the spring to
make the set load larger. Because of this, the set
pressure of the safety valve is switched to the
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
TRAVEL JUNCTION VALVE
Function
• This valve connects both travel circuits to each
other so that the hydraulic oil will be supplied
evenly to both travel motors and the machine will
travel straight.
• When the machine is steered, outside pilot pres-
sure PST closes the travel junction valve to se-
cure high steering performance.
Operation
When pilot pressure is turned ON
• If the pilot pressure from the travel junction sole-
noid valve becomes higher than the force of
spring (14), travel junction spool (13) moves to
the left stroke end and the junction circuit be-
tween port PTL (Left travel circuit) and PTR
(Right travel circuit) is closed.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL JUNCTION VALVE
When pilot pressure is turned OFF
• If pilot pressure PST from the solenoid valve is 0,
travel junction spool (13) is pressed by the force
of spring (14) against the right side and the pass
between ports PTL and PTR is open.
• If the oil flow rates in both travel motors become
different from each other, the oil flows through
the route between port PTL, travel junction spool
(13), and port PTR so that the oil flow rates will
be equalized again.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD VALVE CONTROL
VALVE CONTROL
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Lever positions
1. Travel PPC valve 8. Solenoid valve (1) Hold (9) Swing “RIGHT”
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE
TRAVEL PPC SHUTTLE VALVE
Function
• If boom RAISE or arm IN are operated when the
machine is traveling, the stroke of the spools for the boom and arm is controlled by the travel PPC
pressure and this limits the flow of oil to the boom
and arm cylinders.
• When the boom and arm stroke is controlled, the
travel PPC pressure passes through the circuit
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travel PPC pressure passes through the circuit
inside the control valve to actuate the system.
Operation
1. When travel is at neutral
• Stroke limit signal chambers a and b are con-
nected to the travel PPC valve through orifices
(5) and (6) in pistons (3) and (4) inside the travel
spring case, and the is drained.
• When arm IN is operated, spool (1) moves to the
right by stroke (st0) to a point where it contactsthe end face of spring case (2).
• When boom RAISE is operated, spool (9) moves
to the left by stroke (st3) to a point where it con-
tacts the end face of spring case (10).
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC SHUTTLE VALVE
2. When travel is operated
• When the travel lever is operated to right RE-
VERSE (or FORWARD), the right (REVESE (or
FORWARD) PPC pressure pushes spool (7) to
the left (or right).• Spool (7) pushes piston (3), orifice (5) closes,
and stroke limit signal chamber a is shut off from
the drain circuit of the travel PPC valve.
• At the same time, the right REVERSE (or FOR-
WARD) PPC pressure passes through orifice (6)
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) p p g ( )
in piston (4), acts on the right end face of piston
(8), and pushes piston (8) to the left.
• If arm IN is operated, spool (1) moves to the right,
but the maximum stroke of the spool is limited by
the amount of movement st2 of piston (8) and
becomes st1.
• If boom RAISE is operated, spool (9) tries to
move to the left, but the travel PPC pressure en-
ters stroke control signal chamber b, so the spool
does not move.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
WORK EQUIPMENT • SWING PPC VALVE
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P : From self pressure reducing valve P1 : Left PPC: Arm OUT / Right PPC: Boom LOWER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
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1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (For connection of lever)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
Operation
1) At neutral
Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drainchamber D through fine control hole f in spool
(1)
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2) During fine control (neutral o oo o fine control)
When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2), and moves down.When this happens, fine control hole f is shut off
from drain chamber D, and at almost the same
time, it is connected to pump pressure chamber
PP, so pilot pressure oil from the main pump
passes through fine control hole f and goes from
port P1 to port A.
When the pressure at port P1 becomes higher,
spool (1) is pushed back and fine control hole f
is shut off from pump pressure chamber PP. Atalmost the same time, it is connected to drain
chamber D to release the pressure at port P1.
Wh thi h l (1) d
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT • SWING PPC VALVE
3) During fine control (when control lever is
returned)
• When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)and the pressure at port P1.
When this happens, fine control hole f is con-
nected to drain chamber D and the pressure oil
at port P1 is released.
If the pressure at port P1 drops too far, spool (1)
is pushed down by metering spring (2) and fine
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is pushed down by metering spring (2), and fine
control hole f is shut off from drain chamber D.
At almost the same time, it is connected to
pump pressure chamber PP, and the pump
pressure is supplied until the pressure at port P1
recovers to a pressure that corresponds to the
lever position.
When the spool of the control valve returns, oil
in drain chamber D flows in from fine control
hole f’ in the valve on the side that is not work-
ing. The oil passes through port P2 and enters
chamber B to fill the chamber with oil.
4) At full stroke
When disc (5) pushes down piston (4), andretainer (9) pushes down spool (1), fine control
hole f is shut off from drain chamber D, and is
connected with pump pressure chamber PP.
Therefore, the pilot pressure oil from the main
pump passes through fine control hole f and
flows to chamber A from port P1, and pushes
the control valve spool.
The oil returning from chamber B passes from
port P2 through fine control hole f’ and flows todrain chamber D.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
TRAVEL PPC VALVE
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
Travel signal/Steering function
• Travel signal
If either of the travel levers is operated, the maximum PPC output pressure on both sides is output as the
travel signal. Accordingly, if the machine is traveling is judged by the signal of port P5.• Steering signal
If the operation quantities of both levers are different from each other as in the steering operation, the higher
one of the PPC output pressures on both sides is output as the steering signal.
Any signal is not output from port P6 while the machine is travelling straight (forward or reverse) or in neu-
tral.
Accordingly, if the machine is being steered is judged by the signal of port P6.
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Operation
1. While in NEUTRAL
The signals of the output ports (P1 – P4), travel signal (Port P5), and steering signal (Port P6) are not out-
put.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
2. While travelling straight
(The following drawing shows the circuit for traveling straight forward.)
While the left motor is operating for forward travel (the signal of port P2 is output) and the right motor is also
operating for forward travel (the signal of port P4 is output), the pressures in left spring chamber (k) and
right spring chamber (l) of steering signal valve (j) are set high. Accordingly, the steering signal valve is keptin neutral and the steering signal (Port P6) is not output.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
3. When steered or pivot-turned
(The following drawing shows the circuit for left forward (slow) and right forward (fast) operation.)
If the operation quantities of both levers are different from each other as in the steering operation (If the dif-
ference of the pilot pressure between both sides is higher than a certain level), the pilot pressure is output
as the steering signal.In the case of the following drawing, the pressure in left spring chamber (k) of steering signal valve (j) is P2.
The pressure in right spring chamber (l) is P4.
If (P4 – P2) × (Sectional area of spool) > Set spring load, the spool is changed to the direction of the arrow
and the higher one of both PPC output pressures (the pressure of port P4 in this drawing) is output as the
steering signal to port P6.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRAVEL PPC VALVE
4. When pivot-turned
(The following drawing shows the circuit for left reverse and right forward operation.)
While the left motor is operating for reverse travel (the signal of port P1 is output) and the right motor is
operating for forward travel (the signal of port P4 is output), only the pressure in right spring chamber (l) of
steering signal valve (j) is set high. Accordingly, the steering signal valve moves to the left and outputs thesteering signal (port P6).
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SERVICE PPC VALVE
SERVICE PPC VALVE
a Refer to the section WORK EQUIPMENT •
SWING PPC VALVE for function of this valve.
1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Lever
6. Plate
7. Retainer
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8. Body
T : To tank
P : From main pump
P1 : Port
P2 : Port
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
SOLENOID VALVE
PPC lock, 2-stage relief, travel speed, swing brake, merge-divider, machine push-up, travel junction solenoid
valves
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SOLENOID VALVE
1. Connector
2. Moving core
3. Coil
4. Spool5. Block
6. Spring
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Operation
WHEN SOLENOID IS TURNED OFF
• Since the signal current does not flow from the
controller, solenoid (3) is turned off.
Accordingly, spool (4) is pressed by spring (6)
against the left side.
By this operation, the pass from P to A is closed
and the hydraulic oil from the main pump does
not flow into the actuator.
At this t ime, the oil from the actuator is drained
through ports A and T into the tank.
WHEN SOLENOID IS TURNED ON
• The signal current flows from the controller to so-
lenoid (3), and the latter is turned on.
Accordingly, spool (4) is pressed against to the
right side.
By this operation, the hydraulic oil from the main
pump flows through port P and spool (4) to port
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PPC ACCUMULATOR
PPC ACCUMULATOR
1
2
3
1. Gas plug
2. Shell3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
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4
5
6
SBP00290
Gas capacity: 300 cc (for PPC)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD RETURN OIL FILTER
RETURN OIL FILTER
FOR BREAKER
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Specifications
1. Drain plug Rated pressure : 6.9 MPa {70 kg/cm2}
Fl 200 l/ i2 El t
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION
BOOM HYDRAULIC DRIFT PREVENTION VALVE
Function
• When the boom lever is not being operated,
these valves act to prevent the oil at the boombottom from leaking from spool (1) and prevent
the boom from moving down.
Operation
1. Boom RAISE
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When the boom RAISE is operated, the main
pressure oil acts in the left direction on ring-shaped area A (= Area of ød1 – Area of ød2)
because of the difference in the outside diame-
ter d1 of poppet (5) and seat diameter d2. When
it overcomes the force of spring (4), poppet (5)
moves to the left.
In addition, the main pressure oil acts in the right
direction on seat diameter d3 of valve (6). When
it overcomes the force of spring (4), valve (6)
moves to the right.
As a result, the main pressure oil prom the con-
trol valve passes through the opening of poppet
(5) and flows to the bottom end of the boom cyl-
inder.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION
2. Boom at HOLD
• When the boom is raised and the control lever is
returned to the HOLD position, the oil that has
flowed into the inside of poppet (5) through ori-
fice a in poppet (5) is closed by pilot piston (2).The main pressure oil and hold pressure at the
bottom of the boom cylinder are shut off.
• At the same time, the hold pressure at the bottom
end of the boom cylinder acts in the right direc-
tion on ring-shaped area A (= Area of ød1 – Area
of ød2) because of the difference in the outside
diameter d1 of poppet (5) and seat diameter d2.
Poppet (5) is closed by the total of this force and
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Poppet (5) is closed by the total of this force and
the force of spring (4), so the main pressure oiland hold pressure at the bottom of the boom cyl-
inder are shut off.
• In addition, the hold pressure at the bottom of the
boom cylinder acts in the left direction on outside
diameter d4 of valve (6).
• Valve (6) is closed by the total of this force and
the force of spring (4), so the main pressure oil
and hold pressure at the bottom of the boom cyl-
inder are shut off. As a result, the boom is held in
position.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM HYDRAULIC DRIFT PREVENTION
3. Boom LOWER
• When boom LOWER is operated, the pilot pres-
sure from the PPC valve pushes pilot spool (2),
and the pressure oil chamber b inside the poppet
is drained through orifice c.The oil at the bottom end of the boom flows from
orifice a to chamber b to orifice c to drain, so the
oil pressure in chamber b drops.
When the pressure in chamber b drops below
the pressure at port b, poppet (4) opens, and
the pressure oil from port B goes to port A and
flows to the control valve.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ARM HYDRAULIC DRIFT PREVENTION
ARM HYDRAULIC DRIFT PREVENTION VALVE(If equipped)
Function
• When the arm lever is not being operated, thesevalves act to prevent the oil at the arm head from
leaking from spool (1) and prevent the arm from
moving down.
Operation
1 Arm DUMP
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1. Arm DUMP
When the arm DUMP is operated, the mainpressure oil acts in the left direction on ring-
shaped area A (= Area of ød1 – Area of ød2)
because of the difference in the outside diame-
ter d1 of poppet (5) and seat diameter d2. When
it overcomes the force of spring (4), poppet (5)
moves to the left.
As a result, the main pressure oil prom the con-
trol valve passes through the opening of poppet
(5) and flows to the bottom end of the boom cyl-
inder.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ARM HYDRAULIC DRIFT PREVENTION
2. Arm at HOLD
• When the arm DUMP is operated and the control
lever is returned to the HOLD position, the oil that
has flowed into the inside of poppet (5) through
orifice a in poppet (5) is closed by pilot piston (2).The main pressure oil and hold pressure at the
head of the arm cylinder are shut off.
• At the same time, the hold pressure at the bottom
end of the boom cylinder acts in the right direc-
tion on ring-shaped area A (= Area of ød1 – Area
of ød2) because of the difference in the outside
diameter d1 of poppet (5) and seat diameter d2.
Poppet (5) is closed by the total of this force and
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pp ( ) y
the force of spring (4), so the main pressure oiland hold pressure at the head of the arm cylinder
are shut off.
• In addition, the hold pressure at the bottom of the
boom cylinder acts in the left direction on outside
diameter d4 of valve (6).
As a result, the arm is held in position.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ARM HYDRAULIC DRIFT PREVENTION
3. Arm IN
• When arm IN is operated, the pilot pressure from
the PPC valve pushes pilot spool (2), and the
pressure oil chamber b inside the poppet is
drained through orifice c.The oil at the head end of the arm flows from ori-
fice a to chamber b to orifice c to drain, so the oil
pressure in chamber b drops.
When the pressure in chamber b drops below
the pressure at port b, poppet (4) opens, and
the pressure oil from port B goes to port A and
flows to the control valve.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ARM HYDRAULIC DRIFT PREVENTION
4. When abnormally high pressure is
generated
• If abnormally high pressure is generated in the
boom cylinder bottom circuit, the hydraulic oil in
port B pushes check valve (6) open, then safetyvalve (3) operates.
• If the hydraulic drift prevention valve for the arm
cylinder head circuit is installed (optional), the
hydraulic oil in the boom cylinder bottom circuitor that in the arm cylinder head circuit, having
higher pressure, pushes check valve (6) open,
then safety valve (3) operates.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD QUICK RETURN VALVE
QUICK RETURN VALVE
Function
When arm OUT is operated, this valve reduces the
pressure loss of the large amount of oil returningfrom the cylinder bottom.
Operation
1. Arm at OUT
When arm OUT is operated, the pilot pressure
from the PPC valve pushes pilot spool (1), and
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the pressure oil from chamber b inside the pop-pet is drained through orifice c.
The oil at the bottom end of the arm flows from
orifice a to chamber b to orifice c to drain, so the
oil pressure in chamber b drops.
When the pressure in chamber b drops below the
pressure at port A, the pressure at port A and
acts on ring -shaped area C (= Area of ød1 –
Area of ød2) because of the difference in the out-
side diameter d1 of valve (2) and seat diameter d2. Valve (2) moves to the left and the pressure
oil from port A goes to port B. From port B, the oil
is drained directly to the tank.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD QUICK RETURN VALVE
2. Arm at HOLD
The oil that has flowed through orifice a in valve
(2) is closed by pilot piston (1). At the same
time, the hold pressure at the bottom end of the
arm acts in the right direction on ring-shapedarea C (= Area of ød1 – Area of ød2) because
of the difference in the outside diameter d1 of
valve (2) and seat diameter d2 . Valve (2) is
closed by the total of this force and the force of
spring (3), so port A and port B are shut off.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIFT CHECK VALVE
LIFT CHECK VALVE
Function
This valve applies back pressure to the drain circuit
to prevent generation of negative pressure on thehydraulic devices for the work equipment (motors,
cylinders, etc.)
Operation
1. While engine is stopped
Any oil is not supplied from the pump to the self-
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pressure reducing valve and valve (1) is pressedby only the force of spring (2) toward the right
and drain circuit “a” of the control valve is con-
nected through orifice “b” of valve (1) to port T.
2. While engine is running
• Output pressure PR of the self-pressure reduc-ing valve is applied through the control valve to
spring chamber “c” of the back pressure valve.
• Output pressure PR applied to spring chamber
“c” is applied to the left end of valve (1) (area of
ød) to push valve (1) to the right.
• At this time, pressure PA of drain circuit “a” of the
control valve is applied to the right end of valve
(1) (area of ød1) to push valve (1) to the left.
• Valve (1) is balanced so that the back pressurePA will be as follows.
PA = {(Area of ød) × PR + Force of spring (2)} /
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE
ATTACHMENT CIRCUIT SELECTOR VALVE
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1. Spool V : To control valve
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT CIRCUIT SELECTOR VALVE
Function
When a breaker is installed, the return oil from the
breaker does not pass through the main valve, butreturns directly to the hydraulic tank. When other
attachments (crusher, etc.) are installed, the attach-
ment and the main valve are interconnected.
Operation
1. When attachment other than breaker is in-
t ll d
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stalledSpool (1) is pushed fully to the left by the force
of spring (2), ATT port and port V are intercon-
nected, and ATT port and port T are shut off, so
the attachment and main valve are intercon-
nected.
2. When breaker is installed
When the pilot pressure from the attachment cir-
cuit selector solenoid valve overcomes the force
of spring (2), the spool (1) moves fully to the
right. ATT port and port V are shut off and ATT
port and port T are interconnected, so the oil
returning from the breaker does not pass
through the main valve, but passes through port
T and returns directly to the hydraulic tank.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOLDING VALVE
HOLDING VALVE
Downward movement prevention valve
(For boom and arm)
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V : From control valve
T : To hydraulic tank
CY : To hydraulic cylinder
PI : From PPC valvePCY : Fror pressure pickup and equalizer circuits
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOLDING VALVE
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Unit: mm
1. Pilot spool2. Spring (1st stage of spool)
3. Spring (2nd stage of spool)
4. Safety valve
5. Check valve
6. Spring
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOLDING VALVE
Function
If the piping between the main valve and a work
equipment cylinder bursts, this valve prevents the oil
from flowing back from the work equipment cylinder
to prevent sudden fall of the work equipment.
Operation
1. When the work equipment is in neutral
[When piping is normal]
• Check valve (5) is closed by the work equip-
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• Check valve (5) is closed by the work equip-ment cylinder holding pressure applied
through port CY to chamber “b”.
• When the work equipment is in neutral, no pi-
lot pressure is applied from the PPC valve to
port Pi. Accordingly, pilot spool (1) is moved
to the left end by the force of springs (2) and
(3), then chambers “a” and “b” are shut of
from each other.
• By this operation, oil does not flow betweenthe main valve and the work equipment cyl-
inder, thus the work equipment cylinder held.
• If the pressure in the work equipment cylin-
der rises abnormally high, work equipment
cylinder holding pressure Pb operates safety
valve (4).
• In the downward movement prevention
valves for the boom, chambers “b” of both of
them are connected through ports PCY. Ac-
cordingly, even if the leakages are different
between both valves, the pressures in both
chambers “b” become the same.
[When piping bursts]
Even if piping A between the main valve and
work equipment cylinder bursts, chamber
“a” is shut off from chamber “b” as in thecase where the piping is normal. Accord-
ingly, the work equipment cylinder is held.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOLDING VALVE
2. When oil is sent from main valve to cylinder
[When piping is normal]
• If pressure Pa of the oil sent from the main
valve to chamber “a” is higher than the total
of pressure Pb in chamber “b” connected to
the work equipment cylinder and the force of
spring (6), check valve (5) opens and cham-
bers and the oil flows from the main valve to
the work equipment cylinder.
[When piping bursts]
• If piping A between the main valve and the
work equipment cylinder bursts the oil inh b “ ” fl t th h th b t t
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work equipment cylinder bursts, the oil inchamber “a” flows out through the burst part
and pressure Pa in chamber “a” lowers.
• If Pa lowers below the total of pressure Pb in
chamber “b” and the force of spring (6),
check valve (5) closes and chambers “a” and
“b” are shut off from each other. Accordingly,
pressure Pb in the cylinder is held and the
work equipment does not fall suddenly.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HOLDING VALVE
3. When oil is returned from work equipment
cylinder to main valve
[When piping is normal]
• The work equipment cylinder holding pres-
sure is applied to chamber “b” and check
valve (5) closes.
• The pilot pressure from the PPC valve is ap-
plied to port Pi. If it is higher than the force of
spring (2) (area of ød), spool (1) moves to
the right standby position (1st-stage stroke).
• At this time, chambers “a” and “b” are not
connected to each other.
• If the pilot pressure rises higher than theforce of spring (3) (area of ød) spool (1)
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If the pilot pressure rises higher than theforce of spring (3) (area of ød), spool (1)
moves further to the right and chambers “a”
and “b” connected to each other (2nd-stage
stroke).
• Accordingly, the oil is returned from the work
equipment cylinder to the main valve.
[When piping bursts]
• If piping A between the main valve and work
equipment cylinder bursts, the oil in chamber “a” flows out through the burst part.Since the
oil supplied from chamber “b” to chamber “a”
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
BOOM CYLINDER
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ARM CYLINDER
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC CYLINDER
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Unit: mm
No. Check item Criteria Remedy
1
Clearance
between
piston rod and
bushing
Cylinder Standard
size
Tolerance Standard
clearance
Clearance
limit
Replace
bushing
Shaft Hole
Boom 110 –0.036
–0.090
+0.261
+0.047
0.083 –
0.3510.412
Arm 120 –0.036 –0.090
+0.263+0.048
0.084 –0.353
0.412
0 036 +0 257 0 083
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
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Unit: mm
No. Check item Criteria Remedy
1
Clearance between
connecting pin and bushing
of revolving frame and boom
Standard
size
Tolerance Standard
clearance
Clearance
limitShaft Hole
120 –0.036
–0.090
+0.173
+0.101
0.137 –
0.2631.0
2
Clearance between
connecting pin and bushing
of boom and arm
120 –0.036 –0.090
+0.180+0.112
0.148 –0.270
1.0
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
1. Dimension of arm
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
Model
No.
PC400-7 PC450-7
1 ø110 / ø110 /
2 ø129.3 / 126 ± 1.2 ø129.3 / 126 ± 1.2
3 ø355 / 351 ø355 / 351
4 ø120 / ø120 /
+0.1+0
–0.036 –0.090
+0.1+0
–0.036 –0.090
+1.5+0
+1.5+0
+0.5+0
–0.3 –0.8
+0.5+0
–0.3 –0.8
+0.1
+0
–0.036
–0.090
+0.1
+0
–0.036
–0.090
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5 514.8 570.6
6 195 208.2
7 1,038 1,132.2
8 3,375 3,375
9 2,977.5 2,975.1
10 502 506.8
11 720 720
12 719 719
13 537.1 537.1
14 1,850 1,817
15 ø100 / ø100 /
16 ø371 / 370 ± 0.5 ø371 / 370 ± 0.5
+0.1+0
–0.036 –0.090
+0.1+0
–0.036 –0.090
+1+0
+1+0
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
2. Dimension of bucket
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT
Unit: mm
Model
No.
PC400-7 PC450-7
1 534.1 ± 0.5 534.1 ± 0.5
2 56.3 ± 0.5 56.3 ± 0.5
3 96° 1’ 94° 14’
4 537.1 537.1
5 1,839 1,806
6 190 198
7 — —
8 62° 1’ 46° 1’
A ø140 1 ø140 1+0.1+0
+0.1+0
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9
A ø140.1 ø140.1
B ø130 ø130
C ø100 ø100
10 371 371
11 A 57 58
B 72 7212 144 144
13 562.5 562.5
14 ø26 ø26
15 A ø165 ø165
B — —
16 ø230 ø230
17 146.1 135.5
18 137.6 142.0
19 R115 R115
20 R85 R85
21 410 ± 1 410 ± 1
22 64 64
+0 +0
+0.063 –0
+0.063 –0
+0.1+0
+0.1+0
+1+0
+1+0
+0.5 –2.5
+0.5 –2.5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
ENGINE CONTROL
1. Operation of system
Starting engine
• When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start theengine.
When this happens, the engine controller
checks the signal from the fuel control dial and
sets the engine speed to the speed set by the
fuel control dial.
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Engine speed control
• The fuel control dial sends signal voltages to the
engine controller according to its angle.
The engine controller sends drive signals to the
supply pump according to the signal voltages
received from the fuel control dial and controlsthe fuel injection pump to control the engine
speed.
Stopping engine
• When the engine controller detects that the start-ing switch is at the OFF position, it cuts the signal
to the supply pump drive solenoid to stop the en-
gine.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
2. Components of system
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball5. Potentiometer
6. Connector
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
3. Engine controller
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
CN1 [CN-E11] CN2 [CN-E12]
Pin No. Signal nameInput/
OutputPin No. Signal name
Input/
Output
CN1-1 POWER (+24V constant) CN2-1 GND
CN1-2 POWER (+24V constant) CN2-2 NC
CN1-3 Model selection 1 Input CN2-3 NC Input
CN1-4 GND CN2-4 RS232C_1RX Input
CN1-5 NC Input CN2-5 NC
CN1-6 NC Output CN2-6 NC
CN1-7 GND CN2-7 NC Input
CN1-8 GND CN2-8 NC Input
CN1-9 NC Input CN2-9 Sensor 5V power supply 2 Output
CN1-10 GND CN2-10 Fuel control dial Input
CN1-11 NC Input CN2-11 S_NET_SHIELD GNDCN1-12 NC Output CN2-12 CAN_SHIELD
CN1-13 Key switch (ACC) Input CN2-13 NC Output
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CN1 13 Key switch (ACC) Input CN2 13 NC Output
CN1-14 NC Input CN2-14 RS232C_1TX Output
CN1-15Engine oil pressure switch (For high
pressure)Input
CN2-15 G_SHIELD (GND)
CN2-16 Ne_SHIELD (GND)
CN1-16 Memory clear Input CN2-17 Fuel temperature sensor Input
CN1-17 Model selection 3 Input CN2-18 NC Input
CN1-18 NC Output CN2-19 Sensor 5V power supply 1 OutputCN1-19 Key switch (ACC) Input CN2-20 Boost pressure sensor Input
CN1-20 Starting switch (C) InputCN2-21 S_NET (+)
Input/
OutputCN1-21
Engine oil pressure switch (For low
pressure)Input
CN2-22 CAN0_LInput/
OutputCN1-22 Auto deceleration signal Input
CN1-23 Model selection 2 Input CN2-23 NC
CN1-24 NC Output CN2-24 FWE_switch Input
CN2-25 G pulse (–) Input
CN2-26 Ne pulse (–) Input
CN2-27 Coolant temperature sensor (High) Input
CN2-28 NC Input
CN2-29 Analog GND
CN2-30 NC Input
CN2-31 S_NET (+)Input/
Output
CN2-32 CAN0_HInput/
Output
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE CONTROL
CN3 [CN-E13]
Pin No. Signal nameInput/
Output
CN3-1 Power supply for power
CN3-2 Power supply for power
CN3-3 NC
CN3-4 NC
CN3-5 Injector #3 (+) Output
CN3-6 Injector #2 (+) Output
CN3-7 NC Input
CN3-8 Output mode selection 1 (Test mode) Input
CN3-9 Lever neutral flag (Test mode) Input
CN3-10 Engine rotation pulse output Output
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CN3-11 Power GND Input
CN3-12 Supply pump 1 (+) Output
CN3-13 Supply pump 2 (+) Output
CN3-14 Injector #1 (+) Output
CN3-15 Injector #3 (–) Output
CN3-16 Injector #2 (–) OutputCN3-17 NC Input
CN3-18 Output mode selection 2 (Test mode) Input
CN3-19 NC Input
CN3-20 Q command output Output
CN3-21 Power supply for power
CN3-22 Supply pump 1 (–) Output
CN3-23 Supply pump 2 (–) Output
CN3-24 Injector #1 (–) OutputCN3-25 Injector #6 (+) Output
CN3-26 Injector #4 (+) Output
CN3-27 NC Output
CN3-28 Auto deceleration flag (Test mode) Input
CN3-29 NC Input
CN3-30 GND
CN3-31 Power GND
CN3-32 Power GND
CN3-33 Injector #5 (–) Output
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM
CONTROL FUNCTIONS
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
TOTAL SYSTEM DIAGRAM
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1. Engine and Pump control function
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Function
• The operator can set the work mode switch on
the monitor panel to mode A, E, or B (or L) and
select proper engine torque and pump absorp-
tion torque according to the type of work.
• The engine throttle and pump controller detectsthe speed of the engine governor set with the fuel
control dial and the actual engine speed and con-
trols them so that the pump will absorb all the
torque at each output point of the engine, accord-
ing to the pump absorption torque set in each
mode.
: The L mode is on the multi-monitor specification
machine only.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1) Control method in each mode
Mode A, Mode E
• Matching point in mode A: Rated speed
• If the pump load increases and the pressure ris-
es, the engine speed lowers.
At this time, the controller lowers the pump dis-
charge so that the engine speed will be near the
full output point. If the pressure lowers, the con-
troller increases the pump discharge so that theengine speed will be near the full output point.
By repeating these operations, the controller
constantly uses the engine near the full output
Mode A246.3 kW/1,850 rpm
{331 HP/1,850 rpm}
Mode E 213.3. kW/1,720 rpm{286 HP/1,720 rpm}
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constantly uses the engine near the full output
point.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Mode B / (Mode L)
• At this time, the controller keeps the pump ab-
sorption torque along the constant horsepower
curve and lower the engine horsepower by thecomposite control of the engine and pump.
By this method, the engine is used in the low
fuel consumption area.
Mode Mode B Mode L
Partial output point 82% 61%
Mode B194.9 kW/1,730 rpm
{261 HP / 1,730 rpm}
Mode L150.8 kW/1,250 rpm
{202 HP / 1,250 rpm}
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fuel consumption area.
: The L mode is on the multi-monitor specification
machine only.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
2) Function to control pump during travel
• When the travel is operated in A operation, or E
or B working mode, the working mode stays as it
is, and the pump absorption torque and engine
speed rise to A travel mode.
• If the machine travels in mode L, the working
mode and engine speed do not change, but the
pump absorption torque is increased.: The L mode is on the multi-monitor specification
machine only.
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3) Function to control when emergency pump
drive switch is turned ON
• Even if the controller or a sensor has a trouble,
the functions of the machine can be secured with
pump absorption torque almost equivalent to
mode E by turning on emergency pump drive
switch (10).
In this case, a constant current flows from the
battery to the EPC valve for PC and the oil pres-
sure is sensed by only the EPC valve for PC.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
2. Pump/Valve control function
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1) LS control function
• The change point (LS set differential pressure) of
the pump discharge in the LS valve is changed
by changing the output pressure from the LS-
EPC valve to the LS valve according to the oper-
ating condition of the actuator.
• By this operation, the start-up time of the pump
discharge is optimized and the composite opera-
tion and fine control performance is improved.
2) Cut-off function
• When the cut-off function is turned on, the PC-
EPC current is increased to near the maximum
value.
• By this operation, the flow rate in the relief state
is lowered to reduce fuel consumption.• Operating condition for turning on cut-off function
Condition
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The cut-off function does not work, however, while
the machine is travelling in mode A or the arm crane
operation width swing lock switch is turned on.
1) 2-stage relief function
• The relief pressure in the normal work is 34.8
MPa {355 kg/cm2}. If the 2-stage relief function is
turned on, however, the relief pressure rises to
about 37.2 MPa {380 kg/cm2}.By this operation, the hydraulic force is increased
further.
• Operating condition for turning on 2-stage relief
function
• The average value of the front and rear pressure
sensors is above 27.9 MPa {285 kg/cm2} and the
one-touch power maximizing function is not turned
on
ConditionRelief pres-
sure
• Condition
• During travel 34.8 MPa
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
3. One-touch power maximizing/machine
push-up function
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Function
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1) One-touch power maximizing function
• When the operator needs more digging force to
dig up a large rock, etc., if the left knob switch is
pressed, the hydraulic force is increased about
7% to increase the digging force.
• If the left knob switch is turned on in working
mode “A” or “E”, each function is set automatical-
ly as shown below.
Working
modeEngine/Pump control 2-stage relief function Operation time
Software cut-off
function
A, E Matching at ratedoutput point
34.8 MPa {355 kg/cm2
}
37.2 MPa {380 kg/cm2}
Automatically reset at8.5 sec
Cancel
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2) Machine push-up function
• Operate switch (1) to increase the boom pushing
force when digging ditches or holes on hard
ground.
Switch2-stage safety valve
function
OFF
Setting of safety valve at
boom cylinder
14.7 MPa
{150 kg/cm2}
ON
Setting of safety valve at
boom cylinder
28.4 MPa{290 kg/cm2}
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
4. Auto-deceleration function
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Function
• If all the control levers are set in NEUTRAL while
waiting for a dump truck or work, the enginespeed is automatically lowered to the medium
level to reduce fuel consumption and noise.
• If any lever is operated, the engine speed rises
instantly to the set level.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Operation
WHEN CONTROL LEVERS ARE SET IN NEUTRAL
• If all the control levers are set in NEUTRAL while
the engine speed is above the decelerator oper-
ation level (about 1,300 rpm) for 4 seconds, the
engine speed lowers to the second deceleration
level (about 1,300 rpm) and keeps at that level
until any lever is operated again.
WHEN ANY CONTROL LEVER IS OPERATED
• If any control lever is operated while the engine
speed is kept at the second deceleration level,
the engine speed rises instantly to the level setwith the fuel control dial.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
5. Auto-warm-up/Overheat prevention
function
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Function
• After the engine is started, if the engine coolant
temperature is low, the engine speed is automat-
ically raised to warm the engine. If the coolant
temperature rises too high during work, the pump
load is reduced to prevent overheating.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1) Auto-warm-up function
• After the engine is started, if the engine coolant
temperature is low, the engine speed is automat-
ically raised to warm the engine.
Operating condition (All) Operated
Coolant temperature: Below 30°C.Engine speed: Max. 1,200 rpm
Engine speed: Max. 1,200 rpm
Resetting condition (Any one) Reset
AutoCoolant temperature: Above 30°C
Engine speed: Any level Auto-warm-up operation time: Min. 10 minutes
ManualFuel control dial: Kept at 70% of full level for
3 sec. or longer
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2) Overheat prevention function
• If the engine coolant temperature rises too highduring work, the pump load and engine speed
are reduced to prevent overheating.
• This function is turned on when the coolant tem-perature rises above 95°C.
Operating condition Operation/Remedy Resetting condition
Coolant tempera-
ture: Above 105°C
Work mode: Any mode
Engine speed: Low idle
Monitor alarm lamp: Lights up Alarm buzzer: Sounds
Coolant temperature: Below 105°C
Fuel control dial: Return to low idle
position once.
• Under above condition, controller isset to condition before operation of
function. (Manual reset)
Operating condition Operation/Remedy Resetting condition
Coolant tempera-
ture: Above 102°C
Work mode: Mode A, E, OR B
Engine speed: Keep as is.
Monitor alarm lamp: Lights up.
Lower pump discharge.
Coolant temperature: Below 102°C
• Under above condition, controller is
set to condition before operation of
function. (Automatic reset)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
6. Swing control function
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Function
The swing lock and swing holding brake functions
are installed.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1) Swing lock and swing holding brake func-
tions
• The swing lock function (manual) is used to lock
machine from swinging at any position. The
swing holding brake function (automatic) is used
to prevent hydraulic drift after the machine stops
swinging.
• Swing lock switch and swing lock/holding brake
2) Quick hydraulic oil warm-up function when
swing lock switch is turned on
• If swing lock switch (4) is turned on, the pump-cut
function is cancelled and the relief pressure rises
from 34.8 MPa {355 kg/cm2} to 37.2 MPa {380
kg/cm2}. If the work equipment is relieved under
this condition, the hydraulic oil temperature rises
quickly and the warm-up time can be shortened.
Lock
switch
Lock
lampFunction Operation
OFF OFF
Swing
holding
brake
If swing lever is set in
neutral, swing brake
operates in about 7 sec. If
swing lever is operated,
brake is released andmachine can swing freely.
ON ONSwing
l k
Swing lock operates and
machine is locked from
swinging. Even if swing
l i t d i
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: Operation of swing holding brake release switch
• If the controller, etc. has a problem, the swing
holding brake does not work normally, and the
machine cannot swing, the swing lock can be re-
set with the swing holding brake release switch.
a Even if the swing holding brake release switch is
lock lever is operated, swing
lock is not reset and
machine does not swing.
Swing hold-
ing brake
releaseswitch
ON
(When control has
trouble)
OFF
(When controller is
normal)
Swing lock
switchON OFF ON OFF
Swing
brake
Swing
lock is
turned on
Swing
lock is
canceled
Swing
lock is
turned on
Swing
holding
brake is
turned on
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
7. Travel control function
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Function
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
1) Pump control function during travel
• If the machine travels in a work mode other than
mode A, the work mode and the engine speed
are kept as they are and the pump absorption
torque is increased.
a For details, see ENGINE/PUMP COMPOSITE
CONTROL FUNCTION.
1. Travel speed change function
i) Manual change with travel speed switch
If the travel speed switch is changed
between Lo, ( Mi), and Hi, the governor/
pump controller controls the pump capacity
and motor capacity at each gear speed as
shown at right to change the travel speed.
Travel speed
switch
Lo
(Low speed)
( Mi)
(Middle
Speed)
Hi
(High
speed)
Pump capacity
(%)90 82 100
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ii) Automatic change according to engine speed
If the fuel control dial is used to set the
engine speed to less than 1,200 rpm:
• When traveling in Lo, it will not switch even
when set to Hi or Mi.
• When traveling in Hi or Mi, it will switch auto-
matically to Lo.
iii) Automatic changes according to pump dis-
charge pressure
When traveling with the travel speed switch
set to Hi or Mi, it the load increases, such as
when traveling uphill, and the travel pres-
sure goes above 3.23 MPa {330 kg/cm2} for
more than 0.5 sec, the travel motor capacity
will automatically change to low speed
(equivalent to Lo). (The travel speed switch
will stay at Hi or Mi.) After continuing to travel in Lo, if the load
i h h t li l l
(%)
Motor capacity Max. Max. Min.
Travel speed
(km/h)3.2 4.5 5.5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
8. ATT flow control, circuit selector func-
tion (if equipment)
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Function
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
9. System component parts1) Engine revolution sensor
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Function
• The engine revolution sensor is installed to the
ring gear of the engine flywheel. It electrically cal-
culates the number of the gear teeth which passin front of it and transmits the result to the engine
throttle and pump controller.
• A magnet is used to sense the gear teeth. Each
time a gear tooth passes in front of the magnet,
a current is generated.
1. Sensor
2. Locknut
3. Wiring harness
4. Connector
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
2) PPC oil pressure switch
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Specifications
Type of contacts: Normally open contacts
Operating (ON) pressure: 0.5 ± 0.1 MPa{5.0 ± 1.0 kg/cm2}
Resetting (OFF) Pressure: 0.3 ± 0.5 MPa
{3.0 ± 0.5 kg/cm2}
Function
• The junction block has 7 pressure switches, which
check the operating condition of each actuator bythe PPC pressure and transmit it to the engine
1. Plug
2. Switch
3. Connector
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
3) Pump pressure sensor
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Function
• The pump pressure sensor is installed to the inlet
circuit of the control valve. It converts the pump
discharge pressure into a voltage and transmits
it to the engine throttle and pump controller.
Operation
• The oil pressure applied from the pressure intake
part presses the diaphragm of the oil pressure
sensor, the diaphragm is deformed.
• The gauge layer facing the diaphragm measures
the deformation of the diaphragm by the change
of its resistance, then converts the change of the
resistance into a voltage and transmits it to the
amplifier (voltage amplifier)
1. Sensor
2. Connector
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Pump controller
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
Input and output signals
CN-1 CN-2
Pin No. Signal nameInput/
OutputPin No. Signal name
Input/
Output
1 NC 1 NC
2 R pump pressure sensor Input 2 Swing emergency switch Input
3 NC 3 NC Input
4 NC 4 232C_RxD Input
5 NC 5 NC
6 NC Input 6 NC
7 NC 7 Model selection 4 Input
8 F boom pressure sensor Input 8 Attachment circuit selector signal Output
9 NC 9 NC10 Signal GND 10 NC
11 Knob SW Input 11 NC
12 NC 12 CAN shield
13 Buchet CURL PPC pressure sensor Input 13 Model selection 5 Input
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14 NC 14 232C_TxD Output
15 NC Input 15 NC
16 NC 16 Travel steering signal pressure SW Input
17 Starting switch (Terminal C) Input 17 Model selection 3 Input18 NC 18 NC
19 Arm IN PPC pressure sensor Input 19 Auto deceleration signal Output
20 NC 20 NC
21 NC21 S_NET
Input/
output22 POT_PWR Output
23 Starting switch (terminal ACC) Input22 CAN0_L
Input/
output
24 NC 23 NC
24 FWE_SW Input
25 NC
26 NC
27 Model selection 2 Input
28 NC
29 GND (pulse GND)
30 NC
31 GND (S_NET GND)
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ELECTRONIC CONTROL SYSTEM
CN-3
Pin No. Signal nameInput/
Output
1 VB (controller power) Input
2 VIS (solenoid power) Input
3 SOL_COM (solenoid common gnd)
4 Battery relay drive Output 5 NC
6 LS-EPC Output
7 Travel junction SOL Output
8 NC
9 NC Input
10 Boom RAISE pressure SW Input
11 VB (controller power) Input
12 VIS (solenoid power) Input13 SOL_COM (solenoid common gnd) Input
14 KEY_SIG Input
15 NC
16 PC-EPC Output
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17 Pump merge/divider solenoid Output
18 Heater relay drive Output
19 Bucket DUMP pressure switch Input
20 Boom LOWER pressure switch Input21 GND (controller GND) Input
22 NC
23 SOL_COM (solenoid common gnd) Input
24 KEY_SIG Input
25 NC
26 Service flow adjustment EPC (1) Output
27 Travel Hi/Lo selector solenoid Output
28 2-stage relief solenoid Output29 Swing pressure switch Input
30 Arm IN pressure switch
31 NC Input
32 GND (controller GND) Input
33 GND (controller GND) Input
34 NC
35 NC
36 NC37 Swing parking brake solenoid Output
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR SYSTEM
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• The monitor system monitors the condition of the
machine with sensors installed on various parts
of the machine. It processes and immediately
displays the obtained information on the panel
notifying the operator of the condition of the ma-
chine.The panel is roughly divided as follows.
• The monitor panel also has various mode selec-
tor switches and functions to operate the ma-
chine control system.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
1. Monitor panel
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Outline
• The monitor panel has the functions to display
various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Process-
ing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
Input and output signals
CN-1 CN3
Pin
No.Signal name
Input/
output
Pin
No.Signal name
Input/
output
1 Key ON Input 1 NC Input
2 Key ON Input 2 NC Input
3 Washer motor output Output 3 NC Input4 Starting signal Input 4 NC Input
5 Limit switch (W) Input 5 NC Input
6 GND 6 NC Input
7 GND 7 RS230C CTS Input
8 VB + Input 8 RS230C RXD Input
9 Wiper motor (+) Output 9 RS230C RXD
Input/
Output10 Wiper motor (-) Output
11 Buzzer ON signal Input 10 RS230C RXD Input/Output12 Limit switch (P) Input
11 BOOTSW Input
12 NC Input
CN-2 13 GND
PinSi l
Input/14 CAN (SHIELD) I t
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Pin
No.Signal name
Input/
output14 CAN (SHIELD) Input
1 Engine coolant temperature Input 15 CAN (+) Input
2 Fuel level Input 16 CAN (-) Input
3 Radiator coolant level Input
4 (Hydraulic oil level) Input
5 Air cleaner clogging Input
6 NC Input
7 Engine oil pressure Input
8 Engine oil level Input
9 N/W signalInput/
Output
10 N/W signalInput/
Output
11 Battery charge Input
12 Hydraulic oil temperature (analog) Input
13 GND (for analog signal)
14 Buzzer drive Input
15 Limit SW (window) Input
16 Buzzer cancel Input
17 Swing lock Input
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR CONTROL, DISPLAY PORTION
MONITOR PORTION
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1. Wiper motor 11. Fuel level monitor
2. Preheating monitor 12. Hydraulic oil temperature monitor
3. Swing lock monitor 13. Power max. monitor
4. Engine coolant temperature monitor 14. Auto-deceleration monitor
5. Hydraulic oil temperature gauge 15. Radiator coolant level caution
6. Engine coolant temperature gauge 16. Battery charge caution
7. Working mode monitor 17. Engine oil pressure caution8. Service monitor 18. Engine oil level caution
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
MONITOR ITEMS AND DISPLAY
Symbol Display item Display method
Swing lock
Swing lock switchSwing holding brake
release switchSwing lock monitor
OFF OFF OFF
ON OFF ON
OFF ON Flashes
ON ON ON
Preheating
Continuous set time Preheating monitor status
Up to 30 sec. ON
From 30 sec to 40 sec Flashes
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From 30 sec. to 40 sec. Flashes
More than 40 sec. OFF
Power Max
Power Max. switch status Power Max. monitor status
Being pressedLights up but goes out after
approx. 9 sec when kept pressed
Not being pressed Flashes
Engine coolant
temperature
See gauge display on the next pageHydraulic oil
temperature
Fuel level
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
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Gauge Range Temperature, volume Indicator Buzzer sound
Engine coolant
temperature (°C)
A1 105 Red
A2 102 Red
A3 100 Green
A4 80 Green
A5 60 Green
A6 30 White
B1 105 Red
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
Checks before starting (caution lamps all light up), when maintenance interval is exceeded.
If the checks before starting or maintenance interval is exceeded items light up, the display of the hydraulic oil
temperature gauge and the hydraulic oil temperature monitor are stopped, and the following cautions are dis-
played.
Symbol Display itemCheck before starting
item
When engine is
stopped
When engine is
running
Engine oil pressure q —
When abnormal,
lights up and buzzer
sounds
Battery charge q —Lights up when
abnormal
Radiator coolant level qLights up when
abnormal
When abnormal,
lights up and buzzer
sounds
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Th bl th t h d di l d i d f th l ft
Engine oil level qLights up when
abnormal—
Air cleaner clogging q —Lights up when
abnormal
Maintenance
Lights up when there is a warning. Lights up for
only 30 sec. after key is turned ON, then goes
out.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
Display category Symbol Display item Display range Display method
Monitor
Wiper Displays set condition
Working mode Displays set mode
ON INT OFF
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Travel speed Displays set speed
Auto-decelera-
tionON OFF
Displays actuation
status
Service meter Service meter
indicator When service meter is working
Lights up when service
meter is working
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
SWITCHES
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1. Selector switch
2. Selector switch
3. Display brightness, contrast adjustment switch
4. Control switch5. Window washer switch
6. Wiper switch
7. Maintenance switch
8. Travel speed selector switch
9. Auto-deceleration switch
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
• Working mode selector switch
The condition of the machine changes accord-
ing to the switch that is pressed (A, E, L, B). It is
possible to check the condition on the working
mode monitor display. The relationship between
each working mode and the monitor display is
shown in the table on the right.
• Selector switch
This is used when making detailed settings in
each working mode. (For details, see ATTACH-
MENT FLOW CONTROL FUNCTION for modes
A and E.)
• Maintenance switch
Check the condition of the maintenance items.
(For details, see MAINTENANCE FUNCTION.)
• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
Use the a to deceleration monitor displa to
Switch that is
pressedDisplay
Working mode status
after setting
[A] A A mode (default)
[E] E E mode
[L] L Heavy-lift mode[B] B Swing priority mode
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Use the auto-deceleration monitor display to
check the present condition.
When the working mode switch is operated to
switch the working mode, it is automatically set
to ON.
• Travel speed selector switch
Each time the travel speed selector switch is
pressed, the travel speed changes.
Lo o Hi o Lo ……
Use the travel speed monitor display to check
the present condition.The relationship between the set speed and the
monitor display in the table on the right.
• Wiper switch
Each time the wiper switch is pressed, the wiper
setting changes OFF o INT o ON o OFF o
……
Use the wiper monitor display to check the
present condition.The relationship between the wiper setting and
Display Setting
Crawler symbol + Lo Low speed (default)
Crawler symbol + Mi Medium speed
Crawler symbol + Hi High speed
Display SettingWiper actuation
status
None OFFStowing stopped or
now stowing
Wiper symbol + INT INT Intermittent actuation
Wiper symbol + ON ON Continuous actuation
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
• Window washer switch
While the switch is being pressed, window
washer liquid is sprayed out. There is a time
delay before the wiper starts.
• Control switch
This is used for control when using the mainte-
nance function or select function.(For details, see each function.)
• Display brightness, contrast adjustment switch
Use this switch when adjusting the display
brightness and contrast.
(For details, see each function.)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
SELECT MODE FUNCTION
• This is used when setting the flow in each work-
ing mode. It is possible to make the setting when
genuine attachment piping is installed and the in-
itial value setting function on the service menu
has been used to set to ATTACHMENT IN-
STALLED.• It is possible to check on the working mode mon-
itor if this function can be set.
MEHOD OF USE
a Carry out the setting on the normal screen
1. A mode, E mode
1) Press select switch (1) on the monitor to
Working mode Monitor display
A mode [A] + crusher symbol
E mode [E] + crusher symbol
B mode [B] + flow symbol
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1) Press select switch (1) on the monitor to
move to the adjustment screen.
2) Press control switch (2) to select the flow
level.
3) After completing the level selection, press
input confirmation switch (3).
The selection flow level is confirmed and the
screen moves to the normal screen.
From the moment that the flow level is
selected, the content of the selection is
Control switch Actuation
Flow level bar graph
extends to the right
Flow level bar graphretracts to the left
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
2. B mode
1) Press select switch (1) on the monitor to
move to the screen for selecting the 3-stage
flow level.
2) Press control switch (2), or input [01] – [03]
with the numeral 10-key pad to choose one
on the three flow levels.
3) After completing the level selection, press
No. 10-key pad operation
01
02
03
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) p g , p
input confirmation switch (3).
The selected flow level is selected.
a Before the input confirmation switch is
pressed, the flow level is not confirmed,
so press return switch (4) to return to the
operator screen. This function can be
used to return to the previously set flow.
4) After the flow level is confirmed, the screen
changes to the screen shown in the diagram
on the right.
With this screen, it is possible to make fineadjustment to the flow.
5) Press control switch (2) and select the flow
level.
Control switch Actuation
Flow level bar graph
extends to the right
No. Flow level (L/min.) Remarks
01 230 Default
02 190
03 150
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
6) After completing the level selection, press
input confirmation switch (3).
The selected flow level is confirmed and the
screen moves to the operator screen.
From the moment that the flow level is
selected, the content of the selection is
reflected for the attachment flow.
a Before the input confirmation switch ispressed, the flow level is not confirmed,
se press return switch (4) to return to the
normal screen. This function can be
used to return to the previously set flow.
The relationship between the set flow
level and the flow value is as shown in
the table on the right.
7) Check the set value with the working mode
monitor.The relationship between the display level
and the set value is as shown in the table on
the right, and it is possible to check the level
of the flow that can be set.
Flow
level
When
flow is
140 l/
min.
When
flow is
220 l/
min.
When
flow is
300 l/
min.
Remarks
7 200 280 360
6 180 260 3405 160 240 320
4 140 220 300 Default
3 120 200 280
2 100 180 260
1 80 160 240
Display level Set value (l/min.)
8 220 or 360
7 200 or 340
6 180 or 320
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5 160 or 300
4 140 or 280
3 120 or 260
2 100 or 240
1 80
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
MAINTENANCE FUNCTION
When the maintenance time for replacement,
inspection, or filling has approached for the 10 main-
tenance items, press maintenance switch (1) and
the caution display (yellow or red) appears on the
monitor display for 30 seconds after the starting
switch is turned ON to remind the operator to per-form lubrication maintenance.
a Maintenance items
No. ItemReplacement interval
(hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic filter 1000
05 Hydraulic tank breather 500
06 Corrosion resistor 1000
07 Damper case oil 1000
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a The above replacement intervals are set for
each item, and the time remaining to mainte-
nance is reduced as the machine is operated.
The content of the caution display differs
according to the ramaining time. The relation-ship is as shown in the table below.
07 Damper case oil 1000
08 Final case oil 2000
09 Machinery case oil 1000
10 Hydraulic oil 5000
Display Condition
None
Remaining time for mainte-
nance for all items is more
than 30 hours
Notice display (black sym-bol displayed on yellow
There is one or more items
with less than 30 hoursremaining time for mainte
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
METHOD OF CHECKING STATUS
MAINTENANCE ITEMS
a Operate as follows when on the operator
screen.
1. Press maintenance switch (1) and switch to the
maintenance list display screen.
a The maintenance items are displayed assymbols on the screen.
2. Press control switch (2), or use the 10-key pad
to input the number (01 – 10) of the mainte-
nance item to select the item.
a The cursor moves and the item is highlight-
ed.
a The display method is the same as de-
scribed on the previous page (relationship
between remaining time and caution dis-play). If the remaining time is less than 30
hours, the item is displayed in yellow, and if
it is less than 0 hours, it is displayed in red.
MAINTENANCE OPERATION
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1. After completing the selection, press input con-firmation switch (3).
The screen will change to the maintenance
reset screen.
2. Use the maintenance reset screen to check the
content, and if there is any problem, press input
confirmation switch (3) to move to the check
screen.
If the wrong item is selected, press return switch
(4) to return to the maintenance list screen.3. Check the content on the check screen, and if
there is no problem, press input confirmation
switch (3) to reset the maintenance time.
After the reset is completed, the screen returns
to the maintenance list display screen. To check
the remaining time, or if the wrong item is
selected, press return switch (4) to return to the
maintenance list screen.
a The check screen shows the symbol for the
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
BRIGHTNESS, CONTRAST ADJUSTMENT
FUNCTION
This function is used to adjust the brightness and
contrast of the display.
ADJUSTMENT METHOD
a Operate as follows when on the operator
screen.
1. Press display brightness/contrast adjustment
switch (1) and switch to the adjustment screen.
a Relationship between menu symbol and con-
tent.
No. Symbol Content
01 Return mark Return
02 Contrast
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2. Press control switch (2), or use the 10-key pad
to input the number (00 – 02) to select either
contrast or brightness.
After completing the selection, press input con-
firmation switch (3) and return to the adjustment
screen.
Then press return switch (4) or use the 10-keypas to set to [00] and press input confirmation
switch (3) to return to the normal screen.
3. Press control switch (2) and adjust the bright-
ness and contrast as desired.
03 Brightness
Control switch Actuation
Flow level bar graph
extends to the right
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
SERVICE METER CHECK FUNCTION
• When the starting switch is at the OFF position,
keep return switch (1) and control switch (2) of
the monitor pressed at the same time, and the
service meter is shown on the display.
• This display is shown only while the two switches
are being pressed. When the switches are re-leased, the display goes out.
Note that it takes 3 – 5 seconds after the
switches are pressed for the service meter dis-
play to appear.
DISPLAY LCD CHECK FUNCTION
• On the password input screen or on the normal
screen, if monitor return switch (1) and working
mode (A) switch are kept pressed at the same
time, all the LCD display will light up and the
whole screen will become white, so the display
can be checked.
• If any part of the display is black, the LCD is bro-
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ken.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
USER CODE DISPLAY FUNCTION
• If there is any problem in operating the machine,
the user code is displayed on the monitor to ad-
vise the operator of the steps to take.
This code display appears on the operator
screen.
• On the operator screen, the user code is dis-played on the portion for the hydraulic oil temper-
ature gauge.
• If more than one user code is generated at the
same time, the user codes are displayed in turn
for 2 seconds each to display all the user codes.
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MONITOR SYSTEM
• While the user code is being displayed, if the in-
put confirmation switch is pressed, the service
code and failure code can be displayed.
• If there is more than one service code or failure
code, the display switches every 2 seconds and
displays all the service codes/failure codes thatcaused the user code to be displayed.
Even i f service codes/fai lure codes have
occurred, if they did not cause the user code to
be displayed, this function does not display
them.
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• If the telephone number has been set using the
telephone number input on the service menu, it
is possible to switch on the service code/failure
code and display the telephone symbol and tele-
phone number.
For details of inputting and setting the telephone
number, see SPECIAL FUNCTIONS OF MONI-
TOR PANEL in the TESTING AND ADJUSTING
section.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
7-SEGMENT MONITOR SYSTEM
SJP08775
OR
08931
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• The monitor system monitors the condition of the
machine with sensors installed on various parts
of the machine. It processes and immediatelydi l th bt i d i f ti th l
• The monitor panel also has various mode selec-
tor switches and functions to operate the ma-
chine control system.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
1. Monitor panel
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OUTLINE
• The monitor panel has the functions to display
various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Process-
ing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (LiquidCrystal Display) and LED (Light Emitting Diode).
The switches are flat sheet switches.
INPUT AND OUTPUT SIGNALS
CN-P01 CN-P02
Pin
No.Signal name
Pin
No.Signal name
1 Key switch (Battery) 1 Engine water temperature
2 Key switch (Battery) 2 Fuel
3 Washer motor output 3 Radiator water level
4 Key switch (Terminal C) 4 NC
5 Wiper contact W 5 Air cleaner clogging sensor
6 GND 6 NC
7 GND 7 Engine oil pressure sensor
8 VB + (24 V) 8 Engine oil level sensor
9 Wiper motor (+) 9 Network signal
10 Wiper motor (–) 10 Network signal
11 (Buzzer ON signal input) 11 Charge level
12 Wiper contact P 12 NC
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
Display section of monitor
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1. Service meter display
2. Coolant temperature gauge
3. Coolant temperature caution
4. Digital meter display (Service code and user code
are displayed when trouble occurs
5. Fuel level caution
6. Fuel level gauge
7. Engine oil level caution lamp
8. Preheating pilot lamp
9. Swing holding brake pilot lamp
10. Oil maintenance pilot lamp11 Battery charge caution lamp
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
Monitored items and display
Symbol Displayed item Display rangeWhen engine is
stoppedWhile engine is running
Engine oil pressure
Max. 1,500 rpm
Max. 0.05 MPa
{0.5 kg/cm²}
Min. 1,500 rpm
Max. 0.15 MPa
{1.5 kg/cm²}
Lights when normal.
(Goes off whenengine is started.)
Flashes and buzzer
sounds when abnormal.
Air cleaner clogging When clogged Goes off. Flashes when abnormal.
Charge level When charge isabnormal
Lights when normal.
(Goes off whenengine is started.)
Flashes when abnormal.
Engine oil level Below low levelFlashes when
abnormal.Goes off.
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Packing (Swing lock) When swing islocked
Lights up when swing is locked. Flashes whenswing holding brake release switch is turned on.
Oil maintenance See "OIL MAINTENANCE FUNCTION" on next page.
Preheating When preheated
Lights up for 30 sec. when starting switch is set to
HEAT. Then, flashes for 10 sec. to indicated
completion of preheating.
C lFlashes at 102°C or higher Flashes and
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
Oil maintenance function
1. Function and operation
At a set t ime after the engine oil is replaced, the oil
maintenance function is turned on to notify the oper-
ator by the LED lamp on the monitor panel that it is
time to replace the oil. The function to indicate the
phone number of the place to make contact for ser-vice on the LCD unit is installed, too.
1) Check of elapsed time
Nothing is displayed normally until point B
shown in the figure at right after this function
is reset. If the key is turned on with the
buzzer cancel switch processed (for 2.5
seconds), however, the elapsed time is dis-
played on the service meter section.2) Display of replacement of oil
If time passes point B after this function is
reset, the elapsed time is displayed on the
service meter section and the LED flashes
when the key is turned on.
2. Setting of time interval
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1) The time interval is set in the interval setting
mode. It can be set to "125h", "250h",
"500h", "Not set", or "Demo-mode". The
default is "Not set".
2) To enter the interval setting mode, press
and hold the clock switch for 2.5 seconds.
3) If the buzzer cancel switch is pressed in the
interval setting mode, the clock display sec-
tion changes to "—" o "125" o "250" o
"500" o
"d" in order. ("—" corresponds to"Not set" and "d" corresponds to "Demo-
mode".)
4) To save the time interval, set a desired time
(mode) on the monitor panel and press and
hold the clock switch for 2.5 seconds.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
3. Timing and contents of display
1) When replacement of oil is displayed
2) The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
Phone number is displayed for the next 10
seconds.
If the phone number has not been input,
however, the elapsed time is displayed for 20 seconds after all segments are turned
on.
3) When elapsed time is checked
The elapsed time is displayed for 10 sec-
onds after all segments are turned on.
4. Resetting elapsed time
1) When the replacement of oil and elapsed
time are displayed, press the buzzer cancelswitch 10 seconds after all segments are
turned on (while the elapsed time is dis-
p layed) and hold for 3 seconds. The
elapsed time is reset. After this operation,
"0h" is displayed for 1 second.
2) When the set time is changed, the elapsed
time is reset to "0h".
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5. Demo-mode1) In the demo-mode, the time is set to 250h,
the elapsed time is set to 240h, and replace-
ment of oil is displayed when the key is
turned on. The elapsed time does not
increase, however. The time can be reset in
this mode. Turn on the key 3 times in this
mode, and the time interval is automatically
set to "Not set" at the 4th time and after. The
elapsed time is set to "0h" and counting of
elapsed time is started.
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 7-SEGMENT MONITOR SYSTEM
Mode selector switches1. Travel speed switch
2. Auto-deceleration switch
3. Wiper switch
4. Work mode selector switch
(Including setting switch)
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• There are 4 sets of the mode selector switches
on the switch section. Each time one switch is
pressed, the machine condition changes. The
current condition is indicated by the lighting of
the LED above the switch.
• The initial setting of only the work mode after thestarting switch is turned on can be changed.
a For how to change the setting, see "Work mode
default setting mode" in TROUBLESHOOTING-
Display and special functions of monitor panel.
Operations table of switch section
a The bold letters are the positions of the switches
reset when the starting switch is turned on.
Item Operation
Work mode A↔ E↔ B
Auto-deceleration ON↔ OFF
Wiper OFF↔ Intermittent↔ ON
Travel speed Hi↔ Lo
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
SENSOR
• The signals from the sensors are input to the
panel directly. Either side of a sensor of contact
type is always connected to the chassis ground.
Name of sensor Type of sensor When normal When abnormal
Engine oil level Contact ON (closed) OFF (open)
Engine oil pressure Contact OFF (open) ON (closed)
Hydraulic oil temperature Resistance — —
Coolant temperature Resistance — —
Fuel level Resistance — —
Air cleaner clogging Contact type OFF (open) ON (closed)
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
Engine oil level sensor
Engine oil pressure sensor (For low pressure)
1. Connector
2. Bracket
3. Float
4. Switch
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5 Spring
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Coolant temperature sensor
Hydraulic oil temperature sensor
5. Spring
6. Terminal
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSOR
Fuel level sensor
1. Float
2. Connector
3. Cover
4. Variable resistor
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Air cleaner clogging sensor
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-2
STANDARD VALUE TABLE FOR CHASSIS .................................................................................................. 20-3
TESTING AND ADJUSTING ...................................................................................................................... 20-101
TROUBLESHOOTING................................................................................................................................ 20-201
20 TESTING AND ADJUSTING
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a Note the following when making judgements using the standard value tables for testing, adjusting, or trou-
bleshooting.
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE
Machine modelPC400, 400LC-7
PC450, 450LC-7
Engine SAA6D125E-3
Item Measurement condition Unit Standard value Permissible value
Engine speed
High idling
Low idling
Rated speed
rpm
1,930 ± 50
1,000 ± 25
1,850
1,930 ± 50
1,000 ± 25
1,850
Intake air pressure At rated outputkPa
{mmHg}Min 107 {Min. 800} 87 {650}
Exhaust gaspressure
All speed range(intake air temp: 20°C)
°C Max. 700 Max. 700
Exhaust gas color
At sudden acceleration
At high idling
Bosch
index
Max. 4.0
Max. 1.0
6.0
2.0
Valve clearance
(normal temperature)
Intake valve
Exhaust valve
mm
0.33
0.71
—
—
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Compressionpressure
Oil temperature: 40 – 60°C(Engine speed)
MPa {kg/cm2}(rpm)
Min. 2.9 {Min. 30}(150 – 200)
2.0 {20}(150 – 200)
Blow-by pressure
(Coolant temperature:
within operating range)
At rated output
kPa
{mmH2O}Max. 1.18 {Max. 120} 1.96 {200}
Oil pressure
(Coolant temperature:
within operating range)
At high idling (SAE30)
At high idling (SAE10W)
At low idling (SAE30)
At low idling (SAE10W)
MPa
{kg/cm2}
0.39 – 0.69 {4.0 – 7.0}
0.34 – 0.64 {3.5 – 6.5}
Min. 0.15 {Min. 1.5}
Min. 0.1 {Min. 1.0}
0.21 {2.1}
0.18 {1.8}
0.08 {0.8}
0.07 {0.7}
Oil temperature All speed range (inside oil pan) °C 90 – 120 120
Fan, alternator belt
tension
Deflection when pressed with fin-
ger force of approx. 58.8 N {6 kg} mm Approx. 13 Approx. 13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement conditions Unit Standard value Permissible value
E n g i n e s p e e d
2 pumps at relief
• Engine coolant temperature:Within operating range
• Hydraulic oil temperature:
Within operating range
• Engine at high idling
• Arm in relief condition
rpm
1,930 ± 100 1,930 ± 100
At 2-pump relief + one
touch power up
• Engine coolant temperature:
Within operating range
• Hydraulic oil temperature:
Within operating range• Engine at high idling
• Arm relief + One-touch power
max. switch in ON condition
1,830 ± 100 1,830 ± 100
Speed when auto-
deceleration is oper-
ated
• Engine at high idling
• Auto-deceleration switch in ON
condition
• All control levers in NEUTRAL
condition
1,300 ± 100 1,300 ± 100
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S p o o l s t r o k e
Boom control valve
mm 9.5 ± 0.5 9.5 ± 0.5
Arm control valve
Bucket control valve
Swing control valve
Travel control valve
T r a v e l o f c o n t r o l l e v
e r s Boom control lever
• Engine stopped
• At center of control lever grip
• Max. reading up to stroke end
(excepting lever play in NEU-
TRAL position)
mm
85 ± 10 85 ± 10
Arm control lever 85 ± 10 85 ± 10
Bucket control lever 85 ± 10 85 ± 10
Swing control lever 85 ± 10 85 ± 10
Travel control lever 115 ± 12 115 ± 12
Play of control levers Max. 10 Max. 15
er s
Boom control lever 15.7 ± 4.9
{1.6 ± 0.4}
Max. 24.5
{Max. 2.5}
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement conditions Unit Standard value Permissible value
Unload pressure
• Hydraulic oil temperature:
Within operation range
• Engine at high idling• Working mode: A mode
• Hydraulic pump output pressure
with all control levers in NEU-
TRAL position
4.2 ± 1.0
{42 ± 10}
4.2 ± 1.0
{42 ± 10}
Boom • Hydraulic oil
temperature:
Within opera-
tion range
• Engine at high
idling
RAISE
34.81
(37.27 )
{355 (380 )}
33.34 – 36.77
(35.79 – 39.23)
{340 – 375 (365 – 400)}
L O W E R
At low-pressure
setting
18.14 ± 0.98
{185 ± 10}
16.67 – 19.61
{170 – 200}
At high-
pressure
setting
31.38 ± 1.47
{320 ± 15}
29.2 – 33.34
{300 – 340}
Arm
• Working mode: A mode
• Hydraulic pump output pressure
34.81
(37.27 )
33.34 – 36.77
(35.79 – 39.23)
+1.47 –0.98+1.47
–0.98+15
–10+15
–10
+1.47 –0.98+1.47
–0.98
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H y d r a u l i c p r e s s u r e
MPa
{kg/cm2}
with all measurement circuitsrelieved
• Values inside parenthesis:
Hydraulic oil pressure with one-
touch power max. switch in ON
mode (reference only)
{355 (380 )} {340 – 375 (365 – 400)}
Bucket
34.81
(37.27 )
{355 (380 )}
33.34 – 36.77
(35.79 – 39.23)
{340 – 375 (365 – 400)}
Swing30.89
{315 }
27.95 – 32.85
{285 – 335}
Travel 37.27{380 }
35.79 – 40.70{365 – 415}
Control circuit source
pressure
• Hydraulic oil temperature:
Within operation range
• Engine at high idling
• Self-reducing pressure valve
output pressure with all control
levers in NEUTRAL position
3.24 ± 0.2
{33 ± 2}
2.84 – 3.43
{29 – 35}
• Hydraulic oil tem-perature: Within When allcontrol
+15 –10
+15 –10
+1.47 –0.98+1.47
–0.98+15
–10+15
–10
+1.47 –2.45+15
–25
+2.94
–0.98+30
–10
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement conditions Unit Standard value Permissible value
Swing brake angle • Hydraulic oil temperature:
Within operating range
• Bucket: Empty
• Engine at high idling
• Working mode: A mode
• Swing circle misalignment amount
when stopping after one turn
deg.
(mm)
PC400: Max. 120
PC450: Max. 130
PC400: Max. 150
PC450: Max. 160
Time taken to start
swing
• Hydraulic oil temperature:
Within operation range
• Bucket: Empty
90°
sec.
3.7 ± 0.4 Max. 4.6
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S w i n g
• Engine at high idling• Working mode: A mode
• Time required for passingpoints 90 and 180 degrees
from starting point
180° 5.4 ± 0.5 Max. 6.4
Time taken to swing • Hydraulic oil temperature:
Within operating range
• Bucket: Empty
• Engine at high idling
• Working mode: A mode
• Time required for 5 more turns
after making initial one turn
sec. 33.0 ± 3.3 Max. 38
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
S w
i n g
Leakage from swing
motor
• Hydraulic oil temperature: Within
operation range
• Engine at high idling
• Swing lock switch: ON• Leakage amount for one minute
during swing relief
l/min Max. 5.5 Max. 11
Travel speed(Idle travel) • Hydraulic oil temperature:
Within operation range
• Engine at high idling• Working mode: A mode
• Time required for track shoes
to make 5 turns after making
one initial idle turn
Lo
sec.
STD: 63.2 ± 12.6
LC: 67.3 ± 13.5
STD: 42.0 – 80.0
LC: 45.0 – 84.5
MiSTD: 45.1 ± 6.8
LC: 48.1 ± 7.2
STD: 31.5 – 55.0
LC: 34.0 – 58.0
HiSTD: 34.5 ± 35
LC: 36.7 ± 3.6
STD: 28.0 – 41.5
LC: 32.0 – 44.0
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement conditions Unit Standard value Permissible value
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T r a v e l
Travel speed
(Actual travel)• Hydraulic oil temperature:
Within operation range
• Engine at high idling
• Working mode: A mode• Flat ground
• Time required for traveling
20 m after 10 m trial run
Lo
sec.
24.0 ± 4.8 18.9 – 31.0
Mi 17.1 ± 2.6 14.4 – 21.0
Hi 13.1 – 1.3 11.7 – 15.1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
T r a v e l
Hydraulic drift of travel • Hydraulic oil temperature:
Within operating range
• Engine stopped
• Parking machine on slope 12
degrees with sprocket facing ups-
lope
• Sliding distance for 5 minutes
mm 0 0
Leakage of travel
motor
• Hydraulic oil temperature:
Within operating range
• Engine at high idling
• Travel: Lock sprocket.
