SEBM031308 Mar09) PDF
SEBM031308 Mar09) PDF
SEBM031308 Mar09) PDF
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require. Materials and specifications are subject to change without notice.
© 2007
All Rights Reserved
Printed in Japan 06-07 (01)
00-1
(8)
GENERAL
CONTENTS
No. of page
01 GENERAL ............................................................................................................................ 01-1
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
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).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q’ty Container Main applications, features
Glass
SASH PRIMER 22M-54-27250 20 ml (Using limit: 4 months)
container
GP-402
SUNSTAR Ecocart • Used as adhesive for glass.
PENGUINE 22M-54-27210 320 ml (Special (Using limit: 6 months)
SUPER 560 container)
SUNSTAR • “S” is used for high-temperature
PENGUINE season (April - October) and “W” for
Adhesive Polyethylene
SEAL 580 417-926-3910 320 ml low-temperature season (November -
container
SUPER “S” or April) as adhesive for glass.
“W” (Using limit: 4 months)
Sika Japan, Polyethylene • Used as adhesive for glass.
20Y-54-39850 310 ml
Sikaflex 256HV container (Using limit: 6 months)
SUNSTAR • Used to seal joints of glass parts.
Polyethylene
PENGUINE 417-926-3920 320 ml (Using limit: 4 months)
container
SEAL No. 2505
SEKISUI • Used to seal front window.
Caulking Polyethylene
SILICONE 20Y-54-55130 333 ml (Using limit: 6 months)
material container
SEALANT
GE TOSHIBA • Used to seal joint of glasses.
SILICONES 22M-54-27220 333 ml Cartridge Translucent white seal.
TOSSEAL 381 (Using limit: 12 months)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.20
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands (mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White
Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
0 1 2 3 4 5 6 7 8 9
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
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
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 04-05
01 GENERAL
SPECIFICATION DRAWINGS
BACKHOE SPECIFICATION
DIMENSIONS
WORKING RANGES
DIMENSIONS
WORKING RANGES
WORKING RANGES
DIMENSIONS
WORKING RANGES
SPECIFICATIONS
BACKHOE SPECIFICATION
ture
Min. ground clearance mm 840 840
Tail swing radius mm 4,300 4,245
Min. swing radius of work equip- mm 6,060 5,645
ment
Height of work equipment mm 10,855 9,750
at min. swing radius
Length of track on ground mm 4,500 4,500
Track gauge (when extended) mm 2,780 (3,500) 2,780 (3,500)
Height of machine cab mm 3,560 3,560
Model SAA6D140E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders – bore × stroke mm 6 – 140 × 165
Piston displacement l {cc} 15.24 {15,240}
Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Type × No. 4-spool + 5-spool type × 1
(when extended)
structure
Dimensions
ment
Model SAA6D140E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders – bore × stroke mm 6 – 140 × 165
Piston displacement l {cc} 15.24 {15,240}
Flywheel horsepower kW/rpm {HP/rpm} 338/1,800 {454/1,800}
Performance
Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Control valve
× 2 (MSF-340VP-EH11)
SPECIFICATIONS
Gradeability deg. 35 35
(when extended)
structure
ment
Model SAA6D140E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders – bore × stroke mm 6 – 140 × 165
Piston displacement l {cc} 15.24 {15,240}
Flywheel horsepower kW/rpm {HP/rpm} 338/1,800 {454/1,800}
Performance
Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Model SAA6D140E-3
Type 4-cycle, water-cooled, in-line, vertical, direct injection,
with turbocharger and aftercooler (air cooled)
No. of cylinders – bore × stroke mm 6 – 140 × 165
Piston displacement l {cc} 15.24 {15,240}
Starting motor 24 V, 11 kW
Alternator 24 V, 50 A
Battery 12 V, 170 Ah × 2
Radiator core type CWX-4
Undercarriage
Set pressure MPa {kg/cm2} Piston type: 31.4 {320}, gear type: 2.9 {30}
Type × No. 4-spool + 5-spool type × 1
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components
Unit: kg
Unit: kg
Unit: kg
Unit: kg
PTO
Unit: mm
POWER TRAIN
SWING MACHINERY
Specification
Reduction ratio:
20 + 97 × 19 + 97 = 35.716
20 19
Unit: mm
SWING CIRCLE
Unit: mm
FINAL DRIVE
Unit: mm
SPROCKET
Unit: mm
a The above drawing is reduced to 50%. Enlarge it to 200% to return it to the full scale and make a copy on
an OHP sheet.
Unit: mm
Standard
Tolerance Repair limit
size Rebuild or
Top-to-bottom width of idler +3 replace
10 Track frame 185 185 –2 190
guide
+3 Rebuild or
Track frame 345 345 –2 355
Left-to-right width of idler replace
11
guide
Idler support 340 — 332
IDLER
Unit: mm
CARRIER ROLLER
Unit: mm
TRACK ROLLER
Unit: mm
Unit: mm
Press-fitting Regular
18 312 – 350 kN {31.8 – 35.7 ton} —
force pin
Master
19 249 – 294 kN {25.9 – 30 ton}
pin
(2/2)
Unit: mm
DOUBLE SHOE
Unit: mm
HYDRAULIC TANK
HYDRAULIC PUMP
NO. 1 PUMP ASSEMBLY
HPV95 + 95
1. Front servo valve PA1 : Discharge port Pecn : CO, NC valve output
2. Front CO, NC valve PA2 : Discharge port pressure detection port
3. Rear servo valve Ps : Suction port Pd11 : Drain port
4. Rear CO, NC valve Pt : Jet sensor upstream pressure IN port Pd21 : Drain port
5. TVC valve Pd : Jet sensor downstream pressure IN PCF : CO cancelling pressure
6. Rear pump port pilot port
7. Front pump Psv : Servo basic pressure supply port PCR : CO cancelling pressure
pilot port
Psv1 : Servo valve basic pressure port Psv2A : Servo piston output port
Psv2 : Servo valve basic pressure port Psv1B : Servo valve output port
Psv1A : Servo piston output port Psv2B : Servo valve output port
4. Servo valve
• No. 1 pump front servo valve
Function
Discharge amounts Q1 and Q2 of main pumps PA1
and PA2 are controlled individually by the respective
servo valves. The relationship between pump dis-
charge amount Q and input signal Pecn to the servo
valve is as shown in the graph on the right. Q varies
in proportion to Pecn.
Operation
1) Operation in direction of increase of pump discharge amount (max. angle)
• The control pump pressure Psv is taken to port At the same time, port a is interconnected with
a. port h, so the oil flows through port i to servo
Signal pressure Pecn from the NC valve is piston chamber j, pushes servo piston (19) to
taken from port b to chamber c. the left, increases the swash plate angle in the
• When signal pressure Pecn rises, control piston main piston pump and increases the pump dis-
(8) is pushed to the left by the hydraulic pressure charge amount.
in chamber c, and stops at a point where it bal- • When servo piston (19) moves, arm (6) rotates
ances the pressure of springs (4) and (4A). clockwise with its center at pin (7). Guide spool
At the same time, arm (6) uses servo piston (19) (13) is moved to the right and closes port a, port
as a fulcrum and sways to the left in the same d and port h, so the discharge increases by an
way as control piston (8). This moves guide amount that matches signal pressure Pecn.
spool (13) to the left.
• When guide spool (13) moves, port a and port d
are closed and port d is connected to drain
chamber e. As a result, servo piston chamber f is
also interconnected with chamber e through port
g and port d.
• When signal pressure Pecn goes down, control • When servo piston (19) moves, arm (6) rotates
piston (8) moves to the right and stops at a point counterclockwise with its center at pin (7). Guide
where the hydraulic pressure in chamber c bal- spool (13) is moved to the left and closes port a,
ances the pressure of springs (4) and (4A). port d and port h, so the discharge decreases by
At the same time, arm (6) uses servo piston (19) an amount that matches signal pressure Pecn.
as a fulcrum and sways to the right in the same
way as control piston (8). This moves guide
spool (13) to the right.