• Oil leakage amount for one
minute with traveling in relief con-
dition
l/min Max. 20 Max. 40
Whole work
equipment(tooth PC400: Max 600 PC400: Max 900
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement conditions Unit Standard value Permissible value
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W o r k
e q u i p m e n t
H y d r a u l i c d r i f t o f w o r k e q u i p m e n t
equipment (tooth
tip fall amount)
• Hydraulic oil temperature: Within
operation range
• Flat and level ground
• Work equipment in measure-
ment posture as illustratedabove
• Bucket load: 3,060 kg
• Engine stopped
• Work equipment control lever in
NEUTRAL position
• Fall amount for 15 minutes as
measured every 5 minutes start-
ing immediately after initial setting
mm
PC400: Max. 600PC450: Max. 700
PC400: Max. 900PC450: Max. 1,050
Boom cylinder
(cylinder retrac-
tion amount)
PC400: Max. 25
PC450: Max. 29
PC400: Max. 38
PC450: Max. 44
Arm cylinder (cyl-
inder extensionamount)
PC400: Max. 85
PC450: Max. 100
PC400: Max. 128
PC450: Max. 150
Bucket cylinder
(cylinder retrac-
tion amount)
PC400: Max. 30
PC450: Max. 35
PC400: Max. 45
PC450: Max. 53
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement conditions Unit
Standard value for
new machineService limit value
e q u i p m e n t
u i p m e n t s p e e d
Boom • Hydraulic oil temperature:
Within operation range
• Engine at high idling
• Working mode: A mode
• Time required from raise
stroke end till bucket
touches ground
R A I S
E
sec.
PC400: 4.0 ± 0.4PC450: 4.2 ± 0.4
PC400: Max. 4.8PC450: Max. 5.0
L O W E R
PC400: 2.9 ± 0.3
PC450: 2.8 ± 0.3
PC400: Max. 3.4
PC450: Max. 3.3
Arm • Hydraulic oil temperature:
Within operation range
• Engine at high idling
C U R L PC400: 4.3 ± 0.4
PC450: 4.7 ± 0.5
PC400: Max. 5.0
PC450: Max. 5.4
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W o r k
W o r k e q • Engine at high idling
• Working mode: A mode
• Time required from dump-
ing stroke end to digging
stroke end
D U M P
3.6 ± 0.4 Max. 4.3
Bucket • Hydraulic oil temperature:
Within operation range
• Engine at high idling
• Working mode: A mode
• Time required from dump-
ing stroke end to digging
stroke end
C U R L
3.6 ± 0.4 Max. 4.3
D U M P
2.9 ± 0.3 Max. 3.5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement Condition Unit Standard value Permissible value
g
Boom• Hydraulic oil temperature:
Within operation range
• Engine at low idling
• Working mode: A mode
• Time required from raise stroke
end till bucket touches ground
and pushes up machine front
sec. Max. 3.0 Max. 3.6
• Hydraulic oil temperature: PC400: Max 3 0 PC400: Max 3 6
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W o r k e q u i p m e n t
T i m e l a g
Arm• Hydraulic oil temperature:
Within operation range
• Engine at low idling
• Working mode: A mode
• Time required from dumping
stroke end till bucket stops
momentarily after control lever
is tilted to digging and starts to
move again
sec.
PC400: Max. 3.0
PC450: Max. 4.0
PC400: Max. 3.6
PC450: Max. 4.6
Bucket• Hydraulic oil temperature:
Within operation range
• Engine at low idling
Max. 3.0 Max. 5.0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
P e r f o r m
a n c e i n c o m p o u n d o p e r a t i o n
Swerving amount in
simultaneous opera-
tion of work equip-
ment and travel
• Hydraulic oil temperature:
Within operation range
• Engine at high idling
• Working mode: A mode
• Traveling speed: Lo
• Flat and level ground
• Swerving amount (X) when
traveling 20 m after initial trial
run of 10 m mm Max. 400 Max. 440
er
f o r m a n c e o f
yd
r a u l i c p u m p
Hydraulic pump
deliverySee next page l/min See next page
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement Condition Unit Standard value Permissible value
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P e r h y d
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Applicable modelPC400, 400LC-7
PC450, 450LC-7
Cate-
goryItem Measurement Condition Unit Standard value
Permissible
value
mp
Discharge amount of hydraulic pump (A mode)
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P e r f o
r m a n c e o f h y d r a u l i c p u m p
• Pump speed: At 1,950 rpm, PC current 280 mA
Check point
Test pump
discharge
Discharge
pressure of
Average
pressure
Standard value
for discharge
Judgement
standard lower
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TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE...................................................... 20-102
MEASURING ENGINE SPEED .................................................................................................................. 20-104
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)................................................................ 20-105
MEASURING EXHAUST TEMPERATURE ................................................................................................ 20-106
MEASURING EXHAUST GAS COLOR...................................................................................................... 20-107 ADJUSTING VALVE CLEARANCE ............................................................................................................ 20-108
MEASURING COMPRESSION PRESSURE.............................................................................................. 20-110
MEASURING BLOW-BY PRESSURE........................................................................................................ 20-112
MEASURING ENGINE OIL PRESSURE.................................................................................................... 20-113
HANDLING OF FUEL SYSTEM DEVICES................................................................................................. 20-114
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM .................................................................. 20-114
MEASURING FUEL PRESSURE ............................................................................................................... 20-115
BLEEDING AIR FROM FUEL CIRCUIT ..................................................................................................... 20-116
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE.................................................................................... 20-118
TESTING AND ADJUSTING
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ADJUSTING ENGINE SPEED SENSOR ................................................................................................... 20-119
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELT TENSION........................................ 20-120
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................ 20-121
MEASURING CLEARANCE OF SWING CIRCLE BEARING..................................................................... 20-122
TESTING AND ADJUSTING TRACK SHOE TENSION.............................................................................. 20-123
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,
SWING, AND TRAVEL CIRCUITS....................................................................................................... 20-124
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT....................................................................... 20-128
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ................................... 20-129
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL CIRCUIT.................................... 20-132
MEASURING SOLENOID VALVE OUTPUT PRESSURE.......................................................................... 20-137
MEASURING PPC VALVE OUTPUT PRESSURE..................................................................................... 20-140
ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES................................................ 20-142
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORK EQUIPMENT ................................... 20-143
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT.............................................................. 20-145
MEASURING OIL LEAKAGE...................................................................................................................... 20-146
BLEEDING AIR FROM EACH PART 20 149
TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
Testing/Adjusting item
s y m b o l
Part No. Part name Q ’ t y
Remarks
Measuring intake air pres-
sure (boost pressure) A 799-201-2202 Boost gauge kit 1 –101 – 200 kPa {–760 – 1,500 mmHg}
Measuring exhaust
temperatureB 799-101-1502 Digital thermometer 1 –99.9 – 1,299°C
Measuring exhaust gas
color C
1 799-201-1502 Handy smoke meter 1Pollution level: 0 – 70 % (With standard
color)
(Pollution level × 1/10 Bosch index)2
Commercially
availableSmoke meter 1
Adjusting valve clearance DCommercially
availableFeeler gauge 1
Air intake side: 0.35 mm, Exhaust side:
0.57 mm
Measuring compression
pressureE
1 795-502-1590 Compression gauge 1 0 – 6.9 MPa {0 – 70 kg/cm2}
2795-471-1410 Adapter 1
For 125E-3 engine6217-71-6112 Gasket 1
3 795-799-1170 Puller 1
Measuring blow-by pres-sure
F 799-201-1504 Blow-by checker 1
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surey
Measuring engine oil
pressureG
1799-101-5002 Hydraulic tester 1
(Pressure gauge): 2.5, 5.9, 39.2, 58.8 MPa
{25, 60, 400, 600 kg/cm2}
790-261-1203 Digital hydraulic tester 1 (Pressure gauge): 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 (Pressure gauge): 0.98MPa {10 kg/cm2}
Measuring fuel pressure H 1
799-101-5002 Hydraulic tester 1
Same as G790-261-1203 Digital hydraulic tester 1
2 799-401-2320 Hydraulic tester 1
Measuring clearance of
swing circle bearingJ
Commercially
availableDial gauge 1 with magnet
Measuring and adjusting oil
pressures in work equip-
ment, swing, and travel cir-
cuits
k
1799-101-5002 Hydraulic tester 1
Same as G790-261-1203 Digital hydraulic tester 1
2 799 101 5220 Nipple 2 (Si ) 10 × 1 25
TESTING AND ADJUSTING TESTING, ADJUSTING, AND TROUBLESHOOTING TOOLS TABLE
Testing and adjusting
pressure in pump LS
control circuit
N
1799-101-5002 Hydraulic tester 1
Same as G1790-261-1203 Digital hydraulic tester 1
2799-101-5220 Nipple 4
Same as M2
07002-11023 O-ring 4
3 799-401-2701Differential pressure
gauge1
Measuring solenoid valve
output pressureP
1799-101-5002 Hydraulic tester 1
Same as G1790-261-1203 Digital hydraulic tester 1
2799-401-3100 Adapter 1 (Size): 02
799-401-3200 Adapter 1 (Size): 03
Measuring PPC valve
output pressureQ
1799-101-5002 Hydraulic tester 1
Same as G1790-261-1203 Digital hydraulic tester 1
2 970-301-1740 Joint 1 (Size): PF1/4 + PT1/4
Measuring oil leakage RCommercially
availableMeasuring cylinder 1
Testing wear of sprocket — 799-627-1120 Wear gauge 1
Measuring coolant and oiltemperatures
— 799-101-1502 Digital thermometer 1 Same as B
Testing/Adjusting item
s y m b o l
Part No. Part name Q ’ t y
Remarks
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a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Layout of connec-
tors and electric circuit diagram of each system.
temperatures
Measuring operating effort
and pressing force—
79A-264-0021 Push-pull scale 1 0 – 294 N {0 – 30 kg}
79A-264-0091 Push-pull scale 1 0 – 490 N {0 – 50 kg}
Measuring stroke and
hydraulic drift—
Commercially
availableScale 1
Measuring work equip-
ment speed
—Commercially
available
Stopwatch 1
Measuring voltage and
resistance—
Commercially
availableTester 1
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED
1. Turn the starting switch ON and set the monitor
panel to “Monitoring”.
a For the operating method, see “Special func-
tions of monitor panel”.
• Monitoring code: 01002 Engine Speed
01006 Engine Speed
a Code 01002 is information of the engine control-
ler and code 01006 is information of the pump
controller. The engine speed can be measured
with either of those codes.
a The engine speed is displayed in rpm.
4) Measuring 2-pump relief + one-touch power
maximizing speed (near rated speed):
i) Start the engine and set the fuel control
dial in the high idling position (MAX).
ii) Set the working mode switch in the A-
mode position.
iii) While relieving the arm circuit by moving
the arm in, keep pressing the one-touch
power maximizing switch.
a The one-touch power maximizing func-
tion is reset automatically in about 8.5
seconds even if the switch is kept held.
Accordingly, measure the engine speed
in that period.
5) Measuring auto-deceleration speed1) Start the engine and set the fuel control
dial in the high idling position (MAX).
2) Turn the auto-deceleration switch ON.
3) Set the work equipment control and
swing control levers in neutral.
a The engine speed lowers to a certain
level about 5 seconds after all the levers
are set in neutral. This level is the auto-
deceleration speed.
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2. Run the engine and raise engine coolant and
hydraulic oil temperatures to operating range.
3. Measure the engine speed under each meas-
urement condition.
1) Measuring low idling speed:
i) Start the engine and set the fuel control
dial in the low idling position (MIN).
ii) Set the work equipment control, swing
control, and travel levers in neutral and
measure the engine speed.
2) Measuring high idling speed:
i) Start the engine and set the fuel control
dial in the high idling position (MAX).
ii) Set the working mode switch in the A-
mode position
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
a Measuring instruments for intake air pressure
(boost pressure)
a When installing and removing the measuring
instruments, take care not to touch a hot part of
the engine.
1. Open the engine hood and remove intake air
pressure pick-up plug (1).
4. Run the engine and raise engine coolant and
hydraulic oil temperatures to operating range.
5. Set the working mode switch in the A-mode
position.
6. While running the engine at high idling, relieve
the boom circuit by raising the boom and meas-
ure the intake air pressure (boost pressure).
7. After finishing measurement, remove the meas-uring instruments and return the removed parts
Symbol Part No. Part Name
A 799-201-2202 Boost gauge kit
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2. Install nipple [1] of boost gauge kit A and con-
nect gauge [2].
uring instruments and return the removed parts.
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE
a Measuring instrument of exhaust gas tempera-
ture
k Install and remove the measuring instrument af-
ter the exhaust manifold is cooled.
1. Open the engine hood and remove exhaust
temperature pick-up plug (1).
5. Procedure for measuring exhaust temperature
periodically for preventive maintenance (Pm
Clinic), etc.
1) Set the working mode switch in the A-mode
position.
2) Run the engine at high idling, relieve the
arm circuit by moving the arm in, and meas-
ure the exhaust temperature.
a Measure the exhaust temperature after
it is stabilized.
6 After finishing measurement remove the meas-
Symbol Part No. Part Name
B 799-101-1502 Digital thermometer
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2. Install sensor [1] of digital thermometer B and
connect them to meter [2].
a Clamp the wiring harness of the digital ther-
mometer so that it will not touch a hot part.
6. After finishing measurement, remove the meas
uring instruments and return the removed parts.
TESTING AND ADJUSTING MEASURING EXHAUST GAS COLOR
MEASURING EXHAUST GAS COLOR
a Measuring instrument of exhaust gas color
k When installing and removing the measuring in-
struments, take care not to touch a hot part.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker C1. When recording official data, use
smoke meter C2.
1. Measuring with handy smoke checker C1
1) Stick a sheet of filter paper to C1.
2) Insert the exhaust gas intake pipe in
exhaust pipe (1).
3) Run the engine and raise engine coolant
temperature to operating range.
4) Accelerate the engine suddenly or run it at
high idling and operate the handle of smoke
checker C1 so that the filter paper will
absorb the exhaust gas
2) Connect the probe hose, receptacle of the
accelerator switch, and air hose to smokemeter C2.
a Limit the supplied air pressure to 1.5
MPa {15 kg/cm2}.
3) Connect the power cable to a receptacle of
AC 100 V.
a Before connecting the cable, check that
the power switch of the smoke meter is
turned off.
4) Loosen the cap nut of the suction pump andfit the filter paper.
Symbol Part No. Part Name
C
1 799-101-9000 Handy smoke checker
2
Commercially
available Smoke meter
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absorb the exhaust gas.
5) Remove the filter paper and compare it with
the attached scale
p p
a Fit the filter paper securely so that the
exhaust gas will not leak.
5) Turn on the power switch of smoke meter
C2.
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE
a Adjusting instrument for valve clearance
1. Open the engine hood and remove all cylinder
head covers (1).
a Remove all the intermediate clamps of the
fuel high-pressure tube and disconnect the
sleeve nuts on the common rail side and in-
jector side, and you can remove the cylinder
head covers.
aUse ring wrenches (on the market) for high-pressure pipes to disconnect and connect
the fuel high-pressure tubes.
a Remove the air intake connector, too, from
the top of the No. 1 cylinder head cover.
a After removing the head covers, tighten the
sleeve nuts temporarily so that the fuel high-
pressure tubes will not interfere with the
rocker arms.
the compression top dead center. In this
case, rotate the crankshaft one more turn.
5. Insert feeler gauge D in clearance “b” between
rocker arm (3) and crosshead (4) and adjust the
valve clearance with adjustment screw (5).
a With the feeler gauge inserted, turn the ad-
justment screw to a degree that you can
move the filler gauge lightly.
6. Fix adjustment screw (5) and tighten locknut (6).
3 Locknut:53.0 – 64.7 Nm {5.4 – 6.6 kgm}
Symbol Part No. Part Name
DCommercially
availableFeeler gauge
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2. Remove the belt protection covers (2 pieces)
and loosen the fan belt and alternator belt.
3 Remove the radiator undercover
{ g }
a After tightening the locknut, check the valve
clearance again.
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
8. After finishing adjustment, return the removed
parts.
3 Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
a After tightening the sleeve nuts permanently,
tighten the clamp bolts of the fuel high-pres-
sure tubes permanently.
3 Fuel high-pressure tube sleeve nut:39.2 – 49.0 Nm {4 – 5 kgm}
3 Fuel high-pressure tube clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Air intake connector clamp:
9.8 ± 0.5 Nm {100 ± 5 kgcm}
a Adjust the belt tension. For details, see
TESTING AND ADJUSTING FAN BELT
AND ALTERNATOR BELT TENSION.
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TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE
a Measuring instruments for compression pressure
k When measuring the compression pressure,
take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
1. Run the engine and warm up the engine oil tem-
perature to 40 – 60°C.
2. Open the engine hood and remove cover (1) of
the cylinder head to be measured.
a Remove all the intermediate clamps of the
fuel high-pressure tube and disconnect the
sleeve nuts on the common rail side and in-
jector side, and you can remove the cylinder head cover.
4. Install adapter E2 and connect it to compressiongauge E1.
3 Holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
Symbol Part No. Part Name
E
1 795-502-1590 Compression gauge
2
795-471-1410 Adapter
6217-71-6112 Gasket
3 795-799-1170 Puller
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a Use ring wrenches (on the market) for high-
pressure pipes to disconnect and connect
the fuel high-pressure tubes.
a Remove the air intake connector, too, from
the top of the No. 1 cylinder head cover.
5. Adjust the valve clearance. For details, see
ADJUSTING VALVE CLEARANCE.
6. Remove the engine undercover and disconnect
engine intermediate connectors ER02 and
ER03.
k If the connectors are not disconnected, the
engine starts during measurement, and that
i d A di l b t di
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
8. Crank the engine with the starting motor and
measure the compression pressure.
a Measure the pressure when the pointer of
the gauge is stabilized.
a While measuring the compression pressure,
measure the engine speed, too, and check
that it is in the measurement condition range.
9. After finishing measurement, remove the meas-uring instruments and return the removed parts.
3 Injector holder mounting bolt:
58.8 – 73.5 Nm {6.0 – 7.5 kgm}
3 Cylinder head cover mounting bolt:
9.8 ± 1.0 Nm {1.0 ± 0.1 kgm}
a After tightening the sleeve nuts permanently,
tighten the clamp bolts of the fuel high-pres-
sure tubes permanently.
3 Fuel high-pressure tube sleeve nut:39.2 – 49.0 Nm {4 – 5 kgm}
3 Fuel high-pressure tube clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
3 Air intake connector clamp:
9.8 ± 0.5 Nm {100 ± 5 kgcm}
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TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE
a Measuring instrument for blow-by pressure
1. Remove the engine undercover.
2. Install nozzle [1] of blow-by checker F to blow-by
hose (1) and connect it to gauge [2] by the hose.
3. Run the engine and raise engine coolant and
hydraulic oil temperatures to operating range
Symbol Part No. Part Name
F 799-201-1504 Blow-by checker
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hydraulic oil temperatures to operating range.
4. Run the engine at high idling and measure the
blow-by pressure under the following condition.
• Work equipment mode: A
• Swing lock switch: ON (High pressure relief)
• Work equipment, swing, and travel circuits:
Relieve by moving arm in.
a Read the blow-by checker when its
pointer is stabilized.
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE
a Measuring instruments for engine oil pressure
1. Open the engine hood and remove oil pressure
pick-up plug (1) from the engine cylinder block.
2. Install nipple [1] of hydraulic tester G1 and con-
5. After finishing measurement, remove the meas-uring instruments and return the removed parts.
Symbol Part No. Part Name
G1
799-101-5002 Hydraulic tester
790-261-1203 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
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2. Install nipple [1] of hydraulic tester G1 and con
nect it to hydraulic tester G2.
TESTING AND ADJUSTING
HANDLING OF FUEL SYSTEM DEVICES
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM
HANDLING OF FUEL SYSTEMDEVICES
a Precautions for testing and adjusting fuel sys-
tem
The common rail fuel injection system (CRI)
consists of more precise parts than the conven-
tional fuel injection pump and nozzle. If foreignmatter enters this system, it can cause a trouble.
When testing and adjusting the fuel system,
take care more than the past. If dust, etc. sticks
to any part, wash that part thoroughly with clean
fuel.
a Precautions for replacing fuel filter cartridge
Always use a Komatsu genuine fuel filter car-
tridge.
Since the common rail fuel injection system(CRI) consists of more precise parts than the
conventional fuel injection pump and nozzle, it
employs a high-efficiency special filter to pre-
vent foreign matter from entering it.
If a filter other than a Komatsu genuine filter is
used, the fuel system may have trouble. So
never use any thing but a Komatsu genuine fil-
ter.
RELEASING RESIDUALPRESSURE FROM FUELSYSTEM
a Pressure is generated in the low-pressure circuit
and high-pressure circuit of the fuel system
while the engine is running.
Low-pressure circuit: Feed pump – Fuel filter –Fuel supply pump
High-pressure circuit: Fuel supply pump – Com-
mon rail – Fuel injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
a Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuitmust be released completely. Accordingly,
observe the following.
k Before testing the fuel system or removing
its parts, wait at least 30 seconds after stop-
ping the engine until the residual pressure in
the fuel circuit is released. (Do not start the
work just after stopping the engine since
there is residual pressure.)
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TESTING AND ADJUSTING MEASURING FUEL PRESSURE
MEASURING FUEL PRESSURE
a Measuring instruments for fuel pressure
a Measure only the fuel pressure in the low-pres-
sure circuit from the feed pump to the fuel filter
and fuel supply pump.
k Since the pressure in the high-pressure circuit
from the fuel supply pump to the common rail
and fuel injector is very high, it cannot be meas-ured.
1. Open the engine hood and remove fuel pres-
sure pick-up plug (1).
3. Run the engine at high idling and measure the
fuel pressure.
a If the fuel pressure is in the following range,
it is normal.
0.15 – 0.3 MPa {1.5 – 3 kg/cm2}
4. After finishing measurement, remove the meas-
uring instruments and return the removed parts.
Symbol Part No. Part Name
H1
799-101-5002 Hydraulic tester
790-261-1203 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
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2. Install nipple [1] of hydraulic tester H1 and con-
nect them to hydraulic tester H2.
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
BLEEDING AIR FROM FUEL CIRCUIT
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a If fuel is used up or if a fuel circuit device is
removed and installed, bleed air from the fuel
circuit according to the following procedure.
a Open the engine hood.
1. Remove fuel filter (1) and fill it with fuel and
install it again.
a Fill the fuel filter with clean fuel and take care
TESTING AND ADJUSTING BLEEDING AIR FROM FUEL CIRCUIT
3. Remove air bleed plug (2b) of the fuel filter and
operate priming pump (3).
a Operate the priming pump until the fuel flows
out of the plug hole and install the plug.3 Air bleed plug:
7.8 – 9.8 Nm {0.8 – 1.0 kgm}
4. Loosen air bleeder (4) of the fuel supply pump
and operate priming pump (3) 90 – 100 times.
a Operate the priming pump until fuel flows
from air bleeder (2b) and tighten the air
bleeder. Then operate the priming pumpseveral more times, until it becomes heavy.
3 Air bleeder: 4.9 – 6.9 Nm {0.5 – 0.7 kgm}
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5. Start the engine with the starting motor.
a Air in the high-pressure circuit is automati-
cally bled when the engine is cranked.
a If the engine does not start, there may be still
air in the low-pressure circuit. In this case,
repeat the above procedure from step 2.
TESTING AND ADJUSTING INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE
k Very high pressure is generated in the high-
pressure circuit of the fuel system. If fuel leaks
while the engine is running, it is dangerous
since it can catch fire.
After testing the fuel system or removing its
parts, inspect it for fuel leakage according to the
following procedure.a Clean and degrease the engine and the parts
around it in advance so that you can inspect it
easily for fuel leakage.
1. Spray color checker (developer) over the fuel
supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and
stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel leak-
age.
a Inspect around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
a If any fuel leakage is detected, repair it andinspect again from step 2.
4 R th i t l idli
9. Inspect the fuel piping and devices for fuel leak-
age.
a Inspect around the high-pressure circuit
parts coated with the color checker for fuel
leakage.
a If any fuel leakage is detected, repair it and
inspect again from step 2.a If any fuel leakage is not detected, inspection
is completed.
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4. Run the engine at low idling.
5. Inspect the fuel piping and devices for fuel leak-
age.
a Inspect around the high-pressure circuit
parts coated with the color checker for fuel
leakage.a If any fuel leakage is detected, repair it and
inspect again from step 2.
6. Run the engine at high idling.
7. Inspect the fuel piping and devices for fuel leak-
age.
a Inspect around the high-pressure circuit
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR
a Adjust the engine speed sensor for the pump
controller according to the following procedure.
a The engine G speed sensor and engine Ne
speed sensor for the engine controller cannot be
adjusted.
a Open the engine hood and remove engine
speed sensor (1) before adjusting it and checkthat its tip is free from steel chips and flaws, and
then install it again.
1. Screw in sensor (1) until its tip touches the toothtip of flywheel ring gear (2).
2 Threads: Hydraulic sealant
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2. Return sensor (1) by 1/2 – 2/3 turns.
a Adjust clearance “a” between the sensor tip
and gear tooth tip to 0.75 – 1.00 mm.
3. Secure sensor (1) with nut (3).
3 Nut: 69 – 74 Nm {7.0 – 7.5 kgm}
TESTING AND ADJUSTING
TESTING AND ADJUSTING FAN BELT AND ALTERNA-
TOR BELT TENSION
TESTING AND ADJUSTING FAN BELT AND ALTERNATOR BELTTENSION
Testing
1. Open the engine hood and remove belt protec-
tion covers (2 pieces).
2. Press the intermediate point between alternator
pulley and fan pulley with a finger and measure
deflection “a” of the belt.
a Deflection “a” when pressing force is approx-
imately 58.8 N {approximately 6 kg}: 13 mm
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1. Loosen bolts and nuts (1), (2), and (3).
2. Turn nut (4) to move alternator (5) and adjust
the belt tension.
a If nut (4) is
• Tightened clockwise, the belt tension is
decreased.
• Loosened counterclockwise, the belt
tension is increased.
a Check breakage of the pulleys, wear of theV-grooves and V-belts, and contact of the
belts and V-grooves.
a If a belt is lengthened to the adjustment limit,
cut, or cracked, replace it with a new belt.
3. Tighten nuts and bolts (3), (2), and (1).
a If a V-belt is replaced, readjust its tension af-
ter 1 operating hour.
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TESTING AND ADJUSTING
TESTING AND ADJUSTING AIR CONDITIONER COM-
PRESSOR BELT TENSION
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSORBELT TENSION
Testing
1. Open the engine hood and remove belt protec-
tion covers (2 pieces).
2. Press the intermediate point between air condi-
tioner compressor pulley and crank pulley with a
finger and measure deflection “a” of the belt.
a Deflection “a” when pressing force is approxi-mately 58.8 N {approximately 6 kg}:
14 mm – 16 mm
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1. Loosen bolts (1) and (2).
2. Move compressor (3) to adjust the belt tension.
a Check breakage of the pulleys, wear of the
V-grooves and V-belts, and contact of the
belts and V-grooves.
a If a belt is lengthened to the adjustment l imit,
cut, or cracked, replace it with a new belt.
3. Tighten bolts (2) and (1).a If a V-belt is replaced, readjust its tension af-
ter 1 operating hour.
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TESTING AND ADJUSTING MEASURING CLEARANCE OF SWING CIRCLE BEARING
MEASURING CLEARANCE OF SWING CIRCLE BEARING
a Measuring instrument for clearance of swing cir-
cle bearing
a When measuring the clearance of the swing cir-
cle bearing on the actual machine, observe the
following procedure.
k While measuring, do not put your hands or foot
under the undercarriage.
1. Fix dial gauge J to outer race (1) or inner race(2) of the swing circle and apply the probe to the
end face of inner race (2) or outer race (1) on
the opposite side.
a Set dial gauge J on the front or at rear side
of the machine.
4. Set the arm at almost right angle to the ground
and lower the boom until the track shoe at the
front end of the machine rises.
a At this time, the front end of the upper struc-
ture rises and the rear end lowers.
5. Under this condition, read dial gauge J.a Dial gauge J indicates the clearance of the
bearing.
6. Return the machine to the position of step 2 andcheck that dial gauge J indicates 0 again.
a If dial gauge J does not indicate 0, repeat
steps 3 – 5
Symbol Part No. Part Name
JCommercially
availableDial gauge
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2. Set the work equipment in the maximum reach
position and set the bucket tip at the height of
the revolving frame bottom.
a At this time, the front end of the upper struc-
ture lowers and the rear end rises.
steps 3 5.
TESTING AND ADJUSTING TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION
Testing
1. Run the engine at low idling and move the
machine forward by the length of track on
ground and stop slowly.
2. Place square bar [1] on the track shoe between
idler (1) and 1st carrier roller (2).a As the square bar [1], use angle iron which
has less deflection.
3. Measure maximum distance “a” between square
bar [1] and track shoe.
• Standard maximum distance “a” : 10 – 30 mm
Adjusting
a If the track shoe tension is abnormal, adjust it
according to the following procedure.
1. When tension is too high
Loosen valve (3) to discharge the grease.
k Since the valve may jump out because of
the high-pressure grease, do not loosen it
more than 1 turn.
2. When tension is low
Add grease through valve (3).
a If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
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TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN WORK
EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TESTING AND ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,SWING, AND TRAVEL CIRCUITS
a Testing and adjusting instruments for oil pres-
sure in work equipment, swing, and travel cir-
cuits
a The oil pressure in work equipment, swing, and
travel circuits can be checked with the monitor-ing function of the monitor panel (For the operat-
ing method, see “Special functions of monitor
panel”).
• Monitoring code: 01100 F Pump Pressure
01101 R Pump Pressure
• The pump oil pressure is displayed in 1 MPa
{1 kg/cm2, 1 PSI).
2) Install nipple K2 and connect it to oil pres-
sure gauge [1] of hydraulic tester K1.
a Use the oil pressure gauges of 58.8 MPa
{600 kg/cm2}.
Symbol Part No. Part Name
K
1799-101-5002 Hydraulic tester
790-261-1203 Digital hydraulic tester
2799-101-5220 Nipple (10 × 1.25 mm)
07002-11023 O-ring
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Measuring
1. Preparation work
k Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-
3) Run the engine and raise the hydraulic oil
temperature to the operating range.
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN WORK
EQUIPMENT, SWING, AND TRAVEL CIRCUITS
2. Combination of pump, actuator, and valve
a When the oil from the pumps is divided, the
front pump and rear pump act independently
on each actuator. Note that different actua-
tors relieve different valves.
a When the work equipment circuit or swing
circuit is relieved singly, the oils of the pumps
are merged. When the travel circuit is re-
lieved singly, the oils of the pumps are divid-ed.
a The actuators in the table are arranged in the
order when the control valve is seen from the
front of the machine (and an attachment is
installed to the service valve).
a If the one-touch power maximizing switch is
released, the valve is relieved at low pres-
sure. If the former is pressed, the lower is re-
lieved at high pressure.
a If the swing lock switch is turned ON, the 2-
stage relief valve is kept turned ON and the
valve is relieved at high pressure. Accord-
ingly, keep the swing lock switch turned
OFF.
5. Measuring swing circuit relief pressure
1) Start the engine and turn the swing lock
switch ON.
2) Run the engine at high idling and relieve the
swing circuit and measure the oil pressure.
a The pressure measured when the swing mo-
tor safety valve is relieved is indicated.
a The swing motor relief pressure is lower thanthe main relief valve.
6. Measuring travel circuit relief pressure
1) Start the engine and lock the travel mecha-
nism.
k Set pin [2] between the sprocket and
track frame to lock the travel mecha-
nism securely.
Pump Actuator Valve relieved
Front
(F unload valve) (F main relief valve)
Service Safety valve for service
Boom Hi
Arm HiF main relief valve
Bucket F main relief valve
Left
travelF main relief valve
BoomRAISE: F main relief valveLOWER: Safety-suction
valve
(Pump merge-divider valve) (Travel junction valve)
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3. Measuring unload pressure
1) Start the engine.
2) Run the engine at high idling and set all the
2) Run the engine at high idling and relieve the
travel circuit and measure the oil pressure.
( p g ) ( j )
Rear
(Self-pressure reducing valve)
Swing Swing motor safety valve
Right
travelR main relief valve
Arm Lo R main relief valve
(R unload valve) (R main relief valve)
(Centralized safety valve) (Back pressure valve)
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN WORK
EQUIPMENT, SWING, AND TRAVEL CIRCUITS
Adjusting
a The unload valve cannot be adjusted.
1. Adjusting main relief pressure
a If the relief pressure of the work equipment
circuit and/or travel circuit is abnormal, ad-
just main relief valves (3) and (4) according
to the following procedure.• (3): Front main relief valve
• (4): Rear main relief valve
a When adjusting the main relief valve on the
front pump side, remove the control valve
top cover.
a When adjusting the main relief valve on the
rear pump side, remove the control valve un-
dercover (if the covers are installed).
a Adjust only the low relief pressure of themain relief valve. (If the low relief pressure is
adjusted, the high relief pressure is adjusted
automatically.)
a The low relief pressure is the pressure ap-
plied when the 2-stage relief solenoid valve
is turned OFF and the pilot pressure is not
applied to the selector port.
5) Connect pilot hose (5).
6) After finishing adjustment, check again that
the pressure is normal according to the pro-cedure for measurement described above.
2. Adjustment of boom LOWER relief pressure
(High-pressure setting side)
a If the high relief pressure of the boom LOW-
ER circuit is abnormal, adjust the high pres-
sure setting side of boom LOWER safety-
suction valve (8) according to the following
procedure.
a The high relief pressure is the pressure ap-
plied when the machine push-up switch is
turned ON and the pilot pressure is not ap
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1) Disconnect pilot hose (5).
2) Fixing holder (6), loosen locknut (7).
3) Turn holder (6) to adjust the pressure.
a If the holder is
turned ON and the pilot pressure is not ap-
plied to the selector port.
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN WORK
EQUIPMENT, SWING, AND TRAVEL CIRCUITS
5) Connect pilot hose (9).
6) After finishing adjustment, check again that
the pressure is normal according to the pro-
cedure for measurement described above.a If the high pressure setting side is adjust-
ed, the low pressure setting side chang-
es. Accordingly, adjust the low pressure
setting side.
3. Adjustment of boom LOWER relief pressure
(Low-pressure setting side)
a If the low relief pressure of the boom LOW-
ER circuit is abnormal or the high pressure
setting side was adjusted, adjust the low
pressure setting side of boom LOWER safe-
ty-suction valve according to the following
4. Adjusting swing relief pressure
a If the relief pressure of the swing circuit is ab-
normal, adjust swing motor safety valve (14)
according to the following procedure.
1) Fixing adjustment screw (15), loosen lock-
nut (16).
2) Turn adjustment screw (15) to adjust the
pressure.
a If the adjustment screw is
• Turned to the right, pressure rises.
• Turned to the left, pressure lowers.
a Quantity of adjustment per turn of adjust-
ment screw:
4.70 MPa {47.9 kg/cm2}
3) Fixing adjustment screw (15), tighten lock-
nut (16)
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ty suction valve according to the following
procedure.
a The low relief pressure is the pressure ap-
plied when the machine push-up switch is
turned OFF and the pilot pressure is applied
to the selector port.1) Disconnect pilot hose (9).
2) Fixing holder (12), loosen locknut (13).
3) Turn holder (12) to adjust the pressure.
a If the holder is
• Turned to the right, pressure rises.• Turned to the left, pressure lowers.
a Quantity of adjustment per turn of holder:
Approx. 25.3 MPa {Approx. 258 kg/cm2}
nut (16).
3 Locknut:
147 – 196 Nm {15 – 20 kgm}
TESTING AND ADJUSTING MEASURING BASIC PRESSURE IN CONTROL CIRCUIT
MEASURING BASIC PRESSURE IN CONTROL CIRCUIT
a Measuring instruments for basic pressure in
control circuit
k Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-
eral times to release residual pressure in the
piping, then slowly loosen the hydraulic tank oil
filler cap to release the internal pressure.
1. Remove the control valve top cover and remove
control circuit basic pressure pick-up plug (1).
a The figure shows the control valve seen from
inside of the pump room.
3. Run the engine and raise the hydraulic oil tem-
perature to the operating range.
4. Run the engine at high idling and set all the con-
trol levers in neutral and measure the oil pres-
sure.
5. After finishing measurement, remove the meas-
uring instruments and return the removed parts.
a The relief valve for the control circuit basic
pressure is not adjustable.
Symbol Part No. Part Name
L
1799-101-1502 Hydraulic tester
790-261-1203 Digital hydraulic tester
2799-101-5220 Nipple (10 × 1.25 mm)
07002-11023 O-ring
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2. Install nipple L2 and connect it to oil pressure
gauge [1] of hydraulic tester L1.
a Use the oil pressure gauges of 5.9 MPa {60
kg/cm2}.
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP
PC CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE IN PUMP PC CONTROL
CIRCUIT
a Testing and adjusting instruments for oil pres-
sure in pump PC control circuit
Measuring
a Before measuring the oil pressure in the pump
PC control circuit, check that the oil pressure inthe work equipment, swing, and travel circuits
and the basic pressure in the control circuit are
normal.
k Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-
eral times to release residual pressure in the
piping, then slowly loosen the hydraulic tank oil
filler cap to release the internal pressure.
1. Measuring PC valve output pressure (servo
piston inlet pressure)
a Measure the PC valve output pressure (ser-
2) Install nipple M2 and connect it to oil pres-
sure gauge [1] of hydraulic tester M1.
a Use the oil pressure gauges of 58.8 MPa
{600 kg/cm2}.
• The figure shows the pump discharge
pressure side.
• The figure shows the PC valve output
pressure side.
Symbol Part No. Part Name
M
1 799-101-1502 Hydraulic tester
790-261-1203 Digital hydraulic tester
2799-101-5220 Nipple (10 × 1.25 mm)
07002-11023 O-ring
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a Measure the PC valve output pressure (ser-
vo piston inlet pressure) and pump dis-
charge pressure at the same time and
compare them.
1) Open the pump room cover and remove oil
pressure pick-up plugs (1), (2), (3), and (4).• (1): Front pump discharge pressure pick-
up plug
• (2): Rear pump discharge pressure pick-
up plug
• (3): Front PC valve output pressure pick-
up plug
• (4): Rear PC valve output pressure pick-
up plug
3) Run the engine and raise the hydraulic oil
temperature to the operating range.
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP
PC CONTROL CIRCUIT
4) Run the engine at high idling and measurethe pump discharge pressure and PC valve
output pressure (servo piston inlet pressure)
at the same time under the following condi-
tion.
• Working mode: A
• Swing lock switch: ON
(2-stage relief solenoid valve is turned
ON and oil is relieved at high pressure)• Work equipment, swing, and travel cir-
cuits: Relieve by moving arm IN.
a Judging method:
If the pump discharge pressure and PC
valve output pressure (servo piston out-
put pressure) are as follows, they are
normal.
a If the PC valve or servo piston is abnor-
mal, the PC valve output pressure (servo
piston output pressure) becomes “the
same as the pump discharge pressure”or “almost 0”.
5) After finishing measurement, remove the
measuring instruments and return the
d t
2. Measuring PC-EPC valve output pressure1) Open the pump room cover and remove
PC-EPC valve output pressure pick-up plug
(5).
2) Install nipple M2 and connect it to oil pres-
sure gauge [1] of hydraulic tester M1.
a Use the oil pressure gauges of 5.9 MPa
{60 kg/cm2}.
Measured pressure Pressure ratio
Pump discharge
pressure1
PC valve output
pressure
Approx. 0.6
(Approx. 3/5)
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removed parts.
3) Run the engine and raise the hydraulic oil
temperature to the operating range.
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP
PC CONTROL CIRCUIT
4) Set all the control levers in neutral andmeasure the oil pressure while running the
engine at low idling and high idling.
a If the PC-EPC valve output pressure
changes as shown below, it is normal.
5) After finishing measurement, remove the
measuring instruments and return the
removed parts.
Adjusting
aIf any of the following phenomena occurs andthe PC valve seems to be defective, adjust PC
valves (6) and (7) according to the procedure
shown below.
• When the working load is increased, the en-
gine speed is drastically reduced.
• The engine speed is normal but the work
equipment speed is low.
• (6): Front pump PC valve
• (7): Rear pump PC valvea The width across flats of the PC valve lock-
nut is 13 mm, and the adjustment screw (in-
side width) is 4 mm. Do not turn any other
locknuts or adjustment screws since they ef
2. Turn adjustment screw (9) to the right or left toadjust.
a Turn the adjustment screw in the following
directions.
• If the work equipment speed is low, turn
the adjustment screw to the right (to in-
crease the pump absorption torque).
• If the engine speed lowers, turn the ad-
justment screw to the left (to decreasethe pump absorption torque).
a The adjustable range of the adjustment
screw is as follows.
• Counterclockwise: Max. 1 turn
• Clockwise: Max. 1 turn
3. Tighten locknut (8).
3 Locknut:
27.5 – 34.3 Nm {2.8 – 3.5 kgm}
Engine Control lever Oil pressure
Low idling
Neutral
2.94 MPa
{30 kg/cm2}
High idling0 MPa
{0 kg/cm2}
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locknuts or adjustment screws since they ef-
fect the hydraulic pumps.
4. After finishing adjustment, check that the PC
valve output pressure (servo piston inlet pres-
sure) is normal according to the procedure for measurement described above.
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP
LS CONTROL CIRCUIT
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS CONTROL
CIRCUIT
a Testing and adjusting instruments for oil pres-
sure in pump LS control circuit
Measuring
a Before measuring the oil pressure in the pump LScontrol circuit, check that the oil pressure in the
work equipment, swing, and travel circuits and the
basic pressure in the control circuit are normal.
k Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-
eral times to release residual pressure in the
piping, then slowly loosen the hydraulic tank oil
filler cap to release the internal pressure.
1. Measuring LS valve output pressure (servo
piston inlet pressure)
a Measure the LS valve output pressure (ser-
2) Install nipple N2 and connect it to oil pres-
sure gauge [1] of hydraulic tester N1.
a Use the oil pressure gauges of 58.8 MPa
{600 kg/cm2}.
• The figure shows the pump discharge
pressure side.
• The figure shows the LS valve output
pressure side.
Symbol Part No. Part Name
N
1799-101-5002 Hydraulic tester
790-261-1203 Digital hydraulic tester
2799-101-5220 Nipple (10 × 1.25 mm)
07002-11023 O-ring
3 799-401-2701 Differential pressure gauge
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p p (
vo piston inlet pressure) and pump dis-
charge pressure at the same time and
compare them.
1) Open the pump room cover and remove oil
pressure pick-up plugs (1), (2), (3), and (4).• (1): Front pump discharge pressure pick-
up plug
• (2): Rear pump discharge pressure pick-
up plug
• (3): Front LS valve output pressure pick-
up plug
• (4): Rear LS valve output pressure pick-
up plug
3) Run the engine and raise the hydraulic oil
temperature to the operating range and
push up the track shoe on the side to be
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS
CONTROL CIRCUIT
4) Run the engine at high idling and measure
the pump discharge pressure and LS valve
output pressure (servo piston inlet pressure)
at the same time under the following condi-tion.
• Working mode: A
• Work equipment, swing, and travel con-
trol levers: Measure with all the levers in
neutral and measure with only the travel
lever operated halfway (with the track
shoe on one side driven idle).
a Check the safety around the machine,
drive the track shoe pushed up idle.a Judging method:
If the pump discharge pressure and LS
valve output pressure (servo piston out-
put pressure) are as follows they are
2. Measuring LS differential pressurea Measure the pump discharge pressure and
LS pressure (actuator load pressure) at the
same time and calculate the difference be-
tween them.
1) Open the pump room cover and remove oil
pressure pick-up plugs (1), (2), (5), and (6).
• (1): Front pump discharge pressure pick-up plug
• (2): Rear pump discharge pressure pick-
up plug
• (5): Front LS valve output pressure pick-
up plug• (6): Rear LS valve output pressure pick-
up plug
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put pressure) are as follows, they are
normal.
5) After finishing measurement, remove the
Measured
pressure
Pressure ratio
All leversin neutral
Travel lever
operatedhalfway
Pump discharge
pressure Almost
same
1
LS valve output
pressure
Approx. 0.6
(Approx. 3/5)
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP
LS CONTROL CIRCUIT
a When using oil pressure gauge:Use the oil pressure gauge of 58.8 MPa
{600 kg/cm2}.
Since the differential pressure is about
2.9 MPa {30 kg/cm2} at maximum, meas-
ure it by installing the same gauge to the
pick-up plugs alternately.
• The figure shows the pump discharge
pressure side.
• The figure shows the LS valve output
pressure side.
4) Run the engine at high idling and measure
the pump discharge pressure and LS pres-
sure (actuator load pressure) at the same
time under the following condition.• Working mode: A
• Travel speed: Hi
• Work equipment, swing, and travel con-
trol levers: Measure with all the levers in
neutral and measure with only the travel
lever operated halfway (with the track
shoe on one side driven idle).
a Check the safety around the machine,
drive the track shoe pushed up idle.a Calculation of LS differential pressure
(When oil pressure gauge is used):
LS differential pressure = Pump dis-
charge pressure LS pressure
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3) Run the engine and raise the hydraulic oil
temperature to the operating range and
push up the track shoe on the side to be
measured with the work equipment.
charge pressure – LS pressure
a If the LS differential pressure is as fol-
lows, it is normal.
Operation of lever LS differential
pressure
Set all levers in
neutral
Unload pressure
(See standard valuestable)
Operate travel lever
halfway
(Run track shoe idle)
Specified LS differen-
tial pressure
(See standard values
table)
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP LS
CONTROL CIRCUIT
3. Measuring LS-EPC valve output pressure1) Open the pump room cover and remove LS-
EPC valve output pressure pick-up plug (7).
2) Install nipple N2 and connect it to oil pres-sure gauge [1] of hydraulic tester N1.
a Use the oil pressure gauges of 5.9 MPa
{60 kg/cm2}.
4) Operate the travel speed switch and travellever and measure the oil pressure while
running the engine at high idling.
a If the LS-EPC valve output pressure
changes as shown below, it is normal.
Note: Operate the travel lever to a
degree that the PPC oil pressure
switch is turned ON (Stop before
the machine starts traveling).
5) After finishing measurement, remove the
measuring instruments and return the
removed parts.
Adjusting
a If the LS differential pressure is abnormal, adjust
LS valves (8) and (9) according to the following
procedure.
• (8): Front pump LS valve• (9): Rear pump LS valve
Travel speed Travel lever Oil pressure
Lo Netral2.94 MPa
{30 kg/cm2}
Hi Fine opera-tion (Note)
0 MPa{0 kg/cm2}
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3) Run the engine and raise the hydraulic oil
temperature to the operating range.
1. Fixing adjustment screw (10), loosen locknut
(11)
TESTING AND ADJUSTING
TESTING AND ADJUSTING OIL PRESSURE IN PUMP
LS CONTROL CIRCUIT
3. After finishing adjustment, check that the LS
pressure is normal according to the procedure
for measurement described above.
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TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
MEASURING SOLENOID VALVE OUTPUT PRESSURE
a Measuring instruments for solenoid valve output
pressure
a Before measuring the solenoid valve output
pressure, check that the basic pressure in the
control circuit is normal.
k Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-eral times to release residual pressure in the
piping, then slowly loosen the hydraulic tank oil
filler cap to release the internal pressure.
1. Remove the control valve top cover and discon-
nect outlet hoses (1) – (7) of the solenoid valve
to be removed.
a Since the outlet hoses of the PPC lock sole-
noid valves have quick couplers on the sole-
noid valve side, measure the pressure on the
PPC valve side (on the back side of the op-
erator’s cab).
2. Install adapter P2 and reconnect the hose.
3. Install nipple [1] of hydraulic tester P1 and con-
nect it to hydraulic gauge [2].
a Use the oil pressure gauges of 5.9 MPa {60
kg/cm2}.
a The figure shows the measuring instrumentsconnected to the outlet hose of the 2-stage
relief solenoid valve.
4. Run the engine and raise the engine oil temper-
ature to the operating range.
Symbol Part No. Part Name
P
1799-101-5002 Hydraulic tester
790-261-1203 Digital hydraulic tester
2799-401-3100 Adapter (Size 02)
799-401-3200 Adapter (Size 03)
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5. Run the engine at high idling, operate the con-
trol levers and switches to turn the solenoid
No. Solenoid valve to be measured
1 2-stage relief solenoid valve
2 Machine push-up solenoid valve
3 Swing holding brake solenoid valve
4 Travel speed selector solenoid valve
5 Merge-divider solenoid valve
6 Travel junction solenoid valve
7 PPC lock solenoid valve
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
a If the output pressure is as follows, the sole-noid valve is normal.
6. After finishing measurement, remove the meas-
uring instruments and return the removed parts.
Operation table of 2nd-stage relief solenoid valve
Solenoid valve Output pressure
OFF (Deenergized) 0 MPa {0 kg/cm2}
ON (Energized)
Almost same as control
basic pressure
(See standard values
table)
Operating condition Operation
When overheating No. 1 setting is turned ON OFFWhen all of work equipment, swing, and travel signals are turned OFF
When swing lock switch is turned ON
ON
When travel signal is turned ON
When in L-mode
When boom LOWER signal is turned ON
When in A/E-mode When left knob switchis turned ON
When signal other than swing sin-
gle operation signal is turned ONWhen swing single operation sig-
nal is turned ON OFF
When not under above condition
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Operation table of machine push-up solenoid valve
Operation table of swing holding brake solenoid valve
Operating condition Operation
Machine push-upswitch
OFF ON
ON OFF
Operating condition Operation
Work equipment,
When all are
turned OFFOFF
TESTING AND ADJUSTING MEASURING SOLENOID VALVE OUTPUT PRESSURE
Operation table of merge-divider solenoid valve
Operation table of travel junction solenoid valve
Operation table of PPC lock solenoid valve
Operating condition Operation
When in B-mode When service signal is turned ON
ON
When travel signal is
turned ON
When travel operation is performed singly
When work equipment,
switch, and service sig-nals are turned ON
When not in L-mode
When F or R pump pressure is
above 19.6 MPa {200 kg/cm2}
When F or R pump pressure is
below 14.7 MPa {150 kg/cm2}OFF
When in L-mode
When F or R pump pressure is
above 16.7 MPa {170 kg/cm2}ON
When F or R pump pressure is
below 11.8 MPa {120 kg/cm2}OFF
When travel signal is
turned OFF
When swing signal is
turned OFF
When arm IN and
bucket CURL PPC
pressures are above
1.9 MPa {19.5 kg/cm2}
When F or R pump pressure is
above 24.5 MPa {250 kg/cm2}ON
When F or R pump pressure is
below 19.6 MPa {200 kg/cm2} OFF
When not under above condition
Operating condition Operation
When travel steering signal is turned ON
ON
When travel steering signal is turned OFF
When travel system is
operated singly
When F or R pump pressure is
above 34.3 MPa {350 kg/cm2}
When not under above condition OFF
Operating condition
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Operating condition
Safety lock lever Lock OFF
Free ON
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
a Measuring instruments for PPC valve output
pressure
k Lower the work equipment to the ground and
stop the engine. Operate the control levers sev-
eral times to release residual pressure in the
piping, then slowly loosen the hydraulic tank oil
filler cap to release the internal pressure.
1. Remove the control valve top cover and opera-tor’s cab undercover.
2. Disconnect PPC oil pressure switch or PPC
pressure sensors (1) – (10) of the solenoid valve
to be removed.
a If the starting switch is turned ON while the
arm IN or bucket CURL PPC pressure sen-
sor is disconnected, an electrical equipment
system error is detected. Accordingly, if the
pressure sensor is removed, reconnect it to
the connector and clamp it to the nearest
bracket.
3. Install joint Q2 and nipple [1] of hydraulic tester
Q1 and connect them to oil pressure gauge [2].a Use joint Q2 only when measuring the pres-
sure at the pressure sensor mounting part.
a Use the oil pressure gauges of 5.9 MPa {60
kg/cm2}.
a The figure shows the measuring instruments
installed to the mounting part of the arm IN
PPC pressure sensor.
Symbol Part No. Part Name
Q1
799-101-5002 Hydraulic tester
790-261-1203 Digital hydraulic tester
2 790-301-1740 Joint (PF 1/4 + PT 1/8)
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4. Run the engine and raise the engine oil temper-
ature to the operating range.
No.Circuit to be
measuredNo.
Circuit to be
measured
1 Boom RAISE (S06) 7 Swing LEFT (S07)
2 Boom LOWER (S02) 8 Swing RIGHT (S03)
3 Arm IN (S04) 9 Travel (S30)
4 Arm OUT (S08) 10 Steering (S31)
5 Bucket CURL (S01)
6 Bucket DUMP (S05)
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
5. Run the engine at high idling and measure theoil pressure while the control lever of the meas-
ured circuit is in neutral and while it is operated
to the stroke end.
a If the PPC valve output pressure is as fol-
lows, the solenoid valve is normal.
6. After finishing measurement, remove the meas-
uring instruments and return the removed parts.
Operation of lever Output pressure
In neutral 0 MPa {0 kg/cm2}
Operated to
stroke end
Almost same as control
basic pressure
(See standard values
table)
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TESTING AND ADJUSTING ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
ADJUSTING PLAY OF WORKEQUIPMENT AND SWING PPCVALVES
a If the work equipment and swing levers have
excessive play, adjust them according to the fol-
lowing procedure.
1. Remove the work equipment and swing PPC
valve assembly.
2. Remove bellows (1).
3. Loosen locknut (2) and tighten disc (3) until it
touches the heads of 4 pistons (4).
a Do not move the piston at this time.
4. Fix disc (3) and tighten locknut (2) to the speci-
fied torque.
3 Locknut: 98 – 127 Nm {10 – 13 kgm}
5. Install bellows (1).
6. Install the work equipment and swing PPC valve
assembly.
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TESTING AND ADJUSTING
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF
WORK EQUIPMENT
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF WORKEQUIPMENT
a If the work equipment (cylinder) drifts hydrauli-
cally, check to see if the cause is on the cylinder
packing side or control valve side according to
the following procedure.
1. Testing boom cylinder and bucket cylinder 1) Set the machine in the position of measur-
ing hydraulic drift and stop the engine.
a Fill the bucket with a rated load or with
dirt and sand.
2) When testing the boom cylinder, set the
boom control lever in the RAISE position.
When testing the bucket cylinder, set the
bucket control lever in the CURL position.
2. Testing arm cylinder
1) Stop the arm cylinder about 100 mm before
the IN stroke end and stop the engine.
2) Operate the arm control lever in the IN posi-
tion.
• If the lowering speed is increased at this
time, the cylinder packing is defective.
• If the lowering speed does not change at
this time, the control valve is defective.a Operate the control lever while the start-
ing switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumula-
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• If the lowering speed is increased at this
time, the cylinder packing is defective.
• If the lowering speed does not change at
this time, the control valve is defective.a Operate the control lever while the start-
ing switch is in the ON position.
a If the pressure in the accumulator is lost,
run the engine for about 10 seconds to
heighten the pressure in the accumula-
tor.
tor.
[Reference] Reason why the lowering speed is
increased by the above operationwhen the cylinder packing is the
cause of the hydraulic drift:
1) If the machine is set in the above position
(where the holding pressure is applied to the
bottom side), the oil leaks from the bottom
side to the head side. Since the volume on
the head side is less than that on the bottom
side by the volume of the rod the pressure
TESTING AND ADJUSTING
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT
OF WORK EQUIPMENT
3. Testing PPC valveWhile the pressure in the accumulator is high,
set the safety lock lever in the LOCK/FREE
position and measure the lowering distance.
a Operate the control lever while the starting
switch is in the ON position.
a If the pressure in the accumulator is lost, run
the engine for about 10 seconds to heighten
the pressure in the accumulator.
a If there is a difference in the lowering dis-tance between the LOCK position and FREE
position, the PPC valve is defective (it has an
internal defect).
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TESTING AND ADJUSTING RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
RELEASING RESIDUAL PRESSURE IN HYDRAULIC CIRCUIT
1. Releasing residual pressure in hydraulic tank
k Since the hydraulic tank is enclosed and
pressurized, release the residual pressure
in it when removing a hose or a plug con-
nected to it.
1) Lower the work equipment to the ground in
a stable position and stop the engine.2) Loosen oil filler cap (1) of the hydraulic tank
gradually to release the air in the tank.
2. Releasing residual pressure in hydraulic cyl-inder circuit
k When disconnecting a pipe between a hy-
draulic cylinder and the control valve, re-
lease the residual pressure in the piping
according to the following procedure
3. Releasing residual pressure in swing motor
circuit
a The residual pressure in the swing motor cir-
cuit can be released by performing the oper-
a t i on f o r RELEASING RESIDUAL
PRESSURE IN HYDRAULIC CYLINDER
CIRCUIT. (Operate the control lever in theswing direction only.)
4. Releasing residual pressure in travel motor
circuit
a Since the control valve spool of the travel mo-
tor circuit is open, the pressure in this circuit
can be released by performing RELEASING
RESIDUAL PRESSURE IN HYDRAULICTANK.
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according to the following procedure.
1) Release the residual pressure in the hydrau-
lic tank. For details, see RELEASING
RESIDUAL PRESSURE IN HYDRAULICTANK.
a Keep the oil filler cap of the hydraulic
tank removed.
2) Turn the starting switch ON and set the
safety lock lever in the FREE position, then
operate the work equipment control levers
on both sides forward, backward, to the
right, and to the left.
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE
a Measuring device for oil leakage
1. Measuring oil leakage from boom cylinder 1) Run the engine and raise the engine oil tem-
perature to the operating range.
2) Move the boom cylinder to the RAISE stroke
end and stop the engine.
k Release the residual pressure in the
piping on the boom cylinder head side.
For details, see RELEASING RESIDU-
AL PRESSURE IN HYDRAULIC CIR-CUIT. (Operate the control lever in the
boom RAISE direction only.)
3) Disconnect hose (1) on the cylinder head
side and block the hose side with a plate.
k Take care not to disconnect the hose on
the cylinder bottom side.
a Use the following part to block the hose
side.
07379-01044 (Flange #10)
2. Measuring oil leakage from arm cylinder
1) Run the engine and raise the engine oil tem-
perature to the operating range.
2) Move the arm cylinder to the IN stroke end
and stop the engine.
k Release the residual pressure in the
piping on the arm cylinder head side.For details, see RELEASING RESIDU-
AL PRESSURE IN HYDRAULIC CIR-
CUIT. (Operate the control lever in the
arm IN direction only.)
3) Disconnect hose (2) on the cylinder head
side and block the hose side with a plate.
k Take care not to disconnect the hose on
the cylinder bottom side.a Use the following part to block the hose
side.
07379-01044 (Flange #10)
Symbol Part No. Part Name
RCommercially
availableMeasuring cylinder
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4) Run the engine at high idling and relieve the
boom circuit by raising the boom.
4) Run the engine at high idling and relieve the
arm circuit by moving the arm IN.
k Take care not to “move the arm OUT”.
5) Measure the oil leakage for 1 minute after
30 seconds since relieving is started.
6) After finishing measurement, return the
removed parts.
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
3. Measuring oil leakage from bucket cylinder 1) Run the engine and raise the engine oil tem-
perature to the operating range.
2) Move the bucket cylinder to the CURL
stroke end and stop the engine.
k Release the residual pressure in the
piping on the bucket cylinder head side.
For details, see RELEASING RESIDU-
AL PRESSURE IN HYDRAULIC CIR-CUIT. (Operate the control lever in the
arm CURL direction only.)
3) Disconnect hose (3) on the cylinder head
side and block the hose side with a plate.
k Take care not to disconnect the hose on
the cylinder bottom side.
a Use the following part to block the hose
side.
07379-01044 (Flange #10)
4. Measuring oil leakage from swing motor 1) Run the engine and raise the engine oil tem-
perature to the operating range.
2) Disconnect drain hose (4) and block the
hose side with a plug.
a Use the following part to block the hose
side.
07376-70522 (Plug #05)
3) Turn the swing lock switch ON.
4) Run the engine at high idling and relieve the
swing circuit by swinging.
a Measure the oil leakage for 1 minute af-
ter 30 seconds since relieving is started.a After measuring 1 time, swing 180°, and
then measure again.
5) After finishing measurement, return the
removed parts.
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4) Run the engine at high idling and relieve the
bucket circuit by curling the bucket.
k Take care not to “dump the bucket”.
5) Measure the oil leakage for 1 minute after
30 seconds since relieving is started.
6) After finishing measurement, return the
removed parts.
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
5. Measuring oil leakage from travel motor 1) Remove the travel motor cover.
2) Run the engine and raise the engine oil tem-
perature to the operating range, and then
lock the travel system and stop the engine.
k Put pin [1] between the sprocket and
track frame to lock the travel system se-
curely.
3) Disconnect drain hose (5) of the travel
motor and block the hose side with a plug.
a Use the following part to block the hose
side.07376-70522 (Plug #05)
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4) Run the engine at high idling and relieve the
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
BLEEDING AIR FROM EACH PART
Air bleeding procedure
1 2 3 4 5 6
Bleeding
air from
hydraulic
pump
Starting
engine
Bleeding
air from
cylinder
Bleeding
air from
swing
motor
Bleeding
air from
travel
motor
Check oil
level and
starting
work
• Replacing hydraulic oil
• Cleaning strainer q q q
q
(See note)
q
(See note) q
• Replacing return filter element q q
• Replacing and repairing hydrau-
lic pump
• Removing suction piping
q q q q
• Replacing and repairing control
valve
• Removing control valve piping
q q q
• Replacing and repairing cylinder
• Removing cylinder piping q q q
• Replacing and repairing swing
motor
• Removing swing motor piping
q q q
• Replacing and repairing travel
motor • Removing travel motor piping
q q q
• Replacing and repairing swivel
joint
• Removing swivel joint piping
q q
Work
Air bleeding item
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Note: Bleed air from the swing motor and travel motor only when the oil in the motor cases is drained.
1. Bleeding air from hydraulic pump
1) Loosen bleeder (1) and check that oil flowsout.
2) If the oil does not flow out, disconnect drain
hose (2) and fill the pump case with oil
through the drain port.
a Fix the drain hose adapter to a place
higher than the oil level in the hydraulic
tank.
a Fill the pump case with oil until oil con
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
3. Bleeding air from cylinder a If a cylinder was replaced, bleed air from it
before connecting the work equipment. In
particular, the boom cylinder does not move
to the lowering stroke end, if it is installed to
the work equipment.
1) Run the engine at low idling for about 5 min-
utes.
2) Running the engine at low idling, raise and
lower the boom 4 – 5 times.a Stop the piston rod about 100 mm before
each stroke end. Do not relieve the oil.
3) Running the engine at high idling, perform
step 2).
4) Running the engine at low idling, move the
piston rod to the stroke end and relieve the
oil.
5) Bleed air from the arm cylinder and bucket
cylinder according to steps 2) – 4).
4. Bleeding air from swing motor
1) Run the engine at low idling.
2) Loosen hose (3) of port S slowly and check
that oil flows out.
k At this t ime, do not perform the swing-
ing operation.
3) If the oil does not flow out, stop the engineand disconnect the hose of port S and fill the
pump case with oil.
a After filling the pump case with oil, con-
nect the hose of port S, and then repeat
steps 1) and 2).
5. Bleeding air from travel motor 1) Remove the travel motor cover.
2) Run the engine at low idling.
3) Loosen bleeder (4) and check that oil flows
out.
4) After oil containing no bubbles flows out,
tighten bleeder (4).
3 Bleeder:
9.8 – 12.74 Nm {1.0 – 1.3 kgm}
5) Using the work equipment, raise the track
shoe on either side.
6) Drive the raised track shoe idle slowly for
about 2 minutes.a Drive the track shoe on the opposite side
idle similarly.
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4) After oil containing no bubbles flows out,
tighten the hose of port S.
5) Slowly swing 2 turns or more in each direc-
tion.
TESTING AND ADJUSTING BLEEDING AIR FROM EACH PART
6. Check oil level and starting work1) Run the engine, retract the arm cylinder and
bucket cylinder to the stroke ends, lower the
work equipment to the ground, and stop the
engine.
2) Check the oil level by sight gauge (5) of the
hydraulic tank.
a If the oil level is between lines H and L,
it is normal.
a If the oil level is below line L, add new oil.
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TESTING AND ADJUSTING TESTING PROCEDURE OF DIODE
TESTING PROCEDURE OF DIODEa Test an assembled-type diode or a diode unit
according to the following procedure.
a The conductive direction of an assembled-type
diode is marked as shown in the figure.
a The conductive direction of each diode is
marked on its surface.
2. When using an analog tester
1) Set the tester in the resistance range.2) Apply the test pins as shown and check
movement of the pointer.
i) Apply the red (+) test pin to the anode
(P) side of the diode and the black (–)
test pin to the cathode (N) side.
ii) Apply the red (+) test pin to the cathode
(N) side of the diode and the black (–)
test pin to the anode (P) side.
3) Judge the condition of the diode from move-ment of the pointer.
• The pointer does not move in step i)
above but moves in step ii): Normal
(Moving angle (resistance) depends on
the type and measurement range of the
tester)
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1. When using a digital tester
1) Set the tester in the diode range and check
the indicated value.
a If an ordinary tester is used, the voltage
of the battery in itself is indicated.
2) Apply the red (+) test pin to the anode (P)
side of the diode and the black (–) test pin to
the cathode (N) side and read the indicated
tester)
• The pointer moves in both step i) and
step ii): Defective (Internal short circuit)
• The pointer does not move in either step
i) or step ii): Defective (Internal discon-
nection)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
SPECIAL FUNCTIONS OF MONITOR PANEL
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
Ordinary functions and special functions of monitor panelThe monitor panel has the ordinary functions and special functions and displays various pieces of information
on the multi-display unit.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu
The items in this menu are displayed normally. The operator can display and set them by operating
switches.
2. Special functions: Service menu
The items in this menu are not displayed normally. Each serviceman can display them by operating specialswitches.
Operator’s Menu Service Menu
1 Function of inputting and setting password 16 Function of monitoring [01]
2 Screen to display KOMATSU logo
17
Function of
abnormality
record [02]
Electrical system
3 Function of check before starting Mechanical system
4 Function of displaying maintenance items 18 Function of maintenance record [03]
5 Function of displaying caution items 19 Function of maintenance mode change [04]
6Function of checking working mode and
travel speed20 Function of phone No. entry [05]
7 Function of displaying ordinary screen
21Function ofinitial setting
and default [06]
Mode in which key is ON
8Function of adjusting brightness and contrast
of display
Language
9Function of adjusting flow rate for breaker
and attachmentsUnit
10Function of checking maintenance informa-
tionWith/Without service circuit
11 Function of displaying service meter Pump absorption torque
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22Function of
adjustment [07]12 Function of checking display LCD
Adjustment of flow for
attachment during com-
pound operation
13 Function of displaying cautions 23Function of cylinder cut out mode operation
[09]
14 Function of displaying user code
15Function of displaying error code and failure
code
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
Operation and display of Operator’sMenu (Outline)a Only outline of the operating method is
described in this section. For details of contents
and operation of each menu, see OPERATION
MANUAL or the volume of STRUCTURE AND
FUNCTION.
1. Function of inputting and setting password
When the starting switch is turned ON, the
screen to input a password is displayed.
a This screen is displayed only when the pass-
word function is set.
2. Screen to display KOMATSU logo
When a password is input (if it is set) or when
the starting switch is turned ON, the KOMATSU
logo is displayed for 2 seconds.
3. Function of check before starting
Aft er the KOMATSU logo is di sp layed, the
screen for check before starting is displayed for
2 seconds.
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4 F ti f di l i i t it
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
5. Function of displaying caution items After the screen for check before starting is dis-
played, if any check item is abnormal, the corre-
sponding symbol mark is displayed.
6. Function of checking working mode and trav-
el speed
After the screen for check before starting is dis-
played, the symbol marks of the working modeand travel speed are displayed in large size for 2
seconds to urge the operator to check the set-
ting.
7. Function of displaying ordinary screen
After the screen for checking the working mode
and travel speed is displayed, the ordinary
screen is displayed.
a When the ordinary screen is displayed if the
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a When the ordinary screen is displayed, if the
working mode or travel speed is changed or
if the auto deceleration or windshield wiper isset effective, the corresponding symbol mark
is displayed in large size for 2 seconds.
a The preheating monitor is displayed only
when the preheater is turned ON.
8. Function of adjusting brightness and con-
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
9. Function of adjusting flow rate for breaker and attachments
(for machine with breaker or attachment)
The operator can adjust the pump flow rate for
the breaker or an attachment with the selector
switch.
a The symbol marks and description of the
breaker and attachment shown on the
screen are partly different.
10. Function of checking maintenance informa-
tion
The operator can check the detailed information
about the maintenance items (set time andelapsed time) and reset them after checking
with the maintenance switches.
a The maintenance function is set and reset
and the maintenance time is set with the
service menu.
11. Function of displaying service meter
When the starting switch is turned OFF, the
operator can display only the service meter by
operating the following switches.
• Operation of switches: [ ] + [ ] (Operate
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p [ ] [ ] ( p
these switches simultaneously)
12 Function of checking display LCD
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
13. Function of displaying cautionsIf there is any abnormal item in the calculation
items, the corresponding symbol mark is dis-
played in large size for 2 seconds, then it is dis-
played in small size until the abnormal item is
repaired.
14. Function of displaying user code
If the machine has any failure, the correspond-
ing user code is displayed to urge the operator
to take a proper remedy, depending on the
degree of the failure.a If any switch is operated while the user code
is displayed, the service code and failure
code screen appears (See 15).
a User codes and instructions given to operator
User
codeFailure mode Instructions given to operator
E02 Error in pump control system
If the emergency pump drive switch is set in the upper (emergency) position,
the machine can operate normally Have the machine inspected immediately
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E02 Error in pump control system the machine can operate normally. Have the machine inspected immediately,
however.
E03 Error in swing brake system
Set the swing holding brake release switch in the upper (release) position torelease the brake. Apply the swing brake manually with the swing lock
switch, if necessary. The brake may not be released, depending on the
cause of the failure. In any case, have the machine inspected immediately.
E10
Error in engine controller power
supply or abnormality in engine
controller drive system circuit
(Engine stops)
Have the machine inspected immediately.
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
15. Function of displaying error code and failurecode
While a user code is displayed, if the following
switches are operated, the phone mark (if regis-
tered), phone No. (if registered), error code, and
failure code are displayed in order.
• Operation of switch: [ ]
a The following are displayed in order repeat-
edly as the switch is operated.
(1) Phone mark
(2) Phone No.
(3) Error code and failure code
a The phone mark and phone No. are dis-
played only when the phone No. is regis-
tered in the monitor panel. The phone No. is
registered, changed, or deleted with theservice menu.
a For details of the displayed error code and
failure code, see the error codes and failure
codes table.
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
Table for Error and Failure Code Nos.
U s e r
c o d e Error code Failure code
H i s t o r y
d i v i s i o n
Code Contents Code Component Trouble
— E112 Wiper Drive (For) S/C DY2DKB Wiper motor (Forward) Short Circuit
E l e c t r i c a l s y s t e m
— E113 Wiper Drive (Rev) S/C DYDEKB Wiper Motor (Reverse) Short Circuit
— E114 Washer Drive S/C DY2CKBWindshield Washer
Motor Short Circuit
— E115 Wiper Working Abnormality DY20KA Wiper Motor Disconnection
— E116 Wiper Parking Abnormality DY20MA Wiper Motor Malfunction
— E117 Eng. Controller S-NET Comm Err. DAC0KR Engine Controller
Defective communica-
tion (Abnormality in
related component)
— E118 Pump Controller S-NET Comm Err. DAB0KR Pump Controller
Defective communica-
tion (Abnormality in
related component)
E0E E128 Monitor Comm. Abnormality DAFRMC Monitor CAN Communi-cation
Defective Operation
— E201 Travel Junction Sol. S/C DW91KBTravel Neutral Solenoid
ValveShort Circuit
E03 E203 Swing Brake Sol. S/C DW45KBSwing Holding Brake
Solenoid ValveShort Circuit
— E204 Merge-divider Sol. S/C DWJ0KBPump Merge-divider
Solenoid ValveShort Circuit
— E205 2-stage Relief Sol. S/C DWK0KB2-stage Relief Solenoid
Valve Short Circuit
— E206 Travel Speed Sol. S/C DW43KBTravel Speed Hi/Lo
Selector Solenoid ValveShort Circuit
— E211 Travel Junction Sol. Disc. DW91KATravel Neutral Solenoid
ValveDisconnection
E03 E213 Swing Brake Sol. Disc. DW45KASwing Holding Brake
Solenoid ValveDisconnection
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ESolenoid Valve
— E214 Merge-divider Sol. Disc. DWJ0KA
Pump Merge-divider
Solenoid Valve Disconnection
— E215 2-stage Relief Sol. Disc. DWK0KA2-stage Relief Solenoid
ValveDisconnection
— E216 Travel Speed Sol. Disc. DW43KATravel Speed Hi/Lo
Selector Solenoid ValveDisconnection
— E217 Model Selection Abnormality DA2SKQ
Pump Controller Model
Selection Wiring Har-
ness
Disagreement of Model
Selection Signals
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
E02 E233 PC-EPC Sol. Disc. DXA0KA TVC Solenoid Valve Disconnection
l e c t r i c a l s y s t e m
— E238 Service Return Relay Disc. D196KA ATT Selector Relay Disconnection
— E245 Service Current EPC S/C DXE4KB ATT Flow Throttle EPC
ValveShort Circuit
— E246 Service Current EPC Disc. DXE4KA ATT Flow Throttle EPC
ValveDisconnection
— E247 Arm Curl PPC Sen. Abnormality DHS3MA Arm IN PPC Pressure
Sensor Malfunction
— E248 Bucket Curl PPC Sen. Abnormality DHS4MABucket CURL PPC
Pressure Sensor Malfunction
— E251 Overload Sensor Abnormality DHX1MA Malfunction
E0E E257 Pump Comm. Abnormality DA2RMCPump Controller CAN
CommunicationDefective Operation
— E315 Battery Relay Drive S/C D110KB Battery Relay Short Circuit
E11 E91B Engine Ne Sensor Problem DLE3LC NE Speed Sensor Disagreement of Speed
Signal
E11 E91C Engine G Sensor Problem DLH1LC G Speed Sensor Disagreement of Speed
Signal
E11 E920 Engine Type Selection Error DB29KQ
Engine Controller Model
Selection Wiring Har-
ness
Disagreement of Model
Selection Signals
E11 E921 Engine Type Mismatch DB20KQ Engine Controller Disagreement of Model
Selection SignalsE14 E931 Fuel Dial sys. error DK10KX Throttle Angle Sensor Out of input signal range
E15 E934 Engine Coolant Sensor Hi Error DGE2KXEngine Coolant Temper-
ature Sensor Out of input signal range
E15 E936 Engine Oil Press. Sw. Error DDE2L6Engine Oil Pressure
Switch
Disagreement of signal
with operation of engine
E11 E93C Engine Boost Sensor Error DH30KX Boost Pressure Sensor Out of input signal range
U s e r
c o d e Error code Failure code
H i s t o r y
d i v i s i o n
Code Contents Code Component Trouble
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E
E15 E93D Engine Fuel Temp. Sensor Error DGE4KXFuel Temperature Sen-
sor
Out of input signal range
E0E E953 Engine Comm. Abnormality DB2RMCEngine Controller CAN
CommunicationDefective Operation
— E954 Short Engine Starter SW. DD11KB Starter SW Short Circuit
E0E E955 Engine S-NET error DB2SMCEngine Controller S-
NET CommunicationDefective Operation
E10 E956 Engine Power Failure (1) DB22KKEngine Controller Load
Power Supply Line
Lowering of source volt-
age (Input)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
a Th it i thi t bl d i th d f th d
E11 E979 Rail Press. High 1 AD00L2 Common Rail Abnormally High Fuel
Pressure
E l e c t r i c a l s y s t e m
E11 E97A Rail Press. High 2 AD00MA Common Rail Malfunction
E15 E97B Rail press. low AD10L3 Supply Pump Out of control
E11 E97C Rail press. too low AD10MB Supply Pump Lowering of Function
E11 E97D Rail Press. Out of Control AD10MA Supply Pump MalfunctionE11 E980 Eng. Controller Abnormality DB20KT Engine Controller Abnormality in Controller
E11 E981 Fuel Injector 1 Disc. ADA1KA Injector 1 Solenoid Valve Disconnection
E11 E982 Fuel Injector 2 Disc. ADB1KA Injector 2 Solenoid Valve Disconnection
E11 E983 Fuel Injector 3 Disc. ADC1KA Injector 3 Solenoid Valve Disconnection
E11 E984 Fuel Injector 4 Disc. ADD1KA Injector 4 Solenoid Valve Disconnection
E11 E985 Fuel Injector 5 Disc. ADE1KA Injector 5 Solenoid Valve Disconnection
E11 E986 Fuel Injector 6 Disc. ADF1KA Injector 6 Solenoid Valve Disconnection
E11 E98A Fuel Injector 1 – 3 S/C ADAZKBInjector 1, 2, 3 Solenoid
ValveShort Circuit
E11 E98B Fuel Injector 4 – 6 S/C ADDZKBInjector 4, 5, 6 Solenoid
ValveShort Circuit
E22 E922 Eng. Hi Out of Std A000N1 Engine Overrun
M e c h a n i c a l
s y s t e m
— Eng. Lo Out of Std A000N2 Engine Out of input signal range
— Aircleaner Clogging AA10NX Air Cleaner Element Clogging
— Charge Voltage Low AB00KE Alternator Defective Charge
— Eng. Oil Press. Low B@BAZG Engine Oil Lowering of Oil Pressure
— Eng. Oil LvI. Low B@BAZK Engine Oil Lowering of level
— Eng. Coolant Overheat B@BCNS Coolant Overheating
— Eng. Coolant Lvl Low B@BCZK Coolant Lowering of level
— Hydr. Oil Overheat B@HANS Hydraulic Oil Overheating
U s e r
c o d e Error code Failure code
H i s t o r y
d i v i s i o n
Code Contents Code Component Trouble
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a The items in this table are arranged in the order of the error codes.
aThe error codes having no numbers in the user code column and the failure codes having no numbers inthe user code column and error code column are not displayed on the normal screen, even if abnormality
related to them occurs. They are simply recorded in the failure history of the service menu (Electrical equip-
ment system or mechanical equipment system).
a The history division column shows in which division each failure is classified, the electrical equipment sys-
tem or mechanical equipment system, when it is recorded in the failure history.
a Letter “E” at the head of each error code indicates the following condition.
• With E: The failure has not been repaired yet.
• Without E: The failure has been repaired
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
Operation and display of Service MenuHow to select service menu
a When using the service menu, perform the fol-
lowing special operation to change the screen.
1) Checking display
Check that the ordinary screen is displayed.
a The service menu can be selected only while
the ordinary screen is displayed.
2) Operating switches
Operate the following switches.
• Operation of switches: [ ] o [1] o [2] o [3]
(While pressing [ ], press the numeralkeys)
3) Displaying menu screen
The initial screen of the service menu is dis-
played. Select a menu which you will use.
No. Service menu
00 Return (Finish service menu)
01 Monitoring
02 Abnormality record
03 Maintenance record
04 Maintenance mode change
05 Phone number entry
06 Initial setting/Default
07 Adjust
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4) Finishing menu and function
To finish the service menu screen or each menu
screen, perform one of the following operations.
(1) Press the [ ] switch (This operation is
effective on all screens).
(2) When the “Return” switch is displayed, press
it
j
09 Cylinder cut out mode operation
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
16. Function of monitoring [01]
The monitor panel monitors the signals from various
switches, sensors, and actuators installed to various
parts of the machine. The operator can display and
check the monitoring information in real time by the
following operation.
1) Selecting menu
On the initial screen of the service menu, select
“01 Monitoring” and press the [ ] switch.
2) Setting monitoring items
Select and register monitoring items with the fol-
lowing switches.
• [ ] switch: Select• [ ] switch: Select
• [ ] switch: Register
a You can set up to 4 monitoring items (You
cannot set up to 4 monitoring items, howev-
er, depending on the selected items).
a When monitoring up to 3 items, go to the
monitoring information screen by either of
the following operations after registering
those items.• Hold the [ ] switch (for about 3 sec-
onds).
• Select menu “99999” and press the [ ]
switch.
a If all of the settable items are registered, the
monitoring information screen appears auto-
matically after registering those items.
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y g g
a For the detail, display units, etc. of the moni-
toring items, see the monitoring items table.
3) Operating for monitoring
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
4) Function of holding monitoring information
If the [ ] switch is pressed during the monitor-
ing operation, all the monitoring information is
held. If the [ ] switch is pressed while the mon-
itoring information is held, the monitoring infor-
mation is released.
5) Function of selecting machine setting mode
To change settings of the working mode, travel
speed, or auto deceleration during the monitor-
ing operation, press the switches for thoseitems, and the mode checking screen appears.
a After checking the settings, press the [ ]
switch, and the monitoring screen appears
again.
a If the settings are changed during the moni-
toring operation, the new settings are held
even after monitoring is finished and the
service menu disappears and the operator
menu appears again.
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
Monitoring items list
Code
No.Monitoring item
Unit (Default: ISO)Remarks
SI meter inch
00000 Return (Not displayed) Finish Menu
99999 To Display Screen (Not displayed) Display and Execution Menu
00200 Controller Model Select Numerals
00201 Controller Model Select Numerals
01002 Engine Speed r/min rpm rpm
01601 2nd Eng. Speed Command r/min rpm rpm
01100 F Pump Pressure MPa kg/cm2 psi
01101 R Pump Pressure MPa kg/cm2 psi
07200 Arm Curl PPC Pressure MPa kg/cm2 psi
07300 Bucket Curl PPC Pressure MPa kg/cm2 psi
04102 Engine Coolant Temp. Hi °C °C °F
14200 Fuel Temperature °C °C °F
04401 Hydr. Oil Temperature °C °C °F
01300 PC-EPC Sol. Curr. mA mA mA
01500 LS-EPC Sol. Curr. mA mA mA
01700 Service Sol. Curr. mA mA mA
03200 Battery Voltage V V V
03500 Battery Relay O/P Vol. V V V
04300 Battery Charge Vol. V V V
01006 Engine Speed r/min rpm rpm
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01006 Engine Speed r/min rpm rpm
04107 Engine Coolant Temp. Low °C °C °F
36400 Rail Pressure MPa kg/cm2 psi
36500 Boost Pressure kPa kg/cm2 psi
36700 Torque Ratio % % %
03000 Fuel Dial Vol. V V V
04200 Fuel Level Sensor Vol. V V V
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
01900 Pressure Switch 1
Swing ON/OFF
Travel ON/OFF
Boom Lower ON/OFF
Boom Raise ON/OFF
Arm Curl ON/OFF Arm Dump ON/OFF
01901 Pressure Switch 2
Bucket Curl ON/OFF
Bucket Dump ON/OFF
Service ON/OFF
Travel Steering ON/OFF
02300 Solenoid 1
Travel Junction ON/OFF
Swing Brake ON/OFF
Merge-divider ON/OFF
2-stage Relief ON/OFF
Travel Speed ON/OFF
02301 Solenoid 2 Service Return ON/OFF
02200 Switch Input 1
Lever Sw. ON/OFF
Swing Release Sw. ON/OFF
Swing Brake Sw. ON/OFF
02201 Switch Input 2
Model Select 1 ON/OFF
Model Select 2 ON/OFF
Model Select 3 ON/OFF
Model Select 4 ON/OFF
CodeNo.
Monitoring item Unit (Default: ISO) RemarksSI meter inch
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Model Select 4 ON/OFF
Model Select 5 ON/OFF
02202 Switch Input 3 Key Switch (ACC) ON/OFF
03700 Controller Output 1 Batt. Relay Dr. ON/OFF
04500 Monitor Input 1
Key Switch ON/OFF
Start ON/OFF
Preheat ON/OFF
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
a As the unit of display, one of “SI unit system”, “Metric unit system”, and “Inch unit system” can be selected.
The unit of display can be changed with “Selecting unit” in the “Setting initial values” function of the service
menu.
a “CA” of the unit of display denotes the crankshaft angle.
17400Eng. Controller
Input
Key SW (C) ON/OFF
Eng. Oil Press. Lo ON/OFF
Eng. Oil Press. Hi ON/OFF
Machine Sel. 1 ON/OFF
Machine Sel. 2 ON/OFFMachine Sel. 3 ON/OFF
36800 Q Adjust Switch R (ROT-SW1) Alphanumerals
36801 Q Adjust Switch L (ROT-SW2) Alphanumerals
05100 S-NET ConnectionPump Controller ON/OFF
Eng. Controller ON/OFF
20200 Monitor Prog. Version Numerals
20212 Pump Con. Prog. Version Numerals
20209 Eng. Con. Prog. Version Numerals
CodeNo.
Monitoring item Unit (Default: ISO) RemarksSI meter inch
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
17. Function of abnormality record [02]
The monitor panel classifies and records the
past failures into the electrical system group and
mechanical system group. The operator can
display and check those failures by the following
operation.
1) Selecting menu
On the initial screen of the service menu,
select “02 Abnormality Record” and pressthe [ ] switch.
2) Selecting sub-menu
On the abnormality record menu screen,
select a sub-menu and press the [ }
switch.
3) Contents of electrical system abnormality
record screen
[1]: Reverse sequential order/Total number
of records
[2]: Error code
[3]: Failure code (Component: 4 characters,
Trouble: 2 characters)
No. Sub-menu of abnormality record
00 Return (Finish sub-menu)
01 Electrical systems
02 Mechanical systems
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Trouble: 2 characters)
[4]: Advance of service meter after 1stoccurrence
[5]: Contents of failure
a See “Error codes and failure codes ta-
ble” in the operator menu.
4) Contents of mechanical system abnormality
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
5) Resetting electrical system abnormality recorda Only the abnormality record of the elec-
trical system can be reset (deleted). The
abnormality record of the mechanical
system cannot be reset.
a If necessary, reset each item or all items
of the abnormality record of the electrical
system according to the following proce-
dure.
i) While the electrical system abnormality
record screen is displayed, operate the
following switches to display the reset
screen.
• Operation of switches: [ ] + [1]
[2] [3]
a This operation is the same as that
for selecting the service menu.
ii) Operate the switches according to thedirection shown on the reset screen.
a When resetting only 1 item, be sure
display it with the [ ] switch or [ ]
switch, and then perform the reset
procedure.
a When resetting all the items, you
can perform the reset procedure, re-
gardless of the item displayed on the
screen.
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
18. Function of maintenance record [03]
The monitor panel records the maintenance
information about the filters and oils. The opera-
tor can display and check that information by the
following operation.
1) Selecting menu
On the initial screen of the service menu,
select “03 Maintenance Record” and press
the [ ] switch.
2) Displayed information
(1) Names of oils and filters
(2) Number of replacement times up to now
(3) Service meter reading at previousreplacement
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
19. Function of maintenance mode change [04]
The condition for setting the operation of the
maintenance display function can be changed
according to the following procedure.
• Set the function effective or ineffective.
• Change the set replacement interval.
1) Selecting menu
On the initial screen of the service menu,
select “04 Maintenance Mode Change” andpress the [ ] switch.
2) Selecting item to be changed
On the screen of maintenance mode chang-
ing menu, select an item to be changed.
No. Item of maintenance mode change
00 Return
01 Use/Disuse maintenance mode
02 Replacement interval of engine oil
03 Replacement interval of engine oil filter
04 Replacement interval of fuel filter
05 Replacement interval of hydraulic oil filter
06 Replacement interval of hydraulic tankbreather
07Replacement interval of corrosion resistor
(if equipped)
08 Check and refill interval of damper case oil
09 Replacement interval of final drive case oil
10 Replacement interval of machinery case oil
11 Replacement interval of hydraulic oil
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a Menus “01” and “12” are used to set the
whole maintenance mode and menus
“02” – “11” are used to set the items one
by one.
3) Contents of setting of “maintenance mode
O /Off”
12 Return all items to initial values
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
4) Contents of setting of each item
(1) Default: Maintenance time set in monitor.(Value recommended by manufacturer.Constant value.)
(2) Set value: Maintenance time which oper-ation can set freely. Monitor panel oper-a tes acco rd ing t o t h i s va lue i nmaintenance mode. (This value can be
changed by 50 hours with [ ] and [ ]
switches.)(3) Off: Function of displaying this mainte-
nance item becomes ineffective.(4) On: Function of displaying this mainte-
nance item becomes effective.
a The lower limit of the set time is 50 h.
5) Contents of setting “Return all items to initial
values”
If this menu is selected and the [ ] switchis pressed, all the information items are
changed to the initial values.
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
20. Function of phone number entry [05]
The operator can input a phone No. and change
it according to the following procedure. Once
the phone No. is input, it and service code are
displayed alternately when the user code is dis-
played.
a If a phone No. is not input, the phone No.
screen is not displayed.
1) Selecting menuOn the initial screen of the service menu,
select “05 Phone Number Entry” and press
the [ ] switch.
2) Selecting input screen
Select “Entry” to display the phone No. input
screen.
a Even if a phone No. has been registered,
if the phone No. input screen is dis-played, the registered phone No. is
cleared.
3) Inputting and setting phone No.
On the phone No. input screen, input a
phone No. according to the following proce-
dure (The phone No. is input from the cursor
at the left end automatically).
i) Input a No. with the numeral keys from
the cursor at the left end.
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ii) After finishing inputting the No., press the
[ ] switch.
a Up to 12 digits can be input. You do not
need to input a digit to an unnecessary
place, however.
a If you input a wrong No., press the [B]
switch, and the cursor returns 1 place by
1
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
21. Function of initial setting and default [06]
The operator can change the following items
related to the monitor panel and machine, if nec-
essary.
• Working mode when starting switch is turned
ON
• Language displayed on service menu
• Unit displayed in monitoring function mode
• With/Without attachment
1) Selecting menu
On the initial screen of the service menu,
select “06 Function of initial setting and
default” and press the [ ] switch.
2) Selecting sub-menu
Select a sub-menu to change its setting and
press the [ ] switch.
3) Function of selecting mode when key is ON
When the starting switch is turned ON, a
working mode is displayed on the monitor
panel. The operator can change this work-
ing mode.
• A-mode, E-mode, L-mode, B-mode: If
any of these modes are set, the machine
is started in the selected mode when the
No. Sub-menu of initial value/default
00 Return (Finish initial value/default)
01 Key-on mode
02 Language
03 Unit
04 With/Without service circuit
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is started in the selected mode when the
starting switch is turned ON.
• Mode when key was turned off last: If
this mode is set, the machine is started
in the mode used last when the starting
switch is turned ON.
• Initial value: If this mode is set, the ma-
chine is started in the default mode set in
the factory when the starting switch is
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
4) Function of setting language
The operator can select Japanese or English as the language displayed on the
service menu.
a The default language of the monitor pan-
el is English.
a When using a spare monitor panel in the
Japanese language area, select Japa-
nese with this function.
5) Function of selecting unit
The operator can select 1 of the 3 unit sys-
tems as the unit system used for the data
displayed by the monitoring function of the
service menu.
a The default unit system of the monitor
panel is the SI unit system.
6) Function of selecting “with/without service
circuit”
The operator can set “with/without service
circuit”.
• With service circuit: When attachment is
installed
• Without service circuit: When attach-
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ment is not installed.a When an service circuit is installed, if
“With service circuit” is not set on this
screen, the operator cannot use the se-
lect function (adjustment of oil flow for
the attachment) in the operator mode.
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
22. Function of adjustment [07]
The operator can adjust various items of themachine on the monitor panel.
1) Selecting menu
On the initial screen of the service menu,
select “07 Adjustment” and press the [ ]
switch.
2) Selecting sub-menuSelect a sub-menu to change its setting and
press the [ ] switch.
3) Function of pump absorption torque
The operator can adjust the pump absorp-
tion torque within the ranges shown in the
following table.
No. Sub-menu of adjustment
00 Return (Finish adjustment)
01 Pump absorption torque
02 Adjustment of oil flow for attachment in
compound operation
Adjustment
value
Adjustment
torque
Adjustment
value
Adjustment
torque
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4) Function of adjustment of oil flow for attach-
220 +8.0 kgm 225 –2.0 kgm221 +6.0 kgm 226 –4.0 kgm
222 +4.0 kgm 227 –6.0 kgm
223 +2.0 kgm 228 –8.0 kgm
224 0.0 kgm
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
23. Function of cylinder cut out mode operation
[09]The operator can operate the machine in the
cylinder cut out mode with the monitor panel.
Cylinder cut out mode operation means to run
the engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective cyl-
inders. This operation is used to find out a cylin-
der which does not output power normally (or,
combustion in it is abnormal).
1) Selecting menu
On the initial screen of the service menu,
select “09 Cylinder cut out mode operation”
and press the [ ] switch.
2) Setting cylinders to be disabled
Press switches [1] – [6] on the monitor panel
corresponding to the cylinder Nos. to be dis-abled.
a After a switch is pressed, if the cylinder
No. corresponding to it on the monitor
panel is displayed white in a white frame,
the cylinder is disabled (If setting is
wrong, press the same switch again).
a Only one or more cylinders can be disa-
bled for the reduced cylinder mode oper-
ation.
3) Cancellation of disabled cylinders
Press switches [1] – [6] on the monitor panel
corresponding to the disabled cylinder Nos.
to cancel disabling of those cylinders.
a After a switch is pressed, if the cylinder
No. corresponding to it on the monitor
panel is displayed black in a black frame,
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disabling of the cylinder is cancelled.
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF MONITOR PANEL
4) Function of holding engine speed
I f the [ ] swi tch is p ressed wh ile the
reduced cylinder mode operation screen is
used, the engine speed is held and dis-
played on the lower line.
If the [ ] switch is pressed while the engine
speed is held, holding of the engine speed is
cancelled and the engine speed displayed
on the lower line goes off.
a If the holding function is used, the heldengine speed is displayed in ( ) on the
lower line and the current engine speed
is displayed on the upper line.
a The holding function can be used both in
and out of the cylinder cut out mode.
[Reference]: How to use holding function effec-
tively
The engine speed displayed by the holding
function is held on the screen until the holding
function is cancelled, regardless of setting and
cancellation of the cylinder cut out mode.
Accordingly, a defective cylinder can be found
out effectively according to the following proce-dure.
(1) Run the engine normally (without disabling
any cylinder) and hold the engine speed.
(2) Disable a cylinder to be checked.
(3) Run the engine under the same condition as
the normal operation in step (1) and com-
pare the engine speed at this time with the
held engine speed.
(4) Cancel the c linder c t o t mode regard
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(4) Cancel the cylinder cut out mode, regard-less of the change of the engine speed.
(5) Repeat steps (2) – (4) to check the other
cylinders.
a If the engine speed does not lower at all or
lowers less when a cylinder is selected for
the cylinder cut out mode operation, com-
bustion in that cylinder must be abnormal
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Ordinary functions and special functions of monitor panel
The monitor panel has the ordinary functions and special functions and displays various pieces of informationon display section (1) and service meter section (2).
Some items are displayed automatically according to the internal setting of the monitor panel and the others are
displayed by operating switches.
1. Ordinary functions: Operator menu
The items in this menu are displayed normally or displayed automatically when a trouble occurs.
2. Special functions: Service menu
The items in this menu are not displayed normally. Each serviceman can display them by operating special
switches. These functions are used for special setting, testing, adjusting, or troubleshooting.
Flow of each function
a Each number in [ ] is a code No. displayed in the service meter section when the menu is selected.
Ordinary functions (Operator menu) Special functions (Service menu)
1 Function of displaying service meter
< O p e r a t i o n o f s w i t
c h > O 3 Function of displaying service code [01]
O <Automatic> 4 Monitoring function [02]
2 Function of displaying user code 5 Function of selecting maintenance period [04]
6 Function of selecting default working mode [05]
7 Function of setting installation of attachment [16]
8Special function of monitoring replacement
of engine oil
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Display of operator menu
a Only outline of the operator menu is described in
this section. For details of each menu, see OP-
ERATION MANUAL or the volume of STRUC-
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
2. Function of displaying user code
If the machine has any trouble, the correspond-ing user code is displayed automatically in dis-
play section (1) and the caution buzzer is turned
ON to urge the operator to take a proper rem-
edy, depending on the degree of the trouble.
a Service meter section (2) continues display-
ing the service meter.
a For displayed user codes and the remedies
shown to the operator, see "User codes and
remedies shown to operator".
a Each user code simply shows occurrence of
a trouble to the operator. To find out the
cause of the trouble, a serviceman must
check the service code with the "Function of
displaying service code [01]" in the service
menu.
<Reference> A user code is displayed only when a serious
trouble occurs.
Even if a user code is not displayed, a trouble
may have occurred. If you feel any abnormality,
be sure to check for a service code with the
"Function of displaying service code [01]" in the
service menu.
a User codes and remedies shown to operator
User
codeError mode Remedy (shown to operator)
Caution
buzzer
E02Error in pump
control system
If the emergency pump drive switch is set in the upper position,
the machine can operate normally. Have the machine inspected
immediately, however.
q
E03 Error in swingb k t
Set the swing holding brake release switch in the upper position
to release the brake. When applying the swing brake, operate
the swing lock switch manually. The brake may not be released, q
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E03 Error in swingbrake system
the swing lock switch manually. The brake may not be released,
depending on the cause of the failure. In this case, have the
machine inspected immediately.
q
E10
Error in engine controller
power supply
Abnormality in engine con-
troller drive system circuit
Have the machine inspected immediately. q
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Operation and display of service menu
How to select service menu
a When using the general functions in the service
menu, perform the following switch operation to
change the screen of the monitor panel.
3. Function of displaying service code [01]
4. Monitoring function [02]
5. Function of selecting maintenance period
[04]6. Function of selecting default working
mode [05]
7. Function of setting installation of attach-
ment [16]
1) Operating switches
While holding caution buzzer stop switch (3),
hold auto decelerator switch (4) for 2.5 seconds.
2) Displaying display section and service meter
section
If the switches are operated as shown above,
the first menu No. [01] (Monitoring function) is
displayed in service meter section (2).
a Nothing is displayed in display section (1).
3) Selecting menu
While holding caution buzzer stop switch (3),operate working mode selector switches (7) and
(8) to select a menu you will use.
• UP switch (7): Increase Menu No.
• DOWN switch (8): Decrease Menu No.
Menu
No.
Service menu
(Excluding special functions)
01 Function of displaying error code
02 Monitoring function
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4) Executing menu
Select a menu you will use and press set switch
02 Monitoring function
04 Function of selecting maintenance period
05 Function of selecting default working mode
16 Function of setting installation of attachment
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
a To use the following special function, you must
operate the switches differently from the above.See details of this function "8. Special function
of monitoring replacement of engine oil".
3. Function of displaying service code [01]
With this function, you can check the service
code of a trouble which is occurring at present
or has occurred in the past.
1) Selecting and executing function
i) Select menu No. [01] in the menu selec-
tion mode.
ii) Press set switch (5) to execute this
function.
2) Information displayed in display section and
service meter section 1 (When service codeis recorded)
If a service code is recorded, the following
information is displayed in display section
(1) and service meter section (2).
(a): Service code
(b): Service meter reading increased after
trouble occurred
(c): Mark [E] to indicate that trouble is occur-
ring at presenta Mark [E] to indicate that a trouble is oc-
curring at present indicates that the serv-
ice code is being detected now. It is not
displayed if the trouble has been re-
paired or the service code is not detect-
ed.
a For the service codes which the monitor
panel and engine throttle and pump con-
troller can detect, see the "Service
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codes table".
3) Information displayed in display section and
service meter section 2 (When service code
is not recorded)
If a service code is not recorded, display
section (1) and service meter section (2)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
5) Change of displayed service codes
While holding caution buzzer stop switch(3), operate working mode selector switches
(7) and (8) to change the displayed service
codes.
• UP switch (7):
Next service code appears.
• DOWN switch (8):
Previous service code appears.
6) How to delete service code
i) While holding caution buzzer stop
switch (3), turn the starting switch OFF
and keep holding caution buzzer stop
switch (3).
ii) Under the above condition, turn the
starting switch ON again and hold cau-
tion buzzer stop switch (3) for 5 sec-
onds.a A service code having the mark [E] is not
deleted.
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Service codes table
User code Service code Trouble
— E112 Short circuit in wiper motor drive forward system
— E113 Short circuit in wiper motor drive reverse system
— E114 Short circuit in windshield washer drive system
— E115 Trouble in operation of windshield wiper
— E116 Trouble in storage of windshield wiper
— E117 Abnormality in engine controller S-NET
— E118 Abnormality in pump controller S-NET
E0E E128 Abnormality in communication (monitor)
— E201 Short circuit in travel junction solenoid
E03 E203 Short circuit in swing holding brake solenoid
— E204 Short circuit in merge-divider solenoid
— E205 Short circuit in 2-stage relief solenoid
— E206 Short circuit in travel speed shifting solenoid
— E211 Disconnection in travel junction solenoid
E03 E213 Disconnection in swing holding brake solenoid
— E214 Disconnection in merge-divider solenoid
— E215 Disconnection in 2-stage relief solenoid
— E216 Disconnection in travel speed shifting solenoid
— E217 Abnormality in input model code
— E218 Disconnection in S-NET signal line— E222 Short circuit in LS-EPC solenoid
— E223 Disconnection in LS-EPC solenoid
— E224 Abnormality in F pump pressure sensor
— E225 Abnormality in R pump pressure sensor
— E226 Abnormality in pressure sensor power supply
— E227 Abnormality in engine speed sensor
— E228 Short circuit in ATT return selector relayE02 E232 Short circuit in PC EPC solenoid
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E02 E232 Short circuit in PC-EPC solenoid
E02 E233 Disconnection in PC-EPC solenoid
— E238 Disconnection in ATT return selector relay
— E245 Short circuit in ATT flow adjustment EPC
— E246 Disconnection in ATT flow adjustment EPC
E247 Ab lit i IN PPC
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
E11 E93C Abnormality in boost pressure sensor system
E15 E93D Abnormality in fuel temperature sensor system
E0E E953 Abnormality in communication (engine)
— E954 Short circuit in starting switch C terminal system
E0E E955 Abnormality in network system
E10 E956 Abnormality in power supply system 1
E15 E957 Abnormality in power supply system 2
— E95A Abnormality in Q-adjustment switch signal
E15 E96A Abnormality in coolant low temperature sensor system
E11 E970 Overcurrent in fuel supply pump PCV1 system
E11 E971 Overcurrent in fuel supply pump PCV2 system
E11 E974 Disconnection in fuel supply pump PCV1 system
E11 E975 Disconnection in fuel supply pump PCV2 system
E11 E977 Abnormality in common rail fuel pressure sensor systemE11 E979 Abnormality in common rail fuel high pressure 1
E11 E97A Abnormality in common rail fuel high pressure 2
E15 E97B No-pressure feed by supply pump 1
E11 E97C No-pressure feed by supply pump 2
E11 E97D Abnormality in common rail fuel pressure
E11 E980 Abnormality in controller
E11 E981 Disconnection in fuel injector 1 systemE11 E982 Disconnection in fuel injector 2 system
E11 E983 Disconnection in fuel injector 3 system
E11 E984 Disconnection in fuel injector 4 system
E11 E985 Disconnection in fuel injector 5 system
E11 E986 Disconnection in fuel injector 6 system
E11 E98A Short circuit in fuel injector 1 – 3 systems
E11 E98B Short circuit in fuel injector 4 – 6 systemsE22 E922 Out of engine high idle standard
User code Service code Trouble
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a "E" at the head of each service code indicates the following condition.
• With E: The trouble has not been repaired.
• Without E: The trouble has been repaired.
E22 E922 Out of engine high idle standard
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
4. Monitoring function [02]
With this function, you can monitor the revolu-tion speed, oil pressure, current, voltage, input
condition, output condition, etc. in real time by
the signals from the sensors, switches, and
solenoids installed to various parts of the
machine.
1) Selecting and executing function
i) Select menu No. [02] in the menu selec-
tion mode.ii) Press set switch (5) to execute this
function.
2) Selecting and executing monitoring code
While holding caution buzzer stop switch
(3), operate working mode selector switches
(7) and (8) to select a monitoring code dis-played in service meter section (1).
• UP switch (7): Increase code No.
• DOWN switch (8): Decrease code No.
a This function displays monitoring code
[00200] and its information first.
a For the items and code Nos. which you
can monitor, see the "Monitoring codes
table".
3) Information displayed in display section and
service meter section 1 (When numeral
code is displayed)
If a numeral monitoring code is selected, the
following information is displayed in display
section (1) and service meter section (2).
(a): Monitoring code
(b): Monitoring information (Value is dis-
l d)
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played)
4) Information displayed in display section and
service meter section 2 (When 6 bit code is
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
Monitoring codes table
Code Monitoring item Unit Remarks
00200 Controller model code Numeral
00201 Controller model code Numeral
01002 Engine speed rpm
01601 2nd throttle command rpm
01100 F pump pressure kg/cm2
01101 R pump pressure kg/cm2
07200 Arm IN PPC pressure kg/cm2
07300 Bucket curl PPC pressure kg/cm2
04102 Engine coolant temperature (high) °C
14200 Fuel temperature °C
04401 Hydraulic oil temperature °C
01300 PC-EPC solenoid current mA
01500 LS-EPC solenoid current mA
01700 Service solenoid current mA
03200 Power supply voltage V
03500 Battery relay output voltage V
04300 Charge voltage V
01006 Engine speed rpm
04107 Engine coolant temperature (low) °C
36400 Common rail fuel pressure kg/cm2
36500 Boost pressure kg/cm2
36700 Converted torque %03000 Fuel control dial voltage V
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03000 Fuel control dial voltage V
04200 Fuel sensor voltage V
04106 Engine coolant temperature sensor voltage high V
04105 Engine coolant temperature sensor voltage low V
14201 Fuel temperature sensor voltage V
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
01900 Pressure switch 1
a Swing (6 bit)
b Travel (6 bit)
c Boom LOWER (6 bit)
d Boom RAISE (6 bit)
e Arm IN (6 bit)
f Arm OUT (6 bit)
01901 Pressure switch 2
a Bucket CURL (6 bit)
b Bucket DUMP (6 bit)
c Service (6 bit)
d Travel differential pressure (6 bit)
02300 Solenoid 1
a Travel junction (6 bit)
b Swing holding brake (6 bit)
c Pump merge-divider (6 bit)
d 2-stage relief (6 bit)
e Travel speed shifting (6 bit)
02301 Solenoid 2 ATT return selection (6 bit)
02200 Switch input 1a Knob switch (6 bit)b Swing brake release switch (6 bit)
c Swing holding brake switch (6 bit)
02201 Switch input 2
a Model selection 1 (6 bit)
b Model selection 2 (6 bit)
c Model selection 3 (6 bit)
d Model selection 4 (6 bit)
e Model selection 5 (6 bit)
Code Monitoring item Unit Remarks
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e Model selection 5 (6 bit)
02202 Switch input 3 Key switch (ACC) (6 bit)
03700 Controller output 1 Battery relay drive (6 bit)
a Key switch (6 bit)
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
a When the wiper is stopped, (d) and (f) of code No. [048] light up. When the wiper is operated, (c) and (f) or
(d) and (e) light up.
Display of numeral code Display of 6-bit code
04502 Monitor input 3
a Swing holding brake switch (6 bit)
b Buzzer cancel switch (6 bit)
c Window limit switch (6 bit)
d W limit switch (6 bit)
e P limit switch (6 bit)
17400 Engine controller input state
a Key switch (C) (6 bit)
b Engine oil pressure low (6 bit)
c Engine oil pressure high (6 bit)
d Model selection 1 (6 bit)
e Model selection 2 (6 bit)
f Model selection 3 (6 bit)
36800 Right Q-adjustment switch (ROT-SW1)Numeral and
alphabet
36801 Left Q-adjustment switch (ROT-SW2)Numeral and
alphabet
05100 S-NET connection statea Pump controller (6 bit)
b Engine controller (6 bit)
20200 Program version (monitor) Numeral
20212 Program version (pump controller) Numeral
20209 Program version (engine controller) Numeral
Code Monitoring item Unit Remarks
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
5. Function of selecting maintenance period [04]
With this function, you can adjust the mainte-nance period of the engine oil for the function of
the engine oil replacement monitor.
1) Selecting and executing function
i) Select menu No. [04] in the menu selec-
tion mode.
ii) Press set switch (5) to execute this
function.
2) Selecting maintenance period
The current display mode or maintenance
period is displayed in service meter section
(2). Press set switch (5) to select a mainte-
nance period.
a Nothing is displayed in display section
(1).
a Each time the set switch is pressed, the
display mode or maintenance period
changes in the following order.
3) Settling maintenance period
The d i sp lay o r ma in tenance pe r i od
becomes effective when it is selected
DisplayDisplay mode/
Maintenance period
0 Maintenance function is reset.
125 125-hour interval
250 250-hour interval
500 500-hour interval
d Demonstration mode
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becomes effective when it is selected.
Accordingly, perform the ordinary finishing
operation.
<Special functions of engine oil replacement
monitor>
TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
6. Function of selecting default working mode [05]
With this function, you can freely select theworking mode which is set automatically when
the starting switch is turned ON (When the
machine is delivered, mode A is set).
1) Selecting and executing function
i) Select menu No. [05] in the menu selec-
tion mode.
ii) Press set switch (5) to execute this
function.
2) Selecting default working mode
The currently set working mode is displayed
in service meter section (2). Press working
mode selector switches (7) and (8) to select
a working mode.
• UP switch (7): Next mode is displayed.
• DOWN switch (8): Previous mode is dis-
played.
a Nothing is displayed in display section
(1).
a The working mode changes in the fol-
lowing order: A o E o B
3) Settling default working mode
Press set switch (5) to settle the selected
working mode.
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
7. Function of setting installation of attachment [16]
With this function, you can set installation of attachment.
a When an attachment is installed, if IN-
STALLED is not set with this function, the B-
mode function (automatic single/double op-
eration selecting function) cannot be used.
1) Selecting and executing function
i) Select menu No. [16] in the menu selec-
tion mode.ii) Press set switch (5) to execute this
function.
a While this function is executed, [16SET]
is displayed in the service meter section
(2) and [0] or [1] is displayed in display
section (1).
2) Selecting installation of attachment
i) The current setting is displayed in serv-
ice meter section (1). Check the actual
installation of attachment and setting.
• [0]: Attachment is not installed.
• [1]: Attachment is installed.
ii) While holding caution buzzer stop
switch (3), operate working mode selec-
tor switches (7) and (8) to select [0] or
[1].• UP switch (7): [1] is selected.
• DOWN switch (8): [0] is selected.
3) Settling installation of attachment
Press set switch (5) to settle the selected
setting of installation of attachment.
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TESTING AND ADJUSTING SPECIAL FUNCTIONS OF 7-SEGMENTS MONITOR PANEL
8. Special functions of engine oil replacement monitor
1) Ordinary display of engine oil replacementmonitor
If the rest of time before the set engine oil
replacement time is 10 hours or shorter,
engine oil replacement monitor (10) lights
up and display the elapsed time in service
meter section (2) for 20 seconds each time
the starting switch is turned ON.
2) Checking elapsed timeTo check the elapsed time while engine oil
replacement monitor (10) is OFF, turn the
starting switch OFF and press set switch (5)
and then turn the starting switch ON and
keep holding set switch (5).
3) Clearing elapsed time
To clear the elapsed time after replacing the
engine oil, hold set switch (5) for 3 seconds
while the elapsed time is displayed in serv-
ice meter section (2).
a If the above operation is performed, the
elapsed time in the monitor panel is set
to 0 hours.
4) Function of demonstration mode
If the demonstration mode is selected, youcan perform demonstration of the oil mainte-
nance function when teaching the operation
to a customer.
The functions and display of the demonstra-
tion mode are as follows.
i) The internally set interval is recognized
as 250 hours and the elapsed time is
recognized as 240 hours.
ii) When the starting switch is turned ONafter the demonstration mode is set, the
ordinary display is repeated up to 3
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ordinary display is repeated up to 3
times (number of the times of turning
the starting switch ON).
iii) After the demonstration is finished,
resetting of maintenance setting [0] is
recognized
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TESTING AND ADJUSTING HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER
k The engine controller has a high-voltage circuit
(110 – 130 V) to drive the fuel injector. This cir-
cuit is connected to the wiring harness and con-nectors between the engine controller and fuel
injector.
a Normally, the engine controller outputs the high
voltage to the fuel injector only while the engine
is running and stops outputting if the engine
stops.
k If you touch the high-voltage circuit directly, you
may get an electric shock. To avoid this, ob-serve the following precautions.
1. The following connectors are used in the high-
voltage circuit.
• Engine controller connector: CB3
• Junction connector: ER03
• Injector connectors:
CN1, CN2, CN3, CN4, CN5, CN6
• Injector head terminal (in head cover)
2. When disconnecting or connecting a connector
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2. When disconnecting or connecting a connector
related to the high-voltage circuit, be sure to turn
the starting switch OFF.
3. If a T-adapter is inserted in or connected to a
connector related to the high voltage circuit for
TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING FOR
ELECTRICAL EQUIPMENT SYSTEM
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL
EQUIPMENT SYSTEM
a When carrying out troubleshooting for an elec-
tric circuit related to the monitor panel, engine
controller, or pump controller, expose the related
connectors according to the following proce-
dure.
1. Monitor panel1) Remove cover (1).
a The cover is fixed with the upper and
lower 2 clips. You can remove the cover
by pulling it up.
a If the sunlight sensor for the air condi-
tioner is installed, disconnect connector
P15 on the back side of the cover.
2) Remove the 3 mounting screws and discon-
nect monitor panel (2) from the mount.
a Take care not to drop the mounting
screws in the console.
3) Insert or connect T-adapters in or to con-nectors P01, P02, P70 of the monitor panel.
2. Engine controller
1) Open the right side cover and remove radia-
tor sub tank (3) and bracket together.
2) Remove the 4 mounting bolts and pull out
engine controller (4).
3) Insert or connect T-adapters in or to con-
nectors CB1, CB2, and CB3 of the engine
controller.
a Since the connectors are secured with
screws, loosen those screws before dis-
connecting.
a When connecting the connectors again,
tighten their screws to the specified
torque.
3 Screw: 2.82 Nm {0.288 kgm}
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TESTING AND ADJUSTING
PREPARATION WORK FOR TROUBLESHOOTING FOR
ELECTRICAL EQUIPMENT SYSTEM
3. Pump controller
a The pump controller is installed inside the cover at the rear of the operator’s seat.
1) Remove the 3 mounting bolts and cover (5).
2) Insert or connect T-adapters in or to connectors
C01, C02, and C03 of the pump controller.
a Since the connectors are secured with
screws, loosen those screws before discon-
necting.
a When connecting the connectors again,
tighten their screws to the specified torque.
3 Screw: 2.82 Nm {0.288 kgm}
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PM-CLINIC SERVICE
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MEASURING PROCEDURES
Positions to install measuring devices (Related to engine)
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MEASURING PROCEDURES
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
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Pm-CLINIC SERVICE PC400 (LC), 450 (LC)-7
Visual check of welded structures
a If any crack is found, draw its shape below.
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UNDERCARRIAGE INSPECTION(Program form No.: SELA195001)
Y Komatsu
Undercarriage Inspectio n Customer name:
T20606 Address:
Model Serial# Equip# Work Order No
Location SMR Wet,AR,HD or Dry
Soi l condit ion Dealer Shoe width (mm)
Working condit ion nspector Shoe type
Insp.Date(yyyy/mm/dd) (yyyy/m/d) Wear type
New 100% Measured Wear SMR Hours o Comments/Observation
Wear mm % New Rebuil t Parts:
LH 915.6 927.6
R
RH 915.6 927.6
LH 228.90 231.90
M
RH 228.90 231.90
LH 129.0 119.0
RH 129.0 119.0
New TurnedLH 71 .5 6 6. 5
New Turned
RH 71 .5 6 6. 5
LH 37 .0 2 2. 0
RH 37 .0 2 2. 0
LH 148.0 134.0
Front
RH 148.0 134.0
LH 148.0 134.0
Rear
RH 148.0 134.0
LH 22 .0 2 8. 0
Front
RH 22 .0 2 8. 0
LH 22 .0 2 8. 0
Rear
RH 22 .0 2 8. 0
1 LH 200.0 188.0
2 LH 200.0 188.03 LH 200.0 188.0
4 LH 200.0 188.0
5 LH 200.0 188.0
6 LH 200 0 188 0
PC400/450-7
DRY
TRIPLE
NORMAL
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6 LH 200.0 188.0
7 LH 200.0 188.0
8 LH 200.0 188.0
9 LH 200.0 188.0
10 LH 200.0 188.0
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POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-202
SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................. 20-203
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ....................................................... 20-204
CHECKS BEFORE TROUBLESHOOTING ................................................................................................ 20-212
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING.................................................................... 20-213
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC CIRCUIT DIAGRAM OF
EACH SYSTEM.................................................................................................................................... 20-217
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS ..................................................................... 20-234
T-BRANCH BOX AND T-BRANCH TABLE................................................................................................. 20-256
TROUBLESHOOTING WHEN ERROR CODE “ELECTRICAL SYSTEM”
AND FAILURE CODE “MECHANICAL SYSTEM” ARE DISPLAYED .................................................. 20-301
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) ................................................................. 20-501
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) ................................. 20-601
TROUBLESHOOTING OF ENGINE (S MODE).......................................................................................... 20-701
TROUBLESHOOTING
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TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
k Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
k When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and func-
tion.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry
to disassemble the components.
If components are disassembled immediately
any failure occurs:
• Parts that have no connection with the failure
or other unnecessary parts will be disassem-
bled.
• It will become impossible to find the cause of
the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshoot-
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
5) Other maintenance items can be checked
externally, so check any item that is consid-
ered to be necessary.
4. Confirming failure
• Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or
as a problem with the method of operation,
etc.
a When operating the machine to reenact
the troubleshooting symptoms, do not
carry out any investigation or measure-
ment that may make the problem worse.
5. Troubleshooting
• Use the results of the investigation and in-spection in Items 2 – 4 to narrow down the
causes of failure, then use the troubleshoot-
ing flowchart to locate the position of the fail-
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from the problem that has been reported?
2) Was there anything strange about the
machine before the failure occurred?
3) Did the failure occur suddenly or were there
ure exactly.
a The basic procedure for troubleshooting
is as follows.
1) Start from the simple points
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
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TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before
they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out.
This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the
quality of repairs. For this purpose, it gives sections on “Handling electric equipment“ and “Handling hydraulic
equipment” (particularly gear oil and hydraulic oil).
1. Points to remember when handling electric
equipment
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore, dur-
ing inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness1) Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
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2) Defective crimping or soldering of connec-
tors
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
4) High-pressure water entering connector
The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water
should get into the connector, the pins willbe short-circuited by the water, so if any
water gets in, immediately dry the connector
or take other appropriate action before
passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, theoil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
t i it ff ith d l th bl it d
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tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
tact restorer.
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
2) Removing, installing, and drying connectors
and wiring harnesses
• Disconnecting connectors
1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors and not the wires. For con-
nectors held by a screw, loosen the screw
fully, then hold the male and female connec-
tors in each hand and pull apart. For con-
nectors which have a lock stopper, pressdown the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
2) When removing from clips
When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
a If the connector is twisted up and downor to the left or right, the housing may
break.
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3) Action to take after removing connectors
After removing any connector, cover it with a
vinyl bag to prevent any dust dirt oil or
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Connecting connectors
1) Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation,
defective contact, corrosion, or damage
to the connector pins.
3) Check that there is no damage or break-
age to the outside of the connector.
a If there is any oil, water, or dirt stuck tothe connector, wipe it off with a dry cloth.
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
a If there is any damage or breakage, re-
place the connector.
2) Fix the connector securely. Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
3) Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wir-
ing harness is misaligned, or the clamp is
out of position, adjust it to its correct posi-
tion.
a If the connector cannot be corrected
easily, remove the clamp and adjust the
position.
4) If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
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• Connecting connectors (DT type connector)
Since the DT 8 pole and 12 pole DT type con
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• Drying wiring harness
If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure
water or steam directly on the wiring harness.
If water gets directly on the connector, do as fol-
lows.
1) Disconnect the connector and wipe off the
water with a dry cloth.a If the connector is blown dry with com-
pressed air, there is the risk that oil in the
air may cause defective contact, so re-
move all oil and water from the com-
pressed air before blowing with air.
2) Dry the inside of the connector with a dryer.
If water gets inside the connector, use a
dryer to dry the connector.a Hot air from the dryer can be used, but
regulate the time that the hot air is used
in order not to make the connector or re-
lated parts too hot, as this will cause de-
formation or damage to the connector.
3) Carry out a continuity test on the connector.
After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
a After completely drying the connector,blow it with contact restorer and reas-
semble.
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TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3) Handling control box
1) The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
2) Do not open the cover of the control box
unless necessary.
3) Do not place objects on top of the control
box.
4) Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts withyour hand.
5) During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
6) Do not place the control box on oil, water, or
soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
7) Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arcwelding ground close to the welding point.
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2. Points to remember when troubleshooting electric circuits
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
3. Points to remember when handling hydraulic
equipment
With the increase in pressure and precision of
hydraulic equipment, the most common cause of
failure is dirt (foreign material) in the hydraulic cir-
cuit. When adding hydraulic oil, or when disassem-
bling or assembling hydraulic equipment, it is
necessary to be particularly careful.
1) Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2) Disassembly and maintenance work in the
field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is alsodifficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be confirmed with special test
equipment.
3) Sealing openings After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, col-
lect it and ask the customer to dispose of it, or
take it back with you for disposal.
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4) Do not let any dirt or dust get in during refill-
ing operations
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
5) Change hydraulic oil when the temperature
is high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the con-taminants and sludge in it will mix with the new
oil and will shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primaryflushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,contro l va lve, etc . ) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3µ) particles that the filter
built into the hydraulic equipment cannot
remove, so it is an extremely effective device.
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TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
ItemJudgement
value Action
L u b r i c a t i n g o i l ,
c o o l a n t
1. Check fuel level, type of fuel
2. Check for impurities in fuel
3. Check hydraulic oil level
4. Check hydraulic oil strainer
5. Check swing machinery oil level
6. Check engine oil level (oil pan oil level)
7. Check coolant level8. Check dust indicator for clogging
9. Check hydraulic filter
10. Check final drive oil level
—
—
—
—
—
—
——
—
—
Add fuel
Clean, drain
Add oil
Clean, drain
Add oil
Add oil
Add water Clean or replace
Replace
Add oil
E l e c t r i c a l
e q u i p m e n t
1. Check for looseness, corrosion of battery terminal, wiring
2. Check for looseness, corrosion of alternator terminal, wiring
3. Check for looseness, corrosion of starting motor terminal, wiring
—
—
—
Tighten or replace
Tighten or replace
Tighten or replace
H y d r a
u l i c ,
m e c h a
n i c a l
e q u i p m e n t
1. Check for abnormal noise, smell
2. Check for oil leakage3. Carry out air bleeding
—
——
Repair
Repair Bleed air
E l e c t r i c s , e l e c t
r i c a l e q u i p m e n t
1. Check battery voltage (engine stopped)
2. Check battery electrolyte level
3. Check for discolored, burnt, exposed wiring
4. Check for missing wiring clamps, hanging wiring
5. Check for water leaking on wiring (be particularly careful attention to
water leaking on connectors or terminals)
6. Check for blown, corroded fuses
7. Check alternator voltage (engine running at 1/2 throttle or above)
8. Check operating sound of battery relay
(when switch is turned ON/OFF)
20 – 30V
—
—
—
—
—
Afterrunning for
several
minutes :
27.5 – 29.5V
—
Replace
Add or replace
Replace
Repair
Disconnect
connector and dry
Replace
Replace
Replace
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TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Classification of troubleshooting
Steps for troubleshootingIf some phenomenon occurs on a machine that looks like a failure, identify the corresponding troubleshooting
No. and proceed to the explanations for diagnosis.
1. Troubleshooting steps when calling User Code display in the monitor panel
In the User Code display, select and depress [ ] switch to display Error Code. Following displayed Error
Code for the electrical system, carry out the troubleshooting along the corresponding code display.
2. Troubleshooting steps when the electrical system Error Code or mechanical system Failure Code is
recorded in the failure history:
If not calling User Code in the monitor panel, check the electrical system Error Code or mechanical system
Failure Code, using the failure history function of the monitor panel.
a If Error Code in the electrical system is recorded, delete the all codes once and revive the code in the
display again to check if the same abnormality still persists.
a Failure Code in the mechanical system cannot be deleted.
3. Troubleshooting steps without User Code display and no failure history is available
If there is no display of User Code nor the failure history in the monitor panel, it is possible that a failure that
the monitor panel cannot diagnose by itself may have occurred in any of the electrical, hydraulic or mechan-
ical system. In such a case, reexamine the phenomenon, find out the most similar phenomenon from
among “Failure like Phenomena and Troubleshooting No.” and carry out E mode or H mode troubleshooting
related to the phenomenon in question.
Mode Content
Code displayTroubleshooting when Error Code (electrical system) and Failure Code (mechanical system) are
displayed.
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine
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TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Phenomena considered to be failures and troubleshooting Nos.
No. Phenomena considered to be failures
Troubleshooting
Display of
codeE-mode H-mode S-mode
Possible faults related to user code, error code, or failure code
1 User code is displayed on monitor panel
Accord-
ing to
displayed
code
2When failure history is checked, error code is displayed in electrical
system
3When failure history is checked, error code is displayed in mechani-
cal system
Possible faults related to engine
4 Engine does not start easily (It always takes time to start) S-1
5
Engine does not start
Engine does not crank E-1 S-2 a)
6
Engine cranks but exhaust smoke
does not come out S-2 b)
7Exhaust smoke comes out but engine
does not startS-2 c)
8 Engine speed does not rise sharply (Follow-up performance is low) S-3
9 Engine stops during operation S-4
10 Engine rotation is abnormal (Engine hunts) S-5
11 Output is insufficient (Power is low) S-6
12 Exhaust gas color is bad (Incomplete combustion) S-7
13 Oil is consumed much or exhaust gas color is bad S-8
14 Oil becomes dirty quickly S-9
15 Fuel is consumed much S-10
16 Coolant contains oil (or it blows back or reduces) S-11
17 Engine oil pressure caution lamp lights up (Oil pressure lowers) S-12
18 Oil level rises (Water or fuel is mixed in oil) S-13
19 Water temperature rises too high (Overheating) S-14
20 Abnormal sound comes out S-15
S
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21 Vibration is excessive S-16
22 Engine is not preheated normally E-2
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
Possible faults related to work equipment
30 Speed or power of boom is low H-7
31 Speed or power of arm is low H-8
32 Speed or power of bucket is low H-9
33 Work equipment does not move singly H-10
34 Hydraulic drift of work equipment is large H-11
35 Time lag of work equipment is large H-12
36When a work equipment device is relieved singly, other work equip-
ment device movesH-13
37 One-touch power maximizing function does not work E-6 H-14
38 Machine push-up function does not work normally E-7 H-15
39 Attachment circuit is not selected (when attachment is installed) E-8 H-30
40Oil flow in attachment circuit cannot be adjusted (when attachment is
installed)H-31
Possible faults related to compound operation
41In compound operation of work equipment, speed of part loaded
more is lowH-16
42When machine swings and raises boom simultaneously, boom rising
speed is low
H-17
43When machine swings and travels simultaneously, travel speed low-
ers largelyH-18
Possible faults related to travel
44 Machine deviates during travel H-19
45 Travel speed is low H-20
46 Machine is not steered well or steering power is low H-21
47 Travel speed does not change or it is lower or higher than set speed H-22
48 Travel motor does not work (only 1 side) H-23
49 Travel alarm does not sound or does not stop sounding E-31
Possible faults related to swing
No. Phenomena considered to be failures
Troubleshooting
Display ofcode
E-mode H-mode S-mode
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Possible faults related to swing
47 Machine does not swing H-24
TROUBLESHOOTING CLASSIFICATION AND STEPS FOR TROUBLESHOOTING
58 Engine coolant temperature gauge does not indicate normally E-13
59 Hydraulic oil temperature gauge does not indicate normally E-14
60 Fuel level gauge does not indicate normally E-15
61 Swing lock monitor does not indicate normally E-16
62 When monitor switches are operated, no items are displayed E-17
63 Windshield wiper or windshield washer does not operate E-18
64 Alarm buzzer cannot be cancelled E-19
Possible faults related to monitor panel (Service menu: Special function screen)
65 Monitoring function does not indicate “Boom RAISE” normally. E-20
66 Monitoring function does not indicate “Boom LOWER” normally. E-21
67 Monitoring function does not indicate “Arm IN” normally. E-22
68 Monitoring function does not indicate “Arm OUT” normally. E-23
69 Monitoring function does not indicate “Bucket CURL” normally. E-24
70 Monitoring function does not indicate “Bucket DUMP” normally. E-25
71 Monitoring function does not indicate “Swing” normally. E-26
72 Monitoring function does not indicate “Travel” normally. E-27
73Monitoring function does not indicate “Travel differential pressure”
normally.
E-28
74 Monitoring function does not indicate “Service” normally. E-29
Other failure
75 Air conditioner does not operate
(Troubleshooting for air conditioner system)E-31
No. Phenomena considered to be failures
Troubleshooting
Display ofcode
E-mode H-mode S-mode
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEMConnectors list
a The address of each connector roughly shows the place of the connector in the connectors stereogram and
the circuit diagram of each system.
Connector
No.Type
No. of
pinsName of device
Address
Stereo-
gram
M
circuit
E
circuit
P
circuit
A01 X 4 Intermediate connector T-1 H-6 D-7 G-7 A02 X 4 Intermediate connector T-1 H-6 G-7
A03 DT 12 Intermediate connector N-2 H-6 D-7 G-7
A04 SWP 6 Intermediate connector O-1 G-6
A05 SWP 14 Intermediate connector T-1 H-5 G-6
A06 SWP 14 Intermediate connector O-1 H-5 G-5
A07 SWP 16 Intermediate connector S-1 A-4 D-7 G-5
A09 SWP 8 Intermediate connector N-2 G-5
A10 Terminal 1 Revolving frame grounding H-2 I-1 F-1 J-8 A11 Terminal 1 Revolving frame grounding I-2 F-1
A12 Terminal 1 Revolving frame grounding I-2 I-1
A13 Terminal 1 Revolving frame grounding I-2 I-1 J-8
A14 Terminal 1 Revolving frame grounding F-1 I-1 J-8
A15 Terminal 1 Revolving frame grounding J-3 I-1 J-8
A16 Terminal 1 Revolving frame grounding J-3 I-1 K-8
A20 Terminal 1 Battery relay (Terminal E) D-1 L-5 K-9
A21 Terminal 1 Battery relay (Terminal BR) D-2 J-6 K-9 A22 Terminal 1 Battery relay (Terminal N) F-2 J-5 D-8 K-9
A23 Terminal 1 Battery relay (Terminal B) F-2 J-6 K-9
A31 D 2 Air cleaner clogging sensor H-9 K-4
A33 X 2 Radiator water level sensor H-9 K-5
A34 L 2 Fusible link (65 A) D-2 K-6 K-9
A35 M 2 Fusible link (30 A) G-9 K-6 D-9 K-9
A40 Terminal 1 Horn (Low tone) G-9
A41 Terminal 1 Horn (High tone) G-9 A42 M 1 Intermediate connector H-9 J-7
A43 D 2 Travel alarm J-3 K-5
A44 M 1 Right headlamp D-5 K-7
A50 KES0 2 Windshield washer motor (Tank) L-5 K-5
A51 D 3 F il L 8 L 5
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A51 D 3 F pump oil pressure sensor L-8 L-5
A52 D 3 R pump oil pressure sensor L-7 L-5
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
CB2 DRC 40 Pump controller I-9 K-1 A-5 L-8
CB3 DRC 40 Pump controller J-9 A-3
CB5 DT 8 Model selection connector (Engine controller) J-9 A-7
CN1 DT 2 No. 1 fuel injector AI-2 K-3
CN2 DT 2 No. 2 fuel injector AI-3 K-2
CN3 DT 2 No. 3 fuel injector AJ-3 K-2
CN4 DT 2 No. 4 fuel injector AJ-5 K-2
CN5 DT 2 No. 5 fuel injector AJ-6 K-3
CN6 DT 2 No. 6 fuel injector AJ-6 K-2
D01 SWP 8 Concentrated diode W-7 A-9 A-4
D02 SWP 8 Concentrated diode W-5 A-8 A-4
E06 M 3 Fuel control dial P-7 K-7
ENE DT 2 Engine speed sensor AJ-5
ER02 HD30 31 Intermediate connector AF-8 J-3 I-5 K-6
ER03 HD30 31 Intermediate connector AF-8 I-3
F02 M 2 Rotary lamp AA-9
FB1 — — Fuse box V-2 I-9 E-7 G-8
G YAZAKI 2 Engine G sensor AH-2 K-3
GND DT 2 Joint connector (with diode) AJ-6
GND2 Terminal 1 Engine grounding AJ-5
GND3 Terminal 1 Engine grounding AE-7
H08 M 8 Intermediate connector W-6 J-8
H09 S 8 Intermediate connector W-6 J-8
H10 S 16 Intermediate connector T-9 D-6 I-7 E-2
H11 S 16 Intermediate connector S-9 D-6 E-2
H12 S 12 Intermediate connector S-9 D-5 I-6 E-2
H15 S090 20 Intermediate connector O-7 C-2 I-7 A-2
HT/B Terminal 1 Heater relay B terminal AH-9
HT/S Terminal 1 Heater relay S terminal AJ-7
J01 J 20 Junction connector (Black) T-9 C-9 H-9 B-9
J02 J 20 Junction connector (Black) T-9 D-9 C-1
J03 J 20 Junction connector (Green) U-9 D-9 H-9 C-9
J04 J 20 Junction connector (Green) V-3 E-9 H-9 C-9
J05 J 20 Junction connector (Pink) V-3 E-9 D-9
J06 J 20 Junction connector (Orange) W-3 F-9 I-9 D-9
J07 J 20 Junction connector (Orange) W-5 F-9 I-9 D-9
Connector
No.Type
No. of
pinsName of device
Address
Stereo-
gram
M
circuit
E
circuit
P
circuit
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J08 J 20 Junction connector (Pink) W-5 I-9 E-9
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
M31 M 2 Optional power supply (2) W-7
M32 M 2 Optional power supply (1) W-6
M33 M 2 Optional power supply (3) V-9
M33 SUMITOMO 4 Air conditioner unit W-4
M34 X 1 Air conditioner compressor electromagnetic clutch I-9
M37 Terminal 1 Horn switch (High tone) H-1
M38 Terminal 1 Horn switch (Low tone) G-1
M38 M 2 Machine push-up switch Q-8 A-1
M40 M 2 Working lamp Z-8 K-8
M41 M 2 Working lamp (Additional) Y-7 K-8
M42 M 1 Intermediate connector H-9 J-7, K-7
M43 M 1 Working lamp (Rear) J-9 K-7
M45 D 12 Intermediate connector W-7
M46 X 4 RS232C junction connector V-9 A-4
M71 M 2 Room lamp AA-8
M72 M 4 DC/DC converter U-2
M73 M 2 Speaker (Left) AD-8
M79 M 2 12-V accessory outlet V-9
NE YAZAKI 2 Engine Ne sensor AJ-5 K-4
OL DT 2 Engine oil level sensor AJ-3 K-2
P01 070 12 Monitor panel N-6 A-7 K-7 E-1
P02 040 20 Monitor panel N-5 A-6 K-6 E-1
P03 M 2 Buzzer cancel switch Q-8 D-1
P05 M 2 Rotary lamp switch U-2
P15 Y050 2 Air conditioner daylight sensor N-5
P70 040 16 Monitor panel N-5 A-5 K-6 E-1
PCV1 SUMITOMO 2 Fuel supply pump PCV1 AH-2 K-1
PCV2 SUMITOMO 2 Fuel supply pump PCV2 AI-2 K-1
PSH Terminal 1 Engine oil pressure switch (High pressure) AH-2 L-5
PSL Terminal 1 Engine oil pressure switch (Low pressure) AG-1 L-5
PFUEL AMP 3 Common rail pressure sensor AJ-4 K-5
PIM SUMITOMO 3 Boost pressure sensor AJ-8 K-5
R10 R 5 Light relay P-7 E-1
R11 R 5 Starting motor cutout relay (PPC lock) P-8 E-1
R13 R 5 Starting motor cutout relay (Personal code) Q-8 F-1
R20 R 5 ATT circuit selector relay W-7 E-9
Connector
No.
TypeNo. of
pins
Name of device
Address
Stereo-
gram
M
circuit
E
circuit
P
circuit
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R22 R 5 Power supply relay for engine controller W-6 G-9
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
S21 Terminal 6 Emergency pump drive switch R-9 C-1
S22 Terminal 6 Swing holding brake release switch R-8 D-1
S25 S090 16 Intermediate connector R-9 C-2
S30 X 2 Travel oil pressure switch P-1 A-9
S31 X 2 Travel steering oil pressure switch P-1 A-9
ST DT 2 Starting motor AF-7 K-3 K-6
ST/B Terminal 1 Starting motor B terminal AF-7
T05 Terminal 1 Floor frame grounding V-3 J-8
T06 Terminal 1 Radio body grounding S-9
T06A M 1 Intermediate connector T-2
T11 Terminal 1 Cab grounding K-8
THL DT 3 Spill fuel temperature sensor AJ-4 K-3
TWH DT 2Engine water temperature sensor (High tempera-
ture) AE-7 K-5
TWL DT 3Engine water temperature sensor (Low tempera-
ture) AG-8 K-5
V01 DT 2 PPC oil pressure lock solenoid valve J-3 K-5
V02 DT 2 Travel junction solenoid valve J-2 K-5
V03 D 2 Merge-divider solenoid valve J-2 K-4
V04 D 2 Travel speed solenoid valve J-2 K-4
V05 D 2 Swing holding brake solenoid valve J-2 K-4
V06 D 2 Machine push-up solenoid valve J-2 K-4
V08 D 2 2nd-stage relief solenoid valve J-1 K-4
V12 D 2 ATT return selector solenoid valve J-1 K-4V21 D 2 PC-EPC solenoid valve L-6 L-7
V22 D 2 LS-EPC solenoid valve L-6 L-7
V30 X 2 ATT flow adjustment EPC solenoid valve P-1 F-1
W03 M 2 Rear limit switch (Window) AB-9 K-8
W04 M 6 Wiper motor Y-5 B-9
X05 M 4 Swing lock switch Q-8 D-2 A-1
Connector
No.
TypeNo. of
pins
Name of device
Address
Stereo-
gram
M
circuit
E
circuit
P
circuit
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
Connector type Detailed informationD or DT Japanese and German makes DT type connector (08192-XXXXX)
L Product of Yazaki Corporation L type connector (08056-2XXXX)
J Product of Sumitomo Wiring Systems 090 type splice
M Product of Yazaki M type connector (08056-0XXXX)
R Product of Ryosei Electro-Circuit Systems* PH166-05020 type connector
S Product of Yazaki S type connector (08056-1XXXX)
X Product of Yazaki X type connector (08055-0XXXX)
PA Product of Yazaki PA type connector
SWP Product of Yazaki SWP type connector (08055-1XXXX)
DRC Japanese and German makes DRC type connector
040 Product of Japan AMP 040 type connector
070 Product of Japan AMP 070 type connector
Y050 Product of Yazaki 050 type connector S090 Product of Sumitomo 090 type connector
Y090 Product of Yazaki 090 type connector
YAZAKI Yazaki-made connector
SUMITOMO Product of Sumitomo Wiring Systems 6098 type connector
KES0 KESO type connector (08027-0XXXX)
Terminal Round pin type single terminal connector
Terminal Round terminal
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
Connector Location Stereogram
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
Monitor Panel System Circuit Diagram (M Circuit)
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
a This circuit diagram is made by extracting the monitor panel system, engine preheating/starting/charging
system, light system, and communication network system from the general electric circuit diagram.
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
Engine Control System Circuit Diagram (E Ciruit)
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
a This circuit diagram is made by extracting the engine controller system from the general electric circuit dia-
gram.
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
Pump Controller System Circuit Diagram (P Circuit)
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TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING AND ELECTRIC
CIRCUIT DIAGRAM OF EACH SYSTEM
a This circuit diagram is made by extracting the pump controller system, PPC lock solenoid system, machine
push-up solenoid system, and boom shockless solenoid system from the general electric circuit diagram.
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
a The terms male and female refer to the pins, while the terms male housing and female housing refer to themating portion of the housing.
No.of
pins
X type connector
Male (female housing) Female (male housing)T-adapter
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
Part No.: 08055-00282 Part No.: 08055-00292
3 799-601-7030
Part No.: 08055-00381 Part No.: 08055-00391
4 799-601-7040
Part No.: 08055-00481 Part No.: 08055-00491
—
Terminal part No.: 79A-222-3370
• Electric wire size: 0.85
• Grommet: Black
• Q’ty: 20
Terminal part No.: 79A-222-3390
• Electric wire size: 0.85
• Grommet: Black
• Q’ty : 20
—
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
SWP type connector
Male (female housing) Female (male housing)T-adapter
Part No.
6 799-601-7050
Part No.: 08055-10681 Part No.: 08055-10691
8 799-601-7060
Part No.: 08055-10881 Part No.: 08055-10891
12 799-601-7310
Part No.: 08055-11281 Part No.: 08055-11291
14 799-601-7070
Part No.: 08055-11481 Part No.: 08055-11491
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No. of
pins
SWP type connector
Male (female housing) Female (male housing)T-adapter
Part No.
16 799-601-7320
Part No.: 08055-11681 Part No.: 08055-11691
—
Terminal part No.:
• Electric wire size: 0.85
• Grommet: Black
• Q’ty: 20
Terminal part No.:
• Electric wire size: 0.85
• Grommet: Black
• Q’ty: 20
—
—
Terminal part No.:
• Electric wire size: 1.25
• Grommet: Red
• Q’ty: 20
Terminal part No.:
• Electric wire size: 1.25
• Grommet: Red
• Q’ty: 20
—
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
M type connector
Male (female housing) Female (male housing)T-adapter Part
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
Part No.: 08056-00271 Part No.: 08056-00281
3 799-601-7110
Part No.: 08056-00371 Part No.: 08056-00381
4 799-601-7120
Part No.: 08056-00471 Part No.: 08056-00481
6 799-601-7130
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
S type connector
Male (female housing) Female (male housing)T-adapter
Part No.
8 799-601-7140
Part No.: 08056-10871 Part No.: 08056-10881
10
(White)799-601-7150
Part No.: 08056-11071 Part No.: 08056-11081
12(White)
799-601-7350
Part No.: 08056-11271 Part No.: 08056-11281
16
(White)799-601-7330
Part No.: 08056-11671 Part No.: 08056-11681
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
S type connector
Male (female housing) Female (male housing)T-adapter
Part No.
10
(Blue)—
— —
12
(Blue)799-601-7160
Part No.: 08056-11272 Part No.: 08056-11282
16(Blue)
799-601-7170
Part No.: 08056-11672 Part No.: 08056-11682
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
MIC type connector
Male (female housing) Female (male housing)T-adapter Part
No.