• When guide spool (13) moves, port a and port h
are closed and port h is connected to drain
chamber e. As a result, servo piston chamber j is
also interconnected with chamber e through port
i and port h.
At the same time, port a is interconnected with
port d, so the oil flows through port g to servo
piston chamber f, pushes servo piston (19) to
the right, decreases the swash plate angle in the
main piston pump and decreases the pump dis-
charge amount.
5. TVC valve
Function Operation
• When the power mode is at A mode or E mode, • The command current sent from the controller
the pump discharge amount is controlled to the actuates solenoid push pin (9) and spool (2)
optimum amount by the command current sent moves. When this happens, the piston stops at a
from the controller in accordance with the varia- point where it balances the total of the force of
tion in the engine speed. spring (1), the force of push pin (9), and the force
• When the power mode is at G, or the pump prolix of TVC output pressure Pe acting on piston (3).
switch is ON, the pump discharge amount is con- The command current at this point is small, so
trolled according to the pump discharge pressure spool (2) is balanced at the bottom.
(load) by hydraulic sensing which follows a con- As a result, port a and port b are almost com-
stant pump absorption torque. pletely open, so the pressure oil from the control
pump is almost all output as TVC output pres-
a For details, see MACHINE CONTROL SYS- sure Pe.
TEM. In this way, the pum p disc ha rg e a m ou nt
becomes the maximum.
Operation
• The command current sent from the controller
actuates solenoid push pin (9) and spool (2)
moves. When this happens, the piston stops at a
point where it balances the force of spring (1).
The command current at this point is large, so
spool (2) is balanced at the top.
As a result, the flow of oil from the control pump
at port a and port b is throttled. At the same
time, the area of the opening at port b and port c
(drain port) becomes larger.
In this way, TVC output pressure Pe goes down,
and the pump discharge amount decreases.
CO valve NC valve
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 12. Plug
CO valve NC valve
1. Plug 7. Plug
2. Piston 8. Sleeve
3. Spring 9. Piston
4. Spool 10. Spool
5. Piston 11. Spring
6. Plug 12. Plug
Function Operation
• When the load becomes large during operations • Spool (4) is being pushed down fully by spring
and the main pump discharge pressure rises to a (3).
point close to relief pressure, the cut-off function As a result, port a and port b are fully open and
of the CO valve acts to reduce the pump dis- TVC valve output pressure Pe and CO valve
charge in order to reduce relief loss. output pressure Pec are equal.
• At the same time, it has a cut-off cancel function In this way, CO valve output pressure Pec
actuated by the pilot pressure from the heavy-lift becomes the maximum and the main pump dis-
solenoid valve. charge amount also becomes the maximum.
• The CO valve is controlled by balancing the
spring with the total of main pump discharge
pressure PA and CO valve output pressure Pec.
Function Operation
• The NC valve controls the main pump discharge • Jet sensor differential pressure (Pt – Pd) be-
amount according to the amount that the control comes the maximum, and the force of jet sensor
valve spool is operated. This flow control function output pressure Pt pushing piston (10) becomes
reduces the neutral loss and fine control loss. larger than the total of the force of spring (12)
• The NC valve is controlled by balancing the total and the force of jet sensor output pressure Pd
of the jet sensor output pressure Pt and the NC pushing the bottom of spool (11).
valve output pressure Pecn with the total of the As a result, spool (11) is pushed down, so the
force of NC valve spring (12) and the jet sensor flow to port c and port b is throttled, and the
output pressure Pd. area of the opening of port b and port a (drain
• The jet sensor picks up the flow of oil returning to port) becomes larger. In this way, NC valve out-
the tank through the control valve and takes put pressure Pecn becomes the minimum, and
them as Pt and Pd of the NC valve. the main pump discharge amount also becomes
the minimum.
HPV95 + 95
1. Cover Outline
2. Spring There are two return oil filters installed to the rear face
3. Bypass valve of the hydraulic tank. They remove the dirt and dust in
4. Bypass valve spring the return oil.
5. Element
6. Housing Specifications
• Bypass valve set pressure:
A. From control valve 0.15 ± 0.03 MPa {1.5 ± 0.3 kg/cm2}
B. To hydraulic tank
1. Element
2. Body
3. Cover
1. Cartridge
2. Safety valve
3. Bracket
Unit: mm
1. Main relief valve 6. Spool return spring 11. Check valve spring
2. Spool (R.H. travel) 7. Valve body 12. Straight-travel valve
3. Spool (boom Lo) 8. Jet sensor orifice 13. Suction valve
4. Spool (bucket Lo) 9. Jet sensor relief valve 14. Suction-safety valve
5. Spool (arm Hi) 10. Check valve 15. Suction-safety valve
Unit: mm
STRAIGHT-TRAVEL VALVE
1. Orifice
2. Check valve
3. Spring
4. Spool return spring
5. Body
6. Spool
7. Cover
Function
• When the travel is operated at the same time as
the boom, arm, or bucket, the pressure oil flow-
ing to the left and right travel circuits is divided
and sent to the boom, arm, or bucket circuit. If
the oil in one travel circuit is divided off, the
amount of oil supplied to the travel motor will be
less than in the travel circuit which is not divided,
so the drop in the supply of oil to the travel motor
will cause the machine to deviate.
• To prevent this, the straight-travel valve is
switched to interconnect the left and right travel
circuits. This ensures that the amount of oil sup-
plied to the left and right travel motors is equal,
so the left and right travel motors both rotate at
the same speed, and this prevents any travel de-
viation.
Operation
When travel is operated independently (straight-
travel solenoid valve de-energized)
• The straight-travel solenoid valve is de-ener-
gized, so no pilot pressure flows, and spool (6)
remains pushed to the right.
• Because of this, port P2 (left travel circuit) and
port P1 (right travel circuit) are not interconnect-
ed, and each circuit remains independent.
SWING MOTOR
KMF125AB-5
Unit: mm
1. Outline
The relief portion consists of check valves (2)
and (3), shuttle valves (4) and (5), and relief
valve (1).
2. Function
When the swing is stopped, the outlet port circuit
of the motor from the control valve is closed, but
the motor continues to rotate under inertia, so
the pressure at the output side of the motor
becomes abnormally high, and this may dam-
age the motor.
To prevent this, the abnormally 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
passes through the control valve and is sup-
plied to port MA. As a result, the pressure at
port MA rises, the starting torque is generat-
ed in the motor, and the motor starts to ro-
tate. The oil from the outlet port of the motor
passes from port MB thought the control
valve and returns to the tank. (Fig. 1)
1. Cover
2. Body
3. Slipper seal
4. Oil seal
5. Shaft
Unit: mm
Clearance between rotor and Standard size Standard clearance Clearance limit
6 Replace
shaft 110 0.056 – 0.105 0.111
TRAVEL MOTOR
MSF-340VP-EH
1-1 Motor
Operation
1) At low speed (pilot pressure PI = 0)
• When the pilot signal is ON, pilot pressure PI goes to the control piston chamber. Rocker
from the control pump acts on travel speed se- cam (14) overcomes moment Mx with
lector valve (1) and the capacity is automatically hydraulic force from propulsion force Fc of
changed by the drive pressure of the travel mo- control piston (10). It rotates and holds the
tor. moment balance at the high speed surface
and is held in position (Mx < Fc, L).
Balance of force for travel speed selector valve ii) When operating the steering or traveling
F1 [Force pushing spool (1a) to right (high- uphill, if the motor drive pressure is high, and
speed side)] = A (area of spool (1a) receiv- it goes above the set pressure, the condition
ing pressure) × PI becomes F1 < F2, and spool (1a) is pushed
F2 [Force pushing spool (1a) to left (low-speed to the left.
side)] = A (area of spool (1a) receiving pres- When this happens, the main oil pressure
sure) × PH (motor drive pressure) + force of (M1, M2) passes through spool (1a) and is
spring (1b) drained to the motor case. This creates the
low-speed condition in the same way as
i) When traveling on level ground, if the travel when PI = 0.
motor drive pressure is low, the condition
becomes F1 > F2, and spool (1a) is pushed
to the right.