7 Body part No.: 79A-222-2640 (Q’ty: 5) Body part No.: 79A-222-2630 (Q’ty: 5) —
11 Body part No.: 79A-222-2680 (Q’ty: 5) Body part No.: 79A-222-2670 (Q’ty: 5) —
5 799-601-2710
Body part No.: 79A-222-2620 (Q’ty: 5) Body part No.: 79A-222-2610 (Q’ty: 5)
9 799-601-2950
Body part No.: 79A-222-2660 (Q’ty: 5) Body part No.: 79A-222-2650 (Q’ty: 5)
13 799-601-2720
Body part No.: 79A-222-2710 (Q’ty: 2) Body part No.: 79A-222-2690 (Q’ty: 2)
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
MIC type connector
Male (female housing) Female (male housing)T-adapter Part
No.
17 799-601-2730
Body part No.: 79A-222-2730 (Q’ty: 2) Body part No.: 79A-222-2720 (Q’ty: 2)
21 799-601-2740
Body part No.: 79A-222-2750 (Q’ty: 2) Body part No.: 79A-222-2740 (Q’ty: 2)
Terminal part No.: 79A-222-2770
(Q’ty: 50)
Terminal part No.: 79A-222-2760
(Q’ty: 50)—
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
AMP040 type connector
Male (female housing) Female (male housing)T-adapter Part
No.
8 799-601-7180
— Housing part No.: 79A-222-3430 (Q’ty: 5)
12 799-601-7190
— Housing part No.: 79A-222-3440 (Q’ty: 5)
16 799-601-7210
— Housing part No.: 79A-222-3450 (Q’ty: 5)
20 799-601-7220
— Housing part No.: 79A-222-3460 (Q’ty: 5)
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
AMP070 type connector
Male (female housing) Female (male housing)T-adapter Part
No.
10 799-601-7510
— Part No.: 08195-10210
12 799-601-7520
— Part No.: 08195-12210
14 799-601-7530
— Part No.: 08195-14210
18 799-601-7540
— Part No.: 08195-18210
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.of
pins
L type connector
Male (female housing) Female (male housing)T-adapter Part
No.
2 —
— —
No.of
pins
Connector for PA
Male (female housing) Female (male housing)T-adapter Part
No.
9 —
— —
No.of
pins
Bendix MS connector
Male (female housing) Female (male housing)T-adapter Part
No.
10 799-601-3460
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.ofpins
KES 1 (Automobile) connector
Male (female housing) Female (male housing)T-adapter Part
No.
2 —
Part No.: 08027-10210 (Natural color)
08027-10220 (Black)
Part No.: 08027-10260 (Natural color)
08027-10270 (Black)
3 —
Part No.:08027-10310 Part No.:08027-10360
4 —
Part No.: 08027-10410 (Natural color)
08027-10420 (Black)
Part No.: 08027-10460 (Natural color)
08027-10470 (Black)
6 —
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.ofpins
KES 1 (Automobile) connector
Male (female housing) Female (male housing)T-adapter Part
No.
8 —
Part No.: 08027-10810 (Natural color)
08027-10820 (Black)
Part No.: 08027-10860 (Natural color)
08027-10870 (Black)
No.of
pins
Connector for relay (Socket type)
Male (female housing) Female (male housing) T-adapter PartNo.
5 799-601-7360
— —
6 799-601-7370
— —
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.ofpins
F type connector
Male (female housing) Female (male housing)T-adapter
Part No.
4 —
— —
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell
size
code)
HD30 Series connector
Body (plug) Body (receptacle)T-adapter
Part No.
18-8
(1)
Pin (male terminal) Pin (female termial)
799-601-9210
Part No.: 08191-11201, 08191-11202,
08191-11205, 08191-11206
Part No.: 08191-14101, 08191-14102,
08191-14105, 08191-14106
Pin (female terminal) Pin (male termial)
799-601-9210
Part No.: 08191-12201, 08191-12202,08191-12205, 08191-12206
Part No.: 08191-13101, 08191-13102,08191-13105, 08191-13106
18-14
(2)
Pin (male terminal) Pin (female termial)
799-601-9220
Part No.: 08191-21201, 08191-12202,
08191-21205, 08191-12206
Part No.: 08191-24101, 08191-24102,
08191-24105, 08191-24106
Pin (female terminal) Pin (male termial)
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell
size
code)
HD30 Series connector
Body (plug) Body (receptacle)T-adapter
Part No.
18-20
(3)
Pin (male terminal) Pin (female termial)
799-601-9230
Part No.:08191-31201, 08191-31202 Part No.:08191-34101, 08191-34102
Pin (female terminal) Pin (male termial)
799-601-9230
Part No.:08191-32201, 08191-32202 Part No.:08191-33101, 08191-33102
18-21
(4)
Pin (male terminal) Pin (female termial)
799-601-9240
Part No.:08191-41201, 08191-42202 Part No.:08191-44101, 08191-44102
Pin (female terminal) Pin (male termial)
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell
size
code)
HD30 Series connector
Body (plug) Body (receptacle)T-adapter
Part No.
24-9
(5)
Pin (male terminal) Pin (female termial)
799-601-9250
Part No.:08191-51201, 08191-51202 Part No.:08191-54101, 08191-54102
Pin (female terminal) Pin (male termial)
799-601-9250
Part No.:08191-52201, 08191-52202 Part No.:08191-53101, 08191-53102
24-16
(6)
Pin (male terminal) Pin (female termial)
799-601-9260
Part No.: 08191-61201, 08191-62202,
08191-61205, 08191-62206
Part No.: 08191-64101, 08191-64102,
08191-64105, 08191-64106
Pin (female terminal) Pin (male termial)
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell
size
code)
HD30 Series connector
Body (plug) Body (receptacle)T-adapter
Part No.
24-21
(7)
Pin (male terminal) Pin (female termial)
799-601-9270
Part No.: 08191-71201, 08191-71202,
08191-71205, 08191-71206
Part No.: 08191-74101, 08191-74102,
08191-74105, 08191-74106
Pin (female terminal) Pin (male termial)
799-601-9270
Part No.: 08191-72201, 08191-72202,08191-72205, 08191-72206
Part No.: 08191-73101, 08191-73102,08191-73105, 08191-73106
24-22
Pin (male terminal) Pin (female termial)
799-601-9280
Part No.: 08191-81201, 08191-81202
08191-81203, 08191-81204
08191-81205, 08191-80206
Part No.: 08191-84101, 08191-84102
08191-84103, 08191-84104
08191-84105, 08191-84106
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell
size
code)
HD30 Series connector
Body (plug) Body (receptacle)T-adapter
Part No.
24-31
(9)
Pin (male termial) Pin (female terminal)
799-601-9290
Part No.: 08191-91203, 08191-91204,
08191-91205, 08191-91206
Part No.: 08191-94103, 08191-94104,
08191-94105, 08191-94106
Pin (female terminal) Pin (male termial)
799-601-9290
Part No.: 08191-92203, 08191-92204,08191-92205, 08191-92206
Part No.: 08191-93103, 08191-93104,08191-93105, 08191-93106
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
No.of
pins
DT Series connector
Body (plug)Body (receptacle) T-adapter
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type)
08192-22200 (fine wire type)
Part No.: 08192-12100 (normal type)
08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type)
08192-23200 (fine wire type)
Part No.: 08192-13100 (normal type)
08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type)
08192-24200 (fine wire type)
Part No.: 08192-14100 (normal type)
08192-24100 (fine wire type)
6 799 601 9050
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
No.of
pins
DT Series connector
Body (plug) Body (receptacle) T-adapter Part No.
8
8GR: 799-601-9060
8B: 799-601-90708G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820 (normal type)
08192-2820 (fine wire type)
Part No.: 08192-1810 (normal type)
08192-2810 (fine wire type)
12
12GR: 799-601-9110
12B: 799-601-9120
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920 (normal type)
08192-2920 (fine wire type)
Part No.: 08192-1910 (normal type)
08192-2910 (fine wire type)
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
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TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
[The pin No. is also marked on the connector (electric wire insertion end)]
[The pin No. is also marked on the connector (electric wire insertion end)]
No.of
pins
DTM Series connector
Body (plug) Body (receptacle)T-adapter Part
No.
2799-601-9010
Part No.: 08192-02200 Part No.: 08192-02100
No.of
pins
DTHD Series connector
Body (plug) Body (receptacle)T-adapter Part
No.
2 —
Part No.: 08192-31200 (Contact size#12)
08192-41200 (Contact size #8)
08192-51200 (Contact size #4)
Part No.: 08192-31100 (Contact size#12)
08192-41100 (Contact size #8)
08192-51100 (Contact size #4)
TROUBLESHOOTING T BRANCH BOX AND T BRANCH TABLE
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TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
T-BRANCH BOX AND T-BRANCH TABLE
aThe vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows partnumber of Harness Checker Ass'y.
Part No.Connector type or
part nameNo. of pins
7 9 9 - 6 0 1 - 2 5 0 0
7 9 9 - 6 0 1 - 2 7 0 0
7 9 9 - 6 0 1 - 2 8 0 0
7 9 9 - 6 0 1 - 2 9 0 0
7 9 9 - 6 0 1 - 3 0 0 0
7 9 9 - 6 0 1 - 5 5 0 0
7 9 9 - 6 0 1 - 6 0 0 0
7 9 9 - 6 0 1 - 6 5 0 0
7 9 9 - 6 0 1 - 7 0 0 0
7 9 9 - 6 0 1 - 7 1 0 0
7 9 9 - 6 0 1 - 7 4 0 0
7 9 9 - 6 0 1 - 7 5 0 0
7 9 9 - 6 0 1 - 8 0 0 0
7 9 9 - 6 0 1 - 9 0 0 0
7 9 9 - 6 0 1 - 9 1 0 0
7 9 9 - 6 0 1 - 9 2 0 0
7 9 9 - 6 0 1 - 9 3 0 0
—
799-601-2600 Measurement box Econo-21P
799-601-3100 Measurement box MS-37P799-601-3200 Measurement box MS-37P799-601-3300 Measurement box Econo-24P799-601-3360 Plate For MS box799-601-3370 Plate For MS box799-601-3380 Plate For MS box799-601-3410 BENDIX (MS) 24P799-601-3420 BENDIX (MS) 24P799-601-3430 BENDIX (MS) 17P
799-601-3440 BENDIX (MS) 17P799-601-3450 BENDIX (MS) 5P799-601-3460 BENDIX (MS) 10P799-601-3510 BENDIX (MS) 5P799-601-3520 BENDIX (MS) 14P799-601-3530 BENDIX (MS) 19P799-601-2910 BENDIX (MS) 14P799-601-3470 Case799-601-2710 MIC 5P
799-601-2720 MIC 13P799-601-2730 MIC 17P799-601-2740 MIC 21P799-601-2950 MIC 9P799-601-2750 ECONO 2P799-601-2760 ECONO 3P799-601-2770 ECONO 4P799-601-2780 ECONO 8P799-601-2790 ECONO 12P799-601-2810 DLI 8P799-601-2820 DLI 12P799-601-2830 DLI 16P799-601-2840 Additional cable799-601-2850 Case799-601-7010 X 1P799-601-7020 X 2P
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
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TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
Part No.Connector type or part name
No. of pins
7 9 9 - 6 0 1 - 2
5 0 0
7 9 9 - 6 0 1 - 2
7 0 0
7 9 9 - 6 0 1 - 2
8 0 0
7 9 9 - 6 0 1 - 2
9 0 0
7 9 9 - 6 0 1 - 3
0 0 0
7 9 9 - 6 0 1 - 5
5 0 0
7 9 9 - 6 0 1 - 6
0 0 0
7 9 9 - 6 0 1 - 6
5 0 0
7 9 9 - 6 0 1 - 7
0 0 0
7 9 9 - 6 0 1 - 7
1 0 0
7 9 9 - 6 0 1 - 7
4 0 0
7 9 9 - 6 0 1 - 7
5 0 0
7 9 9 - 6 0 1 - 8
0 0 0
7 9 9 - 6 0 1 - 9
0 0 0
7 9 9 - 6 0 1 - 9
1 0 0
7 9 9 - 6 0 1 - 9
2 0 0
7 9 9 - 6 0 1 - 9
3 0 0
—
799-601-7140 S 8P799-601-7150 S 10P-White799-601-7160 S 12P-Blue799-601-7170 S 16P-Blue799-601-7330 S 16P-White
799-601-7350 S 12P-White799-601-7180 AMP040 8P799-601-7190 AMP040 12P799-601-7210 AMP040 16P799-601-7220 AMP040 20P799-601-7230 Short connector X-2799-601-7240 Case799-601-7270 Case799-601-7510 070 10P
799-601-7520 070 12P799-601-7530 070 14P799-601-7540 070 18P799-601-7550 070 20P799-601-7360 Relay connector 5P799-601-7370 Relay connector 6P799-601-7380 JFC connector 2P799-601-9010 DTM 2P799-601-9020 DT 2P
799-601-9030 DT 3P799-601-9040 DT 4P799-601-9050 DT 6P799-601-9060 DT 8P-Gray799-601-9070 DT 8P-Black799-601-9080 DT 8P-Green799-601-9090 DT 8P-Brown799-601-9110 DT 12P-Gray799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green799-601-9140 DT 12P-Brown799-601-9210 HD30 18-8799-601-9220 HD30 18-14799-601-9230 HD30 18-20799-601-9240 HD30 18-21799 601 9250 HD24 24 9
TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH TABLE
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TROUBLESHOOTING T BRANCH BOX AND T BRANCH TABLE
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and fus-
ible link to see if the power is supplied normally.
Type of
power supplyFuse No. Fuse capacity Destination of powerDestination of power
Switch power supply
(Fusible link: A34)
1 10 A
Pump controller (Controller power supply)
Swing holding brake solenoid
(When emergency brake is released)
PC-EPC solenoid (When emergency pump is driven)
2 20 A
Pump controller (Solenoid power supply)
Machine push-up solenoid
ATT return selector relay & solenoid
3 10 AStarting motor cutout relay (For PPC lock)
PPC lock solenoid
4 10 ACigarette lighter
Windshield washer motor
5 10 A Horn
Switch power supply
(Fusible link: A34)
6 10 A (Spare)
7 10 A Rotary lamp
8 10 A Right front working lamp & boom working lamp
9 10 A
One-touch power maximizing switch
(Input to pump controller input)
Radio
10 10 A (Spare)
Switch power supply
(Fusible link: A34)
11 20 A Air conditioner unit
12 20 AMonitor panel
Starting motor cutout relay (For personal code)
13 20 ALight relay (For right front working lamp & boom working lamp)
Headlamp & additional headlamp
14 10 A Service power supply 1 (M32 connector)
15 10 ATravel alarm
Service power supply 2 (DC/DC converter)
Constant
power supply
(Fusible link: A35)
16 10 A Radio (For backing up)
17 10 A Monitor panel (For backing up)
18 10 A Starting switch
19 10 A Room lamp
20 10 A (Spare)
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INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-304
Error Code in Electrical System [E112]
(Short-circuiting in normal rotation system of windshield wiper motor drive)........................................ 20-306
Error Code in Electrical System [E113]
(Short-circuiting in reverse rotation system of windshield wiper motor drive)....................................... 20-308
Error Code in Electrical System [E114] (Short-circuiting in window washer drive system)......................... 20-310
Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion) ........................................... 20-312
Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper) ................................. 20-314Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)............................................. 20-316
Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)........................................... 20-318
Error Code in Electrical System [E128] (Monitor Comm. Abnormality)....................................................... 20-320
Error Code in Electrical System [E201] (Short-circuiting in travel interlocking solenoid) ............................ 20-322
Error Code in Electrical System [E203] (Short-circuiting in swing holding brake solenoid) ........................ 20-324
Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid).................................... 20-326
Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid) ................................... 20-327
Error Code in Electrical System [E206] (Short-circuiting in travel speed shifting solenoid) ........................ 20-328Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid).............................. 20-329
Error Code in Electrical System [E213] (Disconnection in swing holding brake solenoid).......................... 20-330
Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)..................................... 20-332
Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)..................................... 20-333
Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid).......................... 20-334
Error Code in Electrical System [E217] (Abnormal input model code)........................................................ 20-336
Error Code in Electrical System [E218] (S-Net Comm. Disc.)..................................................................... 20-338
Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid) ........................................... 20-340
Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system) ................................ 20-341Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality) .................................................. 20-342
Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality) .................................................. 20-344
Error Code in Electrical System [E226] (Press. Sensor Power Abnormality).............................................. 20-346
Error Code in Electrical System [E227] (Abnormality in engine rotation sensor) ........................................ 20-348
Error Code in Electrical System [E228] (Short-circuiting in attachment return switching relay).................. 20-349
TROUBLESHOOTING WHEN ERROR CODE
“ELECTRICAL SYSTEM” AND FAILURE CODE
“MECHANICAL SYSTEM” ARE DISPLAYED
TROUBLESHOOTING
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Error Code in Electrical System [E936] (Engine oil press. sw. error) .......................................................... 20-376
Error Code in Electrical System [E93C] (Engine boost sensor error) ......................................................... 20-378
Error Code in Electrical System [E93D] (Engine fuel temp. sensor error) .................................................. 20-380
Error Code in Electrical System [E953] (Engine Comm. Abnormality)........................................................ 20-382Error Code in Electrical System [E954] (Short engine starter sw.).............................................................. 20-384
Error Code in Electrical System [E955] (Engine S-NET error) .................................................................... 20-386
Error Code in Electrical System [E956] (Engine power failure (1)) ............................................................. 20-388
Error Code in Electrical System [E957] (Engine power failure (2)) ............................................................. 20-390
Error Code in Electrical System [E95A] (Engine Q-adj. sw. signal error).................................................... 20-392
Error Code in Electrical System [E96A] (Engine coolant sensor Lo error).................................................. 20-394
Error Code in Electrical System [E970] (PCV1 over current)...................................................................... 20-396
Error Code in Electrical System [E971] (PCV2 over current)...................................................................... 20-397
Error Code in Electrical System [E974] (PCV1 line cut).............................................................................. 20-398
Error Code in Electrical System [E975] (PCV2 line cut).............................................................................. 20-399
Error Code in Electrical System [E977] (Rail press. sensor error) .............................................................. 20-400
Error Code in Electrical System [E979] (Rail press. high)........................................................................... 20-402
Error Code in Electrical System [E97A] (Rail press. abnormal) .................................................................. 20-402
Error Code in Electrical System [E97B] (Rail press. low)............................................................................ 20-403
Error Code in Electrical System [E97C] (Rail press. too low) ..................................................................... 20-405
Error Code in Electrical System [E97D] (Rail press. out of control)............................................................ 20-405
Error Code in Electrical System [E980] (Eng. Controller Abnormality) ....................................................... 20-406Error Code in Electrical System [E981] (Fuel Injector 1 Disc.).................................................................... 20-408
Error Code in Electrical System [E982] (Fuel Injector 2 Disc.).................................................................... 20-409
Error Code in Electrical System [E983] (Fuel Injector 3 Disc.).................................................................... 20-410
Error Code in Electrical System [E984] (Fuel Injector 4 Disc.).................................................................... 20-411
Error Code in Electrical System [E985] (Fuel Injector 5 Disc.).................................................................... 20-412
Error Code in Electrical System [E986] (Fuel Injector 6 Disc.).................................................................... 20-413
Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C) ............................................................... 20-414
Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C) ............................................................... 20-416
Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)........................... 20-418Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard) ............................ 20-418
Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging) ........................................................ 20-420
Failure Code in Mechanical System [AB00KE] (Charge Voltage Low) ....................................................... 20-422
Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)...................................................... 20-424
Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)........................................................ 20-426
Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat).................................................... 20-427
Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)....................................................... 20-428
Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)........................................................ 20-429
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TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
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INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
aThe troubleshooting table and the related circuit diagrams contain the following information. Grasp their con-tents fully before proceeding to actual troubleshooting work.
User Code Error Code Failure CodeFailure
phenomenonTitle of failure phenomenon shown in failure historyDisplay in
monitor panel
Display in
monitor panel
Display in
monitor panel
Failure content Failure status as detected by monitor panel or controller
Response from
monitor panel
or controller
Action taken by the monitor panel or controller to protect an affected system or equipment, when they
detect some failure.
Phenomenon
occurring on
machine
Phenomenon that occurs on the machine, resulting from the above action taken by the monitor panel or
controller
Relative
informationInformation on the failure occurred as well as the troubleshooting
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Cause that presumably
triggered failure in
question (The assigned
No. is for filing purpose
only. It does not stand for
any priority)
<Content Included>• Standard value in normalcy by which to pass “Good” or “No Good” judgement
over the presumed cause
• Reference for passing the above “Good” or “No Good” judgement
<Phenomenon of Wiring Harness Failure>
• Disconnection
There is a faulty contact at the connector or disconnection of wiring harness
occurred.
• Defective grounding
A wiring harness that is not connected with a grounding circuit has a contact withthe grounding circuit.
• Short-circuiting
A wiring harness that is not connected with a 24 V electric circuit has a contact
with the electric circuit.
<Precaution for Troubleshooting>
1) Connector No. display method and handling of T-adapter
Insert or connect T-adapters in the following manner before starting
troubleshooting unless otherwise instructed.• If there is no indication of “male” or “female” in a specific connector No.,
disconnect the connector and insert the T-adapter into both male and female
sides.
• If there is an indication of “male” or “female” in a specific connector No.,
disconnect the connector and connect the T-adepter with only one side of either
“male” or “female”
2
3
4
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
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Relative Electrical Circuit Diagram
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow: Roughly indicates the location in the machine where it is installed.
TROUBLESHOOTING E112
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Error Code in Electrical System [E112](Short-circuiting in normal rotation system of windshield wiper motor drive)
User Code Error Code Failure Code Failure
phenomenon
Short-circuiting in normal rotation system of wind-
shield wiper motor drive (in monitor panel system)— E112 DY2DKB
Failure content • Abnormal current flew to the windshield wiper motor normal rotation circuit, when power is provided.
Response from
Monitor Panel• Power supply to the windshield wiper motor normal rotation circuit is turned OFF.
Phenomenon
occurring on
machine
• The windshield wiper stops moving.
Relative
information
P r e s u m e d c a u s e a n d
s
t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Windshield wiper motor
defective
(Internal short-circuitingor grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position for the troubleshooting.
W04 (female) Continuity and resistance value
Between (3) and (1) Continued
Between (3) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position for the troubleshooting.
Between wiring harness between P01 (female) (9) and
W04 (male) (3) and grounding
Resistance
value
Above
1 Mz
3 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position for the troubleshooting.
P01 Windshield wiper switch Voltage
Between (9) and ground-
ing
OFF Below 3 V
ONBelow 3 V 20 – 30 V
(at constant cycle)
TROUBLESHOOTING E112
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Electric Circuit Diagram for Windshield Wiper Motor
TROUBLESHOOTING E113
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Error Code in Electrical System [E113](Short-circuiting in reverse rotation system of windshield wiper motor drive)
User Code Error Code Failure Code Failure
phenomenon
Short-circuiting in reverse rotation system of wind-
shield wiper motor drive (in Monitor Panel system)— E113 DY2EKB
Failure content• Abnormal current flew to the reverse rotation circuit of the windshield wiper motor drive, when the
windshield wiper was set in motion.
Response from
Monitor Panel• Power supply to the reverse rotation circuit of the windshield wiper motor drive was switched OFF.
Phenomenon
occurring on
machine
• The windshield wiper stopped moving.
Relative
information
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Windshield wiper motor
defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position for the troubleshooting.
W04 (female) Continuity and resistance value
Between (1) and (3) Continued
Between (1) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position for the troubleshooting.
Between wiring harness between P01 (female) (10) and
W04 (male) (1) and grounding
Resistance
value
Above
1 Mz
3 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position for the troubleshooting.
P01 Windshield wiper switch Voltage
Between (10) and
grounding
OFF Below 3 V
ONBelow 3 V 20 – 30 V
(at constant cycle)
TROUBLESHOOTING E113
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Electric Circuit Diagram for Windshield Wiper Motor
TROUBLESHOOTING E114
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Error Code in Electrical System [E114](Short-circuiting in window washer drive system)
User Code Error Code Failure Code Failure
phenomenon
Short-circuiting in window washer drive system
(in Monitor Panel system)— E114 DY2CKB
Failure content• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power
was switched ON.
Response from
Monitor Panel• Power supply to the grounding in the window washer motor circuit was switched OFF.
Phenomenon
occurring on
machine
• The window washer stopped moving.
Relative
information
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c
y
Cause Standard value in normalcy and references for troubleshooting
1
Window washer drive
motor defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position for the troubleshooting.
A50 (male) Resistance value
Between (1) and (2) 5 – 20 z
2
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position for the troubleshooting.
Between wiring harness from P01 (female) (3) to J04 to
A50 (female) (2) and grounding, or between wiring
harness between P01 (female) (3) and D02 (female) (8)
and grounding
Voltage Below 1 V
3 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position for the troubleshooting.P01 Window washer switch Voltage
Between (3) and
grounding
OFF 20 – 30 V
ON Below 1 V
TROUBLESHOOTING E114
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Electrical Circuit Diagram for Window Washer Motor
TROUBLESHOOTING E115
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Error Code in Electrical System [E115] (Abnormal Windshield Wiper Motion)
User Code Error Code Failure Code Failure
phenomenon
Abnormal operation of windshield wiper
(in Monitor Panel system)— E115 DY20KA
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
Monitor Panel• Power to the windshield wiper motor is turned OFF.
Phenomenon
occurring on
machine
• The windshield wiper motor does not work.
Relative
information
• Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
P r e s u m e d c a u s e a n d
s
t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Windshield wiper motor
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position for the troubleshooting.
W04 (female) Windshield wiper blade Resistance value
Between (6) and (5)
At upper end of operation
rangeBelow 1 z
Outside upper end ofoperation range
Above 1 Mz
2
Disconnection of wiring
harness
(Disconnection or faulty
contact with connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position for the troubleshooting.
Wiring harness between P01 (female) (5) and W04
(male) (6)
Resistance
valueBelow 1 z
Wiring harness between W04 (male) (5) and groundingResistance
valueBelow 1 z
3 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ONposition for the troubleshooting.
P01 Windshield wiper blade Voltage
Between (5) and
grounding
At upper end of operation
rangeBelow 1 V
Outside upper end of
operation range2 0 – 3 0 V
TROUBLESHOOTING E115
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Windshield Wiper Motor Electrical Circuit Diagram
TROUBLESHOOTING E116
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Error Code in Electrical System [E116] (Abnormality in retracting windshield wiper)
User Code Error Code Failure Code Failure
phenomenon
Abnormal in retracting windshield wiper
(in Monitor Panel system)— E116 DY20MA
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from
Monitor Panel
• Power supply to the windshield wiper motor is switched OFF, when the wiper is
retracted.
Phenomenon
occurring on
machine
• The windshield wiper cannot be retracted completely.
Relative
information
• It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
range is inputted or not. (Code No.: 04502 Monitor Input 3)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Windshield wiper motor
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position for the troubleshooting.
W04 (female) Windshield wiper blade Resistance value
Between (4) and (5)Retraction range Below 1 z
Operation range Above 1 Mz
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P01 (female) (12) and W04
(male) (4)
Resistance
valueBelow 1 z
Between wiring harness W04 (male) (5) and groundingResistance
valueBelow 1 z
3 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P01 Windshield wiper blade Voltage
Between (12) and
grounding
Retraction range Below 1V
Operation range 20 – 30 V
TROUBLESHOOTING E116
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Windshield Wiper Motor Electrical Circuit Diagram
TROUBLESHOOTING E117
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Error Code in Electrical System [E117] (Eng. Controller S-NET Comm. Err.)
User Code Error Code Failure Code Failure
phenomenon
Eng. Controller S-NET Comm. Err.
(Monitor panel system)— E117 DAC0KR
Failure content• The monitor panel detected communication failure in the S-NET communication circuit to the engine
controller.
Response from
monitor panel
• The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The pump absorption torque is reduced).
• If the working load increases, the engine may stall.
Relative
information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
(Code No. 05100: Connection of S-NET)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Disconnection of wiring
harness
(Disconnection or defec-
tive contact with connec-
tor)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (9), (10) and CB2
(female) (21), (31) or between P02 (female) (9), (10)
and C02 (female) (21)
Resistance
valueBelow 1 z
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P02 (female) (9), (10)
and CB2 (female) (21), (31) or between P02 (female)
(9), (10) and C02 (female) (21) and related circuits and
grounding
Resistance
value Above 1 Mz
3Short-circuiting of wiringharness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P02 (female) (9), (10)
and CB2 (female) (21), (31) or between P02 (female)
(9), (10) and C02 (female) (21) and related circuits and
grounding
Voltage Below 1 V
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
CB2 Voltage
Between (21), (31) and (11) 6 – 9 V
5 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Voltage
Between (9), (10) and (20) 6 – 9 V
TROUBLESHOOTING E117
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Electrical circuit diagram related to S-NET communication
TROUBLESHOOTING E118
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Error Code in Electrical System [E118] (Pump Controller S-NET Comm. Err.)
User Code Error Code Failure Code Failure
phenomenon
Pump Controller S-NET Comm. Err.
(Monitor panel system)— E118 DAB0KR
Failure content• The monitor panel detected communication failure in the S-NET communication circuit to the pump
controller.
Response from
monitor panel
• The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The pump absorption torque is reduced).
• If the working load increases, the engine may stall.
Relativeinformation
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.(Code No. 05100: Connection of S-NET)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Disconnection of wiring
harness
(Disconnection or defec-
tive contact with connec-
tor)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (9), (10) and CB2
(female) (21), (31) or between P02 (female) (9), (10)
and C02 (female) (21)
Resistance
valueBelow 1 z
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P02 (female) (9), (10)
and CB2 (female) (21), (31) or between P02 (female)
(9), (10) and C02 (female) (21) and related circuits and
grounding
Resistance
value Above 1 Mz
3Short-circuiting of wiringharness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P02 (female) (9), (10)
and CB2 (female) (21), (31) or between P02 (female)
(9), (10) and C02 (female) (21) and related circuits and
grounding
Voltage Below 1 V
4Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C02 Voltage
Between (21) and (31) 6 – 9 V
5 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Voltage
Between (9), (10) and (20) 6 – 9 V
TROUBLESHOOTING E118
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Electrical circuit diagram related to S-NET communication
TROUBLESHOOTING E128
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Error Code in Electrical System [E128] (Monitor Comm. Abnormality)
User Code Error Code Failure Code Failure
phenomenon
Monitor Comm. Abnormality
(Monitor panel system)E0E E128 DAF0MC
Failure content• The monitor panel detected communication failure in the CAN communication circuit to the engine con-
troller or pump controller.
Response from
monitor panel
• The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The pump absorption torque is reduced).
• If the working load increases, the engine may stall.
Relativeinformation
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Disconnection of wiring
harness
(Disconnection or defec-
tive contact with connec-tor)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P70 (female) (16) and CB2
(female) (22) or between P70 (female) (16) and C02
(female) (22)
Resistance
valueBelow 1 z
Wiring harness between P70 (female) (15) and CB2
(female) (32) or between P70 (female) (15) and C02
(female) (32)
Resistance
valueBelow 1 z
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P70 (female) (16) and
CB2 (female) (22) or between P70 (female) (16) and
C02 (female) (22) or between P70 (female) (16) and
related circuits and grounding
Resistance
value Above 1 Mz
Between wiring harness between P70 (female) (15) and
CB2 (female) (32) or between P70 (female) (15) and
C02 (female) (32) or between P70 (female) (15) and
related circuits and grounding
Resistance
value Above 1 Mz
3
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P70 (female) (16) and
CB2 (female) (22) or between P70 (female) (16) andC02 (female) (22) or between P70 (female) (16) and
related circuits and grounding
Voltage Below 1 V
Between wiring harness between P70 (female) (15) and
CB2 (female) (32) or between P70 (female) (15) and
C02 (female) (32) or between P70 (female) (15) andVoltage Below 1 V
TROUBLESHOOTING E128
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Electrical circuit diagram related to CAN communication
TROUBLESHOOTING E201
E C d i El t i l S t [E201]
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Error Code in Electrical System [E201](Short-circuiting in travel interlocking solenoid)
Electrical Circuit for Travel Interlocking Solenoid
User Code Error Code Failure Code Failure
phenomenon
Short-circuiting in travel interlocking solenoid
(Pump controller system)— E201 DW91KB
Failure content • Abnormal current flew to the travel interlocking circuit, when power was supplied to the circuit.
Response from
controller
• Power supply to the travel interlocking circuit is switched OFF.
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• It is difficult to steer the machine at turns. (L.H. and R.H. travel circuits connot be disconnected)
Relative
information
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c
y
Cause Standard value in normalcy and references for troubleshooting
1
Travel interlocking sole-
noid defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V02 (male) Resistance value
Between (1) and (2) 20 – 60 zBetween (2) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness from C03 (female) (7) to V02
(female) (2) and grounding
Resistance
value
Above
1 Mz
3Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it running during
the troubleshooting.
C03 R.H. & L.H. travel controllever
Voltage
Between (7) and
grounding
Neutral Below 1 V
Steering 20 – 30 V
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TROUBLESHOOTING E203
Error Code in Electrical System [E203]
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Error Code in Electrical System [E203](Short-circuiting in swing holding brake solenoid)
User Code Error Code Failure Code Failurephenomenon
Short-circuiting in swing holding brake solenoid(Pump controller system)E03 E203 DW45KB
Failure content• Abnormal current flew to the swing holding brake solenoid circuit, when power was supplied to the
circuit.
Response from
controller
• Power supply to the swing holding brake solenoid circuit is switched OFF.
• Even after the failure cause disappears of itself, the swing and steering brake does not return to
normalcy, unless the engine starting switch is once turned OFF.
Phenomenon
occurring onmachine
• The upper structure cannot swing. (The swing holding brake cannot be released.)
Relative
information
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
• If there is no abnormality with the solenoid or wiring harness, the upper structure can swing by turning
the swing holding brake releasing switch to the RELEASE position.
(In this case, however, the holding brake does not work, when stopping the machine)
P r e s u m e
d c a u s e a n d
s t a n d a r d v a
l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Swing holding brake
solenoid defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
V05 (male) Resistance value
Between (1) and (2) 20 – 60 z
Between (2) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with groundingcircuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (37) to D01 to J02 to
X05 to V05 (female) (2), or C03 (female) (37) and S25
(female) (8) and grounding
Resistancevalue
Above1 Mz
3Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it running during
the troubleshooting.
C03L.H. work equipment
control lever Voltage
Between (37) and
grounding
NEUTRAL Below 1 V
Swing operated 20 – 30 V
TROUBLESHOOTING E203
Electrical Circuit Diagram for Swing Holding Brake Solenoid
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Electrical Circuit Diagram for Swing Holding Brake Solenoid
TROUBLESHOOTING E204
Error Code in Electrical System [E204] (Short-circuiting in merge/divide solenoid)
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Error Code in Electrical System [E204] (Short circuiting in merge/divide solenoid)
Electrical Circuit Diagram for Merge/Divide Solenoid
User Code Error Code Failure Code Failure
phenomenon
Short-circuiting in merge/divide solenoid
(Pump controller system)— E204 DWJ0KB
Failure content • Abnormal current flew to the merge/divide solenoid circuit, when power was supplied to the circuit.
Response from
controller
• Power supply to the merge/divide solenoid circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• In L mode, the work equipment moves slowly, or the swing speed is slow in its single operation.
(F•R pumps cannot be disconnected.)
Relativeinformation
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.(Code No.: 02300 Solenoid 1)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Merge/divide solenoid
defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V03 (male) Resistance value
Between (1) and (2) 20 – 60 z
Between (2) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (17) to V03 (female)
(2) and grounding
Resistance
value
Above
1 Mz
3Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it running during
the troubleshooting.
C03L.H. and R.H. travel
control levers
Voltage
Between (17) and
grounding
NEUTRAL Below 1 V
When operating one side
only2 0 – 3 0 V
TROUBLESHOOTING E205
Error Code in Electrical System [E205] (Short-circuiting in 2-stage relief solenoid)
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Error Code in Electrical System [E205] (Short circuiting in 2 stage relief solenoid)
Electric Circuit Diagram for 2-stage Relief Solenoid
User Code Error Code Failure Code Failure
phenomenon
Short-circuiting in 2-stage relief solenoid
(Pump controller system)— E205 DWK0KB
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
Response from
controller
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The one-touch power max. switch does not work.
(The main relief valve cannot be set to high-pressure set.)
Relativeinformation
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.(Code No.: 02300 Solenoid 1)
P r e s u m e d c a u s e
a n d
s t a n d a r d v a l u e i n n o
r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
2-stage relief solenoid
defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V08 (male) Resistance value
Between (1) and (2) 20 – 60 z
Between (2) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (28) to V08 (female)
(2) and grounding
Resistance
value
Above
1 Mz
3Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C03 Working mode Voltage
Between (28) and
grounding
Other than L mode Below 1 V
L mode 20 – 30 V
TROUBLESHOOTING E206
Error Code in Electrical System [E206]
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y [ ](Short-circuiting in travel speed shifting solenoid)
Electrical Circuit Diagram for Travel Speed Shifting Solenoid
User Code Error Code Failure Code Failurephenomenon
Short-circuiting in travel speed shifting solenoid(Pump controller system)— E206 DW43KB
Failure content • Abnormal current flew to the travel speed shifting solenoid, when power was supplied to the circuit.
Response from
controller
• Power supply to the travel speed shifting solenoid circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The travel speed does not turn to Hi.
(The travel motor swash plate angle does not turn to minimum.)
Relative
information
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a
l c y
Cause Standard value in normalcy and references for troubleshooting
1
Travel speed shifting
solenoid defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V04 (male) Resistance value
Between (1) and (2) 20 – 60 zBetween (2) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (27) to V04 (female)
(2) and grounding
Resistance
value
Above
1 Mz
3 Pump controllerdefective
aTurn the engine starting switch OFF for the preparations, and hold it running during
the troubleshooting.
C03 Travel speed + travel lever Voltage
Between (27) and
grounding
Lo + Neutral Below 1 V
Hi + Travel operation 20 – 30 V
TROUBLESHOOTING E211
Error Code in Electrical System [E211] (Disconnection in travel interlocking solenoid)
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Electrical Circuit Diagram for Travel Interlocking Solenoid
User Code Error Code Failure Code Failure
phenomenon
Disconnection in travel interlocking solenoid
(Pump controller system)— E211 DW91KA
Failure content • No current flows to the travel interlocking solenoid circuit, when power is supplied to the circuit.
Response from
controller
• None in particular (The solenoid does not function as there is current flowing to it)
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• It is difficult to steer the machine while traveling. (L.H. and R.H. travel circuits cannot be disconnected.)
Relative
information
• Operation of the travel interlocking solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)• The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power
ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code
[E201].)
P r e s u m e d c a u s e a n d
s t a n d
a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Travel interlocking
solenoid defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V02 (male) Resistance value
Between (1) and (2) 20 – 60 z
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (7) to V02 (female)
(2)
Resistance
valueBelow 1 z
Wiring harness between C03 (female) (3), (13), (23)
and V02 (female) (1)
Resistance
valueBelow 1 z
3Short-circuiting of wiringharness
(Contact with 24 V cir-
cuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Wiring harness from C03 (female) (7) to V02 (female)
(2) and groundingVoltage Below 1 V
4Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
Between (7) and (3), (13), (23) 20 – 60 z
TROUBLESHOOTING E213
Error Code in Electrical System [E213]
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(Disconnection in swing holding brake solenoid)
User Code Error Code Failure Code Failurephenomenon
Disconnection in swing holding brake solenoid(Pump controller system)E03 E213 DW45KA
Failure content • No current flows to the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from
controller
• None in particular (The solenoid does not function as there is no current flowing to it)
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The machine's upper structure does not swing. (The swing holding brake cannot be released.)
Relative
information
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.(Code No.: 02300 Solenoid 1)
• If there is abnormality neither with the solenoid nor with wiring harnesses, the upper structure can
swing by moving the swing holding brake release switch to the RELEASE position. (In this case,
however, the holding brake does not work, when stopping the machine)
• While in troubleshooting, hold both the swing lock switch and the swing holding brake release switch in
the OFF position.
• The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power
ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code
[E203].)
e s u m e d c a u s e
a n d
d a r d v a l u e i n n o
r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Swing holding brake
solenoid defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V05 (male) Resistance value
Between (1) and (2) 20 – 60 z
2Swing lock switchdefective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
X05 (female) Swing lock switch Resistance value
Between (3) and (4)OFF Below 1 z
ON Above 1 Mz
3
Assembled-type diode
D01 defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
D01 (male) Digital type circuit tester Continuity
Between (7) and (3) Diode mode Continued
Disconnection of
wiring harness
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C03 (female) (37) and D01
(female) (7)
Resistance
valueBelow 1 z
Wiring harness from D01 (female) (3) to J02 to X05 Resistance
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TROUBLESHOOTING E214
Error Code in Electrical System [E214] (Disconnection of merge/divide solenoid)
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Electrical Circuit Diagram for Merge/Divide Solenoid
User Code Error Code Failure Code Failure
phenomenon
Disconnection in merge/divide solenoid
(Pump controller system)— E214 DWJ0KA
Failure content • No current flows to the merge/divide solenoid circuit, when power is supplied to the circuit.
Response from
controller
• None in particular (The solenoid does not function as there is no current flowing to it)
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• In L mode, speeds of the work equipment and swing in its single operation are too fast.
(F•R pumps cannot be disconnected.)
Relative
information
• Operation of the merge/divide solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)• The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power
ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code
[E204].)
P r e s u m e d c a u s e a n d
s t a n d
a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Merge/divide solenoid
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V03 (male) Resistance value
Between (1) and (2) 20 – 60 z
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (17) to V03 (female)
(2)
Resistance
valueBelow 1 z
Wiring harness between C03 (female) (3), (13), (23)
and V03 (female) (1)
Resistance
valueBelow 1 z
3
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Wiring harness from C03 (female) (17) to V03 (female)
(2) and groundingVoltage Below 1 V
4Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
Between (17) and (3), (13), (23) 20 – 60 z
TROUBLESHOOTING E215
Error Code in Electrical System [E215] (Disconnection in 2-stage relief solenoid)
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Electrical Circuit Diagram for 2-stage Relief Solenoid
User Code Error Code Failure Code Failure
phenomenon
Disconnection in 2-stage relief solenoid
(Pump controller system)— E215 DWK0KA
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from
controller
• None in particular (The solenoid does not function as there is no current flowing to it)
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The one-touch power max. switch does not work.
(The main relief valve cannot be set to high-pressure set.)
Relative
information
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)• The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power
ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code
[E205].)
P r e s u m e d c a u s e a n d
s t a n d
a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
2-stage relief solenoid
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V08 (male) Resistance value
Between (1) and (2) 20 – 60 z
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (28) to V08 (female)
(2)
Resistance
valueBelow 1 z
Wiring harness between C03 (female) (3), (13), (23)
and V08 (female) (1)
Resistance
valueBelow 1 z
3
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Wiring harness from C03 (female) (28) to V08 (female)
(1) and groundingVoltage Below 1 V
4Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
Between (28) and (3), (13), (23) 20 – 60 z
TROUBLESHOOTING E216
Error Code in Electrical System [E216] (Disconnection in travel speed shifting solenoid)
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Electrical Circuit Diagram for Travel Speed Shifting Solenoid
User Code Error Code Failure Code Failure
phenomenon
Disconnection in travel speed shifting solenoid
(Pump controller system)— E216 DW43KAFailure content • No current flows to the travel speed shifting solenoid circuit, when power is supplied to the circuit.
Response from
controller
• None in particular (The solenoid does not function as there is no current flowing to it)
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The travel speed does not shift to Hi.
(The travel motor swash plate angle does not turn to minimum.)
Relative
information
• Operation of the travel speed shifting solenoid (ON or OFF) can be checked in the monitoring function.
(Code No.: 02300 Solenoid 1)• The controller detects disconnection, when solenoid power is ON. Hence be sure to check it with power
ON after the repairs. (For how to turn power ON or OFF, refer to the troubleshooting under Error Code
[E206].)
P r e s u m e d c a u s e a n d
s t a n d
a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Travel speed shifting
solenoid defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V04 (male) Resistance value
Between (1) and (2) 20 – 60 z
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (27) to V04 (female)
(2)
Resistance
valueBelow 1 z
Wiring harness between C03 (female) (3), (13), (23)
and V04 (female) (1)
Resistance
valueBelow 1 z
3
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Wiring harness from C03 (female) (27) to V04 (female)
(2) and groundingVoltage Below 1 V
4Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
Between (27) and grounding (3), (13), (23) 20 – 60 z
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TROUBLESHOOTING E217
Error Code in Electrical System [E217] (Abnormal input model code)
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User Code Error Code Failure Code Failure
phenomenon
Abnormality in inputting model code
(Pump controller system)— E217 DA2SKQFailure content • A model code signal for a model which is not registered in the controller is inputted.
Response from
controller
• The controller controls the machine as a default model (PC750).
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• Since the controller controls the machine as PC750/800, the working speed changes and operation
becomes difficult.
Relative
information
• The model name (number) recognized by the controller can be checked in the monitoring function.(Code No. 00200: Controller model code)
• Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Code No. 02201: Switch input 2)
P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Model selection connec-
tor defective
(Internal disconnection orshort-circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C09 (female) Resistance value
Between (4), (5), (6) and (8) Min. 1 Mz
Between (1), (2), (3), (7) and (8) Max. 1 z
2
Disconnection of wiring
harness
(Disconnection or defec-tive contact with connec-
tor)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C02 (female) (37) and C09
(male) (1)
Resistance
valueMax, 1 z
Wiring harness between C02 (female) (27) and C09
(male) (2)
Resistance
valueMax, 1 z
Wiring harness between C02 (female) (17) and C09
(male) (3)
Resistance
valueMax, 1 z
Wiring harness between C02 (female) (13) and C09
(male) (7)
Resistance
valueMax, 1 z
Wiring harness between C09 (male) (8), J05, and
grounding
Resistance
valueMax, 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C02 (female) (7) and
C09 (male) (4) and grounding
Resistance
valueMin. 1 Mz
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C02 V lt
TROUBLESHOOTING E217
Electrical circuit diagram related to model selection connector (for pump controller)
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TROUBLESHOOTING E218
Error Code in Electrical System [E218] (S-Net Comm. Disc.)
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User Code Error Code Failure Code Failure
phenomenon
S-Net Comm. Disc.
(Pump controller system)E0E E218 DA2SKA
Failure content• The pump controller detected communication failure in the S-NET communication circuit to the monitor
panel or engine controller.
Response from
controller
• The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The pump absorption torque is reduced).
• If the working load increases, the engine may stall.
Relativeinformation
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.(Code No. 05100: Connection of S-NET)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (9), (10) and CB2
(female) (21), (31) or between P02 (female) (9), (10)
and C02 (female) (21)
Resistance
valueMax. 1 z
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P02 (female) (9), (10)
and CB2 (female) (21), (31) or between P02 (female)
(9), (10) and C02 (female) (21) or between P02 (female)
(9), (10) and related circuits and grounding
Resistance
valueMin. 1 Mz
3 Short-circuiting of wiringharness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P02 (female) (9), (10)and CB2 (female) (21), (31) or between P02 (female)
(9), (10) and C02 (female) (21) or between P02 (female)
(9), (10) and related circuits and grounding
Voltage Max. 1 V
4 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Voltage
Between (9), (10) and (20) 6 – 9 V
5Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ONposition during the troubleshooting.
CB2 Voltage
Between (21), (31) and (11) 6 – 9 V
a O f O
TROUBLESHOOTING E218
Electrical Circuit Diagram for S-NET Communication
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TROUBLESHOOTING E222
Error Code in Electrical System [E222] (Short-circuiting in LS-EPC solenoid)
User Code Error Code Failure Code F il Di i i LS EPC l id
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Electrical Circuit Diagram for LS-EPC Solenoid
User Code Error Code Failure Code Failure
phenomenon
Disconnection in LS-EPC solenoid
(Pump controller system)— E222 DXE0KBFailure content • Abnormal current flew to the LS-EPC solenoid circuit.
Response from
controller
• The controller reduces the output to the LS-EPC solenoid circuit to 0.
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
switch is once turned OFF.
Phenomenon
occurring on
machine
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
fast. (The LS valve set pressure cannot be controlled.)
Relativeinformation
• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.(Code No.: 01500 LS-EPC solenoid current)
P r e s u m e d c a u s e
a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
LS-EPC solenoid
defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V22 (male) Resistance value
Between (1) and (2) 7 – 14 z
Between (1) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (6) and
V22 (female) (1) and grounding
Resistance
value
Above
1 Mz
3Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
Between (6) and (3) (13) (23) 7 – 14 zBetween (6) and grounding Above 1 Mz
TROUBLESHOOTING E223
Error Code in Electrical System [E223] (Disconnection in LS-EPC solenoid system)
User Code Error Code Failure Code F il Di ti i LS EPC l id
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Electrical Circuit Diagram for LS-EPC Solenoid
User Code Error Code Failure Code Failure
phenomenon
Disconnection in LS-EPC solenoid
(Pump controller system)— E223 DXE0KAFailure content • No current flows to the LS-EPC solenoid circuit.
Response from
controller
• None in particular (The solenoid does not function as there is no current flowing to it)
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The travel speed is slow at Mi and Lo, or in L mode, speeds of the work equipment and swing are too
fast. (The LS valve set pressure cannot be controlled.)
Relative
information
• Output to LS-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01500 LS-EPC solenoid current)
P r e s u m e d c a u s e a n
d
s t a n d a r d v a l u e i n n o r m
a l c y
Cause Standard value in normalcy and references for troubleshooting
1
LS-EPC solenoid
defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V22 (male) Resistance value
Between (1) and (2) 7 – 14 z
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (6) and
V22 (female) (1) and grounding
Resistance
valueBelow 1 z
Wiring harness between C03 (female) (3) (13) (23) and
V22 (female) (2)
Resistance
valueBelow 1 z
3
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C03 (female) (6) and
V22 (female) (1) and groundingVoltage Below 1 V
4 Pump controller defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
Between (6) and (3) (13) (23) 7 – 14 z
TROUBLESHOOTING E224
Error Code in Electrical System [E224] (F Pump P. Sensor Abnormality)
User Code Error Code Failure Code Failure F Pump P Sensor Abnormality
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User Code Error Code Failure Code Failure
phenomenon
F Pump P. Sensor Abnormality
(Pump controller system)— E224 DHPAMAFailure content • Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V.
Response from
controller
• The controller sets the F pump pressure to 0 MP {0 kg/cm2} for control.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The travel speed does not shift automatically (The travel load pressure cannot be detected).
Relativeinformation
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
sensor will be broken. Accordingly, take extreme care when checking.• Input from the front pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 01100: Front pump pressure)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Sensor power supply
system defectiveIf error code [226] is displayed, carry out troubleshooting for it first.
2
Front pump pressure
sensor defective
(Internal defect)
aTurn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
A51 Voltage
Between (B) and (A) Power supply 4.5 – 5.5 V
Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C01 (female) (22) and A51
(female) (B)
Resistance
valueMax. 1 z
Wiring harness between C01 (female) (10) and A51
(female) (A)
Resistance
valueMax. 1 z
Wiring harness between C01 (female) (8) and P30
(female) (C)
Resistance
valueMax. 1 z
4
Grounding fault of wiring
harness(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C01 (female) (8) and
A51 (female) (C) and grounding
Resistance
valueMin. 1 Mz
Sh t i iti f i i
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
TROUBLESHOOTING E224
Electrical circuit diagram related to front pump pressure sensor
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TROUBLESHOOTING E225
Error Code in Electrical System [E225] (R Pump P. Sensor Abnormality)
User Code Error Code Failure Code Failure R Pump P. Sensor Abnormality
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Failure
phenomenon
R Pump P. Sensor Abnormality
(Pump controller system)— E225 DHPBMA
Failure content • Signal voltage from the rear pump pressure sensor is below 0.3 V or above 4.42 V.
Response from
controller
• The controller sets the R pump pressure to 0 MP {0 kg/cm2} for control.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The travel speed does not shift automatically (The travel load pressure cannot be detected).
Relativeinformation
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
sensor will be broken. Accordingly, take extreme care when checking.• Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 01101: Rear pump pressure)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Sensor power supply
system defectiveIf error code [226] is displayed, carry out troubleshooting for it first.
2
Rear pump pressure
sensor defective
(Internal defect)
aTurn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
A52 Voltage
Between (B) and (A) Power supply 4.5 – 5.5 V
Between (C) and (A) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.
3
Disconnection of wiring
harness
(Disconnection or defec-
tive contact with connec-
tor)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C01 (female) (22) and A52
(female) (B)
Resistance
valueMax. 1 z
Wiring harness between C01 (female) (10) and A52
(female) (A)
Resistance
valueMax. 1 z
Wiring harness between C01 (female) (2) and A52
(female) (C)
Resistance
valueMax. 1 z
4
Grounding fault of wiring
harness(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C01 (female) (2) and
A52 (female) (C) and grounding
Resistance
valueMin. 1 Mz
Sh t i iti f i i
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
TROUBLESHOOTING E225
Electrical circuit diagram related to rear pump pressure sensor
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TROUBLESHOOTING E226
Error Code in Electrical System [E226] (Press. Sensor Power Abnormality)
User Code Error Code Failure Code Failure Press. Sensor Power Abnormality
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phenomenon (Pump controller system)— E226 DA25KP
Failure content • Abnormal current flowed in the pressure sensor power supply (5 V) circuit.
Response from
controller
• Power to the power supply (5 V) circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The pressure sensor signal is not input normally.
• The error code of abnormality in the pressure sensor is displayed, too.
Relativeinformation
P r e s u m e d c
a u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Pressure sensor
defective(Internal short-circuiting)
aDisconnect the connector when the engine starting switch is in OFF, and hold it in
the ON position during the troubleshooting.
Disconnect the parts
shown at right in order.If the error code goes off
when one of those parts is
disconnected, that part is
defective.
Front pump
pressure sensor Connector A51
Rear pump
pressure sensor Connector A52
Arm IN PPC
pressure sensor Connector S04
Bucket CURL PPC
pressure sensor Connector S01
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C01 (female) (22),
A51 (female) (B) and grounding
[Front pump pressure sensor system]
Resistancevalue
Min. 1 Mz
Between wiring harness between C01 (female) (22),
A51 (female) (B) and grounding
[Rear pump pressure sensor system]
Resistance
valueMin. 1 Mz
Between wiring harness between C01 (female) (22),
S04 (female) (A) and grounding
[Arm IN PPC pressure sensor system]
Resistance
valueMin. 1 Mz
Between wiring harness between C01 (female) (22),S01 (female) (A) and grounding
[Bucket CURL PPC pressure sensor system]
Resistance
valueMin. 1 Mz
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
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TROUBLESHOOTING E227
Error Code in Electrical System [E227] (Abnormality in engine rotation sensor)
User Code Error Code Failure Code Failure
h
Abnormality in engine rotation sensor
(P t ll t )
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Electrical Circuit Diagram for Engine Rotation Sensor
phenomenon (Pump controller system)— E227 DLE2MA
Failure content • A normal pulse signal is not inputted to the signal circuit in the engine rotation sensor.
Response from
controller
• The controller exercises a control equivalent to E mode.
• If the failure cause disappears of itself, the signal input returns to normalcy.
Phenomenon
occurring on
machine
• The machine lacks power a bit. (The engine rotation sensing does not work.)
• The engine speed (in the pump controller system) is not monitored on the monitor panel.
Relative
information
• Input from the engine rotation sensor (rpm) can be confirmed in the monitor function.
(Code No.: 01006 Engine RPM)
P r e s u m e d c a u s e a n d
s t a
n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Engine rotation sensor
fault
(Internal short-circuiting
or disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
ENE (male) Resistance value
Between (1) and (2) 500 – 1,000 z
Between (1) and grounding Above 1 Mz
2 Engine rotation sensoradjustment improper For the inspection and adjustment, refer to the section of “Adjusting Engine RotationSensor” in this manual.
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C02 (female) (40) and ENE
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between C02 (female) (29) (39) and
ENE (female) (2)
Resistance
valueBelow 1 z
4
Short-circuiting of wiringharness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ONposition during the troubleshooting.
Between wiring harness between C02 (female) (40) and
ENE (female) (1) and groundingVoltage Below 1 V
5Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C02 (female) Resistance value
Between (40) and (29) (39) 500 – 1,000 z
Between (40) and grounding Above 1 Mz
TROUBLESHOOTING E228
Error Code in Electrical System [E228](Short-circuiting in attachment return switching relay)
U C d E C d F il C d
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Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
User Code Error Code Failure CodeFailurephenomenon Short-circuiting in attachment return switching relay(Pump controller system)— E228 D196KB
Failure content• Abnormal current flew to the attachment return switching relay circuit , when it was grounded (power
ON).
Response from
controller
• The controller turned OFF power to the attachment return switching relay circuit.
• Even when the failure cause disappears of itself, the current does not return to normalcy.
Phenomenon
occurring on
machine
• The hydraulic circuit for attachments is not switched to the single operation circuit.
(The switching valve is not switched to the tank circuit.)
Relative
information
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
or OFF). (Code No.: 02301 Solenoid 2)
• This error code detects abnormality on the primary side (coil side) of the attachment return selector
relay and cannot detect abnormality on the secondary side (contact side).
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Attachment return
switching relay defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
R20 (male) Resistance valueBetween (1) and (2) 100 – 500 z
2
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C02 (female) (8) and
R20 (female) (2) and groundingVoltage Below 1 V
3 Pump controllerdefective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C02 Working mode Voltage
Between (8) and
grounding
Other than B mode 20 – 30 V
B mode Below 1 V
TROUBLESHOOTING E232
Error Code in Electrical System [E232] (Short-circuiting in PC-EPC Solenoid)
User Code Error Code Failure Code Failure
phenomenon
Disconnection in PC-EPC solenoid
(Pump controller system)
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phenomenon (Pump controller system)E02 E232 DXA0KB
Failure content • Abnormal current flew to the PC-EPC solenoid circuit.
Response from
controller
• The controller reduces the output to the PC-EPC solenoid circuit to OFF.
• Even if the failure cause disappears, the current does not return to normalcy, unless the engine starting
switch is once turned OFF.
Phenomenon
occurring on
machine
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
(The pump absorption torque cannot be controlled.)
Relative
information
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01300 PC-EPC solenoid current)
• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be
operated in a working mode equivalent to E mode by turning the emergency pump drive switch to the
emergency position. (At that time the monitor panel continues to display Error Code No. [E233], but this
is not abnormal)
• Turn the emergency driving switch normal position during the troubleshooting.
P r e s u m e d c a u s e a
n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
PC-EPC solenoiddefective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V21 (male) Resistance value
Between (1) and (2) 7 – 14 z
Between (1) and grounding Above 1 Mz
2
Emergency pump driving
switch defective
(Internal short-circuitingor grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
S25 (male)Emergency pump drive
switchResistance value
Between (3) and (4)
Normal
Above 1 Mz
Between (3) and
grounding Above 1 Mz
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness from C03 (female) (16) to S25
(female) (3) and grounding
Resistance
value
Above
1 Mz
Between wiring harness from S25 (female) (2) to V21(female) (1) and grounding
Resistancevalue
Above1 Mz
4Pump controller
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
TROUBLESHOOTING E232
Electrical Circuit Diagram for PC-EPC Solenoid
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TROUBLESHOOTING E233
Error Code in Electrical System [E233] (Disconnection in PC-EPC solenoid system)
User Code Error Code Failure Code Failure
phenomenon
Disconnection in PC-EPC solenoid
(Pump controller system)E02 E233 DXA0KA
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p ( p y )E02 E233 DXA0KA
Failure content • No current flows to the PC-EPC solenoid circuit.
Response from
controller
• None in particular (The solenoid does not function as there is no current flowing to it)
• When the failure cause disappears of itself, the current returns to normalcy.
Phenomenon
occurring on
machine
• As load to the pump increases, the engine rotation drops sharply and sometimes the engine stalls.
(The pump absorption torque cannot be controlled.)
Relativeinformation
• Output to PC-EPC solenoid (ampere) can be confirmed in the monitor function.
(Code No.: 01300 PC-EPC solenoid current)
• If there is no abnormality with the solenoid or any of the wiring harnesses, the machine can be
operated in a working mode equivalent to E mode by turning the emergency pump driving switch to the
emergency position.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
PC-EPC solenoid
defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V21 (male) Resistance value
Between (1) and (2) 7 – 14 z
2
Emergency pump driving
switch defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
S25 (male)Emergency pump driving
switchResistance value
Between (2) and (3)Normal Below 1 z
Emergency Above 1 Mz
Between (5) and (6)
Normal Below 1 z
Emergency Above 1 Mz
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C03 (female) (16) and S25
(female) (3)
Resistance
valueBelow 1 z
Wiring harness between S25 (female) (2) and V21
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between C03 (female) (3) (13) (23) and
S25 (female) (6)
Resistance
value Below 1 z
Wiring harness between S25 (female) (5) and V21
(female) (2)
Resistance
valueBelow 1 z
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
TROUBLESHOOTING E233
Electrical Circuit Diagram for PC-EPC Solenoid
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TROUBLESHOOTING E238
Error Code in Electrical System [E238] (Disconnection in attachment return switching relay)
User Code Error Code Failure Code Failure
phenomenon
Disconnection in attachment return switching relay
(Pump controller system)— E238 D196KA
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Failure content• When the attachment return switching relay circuit is disconnected from grounding (power OFF), 24 V
voltage is not generated.
Response from
controller
• None in particular
• If the failure cause disappears, the governor returns to normalcy.
Phenomenon
occurring on
machine
• The hydraulic circuit for attachments cannot be switched to the single operation.
(The switching valve cannot be switched to the tank circuit.)
Relative
information
• It can be confirmed in the monitor function how the attachment return switching relay circuit works (ON
or OFF). (Code No.: 02301 Solenoid 2)
• This error code detects abnormality on the primary side (coil side) of the attachment return selector
relay and cannot detect abnormality on the secondary side (contact side).
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1 Fuse No. 2 faultIf fuse No.2 has been blown, there is a big possibility that grounding fault occurred in
the relay circuit. (See Cause 4.)
2
Attachment return
switching relay defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
R20 (male) Resistance value
Between (1) and (2) 100 – 500 z
3
Disconnection in wiring
harness (Disconnection
in wiring or defective
contact in connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C02 (female) (8) and R20
(female) (2)
Resistance
valueBelow 1 z
Wiring harness from R20 (female) (1) to J03 to FB1-2
outlet
Resistance
value
Below 1 z
4
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C02 (female) (8) and
R20 (female) (2) and grounding
Resistance
value
Above
1 Mz
Between wiring harness from R20 (female) (1) to J03 to
FB1-2 outlet and grounding
Resistance
value
Above
1 Mz
5Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.C02 Working mode Voltage
Between (8) and
grounding
Other than B mode 20 – 30 V
B mode Below 1 V
TROUBLESHOOTING E238
Electrical Circuit Diagram for Attachment Return Switching Relay and Solenoid
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TROUBLESHOOTING E245
Error Code in Electrical System [E245](Short-circuiting in attachment oil flow rate adjusting EPC)
User Code Error Code Failure Code Failure Short-circuiting in attachment oil flow rate adjusting
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Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
phenomenon EPC (Pump controller system)— E245 DXE4KB
Failure content • Abnormal current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
controller
• The controller reduces the output to the attachment oil flow rate adjusting EPC solenoid circuit to OFF.
• Even when the failure cause disappears, the EPC solenoid circuit does not return to normalcy, unless
the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
Relative
information
• It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flow
rate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m
a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Attachment oil flow rate
adjusting EPC defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V30 (male) Resistance value
Between (1) and (2) 7 – 14 z
Between (1) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (26) and
V30 (female) (1) and grounding
Resistance
value
Above
1 Mz
3
Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
Between (26) and (3) (13) (23) 7 – 14 z
Between (26) and grounding Above 1 Mz
TROUBLESHOOTING E246
Error Code in Electrical System [E246](Disconnection in attachment oil flow rate adjusting EPC)
User Code Error Code Failure Code Failure
h
Disconnection in attachment oil flow rate adjusting
EPC (P t ll t )
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Electrical Circuit Diagram for Attachment Oil Flow Rate Adjusting EPC Solenoid
phenomenon EPC (Pump controller system)— E246 DXE4KA
Failure content • No current flew to the attachment oil flow rate adjusting EPC solenoid circuit.
Response from
controller
• None in particular (The solenoid does not work, as there is no current flowing to it)
• If the failure cause disappears, the EPC solenoid circuit returns to normalcy of itself.
Phenomenon
occurring on
machine
• The attachments do not move. (The PPC source pressure is not supplied to the service PPC valve.)
Relativeinformation • It can be confirmed in the monitor function how power (ampere) is supplied to the attachment oil flowrate adjusting EPC solenoid circuit. (Code No.: 01700 Service solenoid current)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Attachment oil flow rate
adjusting EPC defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V30 (male) Resistance value
Between (1) and (2) 7 – 14 z
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (26) and
V30 (male) (1) and grounding
Resistance
valueBelow 1 z
Between wiring harness between C03 (female) (3) (13)
(23) and V30 (male) (2) and grounding
Resistance
valueBelow 1 z
3
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C03 (female) (26) and
V30 (female) (1) and grounding Voltage Below 1 V
4Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 (female) Resistance value
Between (26) and (3) (13) (23) 7 – 14 z
TROUBLESHOOTING E247
Error Code in Electrical System [E247](Arm IN PPC pressure sensor abnormality)
User Code Error Code Failure Code Failure
phenomenon
Arm IN PPC pressure sensor abnormality
(Pump controller system)E247 DHS3MA
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phenomenon (Pump controller system)— E247 DHS3MA
Failure content • Signal voltage from the arm IN PPC pressure sensor is below 0.3 V or above 4.42 V.
Response from
controller
• The controller sets the arm IN PPC pressure to 0 MP {0 kg/cm2} for control.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• If auto deceleration is operated, auto deceleration cannot be released when moving the arm IN (The
arm IN PPC circuit pressure cannot be detected).
Relative
information
aIf the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressuresensor will be broken. Accordingly, take extreme care when checking.
• Input from the arm IN PPC pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 07200: Arm IN PPC pressure)
P
r e s u m e d c a u s e a n d
s t a n
d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Sensor power supply
system defectiveIf error code [226] is displayed, carry out troubleshooting for it first.
2
Arm IN PPC pressure
sensor defective
(Internal defect)
aTurn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
S04 Voltage
Between (A) and (C) Power supply 4.5 – 5.5 V
Between (B) and (C) Signal 0.5 – 4.5 V
The pressure voltage is measured with the wiring harness connected. Accordingly, if
the voltage is abnormal, check the wiring harness and controller, too, for another
cause of the trouble, and then judge.
3
Disconnection of wiring
harness
(Disconnection or defec-
tive contact with connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C01 (female) (22) and S04
(female) (A)
Resistance
valueMax. 1 z
Wiring harness between C01 (female) (10) and S04
(female) (C)
Resistance
valueMax. 1 z
Wiring harness between C01 (female) (19) and S04
(female) (E)
Resistance
valueMax. 1 z
4Grounding fault of wiringharness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C01 (female) (19) and
S04 (female) (E) and grounding
Resistance
valueMin. 1 M z
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
TROUBLESHOOTING E247
Circuit diagram related to arm IN PPC pressure sensor
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TROUBLESHOOTING E248
Error Code in Electrical System [E248] (Bucket CURL PPC pressure sensor abnormality)
User Code Error Code Failure Code Failure
phenomenon
Bucket CURL PPC pressure sensor abnormality
(Pump controller system)— E248 DHS4MA
Failure content Signal voltage from the bucket CURL PPC pressure sensor is below 0 3 V or above 4 42 V
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Failure content • Signal voltage from the bucket CURL PPC pressure sensor is below 0.3 V or above 4.42 V.
Response from
controller
• The controller sets the bucket CURL PPC pressure to 0 MP {0 kg/cm2} for control.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• If auto deceleration is operated, when auto deceleration cannot be released when moving the bucket
CURL (The bucket CURL PPC circuit pressure cannot be detected).
Relative
information
a If the 5-V circuit (A) and GND circuit (C) of the pressure sensor are connected inversely, the pressure
sensor will be broken. Accordingly, take extreme care when checking.
• Input from the bucket CURL PPC pressure sensor (pressure) can be checked in the monitoring function.(Code No. 07300: Bucket CURL PPC pressure)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Sensor power supply
system defectiveIf error code [226] is displayed, carry out troubleshooting for it first.
2
Bucket CURL PPC pres-
sure sensor defective
(Internal defect)
aTurn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
S04 Voltage
Between (1) and (3) Power supply 4.5 – 5.5 V
Between (2) and (3) Signal 0.5 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected.
Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.
3
Disconnection of wiring
harness
(Disconnection or defec-
tive contact with connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C01 (female) (22) and S04
(female) (1)
Resistance
valueMax. 1 z
Wiring harness between C01 (female) (10) and S04
(female) (3)
Resistance
valueMax. 1 z
Wiring harness between C01 (female) (13) and S04
(female) (2)
Resistance
valueMax. 1 z
4
Grounding fault of wiring
harness
(Contact with groundingcircuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C01 (female) (13) and
S04 (female) (2) and grounding
Resistance
valueMin. 1 Mz
Sh t i iti f i i
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
TROUBLESHOOTING E248
Circuit diagram related to bucket CURL PPC pressure sensor
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TROUBLESHOOTING E257
Error Code in Electrical System [E257] (Pump Abnormality)
User Code Error Code Failure Code Failure
phenomenon
Pump Abnormality
(Pump controller system)E0E E257 DA2RMC
• The pump controller detected communication failure in the CAN communication circuit to the monitor
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Failure contentThe pump controller detected communication failure in the CAN communication circuit to the monitor
panel or engine controller.
Response from
controller
• The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The pump absorption torque is reduced).
• If the working load increases, the engine may stall.
Relative
information
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Disconnection of wiring
harness
(Disconnection or defec-
tive contact with connec-
tor)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P70 (female) (16) and CB2
(female) (22) or between P70 (female) (16) and C02
(female) (22)
Resistance
valueBelow 1 z
Wiring harness between P70 (female) (15) and CB2(female) (32) or between P70 (female) (15) and C02
(female) (32)
Resistance
valueBelow 1 z
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P70 (female) (16) and
CB2 (female) (22) or between P70 (female) (16) and
C02 (female) (22) or between P70 (female) (16) and
related circuits and grounding
Resistance
value Above 1 Mz
Between wiring harness between P70 (female) (15) and
CB2 (female) (32) or between P70 (female) (15) and
C02 (female) (32) or between P70 (female) (15) and
related circuits and grounding
Resistance
value Above 1 Mz
3
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P70 (female) (16) and
CB2 (female) (22) or between P70 (female) (16) and
C02 (female) (22) or between P70 (female) (16) andrelated circuits and grounding
Voltage Below 1 V
Between wiring harness between P70 (female) (15) and
CB2 (female) (32) or between P70 (female) (15) and
C02 (female) (32) or between P70 (female) (15) andVoltage Below 1 V
TROUBLESHOOTING E257
Electrical circuit diagram related to CAN communication
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TROUBLESHOOTING E315
Error Code in Electrical System [E315] (Battery Relay Drive S/C)
User Code Error Code Failure Code Failure
phenomenon
Battery Relay Drive S/C
(Pump controller system)— E315 D110KB
Failure content • When a signal is output to the battery relay drive circuit, abnormal current flowed.
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g p y y
Response from
controller
• The controller turns OFF the output to the battery relay drive circuit.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
Relative
information
• Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
(Code No. 03700: Controller output 1)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Battery relay defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Battery relay (Unit) Resistance value
Between BR and E Approx. 100 z
Between BR and grounding Min. 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
Between wiring harness between C03 (female) (4), D01,
J01, battery relay terminal BR or between C03 (female)
(4) and starting switch terminal B or between C03
(female) (4) and D01 (female) (2) and grounding
Resistance
valueMin. 1 Mz
3Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C03 (female) Starting switch Voltage
Between (4) and grounding ON o OFF2 0 – 3 0 V
(For 0.5 sec)
TROUBLESHOOTING E315
Electrical circuit diagram related to battery relay drive
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TROUBLESHOOTING E91C
Error Code in Electrical System [E91C] (Engine G sensor problem)
User Code Error Code Failure Code Failure
phenomenon
Engine G sensor problem
(Engine controller system)E11 E91C DLH1LC
Failure content • Cylinder cannot be judged from the engine G speed sensor signal.
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Electrical circuit diagram related to engine G speed sensor
Response from
controller
• The machine is driven with limited output.
• Control is carried out with the Ne speed sensor signal.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
Relative
information • Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.
P r e
s u m e d c a u s e a n d
s t a n d
a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Engine G speed sensor
defective
(Internal disconnection or
short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
G (male) Resistance value
Between (1) and (2) 1.4 k – 3.5 kz
Between (1), (2) and grounding Above 1 Mz
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB2 (female) (35) and G
(female) (2)
Resistance
valueBelow 1 z
Wiring harness between CB2 (female) (25) and G
(female) (1)
Resistance
valueBelow 1 z
3Grounding fault of wiringharness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB2 (female) (35) and
G (female) (2) and grounding
Resistance
value Above 1 Mz
Between wiring harness between CB2 (female) (25) and
G (female) (1) and grounding
Resistance
value Above 1 Mz
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
E12 (female) Resistance value
Between (35) and (25) 1.4 k – 3.5 kz
Between (35), (25) and grounding Above 1 Mz
TROUBLESHOOTING E920
Error Code in Electrical System [E920] (Engine type selection error)
User Code Error Code Failure Code Failure
phenomenon
Engine type selection error
(Engine controller system)E11 E920 DB29KQ
Failure content• The model selection signal directly taken by the engine controller does not conform to the model in the
controller or it is not confirmed
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controller or it is not confirmed.
Response from
controller
• Control is carried out with the default model (PC400).
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
Relative
information
• The model name (figure) recognized by the controller can be checked in the monitoring function.(Code No. 00201: Controller model code)
• Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Code No. 17400: Engine controller input state)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Model selection
connector defective(Internal disconnection or
short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB5 (female) Resistance valueBetween (2), (3) (4), (5), (6), (7), and
(8) Above 1 Mz
Between (1) and (8) Below 1 z
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB1 (female) (3) and CB5
(male) (1)
Resistance
valueBelow 1 z
Wiring harness between CB2 (female) (1) and CB5(male) (8)
Resistancevalue
Below 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB1 (female) (23) and
CB5 (male) (2) and grounding
Resistance
value Above 1 Mz
Between wiring harness between CB1 (female) (17) and
CB5 (male) (3) and grounding
Resistance
value Above 1 Mz
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ONposition during the troubleshooting.
CB1, CB2 Voltage
Between CB1 (23), (17) and CB2 (1) 20 – 30 V
TROUBLESHOOTING E920
Electrical circuit diagram related to model selection connector (for engine controller)
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TROUBLESHOOTING E921
Error Code in Electrical System [E921] (Engine type mismatch)
User Code Error Code Failure Code Failure
phenomenon
Engine type mismatch
(Engine controller system)E11 E921 DB20KQ
Failure content• The model information taken by the engine controller through the model selection connector does not
conform to the model information taken from the pump controller by communication.
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conform to the model information taken from the pump controller by communication.
Response from
controller
• The normal operation is continued.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
Relative
information
• The model name (figure) recognized by the engine controller can be checked in the monitoring func-tion. (Code No. 00201: Controller model code)
• The model name (figure) recognized by the pump controller can be checked in the monitoring function.
(Code No. 00200: Controller model code)
P r e s u m e d c a
u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1Model selection connec-
tor system defectiveIf error code [E920] is displayed, carry out troubleshooting for it.
2Engine controller
defective
Engine controller may be defective. (Since trouble is in the controller, troubleshoot-
ing cannot be carried out.)
3 Pump controller defectivePump controller may be defective. (Since trouble is in the controller, troubleshooting
cannot be carried out.)
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TROUBLESHOOTING E931
Error Code in Electrical System [E931] (Fuel dial sys. error)
User Code Error Code Failure Code Failure
phenomenon
Fuel dial sys. error
(Engine controller system)E14 E931 DK10KX
Failure content • The signal voltage from the fuel control dial is below 0.3 V or above 4.5 V.
• If the abnormality is detected before the engine is started the fuel control dial signal is kept at 0% or
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Response from
controller
If the abnormality is detected before the engine is started, the fuel control dial signal is kept at 0% or
100% after the engine is started.
• If the abnormality is detected while the engine is running, the fuel control dial signal just before the
abnormality is detected is kept.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The engine speed cannot be controlled.
Relative
information
• Input from the fuel control dial (voltage) can be checked in the monitoring function.
(Code No. 03000: Fuel control dial voltage)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c
y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel control dial defective
(Internal disconnection or
short-circuiting)
aTurn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
E06 (male) Resistance value
Between (1) and (3) 4.0 – 6.0 kzBetween (1) and (2) 0.25 – 7.0 kz
Between (3) and (2) 0.25 – 7.0 kz
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB2 (female) (19) and E06
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB2 (female) (10) and E06
(female) (2)
Resistance
value Below 1z
Wiring harness between CB2 (female) (29), (39), and
E06 (female) (3)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB2 (female) (19) and
E06 (female) (1) and grounding
Resistance
value Above 1 Mz
Between wiring harness between CB2 (female) (10) and
E06 (female) (2) and grounding
Resistance
value Above 1 Mz
4
Short-circuiting of wiring
h
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between CB2 (female) (19) andV lt B l 1 V
TROUBLESHOOTING E931
Electrical circuit diagram related to fuel control dial
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TROUBLESHOOTING E934
Error Code in Electrical System [E934] (Engine coolant sensor Hi error)
User Code Error Code Failure Code Failure
phenomenon
Engine coolant sensor Hi error
(Engine controller system)E15 E934 DGE2KX
Failure content • The signal voltage from the engine water high temperature sensor is below 0.5 V or above 4.5 V.
Response from • The signal of the engine water high temperature sensor is kept at 90°C.
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p
controller
g g g p p
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The engine does not start easily when temperature is low.
• The overheat protection function does not operate.
• If the controller is also defective, the engine does not stop.
Relative
information
• Input from the engine water high temperature sensor (voltage and water temperature) can be checked
in the monitoring function.
(Code No. 04106: Engine water temperature sensor Hi, 04102: Engine water temperature (High tem-perature))
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Engine water high
temperature sensor
defective
(Internal disconnection or
short circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
TWH (male) Resistance value
Between (1) and (2) 3.5 k – 90 kz
Between (1), (2) and grounding Above 1 Mz
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB2 (female) (27) and TWH
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB2 (female) (29), (39), and
TWH (female) (2)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between E12 (female) (27) and
TWH (female) (1) and grounding
Resistance
value Above 1 Mz
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB2 Resistance value
Between (27), (29) and (39) 3.5 k – 90 kz
Between (27), (29), (39) and grounding Above 1 Mz
TROUBLESHOOTING E934
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)
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TROUBLESHOOTING E936
Error Code in Electrical System [E936] (Engine oil press. sw. error)
User Code Error Code Failure Code Failure
phenomenon
Engine oil press. sw. error
(Engine controller system)E15 E936 DDE2L6
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit ofthe high-pressure switch is opened (disconnected from grounding) while the engine is running.
• The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine
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Failure content• The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine
is stopped (the starting signal is OFF).
• The signal circuit of the high-pressure switch is opened (disconnected from grounding) while the
engine is stopped (the starting signal is OFF).
Response from
controller
• None in particular.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The engine does not start easily when temperature is low.
• The overheat protection function does not operate.
• If the controller is also defective, the engine does not stop.
Relative
information
• Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring func-
tion. (Code No. 17400: Engine controller input)
P r e s u m
e d c a u s e a n d
s t a n d a r d
v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Engine low-oil pressure
switch defective(Internal disconnection or
short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position and start the engine during the troubleshooting.
PSL Engine Resistance value
Between terminal
and grounding
Stopped Below 1 z
Low idling Above 1 Mz
2
Engine high-oil pressure
switch defective
(Internal disconnection or
short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position and start the engine during the troubleshooting.
PSH Engine Resistance value
Between terminal
and grounding
Stopped Below 1 z
Running at 1,300 rpmor higher
Above 1 Mz
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB1 (female) (21) and PSLResistance
valueBelow 1 z
Wiring harness between CB1 (female) (15) and PSHResistance
valueBelow 1 z
4
Grounding fault of wiring
harness
(Contact with grounding
)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
Between wiring harness between CB1 (female) (21) and
PSL and grounding
Resistance
value Above 1 Mz
TROUBLESHOOTING E936
Electrical circuit diagram related to engine oil press switch (for low pressure and high pressure)
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TROUBLESHOOTING E93D
Error Code in Electrical System [E93D] (Engine fuel temp. sensor error)
User Code Error Code Failure Code Failure
phenomenon
Engine fuel temp. sensor error
(Engine controller system)E15 E93D DGE4KX
Failure content • The signal voltage from the fuel temperature sensor is above 4.5 V.
Response from
controller
• None in particular.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
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controller When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The engine does not start easily when temperature is low.
• The overheat protection function does not operate.
• If the controller is also defective, the engine does not stop.
Relative
information
• Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.
(Code No. 14201: Fuel temperature sensor voltage)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel temperature sensor
defective
(Internal disconnection or
short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
THL (male) Resistance value
Between (1) and (2) 0.3 k – 9 kz
Between (1), (2) and grounding Above 1 Mz
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between E12 (female) (17) and THL
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between E12 (female) (29), (39) and
THL (female) (2)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between E12 (female) (17) and
THL (female) (A) and grounding
Resistance
value Above 1 Mz
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB2 Resistance value
Between (17), (29) and (39) 0.3 k – 9 kz
Between (17) and (29), (39) and
grounding Above 1 Mz
TROUBLESHOOTING E93D
Electrical circuit diagram related to fuel temperature sensor
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TROUBLESHOOTING E953
Error Code in Electrical System [E953] (Engine Comm. Abnormality)
User Code Error Code Failure Code Failure
phenomenon
Engine Comm. Abnormality
(Engine controller system)E0E E953 DB2RMC
Failure content • The engine controller detected communication failure in the CAN communication circuit to the monitorpanel or pump controller.
Response from • The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
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controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The pump absorption torque is reduced).
• If the working load increases, the engine may stall.
Relative
information
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m
a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P70 (female) (16) and CB2
(female) (22) or between P70 (female) (16) and C02
(female) (22)
Resistance
valueBelow 1 z
Wiring harness between P70 (female) (15) and CB2(female) (32) or between P70 (female) (15) and C02
(female) (32)
Resistancevalue
Below 1 z
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P70 (female) (16) and
CB2 (female) (22) or between P70 (female) (16) and
C02 (female) (22) or between P70 (female) (16) and
related circuits and grounding
Resistance
value Above 1 Mz
Between wiring harness between P70 (female) (15) andCB2 (female) (32) or between P70 (female) (15) and
C02 (female) (32) or between P70 (female) (15) and
related circuits and grounding
Resistance
value Above 1 Mz
3
Short-circuiting of wiring
harness(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P70 (female) (16) and
CB2 (female) (22) or between P70 (female) (16) and
C02 (female) (22) or between P70 (female) (16) and
related circuits and grounding
Voltage Below 1 V
Between wiring harness between P70 (female) (15) and
CB2 (female) (32) or between P70 (female) (15) and
C02 (female) (32) or between P70 (female) (15) andVoltage Below 1 V
TROUBLESHOOTING E953
Electrical circuit diagram related to CAN communication
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TROUBLESHOOTING E954
Error Code in Electrical System [E954] (Short engine starter sw.)
User Code Error Code Failure Code Failure
phenomenon
Short engine starter sw.
(Engine controller system)— E954 DD11KB
Failure content • Starting switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).
Response from
controller
• Starting switch signal is recognized to be OFF.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
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Phenomenon
occurring on
machine
• The machine operates normally.
Relative
information
• Input of starting switch signal C (ON or OFF) can be checked in the monitoring function.
(Code No. 17400: Engine controller input)
P r e s u m e d c a u s e a
n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Starting switch defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF and
ON positions during the troubleshooting.
Starting switch Resistance value
Between terminal B
and terminal C
OFF Above 1 Mz
START Below 1 z
2
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between starting switch termi-
nal C, J01, and CB1 (female) (20) or between starting
switch terminal C and C01 (female) (17) or between
starting switch terminal C and P01 (female) (4) or
between starting switch terminal C and R11 (female) (5),
or between starting switch terminal C or related circuits
and grounding
Voltage Below 1 V
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
CB1 Starting switch Voltage
Between (20) and
grounding
ON
(Engine is running)Below 1 V
TROUBLESHOOTING E954
Electrical circuit diagram related to engine preheating, starting, charging
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TROUBLESHOOTING E955
Error Code in Electrical System [E955] (Engine S-NET error)
User Code Error Code Failure Code Failure
phenomenon
Engine S-NET error
(Engine controller system)E0E E955 DB2SMC
Failure content • The engine controller detected communication failure in the S-NET communication circuit to the moni-tor panel or pump controller.
Response from
controller
• The engine output is fixed to the E mode and the pump absorption torque is limited to about 80%.
• When the failure cause disappears of itself the machine operation returns to normalcy
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controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The pump absorption torque is reduced).
• If the working load increases, the engine may stall.
Relative
information
• Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
(Code No. 05100: Connection of S-NET)
P r e s u m e d c
a u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (9), (10) and CB2
(female) (21), (31) or between P02 (female) (9), (10)
and C02 (female) (21)
Resistance
valueBelow 1 z
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P02 (female) (9), (10)
and CB2 (female) (21), (31) or between P02 (female)
(9), (10) and C02 (female) (21) or between P02 (female)
(9), (10) and related circuits and grounding
Resistance
value Above 1 Mz
3
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P02 (female) (9), (10)
and CB2 (female) (21), (31) or between P02 (female)(9), (10) and C02 (female) (21) or between P02 (female)
(9), (10) and related circuits and grounding
Voltage Below 1 V
4 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Voltage
Between (9), (10) and (20) 6 – 9 V
5Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
CB2 Voltage
Between (21), (31) and (11) 6 – 9 V
O f O
TROUBLESHOOTING E955
Electrical circuit diagram related to S-NET communication
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TROUBLESHOOTING E956
Error Code in Electrical System [E956] (Engine power failure (1))
User Code Error Code Failure Code Failure
phenomenon
Engine power failure (1)
(Engine controller system)E10 E956 DB22KK
Failure content • When the starting switch is turned ON, the source voltage of the controller is below 10 V.
Response from
controller
• None in particular.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
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Phenomenon
occurring on
machine
• The engine stalls.
• The engine cannot be started.
Relative
information
P r e s u m e d c a u
s e a n d
s t a n d a r d v a l u e i n
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Circuit breaker 7
defective
If circuit breaker is turned OFF, the circuit probably has grounding fault, etc.
(See cause 4.)
2
Engine controller power
supply relay defective
(Internal disconnection or
short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Replace the power supply relay with another one. If the condition
becomes normal, the relay is defective.R22
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
Wiring harness between CB3 (female) (1), (2), (21) and
R22 (female) (5)
Resistance
valueBelow 1 z
Wiring harness between R22 (female) (3) and B27Resistance
valueBelow 1 z
Wiring harness between B17 and battery relay B terminalResistance
valueBelow 1 z
Wiring harness between R22 (female) (1) and J02(male) (1)
Resistancevalue
Below 1 z
Wiring harness between R22 (female) (2) and groundingResistance
valueBelow 1 z
4
Grounding fault of wiring
harness
(Contact with groundingcircuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (1), (2),
(21) and R22 (female) (5) and grounding
Resistance
value Above 1 Mz
Between wiring harness between R22 (female) (3) andB27
Resistancevalue
Above 1 Mz
Between wiring harness between R22 (female) (1) and
J02 (male) (1) or between R22 (female) (1) and relatedResistance
value Above 1 Mz
TROUBLESHOOTING E956
Electrical circuit diagram related to engine controller power supply
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TROUBLESHOOTING E957
Error Code in Electrical System [E957] (Engine power failure (2))
User Code Error Code Failure Code Failure
phenomenon
Engine power failure (2)
(Engine controller system)E15 E957 D1D0KB
Failure content • When the starting switch is turned OFF, the source voltage of the controller is above 10 V.
Response from
controller
• None in particular.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The engine does not start easily when temperature is low.
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Phenomenon
occurring on
machine
The engine does not start easily when temperature is low.
• The overheat protection function does not operate.
• If the controller is also defective, the engine does not stop.
Relative
information
P r e s u m e d c a
u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Engine controller power
supply relay defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Replace the power supply relay with another one. If the condition
becomes normal, the relay is defective.R22
2
Short-circuiting of wiring
harness(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between E13 (female) (1), (2),(21) and R22 (female) (3) and grounding
Voltage Below 1 V
Between wiring harness between R22 (female) (1) and
J03, J06 (male) (2), or related circuits and groundingVoltage Below 1 V
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF and
ON positions during the troubleshooting.
CB3 Starting switch Voltage
Between (1), (2), (21)
and (11), (31), (32)
OFF Below 1 V
ON 20 – 30 V
TROUBLESHOOTING E957
Electrical circuit diagram related to engine controller power supply
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TROUBLESHOOTING E96A
Error Code in Electrical System [E96A] (Engine coolant sensor Lo error)
User Code Error Code Failure Code Failure
phenomenon
Engine coolant sensor Lo error
(Engine controller system)E15 E96A DGE3L6
Failure content • The signal voltage from the engine water low temperature sensor is above 4.5 V.
Response from
controller
• The signal of the engine water low temperature sensor is kept at 20°C (If the signal of the high temper-
ature sensor is effective, it is used as a substitute).
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Ph Th i d t t t il h t t i l
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Phenomenon
occurring on
machine
• The engine does not start easily when temperature is low.
• The overheat protection function does not operate.
• If the controller is also defective, the engine does not stop.
Relative
information
• Input from the engine water low temperature sensor (voltage and water temperature) can be checked
in the monitoring function. (Code No. 04105: Engine water temperature sensor voltage Lo, 04107:
Engine water temperature (Low temperature))
P
r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Engine water low
temperature sensor
defective
(Internal disconnection or
short circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
TWL (male) Resistance value
Between (1) and (2) 0.3 k – 9 kz
Between (1), (2) and grounding Above 1 Mz
2
Disconnection of wiring
harness
(Disconnection or defec-
tive contact with connec-
tor)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB2 (female) (37) and TWL
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB2 (female) (29), (39), and
TWL (female) (2)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.Between wiring harness between E12 (female) (37) and
TWL (female) (1) and grounding
Resistance
value Above 1 Mz
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
E12 Resistance value
Between (29), (37) and (39) 0.3 k – 9 kz
Between (29), (37), (39) and grounding Above 1 Mz
TROUBLESHOOTING E96A
Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)
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TROUBLESHOOTING E970
Error Code in Electrical System [E970] (PCV1 over current)
User Code Error Code Failure Code Failure
phenomenon
PCV1 over current
(Engine controller system)E11 E970 AD11KB
Failure content • Abnormal current flowed in the fuel supply pump PCV1 circuit.
Response from
controller
• Power to the fuel supply pump PCV1 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced)
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Electrical circuit diagram related to fuel supply pump PCV1
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information • Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
P r e s u m e d c a u s e a n d
s t a
n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel supply pump PCV1
defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
PCV1 (male) Resistance value
Between (1) and (2) 2.3 – 5.3 z
Between (1) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (12) and
PCV1 (female) (1)
Resistance
value Above 1 Mz
3
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between CB3 (female) (12) and
PCV1 (female) (1)
Voltage Below 1 V
Between wiring harness between CB3 (female) (22) and
PCV1 (female) (2)Voltage Below 1 V
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (12) and (22) 2.3 – 5.3 z
Between (12), (22) and grounding Above 1 Mz
TROUBLESHOOTING E971
Error Code in Electrical System [E971] (PCV2 over current)
User Code Error Code Failure Code Failure
phenomenon
PCV2 over current
(Engine controller system)E11 E971 AD51KB
Failure content • Abnormal current flowed in the fuel supply pump PCV2 circuit.
Response from
controller
• Power to the fuel supply pump PCV2 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Ph• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
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Electrical circuit diagram related to fuel supply pump PCV2
Phenomenon
occurring on
machine
The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information • Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
P r e s u m e d c a u s e a n d
s t a
n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel supply pump PCV2
defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
PCV2 (male) Resistance value
Between (1) and (2) 2.3 – 5.3 z
Between (1) and grounding Above 1 Mz
2
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (13) and
PCV2 (female) (1)
Resistance
value Above 1 Mz
3
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between CB3 (female) (13) and
PCV2 (female) (1)
Voltage Below 1 V
Between wiring harness between CB3 (female) (23) and
PCV2 (female) (2)Voltage Below 1 V
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (13) and (23) 2.3 – 5.3 z
Between (13), (23) and grounding Above 1 Mz
TROUBLESHOOTING E974
Error Code in Electrical System [E974] (PCV1 line cut)
User Code Error Code Failure Code Failure
phenomenon
PCV1 line cut
(Engine controller system)E11 E974 AD11KA
Failure content • Fuel supply pump PCV1 circuit is disconnected.
Response from
controller
• Power to the fuel supply pump PCV1 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
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Electrical circuit diagram related to fuel supply pump PCV1
Phenomenon
occurring on
machine
p ( g p p p p q )
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information • Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
P r e s u m e d c a u s e a n d
s t a
n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel supply pump PCV1
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
PCV1 (male) Resistance value
Between (1) and (2) 2.3 – 5.3 z
Between (1) and grounding Above 1 Mz
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (12) and
PCV1 (female) (1)
Resistance
valueBelow 1 z
Between wiring harness between CB3 (female) (22) and
PCV1 (female) (2)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (22) and
PCV1 (female) (2)
Resistance
value Above 1 Mz
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (12) and (22) 2.3 – 5.3 z
Between (12), (22) and grounding Above 1 Mz
TROUBLESHOOTING E975
Error Code in Electrical System [E975] (PCV2 line cut)
User Code Error Code Failure Code Failure
phenomenon
PCV2 line cut
(Engine controller system)E11 E975 AD51KA
Failure content • Fuel supply pump PCV2 circuit is disconnected.
Response from
controller
• Power to the fuel supply pump PCV2 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
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Electrical circuit diagram related to fuel supply pump PCV2
Phenomenon
occurring on
machine
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information • Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
P r e s u m e d c a u s e a n d
s t a
n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel supply pump PCV2
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
PCV2 (male) Resistance value
Between (1) and (2) 2.3 – 5.3 z
Between (1) and grounding Above 1 Mz
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (13) and
PCV2 (female) (1)
Resistance
valueBelow 1 z
Between wiring harness between CB3 (female) (23) and
PCV2 (female) (2)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (23) and
PCV2 (female) (2)
Resistance
value Above 1 Mz
4Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (13) and (23) 2.3 – 5.3 z
Between (13), (23) and grounding Above 1 Mz
TROUBLESHOOTING E977
Error Code in Electrical System [E977] (Rail press. sensor error)
User Code Error Code Failure Code Failure
phenomenon
Rail press. sensor error
(Engine controller system)E11 E977 DH40KX
Failure content • The signal voltage from the common rail fuel pressure sensor is below 0.7 V or above 4.5 V.Response from
controller
• The machine is driven with limited output.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
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machine • The engine speed does not rise above low idling.
Relative
information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a
l c y
Cause Standard value in normalcy and references for troubleshooting
1
Common rail fuel
pressure sensor
defective
(Internal defect)
aTurn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
PFUEL Voltage
Between (3) and (1) Power supply 4.6 – 5.4 V
Between (2) and (1) Signal 0.7 – 4.5 V
The pressure sensor voltage is measured with the wiring harness connected. Accordingly, if the voltage is abnormal, check the wiring harness and controller, too,
for another cause of the trouble, and then judge.
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB2 (female) (9) and PFUEL
(female) (3)
Resistance
valueBelow 1 z
Wiring harness between CB2 (female) (39) and PFUEL
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB2 (female) (40) and PFUEL
(female) (2)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB2 (female) (9) and
PFUEL (female) (3), or between CB2 (female) (9) and
related ciricuits and grounding
Resistance
value Above 1 Mz
Between wiring harness between CB2 (female) (40) and
PFUEL (female) (2) and grounding
Resistance
value Above 1 Mz
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
TROUBLESHOOTING E977
Electrical circuit diagram related to common rail fuel pressure sensor
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TROUBLESHOOTING E979, E97A
Error Code in Electrical System [E979] (Rail press. high)
User Code Error Code Failure Code Failure
phenomenon
Rail press. high
(Engine controller system)E11 E979 AD00L2
Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1).Response from
controller
• The machine is driven with limited output.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling
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Error Code in Electrical System [E97A] (Rail press. abnormal)
machine • The engine speed does not rise above low idling.
Relative
information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Related systems
defective
If any other error code or failure code is displayed, carry out troubleshooting for it
first.
2 Fuel used improper Fuel used may be improper. Check it directly.
3
Electric system of
common rail fuel
pressure sensor defective
Carry out troubleshooting for error code [E977].
4
Mechanical system of
common rail fuel
pressure sensor defective
The common rail fuel pressure sensor may have a mechanical defect. Check itdirectly.
5 Overflow valve defectiveThe overflow valve may have trouble of breakage of spring, wear of seat, or fixing of
ball. Check it directly.
6 Overflow piping clogged The overflow piping may be clogged. Check it directly.
7 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
User Code Error Code Failure Code Failure
phenomenon
Rail press. abnormal
(Engine controller system)E11 E97A AD00MA
Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2).
Response from
controller
• The machine is driven with limited output.• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced)
TROUBLESHOOTING E97B
Error Code in Electrical System [E97B] (Rail press. low)
User Code Error Code Failure Code Failure
phenomenon
Rail press. low
(Engine controller system)E15 E97B AD10L3
Failure content • No-pressure feed by fuel supply pump (level 1) occurred.
Response from
controller
• The machine is driven with limited output.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
• The engine does not start easily when temperature is low.
• The overheat protection function does not operate
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Note 1: Check the low-pressure circuit devices for the following points.
1) Insufficiency of fuel
2) Fixing and wear of feed pump and clogging of filter
3) Leakage from and clogging of low-pressure fuel piping
4) Malfunction of bypass valve and installation of wrong part (See Fig. 1)5) Clogging of fuel filter
6) Entry of fuel in oil pan (Fuel leakage in head cover)
• Fuel low pressure circuit pressure: 0 15 0 3 MPa {1 5 3 0 kg/cm2}
occurring on
machine
• The overheat protection function does not operate.
• If the controller is also defective, the engine does not stop.
Relative
information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
P r e s u m e d c a u s e
a n d
s t a n d a r d v a l u e i n n o
r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Related systems
defective
If any other error code or failure code is displayed, carry out troubleshooting for it
first.
2 Fuel used improper Fuel used may be improper. Check it directly.
3Fuel low-pressure circuit
device defective
A low-pressure circuit device may be defective. Referring to Note 1, carry out
troubleshooting.
4Fuel filter/strainer
clogged
The fuel filter/strainer may be clogged. Referring to Note 2, carry out
troubleshooting.
5
Electrical system of fuel
supply pump PCV1
defective
Carry out troubleshooting for error codes [E970], [E971], [E974], and [E975].
6Fuel supply pump
defectiveThe fuel supply pump may be defective. Check it directly.
7
Common rail fuel
pressure sensor
defective
The common rail fuel pressure sensor may be defective. Check it directly.
8 Pressure limiter defective The pressure limiter may have a mechanical defect. Check it directly.
9 Fuel injector defective The fuel injector may be defective. Referring to Note 3, check it directly.
TROUBLESHOOTING E97B
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• Fuel inlet joint (3): Gauze filter is seen through both holes.
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Note 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check the gauze filter. If it is clogged, clean it.
2) Strainer on upstream side of gauze filter: If the gauze filter is clogged, clean the upstream strainer too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
Note 3: Judge the condition of the fuel injector by
measuring the fuel spill rate.
kWhen performing the follow work, take carenot to scald yourself with the fuel which be-
comes hot (up to 90°C).
1) Disconnect the hose connected to the cen-
3) Run the engine and stall at each speed
(relieve the arm circuit by moving the arm
in). Measure the quantity of the fuel spillingin 1 minute under this condition.
a Limit of spill of fuel (Total of spill from 6
cylinders)
TROUBLESHOOTING E97C, E97D
Error Code in Electrical System [E97C] (Rail press. too low)
User Code Error Code Failure Code Failure
phenomenon
Rail press. too low
(Engine controller system)E11 E97C AD10MB
Failure content • No-pressure feed by fuel supply pump (level 2) occurred.
Response from
controller
• The machine is driven with limited output and speed.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
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Error Code in Electrical System [E97D] (Rail press. out of control)
g
machine
p ( y p p p q )
• The engine speed does not rise above low idling.
Relative
information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed
cause and
standard value
in normalcy
Cause Standard value in normalcy and references for troubleshooting
1Common rail-related
device defectiveCarry out troubleshooting for error code [E97B].
User Code Error Code Failure Code Failure
phenomenon
Rail press. out of control
(Engine controller system)E11 E97D AD10MA
Failure content • Abnormal fuel pressure was generated in the common rail.
Response from
controller
• The machine is driven under the normal control.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
Relative
information
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Presumed
cause and standard value
in normalcy
Cause Standard value in normalcy and references for troubleshooting
1Common rail-relateddevice defective
Carry out troubleshooting for error code [E97B].
TROUBLESHOOTING E980
Error Code in Electrical System [E980] (Eng. Controller Abnormality)
User Code Error Code Failure Code Failure
phenomenon
Eng. Controller Abnormality
(Engine controller system)E10 or E11 E980 DB20KT
Failure content • The controller has abnormality in it.
Response from
controller
• The machine is driven with limited output or all output is turned OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
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occurring on
machine
p ( y p p p q )
• The engine speed does not rise above low idling.
• The engine stop and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s
u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (11), (31), (32)
and grounding
Resistance
valueBelow 1 z
2Engine controller
defective
If cause 1 is not detected, the engine controller may be defective.
(Since trouble is in the engine controller, troubleshooting cannot be carried out.)
TROUBLESHOOTING E980
Electrical circuit diagram related to engine controller power supply
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TROUBLESHOOTING E981
Error Code in Electrical System [E981] (Fuel Injector 1 Disc.)
User Code Error Code Failure Code Failure
phenomenon
Fuel Injector 1 Disc.
(Engine controller system)E11 E981 ADA1KA
Failure content • Fuel injector 1 circuit is disconnected.
Response from
controller
• Power to the fuel injector 1 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
Th i d d t i b l idli
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Electrical circuit diagram related to fuel injector 1
occurring on
machine• The engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Fuel injector 1 defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN1 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (14) and CN1
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB3 (female) (24) and CN1
(female) (2)
Resistance
valueBelow 1 z
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (14) and (24) 0.4 – 1.1 z
TROUBLESHOOTING E982
Error Code in Electrical System [E982] (Fuel Injector 2 Disc.)
User Code Error Code Failure Code Failure
phenomenon
Fuel Injector 2 Disc.
(Engine controller system)E11 E982 ADB1KA
Failure content • Fuel injector 2 circuit is disconnected.
Response from
controller
• Power to the fuel injector 2 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
The engine speed does not rise above low idling
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Electrical circuit diagram related to fuel injector 2
g
machine• The engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Fuel injector 2 defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN2 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (6) and CN2
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB3 (female) (16) and CN2
(female) (2)
Resistance
valueBelow 1 z
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (6) and (16) 0.4 – 1.1 z
TROUBLESHOOTING E983
Error Code in Electrical System [E983] (Fuel Injector 3 Disc.)
User Code Error Code Failure Code Failure
phenomenon
Fuel Injector 3 Disc.
(Engine controller system)E11 E983 ADC1KA
Failure content • Fuel injector 3 circuit is disconnected.
Response from
controller
• Power to the fuel injector 3 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling
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Electrical circuit diagram related to fuel injector 3
machine• The engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Fuel injector 3 defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN3 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
2
Disconnection of wiringharness
(Disconnection or defec-
tive contact with connec-
tor)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (5) and CN3
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB3 (female) (15) and CN3
(female) (2)
Resistance
valueBelow 1 z
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (5) and (15) 0.4 – 1.1 z
TROUBLESHOOTING E984
Error Code in Electrical System [E984] (Fuel Injector 4 Disc.)
User Code Error Code Failure Code Failure
phenomenon
Fuel Injector 4 Disc.
(Engine controller system)E11 E984 ADD1KA
Failure content • Fuel injector 4 circuit is disconnected.
Response from
controller
• Power to the fuel injector 4 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling
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Electrical circuit diagram related to fuel injector 4
machineThe engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Fuel injector 4 defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN4 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (26) and CN4
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB3 (female) (36) and CN4
(female) (2)
Resistance
valueBelow 1 z
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (26) and (36) 0.4 – 1.1 z
TROUBLESHOOTING E985
Error Code in Electrical System [E985] (Fuel Injector 5 Disc.)
User Code Error Code Failure Code Failure
phenomenon
Fuel Injector 5 Disc.
(Engine controller system)E11 E985 ADF1KA
Failure content • Fuel injector 5 circuit is disconnected.
Response from
controller
• Power to the fuel injector 5 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
hi
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
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Electrical circuit diagram related to fuel injector 5
machineThe engine speed does not rise above low idling.
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Fuel injector 5 defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN5 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (33) and CN5
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB3 (female) (34) and CN5
(female) (2)
Resistance
valueBelow 1 z
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (34) and (33) 0.4 – 1.1 z
TROUBLESHOOTING E986
Error Code in Electrical System [E986] (Fuel Injector 6 Disc.)
User Code Error Code Failure Code Failure
phenomenon
Fuel Injector 6 Disc.
(Engine controller system)E11 E986 ADF1KA
Failure content • Fuel injector 6 circuit is disconnected.
Response from
controller
• Power to the fuel injector 6 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
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Electrical circuit diagram related to fuel injector 6
machineg p g
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Fuel injector 6 defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN6 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB3 (female) (25) and CN6
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB3 (female) (35) and CN6
(female) (2)
Resistance
valueBelow 1 z
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (25) and (35) 0.4 – 1.1 z
TROUBLESHOOTING E98A
Error Code in Electrical System [E98A] (Fuel Injector 1 – 3 S/C)
User Code Error Code Failure Code Failure
phenomenon
Fuel Injector 1 – 3 S/C
(Engine controller system)E11 E98A ADAZKB
Failure content • Abnormal current flowed in the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit.
Response from
controller
• Power to the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
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machine• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel injector 1 defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN1 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
Between (1), (2) and grounding Above 1 Mz
2
Fuel injector 2 defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN2 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
Between (1), (2) and grounding Above 1 Mz
3
Fuel injector 3 defective
(Internal short-circuitingor grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN3 (male) Resistance valueBetween (1) and (2) 0.4 – 1.1 z
Between (1), (2) and grounding Above 1 Mz
4
Grounding fault of wiring
harness
(Contact with grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (14) and
CN1 (female) (1) and grounding
Resistance
value Above 1 Mz
Between wiring harness between CB3 (female) (24) and
CN1 (female) (2) and grounding
Resistance
value Above 1 Mz
Between wiring harness between CB3 (female) (6) and
CN2 (female) (1) and grounding
Resistance
value Above 1 Mz
TROUBLESHOOTING E98A
u s e a n d
n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
5
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between CB3 (female) (14) and
CN1 (female) (1) and groundingVoltage Below 1 V
Between wiring harness between CB3 (female) (24) and
CN1 (female) (2) and groundingVoltage Below 1 V
Between wiring harness between CB3 (female) (6) and
CN2 (female) (1) and groundingVoltage Below 1 V
Between wiring harness between CB3 (female) (16) and
CN2 (female) (2) and groundingVoltage Below 1 V
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Electrical circuit diagram related to fuel injectors 1, 2, and 3
P r e s u m
e d c a u
s t a n d a r d v a l u e i n ( ) ( ) g g
Between wiring harness between CB3 (female) (5) and
CN3 (female) (1) and groundingVoltage Below 1 V
Between wiring harness between CB3 (female) (15) and
CN3 (female) (2) and groundingVoltage Below 1 V
6Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (14) and (24) 0.4 – 1.1 z
Between (6) and (16) 0.4 – 1.1 z
Between (5) and (15) 0.4 – 1.1 z
Between (5), (6), (14), (15), (16), (24)
and grounding Above 1 Mz
TROUBLESHOOTING E98B
Error Code in Electrical System [E98B] (Fuel Injector 4 – 6 S/C)
User Code Error Code Failure Code Failure
phenomenon
Fuel Injector 4 – 6 S/C
(Engine controller system)E11 E98B ADDZKB
Failure content • Abnormal current flowed in the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit.
Response from
controller
• Power to the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit is switched OFF.
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on
machine
• The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
• The output lowers (Only the pump absorption torque is reduced).
• The engine speed does not rise above low idling.
Th i t d it t b t t d ( h d [E10] i di l d)
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• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel injector 4 defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN4 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
Between (1), (2) and grounding Above 1 Mz
2
Fuel injector 5 defective
(Internal short-circuiting
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN5 (male) Resistance value
Between (1) and (2) 0.4 – 1.1 z
Between (1), (2) and grounding Above 1 Mz
3
Fuel injector 6 defective
(Internal short-circuitingor grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CN6 (male) Resistance valueBetween (1) and (2) 0.4 – 1.1 z
Between (1), (2) and grounding Above 1 Mz
4
Grounding fault of wiring
harness
(Contact with grounding
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB3 (female) (26) and
CN4 (female) (1) and grounding
Resistance
value Above 1 Mz
Between wiring harness between CB3 (female) (36) and
CN4 (female) (2) and grounding
Resistance
value Above 1 Mz
Between wiring harness between CB3 (female) (34) and
CN5 (female) (1) and grounding
Resistance
value Above 1 Mz
TROUBLESHOOTING E98B
u s e a n d
n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
5
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between CB3 (female) (26) and
CN4 (female) (1) and groundingVoltage Below 1 V
Between wiring harness between CB3 (female) (36) and
CN4 (female) (2) and groundingVoltage Below 1 V
Between wiring harness between CB3 (female) (34) and
CN5 (female) (1) and groundingVoltage Below 1 V
Between wiring harness between CB3 (female) (33) and
CN5 (female) (2) and groundingVoltage Below 1 V
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Electrical circuit diagram related to fuel injectors 4, 5, and 6
P r e s u m
e d c a u
s t a n d a r d v a l u e i
Between wiring harness between CB3 (female) (25) and
CN6 (female) (1) and groundingVoltage Below 1 V
Between wiring harness between CB3 (female) (35) and
CN6 (female) (2) and groundingVoltage Below 1 V
6Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB3 (female) Resistance value
Between (26) and (36) 0.4 – 1.1 z
Between (34) and (33) 0.4 – 1.1 z
Between (25) and (35) 0.4 – 1.1 z
Between (25), (26), (33), (34), (35), (36)
and grounding Above 1 Mz
TROUBLESHOOTING A000N1, A000N2
Error Code in Mechanical System [A000N1] (Engine high-idling speed out of standard)
User Code Error Code Failure Code Failure
phenomenon
Engine high-idling speed out of standard
(Mechanical system)E22 E922 A000N1
Failure content • While the engine is running, its speed above 2,350 rpm is detected.
Response from
controller • None in particular.
Phenomenon
occurring on
machine
• If the machine is used as it is, the engine may be damaged.
Relative
i f ti
• Input from the engine speed sensor (rpm) can be checked in the monitoring function.
(C d N 01006 E i d)
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Error Code in Mechanical System [A000N2] (Engine low-idling speed out of standard)
information (Code No. 01006: Engine speed)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Overrun of engine
(While system is normal)
Check for an external or an internal factor which heightens the engine high-idling
speed, and then check the mechanical system of the engine.
2Engine speed sensor
system abnormalIf error code [E227] is displayed, carry out troubleshooting for it first.
3Engine controller defec-
tive
aTurn the engine starting switch ON for the preparations, and keep the engine
running during the troubleshooting.
Monitoring Engine Engine speed
01006
Engine speedHigh idling 1,880 – 1,980 rpm
User Code Error Code Failure Code Failure
phenomenon
Engine low-idling speed out of standard
(Mechanical system)— — A000N2
Failure content • While the engine is running, its speed below 500 rpm is detected.
Response from
controller
• None in particular.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on
machine
• If the machine is used as it is, the engine may be damaged.
Relative
information
• Input from the engine speed sensor (rpm) can be checked in the monitoring function.
(Code No. 01006: Engine speed)
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TROUBLESHOOTING AA10NX
Failure Code in Mechanical System [AA10NX] (Aircleaner Clogging)
User Code Error Code Failure Code Failure
phenomenon
Aircleaner Clogging
(Mechanical system)— — AA10NX
Failure content
• The signal circuit of the air cleaner clogging switch is closed (connected to grounding) while the engine
is running.
Response from
controller • None in particular.
Phenomenon
occurring on
machine
• If the machine is used as it is, the engine may be damaged.
• If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running this
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Relative
information
• If the air cleaner clogging monitor on the monitor panel lights up in red while the engine is running, this
failure code is recorded.
• Input from the air cleaner clogging switch (ON or OFF) can be checked in the monitoring function.(Code No. 04501: Monitor input 1)
P r e s u m e d c a u s e a n d
s
t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1 Air cleaner clogged
(While system is normal)Check the air cleaner. If it is clogged, clean or replace it.
2
Air cleaner clogging
switch defective(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position or keep the engine running during the troubleshooting.
A31 (male) Air cleaner Resistance value
Between (1) and (2)Normal Below 1 z
Clogged Above 1 Mz
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (5) and A31
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between A31 (female) (2) and groundingResistance
valueBelow 1 z
4 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position or keep the engine running during the troubleshooting.
P02 Air cleaner Voltage
Between (5) and groundingNormal Below 1 V
Clogged 20 – 30 V
TROUBLESHOOTING AA10NX
Electrical circuit diagram related to air cleaner clogging switch
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TROUBLESHOOTING AB00KE
Electrical circuit diagram related to engine preheating, starting, charging
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TROUBLESHOOTING B@BAZG
Failure Code in Mechanical System [B@BAZG] (Eng. Oil Press. Low)
User Code Error Code Failure Code Failure
phenomenon
Eng. Oil Press. Low
(Mechanical system)E11 E924 B@BAZG
Failure content
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of
the high-pressure switch is closed (connected to grounding) while the engine speed is above 600 rpm.• The signal circuit of the low-pressure switch is opened (disconnected from grounding) and the signal
circuit of the high-pressure switch is closed (connected to grounding) while the engine speed is above
1,300 rpm.
Response from
controller • None in particular.
Phenomenon
occurring on • If the machine is used as it is the engine may be damaged
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occurring on
machine
• If the machine is used as it is, the engine may be damaged.
Relative
information
• When this failure occurs, the error code is displayed only when the user code is turned ON and the fail-
ure code is recorded in only the mechanical system of the failure history.
• If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this
failure code is recorded.
• Input from the engine oil pressure switch (ON or OFF) can be checked in the monitoring function.
(Code No. 17400: Engine controller input)
P r e s u m e d c a u s e a n d
s t a n d a r
d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Engine oil pressurelowered
(While system is normal)
Check the engine oil pressure. If it is abnormal, find out the cause and check the
engine for damage, then repair.
2Engine oil pressure
switch system defectiveCarry out troubleshooting for error code [E936].
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position or start the engine during the troubleshooting.
CB1 Engine Voltage
Between (21) and grounding(Low-pressure switch signal)
Stopped Below 1 VLow idling 20 – 30 V
Between (15) and grounding
(High-pressure switch signal)
Stopped Below 1 V
Above 1,300 rpm 20 – 30 V
When carrying out troubleshooting while the engine is running, wait for 15 seconds
after the engine is started.
TROUBLESHOOTING B@BAZG
Electrical circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
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TROUBLESHOOTING B@BAZK
Failure Code in Mechanical System [B@BAZK] (Eng. Oil Level Low)
User Code Error Code Failure Code Failure
phenomenon
Eng. Oil Level Low
(Mechanical system)— — B@BAZK
Failure content
• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the
engine is stopped.
Response from
controller • None in particular.
Phenomenon
occurring on
machine
• If the machine is used as it is, the engine may be damaged.
R l ti
• If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this fail-
d i d d
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Electrical circuit diagram related to engine oil level switch
Relative
information
ure code is recorded.
• Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.(Code No. 04501: Monitor input 2)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Engine oil level low
(While system is normal)
Check the oil level in the engine oil pan. If it is low, add oil. (If it is reduced fre-
quently, find out the cause.)
2
Engine oil level switch
defective(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
OL (male) Engine oil level Resistance value
Between (1) and groundingNormal level Below 1 z
Below normal level Above 1 Mz
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (8) and OL
(female) (1)
Resistance
valueBelow 1 z
4 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Engine oil level Voltage
Between (8) and groundingNormal level Below 1 V
Below normal level 20 – 30 V
TROUBLESHOOTING B@BCNS
Failure Code in Mechanical System [B@BCNS] (Eng. Water Overheat)
User Code Error Code Failure Code Failure
phenomenon
Eng. Water Overheat
(Mechanical system)— — B@BCNS
Failure content • The signal circuit of the engine water high temperature sensor detected temperature above 105°C.
Response from
controller • None in particular.
Phenomenon
occurring on
machine
• If the machine is used as it is, the engine may be damaged.
Relative
• If the engine water temperature monitor on the monitor panel lights up in red while the engine is run-
ning, this failure code is recorded.
• Input from the engine water high temperature sensor (water temperature and voltage) can be checked
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Electrical circuit diagram related to engine water temperature sensor (for low temperature and high
temperature)
information• Input from the engine water high temperature sensor (water temperature and voltage) can be checked
in the monitoring function. (Code No. 04102: Engine water temperature (High), 04106: Engine watertemperature sensor voltage Hi)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Engine overheated
(While system is normal)
Check the engine for overheating. If it has been overheated, find out the cause and
check the engine for damage, then repair.
2
Engine water high
temperature sensor
system defective
Carry out troubleshooting for “Display of engine water temperature gauge on monitor
panel is abnormal” in E mode.
3Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB2 (female) Engine water temperature Resistance value
Between (27) and (29), (39) 105°C 3.28 kz
TROUBLESHOOTING B@BCZK
Failure Code in Mechanical System [B@BCZK] (Eng. Water Lvl Low)
User Code Error Code Failure Code Failure
phenomenon
Eng. Water Lvl Low
(Mechanical system)— — B@BCZK
Failure content• The signal circuit of the radiator water level switch is opened (disconnected from grounding) while the
engine is running.
Response from
controller • None in particular.
Phenomenon
occurring on
machine
• If the machine is used as it is, the engine will overheat.
Relative
• If the radiator water level monitor on the monitor panel lights up in red while the engine is stopped (the
starting switch is at the ON position) this failure code is recorded
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Electrical circuit diagram related to radiator water level switch
Relative
information
starting switch is at the ON position), this failure code is recorded.
• Input from the radiator water level switch (ON or OFF) can be checked in the monitoring function.(Code No. 04500: Monitor input 1)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Sub-tank water level low
(While system is normal)
Check the radiator sub-tank water level. If it is low, add water. (If it is reduced fre-
quently, find out the cause.)
2
Radiator water level
switch defective(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
A33 (male) Sub-tank water level Resistance value
Between (1) and (2)Within normal level Below 1 z
Below LOW level Above 1 Mz
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (3) and A33
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between A33 (female) (2), J08, J12 and
grounding
Resistance
value
Below 1 z
4 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Sub-tank water level Voltage
Between (3) and groundingWithin normal level Below 1 V
Below LOW level 20 – 30 V
TROUBLESHOOTING B@HANS
Failure Code in Mechanical System [B@HANS] (Hydr. Oil Overheat)
User Code Error Code Failure Code Failure
phenomenon
Hydr. Oil Overheat
(Mechanical system)— — B@HANS
Failure content • The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.
Response from
controller • None in particular.
Phenomenon
occurring on
machine
• If the machine is used as it is, the hydraulic equipment may be damaged.
Relative
information
• If the hydraulic oil temperature monitor on the monitor panel lights up in red while the engine is running,
this failure code is recorded.
• Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring func-
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Electrical circuit diagram related to hydraulic oil temperature sensor
information Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring func
tion. (Code No. 04401: Hydraulic oil temperature)
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m
a l c y
Cause Standard value in normalcy and references for troubleshooting
1Hydraulic oil overheated
(While system is normal)
Check the hydraulic oil for overheating. If it has been overheated, find out the cause
and check the hydraulic equipment for damage, then repair.
2
Hydraulic oil temperature
sensor defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
A61 (male) Hydraulic oil temperature Resistance value
Between (1) and (2) 10 – 100°C 90 – 3.5 kzBetween (2) and grounding Above 1 Mz
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P02 (female) (12) and
A61 (female) (2) and grounding
Resistance
value Above 1 Mz
4 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
P02 Hydraulic oil temperature Resistance value
Between (12) and (13)
10 – 100°C
90 – 3.5 kz
Between (12) and
grounding Above 1 Mz
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INFORMATION CONTAINED IN TROUBLESHOOTING TABLE ............................................................... 20-503
E-1 The engine does not start (The engine does not rotate) ...................................................................... 20-504
E-2 Preheater does not operate.................................................................................................................. 20-508
TROUBLESHOOTING OF
ELECTRICAL SYSTEM (E MODE)
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E-3 Auto engine warm-up device does not work ........................................................................................ 20-510E-4 Auto-decelerator does not operate ....................................................................................................... 20-511
E-5 All work equipment, swing and travel do not move .............................................................................. 20-512
E-6 One-touch power max. function does not operate ............................................................................... 20-514
E-7 Machine push-up function does not operate normally.......................................................................... 20-515
E-8 Attachment circuit does not change ..................................................................................................... 20-517
E-9 No display in monitor panel at all ......................................................................................................... 20-519
E-10 Part of display on monitor panel is missing ........................................................................................ 20-520
E-11 Monitor panel displays contents irrelevant to the model..................................................................... 20-520
E-12 Fuel level monitor red lamp lights up while engine is running ............................................................ 20-521E-13 Engine water temperature gauge does not display correctly ............................................................. 20-522
E-14 Hydraulic oil temperature gauge does not display correctly ............................................................... 20-524
E-15 Fuel gauge does not display correctly ................................................................................................ 20-525
E-16 Swing lock monitor does not display correctly.................................................................................... 20-526
E-17 When monitor switch is operated, nothing is displayed...................................................................... 20-528
E-18 Windshield wiper and window washer do not work ............................................................................ 20-530
E-19 Alarm buzzer cannot be cancelled ..................................................................................................... 20-534
E-20 “Boom RAISE” is not correctly displayed in monitor function ............................................................. 20-535
E-21 “Boom LOWER” is not correctly displayed in monitor function........................................................... 20-536E-22 “Arm IN” is not displayed normally in monitoring function .................................................................. 20-537
E-23 “Arm DUMPING” is not correctly displayed in monitor function.......................................................... 20-538
E-24 “Bucket CURL” is not displayed normally in monitoring function........................................................ 20-539
E-25 “Bucket DUMPING” is not correctly displayed in monitor function ..................................................... 20-540
E-26 “Swing” is not displayed normally in monitoring function.................................................................... 20-542
E-27 “TRAVEL” is not correctly displayed in monitor function..................................................................... 20-544
E-28 “Travel Differential Pressure” is not correctly displayed in monitor function ....................................... 20-546
E-29 “Service” is not correctly displayed in monitor function ...................................................................... 20-548
E-30 Travel alarm does not sound or does not stop sounding.................................................................... 20-550
E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM.............................................................. 20-552
TROUBLESHOOTING BEFORE CARRYING OUT TROUBLESHOOTING (E-MODE)
Before carrying out troubleshooting for electrical system (E-mode)
Connection table of fuse box
a This connection table shows the devices to which each power supply of the fuse box supplies power (A
switch power supply is a device which supplies power while the starting switch is at the ON position and a
constant power supply is a device which supplies power while the starting switch is at the OFF position).a When carrying out troubleshooting related to the electrical system, you should check the fuse box to see if
the power is supplied normally.
Type of
power supplyFuse No. Fuse capacity Destination of power
1 10 A
Pump controller (Controller power supply)
Swing holding brake solenoid (When emergency brake is released)
PC-EPC solenoid (When emergency pump is driven)
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Switch power supply
(Fusible link: A34)
2 20 APump controller (Solenoid power supply)Machine push-up solenoid
ATT return selector relay & solenoid
3 10 AStarting motor cutout relay (For PPC lock)
PPC lock solenoid
4 10 ACigarette lighter
Windshield washer motor
5 10 A Horn
Switch power supply
(Fusible link: A34)
6 10 A (Spare)7 10 A Rotary lamp
8 10 A Right front working lamp & boom working lamp
9 10 AOne-touch power maximizing switch (Input to pump controller input)
Radio
10 10 A (Spare)
Switch power supply
(Fusible link: A34)
11 20 A Air conditioner unit
12 20 AMonitor panel
Starting motor cutout relay (For personal code)
13 20 ALight relay (For right front working lamp & boom working lamp)
Headlamp & additional headlamp
14 10 A Service power supply 1 (M32 connector)
15 10 ATravel alarm
Service power supply 2 (DC/DC converter)
Constant power
supply(Fusible link: A35)
16 10 A Radio (For backing up)
17 10 A Monitor panel (For backing up)
18 10 A Starting switch19 10 A Room lamp
20 10 A (Spare)
TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
a The following information are edited and contained in the “Information Contained in Troubleshooting Table”.
You are required to proceed with troubleshooting after fully grasping the contents.
Failureinformation Phenomena occurring on machine
Relative
informationInformation on occurred failures and troubleshooting
Cause Standard value in normalcy and references for troubleshooting
1
<Contents>
• The standard values in normalcy by which to judge “good” or “no good” about
presumed causes
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Relative Electrical Circuit Diagram
P r e s u m e d c a
u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause for presumed
failure(The attached No. for
filing and reference
purpose only. It does not
stand for any priority)
presumed causes.
• References for making judgement of “good” or “no good”
<Phenomena of wiring harness fault>
• Failure due to disconnection
Defective contact with connector or disconnection of wiring harness has occurred.
• Grounding fault
A wiring harness that is not originally connected with a grounding circuit is in
contact with it.
• Failure due to short-circuiting
A wiring harness that is not originally connected with a power source circuit (24 V)is in contact with it.
<Points to remember in troubleshooting>
1) Connector denotation method and handling of T-adapters
Insert or connect T-adapters in the following manner, unless specifically otherwise
instructed.
• If there is no indication of (male) or (female) in the connector No., pull off a
connector and insert a T-adapter into both sides of male and female.
• If there is an indication of (male9 and (female) in the connection No., pull off a
connector and insert a T-adapter into only one side of (male) or (female).
2) Description sequence of pin No. and handling of circuit tester leads
Connect the positive lead (+) and negative lead (–) for troubleshooting in the
following manner unless specifically otherwise instructed.
• Connect the positive lead (+) to a pin No. marked at the front or wiring harness.
• Connect the negative lead (–) to a pin No. marked at the rear or wiring harness.
2
3
4
5
TROUBLESHOOTING E-1
E-1 The engine does not start (The engine does not rotate)
Failure
information• The engine does not start.
Relative
information• The engine starting circuit has the start lock mechanism of the safety lock lever type
Cause Standard value in normalcy and references for troubleshooting
1Insufficient battery
capacity
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Battery voltage Electrolyte specific gravity
Min. 24 V Min. 1.26
2Defective fusible link A35
or fuse No 3 or 17
If the circuit breaker is turned OFF or the fuse is broken, the circuit probably has a
grounding fault (See cause 9)
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
or fuse No. 3 or 17 grounding fault (See cause 9).
3Defective starting switch
(Internal disconnection)
aPrepare with starting switch OFF, then keep starting switch OFF or turn it START
and carry out troubleshooting.
H15 (male) Starting switch Resistance
Between (1) and (4)OFF Min. 1 Mz
START Max. 1 z
4
Defective safety lock
switch(Internal short circuit)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
S14 (female) Safety lock lever Resistance
Between (1) and (3)FREE Min. 1 Mz
LOCK Max. 1 z
5
Defective starting motor
cut-out relay
(Internal defect)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
R11 (female), R13 (female) Resistance
Between (1) and (2) 100 – 500 z
Between (3) and (5) Min. 1 Mz
Between (3) and (6) Max. 1 z
6Defective starting motor
(Internal defect)
aPrepare with starting switch OFF (with wiring harness connected), then turn
starting switch to START and carry out troubleshooting.
Starting motor Voltage
Between terminal B and
chassis ground
B (Power
supply)2 0 – 3 0 V
Between ST (1) and chas-
sis groundS (Start) 20 – 30 V
Between ST (2) and chas-
sis groundR (Charge) Max. 1 V
TROUBLESHOOTING E-1
Cause Standard value in normalcy and references for troubleshooting
8
Disconnection in wiring
harness (Disconnection
in wiring harness or
defective contact in con-
nector)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between battery relay B terminal and
A35 (male) (1) Resistance Max. 1 z
Wiring harness between A35 (male) (2) and H15
(female) (1)Resistance Max. 1 z
Wiring harness between H15 (female) (4), J01, and
R11 (female) (5)Resistance Max. 1 z
Wiring harness between R11 (female) (3) and ST
(female) (1)Resistance Max. 1 z
Wiring harness between FB1-3 and S14 (male) (1) Resistance Max. 1 z
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y
g ( ) ( )
Wiring harness between S14 (male) (3) and R11
(female) (1)Resistance Max. 1 z
Wiring harness between R11 (female) (2) and R13
(female) (6)Resistance Max. 1 z
Wiring harness between R13 (female) (3), J04, and
chassis groundResistance Max. 1 z
9
Short circuit with chas-
sis ground in wiring har-
ness (Contact with
ground circuit)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Between wiring harness between A35 (male) (2) and
H15 (female) (1) and chassis groundResistance Min. 1 Mz
Wiring harness between H15 (female) (4), J01, and
R11 (female) (5), and other related circuits and chassis
ground
Resistance Min. 1 Mz
Wiring harness between R11 (female) (3) and ST
(female) (1) and chassis groundResistance Min. 1 Mz
Wiring harness between FB1-3 and S14 (male) (1) and
chassis ground Resistance Min. 1 Mz
Wiring harness between A14 (male) (3) and R11
(female) (1) and chassis groundResistance Min. 1 Mz
Wiring harness between R11 (female) (2) and R13
(female) (6) and chassis groundResistance Min. 1 Mz
Wiring harness between R13 (female) (2), J05, P02
(female) (14), and other related circuits and chassis
ground
Resistance Min. 1 Mz
10
Short circuit with power
source in wiring harness
(Contact with 24 V cir
aPrepare with starting switch OFF, then turn starting switch ON and carry outtroubleshooting.
Between wiring harness between ST (female) (2),
TROUBLESHOOTING E-1
Electrical circuit diagram for engine preheating, starting, charging
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TROUBLESHOOTING E-1
E-2 Preheater does not operate
Failure
information• The preheater does not operate.
(1) When the starting switch is turned to the HEAT posi-
tion, the preheating monitor does not light up.
Relative
information
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about
30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
• Input of the preheating signal (ON or OFF) can be checked in the monitoring function.
(Code No. 04500: Monitor input 1)
s e a n d
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Starting switch system
defective
If the preheater does not operate (the heater unit is not warmed), carry out trouble-
shooting (2).
Disconnection of wiring
harness
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
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P r e s u m e d c a u s
s t a n d a r d v a l u e i n 2 (Disconnection or
defective contact with
connector)
Wiring harness between P02 (female) (18) and J02
(male) (7)
Resistance
valueBelow 1 z
3 Monitor panel defective
aTurn the engine starting switch OFF for the preparations , and hold it in the OFF or
HEAT position during troubleshooting.
P02 Starting switch Voltage
Between (18) and
grounding
OFF Below 1 V
HEAT 20 – 30 V
Failure
information• The preheater does not operate.
(2) When the starting switch is turned to the HEAT
position, the heater unit is not warmed.
Relative
information
• Check that the starting motor rotates normally.
• (If the starting motor does not rotate, carry out troubleshooting in “Engine does not start”.)
s e a n d
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Starting switch defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF or HEAT position during troubleshooting.
H15 (male) Starting switch Resistance value
Between (1) and (3)OFF Above 1 Mz
HEAT Below 1 z
2Heater relay defective(Internal disconnection)
aTurn the engine starting switch OFF for the preparations (with the wiring harness
connected), and hold it in the OFF or HEAT position during troubleshooting.
Heater relay Starting switchContinuity and
resistance value
Between coil terminalOFF Continued
TROUBLESHOOTING E-2
Electrical circuit diagram for engine preheating, starting, charging
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TROUBLESHOOTING E-3
E-3 Auto engine warm-up device does not work
Failure
information• The auto engine warm-up device does not work.
Relative
information
• The auto engine warm-up device is activated, when the engine cooling water temperature is below
30°C, and raise the engine rotation up to 1,200 rpm.
• The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
• If the engine water temperature is below 10°C, the turbocharger protection function operates to keep
the engine speed below 1,000 rpm for up to 5 seconds after the engine is started.
a n d
o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
aTurn the starting switch ON for the troubleshooting (monitoring).
Monitoring code Item Normal display
C th it
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P r e s u m e d c a u s e
s t a n d a r d v a l u e i n n
1Engine cooling water
temperature signal fault 04107
Engine cooling water
temperature
(low temperature)
Compare the monitorindication with the actual
engine cooling water
temperature.
If the display on the monitor panel is abnormal, carry out troubleshooting in “Engine
water thermometer does not display normally”.
2Engine controller
defective
If cause 1 is not detected, the engine controller may be defective. (Since trouble is in
the engine controller, troubleshooting cannot be carried out.)
TROUBLESHOOTING E-4
E-4 Auto-decelerator does not operate
Failure
information• The auto-decelerator does not operate.
Relativeinformation
• Since the auto-decelerator is set to 1,300 rpm, it does not operate if the fuel control dial is not set above
this level.
• Check the display on the monitor panel while the engine is running.
• If the display on the monitor panel is abnormal, carry out troubleshooting in “ is not displayed
normally in monitoring function”.
Cause Standard value in normalcy and references for troubleshooting
1Boom RAISE signal
defective
Monitoring code Item Normal display
01900
Pressure switch 1Boom RAISE
Lever operated: ON
Lever in neutral: OFF
Monitoring code Item Normal display
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P r e s u m e d c a u s e a n d
s
t a n d a r d v a l u e i n n o r m a l c y
2Boom LOWER signal
defective
Monitoring code Item Normal display
01900
Pressure switch 1Boom LOWER
Lever operated: ON
Lever in neutral: OFF
3 Arm IN signal defective
Monitoring code Item Normal display
01900
Pressure switch 1 Arm IN
Lever operated: ON
Lever in neutral: OFF
4 Arm OUT signal defective
Monitoring code Item Normal display
01900Pressure switch 1 Arm OUT Lever operated: ONLever in neutral: OFF
5Bucket CURL signal
defective
Monitoring code Item Normal display
01901
Pressure switch 2Bucket CURL
Lever operated: ON
Lever in neutral: OFF
6Bucket DUMP signal
defective
Monitoring code Item Normal display
01901
Pressure switch 2Bucket DUMP
Lever operated: ON
Lever in neutral: OFF
7 Swing signal defectiveMonitoring code Item Normal display
01900
Pressure switch 1Swing
Lever operated: ON
Lever in neutral: OFF
8 Travel signal defective
Monitoring code Item Normal display
01900
Pressure switch 1Travel
Lever operated: ON
Lever in neutral: OFF
9 Service signal defective
Monitoring code Item Normal display
01901
Pressure switch 2 Service
Lever operated: ON
Lever in neutral: OFF
10 Pump controller defectiveIf causes 1 – 9 are not detected, the pump controller may be defective.
(Since trouble is in the pump controller troubleshooting cannot be carried out )
TROUBLESHOOTING E-5
E-5 All work equipment, swing and travel do not move
Failure
information• All the work equipment, swing and travel do not move.
Relative
information—
Cause Standard value in normalcy and references for troubleshooting
1 Fuse No. 3 faultIf the fuse is blown, there is a big possibility that grounding fault occurred in the
circuit. (See cause 6.)
2
Safety lock switch
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
S14 (female) Safety lock lever Resistance value
Between (1) and (2) Free Below 1z
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n
o r m a l c y
Between (1) and (2) Free Below 1Lock Above 1 Mz
3
PPC lock solenoid
defective
(Internal disconnection,
short-circuiting, or
grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V08 (male) Resistance value
Between (1) and (2) 20 – 60 z
Between (1) and grounding Above 1 Mz
4 Assembled-type diodeD01 defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
D01 (male) Resistance value (Continuitiy)
Between (4) and (8) Above 1 Mz (No continuitiy)
5
Disconnection of wiring
harness
(Disconnection or
defective contact withconnector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between FB1-3 outlet and S14 (male)
(1)
Resistance
valueBelow 1 z
Wiring harness from S14 (male) (2) and J02 – V01(female) (2) Resistancevalue Below 1 z
Wiring harness between V08 (female) (1) to J13 and
grounding
Resistance
valueBelow 1 z
6
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between FB1-3 outlet and S14
(male) (1) and grounding
Resistance
value Above 1 Mz
Wiring harness from S14 (male) (2) to J02 – V01
(female) (2), or between wiring harness between S14
(male) (2) and D01 (female) (4) and grounding
Resistancevalue
Above 1 Mz
TROUBLESHOOTING E-5
Electrical circuit diagram for PPC lock solenoid
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TROUBLESHOOTING E-6
E-6 One-touch power max. function does not operate
Failure
information• One-touch power max. function does not operate
Relative
information
• If the one-touch power max. switch is pressed while the engine is running, the one-touch power max.
monitor is displayed on the monitor panel.
• Input condition of the one-touch power max. switch (left knob switch) (ON or OFF) can be checked in
the monitoring function. (Code No. 02200: Switch input 1)
Cause Standard value in normalcy and references for troubleshooting
1 Fuse No. 9 defectiveIf the fuse is broken, there is a big possibility that grounding fault occurred in the cir-
cuit. (See cause 4.)
2One-touch power max.
i h d f i (I l
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
M23 (male) One-touch power Resistance value
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Electrical circuit diagram related to one-touch power max. switch
P r e s u m e d
c a u s e a n d
s t a n d a r d v a l u
e i n n o r m a l c y
2One touch power max.switch defective (Internal
disconnection)
M23 (male) One touch powermax. switch
Resistance value
Between (1) and (2)Released Min. 1 Mz
Pressed Max. 1 z
3
Disconnection of wiring
harness (Disconnection
or defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between FB1-9 outlet and M23 (female)
(1)
Resistance
valueMax. 1 z
4
Grounding fault of wiring
harness (Contact with
grounding circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between FB1-9 outlet and M23
(female) (1), or between wiring harness between FB1-9
outlet and other related circuit and grounding
Resistance
valueMin. 1 Mz
Between wiring harness between M23 (female) (2) and
C01 (female) (11) and grounding
Resistance
valueMin. 1 Mz
5 Pump controller defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C01One-touch power
max. switchVoltage
Between (11) and
grounding
Released Max. 1 V
Pressed 20 – 30 V
TROUBLESHOOTING E-7
E-7 Machine push-up function does not operate normally
Failure
information
• Machine push-up function does not operate
normally.(1) The machine push-up function does not operate.
Relative
information• When the machine push-up function is set in the high pressure position, the solenoid is turned OFF.
su m e d c a u s e a n d
ard
v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Machine push-up switch
defective
(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
M38 (female) Machine push-up switch Resistance value
Between (1) and (2)Low pressure position Below 1 z
High pressure position Above 1 Mz
aTurn the engine starting switch OFF for the preparations, and hold it in the ONiti d i t bl h ti
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Electrical circuit diagram related to machine push-up solenoid
P r e s u
s t a n d a r d
2
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
g g p p ,position during troubleshooting.
Between wiring harness between M38 (female) (2), J07
and V06 (female) (2) or between M38 (female) (2) and
D02 (female) (3) and grounding
Voltage Below 1 V
TROUBLESHOOTING E-7
Failure
information
• Machine push-up function does not operate
normally.(2) The machine push-up function is not turned OFF.
Relative
information• When the machine push-up function is set in the low pressure position, the solenoid is turned ON.
Cause Standard value in normalcy and references for troubleshooting
1 Fuse No. 2 defective If the fuse is broken, the circuit probably has grounding fault (See cause 6).
2
Machine push-up switch
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
M38 (female) Machine push-up switch Resistance value
Between (1) and (2)Low pressure position Below 1 z
High pressure position Above 1 Mz
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P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
g
3
Machine push-up
solenoid defective
(Internal disconnection,
short-circuiting or
grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V06 (male) Resistance value
Between (1) and (2) 20 – 60 z
Between (2) and grounding Above 1 Mz
4
Assembled-type diode
D04 defective(Internal short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during troubleshooting.
D02 (male) Resistance value (Continuitiy)
Between (3) and (7) Above 1 Mz (No continuitiy)
5
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between FB1-2 outlet and M38 (male)
(1)
Resistance
valueBelow 1 z
Wiring harness between M38 (male) (2), J07 and V06
(female) (2)
Resistance
valueBelow 1 z
Wiring harness between V06 (female) (1) and groundingResistance
valueBelow 1 z
6
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between FB1-2 outlet and M38
(male) (1) or between FB1-2 outlet and related circuits
and grounding
Resistance
value Above 1 Mz
Between wiring harness between M38 (male) (2), J07
and V06 (female) (2) or between M38 (male) (2) and
D02 (female) (3) and grounding
Resistancevalue
Above 1 Mz
TROUBLESHOOTING E-8
E-8 Attachment circuit does not changeWhen attachment is installed
Failure
information
• Attachment circuit does not
change.
(1) When working mode A or E is selected, attachment circuit is not
switched to crusher circuit (reciprocation circuit).
(2) When working mode B is selected, attachment circuit is not
switched to breaker circuit (one-way circuit).
Relative
information
• If the primary side (coil side) of the attachment return selector relay has a fault (short-circuit or discon-
nection), an error code is displayed. A fault on the secondary side (contact side) cannot be detected,
however.