When this happens, the main oil pressure
(M1, M2) passes through spool (1a) and
1. Shockless piston
2. Poppet
3. Poppet orifice
4. Relief housing orifice
5. Piston stroke
Function
In addition to the pressure control function, this relief
valve has a shockless function (2-stage pressure
increase function). This acts to reduce the shock
generated at the beginning when the speed is
reduced (when the machine is stopped).
Operation
1) When relief valve starts to be actuated (1st
stage)
The area receiving the pressure which lifts pop-
pet (2) becomes area S1 of the poppet seat.
For this reason, it has a much larger pressure-
receiving area than the pressure-receiving area
when it is set (S1 – S2), so the relief actuating
pressure becomes a low pressure of approx.
15.7 MPa {160 kg/cm2}.
This condition is maintained until the movement
of shockless piston (1) is completed (approx.
0.25 sec).
Unit: mm
PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas : Nitrogen gas
Gas volume : 300 cc
Max. actuating pressure : 3.1 MPa {32 kg/cm2}
Min. actuating pressure : 1.2 MPa {12 kg/cm2}
Function
• The accumulator is installed between the PPC
control pump and the PPC valve. Even if the en-
gine is stopped with the work equipment raised,
pilot oil pressure is sent to the main control valve
by the pressure of the nitrogen gas compressed
inside the accumulator, so it is possible to lower
the work equipment under its own weight.
Operation
• After the engine stops, when the PPC valve is at
neutral, chamber A inside the bladder is com-
pressed by the oil pressure in chamber B.
• If the PPC valve is operated, the oil pressure in
chamber B becomes less than 2.9 MPa {30 kg/
cm2}, so the bladder expands under the pressure
of the nitrogen gas in chamber A. The oil enter-
ing chamber B is sent as the pilot pressure to ac-
tuate the main control valve.
VALVE CONTROL
P. From control pump P2. Left: Arm OUT, Right: Boom LOWER
T. To hydraulic tank P3. Left: Swing left, Right: Bucket DUMP
P1. Left: Arm IN, Right: Boom RAISE P4. Left: Swing right, Right: Bucket CURL
Unit: mm
Operation
1) At neutral
Ports A and B of the control valve and ports P1,
P2, P3, and P4 of the PPC valve are connected
to drain chamber D at the bottom. (Fig. 1)
4) At full stroke
When disc (5) pushes down piston (4), and
retainer (9) pushes down spool (1), port P1 is
shut off from drain chamber D, and is connected
to pump pressure chamber PP. Therefore, the
pilot pressure oil from the control pump flows to
chamber A from port P1 to push the control
valve spool.
The return oil from chamber B passes from port
P2 and flows to drain chamber D.
Operation
1. At neutral
• Ports A and B of the control valve and ports P1
and P2 of the PPC valve are connected to drain
chamber D through fine control hole f in spool
(1). (Fig. 1)
4. At full stroke
• Disc (5) pushes down piston (4), and retainer (9)
pushes down spool (1). Fine control hole f is shut
off from drain chamber D, and is connected to
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 to push the con-
trol valve spool.
• The return oil chamber B passes from port P2
through fine control hole f ’ and flows to drain
chamber D. (Fig. 4)
SOLENOID VALVE
For resetting CO, straight travel, heavy lifting, pushing up machine, travel speed
(at center of machine body)
1. Connector
2. Movable core
3. Coil
4. Cage
5. Spool
6. Block
7. Spring
Operation
When solenoid is de-energized
• When the signal current does not flow from the
PPC lock switch or swing lock switch, solenoid
(3) is de-energized.
• For this reason, spool (5) is pushed fully to the
left by spring (6).
• As a result, the circuit between ports P and A
closes and the pressurized oil from the control
pump does not flow to the actuator.
• At the same time, the pressurized oil from the ac-
tuator flows from port A to port T, and is then
drained to the tank.
For swing holding brake (on right side of machine body), for lock (under cab)
T : To tank T : To tank
A : To front and rear swing motors A : To port P of work equipment PPC valve
P : From control pump To port P of travel PPC valve
P : From control pump
1. Connector 7. Spool
2. Solenoid 8. Body
3. Variable iron core 9. Plug
4. Body 10. Spring
5. Plug 11. Spool
6. Spring
Operation
When solenoid is de-energized
• No signal current flows from the controller, so so-
lenoid (2) is de-energized.
• Accordingly, spool (11) is pushed up and spool
(7) is pushed to the left by spring (6).
• As a result, port P is closed, so pressure oil from
the control pump does not flow to the actuator.
At the same time, the oil from the actuator flows
from port A2 to port T and is drained to the tank.
T : To tank
A : To 5-spool control valve
P : From control pump
1. Connector
2. Movable iron core
3. Coil
4. Spool
5. Body
6. Spring
7. Plug
Operation
When solenoid is de-energized
• The signal current does not flow from the control-
ler, so coil (3) is de-energized.
For this reason, spool (4) is returned to the neu-
tral position by spring (6).
As a result, the circuit between ports P and A is
connected, and the pressurized oil from the
PPC valve flows to the control valve.
HYDRAULIC CYLINDER
BACKHOE SPECIFICATION
PC750, 750LC, 800-7 STD
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
Unit: mm
PC750SE, 800SE-7
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
Unit: mm
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
Unit: mm
WORK EQUIPMENT
PC750-7
PC750LC-7
Unit: mm
PC750SE-7
PC800, 800SE-7
Unit: mm
Unit: mm
Unit: mm
Model PC750SE-7
PC750-7 PC800-7 PC800SE-7
PC800SE-7
with 3.6 m
with 3.6 m with 4.6 m with 5.6 m with 2.9 m with 3.6 m
heavy-duty
No. arm arm arm short arm arm
arm
Arm as
519 519 519 519 519 519
one part
18
When press-
535 535 535 535 535 535
fitting bushing
2. BUCKET
Unit: mm
Model PC750SE-7
PC750-7 PC800-7 PC800SE-7
PC800SE-7
with 4.0 m3
with 2.8 m3 with 3.1 m3 with 3.4 m3 with 4.0 m3 with 4.3 m3 with 4.5 m3
Light-load
No. bucket bucket bucket bucket bucket bucket
bucket
19 79 79 79 79 79 79 79
AIR CONDITIONER
AIR CONDITIONER PIPING
STD CAB SPECIFICATION
ENGINE CONTROL
1. Battery Function
2. Battery relay • The engine can be started and stopped simply by
3. Starting switch using starting switch (3).
4. Fuel control dial • A dial-type engine control is used to control the en-
5. Supply pump gine speed. Engine controller (7) receives the con-
6. Starting motor trol signal from fuel control dial (4), sends a drive
7. Engine controller signal to supply pump (5), and controls the angle of
the governor lever in the fuel injection pump.
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 the
engine.
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.
Stopping engine
• When the engine controller detects that the start-
ing switch is at the STOP position, it cuts the sig-
nal to the supply pump drive solenoid to stop the
engine.
2. Components of system
Fuel control dial
1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
6. Connector
Function
• The fuel control dial is installed at the bottom of
the monitor panel. A potentiometer is installed
under the knob, and when the knob is turned, it
rotates the potentiometer shaft.
When the shaft rotates, the resistance of the
variable resistor inside the potentiometer
changes, and the desired throttle signal is sent
to the engine controller.
• The hatched area in the graph on the right is the
abnormality detection area and the engine speed
is set at low idle.
3. Engine controller
CN3 [CN-E13]
Input/
Pin No. Signal name
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
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 (–) Output
CN3-17 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 (–) Output
CN3-25 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
CN3-34 Injector #5 (+) Output
CN3-35 Injector #6 (–) Output
CN3-36 Injector #4 (–) Output
CN3-37 NC Output
CN3-38 Auto deceleration control (Test mode) Input
CN3-39 NC Input
CN3-40 GND
Function
• If all the control levers are at neutral when wait-
ing for work or waiting for a dump truck, the en-
gine speed is automatically reduced to a
midrange speed to reduce fuel consumption and
noise.
• If any lever is operated, the engine speed returns
immediately to the set speed.
Operation
Model PC750-7
Mode PC800-7
2) Cut-off function
• If the load during operation increase and the
pump discharge pressure rises to near the relief
pressure, the main pump cut-off valve is actuat-
ed to reduce the relief loss.
Outline
• This function increases the boom lifting power by
approx. 10%.
• It can be actuated only when the boom RAISE is
being actuated independently. If the arm IN or
bucket CURL are operated at the same time, the
heavy-lift function is automatically canceled.
Operation
Lever operation Heavy-lift Main relief
Heavy-lift CO valve Boom lifting
Arm IN or solenoid valve set
switch Boom RAISE switch force
bucket CURL valve pressure
31.4 MPa
OFF Operated — De-energized Actuated Normal
{320 kg/cm2}
34.3 MPa
Neutral Energized Canceled 10% up
{350 kg/cm2}
Outline
• This function switches the pushing force of the
boom. It is aimed to provide both increased dig-
ging efficiency by reducing the digging resist-
ance of the boom, and increased ease of
operation by increasing the thrusting force for ex-
cavation, digging square holes, carrying out twist
turns, or escaping from soft ground.
Operation
• This function acts to change the set pressure of the safety valve at the boom cylinder end of the R.H. 4-spool
control valve boom Lo in 2 ways: to low pressure (14.7 MPa {150 kg/cm2}) and high pressure (33.3 MPa {340
kg/cm2}.
Machine push-up Machine push-up Safety valve set
Mode Effect
switch solenoid valve pressure
Function
• The system is provided with a swing lock and
swing holding brake function.
Actuation
Swing lock Swing lock Swing brake
Mode Actuation
switch monitor solenoid valve
When swing and work equipment levers are placed at
neutral, swing brake is applied after approx. 10 sec;
when any swing or work equipment lever is operated,
brake is canceled and swing can be operated freely.
6. Engine automatic warming-up, overheat prevention function, turbo protect function, split
injection function
Function
• If the coolant temperature is low, this automati-
cally raises the engine speed to warm up the en-
gine after it is started. In addition, if the coolant
temperature rises too high during operations, it
reduces the load of the pump to prevent over-
heating.
• To protect the turbocharger bearing during cold
weather, the engine speed is kept below the
fixed speed when the engine is started. In addi-
tion, to improve the starting ability, a small
amount of fuel is injected two or more times be-
fore the main injection.
Actuation condition
Engine coolant Turbo protect time
temperature (sec)
More than +10°C 0
Gradually changes
+10°C to –10°C
between 0 and 5
Less than –10°C 5
Actuation condition
Split injection time
Coolant temperature
(sec)
More than 20°C 0
20°C to –30°C 0 – 15
Less than –30°C 15
Outline
• To maintain the drawbar pull when traveling, the
cut-off is canceled and the main relief pressure is
raised from 31.4 MPa {320 kg/cm2} to 34.3 MPa
{350 kg/cm2}.
Operation
Pressure increase Main relief valve Cut-off cancel
CO valve
solenoid valve set pressure solenoid valve
34.3 MPa
When traveling Energized Energized Canceled
{350 kg/cm2}
31.4 MPa
When not traveling De-energized De-energized Actuated
{320 kg/cm2}
Actuation
Boom shockless Cancel solenoid Boom shockless
Remarks
switch valve control
ON
De-energized ON Suitable for normal operations
(Contacts open)
OFF
Energized Canceled Suitable for compacting or skeleton work
(Contacts closed)
• If the boom is raised, the pilot pressure from the PPC valve is generated in line A. When this happens, the
pressure in line A passes through check valve (2) and pushes the spool of the main valve in the direction of
the arrow. The pilot oil at the left end of the spool passes through line B and the PPC valve, and returns to
the tank. However, when this happens, check valve (4) is being pushed open by the pressure in line A, so it
also allows the oil to pass in the opposite direction. For this reason, the boom can be raised without any delay
in response.
• In this condition, if the boom RAISE operation is stopped, the spool of the main valve moves in the opposite
direction to the arrow and drains the oil from line A. However, the action of check valve (2) means that the
oil must pass through orifice (1). As a result, the spool returns slowly to the neutral position to prevent any
shock.
9. Straight-travel function
Outline
• When the travel is operated at the same time as • To prevent this, the straight-travel valve is
the boom, arm, or bucket, the pressure oil flow- switched to interconnect the left and right travel
ing to the left and right travel circuits is divided circuits. This ensures that the amount of oil sup-
and sent to the boom, arm, or bucket circuit. plied to the left and right travel motors is equal,
If the oil in one travel circuit is divided off, the so the left and right travel motors both rotate at
amount of oil supplied to the travel motor will be the same speed, and this prevents any travel de-
less than in the travel circuit which is not divided, viation.
so the drop in the supply of oil to the travel
motor will cause the machine to deviate.
Operation
Work equipment
Left and right Straight-travel Straight-travel
control lever, Remarks
travel levers solenoid valve valve
swing lever
Left and right travel motor circuits
Neutral De-energized Not actuated
independent
Operation
Left and right travel motor circuits
Operated Energized Actuated
assist
Operation
• If the swing PPC pressure goes above 1.5 MPa {15 kg/cm2} (the control lever is operated approximately half
or more), the swing assurance selector valve is actuated and the swing drive pressure locks the pilot check
valve of the 5-spool valve arm and bucket throttle valves.
• In this condition, the circuits are in parallel, so the oil from the 5-spool valve flowing to the arm or bucket is
throttled by the throttle valve, so the swing drive pressure rises. In this way, the swing drive is assured.
1. Wire Function
2. Magnet • The engine speed sensor is installed to the ring
3. Terminal gear portion of the engine flywheel. It counts elec-
4. Housing trically the number of gear teeth that pass in front of
5. Connector the sensor, and sends the results to the engine con-
troller and pump controller.
• This detection is carried out by a magnet, and an
electric current is generated every time the gear
tooth passes in front of the magnet.
Specifications
Composition of points: N.O. points
Actuation (ON) pressure:
0.5 ± 0.1 MPa {5.0 ± 1.0 kg/cm2}
Reset (OFF) pressure:
0.3 ± 0.05 MPa {3.0 ± 0.5 kg/cm2}
Function
• There are 12 switches installed to
the PPC block. The operating condi-
tion of each actuator is detected
from the PPC pressure, and this is
sent to the engine controller and
pump controller.
1. Resistor
2. Connector
Specification Function
Resistance: 20 z • This resistor acts to allow a suitable current to
flow to the TVC solenoid when the TVC prolix
switch is ON.
• No current flows when the TVC prolix switch is
OFF.
5) Monitor panel
a See MONITOR SYSTEM.
6) TVC valve
a See HYDRAULIC PUMP.