Cause Standard value in normalcy and references for troubleshooting
1
Attachment return selec-
tor solenoid defective
(Internal disconnectionor short circ it)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
V12 (male) Resistance value
Between (1) and (2) 20 – 60 z
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P r e s u m e d
c a u s e a n d
s t a n d a r d v a l u
e i n n o r m a l c y
or short-circuit) Between (1) and (2) 20 60 z
Between (2) and grounding Above 1 Mz
2
Attachment return selec-
tor relay defective
(Internal disconnection
or short-circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
R20 (male) Resistance value
Between (3) and (5) Below 1 z
Between (3) and (6) Above 1 Mz
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between J03 (male) (8) and R20
(female) (3)
Resistance
valueBelow 1 z
Wiring harness between R20 (female) (5) and V12
(female) (2)
Resistance
valueBelow 1 z
Wiring harness between C03 (female) (3), (13), (23)
and V12 (female) (1)
Resistance
valueBelow 1 z
4
Short-circuit of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness and R20 (female) (5) and V12
(female) (2) and groundingVoltage Below 1 V
TROUBLESHOOTING E-8
Electric Circuit Diagram for Attachment Return Selector Relay and Solenoid
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TROUBLESHOOTING E-9
E-9 No display in monitor panel at all
Failure
information
• No display in monitor panel at all.
When the engine starting switch is turned ON, there appears no display at all in the monitor panel.
Relative
information—
a n d r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1 Fuse No. 12 faultIf the fuse No. 12 is blown, there is a big possibility that grounding fault occurred in
the circuit. (See Cause 3.)
2
Disconnection of wiring
harness
(Disconnection or defect
contact with connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from P01 (female) (1) (2) to J07 to FB1-
12
Resistance
valueBelow 1 z
Wiring harness from P01 (female) (6) (7) to J04 andgrounding
Resistancevalue
Below 1 z
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Electrical Circuit Diagram for Power Source in Monitor Panel
P r e s u m e d c a u s e a
s t a n d a r d v a l u e i n n o r grounding value
3
Grounding fault of wiring
harness
(Contact with grounding
(GND)
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness from P01 (female) (1) (2) to
J07 to FB1-12 outlet or related circuits and grounding
Resistance
value
Above
1 Mz
4Monitor panel
controller defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P01 Starting switchVoltage and resistance
value
Between (1) (2) and
groundingON Voltage: 20 – 30 V
Between (6) (7) and
groundingOFF
Resistance value: Below
1 z
TROUBLESHOOTING E-10, E-11
E-10 Part of display on monitor panel is missing
Failure
information• Part of display on monitor panel is missing
Part of the display in the monitor panel is missing during
starting switch in ON.
Relative
information—
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1 Monitor panel LCD fault
aTurn the starting switch ON during the troubleshooting.
If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen
becomes totally white) by the following switching operation, then the monitor panel is
normal.
• Switching operation: [ ] + [ A ] (push swiches simultaneously.)
2 Monitor paneldefective
If cause 1 is not detected, the monitor panel may be defective. (Since trouble is inthe monitor panel troubleshooting cannot be carried out )
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E-11 Monitor panel displays contents irrelevant to the model
s defective the monitor panel, troubleshooting cannot be carried out.)
Failure
information• The monitor panels displays contents that have nothing to do with the model on which it is installed.
Relative
information—
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1Model code signal fault
(Internal failure)
aTurn the starting switch in ON during the troubleshooting (monitoring).
Monitoring code Item Normal display
00200 Controller model code PC400-a
If the display on the monitor panel is normal, troubleshoot Error Code [E217].
2Monitor panel
defective
If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in
the monitor panel, troubleshooting cannot be carried out.)
TROUBLESHOOTING E-10, E-11
E-12 Fuel level monitor red lamp lights up while engine is running
Failure
information• The fuel level monitor red lamp lights up while the engine was running.
Relative
information
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
• (5) Input signal from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No.: 04200 Fuel level sensor)
s e a n d
n o r m
a l c y
Cause Standard value in normalcy and references for troubleshooting
1Fuel level lowered (sys-
tem in normal condition) aCheck fuel level in fuel tank. If insufficient, refill fuel.
2
Fuel level sensor fault
(Internal
disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
A60 (male) Fuel level Resistance value
Between (1) and ground-ing
FULL (Upper limit) Approx. 12 zEMPTY (Lower limit) 85 – 110 z
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Electrical Circuit Diagram for Fuel Level Sensor
P r e s u m e d c a u s
s t a n d a r d v a l u e i n
ing EMPTY (Lower limit) 85 – 110 z
3
Grounding fault of wiring
harness
(Contact with grounding
(GND)
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (2) and A60
(female) (1)
Resistance
valueBelow 1 z
4Monitor panal
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
P02 (female) Fuel level Resistance value
Between (2) and
grounding
FULL (Upper limit) Approx. 12 z
EMPTY (Lower limit) 85 – 110 z
TROUBLESHOOTING E-13
E-13 Engine water temperature gauge does not display correctly
Failure
information
• Engine water temperature gauge does not
display correctly
(1) While the engine water temperature rises normally,
the temperature gauge does not rise above the white
range (C).
(2) While the engine water temperature is stabilized
normally, the temperature gauge rises up to the redrange (H).
Relative
information
• The signal of the engine water high temperature sensor for the water temperature gauge is received
from the engine controller through the communication line.
• If the engine water high temperature sensor system becomes defective, error code [E934] may be dis-
played.
• Input from the engine water high temperature sensor (voltage and temperature) can be checked in the
monitoring function. (Code No. 04106: Engine water sensor voltage Hi, 04102: Engine water tempera-
ture (High temperature))
Cause Standard value in normalcy and references for troubleshooting
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P r e s u
m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
1
Engine water high
temperature sensor
defective
(Internal disconnection,
short-circuiting or
grounding fault)
aTurn the engine starting switch OFF for the preparations, and turn to ON or keep
the engine running during the troubleshooting.
TWH (male) Resistance value
Between (1) and (2) 3.5 k – 90 kz
Between (1), (2) and grounding Above 1 Mz
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between CB2 (female) (27) and TWH
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between CB2 (female) (29), (39) and
TWH (female) (2)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between CB2 (female) (27) and
TWH (female) (1) and grounding
Resistance
value Above 1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between CB2 (female) (27) and
TWH (female) (1) and groundingVoltage Below 1 V
5Engine controller
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
CB2 (female) Resistance value
Between (27), (29) and (39) 3.5 k – 90 kz
Between (27), (29), (39) and grounding Above 1 Mz
TROUBLESHOOTING E-13
Electrical circuit diagram related to engine water high temperature sensor
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TROUBLESHOOTING E-14
E-14 Hydraulic oil temperature gauge does not display correctly
Failure
information
• Hydraulic oil temperature gauge does not display correctly
(1) Hydraulic oil temperature rises normally, but the display does not rise from the white range (C).
(2) Hydraulic oil temperature remains stable, but the display rises up the red range (H).
Relative
information
• Input from the hydraulic oil temperature sensor can be confirmed in the monitor function.
(Code No.: 04401 Hydraulic oil temperature)
Cause Standard value in normalcy and references for troubleshooting
1
Hydraulic oil temperature
sensor fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
A61Engine cooling water
temperatureResistance value
Between (1) and (2)
10 – 100 °C
90 – 3.5 kz
Between (2) and ground-ing
Above 1 Mz
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Electrical Circuit Diagram for Hydraulic Oil Temperature Sensor
P r e s u m e d
c a u s e a n d
s t a n d a r d v a l u
e i n n o r m a l c y
2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (12) and A61
(female) (2)
Resistance
valueBelow 1 z
Wiring harness between P02 (female) (13) and A61
(female) (1)
Resistance
valueBelow 1 z
3
Grounding fault of wiringharness
(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
Between wiring harness between P02 (female) (12) and
A61 (female) (2) and grounding
Resistance
value
Above
1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P02 (female) (12) and
A61 (female) (2) and groundingVoltage Below 1 V
5Monitor panal
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
P02Engine cooling water
temperatureResistance value
Between (12) and (13)
10 – 100 °C
90 – 3.5 kz
Between (12) and
grounding90 – 3.5 kz
TROUBLESHOOTING E-15
E-15 Fuel gauge does not display correctly
Failure
information
• Fuel gauge does not display correctly
(1) Though fuel was refilled, the display does not exceed the red range (E).
(2) Though the remaining fuel level is low, the display does not drop below the green range (F).
Relative
information
• Input from the fuel level sensor (voltage) can be confirmed in the monitor function.
(Code No.: 04200 Fuel sensor voltage)
y
Cause Standard value in normalcy and references for troubleshooting
1
Fuel level sensor fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
A60 (male) Fuel level Resistance value
Between (1) and
grounding
FULL (Upper limit) Approx. 12 z
EMPTY (Lower limit) 85 – 110 z
Disconnection of wiringharness
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
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Electrical Circuit Diagram for Fuel Level Sensor
P r e s u m e d c a u s e a n d
s t a n d
a r d v a l u e i n n o r m a l c
2 (Disconnection or
defective contact with
connector)
Wiring harness between P02 (female) (2) and A60
(female) (1)
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P02 (female) (2) and
A60 (female) (1) and grounding
Resistance
value
Above
1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P02 (female) (2) and
A60 (female) (1) and groundingVoltage Below 1 V
5Monitor panal
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
P01 Fuel level Resistance value
Between (2) and ground-ing
FULL (Upper limit) Approx. 12 zEMPTY (Lower limit) 85 – 110 z
TROUBLESHOOTING E-16
E-16 Swing lock monitor does not display correctly
Failure
information• Swing lock monitor does not display correctly
(1) Though the swing lock switch was turned ON, the
swing lock monitor does not light up.
(2) Though the swing lock switch was turned OFF, the
swing lock monitor lights up.
Relativeinformation
• Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.(Code No.: 04502 Monitor input 3)
Cause Standard value in normalcy and references for troubleshooting
1
Swing lock switch
defective
(Internal disconnection or
short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
X05 (female) Swing lock switch Resistance value
Between (1) and (2)
OFF Above 1 Mz
ON Below 1 z
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y 2
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
a g g p p ,
position during the troubleshooting.
Wiring harness from P02 (female) (17) to J02 and X05
(male) (1)
Resistance
valueBelow 1 z
Wiring harness from X05 (male) (2) to J05 and
grounding
Resistance
valueBelow 1 z
3
Grounding fault of wiringharness
(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness from P02 (female) (17) to J02
and X05 (male) (1), or between P02 (female) (17) to
C02 (female) (38) and grounding
Resistance
value Above 1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness from P02 (female) (17) to J02
and X05 (male) (1), or between P02 (female) (17) to
C02 (female) (38) and grounding
Voltage Below 1 V
5 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Swing lock switch Voltage
Between (17) and
grounding
OFF 20 – 30 V
ON Below 1 V
TROUBLESHOOTING E-16
Electrical circuit diagram related to swing holding brake solenoid
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TROUBLESHOOTING E-17
E-17 When monitor switch is operated, nothing is displayed
Failure
information
• When monitor switch is operated, nothing is dis-
played.
(1) When mode selector switch is operated, working
mode monitor is not displayed.
Relative
information—
Presumed
cause and
standard value
in normalcy
Cause Standard value in normalcy and references for troubleshooting
1Monitor panel
defective As this is an internal failure, troubleshooting cannot be conducted.
Failure
information
• When monitor switch is operated, nothing is
displayed.
(2) When LCD monitor adjustment switch is oper-
ated, mode selection screen is not displayed.Relative
information—
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information
Presumed
cause and
standard value
in normalcy
Cause Standard value in normalcy and references for troubleshooting
1Monitor panel
defective As this is an internal failure, troubleshooting cannot be conducted.
Failure
information
• When monitor switch is operated, nothing is
displayed.
(3) When selector switch is operated, flow rate
adjustment screen or flow rate selection screen
is not displayed.
Relative
information—
Presumed
cause and
standard valuein normalcy
Cause Standard value in normalcy and references for troubleshooting
1 Monitor paneldefective
As this is an internal failure, troubleshooting cannot be conducted.
Failure
information
• When monitor switch is operated, nothing is
displayed.
(4) When maintenance switch is operated, item
selection screen is not displayed.
Relative
information—
Presumed
cause and
Cause Standard value in normalcy and references for troubleshooting
TROUBLESHOOTING E-17
Failure
information
• When monitor switch is operated, nothing is
displayed.
(6) When travel speed selector switch is operated,
travel speed monitor is not displayed.
Relative
information• When the travel speed does not change either, conduct the troubleshooting for H-22.
Presumedcause and
standard value
in normalcy
Cause Standard value in normalcy and references for troubleshooting
1Monitor panel
defective As this is an internal failure, troubleshooting cannot be conducted.
Failure
information
• When monitor switch is operated, nothing is
displayed.
(7) When wiper switch is operated, wiper monitor is
not displayed.
Relativeinformation
• When the wiper does not operate either, conduct the troubleshooting for E-18.
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Presumed
cause and
standard value
in normalcy
Cause Standard value in normalcy and references for troubleshooting
1Monitor panel
defective As this is an internal failure, troubleshooting cannot be conducted.
TROUBLESHOOTING E-18
E-18 Windshield wiper and window washer do not work
Failure
information
• Windshield wiper and window washer do not
work.(1) The windshield wiper does not work.
Relative
information
• Input from the window rear limit switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
Cause Standard value in normalcy and references for troubleshooting
1
Window rear limit switch
fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
W03 (female) Front window Resistance value
Between (1) and (2)When installed at front Above 1 Mz
When retracted at rear Below 1 z
2Windshield wiper motorfault
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
W04 (male) Continuity and resistance value
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
( )Between (3) and (1) Continued
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P01 (female) (9) and W04
(female) (3)
Resistance
valueBelow 1 z
Wiring harness between P01 (female) (10) and W04
(female) (1)
Resistance
value Below 1 z
4
Grounding fault of wiring
harness
(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between P02 (female) (15) and
W03 (2)
Resistance
value
Above
1 Mz
5
Monitor panel fault
(Window rear limit switch
system)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Front window Voltage
Between (15) and ground-
ing
When installed at front 20 – 30 V
When retracted at rear Below 1 V
Monitor panel fault
(Windshield wiper motor
system)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P01 Windshield wiper switch Resistance value
Between (9) and
grounding
Between (10) andgrounding
OFF Below 3 V
ON
Below 3 V 20 – 30 V
(Constant cycle)
TROUBLESHOOTING E-18
Electrical Circuit Diagram for Windshield Wiper Motor and Window Rear Limit Switch
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TROUBLESHOOTING E-18
Failure
information
• Windshield wiper and window washer do not
work.(2) Windshield washer does not operate.
Relative
information—
d a l c y
Cause Standard value in normalcy and references for troubleshooting
1 Fuse No. 4 defective If fuse No. 4 is broken, the circuit probably has grounding fault, etc. (See cause 4.)
2
Washer motor defective
(Internal disconnection
or grounding fault)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
A50 (male) Resistance value
Between (1) and (2) 5 – 20 z
Between (1) and grounding Above 1 Mz
Disconnection of wiring
harness
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
Wiring harness from FB1 4 to J03 to J06 and A50 Resistance
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P r e s u m e d c a u s e a n d
s t a n d
a r d v a l u e i n n o r m a
3 (Disconnection or
defective contact with
connector)
Wiring harness from FB1-4 to J03 to J06 and A50
(female) (1)
Resistance
valueBelow 1 z
Wiring harness from A50 (female) (2) to J04 and P01
(female) (3)
Resistance
valueBelow 1 z
4
Grounding fault of wiringharness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness from FB1-4 to J03 to J06 and A50 (female) (1), or FB1-4 to D02 (female) (4), and to
other relative circuits and grounding
Resistance
value
Above
1 Mz
Between wiring harness from A50 (female) (2) to J04
and P01 (female) (3), or A50 (female) (2) to D02
(female) (8) and grounding
Resistance
value
Above
1 Mz
5Monitor panel
defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P01 Windshield washer switch VoltageBetween (3) and
grounding
OFF 20 – 30 V
ON Below 1 V
TROUBLESHOOTING E-18
Electrical Circuit Diagram for Window Washer Motor
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TROUBLESHOOTING E-19
E-19 Alarm buzzer cannot be cancelled
Failure
information• The alarm buzzer cannot be cancelled.
Relative
information
• Input from the alarm buzzer stop switch (ON or OFF) can be confirmed in the monitor function.
(Code No.: 04502 Monitor input 3)
s e a n d
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Alarm buzzer stop switch
defective
(Internal disconnection)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
P03 (female) Alarm buzzer
stop switchResistance value
Between (1) and (2)Release Above 1 Mz
Depress Below 1 z
Disconnection of wiring
harness
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between P02 (female) (16) and P03 Resistance
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Electrical circuit diagram related to alarm buzzer stop switch
P r e s u m e d c a u s
s t a n d a r d v a l u e i n n
2 (Disconnection or
defective contact with
connector)
Wiring harness between P02 (female) (16) and P03
(male) (1)
Resistance
valueBelow 1 z
Wiring harness from P03 (male) (2) to J05 to groundingResistance
valueBelow 1 z
3
Short-circuiting of wiring
harness(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between P02 (female) (16) and
P03 (male) (1) and groundingVoltage Below 1 V
4 Monitor panel defective
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P02 Alarm buzzer stop switch Voltage
Between (16) and
grounding
Release 20 – 30 V
Depress Below 1 V
TROUBLESHOOTING E-20
E-20 “Boom RAISE” is not correctly displayed in monitor function
Failure
information
• “Boom RAISE” is not correctly displayed in monitor function
“Boom RAISE” is not correctly displayed in the monitor function on the monitor panel.
Relative
information—
c y
Cause Standard value in normalcy and references for troubleshooting
1
Boom RAISE PPC
hydraulic switch fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S06 (male)R.H. work equipment
control lever Resistance value
Between (1) and (2)NEUTRAL Above 1 Mz
Boom RAISE Below 1 z
2
Disconnection of wiring
harness
(Disconnection or
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
Wiring harness between C03 (female) (10) and S06 ResistanceBelow 1 z
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Electrical Circuit Diagram for Boom RAISE PPC Hydraulic Switch
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c 2 (Disconnection or
defective contact with
connector)
(female) (2) valueBelow 1 z
Wiring harness between S06 (female) (1) and
grounding
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
(GND)
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (10) andS06 (female) (2) and grounding
Resistancevalue
Above1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C03 (female) (10) and
S06 (female) (2) and groundingVoltage Below 1 V
5Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
C03R.H. work equipment
control lever Voltage
Between (10) and
grounding
NEUTRAL 20 – 30 V
Boom RAISE Below 1 V
TROUBLESHOOTING E-21
E-21 “Boom LOWER” is not correctly displayed in monitor function
Failure
information
• “Boom LOWER” is not correctly displayed in monitor function
“Boom LOWER” is not correctly displayed in the monitor function on the monitor panel.
Relative
information—
a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Boom LOWER PPC
hydraulic switch fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S02 (male)R.H. work equipment
control lever Resistance value
Between (1) and (2)NEUTRAL Above 1 Mz
Boom LOWER Below 1 z
2
Disconnection of wiring
harness
(Disconnection or
aTurn the engine starting switch OFF for the preparations, and hold it in the OFFposition during the troubleshooting.
Wiring harness between C03 (female) (20) and S02
(f l ) (2)
Resistance
lBelow 1 z
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Electrical Circuit Diagram for Boom LOWER PPC Hydraulic Switch
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a 2 (Disconnection or
defective contact with
connector)
(female) (2) valueBelow 1 z
Wiring harness between S02 (female) (1) and ground-
ing
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (20) andS02 (female) (2) and grounding
Resistancevalue
Above1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V cir-
cuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C03 (female) (20) and
S02 (female) (2) and groundingVoltage Below 1 V
5 Pump controllerdefective
aTurn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
C03 R.H. work equipmentcontrol lever
Voltage
Between (20) and ground-
ing
NEUTRAL 20 – 30 V
Boom LOWER Below 1 V
TROUBLESHOOTING E-22
E-22 “Arm IN” is not displayed normally in monitoring function
Failure
information
• “Arm IN” is not displayed normally in monitoring
function.
“Arm IN” is not displayed normally in monitoring
function (special function) of monitor panel.
Relative
information
P r e s u m e d c a u s e a n d
s t a
n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1 Arm IN PPC pressure
sensor defective
The arm IN PPC pressure sensor may be defective. Carry out troubleshooting for
error code [E247].
2Pump controller
defective
If cause 1 is not the cause of the trouble, the pump controller may be defective
(Troubleshooting cannot be carried out since the defect is in the pump controller).
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TROUBLESHOOTING E-23
E-23 “Arm DUMPING” is not correctly displayed in monitor function
Failure
information
• “Arm DUMPING” is not correctly displayed in monitor function
“Arm DUMPING” is not correctly displayed in the monitor function (special function) on the monitor
panel.
Relative
information
—
y
Cause Standard value in normalcy and references for troubleshooting
1
Arm DUMPING PPC
hydraulic switch defect
(Internal disconnection
and short-circuiting)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S08 (male)L.H. work equipment
control lever Resistance value
Between (1) and (2)NEUTRAL Above 1 Mz
Arm DUMPING Below 1 z
Disconnection of wiring
harness
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C03 (female) (40) and S08 Resistance
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Electrical Circuit Diagram for Arm DUMPING PPC Hydraulic Switch
P r e s u m
e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
2 (Disconnection or
defective contact with
connector)
Wiring harness between C03 (female) (40) and S08
(female) (2)
Resistance
valueBelow 1 z
Wiring harness between S08 (female) (1) and
grounding
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (40) and
S08 (female) (2) and grounding
Resistance
value
Above
1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C03 (female) (40) and
S08 (female) (2) and groundingVoltage Below 1 V
5Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
C03L.H. work equipment
control lever Voltage
Between (40) and ground-
ing
NEUTRAL 20 – 30 V
Arm DUMPING Below 1 V
TROUBLESHOOTING E-24
E-24 “Bucket CURL” is not displayed normally in monitoring function
Failure
information
• “Bucket CURL” is not displayed normally in
monitoring function.
“Bucket CURL” is not displayed normally in
monitoring function (special function) of monitor
panel.
Relative
information
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1Bucket CURL PPC pres-
sure sensor defective
The bucket CURL PPC pressure sensor may be defective. Carry out troubleshoot-
ing for error code [E248].
2Pump controller
defective
If cause 1 is not the cause of the trouble, the pump controller may be defective
(Troubleshooting cannot be carried out since the defect is in the pump controller).
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TROUBLESHOOTING E-25
E-25 “Bucket DUMPING” is not correctly displayed in monitor function
Failure
information
• “Bucket DUMPING” is not correctly displayed in monitor function
“Bucket DUMPING” is not correctly displayed in the monitor function (special function) on the monitor
panel.
Relative
information
—
c y
Cause Standard value in normalcy and references for troubleshooting
1
Bucket DUMPING PPC
hydraulic switch fault
(Internal disconnection
and short-circuiting)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S05 (male)R.H. work equipment
control lever Resistance value
Between (1) and (2)NEUTRAL Above 1 Mz
Bucket DUMPING Below 1 z
2
Disconnection of wiring
harness
(Di ti
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C03 (female) (19) and S05 ResistanceB l 1 z
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Electrical Circuit Diagram for Bucket DUMPING PPC hydraulic Switch
P r e s u m e d c a u s e a n d
s t a n d a r d
v a l u e i n n o r m a l c 2 (Disconnection or
defective contact with
connector)
g ( ) ( )
(female) (2) valueBelow 1 z
Wiring harness between S05 (female) (1) and
grounding
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (19) and
S05 (female) (2) and grounding
Resistance
value
Above
1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C03 (female) (19) and
S05 (female) (2) and groundingVoltage Below 1 V
5Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
C03R.H. work equipment
control lever Voltage
Between (19) and
grounding
NEUTRAL 20 – 30 V
Bucket DUMPING Below 1 V
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TROUBLESHOOTING E-26
E-26 “Swing” is not displayed normally in monitoring function
Failure
information
• “Swing” is not displayed normally in monitor-
ing function.
“Swing” is not displayed normally in monitoring
function (special function) of monitor panel.
Relative
information
Cause Standard value in normalcy and references for troubleshooting
1
Swing left PPC pressure
switch defective
(Internal disconnection or
short-circuit)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S07 (male)Left work equipment
control lever Resistance value
Between (1) and (2)Neutral Min. 1 Mz
Left swing position Max. 1 z
2
Swing right PPC pres-
sure switch defective
(I t l di ti
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S03 (male)Left work equipment
control leverResistance value
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
2(Internal disconnection or
short-circuit)
( )control lever
Between (1) and (2)Neutral Min. 1 Mz
Right swing position Max. 1 z
3
Disconnection of wiring
harness
(Disconnection or defective
contact with connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C03 (female) (29) and S07
(female) (2) or S03 (female) (2)
Resistance
valueMax. 1 z
Wiring harness between S07 (female) (1) and groundingResistance
valueMax. 1 z
Wiring harness between S03 (female) (1) and groundingResistance
valueMax. 1 z
4
Grounding fault of wiring
harness
(Contact with grounding
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C03 (female) (29) and
S07 (female) (2) or S03 (female) (2) and grounding
Resistance
valueMin. 1 Mz
5
Short-circuiting of wiring
harness
(Contact with 24 V circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C03 (female) (29) and
S07 (female) (2) or S03 (female) (2) and groundingVoltage Max. 1 V
6 Pump controller defective
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
C03Left work equipment
control leverVoltage
TROUBLESHOOTING E-26
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
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TROUBLESHOOTING E-27
E-27 “TRAVEL” is not correctly displayed in monitor function
Failure
information
• “TRAVEL” is not correctly displayed in monitor function
“TRAVEL” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information—
a n d
rm a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Travel PPC hydraulic
switch fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S30 (male) Travel control lever Resistance value
Between (1) and (2)NEUTRAL Above 1 Mz
Forward or reverse Below 1 z
2
Disconnection of wiringharness
(Disconnection or
defective contact with
connector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.Wiring harness from C03 (female) (39) to J01 to S30
(female) (2)
Resistance
valueBelow 1 z
Wiring harness from S30 (female) (1) to J05 to ground- ResistanceBelow 1 z
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P r e
s u m e d c a u s e a
s t a n d a
r d v a l u e i n n o r )
ing valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness from C03 (female) (39) to J01 to S30
(female) (2), or between wiring harness between C03(female) (39) and A43 (female) (2) and grounding
Resistance
value
Above
1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Wiring harness from C03 (female) (39) to J01 to S30
(female) (2), or between wiring harness between C03
(female) (39) and A43 (female) (2) and grounding
Voltage Below 1 V
5Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
C03 Travel control lever Voltage
Between (39) and
grounding
NEUTRAL 20 – 30 V
Forward or backward Below 1 V
TROUBLESHOOTING E-27
Electrical Circuit Diagram for Travel PPC hydraulic Switch and Travel Alarm
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TROUBLESHOOTING E-28
E-28 “Travel Differential Pressure” is not correctly displayed in monitor function
Failure
information
• “Travel Differential Pressure” is not correctly displayed in monitor function
“Travel Differential Pressure” is not correctly displayed in the monitor function (special function) on the
monitor panel.
Relative
information
• When pressure difference is created between the right and left travel PPC circuits (in steering), the
travel differential mechanism is turned ON.
d a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Travel steering PPC
hydraulic switch fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S31 (male) Travel control lever Resistance value
Between (1) and (2)
NEUTRAL Above 1 Mz
One side of right or left
onlyBelow 1 z
2
Disconnection of wiring
harness
(Disconnection or
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C02 (female) (16) and S31
(female) (2)
Resistance
valueBelow 1 z
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P r e s u m e d c a u s e a n d
s t a n d a r d
v a l u e i n n o r m a
defective contact with
connector)
(female) (2) value
Wiring harness from S31 (female) (1) to J05 to
grounding
Resistance
valueBelow 1 z
3
Grounding fault of wiring
harness
(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between C02 (female) (16) and
S31 (female) (2) and grounding
Resistance
value
Above
1 Mz
4
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Between wiring harness between C02 (female) (16) and
S31 (female) (2) and groundingVoltage Below 1 V
5Pump controller
defective
aTurn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
C02 Travel control lever Voltage
Between (16) and ground-
ing
NEUTRAL 20 – 30 V
One side of right or left
onlyBelow 1 V
TROUBLESHOOTING E-28
Electrical Circuit Diagram for Travel and Steering PPC hydraulic Switch
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TROUBLESHOOTING E-29
E-29 “Service” is not correctly displayed in monitor function
Failure
information
• “Service” is not correctly displayed in monitor function
“Service” is not correctly displayed in the monitor function (special function) on the monitor panel.
Relative
information—
Cause Standard value in normalcy and references for troubleshooting
1
Service (front) PPC
hydraulic switch fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
S10 (male) Service pedal Resistance value
Between (1) and (2)NEUTRAL Above 1 Mz
Operated to front Below 1 z
2Service (rear) PPChydraulic switch fault
(Internal disconnection
or short-circuiting)
aTurn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.S11 (male) Service pedal Resistance value
Between (1) and (2)NEUTRAL Above 1 Mz
Operated to rear Below 1 z
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
3
Disconnection of wiring
harness
(Disconnection or
defective contact withconnector)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C02 (female) (35) and S10
(female) (2), or wiring harness between C02 (female)
(35) and S11 (female) (2)
Resistance
valueBelow 1 z
Wiring harness between S10 (female) (1) and ground-
ing
Resistance
valueBelow 1 z
4
Grounding fault of wiring
harness
(Contact with grounding
(GND)
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between C02 (female) (35) and S10
(female) (2), or between wiring harness between C02
(female) (35) and S11 (female) (2) and grounding
Resistance
value
Above
1 Mz
5
Short-circuiting of wiring
harness
(Contact with 24 V
circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the ONposition during the troubleshooting.
Wiring harness between C02 (female) (35) and S10
(female) (2), or between wiring harness between C02
(female) (35) and S11 (female) (2) and grounding
Voltage Below 1 V
6 Pump controller defective
aTurn the engine starting switch OFF for the preparations, and start the engine
during the troubleshooting.
C02 Service pedal Voltage
Between (35) and ground-ing
NEUTRAL 20 – 30 VOperated to front or rear Below 1 V
TROUBLESHOOTING E-29
Electrical Circuit Diagram for Service PPC hydraulic Switch
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TROUBLESHOOTING E-30
E-30 Travel alarm does not sound or does not stop sounding
Failure
information
• Travel alarm does not sound or does not stop sounding.
(1) The travel alarm does not sound while the machine is traveling.
(2) The alarm begins to sound when the machine is at a standstill.
Relative
information—
u s e a n d
n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1 Fuse No. 15 faultWhen fuse No.15 is blown, there is a big possibility that grounding fault occurred in
the circuit. (See Cause 4.)
2 Travel signal fault
aStart the engine during the troubleshooting (monitoring).
Monitoring code Item Normal display
01900 Travel
Control lever operated:
ON
Control lever NEUTRAL:OFF
If the monitor display is not correct, proceed to No. E-29 Troubleshooting.
Di ti f i iaTurn the engine starting switch OFF for the preparations, and hold it in the OFF
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P
r e s u m e d c a u
s t a n
d a r d v a l u e i n
3
Disconnection of wiring
harness
(Disconnection or
defective contact with
connector)
position during the troubleshooting.
Wiring harness between FB1-15 outlet to J03 and A43
(female) (1)
Resistance
valueBelow 1 z
Wiring harness between A43 (female) (2) and J01 (19)
Resistance
value Below 1z
4
Grounding fault of wiring
harness
(Contact with grounding
(GND) circuit)
aTurn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between FB1-15 outlet to J03
and A43 (female) (1), or between wiring harness
between FB1-15 outlet and other related circuit and
grounding
Resistance
value
Above
1 Mz
5 Travel alarm fault
As this is an internal failure, troubleshooting cannot be conducted. (If none of the
causes listed in Item 1 through 4 above is found, the travel alarm is judged asdefective)
TROUBLESHOOTING E-30
Electrical Circuit Diagram for Travel PPC Hydraulic Switch and Travel Alarm
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TROUBLESHOOTING E-31
E-31 TROUBLESHOOTING FOR AIR CONDITIONER SYSTEM
Troubleshooting procedure for air conditioner system
a The control panel of the air conditioner constantly monitors the sensors and other devices in the system .
When it detects any abnormality, “Self-diagnosis notice” is displayed by operating switches specially.
a If you feel any abnormality in the air conditioner system, check the “Self-diagnosis notice” first according to
the procedure for “Troubleshooting by self-diagnosis notice”, and then;
• If the “Self-diagnosis notice” is displayed, continue the “Troubleshooting by self-diagnosis notice”.
• If the “Self-diagnosis notice” is not displayed, carry out the “Troubleshooting by failure phenomenon”.
Troubleshooting by self-diagnosis notice
a Check the “Self-diagnosis notice” on the control
panel according to the following procedure.
• How to display “Self-diagnosis notice”
1) Turn the starting switch ON.
2) Press OFF switch (1) and check that any-
thing is not displayed on display monitor (2).
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3) Hold the UP switch ( ) and DOWN switch
( ) of temperature setting switch (3) simul-
taneously for 3 seconds or more.
4) Check the “Self-diagnosis notice” displayed
on display monitor (2).
• How to select “Self-diagnosis notice”
If multiple “Self-diagnosis notices” are recorded,
press the UP switch ( ) or DOWN switch ( )
of temperature setting switch (3) to select
another notice.
• How to delete “Self-diagnosis notice”When reproducing the “Self-diagnosis notices”
or after removing the cause of a failure, press
the switches on both sides of recirc/fresh air
selector switch (4) simultaneously for 3 seconds
or more, and all the “Self-diagnosis notices” are
deleted.
• Finishing display of “Self-diagnosis notice”
To finish display of the “Self-diagnosis notice”,press OFF switch (1) or turn the starting switch
Self-diagnosis
noticeFailure mode
E-- No failures
E11Disconnection in recirculated air
sensor
E12 Short-circuit in recirculated air sensor
E15 Disconnection in water temperaturesensor
E16Short-circuit in water temperature
sensor
E18 Short-circuit in daylight sensor
E43 Abnormality in air outlet damper
E44 Abnormality in air mix damper
E45 Abnormality in recirculated and fresh
air damper
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Disconnection in recirculated air sensor
E11
Contents of
trouble• Disconnection in the recirculated air sensor system is detected.
Action of
control panel
• Fixes the recirculated air temperature for control.
• When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
s e s a n d
n o r m a l s t a t e
Cause Standard value in normal state/Remarks on troubleshooting
1
Defective recirculated
air sensor
(Internal disconnection)
aPrepare with starting switch OFF, then carry out troubleshooting without turningstarting switch ON.
THI (male) Resistance
Between (1) and (2) 300 z – 430 kz
aPrepare with starting switch OFF then carry out troubleshooting without turning
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P
o s s i b l e c a u s
s t a n d a r d v a l u e i n
2
Disconnection of wiring
harness (Disconnection
or defective contact with
connector)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between M30 (female) (12) and TH I
(female) (2)Resistance Max. 1z
Wiring harness between M29 (female) (11) and TH I (female) (1)
Resistance Max. 1z
3Defective air conditioner
system
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in recirculated air sensor
E12Contents of
trouble• Short circuit in the recirculated air sensor system is detected.
Action of
control panel
• Fixes the recirculated air temperature for control.
• When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
Cause Standard value in normal state/Remarks on troubleshooting
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Disconnection in water temperature sensor
E15
Contents of
trouble• Disconnection in the water temperature sensor system is detected.
Action of
control panel
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
• When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
s e s a n d
n o r m a l s t a t e
Cause Standard value in normal state/Remarks on troubleshooting
1
Defective water tempera-
ture sensor (Internal dis-
connection)
aPrepare with starting switch OFF, then carry out troubleshooting without turningstarting switch ON.
THW (male) Resistance
Between (1) and (2) 95 z – 455 kz
aPrepare with starting switch OFF then carry out troubleshooting without turning
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P
o s s i b l e c a u
s t a n d a r d v a l u e i n
2
Disconnection of wiring
harness (Disconnection
or defective contact with
connector)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between M30 (female) (14) and THW
(female) (2)Resistance Max. 1z
Wiring harness between M29 (female) (11) and THW (female) (1)
Resistance Max. 1z
3Defective air conditioner
system
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Short circuit in water temperature sensor
E16Contents of
trouble• Short circuit in the water temperature sensor system is detected.
Action of
control panel
• Ignores the warm-up control and fixes the engine water temperature at 60°C for control.
• When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
Cause Standard value in normal state/Remarks on troubleshooting
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Short circuit in daylight sensor
E18
Contents of
trouble• Short circuit in the daylight sensor system is detected.
Action of
control panel
• Assumes that the daylight sensor is not installed for control.
• When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
c a u s e s a n d
u e i n n o r m a l s t a
t eCause Standard value in normal state/Remarks on troubleshooting
1 Defective daylight sen-sor (Internal short circuit)
The daylight sensor may be defective. Check it directly.
2
Disconnection of wiring
harness (Disconnection
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between M30 (female) (16) and P15Resistance Max 1z
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P o s s i b l e
s t a n d a r d v a l u 2
or defective contact with
connector)
(female) (2)Resistance Max. 1z
Wiring harness between M30 (female) (3) and P15
(female) (1)Resistance Max. 1z
3 Defective air conditionersystem
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner systemmay be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
Self-diagnosis
notice Trouble Abnormality in air outlet damper
E43
Contents of
trouble• Abnormality in air outlet servomotor system is detected.
Action of
control panel
• Stops the air outlet servomotor.
• When the following condition is satisfied, the operation returns to normalcy.
• <Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
aDo not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
the motor output shaft and break the motor coils.
Cause Standard value in normalcy and references for troubleshooting
1 Defective air outlet servo-motor (Internal defect)
The air outlet servomotor may be defective. Check it directly.
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Abnormality in air mix damper
E44
Contents of
trouble• Abnormality in air mix servomotor system is detected.
Action of
control panel
• Stops the air mix servomotor.
• When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
aDo not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
the motor output shaft and break the motor coils.
a n d
m a l s t a t e
Cause Standard value in normal state/Remarks on troubleshooting
1 Defective air mix servo-motor (Internal defect)
The air mix servomotor may be defective. Check it directly.
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between M AM (female) (1) and M29Resistance Max 1z
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P o s s i b l e c a u s e s a
s t a n d a r d v a
l u e i n n o r m
2
Disconnection in wiring
harness (Disconnection
in wiring harness or
defective contact in con-nector)
(female) (11)Resistance Max. 1z
Wiring harness between M AM (female) (3) and M30
(female) (3)Resistance Max. 1z
Wiring harness between M AM (female) (5) and M30(female) (2)
Resistance Max. 1z
Wiring harness between M AM (female) (6) and M29
(female) (4)Resistance Max. 1z
Wiring harness between M AM (female) (7) and M29
(female) (5)Resistance Max. 1z
3Defective air conditioner
system
If neither of causes 1 and 2 is the cause of the trouble, the air conditioner system
may be defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
TROUBLESHOOTING E-31
Self-diagnosis
notice Trouble Abnormality in recirculated and fresh air damper
E45
Contents of
trouble• Abnormality in recirculated and fresh air servomotor system is detected.
Action of
control panel
• Stops the recirculated and fresh air servomotor.
• When the following condition is satisfied, the operation returns to normalcy.
<Completion of removal of cause> + <Deletion of self-diagnosis notice> + <Turning starting switch OFF
and ON> + <Starting air conditioner>
Related
information
aDo not connect the power cables to the motor terminals directly to drive the motor. Doing so can damage
the motor output shaft and break the motor coils.
s a n d
r m a l s t a t e
Cause Standard value in normal state/Remarks on troubleshooting
1Defective recirculatedand fresh air servomotor
(Internal defect)
The recirculated and fresh air servomotor may be defective. Check it directly.
2 Defective fuse (in unit)If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.
Check the related circuits.
aP ith t ti it h OFF th t t bl h ti ith t t i
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P o s s
i b l e c a u s e s
s t a n d a r d v a l u e i n n o
3
Disconnection in wiring
harness (Disconnection
in wiring harness ordefective contact in con-
nector)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between MRF (female) (1) and M29
(female) (6)Resistance Max. 1z
Wiring harness between MRF (female) (3) and M29
(female) (7)Resistance Max. 1z
Wiring harness between MRF (female) (7), fuse in unit,
and M33 (female) (3)Resistance Max. 1z
4Defective air conditioner
system
If none of causes 1 – 3 is the cause of the trouble, the air conditioner system may be
defective. Refer to CHASSIS COMPONENT, Shop Manual, “Air conditioner”.
TROUBLESHOOTING E-31
Electrical Circuit Diagram for Air Conditioner
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TROUBLESHOOTING E-31
Troubleshooting by failure phenomenon
Trouble • The air conditioner does not operate. (1) The air conditioner does not operate at all.
Related
information
s a n d
r m a l s t a t e
Cause Standard value in normal state/Remarks on troubleshooting
1 Defective fuse No. 11 If the fuse is broken, the circuit probably has a grounding fault, etc. (Refer to cause 3.)
2
Disconnection in wiring
harness (Disconnection
in wiring harness or
defective contact in con-
nector)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between fuse 11 outlet and M33 (male)
(3)Resistance Max. 1z
Wiring harness between M27 (female) (14) and M30
(female) (6)Resistance Max. 1z
Wiring harness between M33 (male) (2) and chassisground
Resistance Max. 1z
Wiring harness between M29 (female) (12) and chassis
groundResistance Max. 1z
Sh t i it ith h i
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON
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P o s s i b l e c a u s e s
s t a n d a r d v
a l u e i n n o r
3
Short circuit with chassis
ground in wiring harness
(Contact with ground cir-
cuit)
starting switch ON.
Between wiring harness between circuit breaker fuse 11
outlet and M33 (male) (3) and chassis groundResistance Min. 1 Mz
Between wiring harness between M27 (female) (14) andM30 (female) (6) and chassis ground
Resistance Min. 1 Mz
4Defective air conditioner
unit
aPrepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
M33 Voltage
Between (2) and (3) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the air condi-
tioner is defective.
5 Defective control panel
aPrepare with starting switch OFF, then turn starting switch ON and carry outtroubleshooting.
M30, M29 Voltage
Between M30 (6) and M29 (12) 20 V – 30 V
If the above voltage is normal and the air conditioner does not operate, the control
panel is defective.
TROUBLESHOOTING E-31
Trouble • The air conditioner does not operate. (2)A ir does not come out (Air flow is insufficient).
Related
information
Cause Standard value in normal state/Remarks on troubleshooting
1 Defective fuse (in unit) If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.Check the related circuits.
2Defective blower relay
(on coil side)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
R30 (male) Resistance
Between (1) and (3) 140 – 340 z
3 Defective blower relay(on contact side)
aPrepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
R30 Fan switch Voltage
Between (4) and
chassis groundON (Operated) 20 – 30 V
Defective power transis-
aPrepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting.
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P o s s i b l e c a u s e s a n d
s t a
n d a r d v a l u e i n n o r m a l s t a t e
4Defective power transis
tor (Internal defect) Fan switch If air flow can be changed with fan switch,
power transistor is normal.Operate in range of Low, Medium, and High
5Defective blower motor
(Internal defect)
aPrepare with starting switch OFF, then turn starting switch ON and carry outtroubleshooting.
MB (female) Fan switch Voltage
Between (1) and (2) ON (Operated) 20 – 30 V
If the above voltage is normal and the blower motor does not rotate, the blower motor
is defective.
6
Disconnection in wiring
harness (Disconnection
in wiring harness or
defective contact in con-
nector)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between fuse 11 outlet, fuse in unit, R30(3), R31 (female) (1), and M30 (female) (6)
Resistance Max. 1z
Wiring harness between M29 (female) (3) and R30
(female) (1)Resistance Max. 1z
Wiring harness between M29 (female) (12) and chassis
groundResistance Max. 1z
Wiring harness between MB (female) (1) and R30
(female) (4)Resistance Max. 1z
Wiring harness between MB (female) (2) and PTR (female) (3)
Resistance Max. 1z
TROUBLESHOOTING E-31
Trouble • The air conditioner does not operate. (3) Air is not cooled (Cooling capacity is low).
Related
information
Cause Standard value in normal state/Remarks on troubleshooting
1 Defective fuse (in unit) If the fuse (in the unit) is broken, the circuit probably has a grounding fault, etc.Check the related circuits.
2Defective compressor
relay (on coil side)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
R31 (male) Resistance
Between (1) and (2) 140 – 340 z
3 Defective compressorrelay (on contact side)
aPrepare with starting switch OFF, then turn starting switch ON and carry out
troubleshooting (Setting of temperature: Highest cooling position).
R31 Fan switch Voltage
Between (4) and chassis
groundON (Operated) 20 – 30 V
4Defective thermostat
(Internal defect)The thermostat may be defective. Check it directly.
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P o s s i b l e c a u s e s a n d
s t a n d a r d v a l u e i n n o r m a l
s t a t e
5
Defective high/low pres-
sure switch (Internal dis-
connection)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
P17 (male) Resistance
Between (1) and (2) Max. 1 z
6Defective compressor
clutch (Internal defect)The compressor clutch may be defective. Check it directly.
7Defective compressor
(Internal defect)The compressor may be defective. Check it directly.
8
Disconnection in wiring
harness (Disconnection
in wiring harness or
defective contact in con-
nector)
aPrepare with starting switch OFF, then carry out troubleshooting without turning
starting switch ON.
Wiring harness between M30 (female) (4) and P17(female) (1)
Resistance Max. 1 z
Wiring harness between P17 (female) (2) and chassis
groundResistance Max. 1 z
Wiring harness between fuse 11 outlet, R31 (female)
(2), fuse in unit, R31 (female) (1), and M30 (female) (6)Resistance Max. 1 z
Wiring harness between ST1 (female) (1) and R31
(female) (3)Resistance Max. 1 z
Wiring harness between M29 (female) (2) and ST1 (female) (2)
Resistance Max. 1 z
TROUBLESHOOTING E-31
Electrical Circuit Diagram for Air Conditioner
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System chart for hydraulic and mechanical system .................................................................................... 20-602
H-1 All work equipment lack power, or travel and swing speeds are slow.................................................. 20-605
H-2 Engine speed sharply drops or engine stalls ....................................................................................... 20-606
H-3 No work equipment, travel or swing move ........................................................................................... 20-607
H-4 Abnormal noise is heard from around hydraulic pump......................................................................... 20-607
H-5 Auto-decelerator does not work ........................................................................................................... 20-608H-6 Fine control mode does not function.................................................................................................... 20-608
H-7 Boom moves slowly or lacks power ..................................................................................................... 20-609
H-8 Arm moves slowly or lacks power ........................................................................................................ 20-610
H-9 Bucket moves slowly or lacks power.................................................................................................... 20-611
H-10 Work equipment does not move in its single operation...................................................................... 20-611
TROUBLESHOOTING OF HYDRAULIC
AND MECHANICAL SYSTEM (H MODE)
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q p g p
H-11 Work equipment has a bit too fast hydraulic drift................................................................................ 20-612
H-12 Work equipment has big time lag....................................................................................................... 20-613
H-13 Other work equipment moves when relieving single circuit................................................................ 20-613
H-14 One-touch power max. function does not work.................................................................................. 20-613
H-15 Machine push-up function does not work........................................................................................... 20-614
H-16 In compound operation, work equipment with larger load moves slowly ........................................... 20-615
H-17 In swing + boom RAISE operation, boom moves slowly.................................................................... 20-615
H-18 In swing + travel, travel speed drops sharply ..................................................................................... 20-615
H-19 Machine swerves in travel.................................................................................................................. 20-616
H-20 Machine travels slowly ....................................................................................................................... 20-617
H-21 Machine cannot be easily steered or lacks power ............................................................................. 20-618
H-22 Travel speed does not shift, or it is slower or faster than preset speed. ............................................ 20-619H-23 Track shoe does not turn (on one side only) ...................................................................................... 20-620
H-24 Machine does not swing..................................................................................................................... 20-621
H-25 Swing acceleration is poor, or swing speed is slow ........................................................................... 20-622
H-26 Excessive overrun when stopping swing ........................................................................................... 20-623
H-27 There is big shock when stopping swing............................................................................................ 20-624
H-28 There is big abnormal noise caused when stopping swing................................................................ 20-624
H-29 Swing natural drift is too big ............................................................................................................... 20-625
H-30 Attachment circuit does not change ................................................................................................... 20-626
H-31 Flow rate in attachment circuit cannot be adjusted ............................................................................ 20-626
TROUBLESHOOTING
BEFORE TROUBLESHOOTING FOR HYDRAULIC
AND MECHANICAL SYSTEMS (H MODE)
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEM
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TROUBLESHOOTING
BEFORE TROUBLESHOOTING FOR HYDRAULIC
AND MECHANICAL SYSTEMS (H MODE)
a This is a system chart that has been drawn up by simplifying the whole hydraulic circuit chart. Use it as a
reference material when troubleshooting the hydraulic and mechanical systems.
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TROUBLESHOOTING INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE
a Troubleshooting Table and Related Circuit Diagram collectively carry the following information. Carry out
troubleshooting work after fully grasping their contents.
Failure information Phenomena occurring on machine
Relative information Information on occurred failures and troubleshooting
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Cause for presumed
failure
(The attached No. for
filing and reference
purpose only. It does not
stand for any priority)
<Contents>
• The standard values in normalcy by which to judge “good” or “no good” about pre-
sumed causes.
• References for making judgement of “good” or “no good”
2
3
4
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5
TROUBLESHOOTING H-1
H-1 All work equipment lack power, or travel and swing speeds are slow
Failure information • All the work equipment lack power, or their travel and swing speeds are slow.
Relative information • Set the working mode at A mode for troubleshooting.
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of unload
valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Control lever Unload pressure
All control levers in NEUTRAL4.12 ± 1.0 MPa
{42 ± 10kg/cm2}
2
Improper adjustment or
malfunctioning of main
relief valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Control lever Main relief pressure
Arm, DIGGING33.34 – 36.77 MPa
{340 – 375kg/cm2}
If the pressure does not return to normalcy even after the adjustment, malfunctioningof main relief valve or its internal failure is suspected. In that case, check the valve
itself.
3
Malfunctioning of
self pressure
decompression valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Control lever Control circuit source pressure
All control levers in NEUTRAL2.84 – 3.43 MPa
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P
r e s u m e d c a u s e a n d
s t a n
d a r d v a l u e i n n o r m a l c y
p All control levers in NEUTRAL{29 – 35kg/cm2}
4
Improper adjustment or
malfunctioning of PC
valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be mea-sured
Measurement condition Oil pressure ratio
Pump delivery pressureSwing lock: ON
Arm: Digging relief
1
PC valve output pressure Approx. 0.6
(Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment,
malfunctioning of PC valve or its internal failure is suspected. In that case, check the
valve itself.
5Malfunctioning of
LS-EPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever LS-EPC output pressure
Lo NEUTRAL Approx. 1.37 MPa
{Approx. 14 kg/cm2}
Hi OPERATED 0 MPa {0 kg/cm2}
aStop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be mea-sured
Oil pressure ratio
All control levers in
NEUTRAL
Travel without load (con-trol lever held at half
TROUBLESHOOTING H-2
H-2 Engine speed sharply drops or engine stalls
Failure information • The engine speed sharply drops or the engine stalls.
Relative information • Relative Information
c a u s e a n d
e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Improper adjustment or
malfunctioning of main
relief valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Control lever Main relief pressure
Arm, DIGGING33.34 – 36.77 MPa
{340 – 375kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment,
malfunctioning of the main relief valve or its internal failure is suspected. In that
case, check the valve itself.
2
Improper adjustment or
malfunctioning of PC
valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be
measured Measurement condition Oil pressure ratio
Pump delivery pressureSwing lock: ON
Arm: Digging relief
1
PC valve output pressure Approx. 0.6
(Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment,
malfunctioning of the PC valve or its internal failure is suspected In that case check
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P r e s
u m e d c
s t a n d a r d v a l u e malfunctioning of the PC valve or its internal failure is suspected. In that case, check
the valve itself.
3
Improper adjustment or
malfunctioning of LS
valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be
measured
Oil pressure ratio
All control levers in
NEUTRAL
Travel without load
(control lever held at half
stroke)
Pump delivery pressure
Nearly equal pressure
1
LS valve output pressure Approx. 0.6
(Approx. 3/5)
If the oil pressure does not return to normalcy even after the adjustment,malfunctioning of the LS valve or its internal failure is suspected. In that case, check
the valve itself.
4Orifice or filter in servo
equipment clogged
The orifice or filter in the pump servo equipment is suspected of clogging. Check the
equipment itself.
5Malfunction of servo
pistonThe servo piston is suspected of malfunction. Check the piston itself.
TROUBLESHOOTING H-3, H-4
H-3 No work equipment, travel or swing move
Failure information • No work equipment nor travel and swing functions can be set in motion.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s
u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of PPC
lock solenoid valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Safety lock lever Solenoid output pressure
Locked 0 MPa {0 kg/cm2}
Released2.84 – 3.43 MPa
{29 – 35kg/cm2}
2
Malfunctioning of
self pressure
decompression valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Control lever Control circuit source pressure
All control levers in NEUTRAL position2.84 – 3.43 MPa
{29 – 35kg/cm2
}
3 Piston pump defective
The piston pump is suspected of malfunctioning or an internal failure. Diagnose it in
the following manner.
• Remove the main oil pressure measurement plug and crank the engine. If oil flows
out, it is in normal condition.
4 Damper defectiveIt is presumed that the pump shaft does not rotate due to some internal failure of the
damper Check the damper itself
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H-4 Abnormal noise is heard from around hydraulic pump
damper. Check the damper itself.
Failure information • An abnormal noise is heard from around the hydraulic pump.
Relative information —
s u m e d c a u s e a n d
r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Hydraulic oil level
loweredMake a visual check.
2Quality of hydraulic oil
bad Air may have get mixed with the oil. Make a visual check.
3Hydraulic tank cap
breather clogged
It is presumed that the breather in the cap of hydraulic tanks is clogged, thereby
causing negative pressure inside the tank. Make a visual check.
TROUBLESHOOTING H-5, H-6
H-5 Auto-decelerator does not work
H 6 Fi t l d d t f ti
Failure information • The auto-decelerator does not work.
Relative information
• This troubleshooting mode is applied when the auto-decelerator does not work, while operating
the travel control lever. (A shuttle valve is provided between PPC valve and the hydraulic switch
only in the travel circuit -actually located inside PPC valve)
• Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n d
s t a
n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of travel
PPC valve (shuttle valve)
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Operation Above 2.75 MPa
{Above 28 kg/cm2}
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H-6 Fine control mode does not function
Failure information • The fine control mode poorly functions or its response is slow.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n d
a n d
a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of LS-
EPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever LS-EPC valve output
pressure
Lo NEUTRAL Approx. 1.37 MPa
{Approx. 14 kg/cm2
}Hi OPERATED 0 MPa {0 kg/cm2}
2Orifice in LS circuit
cloggedThe orifice in the LS circuit is presumed to be clogged. Check the orifice itself.
3Improper adjustment ormalfunctioning of LS
aStop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be
measured
Oil pressure ratio
All control levers in
NEUTRAL
Travel without load
(control lever held at half
stroke)
TROUBLESHOOTING H-7
H-7 Boom moves slowly or lacks power
Failure information • The boom moves slowly or lacks power
Relative information • Set the working mode at A mode for the troubleshooting.
Cause Standard value in normalcy and references for troubleshooting
1
Malfunctioning of right
PPC valve
(in boom circuit)
aStop engine for preparations. Start troubleshooting at engine high idling.
R.H. work equipment control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Boom RAISE
Boom LOWER
Above 2.75 MPa
{Above 28 kg/cm2}
2Malfunction of merge/
divide solenoid valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel lever Solenoid output pressure
Neutral 0 MPa {0 kg/cm2}
Operated (Note) 2.84 – 3.43 MPa{29 – 35 kg/cm2}
3
Malfunctioning of merge/
divide valve (main and
LS valves)
The merge/divide valve of control valve (main and LS valves) is presumed to
malfunction. Check the valve itself.
4Malfunctioning of boom
control valve (spool)
The spool in the boom control valve (Lo • Hi) is presumed to malfunction. Check the
valve itself
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a
l c y
control valve (spool) valve itself.
5
Malfunctioning of boom
control valve (pressurecompensation valve)
The pressure compensation valve in the boom control valve (Lo • Hi) is presumed to
malfunction. Check the valve itself.
6
Malfunctioning of boom
control valve
(regeneration valve)
The regeneration valve in the boom control valve (Lo) or the seal is presumed to
malfunction. Check the valve itself.
7Malfunctioning of boom
control valve (lock valve)
The lock valve in the boom control valve (Lo) is presumed to malfunction. Check the
valve itself.
8Malfunction of boom con-
trol valve (check valve)
The check valve in the boom control valve (Hi) is presumed to malfunction. Check
the valve itself.
9
Malfunctioning of safety
valve for lock valve or
seal defective
The safety valve for the lock valve is presumed to malfunction, or the seal is
suspected to be defective. Check the valve itself.
10
Malfunctioning of boom
control valve (suction
valve) or seal defective
The suction valve (bottom side) in the boom control valve (Lo) is presumed to
malfunction, or the seal is suspected to be defective.
11
Malfunctioning of boom
control valve (safety and
suction valves) or sealdefective
The safety and suction valves (head side) in the boom control valve (Lo) are
presumed to malfunction, or the seal is suspected to be defective. Check those
valves themselves.
TROUBLESHOOTING H-8
H-8 Arm moves slowly or lacks power
Failure information • The arm moves slowly, or lacks power.
Relative information • Set the working mode at A mode for the troubleshooting.
s e a n d
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of left
PPC valve (arm circuit)
aStop engine for preparations. Start troubleshooting at engine high idling.
L.H. work equipment control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Arm DIGGING
Arm DUMPING
Above 2.75 MPa
{Above 28 kg/cm2}
2Malfunctioning of merge/
divide solenoid valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel lever Solenoid output pressure
Neutral 0 MPa {0 kg/cm2}
Operated (Note) 2.84 – 3.43 MPa{29 – 35 kg/cm2}
3
Malfunctioning of merge/
divide valve (main and
LS valves)
The merge/divide valve of control valve (main and LS valves) is presumed to
malfunction. Check the valve itself.
4Malfunctioning of arm
control valve (spool)
The spool in the arm control valve (Lo • Hi) is presumed to malfunction. Check the
valve itself.
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P r e s u m e
d c a u s
s t a n d a r d v a
l u e i n
control valve (spool) valve itself.
5
Malfunctioning of arm
control valve (pressurecompensation valve)
The pressure compensation valve in the arm control valve (Lo • Hi) is presumed to
malfunction. Check the valve itself.
6
Malfunctioning of arm
control valve
(regeneration valve)
The generation valve in the arm control valve (Lo) is presumed to malfunction, or the
seal is suspected to be defective. Check the valve itself.
7
Malfunctioning of arm
control valve (safety and
suction valves) or seal
defective
The safety and suction valves in the arm control valve (Lo • Hi) are presumed to
malfunction, or the seal is suspected of defect. Check those valves themselves.
8Malfunction of arm control
valve (quick return valve)
The quick return valve in the arm control valve (Hi) is presumed to malfunction.
Check the valve itself.
9
Malfunctioning of LS
shuttle valve (right travel,
boom, left travel, bucket
and service valves)
LS shuttle valves in the right travel control valve, boom control valve, left travel
control valve, bucket control valve and service valve are presumed to malfunction.
Check those valves themselves.
10 Arm cylinder defective
aStop engine for preparations. Start troubleshooting at engine high idling.
Arm cylinder Amount oil leakage from cylinder
Digging relief 20 cc/min
TROUBLESHOOTING H-9, H-10
H-9 Bucket moves slowly or lacks power
Failure information • The bucket moves slowly, or lacks power.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d
c a u s e a n d
s t a n d a r d v a l u
e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Malfunctioning of right
PPC valve
(bucket circuit)
aStop engine for preparations. Start troubleshooting at engine high idling.
R.H. work equipment control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Bucket DIGGING
Bucket DUMPING
Above 2.75 MPa
{Above 28 kg/cm2}
2Malfunctioning of bucket
control valve (spool)
The spool in the bucket control valve is presumed to malfunction. Check the valve
itself.
3
Malfunctioning of bucket
control valve (pressure
compensation valve)
The pressure compensation valve in the bucket control valve is presumed to
malfunction. Check the valve itself.
4
Malfunctioning of bucket
control valve (safety and
suction valves) or seal
defective
The safety and suction valves in the bucket control valve are presumed to
malfunction, or the seal is suspected to be defective. Check those valves
themselves.
5Malfunction of LS shut-
tle valve (service valve)
The LS shuttle valve in the service control valve is presumed to malfunction. Check
the valve itself
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H-10 Work equipment does not move in its single operation
tle valve (service valve) the valve itself.
6 Bucket cylinder defective
aStop engine for preparations. Start troubleshooting at engine high idling.
Bucket cylinder Amount oil leakage from cylinder
Digging relief 20 cc/min
Failure information
• Work equipment does not move in its single operation
(1) The boom does not move when operated independently.
(2) The arm does not move when operated independently.
(3) The bucket does not move when operated independently.
Relative information • Set the working mode at A mode for the troubleshooting.
e a n d
n o r m
a l c y Cause Standard value in normalcy and references for troubleshooting
M lf ti i f PPC
aStop engine for preparations. Start troubleshooting at engine high idling.
Work equipment control lever PPC valve output pressure
TROUBLESHOOTING H-11
H-11 Work equipment has a bit too fast hydraulic drift
Failure information• Work equipment has a bit too fast hydraulic drift
(1) Hydraulic drift of the boom is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1 Boom cylinder defective
aStop engine for preparations. Start troubleshooting at engine high idling.
Boom cylinder Amount oil leakage from cylinder
Raise relief 20 cc/min
2Boom control lever (lock
valve) seal defective
The seal at lock valve in the boom control lever is suspected to be defective. Check
the valve itself.
3Seal at safety valve for
lock valve defective
The seal at the safety valve in the lock valve (Lo) is suspected to be defective.
Check the valve itself.
Failure information• Work equipment has a bit too fast hydraulic drift
(2) Hydraulic drift of the arm is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.
Cause Standard value in normalcy and references for troubleshooting
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c
y1 Arm cylinder defective
aStop engine for preparations. Start troubleshooting at engine high idling.
Arm cylinder Amount oil leakage from cylinder Digging relief 20 cc/min
2
Arm control valve (safety
and suction valves) seal
defective
The seal for safety and suction valves (bottom side) in the arm control valve (Lo • Hi)
is suspected to be defective. Check the valve itself.
(Whether the seal is defective or not may well be determined by changing for other
safety and suction valves.)
3 Arm control valve (spool)
seal defective
The seal for spool in the arm control valve (Lo • Hi) is suspected to be defective.
Check the seal itself.
4 Arm control valve(pressure compensation
valve) seal defective
The seal for pressure compensation valve (bottom side) in the arm control valve(Lo • Hi) is suspected to be defective. Check the seal itself.
Failure information• Work equipment has a bit too fast hydraulic drift
(3) Hydraulic drift of the bucket is a bit too fast.
Relative information • Set the working mode at A mode for the troubleshooting.
Cause Standard value in normalcy and references for troubleshooting
TROUBLESHOOTING H-12, H-13, H-14
H-12 Work equipment has big time lag
Failure information • The work equipment has a big time lag.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m
e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of
LS-EPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever LS-EPC valve output
pressure
Lo NEUTRAL Approx. 1.37 MPa
{approx. 14 kg/cm2}
Hi Operation 0 MPa {0 kg/cm2}
2
Malfunctioning of control
valve (regeneration
valve) - with boom and
arm only
The regeneration valve in the control valve is presumed to malfunction. Check the
valve itself.
3
Malfunctioning of control
valves (safety & suction
valve)
The safety and suction valves (boom : head side, arm and bucket : bottom side) of
the control valve are presumed to malfunction. Check those valves themselves
directly.
(Whether they are defective or not may well be determined by changing them for
other safety and suction valves.)
4
Malfunctioning of control
l (The pressure compensation valve of the control valve is presumed to malfunction.
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H-13 Other work equipment moves when relieving single circuit
4 valve (pressure
compensation valve)
The pressure compensation valve of the control valve is presumed to malfunction.
Check the valve itself directly.
Failure information • Other work equipment moves when relieving the single circuit of specific work equipment.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a
l c y Cause Standard value in normalcy and references for troubleshooting
1
Control valve (pressure
compensation valve)
seal defective
The seal for pressure compression valve in the control valve is suspected to be
defective. Check the seal itself.
TROUBLESHOOTING H-15
H-15 Machine push-up function does not work
Failure information • The machine push-up function does not work
Relative information • When carrying out troubleshooting, set the working mode in A-mode.
P r e s u m e d c a u s e a
n d
s t a n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1Malfunction of machine
push-up solenoid valve
aPrepare with starting switch OFF, then run engine at high idling and carry out
troubleshooting.
Machine push-up switch Solenoid outlet pressure
OFF Min. 2.75 MPa {Min. 28 kg/cm3}
ON 0 MPa {0 kg/cm2}
2
Malfunction of boom
control valve
(safety-suction valve)
The safety-suction valve of the boom control valve (Lo) (on the high-pressure setting
side on the head side) may be malfunctioning. Check it directly.
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TROUBLESHOOTING H-16, H-17, H-18
H-16 In compound operation, work equipment with larger load moves slowly
Failure information • In a compound operation, work equipment with larger load tends to move slowly.
Relative information —
P
r e s u m e d c a u s e a n d
s t a n
d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Malfunctioning of
pressure compensation
valve for work equipment
with larger load
The pressure compensation valve for the work equipment with larger load is
presumed to malfunction. Check the valve itself.
Combination of compound
operation
Work equipment with
larger load
Work equipment with
smaller load
Boom RAISE +
arm DIGGINGBoom Arm
Boom RAISE +
arm DUMPING Arm Boom
Boom RAISE +
bucket DIGGINGBoom Bucket
Arm DUMPING +
bucket DIGGING Arm Bucket
Boom LOWER +
arm DUMPING Arm Boom
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H-17 In swing + boom RAISE operation, boom moves slowly
H-18 In swing + travel, travel speed drops sharply
Failure information • In a compound operation of swing + boom RAISE, the boom tends to move slowly.
Relative information • If the boom moves slowly in the single operation of boom RAISE, carry out the H-7 check first.
P r e s u m e d
c a u s e a n d
s t a n d a r d v a l u
e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1
Malfunctioning of LS
select valve or sealdefective
The LS select valve of control valve is presumed to malfunction, or the seal issuspected to be defective. Check the valve and seal themselves.
Failure information • In a compound operation of swing + travel, the travel speed drops sharply.
TROUBLESHOOTING H-19
H-19 Machine swerves in travel
Failure information • The machine tends to swerve while traveling.
Relative information • Set the working mode at A mode for the troubleshooting.
s e a n d
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of travel
PPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure
Operated to Forward
Operated to Reverse
Above 2.75 MPa
{Above 28 kg/cm2}
Differential output between right
and left sides0.4 MPa {4 kg/cm2}
2
Malfunctioning of
self-pressure
decompression valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Control lever Control circuit source pressure
All control levers in NEUTRAL 2.84 – 3.43 MPa{29 – 35 kg/cm2}
3
Improper adjustment or
malfunctioning of LS
valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Oil pressure to be
measured
Oil Pressure ratio
All control levers in
NEUTRAL
Travel without load
(control lever held at half
stroke)
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P r e s u m e d
c a u
s t a n d a r d v a l u
e i n Pump delivery pressure
Nearly equal pressure
1
LS valve output pressure Approx. 0.6(Approx. 3/5)
4
Malfunctioning of travel
interlocking solenoid
valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Operating one side only2.84 – 3.43 MPa
{29 – 35 kg/cm2}
5
Malfunctioning of travel
interlocking valve
The travel interlocking valve of control valve is presumed to malfunction. Check the
valve itself.
6Malfunctioning of travel
control valve (spool)
The spool in the travel interlocking valve is presumed to malfunction. Check the
spool itself.
7Malfunction of travel
motor
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever Amount of oil leakage from travel motor
Travel relief 40 l/min
8 Final drive defective
The final drive is suspected of an internal failure. Check the inside of the final drive
directly.(An internal failure in the final drive may well be determined by an abnormal noise
TROUBLESHOOTING H-20
H-20 Machine travels slowly
Failure information aThe machine's travel speed is slow.
Relative information aSet the working mode at A mode for the troubleshooting.
c a u s e a n d
e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of travel
PPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure
Operated to Forward
Operated to Reverse
Above 2.75 MPa
{Above 28 kg/cm2}
Output differential between right and left
or front and rear
Below 0.4 MPa
{Below 4 kg/cm2}
2
Malfunctioning of
self-pressure
decompression valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Control lever Control circuit source pressure
All control levers in NEUTRAL 2.84 – 3.43 MPa{29 – 35kg/cm2}
3Malfunctioning of
LS-EPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever LS-EPC valve output
pressure
Lo NEUTRAL Approx. 1.37 MPa
{approx. 14 kg/cm2}
Hi O t d 0 MP {0 k / 2}
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P r e s u m
e d c
s t a n d a r d v
a l u e Hi Operated 0 MPa {0 kg/cm2}
4 Malfunction of travelcontrol valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spoolitself.
5
Malfunctioning of travel
control valve (pressure
compensation valve)
The pressure compensation valve in the travel control valve is presumed to
malfunction. Check the valve itself.
6
Malfunctioning of travel
control valve (suction
valve)
The suction valve in the travel control valve is presumed to malfunction. Check the
valve itself.
7Malfunctioning of LS
shuttle valve (bucket)
The LS shuttle valve in the bucket control valve is presumed to malfunction. Check
the valve itself.
7Malfunction of travel
motor
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever Amount of oil leakage from travel motor
Travel relief 40 l/min
8 Final drive defective
The final drive is suspected of an internal failure. Check the inside of the final drive
directly.
(An internal failure in the final drive may well be determined by an abnormal noise
from within, abnormal heat or metal chip or dust contained in the drained oil.)
TROUBLESHOOTING H-21
H-21 Machine cannot be easily steered or lacks power
Failure information • The machine cannot be easily steered.
Relative information • Set the working mode at A mode for the troubleshooting.
l c y
Cause Standard value in normalcy and references for troubleshooting
1
Malfunctioning of travel
PPC valve (steering
spool)
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever PPC valve output pressure (steering)
NEUTRAL on both sides 0 MPa {0 kg/cm2}
Operating one side only Above 2.75 MPa
{Above 28 kg/cm2}
2
Malfunctioning of travel
interlocking solenoid
valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever Solenoid valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Operating one side only 2.84 – 3.43 MPa{29 – 35 kg/cm2}
3Malfunctioning of travel
interlocking valve
The travel interlocking valve of control valve is presumed to malfunction. Check the
valve itself.
4Malfunctioning of merge/
divide solenoid valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever Solenoid valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a divide solenoid valve
OPERATED
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
5Malfunctioning of merge/
divide valve
The merge/divide valve of control valve is presumed to malfunction. Check the valve
itself.
6Malfunction of travel
control valve (spool)
The spool in the travel control valve is presumed to malfunction. Check the spool
itself.
7
Malfunctioning of travel
control valve (pressure
compensation valve)
The pressure compensation valve in the travel control valve is presumed to
malfunction. Check the valve itself.
8Malfunctioning of travelcontrol valve (suction
valve)
The suction valve in the travel control valve is presumed to malfunction. Check the
valve itself.
9Malfunctioning of LS
shuttle valve (bucket)
The LS shuttle valve in the bucket control valve is presumed to malfunction. Check
the valve itself.
10
Check valve seal
defective at LS oil
pressure pick-up port
The seal in the check valve of LS oil pressure pick-up port is suspected to be
defective. Check the seal itself.
Malfunctioning of travelThe seal in the check valve of the travel motor is suspected to be defective. Checkthe seal itself
TROUBLESHOOTING H-22
H-22 Travel speed does not shift, or it is slower or faster than preset speed.