7) Pump controller
CN3 [CN-C03]
Input/
Pin No. Signal name
Output
CN3-1 VB (Controller PWR) Input
CN3-2 VIS (Solenoid PWR) Input
CN3-3 TVC solenoid (–) Input
CN3-4 Battery relay drive Output
CN3-5 Step light power holding relay Output
CN3-6 NC Output
CN3-7 Straight travel solenoid Output
CN3-8 Travel alarm Output
CN3-9 Bucket CURL pressure switch Input
CN3-10 Boom RAISE pressure switch Input
CN3-11 VB (Controller PWR) Input
CN3-12 VIS (Solenoid PWR) Input
CN3-13 NC Input
CN3-14 VB (Controller PWR) Input
CN3-15 Step light drive relay Output
CN3-16 TVC solenoid (+) Output
CN3-17 CO cancel solenoid Output
CN3-18 NC Output
CN3-19 Bucket DUMP pressure switch Input
CN3-20 Boom LOWER pressure switch Input
CN3-21 GND (Controller GND) Input
CN3-22 NC Input
CN3-23 NC Input
CN3-24 VB (Controller PWR) Input
CN3-25 Flash light driver relay Output
CN3-26 NC Output
CN3-27 Travel Hi/Lo selector solenoid Output
CN3-28 2-stage relief solenoid Output
CN3-29 Swing pressure switch Input
CN3-30 Arm IN pressure switch Input
CN3-31 GND (Controller GND) Input
CN3-32 GND (Controller GND) Input
CN3-33 GND (Controller GND) Input
CN3-34 NC
CN3-35 NC Output
CN3-36 NC Output
CN3-37 Swing holding brake solenoid Output
CN3-38 Swing priority solenoid Output
CN3-39 Right travel pressure switch Input
CN3-40 Arm OUT pressure switch Input
MONITOR SYSTEM
1. Monitor panel
Outline
• The monitor panel has the functions to display
various items and the functions to select modes
and electric parts.
The monitor panel has a CPU (Central Process-
ing Unit) in it to process, display, and output the
information.
The monitor display unit consists of LCD (Liquid
Crystal Display). The switches are flat sheet
switches.
CN1 CN3
Pin Input/ Pin Input/
Signal name Signal name
No. output No. output
1 Key switch (Battery) Input 1 NC Input
2 Key switch (Battery) Input 2 NC Input
3 Washer motor output Output 3 NC Input
4 Key switch (Terminal C) Input 4 NC Input
5 Wiper contact W (Lower wiper contact P) Input 5 NC Input
6 GND 6 NC Input
7 GND 7 NC Input
8 VB + (24 V) Input 8 NC Input
9 Wiper motor (+) <Upper wiper motor (+)> Output Input/
9 NC
10 Wiper motor (–) <Lower wiper motor (–)> Output output
11 NC Input Input/
10 NC
12 Wiper contact P (Upper wiper contact P) Input output
11 NC Input
12 NC Input
CN2 13 NC
Pin Input/ 14 CAN (Shield) Input
Signal name
No. output 15 CAN (+) Input
1 NC Input 16 CAN (–) Input
2 Fuel Input
3 Radiator coolant level Input
4 NC Input
5 Air cleaner clogging sensor Input
6 NC Input
7 NC Input
8 Engine oil level sensor Input
Input/
9 Network (S-NET signal)
output
Input/
10 Network (S-NET signal)
output
11 Charge level Input
12 Hydraulic oil temperature (Analog) Input
13 GND (For analog signal)
14 Personal code relay (Lo) Input
15 Window limit switch <Lower wiper switch> Input
16 Buzzer cancel Input
17 Swing lock Input
18 Preheating Input
19 Light switch Input
20 Network (S-NET GND)
MONITOR PORTION
Engine coolant
temperature
Hydraulic oil
See gauge display on the next page
temperature
Fuel level
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.
When abnormal,
Engine oil pressure q — lights up and buzzer
sounds
Lights up when
Battery charge q —
abnormal
When abnormal,
Radiator coolant Lights up when
q lights up and buzzer
level abnormal
sounds
Lights up when
Engine oil level q —
abnormal
Lights up when
Air cleaner clogging q —
abnormal
The problems that have occurred are displayed in order from the left.
When the above cautions are displayed, if the hydraulic oil temperature is high or low, only the symbol is dis-
played.
INT ON OFF
Wiper Displays set condition
Monitor
SWITCHES
• Maintenance switch
Check the condition of the maintenance items.
(For details, see MAINTENANCE FUNCTION.) Swing priority mode
• Auto-deceleration switch
Each time the auto-deceleration switch is
pressed, the auto-deceleration function is
switched ON/OFF.
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.
• Control switch
This is used for control when using the mainte-
nance function or select function.
(For details, see each function.)
MAINTENANCE FUNCTION
a Maintenance items
Replacement
No. Item
interval (hours)
01 Engine oil 500
02 Engine oil filter 500
03 Fuel filter 500
04 Hydraulic filter 1,000
05 Hydraulic tank breather 1,000
06 Corrosion resistor 1,000
07 Damper case oil 1,000
08 Final case oil 2,000
09 Machinery case oil 1,000
10 Hydraulic oil 5,000
11 Pilot filter 500
12 Drain filter 500
Display Condition
Remaining time for mainte-
None nance for all items is more
than 30 hours
There is one or more items
Notice display (black sym-
with less than 30 hours
bol displayed on yellow
remaining time for mainte-
background)
nance
There is one or more items
Warning display (wiper
with not more than 0 hours
symbol displayed on red
remaining time for mainte-
background)
nance
MAINTENANCE ITEMS
MAINTENANCE OPERATION
Adjustment method
01 Contrast
02 Brightness
SENSORS
• The signals from the sensors are input directly to The contact type sensors are always connected
the engine controller and the pump controller at one end to the chassis GND.
monitor.
Name of sensor Type of sensor When normal When abnormal Input controller
Coolant level Contact type ON (closed) OFF (open) Monitor
Engine oil level Contact type ON (closed) OFF (open) Monitor
Engine oil pressure Contact type ON (closed) OFF (open) Engine controller
Coolant temperature Resistance type — — Engine controller
Fuel level Resistance type — — Monitor
Air cleaner clogging Contact type ON (open) OFF (closed) Monitor
Hydraulic oil temperature Contact type — — Monitor
Main pump oil pressure Analog — — Pump controller
1. Sub-tank
2. Float
3. Sensor
4. Connector
1. Connector
2. Bracket
3. Float
4. Switch
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
1. Float
2. Connector
3. Cover
4. Variable resistor
1. Thermistor 4. Tube
2. Body 5. Wire
3. Tube 6. Connector
1. Sensor
2. Connector
Engine SAA6D140E-3
lever knob
• Read max.
Bucket control lever value to end N o Curl, Dump 85 ± 10 85 ± 10
of travel
Swing control lever (Exclude play N o R.H., L.H. 85 ± 10 85 ± 10
at neutral.)
• Engine N o F, R
Travel control lever stopped 115 ± 12 115 ± 12
(L.H., R.H.)
Work equipment,
Play of control levers Max. 10 Max. 15
swing, travel
All control
2.21 ± 0.2 Min. 1.76
• Hydraulic oil levers at
{22.5 ± 2} {Min. 18}
temperature: neutral
Within operat-
TVC valve output ing range Boom RAISE 1.23 ± 0.2 1.18 ± 0.2
pressure • Engine at high relief (Normal) {12.5 ± 2} {12 ± 2}
idle
• Working Heavy lift ON +
1.19 ± 0.2 1.14 ± 0.2
mode: A Boom RAISE
{12.1 ± 2} {11.6 ± 2}
relief
• Hydraulic oil
All control Min. 1.14 Min. 1.14
temperature: MPa
levers at neutral {Min. 11.6} {Min. 11.6}
Within operat- {kg/cm2}
Jet sensor output ing range
negative pressure • Engine at high Track running
idle Max. 0.15 Max. 0.15
idle (Lever at
• Working {Max. 1.5} {Max. 1.5}
stroke end)
mode: A
• Hydraulic oil temperature:
PPC valve output Within operating range
pressure • Engine at high idle
• Control lever at stroke end
• Hydraulic oil temperature:
Within operating range
Max. 2.0 Max. 2.9
Oil pressure drop • Difference between relief pres-
{Max. 20} {Max. 30}
sure at high idle and that at low
idle
74 – 90 74 –90
Lo (PC750LC-7: (PC750LC-7:
80 – 98) 80 – 98)
Lo 22 – 29 22 – 29
• Working mode: A
• On level ground
• Run up for at least 10 m, Hi 15 – 19 15 – 19
and measure time taken
to travel next 20 m on flat
ground.