Failure information • Travel speed does not shift, or it is slower or faster than preset speed.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c
a u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of
LS-EPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever Monitoring [01500]
Lo Fine control
(to the extent that the
decelerator is released)
690 mA
Mi 740 mA
Hi 0 mA
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever LS-EPC valve output
pressure
Lo NEUTRAL Approx. 1.37 MPa{approx. 14 kg/cm2}
Hi Operation 0 MPa {0 kg/cm2}
2Malfunctioning of travel
speed solenoid valve
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel speed Travel control lever Solenoid output
pressure
Lo NEUTRAL 0 MPa {0 kg/cm2}
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Hi Operation
2.84 – 3.43 MPa
{29 – 35 kg/cm2}
3Malfunctioning of travel
motor (speed shifting)
The travel motor is presumed to malfunction when shifting speed. Check the speed
shifting portion directly.
TROUBLESHOOTING H-23
H-23 Track shoe does not turn (on one side only)
Failure information • A track shoe does not turn (only on one side).
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n d
s t a
n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Travel control valve (suc-
tion valve) seat defective
The suction valve seat in the travel control valve is suspected of defect. Check the
seat itself.
2Travel motor (safety
valve) seat defectiveThe safety valve seat in the travel motor is suspected of defect. Check the seat itself.
3Travel motor (check
valve) seat defectiveThe check valve seat in the travel motor is suspected of defect. Check the seat itself.
4 Travel Motor speed
aStop engine for preparations. Start troubleshooting at engine high idling.
Travel control lever Amount of oil leakage from travel motor
Travel relief 40 l/min
5 Final drive defective
The final drive is suspected of an internal failure. Check the inside of the final drive
directly.
(A failure inside the final drive may well be determined by an abnormal noise from
within, abnormal heat generated or metal dust or chips contained in the drained oil.)
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TROUBLESHOOTING H-24
H-24 Machine does not swing
Failure information• Machine does not swing
(1) The machine swings neither to the right nor to the left.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Malfunctioning of swing
holding brake solenoid
valve
aStop engine for preparations. Start troubleshooting at engine high idling.R.H. work equipment control lever Solenoid valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Swing operated 2.84 – 3.43 MPa {29 – 35 kg/cm2}
2Malfunctioning of swing
motor (holding brake)
The parking brake portion of the swing motor is presumed to malfunction.
Check it directly.
3
Improper adjustment or
malfunctioning of swing
motor (safety valve)
aStop engine for preparations. Start troubleshooting at engine high idling.
Swing lock switchL.H. work equipment
control lever Swing relief pressure
ON Swing relief 27.95 – 32.85 MPa
{285 – 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety
valve is presumed to malfunction, or suspected of an internal failure. Check the
valve itself.
aStop engine for preparations. Start troubleshooting at engine high idling.
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4 Swing motor defective L.H. work equipment control lever Amount of oil leakage from swing motor
Swing relief Below 11 l/min
5Swing machinery
defective
The swing machinery is suspected of an internal failure. Check the inside of the
swing machinery directly.
(A failure inside the swing machinery may well be determined by an abnormal noise
from within, abnormal heat generated or metal dust or chips contained in the drained
oil.)
Failure information• Machine does not swing
(2) The machine does not swing in one direction.
Relative information • Set the working mode at A mode for the troubleshooting.
and ma
l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of swing
PPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
L.H. work equipment control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Swing operated Above 2 75 MPa {Above 28 kg/cm2}
TROUBLESHOOTING H-25
H-25 Swing acceleration is poor, or swing speed is slow
Failure information• Swing acceleration is poor, or swing speed is slow
(1) Swing acceleration is poor, or swing speed is slow.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e
i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of LSshuttle valve
(all LS shuttles)
The LS shuttle valves for all the control valves are presumed to malfunction. Check
them directly.
2Malfunctioning of swing
motor (holding brake)
The swing holding brake portion of the swing motor is presumed to malfunction.
Check it directly.
3
Improper adjustment or
malfunctioning of swingmotor (safety valve)
aStop engine for preparations. Start troubleshooting at engine high idling.
Swing lock switchL.H. work equipment
control lever Swing relief pressure
ON Swing relief 27.95 – 32.85 MPa{285 – 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety
valve is presumed to malfunction, or suspected of an internal failure. Check the
valve itself.
4 Swing motor defective
aStop engine for preparations. Start troubleshooting at engine high idling.
L.H. work equipment control lever Amount of oil leakage from swing motor
Swing relief Below 11 l/min
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Swing relief Below 11 l/min
5Swing machinery
defective
Inside of the swing machinery is presumed to malfunction. Check itself.(Whether it is defective or not may well be determined by abnormal noise, abnormal
generation of heat and the mixture of the metal particles in drain oil.)
Failure information• Swing acceleration is poor, or swing speed is slow
(2) Swing acceleration is poor only on one side, or swing speed is slow.
Relative information • Set the working mode at A mode for the troubleshooting.
cau
s e a n d
ein
n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of swing
PPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
L.H. work equipment control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Swing operated Above 2.75 MPa {Above 28 kg/cm2}
2Malfunctioning of swing
control valve (spool)
The spool in the swing control valve is presumed to malfunction. Check the valve
itself.
Malfunctioning of swingThe pressure compensation valve in the swing motor is presumed to malfunction
TROUBLESHOOTING H-26
H-26 Excessive overrun when stopping swing
Failure information• Excessive overrun when stopping swing
(1) The work equipment overruns excessively when stopping swing.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Improper adjustment or
malfunctioning of swing
motor (safety valve)
aStop engine for preparations. Start troubleshooting at engine high idling.
Swing lock switchL.H. work equipment
control lever Swing relief pressure
ON Swing relief 27.95 – 32.85 MPa
{285 – 335 kg/cm2}
If the oil pressure does not return to normalcy even after the adjustment, the safety
valve is presumed to malfunction, or suspected of an internal failure. Check the
valve itself.
2 Swing motor defectiveaStop engine for preparations. Start troubleshooting at engine high idling.
L.H. work equipment control lever Amount of oil leakage from swing motor
Swing relief Below 11 l/min
Failure information• Excessive overrun when stopping swing
(2) Swing acceleration is poor only on one side, or swing speed is slow.
R l ti i f ti S t th ki d t A d f th t bl h ti
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Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s
e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of swing
PPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
L.H. work equipment control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Swing operated Above 2.75 MPa {Above 28 kg/cm2}
2Swing PPC slow return
valve clogged
The PPC slow return valve is suspected of clogging. Check the valve itself.
(Whether the valve is clogged or not may well be determined by swapping the right
and left valves and watching the result.)
3Malfunctioning of swing
control valve (spool)
The spool in the swing control valve is resumed to malfunction. Check the valve
itself.
4Swing motor (suction
valve) seal defective
The seal in the suction valve of the swing motor is suspected of defect. Check the
seal itself.
(Whether the seal is defective or not may well be determined by swapping the right
and left suction valves and watching the result.)
5 Swing motor (checkl ) l d f ti
The seal in the check valve of the swing motor is suspected of defect. Check the
seal itself.(Wh th th l i d f ti t ll b d t i d b i th i ht
TROUBLESHOOTING H-27, H-28
H-27 There is big shock when stopping swing
H-28 There is big abnormal noise caused when stopping swing
Failure information • There is a big shock caused when stopping a swing motion.
Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d c a u s e a n
d
s t a n d a r d v a l u e i n n o r m
a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of swing
PPC valve
aStop engine for preparations. Start troubleshooting at engine high idling.
L.H. work equipment control lever PPC valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Swing operated Above 2.75 MPa {Above 28 kg/cm2}
2Malfunctioning of swing
PPC slow return valve
The swing PPC slow return valve is presumed to malfunction. Check the valve itself.
(Whether the valve malfunctions or not may well be determined by swapping the
right and left valves and watching the result.)
3Malfunctioning of swing
motor (shockless valve)The swing motor shockless valve is presumed to malfunction. Check the valve itself.
Failure information • There is a big abnormal noise caused when stopping a swing motion.
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Relative information • Set the working mode at A mode for the troubleshooting.
P r e s u m e d
c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Malfunctioning of
backpressure valveThe backpressure valve is presumed to malfunction. Check the valve itself.
2Malfunction of swing
motor (safety valve)
The safety valve in the swing motor is presumed to malfunction. Check the valve
itself.
3Malfunction of swing
motor (suction valve)
The seal in suction valve of the swing motor is suspected of defect. Check the seal
itself.
(Whether the seal is defective or not may well be determined by swapping the right
and left valves and watching the result.)
4Swing machinery
defective
The swing machinery is suspected of an internal failure. Check the inside of the
machinery itself.
(A failure inside the swing machinery may well be determined by monitoring
abnormal noise, abnormal heat generated or metal dust or chips contained in the
drained oil.)
TROUBLESHOOTING H-29
H-29 Swing natural drift is too big
Failure information• Swing natural drift is too big.
(1) When the swing holding brake is activated.
Relative information
• When the swing lock switch is ON position, or the swing holding brake release switch is in the
normal position, the swing brake is activated and the swing is fixed with a disc brake.
• Set the working mode in A mode for troubleshooting.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y Cause Standard value in normalcy and references for troubleshooting
1
Swing and holding brake
solenoid valve
malfunctioned
aStop engine for preparations. Start troubleshooting at engine high idling.
R.H. work equipment control lever Solenoid valve output pressure
NEUTRAL 0 MPa {0 kg/cm2}
Swing operated 2.84 – 3.43 MPa {29 – 35 kg/cm2}
2
Swing motor (parking
brake portion)
malfunctioned
The parking portion of the swing motor is suspected of malfunctioning and interior
failure. Check that portion directly.
Failure information• Swing natural drift is too big.
(2) When the swing holding brake is released.
Relative information
• When the swing holding brake release switch is in the emergency condition, the swing brake is
released and the swing is retained only hydraulically.
• Set the working mode in A mode for troubleshooting.
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P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c y
Cause Standard value in normalcy and references for troubleshooting
1Swing control valve
(spool) malfunctioned
The seal in the spool of the swing control valve is suspected of defect. Check the
spool itself directly.
2
Swing control valve
(pressure compensation
valve) malfunctioned
The pressure compensation valve seal in the swing control valve is suspected of
defect. Check the valve itself directly.
3Swing motor (safety
valve) defective
The safety valve seal in the swing motor is suspected of defect. Check the valve
itself directly.
4Swing motor (suction
valve) defective
The suction valve seal in the swing motor is suspected of defect. Check the valve
itself directly.
5Swing motor (check
valve) defective
The check valve seal in the swing motor is suspected of defect. Check the valve
itself directly.
6
Swing motor (shockless
valve) malfunctioned or
seal defective
The shockless valve in the swing motor is suspected of malfunction or the seal is
suspected of defect. Check the valve or seal itself directly.
TROUBLESHOOTING H-30, H-31
H-30 Attachment circuit does not change
When attachment is installed
Failure information • The return circuit of the attachment circuit does not change.
Relative information
• If an attachment is installed, the service circuit changes according to the selected working mode
as shown below.
1) In mode A or E: The double acting circuit is selected and the safety valve is set to the lowpressure.
2) In mode B: The single acting circuit is selected and the safety valve is set to the high
pressure.
* Setting of the safety valve on only port B side is changed. Port A is always set to the low
pressure.
P r e s u m e d c a u s e a n d
s t a n d a r d v a l u e i n n o r m a l c
y
Cause Standard value in normalcy and references for troubleshooting
1
Malfunction of
attachment return
selector solenoid valve
aKeep the engine stopped for the preparations, and keep it running at high idling
during the troubleshooting.
Working mode Solenoid valve output pressure
Mode E or A 0 MPa {0 kg/cm2}
Mode B2.84 – 3.43 MPa
{29 – 35 kg/cm2}
2
Malfunction of
attachment return
selector valve
The attachment return selector valve may have a malfunction. Check it directly.
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H-31 Flow rate in attachment circuit cannot be adjusted
When attachment is installed
s
3 Malfunction of servicecontrol valve (safety
valve)
The safety valve of the service control valve (on port B side) may have amalfunction. Check it directly.
Failure information • Flow rate in attachment circuit cannot be adjusted.
Relative information
• If an attachment is installed, the flow rate in the service circuit changes according to the
selected working mode.
• How to adjust the flow rate in modes A and E is different from that in mode B. For details, see
OPERATION MANUAL.
an
d
rm
a l c y
Cause Standard value in normalcy and references for troubleshooting
1
Malfunction of
attachment flow rate
adjustment EPC valve
The attachment flow rate adjustment EPC valve may have a malfunction. Check it
directly.
POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................... 20-702
METHOD OF USING TROUBLESHOOTING CHARTS ............................................................................. 20-703
S-1 Starting performance is poor (starting always takes time).................................................................... 20-706
S-2 Engine does not start ........................................................................................................................... 20-707
S-3 Engine does not pick up smoothly (follow-up is poor) .......................................................................... 20-710
S-4 Engine stops during operations ............................................................................................................ 20-711S-5 Engine does not rotate smoothly (hunting)........................................................................................... 20-712
S-6 Engine lacks output (or lacks power) ................................................................................................... 20-713
S-7 Exhaust smoke is black (incomplete combustion)................................................................................ 20-714
S-8 Oil consumption is excessive (or exhaust smoke is blue) .................................................................... 20-715
S-9 Oil becomes contaminated quickly ....................................................................................................... 20-716
S-10 Fuel consumption is excessive........................................................................................................... 20-717
S-11 Oil is in cooling water (or water spurts back, or water level goes down) ............................................ 20-718
S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................. 20-719
TROUBLESHOOTING OF ENGINE
(S MODE)
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S-13 Oil level rises (water, fuel in oil) .......................................................................................................... 20-720S-14 Water temperature becomes too high (overheating) .......................................................................... 20-721
S-15 Abnormal noise is made..................................................................................................................... 20-722
S-16 Vibration is excessive ......................................................................................................................... 20-723
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TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton with-
out using troubleshooting tools.Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make
final confirmation.
[Questions]Sections + in the chart on the right corre-
sponds to the items where answers can be
obtained from the user. The items in are
items that can be obtained from the user,depending on the user 's level.
[Check items]The serviceman carries out simple inspection to
narrow down the causes. The items under in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information that he has obtained from the
user and the results of that he has obtained
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user and the results of that he has obtained
from his own inspection.
[Troubleshooting]Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chartis as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with , and of these, causes that have a high prob-
ability are marked with .
Check each of the [Questions] and [Check items]
in turn, and marked the or in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example of troubleshooting> Exhaust smoke is black
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black
• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because
an error has occurred in the electrical system.)
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TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
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TROUBLESHOOTING S-1
S-1 Starting performance is poor (starting always takes time)
General causes why starting performance is poor
• Defective electrical system
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel
a With the common rail fuel injection system, the
fuel injection timing is recognized electrically, so
even when the starting operation is carried out,
the engine may not start until the crankshaft has
completed two rotations. However, this does
not indicate any abnormality.
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TROUBLESHOOTING S-2
S-2 Engine does not start
a) Engine does not turn
General causes why engine does not turn
• Internal parts of engine seized
a See “Engine stops during operations”.
• Defective electrical system
• Failure on chassis side
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TROUBLESHOOTING S-2
b) Engine turns but no exhaust smoke comes out
General causes why engine turns but no exhaust
smoke comes out
• Fuel is not being supplied
• Supply of fuel is extremely small
• Improper selection of fuel (particularly in winter)
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TROUBLESHOOTING S-2
c) Exhaust smoke comes out but engine does not
start (Fuel is being injected)
General causes why exhaust smoke comes out
but engine does not start
• Lack of rotating force due to defective electrical
system
• Insufficient supply of fuel
• Insufficient intake of air
• Improper selection of fuel
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TROUBLESHOOTING S-3
S-3 Engine does not pick up smoothly (follow-up is poor)
General causes why engine does not pick up smoothly
• Insufficient intake of air
• Insufficient supply of fuel
• Abnormal fuel injection condition
• Improper selection of fuel
• Controller controlled by delayed mode
(The injection amount (output) is limited because
an error has occurred in the electrical system.)
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TROUBLESHOOTING S-4
S-4 Engine stops during operations
General causes why engine stops
• Internal part of engine seized
• Insufficient supply of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Failure on chassis side
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TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly
• Air in fuel system
• Speed sensor is not normal
(abnormality not big enough to generate error display)
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TROUBLESHOOTING S-6
S-6 Engine lacks output (or lacks power)
General causes why engine lacks output
• Insufficient intake of air
• Insufficient supply of fuel
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because
an error has occurred in the electrical system.)
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TROUBLESHOOTING S-7
S-7 Exhaust smoke is black (incomplete combustion)
General causes why exhaust smoke is black
• Insufficient intake of air
• There is excessive fuel.
• Abnormal fuel injection condition
• Improper selection of fuel
• Engine overheating
a See troubleshooting for [Overheat].
• Controller controlled by delayed mode
(The injection amount (output) is limited because
an error has occurred in the electrical system.)
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TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)
General causes why oil consumption is excessive
• Abnormal combustion of oil
• The engine has been run at low or high idling for a
long time continuously (more than 20 minutes con-
tinuous operation is not allowed).
• External leakage of oil
• Wear of lubrication system
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TROUBLESHOOTING S-9
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated quickly
• Entry of exhaust gas into oil due to internal wear
• Clogging of lubrication passage
• Improper fuel used
• Improper oil used
• Operation under excessive load
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TROUBLESHOOTING S-10
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive
• Leakage of fuel
• Improper condition of fuel injection (injection pressure,
injection timing)
• Excessive injection of fuel
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TROUBLESHOOTING S-11
S-11 Oil is in cooling water (or water spurts back, or water level goes down)
General causes why oil is in cooling water
• Internal leakage in lubrication system
• Internal leakage in cooling system
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TROUBLESHOOTING S-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure)
General causes why oil pressure drops
• Leakage, clogging, wear of lubricating system
• Defective oil pressure control
• Improper oil used (improper viscosity)
• Deterioration of oil due to overheating
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TROUBLESHOOTING S-13
S-13 Oil level rises (water, fuel in oil)
General causes why oil level rises
• Water in oil (cloudy white)
• Fuel in oil (diluted, smells of diesel fuel)
a If there is oil in the cooling water, carry out troubleshooting
for “Oil is in cooling water”.
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TROUBLESHOOTING S-14
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes too high
• Lack of cooling air (deformation, damage of fan)
• Drop in heat dissipation efficiency
• Defective cooling circulation system
• Rise of hydraulic oil temperature on chassis side
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TROUBLESHOOTING S-15
S-15 Abnormal noise is made
General causes why abnormal noise is made
• Abnormality due to defective parts
• Abnormal combustion
• Air sucked in from intake system
a Judge if the noise is an internal noise or an external noise.
a If the engine is not thoroughly warmed up, the enginesound becomes slightly louder because it is operated in the
low temperature mode, but this is not an abnormality.
a When the engine is accelerated, it enters the acceleration
mode and the engine noise is higher for 3 seconds, but this
is not an abnormality.
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TROUBLESHOOTING S-16
S-16 Vibration is excessive
General causes why vibration is excessive
• Defective parts (abnormal wear, breakage)
• Improper alignment with machine
• Abnormal combustion
a If there is abnormal noise together with the vibration, carry
out troubleshooting also for “Abnormal noise is made”.
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HOW TO READ THIS MANUAL....................30- 2
PRECAUTIONS WHEN PERFORMING
OPERATION............................................30- 4
SPECIAL TOOL LIST....................................30- 6
REMOVAL AND INSTALLATION OF
CYLINDER HEAD ASSEMBLY................30- 13
REMOVAL AND INSTALLATION OF ENGINE
REAR SEAL.............................................30- 20
REMOVAL AND INSTALLATION OF ENGINE
FRONT SEAL...........................................30- 24
REMOVAL AND INSTALLATION OF FUEL
SUPPLY PUMP ASSEMBLY....................30- 27REMOVAL AND INSTALLATION OF FUEL
INJECTOR ASSEMBLY 30- 30
DISASSEMBLY AND ASSEMBLY OF
RECOIL SPRING ASSEMBLY................. 30- 69
EXPANSION AND INSTALLATION OF TRACK
SHOE ASSEMBLY................................... 30- 71
REMOVAL AND INSTALLATION OF AIR
CONDITIONER UNIT ASSEMBLY .......... 30- 73
REMOVAL AND INSTALLATION OF
OPERATOR’S CAB ................................. 30- 75
REMOVAL AND INSTALLATION OF
MONITOR ASSEMBLY............................ 30- 78
REMOVAL AND INSTALLATION OF PUMP
CONTROLLER ........................................ 30- 79REMOVAL AND INSTALLATION OF ENGINE
CONTROLLER 30- 80
30 DISASSEMBLY AND
ASSEMBLY
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INJECTOR ASSEMBLY ...........................30 30
REMOVAL AND INSTALLATION OF
NOZZLE TIP ............................................30- 33
REMOVAL AND INSTALLATION OF
STARTING MOTOR ASSEMBLY.............30- 35
REMOVAL AND INSTALLATION OF
RADIATOR ASSEMBLY...........................30- 36
REMOVAL AND INSTALLATION OFHYDRAULIC OIL COOLER ASSEMBLY .30- 38
REMOVAL AND INSTALLATION OF ENGINE
AND HYDRAULIC PUMP ASSEMBLY ....30- 40
REMOVAL AND INSTALLATION OF SWING
CIRCLE ASSEMBLY................................30- 45
REMOVAL AND INSTALLATION OF SWING
MOTOR AND SWING MACHINERY
ASSEMBLY.............................................. 30- 46
DISASSEMBLY AND ASSEMBLY OF SWING
CONTROLLER ........................................ 30 80
REMOVAL AND INSTALLATION OF
REVOLVING FRAME ASSEMBLY .......... 30- 81
REMOVAL AND INSTALLATION OF
COUNTERWEIGHT ASSEMBLY............. 30- 84
REMOVAL AND INSTALLATION OF
HYDRAULIC TANK ASSEMBLY.............. 30- 85
REMOVAL AND INSTALLATION OFHYDRAULIC PUMP ASSEMBLY............. 30- 87
REMOVAL AND INSTALLATION OF OIL SEAL
IN HYDRAULIC PUMP INPUT SHAFT ... 30- 90
REMOVAL AND INSTALLATION OF
CONTROL VALVE ASSEMBLY ............... 30- 91
DISASSEMBLY AND ASSEMBLY OF
CONTROL VALVE ASSEMBLY ............... 30- 94
REMOVAL AND INSTALLATION OF
CENTER SWIVEL JOINT ASSEMBLY 30 98
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES
SPECIAL TOOLS
• Special tools that are deemed necessary for
removal or installation of parts are listed.
• List of the special tools contains the followingkind of information.
1) Necessity
t: Special tools which cannot be substi-
tuted, should always be used.
q:Special tools which are very useful if
available, can be substituted with com-
mercially available tools.
2) Distinction of new and existing special toolsN: Tools with new part numbers, newly
developed for this model.
R: Tools with upgraded part numbers,
remodeled from already available tools
for other models.
Blank: Tools already available for other mod-
els, used without any modification.
3) Circle mark (Q) in sketch column:
A circle mark means that a ske tch of thespecial tool is presented in the section of
Sk t h f S i l T l
INSTALLATION OF PARTS
• Except where otherwise instructed, install parts
is the reverse order of removal.
• Instructions and precautions for installing partsare shown with [*1] mark in the INSTALLATION
Section, identifying which step the instructions
are intended for.
• Marks shown in the INSTALLATION Section
stand for the following.
k This mark indicates safety-related pre-
cautions which must be followed when
doing the work.a This mark gives guidance or precau-
tions when doing the procedure.
2 This mark stands for a specific coating
agent to be used.
3 This mark indicates the specified
torque.
5 This mark indicates an amount of oil or
water to be added.
SKETCHES OF SPECIAL TOOLS
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Sketches for Special Tools.
a Part No. of special tools starting with 79*T means
that they are locally made parts and as such not
interchangeable with those made by Komatsu in
Japan e.g. 79*T--- xxx --- xxxx.
REMOVAL OF PARTS
• The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
• Various symbols used in the REMOVAL Section
are explained and listed below.
k This mark indicates safety-related pre-
cautions which must be followed when
d i th k
SKETCHES OF SPECIAL TOOLS
• Various special tools are illustrated for the con-
venience of local manufacture.
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
SPECIAL TOOLS
• Special tools which are deemed necessary for
disassembly and assembly are listed in this sec-
tion. • List of the special tools contains the following
kind of information.
1) Necessity
t: Special tools which cannot be substi-
tuted, should always be used.
q: Special tools which are very useful if
available, can be substituted with com-
mercially available tools.
2) Distinction of new and existing special tools
N: Tools with new part numbers, newly
developed for this model.
R: Tools with upgraded part numbers,
remodeled from already available tools
for other models.
Blank: Tools already available for other mod-
els, used without any modification.
3) Circle mark (Q) in sketch column: A circle mark means that a sketch of the
special tool is presented in the section of
ASSEMBLY
• Section titled ASSEMBLY contain procedures,
precautions and the know-how for the work, as
well as the amount of oil or water to be added. • Various symbols used in the ASSEMBLY Sec-
tion are explained and listed below.
k This mark indicates safety-related pre-
cautions which must be followed when
doing the work.
a This mark gives guidance or precau-
tions when doing the procedure.
2 This mark stands for a specific coatingagent to be used.
3 This mark indicates the specified
torque.
5 This mark indicates an amount of oil or
water to be added.
SKETCHES OF SPECIAL TOOLS
• Various special tools are illustrated for the con-venience of local manufacture.
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special tool is presented in the section of
Sketches for Special Tools.
4) Part No. of special tools starting with 79*T
means that they are locally made parts and
as such not interchangeable with those
made by Komatsu in Japan e.g. 79*T--- xxx
--- xxxx.
DISASSEMBLY
• The DISASSEMBLY Section contains proce-
dures, precautions and the amount of oil or
water to be drained.
• Various symbols used in the DISASSEMBLY
Section are explained and listed below.
Thi k i di t f t l t d
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
PRECAUTIONS WHEN PERFORMING OPERATION
Be sure to follow the general precautions given below when performing removal or installation (disassembly or
assembly) of units.
1. Precautions when performing removal work
• If the engine coolant water contains antifreeze, dispose of it properly.
• After disconnecting hoses or tubes, cover them or install blind plugs to prevent dirt or dust from entering.
• When draining oil, prepare a container of adequate size to catch the oil.
• Confirm the match marks showing the installation position, and make match marks in the necessary placesbefore removal to prevent any mistake during assembly.
• To avoid loosening any wire contacts, do not pull on the wires. In-order to prevent excessive force to the wir-
ing, hold onto the connectors when disconnecting them.
• Fasten tags to wires and hoses to identify them and show their installation position. This helps prevent any
mistakes when re-installing.
• Count and check the number and thickness of the shims, and keep them in a safe place.
• When raising or lifting components, be sure to use proper lifting equipment of ample strength and safety.
• When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
• Before removing any unit, clean the surrounding area and install a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Install the following blind plugs into the piping after disconnecting it during disassembly operations.
A. Face seal type hoses and tubes
Nominal number Plug (nut end) Nut (elbow end)
02 07376-70210 02789-0021003 07376-70315 02789-00315
04 07376 70422 02789 00422
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B. Split flange type hoses and tubes
C. If the part is not under hydraulic pressure, the following corks can be used.
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
Nominal number Flange (hose end) Sleeve head (tube end) Split flange04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
Nominal number Part Number Dimensions
D d L
06 0 049 00608 6 8
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN PERFORMING OPERATION
2. Precautions when carrying out installation work
• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with two or three drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant. • Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press-fitting parts, coat the surface with anti-friction compound (LM-P).
• After installing snap rings, check that the snap ring is installed securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect it
securely.
• When using eye bolts, check that there is no deformation or deterioration. Screw them in fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling the cylinders, pumps and other
hydraulic equipment removed for repair, bleed the air as follows:
1) Start the engine and run it at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinders, 4 – 5 times, stopping the
cylinders 100 mm from the end of their stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3 Precautions when completing the operations
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3. Precautions when completing the operations
• If the engine coolant water has been drained, tighten the drain valve, and add coolant water to the specified
level. Run the engine to circulate the coolant water through the system. Then check the coolant water level
again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment have been removed for repair, bleed the air from the system after reas-sembling the parts.
a For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
a Tools with part number 79 T- - cannot be supplied (they are items to be locally manufac-
tured).
a Necessity: t............Cannot be substituted, must always be installed (used)
q............Extremely useful if available or can be substituted with commercially available part
a New/Remodel: N............Tools with new part numbers, newly developed for this model
R:...........Tools with upgraded part numbers, remodeled from items already available for oth-er models
Blank: ....Tools already available for other models, can be used without any modification
a Tools markedQ in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
Component
S y m b o l
Part No. Part Name
N e c e s s i t
y
Q ' t y
N e w / r e m o d e l
S k e t c h
Nature of work, remarks
1 795-799-1170 Puller t 1Removal, installation of noz-
zle holder assembly
2 790-331-1110 Wrench q 1Tightening of cylinder head
bolt
3 795-931-1100 Seal puller t 1 Removal of engine seal
795-931-1210 Push tool t 1
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Engine assembly A
4Press fitting of engine rear
seal
• 01050-31625 • Bolt t 3
• 01050-31645 • Bolt t 3
5795-931-1220 Push tool t 1
• 01050-31645 • Bolt t 3
6
795T-521-1140 Push tool t
1 Q
Press fitting of engine front
seal
• 790-101-5221 • Grip t 1
• 01010-81225 • Bolt t 1
• 01050-31640 • Bolt t 3
795-471-1800 Remover t 1 N
• 795-471-1810 • Plate t 1
• 795-471-1820 • Bolt t 1
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Swing motor and
swing machinery
assembly
D
1 796T-627-1630 Push tool q 1 Q Removal of shaft
2 790-201-2350 Push tool t 1 Removal of bearing
3 790-201-2510 Push tool t 1 Press fitting of bearing
4
790-101-5401 Push tool kit t 1
Press fitting of oil seal• 790-101-5531 • Plate 1
• 790-101-5421 • Grip 1
• 01010-51240 • Bolt 1
5 790-201-2870 Push tool t 1Press fitting of bearing inner
race
6 790-201-2770 Push tool t 1Press fitting of bearing inner
race
7 796T-626-1110 Push tool t 1 Q Press fitting of bearing
1
796-627-1210 Wrench assembly t 1
Removal, installation of
round nut
• 796-627-1220 • Wrench 1
• 796-427-1140 • Pin 3
• 01314-20612 • Screw 3
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1
Component
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ' t y
N e w / r e m o d e l
S k e t c h
Nature of work, remarks
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Final drive assem-
blyE
2Pressing of bearing inner
race
791-122-1130 Plate q 1
790-101-2550 Leg q 2
790-101-2740 Adapter q 2
790-101-2570 Plate q 4
790-101-2560 Nut q 2
790-101-2102 Puller (294 kN {30 t}) t 1
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1 Installation of floating seal
Carrier roller
assemblyF
791-430-3230 Installer t 1
791-601-1000 Oil pump t 1
Track roller 791-630-1780 Installer t 1
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Track shoe
assembly K
791-650-3000Remover and
installer t 1
Pulling out of master pin790-101-1300 Cylinder(980 kN {100 t})
t 1
790-101-1102 Pump t 1
Control valveassembly L
1
796-946-1310 Guide 21.81
Replacement of pressurecompensation valve seal
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide 20.91
(For 723-46-44100)
796-946-2210 Guide 20.61
(For 723-46-45100, 723-46-45500)
2
796-946-1320 Guide1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide 21.61
(For 723-46-42800)
796-946-2120 Guide1
(For 723-46-44100)
796-946-2220 Guide1
Component
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ' t y
N e w / r e m o d e l
S k e t c h
Nature of work, remarks
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1(For 723-46-45100, 723-46-45500)
3
796-946-1330 Sleeve1
(For 723-46-40100, 723-46-40601)
796-946-1430 Sleeve1
(For 723-46-42800)
796-946-2130 Sleeve1
(For 723-46-44100)
796-946-2230 Sleeve1
(For 723-46-45100, 723-46-45500)
790-101-2501 Push puller t 1
• 790-101-2510 • Block 1
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Hydraulic cylinder
assemblyN
1 790-502-1003 Cylinder repair stand t 1Disassembly, assembly of
hydraulic cylinder assembly
2 790-102-4300 Wrench assembly t 1 Removal, installation of pis-ton assembly790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
Installation of piston ring4
796-720-1680Ring (For boom and
bucket) q 1
07281-01589Clamp (For boom
and bucket) q 1
796-720-1690 Ring (For arm) q
107281-01919 Clamp (For arm) q 1
5
790-201-1702 Push tool kit t 1
Press fitting of bushing
• 790-201-1851• Push tool
(For bucket)1
• 790-201-1861• Push tool
(For boom)1
• 790-201-1871 • Push tool (For arm)120 1
• 790-101-5021 • Grip 1
Component
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ' t y
N e w / r e m o d e l
S k e t c h
Nature of work, remarks
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• 01010-50816 • Bolt 1
6
790-201-1500 Push tool kit t 1
Press fitting of dust seal
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
• 790-201-1660 • Plate(For bucket)
1
• 790-201-1670 • Plate (For boom) 1
• 790-201-1680 • Plate (For arm) 1
796-670-1100 Remover q 1
• 796-670-1110 • Sleeve 1
• 796-670-1120 • Plate 1
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Air conditioner
unit assemblyQ
799-703-1200 Service tool kit t 1
Filling with air conditioner
refrigerant (gas)
799-703-1100Vacuum pump
(100V)
t 1
799-703-1110Vacuum pump
(220V) t 1
799-703-1120Vacuum pump
(240V) t 1
799-703-1401 Gas leak detector t 1
Operator’s cab
glassY
1 793-498-1210Lifter
(Suction cup) t 2 Removal and Installation of
operator’s cab glass2 20Y-54-13180 Adapter t 2
Component
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ' t y
N e w / r e m o d e l
S k e t c h
Nature of work, remarks
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DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
A6. Push tool
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A8. Wrench
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
B. Stopper
D1. Push tool
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DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
D7. Push tool
E2. Push tool
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DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove 2 engine undercovers (1).
7. Remove fuel filter (8) and bracket (9).
8. Remove clamp (10), 2 tubes (11), and filter (12).
9. Remove cap (13) and disconnect wire (15).
10. Disconnect heater switch (14).
11. Remove the 2 clips on the back side and
remove bracket (16).
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
A1 795-799-1170 Puller t 1
2 790-331-1110 Wrench q 1
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2. Drain the coolant.
6 Coolant: Approx. 35
3. Open the engine hood.
4. Remove tube (2). [*1]
a Remove the tube and bracket together.
5. Remove clamp (4) and disconnect the bracket
12. Disconnect fuel supply pump wiring connectors
PCV1 (17) and PCV2 (18) and remove 2 clips
(19).
13. Disconnect bracket (20) and connector PIM (21)
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
14. Disconnect clip (23) and bracket (24), and then
disconnect 6 fuel injector connectors (25).
a Place disconnected wiring harness assem-
bly (26) so that it will not be an obstacle. [*4]
a To disconnect fuel injector connector "c", in-sert flat-head screwdriver [1] in stepped part
"a" and move it in direction "X", pressing
stopper "b".
17. Remove 3 high-pressure pipe clamps (31) and 3
brackets (32). [*6]
18. Remove lubrication tube clamp (33).
19. Sling air intake manifold assembly (34) tempo-rarily and remove the air intake manifold mount-
ing bolts. [*7]
a Do not remove XX.
20. Lift off air intake manifold assembly (34).
4 Air intake manifold assembly: 45 kg
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15. Remove common rail-side high-pressure pipeclamp (28), cover (27), and gate-type bracket
(29). [*5]
16. Remove each high-pressure pipe cover (30).
[*5]
21. Remove mounting bolts (35) and disconnect
lower lubrication tube (36).
22. Remove heat insulation cover (37) and cover
(38).
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
23. Remove clip (39) and lubrication tubes (40) and
(36). [*8]
a Take care of the spacer.
24. Remove clamp (41). [*9]
25. Remove cover (44).
26. Remove clamp (42) and disconnect hose (43).[*10]
27. Sling turbocharger assembly (45) temporarily
and remove the mounting bolts of exhaust mani-
fold (46). [*11]
29. Remove coolant tube (48). [*13]
30. Remove each high-pressure pipe cover (49).
[*14]
31. Remove 6 high-pressure pipe sleeve nuts (50)on the common rail side. [*15]
32. Loosen 6 high-pressure pipe sleeve nuts (51) on
the head side and remove 6 high-pressure pipes
(52). [*16]
33. Remove spill tube (55). [*17]
34. Remove return tube (53). [*18]
35. Remove 6 head covers (54). [*19]
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28. Lift off turbocharger and exhaust manifold
assembly (47).
4 Turbocharger and exhaust manifold
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
36. Remove capture nut (56) and disconnect the
wiring harness from the injector. [*20]
37. Remove rocker shaft mounting bolts (57) and
rocker arm and rocker shaft assembly (58). [*21]
38. Remove injector mounting bolts (59) and injec-
tor assembly (60). [*22]
aIf the injector assembly is not removed easi-ly, use tool A1.
a Do not hold the solenoid valve on the top of
the injector with pliers, etc.
39. Remove cross head (61). [*23]
40. Remove 2 push rods (62).
INSTALLATION • Carry out installation of all the parts, except the
high-pressure pipe, in the reverse order to
removal.
[*1]
3 Hose clamp:
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*2]
3 Air aftercooler pipe clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
3 Fuel tube (7):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*4]Install wiring harness assembly (26) and other
wiring harnesses at least 10 mm apart from the
high-pressure pipe.
[*7]
The tightening torque and tightening order of the
air intake manifold assembly mounting bolts are
not specified.
[*8]
3 Joint bolt on engine block side of lubri-
cation tube:
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41. Remove 6 mounting bolts (63) and rocker hous-
ing (64). [*24]
ca o ube
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*9]
3 Clamp (41):
68.6 – 98 Nm {7 – 10 kgm}
[*10]
3 Hose clamp:
10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*11]
Tighten the following 3 exhaust manifold assem-
bly mounting bolts first in the given order, and
then tighten the other bolts.
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
[*12]2 All periphery of inserting part of
exhaust pipe: Thermosetting sealant
(FIREGUM manufactured by HOLTS
or equivalent)
[*13]
3 Coolant tube (48):
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*14]
a For the installation procedure for high-pressure
pipe cover (49), see REMOVAL AND INSTALLA-
TION OF FUEL INJECTOR ASSEMBLY.
[*5] [*6] [*15] [*16]
Installation procedure for high-pressure pipe
a Do not correct the high-pressure pipe by bendingbefore installing it.
1) Tighten high-pressure pipe (52) perma-
nently.
3 Sleeve nuts (50) and (51):
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
2) Tighten high-pressure pipe clamps (28) and
(31) and bracket (32) with your fingers.
3) Tighten high-pressure pipe clamps (28) and
(31) permanently.3 Clamp bolt:
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
4) Tighten bracket (32) permanently.
[*17]
3 Spill tube (55):
24.5 – 34.3 Nm {2.5 – 3.5 kgm}
[*18]
3 Return tube:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
[*19]
3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*20]
3 Capture nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
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5) Install cover (30).
a Set the slit on the cylinder head side.
6) Install gate-type bracket (29) and cover
(which is used as the clamp, too) (27) tem-
porarily.
7) Tighten cover (27) permanently.
3 Cover mounting bolt:
11.8 – 14.7 kgm {1.2 – 1.5 kgm}
8) Tighten the gate-type bracket permanently.
[*21]
1) Loosen the locknut and install the rocker arm
and rocker shaft assembly.
3 Rocker shaft mounting bolt:
58.8 – 73.5 Nm {6 – 7.5 kgm}2) Remove covers (70) and (71) and adjust the
valve clearance. The pointer is under cover (70).
• Valve clearance
Intake: 0.33 mm
Exhaust: 0.71 mm
a For the adjustment procedure for the valve clear-
ance, see TESTING AND ADJUSTING, Adjust-
ing valve clearance.
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
[*22]a For the installation procedure for the injector and
holder, see REMOVAL AND INSTALLATION OF
FUEL INJECTOR ASSEMBLY.
[*23]
a Apply engine oil (EO30-CD) to the cross head
guide and cross head top sufficiently.
a Adjust the cross head according to the followingprocedure.
1) Loosen locknut (73) and return the adjust-
ment screw.
2) Press the cross head top lightly to put it to
valve stem (74) and tighten the adjustment
screw.
3) After the adjustment screw touches the
valve stem, tighten it further by 20°.4) Tighten the locknut at this position.
3 Locknut: 58.8 – 73.5 Nm {6 – 7.5 kgm}
[*25]a Clean the underside of the head, top of the block,
and liner with dry cloths or cloths soaked with
solvent.
a If a bolt has 5 punch marks on its head, replace it.
a Tighten the bolts with your fingers into the block
at least 2 turns.
2 Bolt threads and underside of bolt
head: LM-P or engine oil (EO30-CD)a Tighten the cylinder head mounting bolts in the
following order.
3 Cylinder head mounting bolts 1 – 6:
1st time: 88.3 – 108 Nm {9 – 11 kgm}
2nd time: 157 – 167 Nm {16 – 17 kgm}
3rd time:
1) When using tool A2
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[*24]
3 Rocker housing mounting bolt:58.8 – 73.5 Nm {6 – 7.5 kgm}
Using tool A2 , retighten the bolts in the
order of 1 – 6 by 90° .+30° 0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
2) When not using tool A2Make marks on the bolt heads with a marker
pen and retighten the bolts in the order of 1
– 6 by 90° .
a After tightening bolts 1 – 6, tighten auxil-
iary bolt 7.
3 Cylinder head auxiliary mounting
bolt 7:
66.2 ± 7.4 Nm {6.8 ± 0.8 kgm}a After tightening the bolts, make a punch
mark on each bolt head to show the
number of tightening time.
• Refilling with coolant
Add coolant through the coolant filler of the radi-
ator to the specified level. Run the engine to cir-
culate the coolant through the piping. Then,
check the coolant level again.
+30° 0
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5 Coolant: Approx. 35
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
SPECIAL TOOLS
REMOVAL1. Remove they hydraulic pump assembly. For
details, see REMOVAL AND INSTALLATION OF
HYDRAULIC PUMP ASSEMBLY.
2. Using guide bolt [1], remove damper assembly(1). [*1]
4. Leave 1 mounting bolt (5) and sling flywheel (4)
temporarily. [*3]
a Sling [2] becomes diagonal because of the
muffler.
5. Lift off flywheel assembly (4). [*3]
4 Flywheel assembly: 50 kg
k When the flywheel is hung temporarily, sling
[2] becomes diagonal. Accordingly, when
flywheel assembly (4) (which has been fit-
ted firmly) is removed, it swings. Take care.
6. Rear seal
Remove rear seal (6) according to the following
procedure. [*4]
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N
e w / R e m o d e l
S k e t c h
A
3 795-931-1100 Seal puller t 1
4
795-931-1210 Push tool t 1
• 01050-31625 • Bolt t 3
• 01050-31645 • Bolt t 3
5
795-931-1220 Push tool t 1
• 01050-31645 • Bolt t 3
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3. Disconnect engine speed sensor connector
EREV (2), loosen speed sensor locknut (3), and
procedure. [ 4]
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
• Removal of original rear seal
Set the drill-type tip to tool A3, make a hole
on the seal, and pull out the seal with the
impact force of the slide hammer (SH).
a Remove all the chips.
• Removal of spare rear seal
1) Set the hook-type tip to tool A3, hook it to
the metallic ring of seal (6), and pull out the
seal with the impact force of the slide ham-
mer (SH).
a Drive in the seal a little before pulling itout to separate it from the housing, and
you can put it out easily.
2) If sleeve (9) is installed, cut and remove it
with a chisel and a hammer.
INSTALLATION • Carry out installation in the reverse order to
removal.
[*1]
2 Mounting bolt: Adhesive (LT-2)
[*2]
Installation procedure for sensor
1)
2 Threads of sensor: Hydraulic
sealant manufactured by LOC-
TITE
2) Screw the sensor into the flywheel housing
to touch it to the ring gear.
3) Return the sensor by 1/2 – 2/3 turns. (Clear-ance between the sensor and ring gear:
0.75 – 1 mm)
4)
3 Sensor locknut:
69 – 74 Nm {7 – 7.5 kgm}
[*3]
a Apply sufficient amount of clean lubricating
oil (EO30-CD) to the threads of the bolt, seat,
and washer.
a Tighten the 6 flywheel assembly mounting
bolts in the order of 1 – 6 shown in the follow-
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a When cutting sleeve (9), take care ex-
tremely not to damage crankshaft (8).
a If chips are made, remove all of them.
ing figure.
a Tighten the flywheel assembly mounting
bolts 2 times.
3 Mounting bolt:1st tightening torque:
147 ± 19.6 Nm {15 ± 2.0 kgm}
2nd tightening torque:
289.1 ± 19.6 Nm {29.5 ± 2.0 kgm}
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
[*4] • Installation procedure for engine rear seal (6)
a Rear seal 6151-21-4161: Check the shaft for
wear and install "standard seal A" or
"sleeved seal B" according to the check re-
sult.
The part No. of the spare rear seal is 6151-
29-4160 (same as one installed to PC400-6)
and its shape is different from that of the
seal installed when shipped.
a If the shaft is still glossy (If the wear depth felt
with a finger cushion is 10 m or less) and
it does not have a flaw, install "standard seal
A". In other cases, install "sleeved seal B".
a Part (7) is the internal plastic cylinder which
is also used as a installation guide.
a Part (9) is the sleeve.
a Wipe off oil from the crankshaft and installthe seal while the crankshaft is dry (Do no
apply lubricating oil to the lip).
1) Put large inside diameter side "b" of internalplastic cylinder (7) to the end of crankshaft
(8).
a Take care not to mistake the direction of
the plastic internal cylinder.
2) Evenly push in the metallic ring of seal (6)
with both hands, getting over the large
diameter side of the internal plastic cylinder.
3) After pushing in seal (6), remove internal
plastic cylinder (7).
a When removing, take care not to dam-
age the seal lip.
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• Installation procedure for standard seal A
aBefore installing the seal, check the rims of the crankshaft end, sliding surfaces of the
lip, and housing for flaw, burr, rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thoroughly
from the shaft.
a Never remove internal plastic cylinder (7) of
the spare seal before installing the seal.
4) Tighten the bolt of tool A4 evenly until the
end of tool A4 touches the end of crankshaft
(8) to press fit seal (6).
a When press fitting the seal, take care not
to damage the lip on the damper side
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
• Installation procedure for sleeved seal Ba Before installing the seal, check the rims of
the crankshaft end, sliding faces of the lip,
and housing for flaw, burr, sharp fin, rust, etc.
a When installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thoroughly
from the shaft.
a Handle the seal and sleeve as an assembly.
Never separate them from each other.
1) Set sleeved seal (6) to tool A5.
a Take care not to mistake the direction of
the seal.
2 Internal cylinder (C) of sleeve:
Gasket sealant (LG-7)
2) Put the sleeve of the seal to the end of the
crankshaft and tighten the bolt of tool A5
evenly until the end of tool A5 touches the
end of crankshaft (8) to press fit sleeved
3) Remove tool A5 and install tool A4.4) Tighten the bolt of tool A4 evenly until the
end of tool A4 touches the end of crankshaft
(8) to press fit sleeved seal (6).
a After press fitting the seal, remove the
red sealant layer on its periphery.
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end of crankshaft (8) to press fit sleeved
seal (6).
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
SPECIAL TOOLS
REMOVAL1. Remove the radiator and hydraulic oil cooler.
For details, see REMOVAL AND INSTALLA-
TION OF RADIATOR and REMOVAL AND
INSTALLATION OF HYDRAULIC OIL COOLER.
2. Open the right side cover.
3. Remove reservoir tank bracket (1) and discon-
nect air aftercooler hoses (2) and (3). [*1]
5. Remove covers (5) and (6).
6. Loosen the air conditioner compressor assem-
bly mounting bolt and adjustment screw (7). [*2]
7. Loosen alternator assembly mounting bolt (11),
adjustment bolt nuts (8) and (9), and adjustment
bolt guide bolt (10). [*3]
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N
e w / R e m o d e l
S k e t c h
A3 795-931-1100Seal puller
assembly t 1
A6
795T-521-1140 Push tool t 1 Q
• 790-101-5221 • Grip t 1
• 01010-81225 • Bolt t 1
• 01050-31640 • Bolt t 3
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4. Remove the 4 mounting bolts and air aftercooler
(4).
8. Remove fan (12).
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
9. Remove alternator belt (13) and air conditioner
compressor belt (14).
10. Remove 6 pulley mounting bolts (15) and (16) in
total, and then remove pulley and damper
assembly (17).
a One mounting bolt (16) is small in diameter.[*4]
11. Using the seal pulley assembly and tool A3,
remove the front seal. [*5]
aRemove all the chips.
INSTALLATION • Carry out installation in the reverse order to
removal.
[*1]
3 Air aftercooler hose clamp:
10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*2]
a Belt tension: 14 – 16 mm
(When pressed with finger to about 58.8 N
{6 kg})
3 Mounting bolt:
24.5 – 29.4 Nm {2.5 – 3.0 kgm}
[*3]• Tense the belt according to the following pro-
cedure.
1) Loosen mounting bolt (11), nut (9), and bolt
(10).
2) Tense the belt with nut (8).
3) Tighten mounting bolt (11), nut (9), and bolt
(10).
a Tension of belt: 13 mm
(When pressed with finger to about 58.8
N {6 kg})
3 Bolt:
107.8 – 147 Nm {11 – 15 kgm}
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[*4]
3 Pulley mounting bolt:
(M14): 156.8 – 196 Nm {16 – 20 kgm}
(M16): 245 – 308.7 Nm {25 – 31 kgm}
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
[*5]
4) Installation procedure for front seal (18)
a Before installing the seal, check the rims
of the crankshaft end, sliding surfaces of
the lip, and housing for flaw, burr, rust,
etc.a When installing the seal, do not apply oil,
grease, etc. to the shaft. Wipe oil thor-
oughly from the shaft.
a Never remove internal plastic cylinder of
the spare seal before installing the seal.
i) Put large inside diameter side "b" of
internal plastic cylinder (19) to the end
of crankshaft (20).
a T k i k h di i f
ii) Evenly push in the metallic ring of seal
(18) with both hands, getting over the
large diameter side of the internal plas-
tic cylinder.
iii) After pushing in seal (18), remove inter-
nal plastic cylinder (19).a When removing, take care not to dam-
age the seal lip.
iv) Tighten the bolt of tool A5 evenly until
the end of tool A6 touches the end of crankshaft (20) to press fit seal (18).
a When press fitting the seal, take care not
to damage the lip on the pulley side with
the tool, etc.
a Af fi i h l h
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a Take care not to mistake the direction of
the plastic internal cylinder.
2 Lip: Lithium grease (G2-LI)
a After press fitting the seal, remove the
red sealant layer on its periphery.
a Seal driving dimension "a": 16 mm+1 0
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMPASSEMBLY
SPECIAL TOOLS
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Release the residual pressure from the fuel sys-
tem. For details, see TESTING AND ADJUST-
ING, Releasing residual pressure from fuel
system.
4. Open the engine hood.
5. Remove air cleaner tube (2) and bracket
together. [*1]
6. Fix hose (3) with cords apart from the engine.
7. Remove cover (4).
8. Remove clamp (5).
9. Disconnect fuel supply pump wiring connectors
PCV1 (6), PCV2 (7), and G (8).
10. Remove fuel hoses (9) and (10). [*2]
S
y m b o l
Part No. Part Name
N e
c e s s i t y
Q ’ t y
N e w / R e m o d e l
S
k e t c h
A7
795-471-1800 Remover t 1 N
• 795-471-1810 • Plate 1
• 795-471-1820 • Bolt 1
• 795-471-1830 • Bracket 1
• 01435-01035 • Bolt 3
• 01435-01025 • Bolt 1
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2. Close the fuel supply valve of the fuel tank.
3. Remove two engine undercovers (1).
11. Remove cover (11). [*3]
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
12. Remove 4 high-pressure pipe clamps (12). [*4]
13. Remove 2 clamps (13) and fuel tubes (14) and
(15). [*5]
14. Remove 2 covers (16). [*3]
15. Remove 2 high-pressure pipes (17). [*6]
16. Remove lubrication tube (18). [*7]
17. Setting tool to remove fuel supply pump
drive gear
1) Remove 2 mounting bolts (19) and cover
(20). [*8]
4) Install plate (23) of tool A7 to installationhole B and install bracket (24) of tool A7 to
C.
5) Set bolt (25) of tool A7.
a Keep tool A7 installed until the pump is in-
stalled so that meshing point of the fuel sup-
ply pump drive gear and camshaft will
change.
18. Remove bracket (26) and mounting bolts of fuel
supply pump assembly (27) and install guide
bolt [1]. [*10]
a The proper length of the guide bolt is a half
of the length shown in the photo.
19. Remove the remaining 3 mounting bolts.
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2) Remove mounting nut (22) and the washer
of fuel supply pump drive gear (21). [*9]
3) Rotate the crankshaft so that key way A of
20. Tighten bolt (25) of tool A7 to remove fuel sup-
ply pump assembly (27).
DISASSEMBLY AND ASSEMBLY FUEL SUPPLY PUMP
INSTALLATION • Carry out installation in the reverse order to
removal.
[*1]
3 Air cleaner hose clamp:
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*2]
3 Fuel hoses (9) and (10):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*3]
a Install cover (11) with the slit on the cylinder
block side and install cover (16) with the slit di-
rected down.
[*4], [*6], [*10]k Do not correct the high-pressure pipe by bend-
ing before installing it.
k Be sure to use the genuine high-pressure pipe
clamps and tighten them to the specified torque.
k Install the wiring harnesses at least 10 mm apart
from the high-pressure pipe.
a When installing each high-pressure pipe, check
the taper seal of its joint (Part "a": Part of 2 mm
from the end) for visible lengthwise slit "b" andspot "c" and check part "d" (End of taper seal:
Part of 2 mm from the end) for stepped-type wear
caused by fatigue which your nail can feel. If
there is any of those defects, it can cause fuel
leakage In this case replace the high pressure
3) Tighten the fuel supply pump mountingbolts.
4) Tighten the mounting bolts of bracket (26).
5) Tighten 4 high-pressure pipe clamps (12)
temporarily with your fingers.
6) Tighten 4 high-pressure pipe clamps (12) to
the following torque.
3 High-pressure pipe clamp:
8.82 – 14.7 Nm {0.9 – 1.5 kgm}
[*5]
3 Fuel tubes (14) and (15):24.5 – 34.3 {2.5 – 3.5 kgm}
[*7]
3 Lubrication tube (20)
F l l id
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leakage. In this case, replace the high-pressure
pipe.Fuel supply pump side:
7.9 – 12.7 Nm {0.8 – 1.3 kgm}
Cylinder block side:
9.8 – 12.7 Nm {1.0 – 1.3 kgm}
Clamp: 8.82 – 14.7 Nm {0.9 – 1.5 kgm}
[*8]
3 Cover: 14.7 – 17.6 Nm {1.5 – 1.8 kgm}
[*9]
3 Fuel supply pump drive gear:
127 – 147 Nm {13 – 15 kgm}
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY
SPECIAL TOOL
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open the engine hood.
2. Remove air cleaner tube (1) and the bracket
together. [*1]
5. Remove gate-type bracket (4). [*4]
6. Remove injector-side covers (6) and common
rail-side covers (5) from the high-pressure pipe
jo int s acco rd ing to the fue l in je ctors to be
removed and installed. [*5]
7. Remove high-pressure pipe clamp cover (7) and
its clamp (77) according to the fuel injectors to
be removed and installed. [*6]
a Do not remove bracket X. If it is removed,
tighten it permanently after tightening the
high-pressure pipe and all the high-pressure
pipe clamps in the assembly procedure.
8. Loosen common rail-side sleeve nuts (8) and
fuel injector-side sleeve nut (10) and remove
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N
e w / R e m o d e l
S k e t c h
A1 795-799-1170 Puller t 1
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3. Remove common rail cover (2). [*2]
4. Remove high-pressure pipe clamps (3) accord-
ing to the fuel injectors to be removed and
installed. [*3]
high-pressure pipe (9). [*7]
9. Remove head cover (11). [*8]
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
10. Remove capture nuts (12) and disconnect wiring
harness (13) from the fuel injector. [*9]
11. Remove holder mounting bolt (14), and then
remove the holder and fuel injector assembly
(16) together. [*10]
aDo not grip the solenoid valve at the top of the injector with pliers, etc.
a If the fuel injector is not removed easily, use
tool A1.
INSTALLATION • Carry out installation in the reverse order to
removal.
a Install high-pressure pipe (9) between the
common rail and fuel injector according to
the following procedure.1) Tighten sleeve nuts (8) and (10) of high-
pressure pipe (9).
3 High-pressure pipe sleeve nut:
39.2 – 49.0 Nm {4.0 – 5.0 kgm}
2) Tighten high-pressure pipe clamps (3) and
(77) temporarily with your fingers, and then
tighten them permanently.
3) Install common rail cover (2) and gate-type
bracket (4) temporarily.
4) Tighten common rail cover (2) (which is also
used as a high-pressure pipe clamp) perma-
nently first, then tighten gate-type bracket
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[*1]
3 Air cleaner tube band:
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
[*2] [*3] [*4] [*6] [*7]
k Do not correct the high-pressure pipe by bend-
ing before installing it.
k Be sure to use the genuine high-pressure pipe
clamps and tighten them to the specified torque.
k Install the wiring harnesses at least 10 mm apart
from the high-pressure pipe.
a When installing each high-pressure pipe, check
(4) permanently.
3 Common rail cover:
8.82 – 14.7 Nm {0.9 – 1.5 kgm}
DISASSEMBLY AND ASSEMBLY FUEL INJECTOR
[*5]
a Install common rail-side cover (5) with the slit
on the cylinder block side.
a Set the slit on fuel injector-side cover (6) at
position "a" in the figure and match it to the
center of the clip.
[*8]
3 Head cover mounting bolt:
9.8 ± 1 Nm {1.0 ± 0.1 kgm}
[*9]
3 Wiring harness mounting nut:
2.0 – 2.4 Nm {0.2 – 0.24 kgm}
[*10]
a Install fuel injector assembly (16) according to
th f ll i d
• Checking for fuel leakage
Check the fuel system for leakage. For details,
see TESTING AND ADJUSTING, Checking fuelsystem for leakage.
• Bleeding air
Bleed air from the fuel circuit. For details, see
TESTING AND ADJUSTING, Bleeding air from
fuel circuit.
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the following procedure.
1) Insert gasket (b) and O-ring (c) in fuel injec-
tor (a).
2) Put holder (d) in injector (a) and install themto the rocker housing temporarily.
a Matching key (g) of the injector to key
way (h) of the rocker housing, insert the
holder securely until the sealing surface
of the injector touches the sealing sur-
face on the cylinder head side.
3) Apply engine oil to the spherical part of
spherical washer (e).
DISASSEMBLY AND ASSEMBLY NOZZLE TIP
REMOVAL AND INSTALLATION OF NOZZLE TIP
a [ERA Regulation]
In a country where EPA Regulation is applied,
replace the nozzle of the common rail engine by
the assembly. In a country where EPA Regula-
tion is not applied, however, only the nozzle tip
can be replaced according to the following pro-
cedure.(EPA: Environmental Protection Agency)
SPECIAL TOOLS
REMOVAL1. Grip tool A8 with vise [1].
a Do not grip the injector directly with the vice.
3. Using 19-mm deep socket [3], loosen retaining
nut (4).
4. Remove retaining nut (4) from injector assembly(3).
5. Lift up and remove nozzle assembly (5) verti-
cally.
a Do not remove tip guide (6). (The tip guide
cannot be disassembled.)
a Take care that dirt will not stick to the parts.
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
A8 795T-471-1550 Wrench q 1
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2. Set injector assembly (3) to tool A8.
DISASSEMBLY AND ASSEMBLY NOZZLE TIP
INSTALLATION1. Grip tool A8 with vise [1].
a Do not hold the injector directly with the vice.
2. Set injector assembly (1) to tool A8.
3. Clean the lower body and the threads of retain-
ing nut (2) throughly with parts cleaner and blow
air against them.
5. Install nozzle assembly (3) and tighten retaining
nut (2) with the fingers.
6. Set 19-mm deep socket [2] to a torque wrench
and tighten the retaining nut according to the fol-
lowing procedure.
a Apply rust-preventive oil to the nozzle body.
1) Tighten the retaining nut to 88.3 Nm {9.0
kgm}.
2) Make match marks (6) on retaining nut (2)
and lower body (5).3) Tighten the retaining nut by 45° (Angle tight-
ening).
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4. Install new nozzle assembly (3), matching it to
the dowel pin of tip guide (4).
a Take care not to drop the tip.
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL AND INSTALLATION OF STARTING MOTORASSEMBLY
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open the engine hood.
2. Disconnect the following 2 starting motor wires.
[*1]
• (1) and (2): Terminal B
3. Remove 3 mounting bolts (3) and starting motor
assembly (4).
INSTALLATION • Carry out installation in the reverse order to
removal.
[*1]
3 Mounting nut of starting motor terminalB: 19.6 – 25.5 Nm {2 – 2.6 kgm}
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DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL1. Remove cover (1).
2. Drain the coolant.
6 Coolant: Approx. 35
3. Erect the engine hood according to the following
procedure.
1) Open engine hood (2) and sling it temporar-
ily.
a When slinging the engine hood, take
care not to damage the rubber seal.
2) Prepare M10 bolt [1].
• When removing the radiator, L = 50 or
longer.
• When removing the oil cooler, L = 70 or
longer
4. Disconnect reservoir tank hose (6).
a Disconnect the hose from the radiator.
5. Disconnect radiator hoses (7), (8), and (9). [*1]
6. Remove covers (10) and (11).
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longer.
3) Remove bolt (4).
4) Remove pin (5) from the lower part of stay
(3).5) Adjust the engine hood so that center hole A
of stay (3) will be at the bolt (4).
6) Install stay (3) with bolt [1] and fix engine
hood (2) vertically.
7. Remove cover (12).
8. Disconnect radiator hose (13). [*1]
DISASSEMBLY AND ASSEMBLY RADIATOR
9. Remove 2 mounting bolts (14).
10. Lift off radiator assembly (15).
4 Radiator assembly: 30 kg
INSTALLATION • Carry out installation in the reverse order to
removal.
• Refilling with coolant
Add coolant through the coolant fi ller to the
specified level. Run the engine to circulate thecoolant through the system. Then, check the
coolant level again.
5 Coolant: Approx. 35
[*1]
3 Radiator hose clamps
(7): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}
(8): 4.4 ± 0.49 Nm {0.49 ± 0.05 kgm}(9), (13): 8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
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DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLERASSEMBLY
REMOVAL1. Remove cover (1).
2. Remove plug (2) of the hydraulic oil cooler drain
hose to drain the hydraulic oil.
a Before draining, open the hydraulic tank cap
to release the pressure in the tank. Then,
drain the oil through the cooler hose.
4. Remove covers (3) and (4).
5. Remove hydraulic oil cooler tube mounting bolts
(5) and (6)
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3. Erect the engine hood according to the following
procedure.
1) Open engine hood (100) and sling it tempo-
rarily.
a When slinging the engine hood, take
care not to damage the rubber seal.
(5) and (6).
6. Remove right and left hydraulic oil cooler mount-
ing bolts (7).
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DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF ENGINE AND HYDRAULICPUMP ASSEMBLY
SPECIAL TOOLS
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
a Put tags to the disconnected hoses and tubes to
prevent a mistake in re-connecting them.
1. Remove the 4 engine undercovers.
2. Remove the hydraulic tank strainer. Using tool
C, stop the oil.
a When not using tool C, remove the drain plug
t d i th il f th h d li t k d
3. Drain the coolant.
6 Coolant: Approx. 35
4. Close the fuel stop valve of the fuel tank.
5. Erect the engine hood according to the following
procedure.
1) Open engine hood (100) and sling it tempo-
rarily.
a When slinging the engine hood, take
care not to damage the rubber seal.
2) Prepare M10 bolt [1].
3) Remove bolt (102).
4) Remove pin (103) from the lower part of stay (101).
5) Adjust the engine hood so that center hole A
of stay (101) will be at the bolt (102).
6) Install stay (101) with bolt [1] and fix engine
hood (100) vertically.
S
y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w
/ R e m o d e l
S k e t c h
B 796-601-1110 Stopper t 1 N
C796-460-1210 Oil stopper t 1
796-770-1320 Adapter t 1
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to drain the oil from the hydraulic tank and
piping.
6 Hydraulic tank: Approx. 335
6. Remove tube (1). [*1]
a Remove the tube and bracket together.
7. Disconnect clamp (2) and pipe (3). [*2]
a Remove the clamp, pipe, and bracket (4) to-
gether.
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
8. Disconnect fuel inlet hose (5) and fuel return
hoses (6) and (7). [*3]
9. Disconnect clamp (8) and radiator hoses (9),
(10), and (11). [*4]
10. Remove covers (12) and (13).
11. Remove fan guard (14).
a Bolt [1] is used to fix the engine hood verti-
cally.
15. Disconnect aftercooler hose (21) and heater
hose (22). [*6]
16. Remove cover (23).
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12. Loosen adjustment bolt (15) and remove belt
(16). [*5]
13 R i di i bl
6 e o e co e ( 3)
17. Disconnect radiator hose (24). [*4]
DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
18. Disconnect heater hose (25).
19. Disconnect the following 2 wiring connectors.
• (26): ERO2 (Various sensors)
• (27): ERO3 (Each injector and fuel supply
pump)
20. Remove mounting bolts (28) and bracket (29).
24. Disconnect the following 2 pump wiring connec-
tors.
• (34): V22 (PC-EPC solenoid valve)
Band color: Red• (35): V21 (LS-EPC solenoid valve)
Band color: White
25. Disconnect the following 10 hoses and 1 tube.
• (36): EPC basic pressure port hose
(Band color: Yellow)
• (37): Rear pressure port hose
(Band color: Yellow)
• (38): Rear pump discharge port hose• (39): Front pump discharge port hose
• (40): Drain port hose
• (41): Front load pressure input port hose
• (42): Rear load pressure input port hose
(Band color: Red)
• (43): Front pressure input port hose
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21. Open the main pump side cover.
22. Lift off covers (30) and (31) together.
23. Remove cover (32) and stay (33).
( ) p p p
• (44): Pump suction port tube
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DISASSEMBLY AND ASSEMBLY ENGINE AND HYDRAULIC PUMP
INSTALLATION • Carry out installation in the reverse order to
removal.
[*1]
3 Hose clamp:
9.8 ± 0.5 Nm {0.1 ± 0.05 kgm}
[*2]
3 Clamp:
10.5 ± 0.5 Nm {1.07 ± 0.05 kgm}
[*3]
3 Fuel hoses (5), (6), and (7):
14.8 – 19.6 Nm {1.5 – 2.0 kgm}
[*4]
3 Radiator hoses:
(9): 3.3 ± 0.49 Nm {0.3 ± 0.05 kgm}
(10): 4.4 ± 0.49 Nm {0.45 ± 0.05 kgm}
(11), (24):
8.8 ± 0.5 Nm {0.9 ± 0.05 kgm}
[*5]
a See TESTING AND ADJUSTING, Testingand adjusting air conditioner compressor
belt tension or REMOVAL AND INSTALLA-
TION OF ENGINE FRONT SEAL.
[*6]
3 Air aftercooler hose clamp:
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10.8 ± 1 Nm {1.1 ± 0.1 kgm}
[*7]3 Engine mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
• Refilling with coolant
Add coolant through the coolant fi ller to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL AND INSTALLATION OF SWING CIRCLE ASSEMBLYREMOVAL
1. Remove the revolving frame assembly. For
deta i ls , see REMOVAL OF REVOLVING
FRAME ASSEMBLY.
2. Sling swing circle assembly (1) by 3 points tem-
porarily, remove 40 mounting bolts, and lift off
the swing circle assembly. [*1]
4 Swing circle assembly: 600 kg
INSTALLATION • Carry out installation in the reverse order to
removal.
[*1]
2 Mating face of swing circle:
Gasket sealant (LG-6)
2 Threads of swing circle mounting bolt:
Adhesive (LT-2)
3 Swing circle mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
Target: 927 Nm {94.5 kgm}
a When installing the swing circle to the track
frame, bring soft zone mark S of the inner
race and soft zone mark P of the outer race
to the right side of the chassis as shown be-low.
2 Quantity of grease in grease bath:
Grease (G2-LI), 33
(Use GLT2-LI for 50°C specification)
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DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
REMOVAL AND INSTALLATION OF SWING MOTOR AND SWINGMACHINERY ASSEMBLY
REMOVALk Release the residual pressure in the hydraulic
circuit. Refer to the Releasing of Residual Pres-
sure in Hydraulic Circuit section in the TESTING
AND ADJUSTING chapter of this manual.
k Lower the work equipment to the ground for oilfiller cap on the fuel tank to release the residual
pressure inside the tank and move the safty lock
lever to the LOCK position.
1. Disconnect five swing motor hoses (1) through
(5).
• (1): Between swing motor and control valve
(MA port)
• (2): Between swing motor and control valve(MB port)
• (3): Suction hose (S port)
• (4): Drain hose (T port)
• (5): Swing brake releasing pilot hose (B
port)
3. Lift and remove swing motor and swing machin-
ery assembly (6).
a When lifting the swing motor and swing ma-
chinery assembly for removal, do so slowly
so that the hoses and other parts will not be
damaged.
aTake good care, when lifting the assem-bly, until the spigot joint portion is pulled
out.
4 Swing motor and swing machinery
assembly: 550 kg
INSTALLATION • Install in reverse order of removal.
[*1]
3 Mounting bolt:
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2. Detach the swing motor and swing machinery
assembly (6), using forcing screw [1] after
removing the mounting bolts. [*1]
3 Mounting bolt:
824 – 1,030 Nm {84 – 105 kgm}
• Refilling hydraulic oil
Refill hydraulic oil through the oil filler port to the
specfied level. Let the oil cirdulate in the
hydraulic system by starting the engine. Then
check the oil level again.
• Air bleeding
Refer to the Air Bleeding of Various Parts sec
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DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
5. Ring gear Remove the mounting bolts and ring gear (10).
6. No. 2 sun gear
Remove No. 2 sun gear (11).
7. Bolt
Remove holder mounting bolt (12).
8. No. 2 carrier assembly1) Lift of No. 2 carrier assembly (13).
2) Disassemble the No. 2 carrier assembly
according to the following procedure.
i) Push in pin (14) and drive out shaft (15)
from carrier (16).
a After removing the shaft, remove pin
(14).
ii) Remove thrust washer (17), gear (18),
bearing (19), and thrust washer (20).
iii) Remove plate (21).
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9. Shaft assembly
1) Turn over case and pinion assembly (24)
and remove 12 mounting bolts (23) of cover
assembly (22).
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
2) Turn over case and pinion assembly (24)and set it on the press stand. Using push
tool [2], D1 and the press, pull out pinion
shaft assembly (25).
a Set a wood block under the press so that
the pinion shaft will not be damaged
when it comes off.
a A rough standard pressing force is 20
odd tons.
10. Disassemble the pinion shaft assembly (25)
according to the following procedure.
1) Using the push tool, remove cover assembly
(22) and bearing (26) from shaft (27).
a A rough standard pressing force is 30tons.