*RAISE
5.3 ± 0.5 Max. 6.7
PC750SE PC750SE
Boom 5.6 ± 0.6 Max. 7.2
5.7 ± 0.6 Max. 7.0
Lower bucket • Run engine at full throttle. PC800 PC800
tooth to ground. 5.3 ± 0.5 Max. 6.7
• Set in mode A. PC800SE PC800SE
• Hydraulic oil temperature: 5.6 ± 0.6 Max. 7.2
Extract cylinder 45 - 55°C PC750(LC) PC750(LC)
to stroke end. 4.3 ± 0.4 Max. 5.1
PC750SE PC750SE
LOWER
4.4 ± 0.4 Max. 5.2
5.0 ± 0.5 Max. 6.5
PC800 PC800
4.2 ± 0.4 Max. 5.0
PC800SE PC800SE
4.4 ± 0.4 Max. 5.2
PC750(LC) PC750(LC)
4.7 ± 0.5 Max. 5.9
PC750SE PC750SE
5.4 ± 0.5 Max. 6.6
*IN
PC750(LC) PC750(LC)
3.3 ± 0.3 Max. 3.9
PC750SE PC750SE
4.6 ± 0.5 Max. 5.6
*IN
Retract cylinder
to stroke end. — 1.6 ± 0.3 — Max. 2.5
Extract cylinder
CLOSE
to stroke end.
• Run engine at full throttle.
(PC750-7 — 1.7 ± 0.3 — Max. 2.6
loading shovel • Hydraulic oil temperature:
specification) 45 - 55°C
* Includes the operating time of the cylinder cushion.
Boom
45 - 55°C
Work equipment
sec.
Bottom cylinder
(PC750-7
• Time from stop of cylinder to start Max. 3 Max. 3
loading shovel
specification) after lever is set to closing posi-
tion when bottom is open fully.
• Run engine at slow speed.
• Hydraulic oil temperature:
45 - 55°C
Oil leakage
Hydraulic pump
• See following page. l/min See following page.
discharge amount
Cate-
Discharge amount of one hydraulic pump
gory
Performance of hydraulic pump
a As far as possible, bring pump discharge pressure P1 and P2 as close as possible to the average pressure when
measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
a When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the speci-
fied speed with the fuel control dial, take the pump discharge amount and the engine speed at the point of mea-
surement, and use them as a base for calculating the pump discharge amount at the specified speed.
symbol
Q’ty
Test, measuremnt item Part No. Part name Remarks
Measuring exhaust gas 1 799-201-9001 Handy smoke checker 1 Bosch index: 0 to 9 (With standard color)
C
color 2 Purchased Smoke meter 1
Adjusting valve clearance D Purchased Feeler gauge 1 (Intake: 0.35 mm, Exhaust: 0.57 mm)
1 795-502-1590 Compression gauge 1 0 to 6.9 MPa {0 to 70 kg/cm2}
Measuring compression
E 795-471-1310 Adapter 1 For 140E-3 engine
pressure 2
6217-71-6110 Gasket 1 For 140E-3 engine
Measuring blow-by pres-
F 799-201-1504 Blow-by checker 1
sure
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring engine oil pres-
G
sure 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
1 {25, 60, 400, 600 kg/cm2}
Measuring fuel pressure H
790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
2 799-401-2320 Hydraulic tester 1 Pressure gauge: 0.98 MPa {10 kg/cm2}
1 6151-51-8490 Spacer 1 Inside diameter: 14 mm
2 6206-71-1770 Joint 1 Joint diameter: 10 mm
3 6217-71-8820 Joint 1 Joint diameter: 14 mm
Testing of leakage through
pressure limiter and return S 4 Purchased Hose 1 Size x Length: Ø 5 mm x (2 to 3 m)
rate from injector
5 Purchased Hose 1 Size x Length: Ø 15 mm x (2 to 3 m)
6 Purchased Measuring cylinder 1 Capacity: 1 l
7 Purchased Stopwatch 1
Measuring clearance of
J Purchased Dial gauge 1 With magnet
swing circle bearing
Testing and adjusting in Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
799-101-5002 Hydraulic tester 1
work equipment, swing, {25, 60, 400, 600 kg/cm2}
K
and travel circuit oil pres-
sures 790-261-1204 Digital hydraulic tester 1 Pressure gauge: 58.8 MPa {600 kg/cm2}
symbol
Q’ty
Test, measuremnt item Part No. Part name Remarks
a For the model names and part Nos. of the T-adapters and boxes used for troubleshooting for the monitor
panel, controllers, sensors, actuators, and wiring harnesses, see TROUBLESHOOTING, Connector
arrangement drawing and electric circuit diagram of each system.
4 Engine hood assembly: 260 kg 4. Tighen locknut (6) to hold adjustment screw (5)
3 Locknut:
in position.
1. Remove the engine hood assembly and head 4. Install adapter E2 and connect it to compression
cover (1) of the cylinder to measure the com- gauge E1.
pression pressure.
3 Mounting bolt:
a Secure the adapter with the injector holder.
3 Mounting bolt:
valve clearance.
6. Disconnect engine intermediate connectors E21 3) Tighten sleeve nut (14) of the fuel high-pres-
(5) and E22 (6). sure tube to injector (11) lightly.
3 Mounting bolt:
4) Tighten mounting bolt (13) securely.
(body side) with a vinyl sheet, etc. to pre-
vent electric leakage and grounding fault. 58.8 – 73.5 Nm {6.0 – 7.5 kgm}
5) Tighten sleeve nut (14) of the fuel high-pres-
3 Sleeve nut:
sure tube securely.
a Measuring instruments for engine oil pressure 4. Start the engine and measure the oil pressure
with the engine at low idle and high idle.
Symbol Part No. Part Name
799-101-5002 Hydraulic tester
1
G 790-261-1204 Digital hydraulic tester
2 799-401-2320 Hydraulic tester
2. Testing leakage through pressure limiter 3. Testing return rate from injector
1) Adjust test hose S4 so that it will not sag a While testing the return rate from the injec-
and put its end in the oil pan (receiving pan). tor, keep the hose on the pressure limiter
2) Turn the starting switch ON and set the side connected and keep its end in the oil
monitor panel in the monitoring mode to pan (receiving pan).
check the engine speed. 1) Disconnect hose (5) from return block (4)
• Function name: 01 Monitoring and connect joint S3 and hose S5.
• Item name: 01002 Engine speed a Stop the hose end with a cork plug and
a For details of the operating method, see fix it to the machine.
Special function of monitor panel. a Be sure to fit gaskets to both sides of the
3) Start the engine and set its speed to 1,600 joint.
rpm at no load. a Bind the connecting parts with wires so
4) After the engine speed is stabilized, make a that the hose will not come off.
sign to the measurer to measure the leak- 2) Adjust test hose S5 so that it will not sag
age with measuring cylinder S6 for 1 and put its end in the oil pan (receiving pan).
minute.
a You may measure for 20 seconds and
multiply the obtained leakage by 3.
• Standard leakage: Max. 10 cc/min
(at 1,600 rpm)
1,600 960
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
1. Remove the fuel filter (1), fill the circuit with the
fuel and mount the filter again.
a Fill the circuit with clean fuel and be careful
to prevent dusts from entering the circuit.
a Pour the fuel in the inlet ports (1a) (at 8 plac-
es) of the filter. The portion (1b) is the outlet
port (clean side) after filtration, and do not
pour the filter in this port.
a When clean fuel is not readily available, do
not remove the fuel filter and fill the filter with
the fuel by operating the priming pump.
3 Air bleeder :
times until it become tight.
Testing Adjusting
The tension of this fan belt does not need to be 1. Tighten adjustment screw (2) until it touches
tested or adjusted until when the belt is replaced. bracket (5).
3 Locknut:
1. Open the engine compartment cover on the secure it with locknut (1).
counterweight side.