2) Remove oil seal (28) from cover (29).
11. BearingUsing multiple push tools [3], remove bearing
(30) from case (31).
a Push tool to be set contact with bearing: D2
ASSEMBLYa Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
1. Bearing
Using push tool D3 and [4], press fit bearing (26)
to case (31).
a A rough standard pressing force is severaltons.
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DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
2. Cover assembly1) Using push tool D4, press fit oil seal (28) to
cover (29).
2 Periphery of oil seal:
Gasket sealant (LG-6)
a Take care that the gasket sealant (LG-6)
will not stick to the oil seal lip and shaft
assembly (22).
2) Install cover assembly (22) to case (31) and
tighten mounting bolts (23).
a Match the oil path of cover (22) to the
drilled hole of case (31).
2 Cover fitting face:
Gasket sealant (LG-6)
3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
2 Oil seal lip: Grease (G2-LI)
3. Case assembly1) Turn over case assembly (32) and set it to
shaft (27). Using push tools D5 and D6 [5],
press fit the bearing inner race.
a When setting the case assembly to the
shaft, take care extremely not to damage
the oil seal.
a A rough standard pressing force is 30
tons.
2) Bearing
Using too D7, press fit bearing (30).
a Press both inner race and outer race of
the bearing simultaneously. Do not
press only the inner race.a A rough standard pressing force is 20
odd tons.
a After press fitting the bearing, check that
the case turns smoothly.
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DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
4. No. 2 carrier assembly1) Assemble the No. 2 carrier assembly
according to the following procedure.
a There is a caulking mark made when the
pin was inserted at the end of carrier
side hole "a" and the inside wall of the
hole is swelled at that mark. Flatten the
swelled part in advance.
i) Install plate (21) to carrier (16).
ii) Install bearing (19) to gear (18) and fittop and bottom thrust washers (17) and
(20), and then set the gear assembly to
carrier (16).
iii) Aligning the pin holes of shaft (15) andcarrier, lightly hit the shaft with a plastic
hammer, etc. to install.
a When installing the shaft, revolve the
planetary gear and take care not to dam-
age the thrust washers.
iv) Insert pin (14).
a
When inserting the pin, do not set the 3claws (parts "a") on the periphery to the
thin part of the carrier (part "b").
The thin part may be on the opposite
side, however. Check each carrier and
avoid setting a claw to the thin part.
a After inserting the pin, caulk the pin part
of the carrier.
2) Install No. 2 carrier assembly (13).
5. Bolt and O-ring
1) Tighten bolt (12).
2 Threads of mounting bolt:
Adhesive (LT-2)3 Mounting bolt:
343 – 427 Nm {34 – 43.5 kgm}
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2) Fit the O-ring to case (31).
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
7. Ring gear
Using the eyebolt (M12 x 1.75), install ring gear
(10).
a When installing ring gear (10), set its match
mark (part "d") and the projection of the case
flange (part "c") as shown in the following fig-
ure.
8. No. 1 carrier assembly
1) Assemble the No. 1 carrier assembly
according to the following procedure.
i) Press fit shaft (5) to the carrier in the
direction of the arrow until the snap ring
groove is seen.
ii) After installing snap ring (4), press back
the shaft from the opposite side until the
snap ring is fitted to face P of the carrier.
At this time, take care not to press backtoo much.
iii) After installing plate (9), install thrust
washer (8), bearing (7), gear (6), and
snap ring (4).
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2) Install No. 1 carrier assembly (3).
DISASSEMBLY AND ASSEMBLY SWING MOTOR AND SWING MACHINERY
9. No. 1 sun gear assembly
Install No. 1 sun gear (2).
a Take care not to install the No. 1 sun gear
upside down.
a Install the No. 1 sun gear with the tooth (part
"e") down.
10. Swing motor assembly
Install swing motor assembly (1) to ring gear
• Refilling with oil
Tighten the drain plug and add engine oil
(EO30-CD, or SHC 5W-30K for extremely cold
district) through the oil filler to the specified
level.
5 Swing machinery case: Approx. 21
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g y ( ) g g
(10).
a When installing the swing motor assembly,set the relief valve (part f ) and the projection
of the case (part c) as shown in the following
figure.
a Degrease the mating faces of swing motor
assembly (1) and ring gear (10).
2 Mating faces of swing motor
DISASSEMBLY AND ASSEMBLY SPROCKET
REMOVAL AND INSTALLATION OF SPROCKET
REMOVAL1. Remove track shoe assembly. For details, see
REMOVAL OF TRACK SHOE ASSEMBLY.
2. Swing work equipment 90°, push up chassis
with work equipment and place block [1]
between track frame and track shoe.
3. Remove mounting bolts and lift off sprocket (1).
[*1]
4 Sprocket: 70 kg
INSTALLATION • Install in reverse order of removal.
[*1]
2 Thread of sprocket mounting bolt:
Gasket sealant (LG-6)
3 Sprocket mounting bolt:
640 – 785 Nm {65 – 80 kgm}
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DISASSEMBLY AND ASSEMBLY TRAVEL MOTOR AND FINAL DRIVE
REMOVAL AND INSTALLATION OF TRAVEL MOTOR AND FINALDRIVE ASSEMBLY
REMOVAL1. Remove the sprocket. For details, see Removal
of sprocket.
k Lower the work equipment to the ground
and stop the engine. Then, loosen the hy-
draulic oil filler cap slowly to release the in-
ternal pressure of the hydraulic tank.
2. Remove cover (1).
3. Disconnect drain hose (2), travel speed selector
hose (3), and motor hoses (4) and (5).
a Remove the nipples, too.
4. Remove the 24 mounting bolts and lift off the
final drive assembly (6). [*1]
a Take care extremely not to damage the nip-
ple sealing faces of the hose joints.
a When slinging the final drive assembly, do
not use the tap hole for the cover.
4 Final drive assembly: 700 kg
INSTALLATION • Carry out installation in the reverse order to
removal.
[*1]
3 Mounting bolt:
490 – 608 Nm {50 – 62 kgm}
• Refilling with oil (Hydraulic tank)
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Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level.Run the engine to circulate the oil through the
system. Then, check the oil level again.
• Bleeding air
See TESTING AND ADJUSTING, Bleeding air
from each part.
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLYSPECIAL TOOLS
DISASSEMBLY
2) Using eyebolt [2], remove cover (1).
3. Spacer
Remove spacer (2).
4. No. 1 carrier assembly
1) Remove No. 1 carrier assembly (3).
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
E
1
796-627-1210Wrench
assembly t 1
• 796-627-1220 • Wrench 1
• 796-427-1140 • Pin 3
• 01314-20612 • Screw 3
2
796T-627-1230 Push tool t 1 Q
790-101-2510 Block q 1
791-122-1130 Plate q 1
790-101-2550 Leg q 2
790-101-2740 Adapter q 2
790-101-2570 Plate q 4
790-101-2560 Nut q
2790-101-2102 Puller (30 tons) t 1
790-101-1102 Pump t 1
3 796-627-1020 Installer t 1
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DISASSEMBLY
1. Draining oilRemove the drain plug to drain the oil from the
final drive case.
6 Final drive case: Approx. 11
2. Cover
1) Place the final drive on block [1] and remove
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
2) Disassemble the No. 1 carrier assembly
according to the following procedure.
i) Push in pin (5) to drive out shaft (6) from
carrier (7).
a After removing the shaft, remove pin
(5).
ii) Remove thrust washer (8), gear (9),
bearing (10), and thrust washer (11).
5. No. 1 sun gear shaft
Remove spacer (4), No. 1 sun gear (12), and
No. 2 sun gear (13).
7. No. 2 carrier assembly
1) Sling No. 2 carrier assembly (15) with wires,
etc. and remove it.
2) Disassemble No. 2 carrier assembly accord-
ing to the following procedure.
i) Push in pin (16) to drive out shaft (17)
from carrier (18).
a After removing the shaft, remove pin
(16).
ii) Remove thrust washer (19), gear (20),
bearing (21), and thrust washer (22).
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6. Thrust washer
Remove thrust washer (14).
8. Nut
1) Remove lock plate (23).
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
2) Using tool E1, remove nut (24).
9. Hub assembly
1) Using eyebolts [3], remove hub assembly
(25) from the travel motor.
2) Disassemble hub assembly (25) according
to the following procedure.
i) Remove bearing (26) from hub (32).
ii) Remove floating seal (27) from hub
(32).
iii) Remove bearings (28) and (29) from
hub (32).
3) Remove floating seal (30) from travel motor
(31).
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DISASSEMBLY AND ASSEMBLY FINAL DRIVE
4) Using puller [4], remove bearing (34) and
collar (33) together.
a You can remove bearing (34) and collar
(33) without using puller [4] in some cas-
es.
ASSEMBLYa Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
1. Hub assembly
1) Using the push tool, press fit bearings (28)
and (29) to hub (32).
3) Install collar (33) and bearing (34) to travel
motor (31).
4) Using tool E3, install floating seal (30)
(which is hidden and not seen behind tool
E3) to travel motor (31).
a Thoroughly degrease and dry the O-ring
and O-ring fitting surface of the floating
seal before installing.
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2) Using tool E3, install floating seal (27) to
hub (32).
a Thoroughly degrease and dry the O-ring
seal before installing.
a After installing the floating seal, checkthat its slant is less than 1 mm.
a After installing the floating seal, thinly
apply engine oil to the sliding surfaces.
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
5) Using eyebolts [3], set hub assembly (25) to
the travel motor. Using the push tool, lightly
hit the bearing to press fit it.
2. Nut
Install the nut according to the following proce-
dure.1) Rotate the hub 2 – 3 turns.
2) Using tool E2, press the bearing inner race.
a Pressing force: 29.4 – 38.3 kN {3.0 – 3.9
tons}
3) While the bearing is pressed, rotate the hub
at least 5 turns in 1 direction.
4) Release the pressing force.
5) Press the bearing again.
a Pressing force: 14.7 – 18.6 kN {1.5 – 1.9
tons}
7) Measure thickness "b" of nut (24).
8) Obtain a – b = c.
9) Using tool D1, tighten nut (24) until dimen-
sion "c" is as follows.
a Dimension "c": c mm
10) Using push-pull gauge [5], measure the tan-gential force of the hub in its revolving direc-
tion on the motor case.
a Tangential force: Max. 765 N {78 kg}
a The tangential force means the maxi-
mum force at the beginning of rotation.
+0.07 –0.03
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6) Under the condition in 5) above, measure
11) Install lock plate (23), fitting it to the motor
spline.
2 Threads of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
3. No. 2 carrier assembly
1) Assemble the No. 2 carrier assembly
according to the following procedure.
a There is a caulking mark made when the
pin was inserted at the end of carrier
side hole "h" and the inside wall of the
hole is swelled at that mark. Flatten the
swelled part in advance.
i) Install bearing (21) to gear (20) and fit
top and bottom thrust washers (19) and(22), and then set the gear assembly to
carrier (18).
ii) Aligning the pin holes of shaft (17) and
carrier, lightly hit the shaft with a plastic
hammer, etc. to install.
a When installing the shaft, revolve
the planetary gear and take care not
to damage the thrust washers.
iii) Insert pin (16).
a After inserting the pin, caulk the pin
part of the carrier.
a After assembling the carrier assembly,
4. Thrust washer
Install thrust washer (14).
5. No. 2 sun gear
Install spacer (4) and No. 2 sun gear (13).
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check that the gear (20) turns smoothly.
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
i) Install bearing (10) to gear (9) and fit top
and bottom thrust washers (8) and (11),
and then set the gear assembly to car-
rier (7).
ii) Aligning the pin holes of shaft (6) and
carrier, lightly hit the shaft with a plastic
hammer, etc. to install.
a When installing the shaft, revolve
the planetary gear and take care not
to damage the thrust washers.
iii) Insert pin (5).a After inserting the pin, caulk the pin
part of the carrier.
a After assembling the carrier assembly,
check that the gear (9) turns smoothly.
7. No. 1 sun gear shaft
Install No. 1 sun gear shaft (12).
8. Spacer
Install spacer (2).
9. Cover
Using eyebolts [2], install cover (1) and tighten
the mounting bolts.
2 Cover mounting face:
Gasket sealant (LG-6)3 Mounting bolt:
98 – 123 Nm {10 – 12.5 kgm}
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R filli ith il
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLERASSEMBLY
a Only precautions for assembling the carrier roller
assembly are explained below.
SPECIAL TOOLS
4 Carrier roller assembly: 35 kg
ASSEMBLY • Press fitting of support (2)
1) The threads of shaft (1) must be in the
range of the following figure.
2) Press fitting dimension of shaft: (Shown in
the following figure)
3) Using push tool [1], press fit support (2) toshaft (1). At this time, apply press fitting
force of at least 79 kN {8.1 tons}.
• Floating seal
a When installing the floating seal, thoroughly
clean, degrease, and dry the contact surfac-
es of the O-ring and floating seal (hatched
parts). Take care that dirt will not stick to the
floating seal contact surfaces.
a Be sure to use the installer F to insert thefloating seal assembly in the housing.
a After installing the floating seal, check that its
slant is less than 1 mm and its projection "a"
is 5 – 7 mm.
• Carrier roller
a Using tool F, apply the standard pressure to
the oil filler to check the seal for air leakage.
a Keep the following standard pressure for 10
seconds and check that the pointer of the
gauge does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
S y m b o l
Part No. Part Name
N e c e s s i t
y
Q ’ t y
N e w / R e m o
d e l
S k e t c h
F1 791-430-3230 Installer t 1
2 791-601-1000 Oil pump t 1
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DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
a Using tool F, fill the carrier roller assembly
with oil and tighten the plug.
5 Carrier roller: 170 – 180 cc (EO30-CD)
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DISASSEMBLY AND ASSEMBLY TRACK ROLLER
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLYa Only precautions for assembling the track roller
assembly are explained below.
SPECIAL TOOLS
4 Track roller assembly: 80 kg
ASSEMBLY• Floating seal
a When installing the floating seal, thoroughly
clean, degrease, and dry the contact surfac-
es of the O-ring and floating seal (hatched
parts). Take care that dirt will not stick to the
floating seal contact surfaces.
a Be sure to use the installer G to insert thefloating seal assembly in the housing.
a After installing the floating seal, check that its
slant is less than 1 mm and its projection "a"
is 5 – 7 mm.
• Track roller
a Using tool G, apply the standard pressure to
the oil filler to check the seal for air leakage.
a Keep the following standard pressure for 10
seconds and check that the pointer of the
gauge does not lower.
Standard pressure: 0.1 MPa {1 kg/cm2}
a Using tool G, fill the track roller assembly
with oil and tighten the plug.
5 Track roller: 280 – 310 cc (EO30-CD)
3 Plug: 10 – 20 Nm {1 – 2 kgm}
S y m
b o l
Part No. Part Name
N e c e
s s i t y
Q ’ t y
N e w / R e m o d e l
S k e
t c h
G1 791-630-1780 Installer t 1
2 791-601-1000 Oil pump t 1
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DISASSEMBLY AND ASSEMBLY IDLER
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLYSPECIAL TOOLS
4 Idler assembly: 250 kg
DISASSEMBLY
4. Remove floating seal (7) on the opposite side
from idler (5) and shaft and support assembly
(6).
5. Remove nut (8), pull out bolt (9), and then
remove support (10) from shaft (11).
6. Remove bushing (12) from idler (5).
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
H791-575-1520 Installer t 1
791-601-1000 Oil pump t 1
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DISASSEMBLY AND ASSEMBLY IDLER
ASSEMBLY1. Press fit bushings (12) (on both sides) to idler
(5).
2. Fit the O-ring and install support (10) to shaft
(11) with bolt (9) and tighten nut (8).
a Install the shaft with the UP mark up.
3 U i t l H i t ll fl ti l (7) t idl (5)
a When installing the floating seal, thoroughly
clean, degrease, and dry the contact surfac-
es of the O-ring and floating seal (hatched
parts). Take care that dirt will not stick to the
floating seal contact surfaces.
a Be sure to use the installer H to insert the
floating seal assembly in the housing.
a After installing the floating seal, check that itsslant is less than 1 mm and its projection "a"
is 9 – 11 mm.
4. Install shaft and support assembly (6) to idler
(5).
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3. Using tool H, install floating seal (7) to idler (5)
and shaft and support assembly (6).
5. Similarly, using too H, install floating seal (4) to
idler (5) and support (3).
DISASSEMBLY AND ASSEMBLY IDLER
a Coat the sliding surface of the floating seal
with oil and take care that dirt will not stick to
it.
a Degrease the floating seal and the O-ring
contact surfaces.
6. Fit the O-ring, set support (3), install bolt (2), and
tighten nut (1).
7. Add oil and tighten the plug.
5 Quantity of oil:
Approx. 345 ± 10 cc (EO-30CD)
3 Plug: 130 – 180 Nm {13 – 18 kgm}
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DISASSEMBLY AND ASSEMBLY RECOIL SPRING
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLYSPECIAL TOOLS
4 Recoil spring (Excluding idler): 900 kg
DISSASSEMBLY
1. Remove piston assembly (2) from recoil spring
assembly (1).
2. Disassembly of recoil spring assembly
1) Set tool J1 to recoil spring assembly (1).
k Since the installed load of the spring is large
and dangerous, set the tool securely.
a Installed load of spring:
239.037 kN {24,375 kg}
2) Apply oil pressure gradually to compress the
spring and remove lock plate (3) and nut (4).a Compress the spring to a degree that
you can loosen the nut.
a Release the oil pressure gradually to re-
duce the spring tension to 0 (zero).
a Free length of spring: 845.3 mm
3) Remove yoke (6), cylinder (7), collar (8),
and dust seal (9) from spring (5).
3 Disassembly of piston assembly
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
J
1
791-685-8006 Compressor t 1
791-635-3160 Extension t 1
790-101-1600Cylinder
(686 kN {70 t}) t 3
790-101-1102 Pump t 3
2
790-201-1500 Push tool kit 1
• 790-201-1660 • Plate
• 790-101-5021 • Grip
• 01010-50816 • Bolt
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3. Disassembly of piston assembly1) Remove lock plate (11) from piston (10),
and then remove valve (12).
2) Remove snap ring (13), U-packing (14), and
ring (15).
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
ASSEMBLY
1. Assembly of piston assembly
1) Install ring (15) and U-packing (14) to piston
(10) and secure them with snap ring (13).
2) Tighten valve (12) temporarily and secure it
with lock plate (11)
2) Install cylinder (7), collar (8), and yoke (6) to
spring (5), and then set them to tool J1.
2 Sliding parts of cylinder:
Grease (G2-LI)
3) Apply oil pressure gradually to compress the
spring and tighten nut (4) so that installed
length of the spring will be "a", and then
secure it with lock plate (3).
a Installed length of spring "a":
Approx. 690 mm
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with lock plate (11).
2. Assembly of recoil spring assembly
1) Using tool J2, install dust seal (9) to cylinder
(7).4) Remove recoil spring assembly (1) from tool
J1.
3. Install piston assembly (2) to recoil spring
assembly (1)
DISASSEMBLY AND ASSEMBLY TRACK SHOE
EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLYSPECIAL TOOLS
EXPANSION OF TRACK SHOE1. Start the engine and set the master pin to above
the idler.
2. Remove track shoes (2) on the right and left
sides of master pin (1). [*1]
3. Lower the work equipment to the ground and
loosen lubricator (3) to slacken the track shoe.
[*2]k Since the internal pressure of the adjust-
ment cylinder is very high, do not loosen the
lubricator more than 1 turn. If the grease
does not come out sufficiently, move the
machine forward and in reverse.
4. Using tool K, remove master pin (1). [*3]
5. Move the master pin forward and set block [1]
under the track shoe in front of the idler.
6. Pull out pusher K.
7. Move the machine in reverse slowly to expand
the track shoe. [*4]
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
K
791-650-3000 Remover andinstaller
t 1
790-101-1300Cylinder (980
kN {100 t}) t 1
790-101-1102 Pump t 1
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DISASSEMBLY AND ASSEMBLY TRACK SHOE
INSTALLATION OF TRACK SHOE • Carry out installation in the reverse order to
expansion.
[*1]
2 Mounting bolt: Anti-seizure com-
pound (MARUZEN MOLYMAX No. 2or equivalent)
3 Mounting bolt: Tighten the 4 bolts first
to 392 ± 39 Nm {40 ± 4 kgm}. Check
that the mating faces are fitted, then
retighten each bolt by 120° ± 10°.
[*2]
a Adjust the tension of the track shoe. For de-
tail, see TESTING AND ADJUSTING, Test-
ing and adjusting track shoe tension.
3 Tightening torque for lubricator:
58.8 – 88.3 Nm {6 – 9 kgm}
[*3]
a Using the tool, press fit the master pin so that
its projection "a" will be as follows.• Dimension "a": 4.4 ± 2 mm
2 Apply grease to the contact faces of
dust seal (5) and bushing (4) (all over
the end face of the dust seal or bush-
ing) (parts marked Q). Do not apply
grease to the pars marked X, however.
R: Detail of regular pin position
M: Detail of master pin position(Pins are not inserted, however)
[*4]
Set the track shoe and sprocket (4) as shown in
the following figure (on both right and left sides).
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2 Supply grease to the space between
the bushing and pin so that filling rate
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNITASSEMBLY
SPECIAL TOOLS
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Swing the upper structure by 90°.
2. Open the engine hood.
3. Connect tool Q to cap [1] and collect the air con-
ditioner refrigerant.
4. Remove rear covers (1), (2), (3), and (4).
5.Remove duct (5), cover (6), and plate (7).
6. Remove plate (8) and duct (9).
a Remove the duct lock clip.
7. Remove ducts (10) and (11).
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
Q
799-703-1200 Service tool kit t 1
799-703-1100Vacuum pump
(100V) t 1
799-703-1110Vacuum pump
(220V) t 1
799-703-1120Vacuum pump
(240V)
t 1
799-703-1401Gas leak detec-
tor t 1
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8. Disconnect connectors D01 (12), D02 (13), C09
(14), R22 (15), R20 (16), and K19 (17).
9. Remove and sling controller (18).
10. Remove plate (19).
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
12. Remove the air conditioner unit undercover.
a Part A
13. Remove mounting bolt (24) and connector (25).
[*1]
14. Disconnect heater hoses (22) and (23) and air
conditioner tube (26). [*1]
a Put tags to the disconnected hoses and
tubes to prevent a mistake in re-connecting
them.
INSTALLATION • Carry out installation in the reverse order to
removal.
a When installing the air conditioner circuit
hoses, take care that dirt, water, etc. will not
enter them.
a When connecting each air conditioner hose,
check that the O-ring is fitted to the joint.a Check that each O-ring is free from flaw and
deterioration.
[*1]
a Apply compressor oil (ND-OIL8) to the
threads of the refrigerant pipe joints and
tighten each nut with double spanner.
3 Hose clamp (M6 bolt):8 – 12 Nm {0.8 – 1.2 kgm}
3 Hose screw of M16 x 1.5:
12 – 15 Nm {1.2 – 1.5 kgm}
3 Hose screw of M22 x 1.5:
20 – 25 Nm {2.0 – 2.5 kgm}
3 Hose screw of M24 x 1.5:
30 – 35 Nm {3.0 – 3.5 kgm}
• Charging air conditioner with refrigerant gas
Using tool Q, charge the air conditioner circuit
with refrigerant (HFC R134a) from the compres-
sor.
a Quantity of refrigerant: 950 ± 50 g
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15. Remove the 7 mounting bolts and air condi-
tioner unit assembly (27).
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
REMOVAL AND INSTALLATION OF OPERATOR’S CAB
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove rear covers (1), (2), (3), and (4).
2. Remove duct (5), cover (6), and plate (7).
3. Remove plate (8), duct (9) and the element.
a Remove the duct lock clip.
6. Disconnect connectors M71 (15), H10 (16), H11
(17), and H12 (18).
7. Disconnect upper and lower duct joints (19) and
(20).
8. Remove controller sub-plate (21) and incline it
against the air conditioner.
9. Remove cover (22) and floor mat (23).
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4. Remove clip (10) and disconnect cab wiring
connectors M45 (11), H08 (12), and H09 (13).
5. Remove air conditioner connector plate (14).
10. Move right console (24) into the cab.
11. Remove monitor panel undercover (25).
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
12. Disconnect cab wiring connector W04 (26)
(Wiper motor).
13. Remove ducts (27) and (28).
a Both (27) and (28) are 2 in number.
a Cut the tie-wrap on the monitor wiring har-
ness.
14. Remove cover (29) and monitor assembly (30).
15. Disconnect radio antenna (31).
16. Remove clip (32) and take wiring harness (33)
out of grommet (34).
20. Using lever block [1], lift off operator's cab
assembly (39).
4 Operator's cab assembly: 300 kg
21. When starting the engine while the operator's
cab is removed (for transportation, etc.), use the
following brackets.
1) Bracket (41) for controller (40)
Part No.: 208-53-13920
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17. Take grommet (35) out of the right front of the
cab.
18. Disconnect the windshield washer hose from
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
2) Bracket (42) for monitor panel assembly
(30)Part No.: 208-53-13910
INSTALLATION
• Carry out installation in the reverse order toremoval.
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DISASSEMBLY AND ASSEMBLY MONITOR
REMOVAL AND INSTALLATION OF MONITOR ASSEMBLY
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove cover (1) and disconnect wiring con-
nector P15 of air conditioner sunlight sensor (2).
a Raise and remove the cover.
2. Remove the 3 mounting screws and monitor
assembly (3).
a Disconnect monitor panel wiring connectors
P01, P02, and P70 before removing the
monitor assembly.
INSTALLATION • Carry out installation in the reverse order to
removal.
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DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
REMOVAL AND INSTALLATION OF PUMP CONTROLLER
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove covers (1), (2), and (3).
2. Disconnect pump controller wiring connectors
C01 (4), C02 (5), and C03 (6).
3. Remove the 4 mounting bolts and pump control-
ler assembly (7).
INSTALLATION • Carry out installation in the reverse order to
removal.
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DISASSEMBLY AND ASSEMBLY ENGINE CONTROLLER
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open the right side cover (cooler).
2. Remove bracket (1).
3. Remove the 4 mounting bolts and engine con-
troller assembly (2).
4. Disconnect engine controller wiring connectorsCB1 (3), CB2 (4), and CB3 (5).
INSTALLATION • Carry out installation in the reverse order to
removal.
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DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL AND INSTALLATION OF REVOLVING FRAMEASSEMBLY
REMOVALk Extend the arm and bucket fully, lower the work
equipment to the ground, and set the safety lock
lever to the LOCK position.
1. Remove the work equipment assembly. For
details, see REMOVAL AND INSTALLATION OFWORK EQUIPMENT.
2. Remove the counterweight assembly. For
details, see REMOVAL AND INSTALLATION OF
COUNTERWEIGHT.
3. Disconnect 4 boom cylinder hoses (1).
a Plug the hoses to stop oil.
4. Sling boom cylinder assembly (2) temporarily.
5. Remove plate (3) and pin (4) and lift off boom
cylinder assembly (2).
a Remove the boom cylinder on the oppositeside similarly.
6. Disconnect 7 hoses (5) – (11).
• (5): Center swivel joint (Port D) – Swing mo-
tor (Port T)
• (6): Center swivel joint (Port D) – Hydraulic
tank
• (7): Center swivel joint (Port E) – Solenoid
valve
• (8): Center swivel joint (Port B) – Control
valve left travel (Port B2)
• (9): Center swivel joint (Port D) – Controlvalve right travel (Port B5)
• (10):Center swivel joint (Port A) – Control
valve left travel (Port A2)
• (11):Center swivel joint (Port C) – Control
valve right travel (Port A5)
7. Pull out pin (12) on the center swivel joint side
and disconnect the lock plate from the center
swivel joint.
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4 Boom cylinder assembly: 360 kg
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
8. Remove 29 mounting bolts (13), leaving 3 each
at the front and rear sides.
9. Using a lever block, sling the revolving frame
assembly temporarily, balancing it in each direc-
tion.
a Put wood liners to the rear side of the frame.• Rough standard length of sling:
Front: 8 m in total
Rear: 6 m
a If the engine hood interferes with the sling,
erect the engine hood, referring to REMOV-
AL AND INSTALLATION OF RADIATOR
ASSEMBLY.
10. Remove the remaining 6 bolts and lift off revolv-ing frame assembly (14). [*1]
k When removing the revolving frame assem-
bly, take care that it will not interfere with the
center swivel joint assembly.
4 Revolving frame assembly: 10,000 kg
INSTALLATION
• Carry out installation in the reverse order toremoval.
[*1]
• Match the soft zone point (P) of the outer
race and the soft zone point (S) of the inner
race.
2 Mating face of swing circle:
Gasket sealant (LG-6)
2 Threads of revolving frame mountingbolt: Adhesive (LT-2)
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DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
3 Revolving frame mounting bolt
1. Tighten the bolts marked with A (at 4 places)according to the following steps 1) – 3).
1) Tighten each bolt to 392 Nm {40 kgm} first.
2) Then, tighten the bolt by 90° ± 5°.
• Make a mark on the bolt head with a
marker pen (to check the angle).
3) The tightening torque of the bolt tighten in 2)
above must be 1,176 Nm {120 kgm} or
larger.
2. Tighten each bolt 208-25-71230 which is not
marked withA according to above steps 1) – 3).If the tightening torque reaches 2,254 Nm {230
kgm} before completing the above steps and the
tightening angle is 35° – 95°, however, stop
tightening.
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a Marks P and S are the soft zone points.
• Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
t Th h k th il l l i
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL AND INSTALLATION OF COUNTERWEIGHTASSEMBLY
REMOVAL1. Set eyebolt [1] to counterweight assembly (1).
2. Remove 4 mounting bolts (2). [*1]
a Check where shims have been used.
3. Lift off counterweight assembly (1). [*2]
a When lifting off the counterweight, take care
not to strike it against the engine, radiator
and cooler assembly, etc.
4 Counterweight assembly: 9,500 kg
INSTALLATION • Carry out installation in the reverse order to
removal.
a If heat insulation cover (3) of the engine com-
partment is flattened, replace it.
[*1]
2 Threads of mounting bolt:
Adhesive (LT-2)
3 Mounting bolt:
3,430 – 4,212 Nm {350 – 430 kgm}
[*2]
a Installation and adjustment of counterweight
1) Adjust the level difference from the
exterior parts (horizontal clearance) with
shims.
• Kinds of shim thickness: 0.5 mm, 1
mm
2) Insert the shims so that the clearance
between the door and counterweightand that between the revolving frame
and counterweight will be 10 ± 5 mm
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and counterweight will be 10 ± 5 mm
evenly.
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL1. Remove 3 lower covers (1).
2. Drain the oil from the hydraulic tank.
6 Capacity of hydraulic tank:
Approx. 335
3. Open engine hood (2) and remove control valve
top cover (3).
7. Disconnect drain hoses (8), (9), and (10).
8. Disconnect 2 clamps (11).
9. Remove side cover (12).
10. Remove sensor (13).
11. Disconnect suction tube (14).
12. Sling the hydraulic tank assembly temporarily
and remove 6 mounting bolts (15).
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4. Remove cover (4).
5. Disconnect drain hoses (5) and (6). 13. Lift off hydraulic tank assembly (16).
4 H d li k bl 200 k
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION • Carry out installation in the reverse order to
removal.
• Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through thesystem. Then, check the oil level again.
5 Capacity of hydraulic tank:
Approx. 335
Quantity of oil in tank (Center of oil
level gauge): 248
• Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL AND INSTALLATION OF HYDRAULIC PUMP
ASSEMBLY
SPECIAL TOOLS
REMOVALk Disconnect the cable from the negative (–) ter-
minal of the battery.
k Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank.
a Put tags to the disconnected hoses and tubes to
prevent a mistake in re-connecting them.
1. Remove 2 lower covers (1).
3. Drain the oil from the flywheel housing.
4. Open the main pump side cover.
5. Open the engine hood.
6. Lift off covers (2) and (3) together.
7. Remove cover (4).
8. Remove stay (5).
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N
e w / R e m o d e l
S k e t c h
C796-460-1210 Oil stopper q 1
796-770-1320 Adapter q 1
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2. Remove the hydraulic tank strainer. Using tool
C, stop the oil.
a When not using tool C, remove the drain plug
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
9. Disconnect the following 2 pump wiring connec-
tors.• (6): V22 (PC-EPC solenoid valve)
Band color: Red
• (7): V21 (LS-EPC solenoid valve)
Band color: White
10. Disconnect the following 10 hoses and 1 tube.
• (8): EPC basic pressure port hose
(Band color: Yellow)
• (9): Rear pump pressure input port hose(Band color: Red)
• (10): Rear pump discharge port hose
• (11): Front pump discharge port hose
• (12): Drain port hose
• (13): Front load pressure input port hose
• (14): Rear load pressure input port hose
(Band color: Red)
• (15): Front pump pressure input port hose
• (16): Pump suction port tube
11. Sling hydraulic pump assembly (18) temporarily
and remove 12 mounting bolts (17).
12. Lift off hydraulic pump assembly (18). [*1]
4 Hydraulic pump assembly: 255 kg
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DISASSEMBLY AND ASSEMBLY OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT
REMOVAL AND INSTALLATION OF OIL SEAL IN HYDRAULIC
PUMP INPUT SHAFT
REMOVAL1. Remove the hydraulic pump assembly. Refer to
the REMOVAL OF HYDRAULIC PUMP
ASSEMBLY section.
2. Remove snap ring (1) and then remove spacer
(2).
3. Pry off oil seal (3) with a screwdriver. [*1]
a When attempting to pry off the seal, do not
damage the shaft.
INSTALLATION • Install in reverse order of removal.
[*1]
2 Oil seal lip portion: Grease (G2-LI)
2 Oil seal outer circumference:
Grease (G2-LI)a Coat the oil seal outer circumference thinly
with grease.
a Press-fit oil seal (3), using tool .
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY
REMOVALk Lower the work equipment to the ground and
stop the engine. Then, loosen the hydraulic oil
filler cap slowly to release the internal pressure
of the hydraulic tank and set the safety lock lever
to the LOCK position..
a Put tags to the disconnected hoses and tubes toprevent a mistake in re-connecting them.
1. Open engine hood (1).
2. Remove control valve top cover (2).
3. Remove partition covers (3), (4), and (5)
between the engine and control valve.
6. Disconnect the following 4 control valve hoses:
• (16): Port PPS1 hose (Front pump)
• (17): Port PLS2 hose (Hose band: Red)• (18): Port PLS1 hose
• (19): Port PX1 hose (Hose band: Blue)
7. Remove relay bracket (20) and clamp (21).
8. Disconnect drain hose (22). (To tank)
9. Disconnect the following 6 left PPC hoses.
• (23): In order from top
Bucket CURL (Hose band: White)
Left travel REVERSE
Boom RAISE (Hose band: Green)
Left SWING (Hose band: Red)
Right travel REVERSE (Hose band: Blue)
Arm DUMP (Hose band: Yellow)
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
10. Disconnect 4 boom hoses (24).
11. Remove boom tube clamps (25) and (26).
12. Disconnect port TSW hose (27) (Swing motor
port S).
13. (28): In order from top
Remove port A-1 tube (Boom Hi bottom side).
Remove port A1 tube (Bucket bottom side).
Disconnect port A2 hose (Swivel joint port A).
After removing the hoses from ports B, remove
port A3 tube (Boom bottom side).
Remove port A4 hose (Swing motor port MB).
Disconnect port A5 hose (Swivel joint port C).
Remove port A6 tube (Arm head side).
14. (29): In order from top
Disconnect port B-1 hose (Arm Hi bottom side).
Disconnect port B1 hose (Bucket head side).
Disconnect port B2 hose (Swivel joint port B).
Remove port B3 tube (Boom head side).
Remove port B4 hose (Swing motor port MA).
Disconnect port B5 hose (Swivel joint port D).
Remove port B6 tube (Arm bottom side).
15. Disconnect the following 6 right PPC hoses.
• (30): Bucket DUMP (Hose band: Black)• (31): Left travel FORWARD
(Hose band: Red)
• (32): Boom LOWER (Hose band: Brown)
• (33): Right SWING
• (34): Right travel FORWARD
(Hose band: Green)
• (35): Arm IN (Hose band: Blue)
16. Disconnect the following 3 control valve hoses.
a Do not disconnect hose C.
• (36): Port BP5 hose (To solenoid)
• (37): Port PX2 hose
• (38): Port TS hose
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
17. Sling control valve assembly (40) temporarily
and remove 3 mounting bolts (39).
18. Lift off control valve assembly (40).
4 Control valve assembly: 250 kg
INSTALLATION
• Carry out installation in the reverse order toremoval.
• Refilling with oil (Hydraulic tank)
Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then, check the oil level again.
• Bleeding air
See TESTING AND ADJUSTING, Bleeding air from each part.
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DISASSEMBLY AND ASSEMBLY CONTROL VALVE
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY
a Only precautions for assembling the pressure
compensation valve assembly and control valve
assembly are explained below.
SPECIAL TOOLS
REPLACEMENT PROCEDURE FOR PRES-
SURE COMPENSATION VALVE SEALa Since there many types of the pressure compen-
sation valves, make a mark on each valve to in-
dicate from where it was removed.
1. Remove piston (2), plug (3), and spring (4) from
pressure compensation valve (1).
2. Remove seal (5) and O-ring (6) from piston (2).
a There many types of the pistons.
a Clean the pressure compensation valve
thoroughly. Then, using the tool, install sealsas shown in the figure.
3. Fit O-ring (6) to piston (2).
4. Set tool L1 to piston (2) and push it in with your
hand slowly so that seal (5) will expand evenly.
a You may push in the seal to the flat part of
the tool first, and then install the tool to thepiston and push in the seal further.
S y m b o l
Part No. Part Name
N e c e s
s i t y
Q ’ t y
N e w / R e m o d e l
S k e t
c h
L
1
796-946-1310 Guide 21.81
(For 723-46-40100, 723-46-40601)
796-946-2110 Guide 20.91
(For 723-46-44100)
796-946-2210 Guide 20.61
(For 723-46-45100, 723-46-45500)
2
796-946-1320 Guide1
(For 723-46-40100, 723-46-40601)
796-946-1420 Guide 21.61
(For 723-46-42800)
796-946-2120 Guide1
(For 723-46-44100)
796-946-2220 Guide1
(For 723-46-45100, 723-46-45500)
3
796-946-1330 Sleeve1
(For 723-46-40100, 723-46-40601)
796-946-1430 Sleeve1
(For 723-46-42800)
796 946 2130 Sleeve
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796-946-2130 Sleeve1
(For 723-46-44100)
796-946-2230 Sleeve1
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
5. Set tool L2 to piston (1) for other seal (3) and
push it in with your hand slowly so that seal (3)
will expand evenly.
a You may push in the seal to the flat part of
the tool first, and then install the tool to the
piston and push in the seal further.
6. Install correcting tool L3 to piston (1) for about 1
minute to fit seals (2) and (3).
a Check that the seal are not projected or bro-
ken.
7. Fit plug (3) and spring (4) to piston (2) and
ASSEMBLY • Apply engine oil to the sliding surfaces of the
parts before installing.
• When installing spools (7) and (10) in the valve
chamber, direct drilled holes (8) and (11) toward
cylinder ports (9) and (12).
• Install filters (13) to the bottom of ports PLS1
and PLS2 as shown below.
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p g ( ) p g ( ) p ( )
assemble pressure compensation valve (1).
a If these parts are difficult to install, do not
push them in forcibly, but install them to cor-
recting tool L3 to fit the seals and then install
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
• Control valve top and bottom covers
2 Mating faces of control valve top and
bottom covers:
SEALEND 242 or equivalent
a Use 2 washers (W2) each for only 2 places
of the control valve top cover.
• Tighten the mounting bolts of the control valve
top and bottom covers in the following order.
(A o D o C o B)
3 Mounting bolt of control valve top and
bottom covers:
156.9 – 176.5 Nm {16 – 18 kgm}
3 Mounting bolt of boom Hi check valve,
quick return valve, lock valve, and armplate: 58.8 – 73.6 Nm {6 – 7.5 kgm}
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• Merge-divider valve
2 Mating face of merge-divider valve:
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
3 Mounting bolts of back-pressure valve,
boom Hi check valve, quick returnvalve, lock valve and arm plate:
58.8 – 73.6 Nm {6 – 7.5 kgm}
• Pressure compensation valve
a When installing each pressure compensa-
tion valve, check the mark made when it was
removed.
• Main relief valve assembly After installing the main relief valve to the control
valve, see TESTING AND ADJUSTING, Testing
and adjusting oil pressures in work equipment,
swing, and travel circuits.
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DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL AND INSTALLATION OF CENTER SWIVEL JOINT
ASSEMBLY
REMOVALk Replace the remaining pressure in the hydraulic
circuit. For details, see TESTING AND AD-
JUSTING, release of remaining pressure in hy-
draulic circuit.
a Mark all the piping with tags to prevent mistakes
in the mounting position when installing.
1. Disconnect six hoses (1) through (6) between
travel motor and center swivel joint.
• (1): Center swivel joint (T port) – Left travel
motor (T port)
• (2): Center swivel joint (T port) – Right trav-
el motor (T port)
• (3): Center swivel joint (B port) – Left travel
motor (PA port)• (4): Center swivel joint (D port) – Right trav-
el motor (PB port)
• (5): Center swivel joint (A port) – Left travel
motor (PB port)
• (6): Center swivel joint (C port) – Right trav-
el motor (PA port)
2. Disconnect nine hoses (7) through (15).
3. Pull out pin (16) on the side of center swivel joint
and remove the jam plate from the center swivel
joint.
4. Remove four mounting bolts (17).
5. Remove center swivel joint assembly (18). [*1]
4 Center swivel joint assembly: 40 kg
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• (7): Center swivel joint (E port) – Left travel
motor (P port)
• (8): Center swivel joint (E port) – Right trav-
el motor (P port)
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
INSTALLATION • Install in reverse order of removal.
[*1]
Install the center swivel joint facing in the direc-
tion shown in the diagram.
(The diagram shows the machine as seen fromabove)
• Refilling with oil (hydraulic tank)
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
Bleed the air from the travel motor. For details
see TESTING AND ADUSTING, Air Bleeding of
Various Parts.
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DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
DISASSEMBLY AND ASSEMBLY OF OF CENTER SWIVEL JOINT
ASSEMBLYSPECIAL TOOLS
DISASSEMBLY
1. Remove cover (1).
2. Remove snap ring (2).
3. Using tool M, pull out swivel rotor (4) and ring (3)
from swivel shaft (5).
4. Remove seal (6) from swivel shaft (5).
5. Remove O-ring (7) and slipper seal (8) from
swivel rotor (4).
ASSEMBLY1. Assemble slipper seal (8) and O-ring (7) to
swivel rotor (4).
2. Assemble seal (6) in swivel shaft (5).
3. Set swivel shaft (5) to block, then using push
tool, tap swivel rotor (4) with a plastic hammer toinstall.
2 Contact surface of rotor, shaft:
Grease (G0-LI or G2-LI)
a When installing the rotor be extremely care
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N
e w / R e m o d e l
S k e t c h
M
790-101-2501 Push puller q 1
• 790-101-2510 • Block 1
• 790-101-2520 • Screw 1
• 791-112-1180 • Nut 1
• 790-101-2540 • Washer 1
• 790-101-2630 • Leg 2
• 790-101-2570 • Plate 4
• 790-101-2560 • Nut 2
• 790-101-2650 • Adapter 2
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a When installing the rotor, be extremely care-
ful not to damage the slipper seal and the O-
ring.
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT PPC VELVE
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT PPC
V ALVE ASSEMBLYa Only precautions for assembling the work equip-
ment PPC valve assembly are explained below.
ASSEMBLY • Work equipment PPC valve assembly
a Install springs (11 ) with the small-diameter
(inside diameter) end on the shim (12) side.
a Springs (10 ) having different number of
turns are used for the following hydraulic
ports. Take care when installing them.
a When installing pistons (8), apply grease to
their outside and the inside of the valve body
holes.
3 Mounting bolt of plate (5):
11.8 – 14.7 Nm {1.2 – 1.5 kgm}
2 Sliding parts of joint (4):
2 – 4 cc of Grease (G2-LI)
2 Female threads of body (A):
Adhesive (LT-2)
a Apply a drop (about 0.02 g) of LOCTITE to
each of the 2 threaded parts of the body as
shown in the figure, and then tighten joint (4).
3 Joint (4): 39 – 49 Nm {4 – 5 kgm}
a Observe the tightening torque of the joint.
2 Contact parts of piston and disc
(2): Grease 0.3 – 0.8 cc (G2-LI)
3 Nut (1): 69 – 88 Nm {7 – 9 kgm}
a When installing disc (2), adjust the play to
0.5 – 3mm at 200 mm from the turning center
of the lever.
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p g
Installed height: 31.9 mm (Common to all
springs)
Installed load:
DISASSEMBLY AND ASSEMBLY TRAVEL PPC VALVE
DISASSEMBLY AND ASSEMBLY OF TRAVEL PPC VALVE
ASSEMBLY
DISASSEMBLYa Only precautions for assembling the travel PPC
valve assembly are explained below.
ASSEMBLY • Travel PPC valve assembly
a Insert shim (3) of the thickness and quantity
checked when disassembled.
Standard shim thickness 0 3 mm
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Standard shim thickness: 0.3 mm
a Since spring (4) is not symmetric vertically,
install it with the small-diameter (inside diam-
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER
ASSEMBLYSPECIAL TOOLS
DISASSEMBLY1. Piston rod assembly
1) Remove the piping from the cylinder assem-
bly.
2) Remove the mounting bolts and disconnect
cylinder head assembly (1).
3) Pull out piston rod assembly (2).
a Put a container under the cylinder to re-
ceive oil.
4) Disassemble the piston rod assembly
according to the following procedure.
i) Set piston rod assembly (2) to tool N1.
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
N
1 790-502-1003Cylinder repair
stand t 1
2790-102-4300
Wrench assem-
bly t 1
790-102-4310 Pin t 2
3 790-720-1000 Expander q 1
4
796-720-1680 Ring (For boomand bucket) q 1
07281-01589
Clamp (For
boom and
bucket)
q 1
796-720-1690 Ring (For arm) q 1
07281-01919 Clamp (For arm) q 1
5
790-201-1702 Push tool kit t 1
• 790-201-1851• Push tool
(For bucket)1
• 790-201-1861• Push tool
(For boom)1
• 790-201-1871• Push tool
(For arm)1
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
790-201-1500 Push tool kit 1
790 101 5021 G i 1
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ii) Remove piston assembly lock screw
(3).
• 790-101-5021 • Grip 1
• 01010-50816 • Bolt 1
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
a If screw (3) is so caulked that you cannot
remove it, tighten it temporarily and tap
the threads on it, and then remove it.
iii) Using tool N2, remove piston assembly
(4).
• When not using tool N2, loosen the
piston assembly by using the drilledholes (Ø10: 2 places) (in which the
pins of N2 are inserted in the follow-
ing figure).
iv) Remove plunger (5).• Perform this work for only the boom
and arm cylinder.
v) Remove collar (6).
Perform this work for only the boom
vii) Remove cap (8), 11 balls (9), and
plunger (10).
• Perform this work for only the arm
cylinder.
a Since cap (8) is made of nylon, tight-
en a screw into it and pull it with pli-
ers.
2. Disassembly of piston assembly
1) Remove rings (11).
2) Remove wear rings (12).
3) Remove piston ring (13).
4) Remove the O-ring and backup rings (14).
3. Disassembly of cylinder head assembly
1) Remove the O-ring and backup ring (15).
2) Remove snap ring (16) and dust seal (17)
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• Perform this work for only the boom
and arm cylinder.
vi) Remove head assembly (7).
2) Remove snap ring (16) and dust seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLYa Take care not to damage the packings, dust
seals, O-rings, etc.
a Clean the all parts. After installing them, cover
the piping ports and pin holes to prevent dirt from
entering.
a Do not insert each backup ring forcibly, but warm
it in water at 50 – 60°C and then insert it.
1. Assembly of cylinder head assembly
1) Using tool N5, press fit bushing (20).
2) Install buffer ring (19).
3) Install rod packing (18).
4) Using tool N6, install dust seal (17) and
secure it with snap ring (16).
5) Install backup ring and O-ring (15).6) Install snap ring (21).
2. Assembly of piston assembly
1) Using tool N3, expand piston ring (13).
a Set piston ring (13) to tool N3 and turn
the handle 8 – 10 times to expand the
piston ring.
2) Set tool N4 and contract piston ring (13).
3) Install backup ring and O-ring (14).4) Install wear ring (12).
5) Install ring (11).
a Do not increase the closed gap of the
ring too much.
2 Ring groove: Grease (G2-LI)
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DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
3. Piston rod assembly
1) Set the piston rod to tool N1.
2) Install cylinder head assembly (7) to the pis-
ton rod.
3) Fit the O-ring and backup ring to collar (6),
and then install them.
• Perform this work for only the boom and
arm cylinders.
4) Install plunger (5).
• Perform this work for only the boom and
arm cylinders.
5) Set plunger (10) to the piston rod. Install 11
balls (9) and secure them with cap (8).
a After installing the plunger, check that it
has a little play at its end.
• Perform this work for only the arm
cylinder.
6) Assemble piston assembly (4) according to
the following procedure.
• When reusing the rod and piston as-
sembly (4)
i) Tighten piston assembly (4). Then,
using tool N2, tighten piston assembly
(4) until the screw holes are aligned.
a Remove the burrs from the threads
with a file.
Go to iv).
• When replacing either or both of the
rod and piston assembly (4) with new
ones
a Make a mark of the cushion plug position
on the end of the rod having the bottom
cushion.
• Perform this work for only the arm
cylinder.
ii) Using the tool, tighten piston assembly
(4) until it reaches the end of the rod.
3 Piston assembly:
294 ± 29.4 Nm {30 ± 3.0 kgm}
a After tightening the piston, checkthat plunger (5) has some play.
• Perform this work for only the boom
and arm cylinders.
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DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
iii) Make a screw hole to install screw (3).
a Apply a drill to the V-groove of the
threaded parts of piston (4) and rod
(2) and make a hole.
a When making a hole on the cylinder
(arm cylinder) having the bottom
cushion, make it around the cushion
plug.
• Dimensions of screw hole (mm)
iv) Tighten screw (3).
a Clean the parts thoroughly and re-
move metal chips, dirt, etc.
2 Threads of screw:
Adhesive (LOCTITE No. 262)
3 Screw:
58.9 – 73.6 Nm {6 – 7.5 kgm}
v) Caulk the threaded part by 4 placeswith a punch.
7) Install piston rod assembly (2).
a Set the abutment joint of the ring at a
side and insert the piston rod, aligning it
with the cylinder tube.
a After inserting the piston rod, check that
the ring is not broken or removed, and
then insert to the end.
8) Tighten the mounting bolts of cylinder head
assembly (7).
3 Mounting bolt:
9) Install the piping.
Tap drill diameter Tap to be used
10.3 12 x 1.75
Tap drill
hole depth
Tapping
depth
Bucket/Boom 27 20
Arm 36 29
Cylinder
nameTightening torque
Bucket 530 ± 78.5 Nm {54.0 ± 8 kgm} Arm 892 ± 137 Nm {91.0 ± 14 kgm}
Boom 530 ± 78.5 Nm {54.0 ± 8 kgm}
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DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL AND INSTALLATION OF WORK EQUIPMENT
ASSEMBLYSPECIAL TOOLS
REMOVALk Extend the arm and bucket fully, lower the work
equipment to the ground, and set the safety lock
lever to the LOCK position.
k See TESTING AND ADJUSTING, Releasing re-
sidual pressure in hydraulic circuit.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2) temporarily
and remove lock bolt and nut (3). [*1]
3. Remove plate (4) and head pin (5). [*2]
4. Start the engine and retract the piston rod.
a Bind the rod with wires, etc. so that it will not
be extracted and lower it onto a stand or put
a wood block to the bottom side so that the
cylinder will not lower. When putting the
wood block, remove the grease fitting on the
bottom side.
a Disconnect the boom cylinder on the oppo-site side similarly.
a When slinging the boom cylinder, if the sling
interferes with the work equipment lamp, re-
move the work equipment lamp.
5. Disconnect intermediate connector A42 (6) for
the work equipment lamp.
6. Disconnect 3 arm cylinder hoses (7) and 2
bucket cylinder hoses (8).
a Put oil stopper plugs and secure the hoses to
the valve side with ropes.
7. Sling work equipment assembly (12) tempo-
rarily.
8. Remove cover (9), plate (10), and foot pin (11)
to disconnect work equipment assembly (12)
S y m b o l
Part No. Part Name
N e c e s s i t y
Q ’ t y
N e w / R e m o d e l
S k e t c h
P
796-670-1100 Remover q 1
• 796-670-1110 • Sleeve 1
• 796-670-1120 • Plate 1
• 796-670-1130 • Screw 1
• 796-870-1110 • Adapter 1
• 01643-33080 • Washer 1
• 01803-13034 • Nut 1
790-101-4000Puller (490 kN
{50t}, long) q 1
790-101-1102Pump (294 kN
{30t}) q 1
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p ( ) p ( ) [ ]
a Check the quantity and positions of the in-
serted shims.
to disconnect work equipment assembly (12).
[*3]
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
• When removing with tool P
Remove plate (10). Sling and set tool P and
remove foot pin (11) to disconnect work
equipment assembly (12).
a Check the quantity and positions of the in-
serted shims.
9. Move the machine in reverse to remove work
equipment assembly (12).
4 Work equipment assembly:
PC400-7, PC400LC-7: 7,400 kg
PC450-7, PC450LC-7: 8,400 kg
INSTALLATION • Carry out installation in the reverse order to
removal.
[*1]
a Tighten the locknut so that clearance "a" be-
tween the plate and nut will be 0.5 – 1.5 mm.
[*2]
2 Inside wall of bushing before assem-
bling pin:
Anti-friction composition (LM-P)
2 Greasing after assembling pin:Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.
a Adjust the shim thickness so that clearance
"b" between cylinder rod (12) and plate (4)
will be 1.5 mm or less.
Standard shim: 1.0, 2.0 mm
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DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
[*3]
2 Inside wall of bushing before assem-
bling pin:
Anti-friction composition (LM-P)
2 Greasing after assembling pin:
Grease (LM-G)
k When aligning the pin holes, never insert
your fingers in them.a Adjust the shim thickness so that clearance
"c" between boom (13) and bracket (14) will
be 1 mm or less.
Standard shim: 2.0, 2.5, 3.0, 3.5 mm
• Bleeding air
See TESTING AND ADJUSTING, Bleeding air
from each part.
• 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.
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DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
REMOVAL AND INSTALLATION OF OPERATOR’S CAB GLASS
(STUCK GLASS)
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DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
SPECIAL TOOLS
REMOVALa Remove the window glass to be replaced ac-
cording to the following procedure.
1. Using seal cutter [1], cut the adhesive between
broken window glass (7) and operator's cab
(metal sheet) (8).
a If a seal cutter is not available, make holes
on the adhesive and both-sided adhesive
tape with a drill and pass a fine wire (piano
wire, etc.) [2] through the holes. Grip the
both ends of the wire with priors [3], etc. (or
hold them by winding them onto something)
and move the wire to the right and left to cut
the adhesive and both-sided adhesive tape.
Since the wire may be broken by the friction-
(The figure shows the operator's cab of a
wheel loader.)
a If the window glass is broken finely, it may be
removed with knife [4] and a screwdriver.
a Widening the cut with a screwdriver, cut the
adhesive and both-sided adhesive tape with
knife [4].
(The figure shows the operator's cab of a
wheel loader.)
2. Remove the window glass.
S y m b o l
Part No. Part name
N e c e s s i t y
Q ' t y
N e w / R e m o d e
l
S k e t c h
Y1 793-498-1210
Lifter
(Suction cup) t 2
2 20Y-54-13180 Adapter t 2
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y y
al heat, apply lubricant to it.
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
INSTALLATION1. Using a knife and scraper [5], remove the
remaining adhesive and both-sided adhesivetape from the metal sheets (glass sticking sur-
faces) of the operator's cab.
a Remove the adhesive and both-sided adhe-
sive tape to a degree that they will not affect
adhesion of the new adhesive. Take care
not to scratch the painted surfaces. (If the
painted surfaces are scratched, adhesion
will be lowered.)
(The figure shows the operator's cab of a
wheel loader.)
2. Remove oil, dust, dirt, etc. from the sticking sur-
faces of cab (8) and window glass (9) with white
gasoline.
a If the sticking surfaces are not cleaned well,
the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
(The figure shows the operator's cab of a
wheel loader.)
3. Apply primer (10).
a The using limit of primer (10) is 4 months af-
ter the date of manufacture. Do not use prim-er (10) after this limit.
a Use the primer within 2 hours after unpack-
ing it.
a Even if the primer is packed again just after
it is unpacked, use it within 24 hours after it
is unpacked for the first time. (Discard the
primer 24 hours after it is packed.)
1) Stir the primers for paint and glass suffi-
ciently before using them.
a If the primer has been stored in a refrig-
erator, leave it at the room temperature
for at least half a day before stirring it. (If
the primer is unpacked just after taken
out of the refrigerator, water will be con-
densed. Accordingly, leave the primer at
the room temperature for a sufficient
time.)2) When reusing primer brush (11), wash it in
white gasoline.
a After washing the brush, check it again
for dirt and foreign matter.
a Prepare respective brushes for the paint
primer glass primer.
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DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
3) Evenly apply paint primer to the surfaces to
stick both-sided adhesive tapes and the sur-
faces out of those surfaces on operator'scab (8) which will be coated with the adhe-
sive.
2 Paint primer:
SUNSTAR PAINT PRIMER
580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Parts to be coated with primer: Apply the
primer all over dimension (a).
• Dimension to apply primer (a): 25 mm
a In addition to the above parts, apply the
primer to right side window glass (1) and
door lower window glass (3).• Range to apply primer additionally for
right side window glass (1): (b)
• Range to apply primer additionally for
door lower window glass (3): (c)
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it off with white gasoline.
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DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
4) Evenly apply glass primer to the sticking
surfaces of window glass (9).
2 Glass primer:SUNSTAR GLASS PRIMER
580 SUPER or equivalent
a Do not apply the primer more than 2
times. (If it is applied more than 2 times,
its performance will be lowered.)
a Parts to be coated with primer: Apply the
primer to the sticking surfaces of window
glass (9) and all over dimension (d)
which will be on both-sided adhesive
tape (6) and operator's cab (8).
a Do not apply the primer to the boarder
about 5 mm wide between the black part
and transparent part of the glass.
a After applying the primer, leave it for at
least 5 minutes (within 8 hours) to dry.
a Never apply wrong primer. If the glass
primer is applied by mistake, wipe it off
with white gasoline.
4. Stick both-sided adhesive tape (6) along the
inside edge of the glass sticking section.
a Do not remove the release tape of the both-sided adhesive tape on the glass sticking
side before sticking the glass.
a When sticking the both-sided adhesive tape,
do not touch the cleaned surface as long as
possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
a When sticking both-sided adhesive tape (6)
around a frame, do not lap its finishing end
over the starting end but make clearance e of
about 5 mm between them.
1) Stick both-sided adhesive tape (6) for right
side window glass (1) as shown in the fig-
ure.
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DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
a Stick both-sided adhesive tape (6a) addition-
ally for right side window glass (1).
• Positions to stick additional both-sided adhe-sive tape for right side window glass:
(f ) : 50 mm
(g) : 90 mm
(h) : 250 mm
2) Stick both-sided adhesive tape (6) for left
side rear window glass (2) as shown in the
figure.
3) Stick both-sided adhesive tape (6) for door lower window glass (3) as shown in the fig-
ure.
a Stick both-sided adhesive tape (6b) ad-
ditionally for door lower window glass
(3).a Positions to stick additional both-sided
adhesive tape for door lower window
glass:
( j) : 110 mm
(k) : 90 mm
(m) : 200 mm
4) Stick both-sided adhesive tape (6) for front
window glass (4) as shown in the figure.
a Stick both-sided adhesive tape (6c) of
the lower side of the front window glass
along the outside edge of the lower line,
differently from other both-sided adhe-
sive tapes (6). (If it is stuck along the in-
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p ( ) ( g
s ide, i t w i l l be seen through the
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
5. Position the new window glass.
1) Check the clearance between the window
glass and the operator's cab on the right,left, upper, and lower sides, and then adjust
it evenly.
2) Stick tapes [6] between window glass (9)
and operator's cab (8) and draw positioning
line n.
a Stick tapes [6] to the right, left, and lower
parts of the right side window glass, left
side rear window glass, and door lower
window glass for accurate positioning.
3) Cut the tape between window glass (9) and
operator's cab (8) with a knife, and then
remove the window glass.
a Do not remove the tapes left on the win-
dow glass and operator's cab before in-
stalling the window glass.
a When positioning front window glass (4),
set its horizontal position to the frame
width and set its vertical position so thatheight difference (p) between it and the
frame top will be 3 mm.
6. Apply adhesive.
a Use either of the 2 types of the adhesive.2 Adhesive (Summer):
SUNSTAR PENGUINE
SEAL 580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use the
adhesive after this limit.a Keep the adhesive in a dark place where the
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the noz-
zle.
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DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
2) Cut the tip of the adhesive nozzle (14) so
that dimensions (q) and (r) will be as fol-
lows.• Dimension (q): 10 mm
• Dimension (r ) : 15 mm
3) Set adhesive cartridge (12) to caulking gun
[7].a An electric caulking gun is more efficient.
4) Remove the release tape of the both-sided
adhesive tape on the glass side.
5) Apply adhesive (15) to the outside of both-sided adhesive tape (6) of the operator's
cab.
a Apply adhesive (15) to dimensions (s)
and (t) of both-sided adhesive tape (6) of
operator's cab (8).• Dimension (s) : 10 mm
• Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (6).
a Apply the adhesive evenly.
a Apply adhesive (15) additionally for ad-
ditional both-sided adhesive tape (6a) of
the right side window glass and addition-
al both-sided adhesive tape (6b) of door
lower window glass.
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DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
7. Install the window glass.
1) Install window glass (9), matching it to the
lines of the positioning tapes drawn in step5.
a Since the window glass cannot be re-
moved and stuck again, stick it very
carefully.
a Stick the glass within 5 minutes after ap-
plying the adhesive.
2) After sticking window glass (9), press all
around it until it is stuck to the both-sided
adhesive tape.
a Press the corners of the window glass
firmly.
a You can perform this work efficiently by
pulling window glass (9) from inside of the operator's cab with suction cup Y1.
a After installing front window glass (4), fill
the clearances between it and center
trim seal (16) with caulking material inrange (s) to dimensions (t) and (u).
After applying the primer to glass (4) of
section A – A, apply adhesive as caulk-
ing material.
• Caulking dimension (t) : 2 mm
• Caulking dimension (u) : 5 mm
a When caulking, mask the glass side and
form the adhesive with a rubber spatula
as shown in the figure.
a Wipe off projected adhesive.
2 Glass primer:
SUNSTAR GLASS
PRIMER 580 SUPER
2 Adhesive:
SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
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DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB GLASS (STUCK GLASS)
8. Fix the window glass.
1) After installing right window glass (1) to the
operator's cab, insert stopper rubbers Y2 to
2 places (v) at the bottom of the glass to fix
the glass.
2) Using styrene foam blocks [9] and rubber
bands [10], fix the window glass and both-
sided adhesive tape to fit them completely.
9. After installing the window glass, remove the
primer and adhesive from the operator's cab
and window glass.
a Using white gasoline, wipe off the adhesive
before it is dried up.
a When cleaning the glass, do not give an im-
pact to it.
10. Protect the stuck window glass.1) Keep the stopper rubbers, styrene foam
blocks, and rubber bands installed for 10
hours (at temperature of 20°C and humidity
of 60%).
2) After removing the stopper rubbers, styrene
foam blocks, and rubber bands, wait at least
14 hours, at least 24 hours in total, before
operating the machine actually.
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DISASSEMBLY AND ASSEMBLY FRONT WINDOW
REMOVAL AND INSTALLATION OF FRONT WINDOW ASSEMBLY
k Lower the work equipment to the ground and
stop the engine.
a To replace the front window glass, the front win-
dow assembly must be removed from the opera-
tor's cab. The procedure for removing and
installing the front window assembly (front frame
and front window glass) is explained below.
REMOVAL1. Raise the front window assembly to the ceiling
and fix it with the rear locks (on both sides).
2. Remove left corner blocks (1) and (2) and right
corner block (3). [*1]
3. Remove left striker bolt (4), right striker bolt (5),
left corner block bracket, and right corner block
bracket (7). [*2]
4. Install left striker bolt (4) to the operator's cab
again and tighten it lightly.
a This bolt will be used to hang the pull-up as-
sist cable in step 8.
5. Release the rear locks.
6. Lower the front window assembly carefully a lit-
tle. Put out rollers (8) and (9) under the both
sides of the front window through the portion
from which the corner blocks were removed in
step 3 (the portion where the rail is open) and
hold them.
7. Remove rollers (8) and (9) under the both sides
of the front window.
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DISASSEMBLY AND ASSEMBLY FRONT WINDOW
8. Remove left lower pin (10). [*3]
a If left lower pin (10) is removed, plate (12) at
the end of pull-up assist cable (11) comesoff.
a Hang plate (12) on the left striker bolt.
k The return load of 58.8 N {6 kg} is applied to
the rear of the operator's cab. Accordingly,
take care when removing left lower pin (10)
to disconnect pull-up assist cable (11).
9. Put out the bottom of front window assembly
(13) through the rail opening portion and lower itgradually.
10. Lower front window assembly (13) completely.
a Do not let the front window assembly touch
the monitor.
11. Twist front window assembly (13) to the right
and left to remove both upper rollers (14) and
(15) from the rails, and then remove front win-
dow assembly (13).
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DISASSEMBLY AND ASSEMBLY FRONT WINDOW
INSTALLATION
• Carry out installation in the reverse order toremoval.
[*1] [*2]
• Adjust opening and closing of the front window
assembly according to the following procedure.
1. Open and close the front window to check that it
does not interfere with the rails and the rollers
are not hitch.
2. If there is any problem in opening or closing of
the front window, loosen the mounting bolts of
roller adjustment brackets (16) and (17) and
adjust the condition of the front window, and
then tighten the mounting bolts again.
3 Mounting bolt: 98 Nm {1.0 kgm}
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DISASSEMBLY AND ASSEMBLY FRONT WINDOW
3. Raise the front window assembly and fix it with
the rear locks (on both sides).
a Check that the locks in the rear of the opera-tor's cab are applied securely.
4. Install right corner block (3) and fix right corner
block bracket (7) with right striker bolt (5).
a Tighten the striker bolt securely after adjust-
ing it in step 6.
a Install the right corner block so that there will
be no level difference at part (a).
a Install the right corner block so that level dif-ference (b) between the rail and right corner
block (3) at part PF will be 0 – 1.0 mm.
Check that the right corner block is not pro-
jected from the rail at the rolling surface of
the roller.
a Secure roller clearance (c) at part PJ.
5. Install left corner blocks (1) and (2) and secure
left corner bracket (6) with left striker bolt (4).
a Tighten the striker bolt securely after adjust-ing it in step 6.
a Install the left corner blocks so that there will
be no level difference at 2 part (d).
a Secure roller clearance (e).
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DISASSEMBLY AND ASSEMBLY FRONT WINDOW
6. Adjust the striker bolts according to the following
procedure (Adjust the "CLOSE" positions of the
front window assembly locks).1) Tighten left striker bolt (4) and right striker
bolt (5) at roughly right positions so that
front window glass (18) will be fitted to cab-
side trim seal (19).
2) Open and close the front window assembly
and check the working condition of both
locks (20) and (21).i) If both locks do not work normally, move
the striker bolts toward the rear of the
cab and tighten them again.
ii) After moving the striker bolts, check the
fitness of the front window glass and
cab-side trim seal which was checked in
step 6.
iii) Repeat the work in i) and ii) until the fit-
ness of the front window and the work-ing condition of both locks (20) and (21)
are acceptable, and then tighten the
striker bolts.
7. After adjusting the striker bolts, splash water heavily over the front window glass and check
that the water does not leak into the cab.
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DISASSEMBLY AND ASSEMBLY FRONT WINDOW
8. Adjust the "opening" lock of the front window
assembly.
1) After adjusting the "closing" lock of the frontwindow in step 6, raise the front window
assembly to the ceiling.
2) Set the right and left front window assembly
locks at the rear of the operator's cab to the
"OPEN" positions, and then check the fol-
lowing items.
• Check that right and left locks (20) and
(21) are closed normally.
• Check that right and left locks (20) and(21) are inserted in parallel in right and
left striker plates (22).
• Check that right and left rubber stoppers
(24) are in contact with the front window
assembly and their deflection allowance
is 1.5 – 3.0 mm.
3) After checking the above items, if neces-
sary, adjust them by moving right and left
striker plates (22) at the rear of the opera-
tor's cab.
9. Adjust the front window stoppers.
1) After adjusting "closing" lock of the front win-
dow assembly in step 9, check the contactof both front window stoppers (23).
2) If both stoppers (23) do not contact nor-
mally, adjust and fix them at places where
they contact normally.
10. Check the latching effort of the front window
assembly.
1) After finishing steps 6 – 9, check that latch-
ing efforts of both locks (20) and (21) are
even.
a Check the latching efforts on both "clos-
ing" side (in the front of the operator's
cab) and "opening" side (in the rear of
the operator's cab).
[*3]
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HYDRAULIC CIRCUIT DIAGRAM (1/2)........................................................................................................90- 3
HYDRAULIC CIRCUIT DIAGRAM (2/2)........................................................................................................90- 5
ELECTRICAL CIRCUIT DIAGRAM (1/5) ......................................................................................................90- 7
ELECTRICAL CIRCUIT DIAGRAM (2/5) ......................................................................................................90- 9
ELECTRICAL CIRCUIT DIAGRAM (3/5) ......................................................................................................90- 11
ELECTRICAL CIRCUIT DIAGRAM (4/5) ......................................................................................................90- 13ELECTRICAL CIRCUIT DIAGRAM (5/5) ......................................................................................................90- 15
AIR CONDITIONER ELECTRICAL CIRCUIT ...............................................................................................90- 17
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)..............................................................................................90- 19
CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)........................................................ 90- 21
90 OTHERS
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HYDRAULIC CIRCUIT DIAGRAM (1/2)
PC400/450(LC)-7 90-3
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PC400/450(LC)-7 90-5
HYDRAULIC CIRCUIT DIAGRAM (2/2)
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PC400/450(LC)-7 90-7(4)
ELECTRICAL CIRCUIT DIAGRAM (1/5)
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PC400/450(LC)-7 90-9(4)
ELECTRICAL CIRCUIT DIAGRAM (2/5)
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PC400/450(LC)-7 90-11(4)
ELECTRICAL CIRCUIT DIAGRAM (3/5)
7/21/2019 Parts Manual - PC400
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PC400/450(LC)-7 90-13(4)
ELECTRICAL CIRCUIT DIAGRAM (4/5)
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PC400/450(LC)-7 90-15(4)
ELECTRICAL CIRCUIT DIAGRAM (5/5)
7/21/2019 Parts Manual - PC400
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PC400/450(LC)-7 90-17
AIR CONDITIONER ELECTRICAL CIRCUIT
7/21/2019 Parts Manual - PC400
http://slidepdf.com/reader/full/parts-manual-pc400 803/804
PC400/450(LC)-7
ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) PC400, 450-7