245.0 – 308.7 Nm {25.0 – 31.5 kgm}
2. Loosen locknut (1), and then fully loosen adjust-
ment screw (2) toward the counterweight. a If any clearance is made between adjustment
screw (2) and bracket (5), eliminate it by the
3. Insert a bar about 50 cm long in the hole (ø18) above procedure.
of tension pulley (3) and press tension pulley (3) a If the fan belts creak, adjust them by the above
toward the crank pulley to loosen the belt. procedure.
2. Measure the belt deflection (a) when pushing a 1. Loosen nuts and bolts (1), (2), (3) and (4) in this
point midway between the alternator pulley and order.
the drive pulley with the finger.
2. Turn nut (5) to move alternator (6), and adjust
a Deflection (a) when pressing force is approx. the belt tension.
58.8 N {approx. 6 kg}: 10 – 15 mm a Nut (5):
• It is moved to the side that belt is loos-
ened when fastening it clockwise.
• It is moved to the side that belt is ten-
sioned when loosening it counterclock-
wise.
a Test for breakage of each pulley, friction of
V-ditch, friction of belt, and contact between
belt and V-ditch.
a Replace it with new belt if it was too
stretched so that adjustability was lost, or cut
and crack occurred.
3. Tighten nuts and bolts (4), (3), (2) and (1) in this
order.
a When the belt was replaced, readjust it after
one-hour operation.
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
3. Measure max. clearance (a) between bar [1] 2. When the tension is too weak
and the track shoe. Add grease through grease fitting (4).
• Max. standard clearance (a): 10 – 30 mm a If the normal track shoe tension is not re-
stored even after greasing, move the ma-
chine slowly back and forth.
1. Preparation work
3 Locknut:
5) Fix holder (9) and tighten locknut (10). 2. Adjusting main relief valve (low-pressure set-
ting) of left 5-spool control valve
93 – 123 Nm {9.5 – 12.5 kgm} a If the work equipment oil pressure in the front
a If the high-pressure setting side is ad- pump circuit (during normal relief operation)
justed, the low-pressure setting side is abnormal or the high-pressure setting side
changes. Accordingly, adjust the low- was adjusted, adjust the low-pressure set-
pressure setting side, too. ting side of main relief valve (5) of the left 5-
spool control valve according to the following
procedure.
a The low-pressure setting is the state in which
the 2-stage relief solenoid valve is turned
OFF and the pilot pressure is not applied to
the changeover port.
1) Disconnect hose (6).
2) Loosen locknut (7) and set elbow (8) free.
3) Fix union (11) and loosen locknut (12).
4) Turn union (11) to adjust the pressure.
a If the union is
• turned to the right, the pressure ris-
es.
• turned to the left, the pressure low-
6) Fix elbow (8) and tighten locknut (7). ers.
7) Connect hose (6). a Pressure changed by 1 turn of union:
8) After finishing adjustment, check the oil 21.8 MPa {222 kg/cm2}
pressure again according to the above
3 Locknut:
described measurement procedure. 5) Fix union (11) and tighten locknut (12).
3. Adjusting main relief valve (high-pressure • (15): Safety valve of rear swing motor
setting) of right 4-spool control valve
a If the work equipment oil pressure in the rear
pump circuit (during heavy lift operation) and
the right travel oil pressure are abnormal, ad-
just the high-pressure setting side of main
relief valve (13) of the right 4-spool control
valve according to the following procedure.
3 Locknut:
ting side of main relief valve (13) of the right (17).
4-spool control valve according to the follow-
ing procedure. 147 –186 Nm {15 – 19 kgm}
a Adjust the right 4-spool control valve similar-
ly to the left 5-spool control valve.
Measuring
a Measure the control circuit oil pressure under
the following condition.
• Hydraulic oil temperature: Within operating
MEASUREMENT
a Measure the piston pump control oil pressure
under the following conditions: 4) Start the engine and set the working mode
• Hydraulic oil temperature: Within the operat- switch in the A-mode position.
5) Set all the control levers in neutral and
k Lower the work equipment to the ground and
ing range
measure the TVC valve output pressure
stop the engine. Operate the control levers sev- under the following condition.
eral times to release the residual pressure in the i) Set all the control levers in neutral.
piping, and then loosen the oil filler cap of the ii) Run the engine at high idle and measure
hydraulic tank slowly to release the internal the output pressure.
pressure of the hydraulic tank. 6) Relieve the boom circuit by raising the boom
(normally), and measure the TVC valve out-
1. Measuring TVC valve output pressure put pressure under the following condition.
a Since the TVC valve output pressure varies i) Turn the heavy lift switch OFF.
with the discharge pressure of each pump, ii) Run the engine at high idle, relieve the
check that the oil pressure in the work equip- boom circuit by raising the boom, and
ment, swing, and travel circuits is normal be- measure the output pressure.
fore starting measurement. 7) Turn the heavy lift switch ON, relieve the
a Since the basic pressure of the TVC valve boom circuit by raising the boom, and meas-
output pressure is the control circuit pres- ure the TVC valve output pressure under
sure, check that the control circuit pressure the following condition.
is normal before starting measurement. i) Turn the heavy lift switch ON.
1) Open the undercover of the No. 1 pump. ii) Run the engine at high idle, relieve the
2) Remove oil pressure pickup plug (1) of the boom circuit by raising the boom, and
No. 1 front pump. measure the output pressure.
3) Install nipple M3 and connect oil pressure 8) After finishing measurement, remove the
gauge [1] of hydraulic tester M1. measuring instruments and return the
removed parts.
2. Measuring CO-NC valve output pressure 7) Drive the travel motor idle and measure the
1) Open the undercover of the No. 2 pump. CO-NC valve output pressure under the fol-
2) Remove oil pressure pickup plugs (2) and lowing condition.
(3) of the No. 2 pump. i) Raise the track shoe to be measured by
• (2): For front pump circuit using the boom and arm.
• (3): For rear pump circuit ii) Run the engine at high idle, drive the
travel motor idle (with the lever at the
stroke end), and measure the output
pressure.
8) Turn the heavy lift switch ON, relieve the
boom circuit by raising the boom, and meas-
ure the output pressure under the following
condition.
i) Turn the heavy lift switch ON.
ii) Run the engine at high idle, relieve the
boom circuit by raising the boom, and
measure the output pressure.
3 Locknut:
(10).
6) After finishing measurement, remove the 5.9 – 9.8 Nm {0.6 – 1.0 kgm}
measuring instruments and return the
removed parts.
ADJUSTING
1. Adjusting TVC valve
a When adjusting the TVC valve, open the
pump compartment cover.
a If the TVC valve output pressure is abnor-
mal, adjust TVC valve (8) of the No. 1 pump
according to the following procedure.
3 Locknut:
locknut (18).
3 Locknut:
locknut (16).
iv) After finishing adjustment, check the oil
5.9 – 9.8 Nm {0.6 – 1.0 kgm} pressure again according to the above
described measurement procedure.
3 Locknut: 59 – 78 Nm {6 – 8 kgm}
nut (22).
1. Preparation of tool
Drill a through hole PT1/4 in the center of the
cap N1 and screw the disc gauge N2 in the hole.
a Prepare the cap for the side where the spring
of the hydraulic pump servo piston is fitted.
stop the engine. Operate the control levers sev- 4. Run the engine at high idle, operate the control
eral times to release the residual pressure in the lever of the PPC circuit to be measured, and
piping, and then loosen the oil filler cap of the measure the oil pressure.
hydraulic tank slowly to release the internal a Move the control lever to the stroke end.
pressure of the hydraulic tank. a Condition of actuator to be measured
• When measuring the pressure for the
1. Remove the control valve top cover. work equipment, move each cylinder to
the stroke end.
2. Disconnect hose (1) of the PPC circuit to be • When measuring the pressure for swing,
measured. Install adapter P2 and connect the turn the swing lock switch ON.
hose again. • When measuring the pressure for travel,
a For the hose to be disconnected, see the put pin [3] between the sprocket and
connection diagram on the next page. track frame to lock the track shoe.
a The colors in ( ) in the figure are the colors of the tapes wound onto the hoses.
NOTE: The inlet pressure of the swing priority solenoid valve is the boom RAISE PPC circuit pressure.
Accordingly, when measuring the outlet pressure, move the boom control lever to the RAISE stroke end
(The boom cylinder may be at the RAISE stroke end).
2. Measuring outlet pressure of swing PPC 3. Measuring outlet pressure of swing priority
shuttle valve selector valve
1) Disconnect outlet hose (9) of the swing PPC 1) Disconnect outlet hoses (10) and (11) of the
shuttle valve. Install adapter Q2 and con- swing priority selector valve. Install adapt-
nect the hose again. ers Q2 and connect the hoses again.
a When measuring the swing PPC shuttle a When measuring the swing priority se-
valve, remove the control valve top cover. lector valve, remove the control valve
top cover.
• (10): Port A1 (For swing)
• (11): Port A2 (For arm Lo and bucket Hi)
3 Locknut :
(2) to the specified torque.
• No. 1 pump
• No. 2 pump
• No. 2 pump
3. Add shim (2) according to the deviation and
tighten bolt (1).
a Limit the thickness of the added shim to 3
a Measure the oil leakage under the following PRESSURE FROM HYDRAULIC CIR-
condition. CUIT, release the residual pressure
• Hydraulic oil temperature: Within operating from the piping on the arm cylinder
range head side (Operate the lever only in the
IN direction, however).
1. Measuring leakage from boom cylinder 2) Disconnect hose (2) on the cylinder head
1) Run the engine and raise the boom to the side and block it with a flange.
3. Measuring leakage from bucket cylinder 4. Measuring leakage from swing motor
1) Run the engine and curl the bucket to the 1) Disconnect drain hoses (4) and (5) and plug
stroke end. them.
5. Measuring leakage from travel motor 6. Measuring leakage from center swivel joint
1) Remove the travel motor cover. 1) Put block [1] between the sprocket and
2) Disconnect the hoses of the upper and 3) Run the engine at high idle and measure the
lower measurement ports of the inspection oil leakage through the measurement ports.
port from the top of the swivel joint and a When measuring ports A, B, C, and D,
block them. relieve the travel motor slowly in the re-
a For combination of the inspection port volving direction (See the table on the
and measurement ports, see the above last page).
table. a When measuring port P, set the travel
a Use the following parts to block the hos- speed shifting switch in the Hi position.
es. 4) Start measuring the oil leakage 1 minute
• Ports A, B, C, and D: 07379-01044 after the center swivel joint is relieved and
(Flange #10) measure for 1 minute.
• Port P: 07376-70315 (Plug #03)
• Port T: 07376-70522 (Plug #05)
NOTE: Bleed air from the swing motor and travel motor only when the oil was drained from the motor cases.
1. Bleeding air from hydraulic pump 3) After clear oil flows out of bleeders (1) and
3 Bleeder:
1) Loosen air bleeders (1) and (2) by 4 turns (2), tighten the bleeders.
and remove the oil filler cap of the hydraulic
tank. 7.8 – 9.8 Nm {0.8 – 1.0 kgm}
a Leave the machine under the above
condition for 10 minutes or more.
2) After oil flows out of bleeders (1) and (2),
run the engine at low idle.
a If the engine coolant temperature is low
and the automatic warm-up operation is
started, stop the engine temporarily and
reset the automatic warm-up operation
with the fuel control dial (Set the starting
switch in the ON position and hold the
fuel control dial in the MAX position for 3
seconds, and the automatic warm-up
operation is reset).
a Set the lock lever in the LOCK position
so that you will not operate a lever by
mistake.
3 Bleeder:
gree that the machine starts traveling.
[1] Figure input switch 1 [6] Figure input switch 6 [ ] Return switch
[2] Figure input switch 2 [7] Figure input switch 7 [ ] Upward move switch
[3] Figure input switch 3 [8] Figure input switch 8 [ ] Downward move switch
[4] Figure input switch 4 [9] Figure input switch 9 [ ] Input confirmation switch
[5] Figure input switch 5 [0] Figure input switch 0
division
History
code
User
Electrical system
— E205 Swing Priority Sol. S/C DW41KB Swing solenoid valve Short circuit
Travel high-low selector
— E206 Travel Speed Sol. S/C DW43KB Short circuit
solenoid valve
— E207 Flash Light Relay S/C D163KB Flash light drive relay Short circuit
Cut-off cancel solenoid
— E211 CO Cancel Sol. Disc. DW48KA Disconnection
valve
Travel neutral solenoid
— E212 Travel Junction Sol. Disc. DW91KA Disconnection
valve
Swing holding brake
E03 E213 Swing Brake Sol. Disc. DW45KA Disconnection
solenoid valve
2-stage relief solenoid
— E214 2-stage Relief Sol. Disc. DWK0KA Disconnection
valve
— E215 Swing Priority Sol. Disc. DW41KA Swing solenoid valve Disconnection
Travel high-low selector
— E216 Travel Speed Sol. Disc. DW43KA Disconnection
solenoid valve
Pump controller model Disagreement of model
— E217 Model selection Abnormality DA2SKQ
selection wiring harness selection signals
Pump controller S-NET
E0E E218 S-Net Comm. Disc. DA2SKA Disconnection
communication
— E221 Travel Alarm S/C DV20KB Backup alarm buzzer Short circuit
Front pump pressure
— E224 F Pump P. Sensor Abnormality DHPAMA Malfunction
sensor
Rear pump pressure
— E225 R Pump P. Sensor Abnormality DHPBMA Malfunction
sensor
Output of pump control- Lowering of output
— E226 Press. Sensor Power Abnormality DA25KP
ler power supply voltage
division
History
code
User
Electrical system
E11 E93C Engine boost sensor error DH30KX Boost pressure sensor Out of input signal range
E15 E93D Engine fuel temp. sensor error DGE4KX Fuel temperature sensor Out of input signal range
Engine controller CAN
E0E E953 Engine Comm. Abnormality DB2RMC Defective operation
communication
— E954 Short engine starter sw. DD11KB Starting switch Short circuit
Engine controller S-NET
E0E E955 Engine S-NET error DB2SMC Defective operation
communication
Engine controller load Lowering of source
E10 E956 Engine power failure (1) DB22KK
power source line voltage (Input)
Engine controller load
E15 E957 Engine power failure (2) D1D0KB Short circuit
power source relay
Rotary switch in engine
— E95A Engine Q-adj. sw. signal error DB2AMA Malfunction
controller
Engine coolant tempera- Disagreement of signals
E15 E96A Engine coolant sensor Lo error DGE3L6
ture sensor 2 and run/stop of engine
Supply pump (1)
E11 E970 PCV1 over current AD11KB Short circuit
solenoid valve
Supply pump (2)
E11 E971 PCV2 over current AD51KB Short circuit
solenoid valve
Supply pump (1)
E11 E974 PCV1 line cut AD11KA Disconnection
solenoid valve
Supply pump (2)
E11 E975 PCV2 line cut AD51KA Disconnection
solenoid valve
Common rail fuel
E11 E977 Rail press. sensor error DH40KX Out of input signal range
pressure sensor
E11 E979 Rail press. high AD00L2 Common rail Fuel pressure is too high
division
History
code
User
Electrical system
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
Injector 1, 2, 3 solenoid
E11 E98A Fuel Injector 1 – 3 S/C ADAZKB Short circuit
valve
Injector 4, 5, 6 solenoid
E11 E98B Fuel Injector 4 – 6 S/C ADDZKB Short circuit
valve
— None Eng. Lo Out of Std A000KX Engine Out of input signal range
— None Eng. Hi Out of Std A000N1 Engine Overrun
— None Aircleaner Clogging AA10NX Air cleaner element Clogging
Mechanical system
— None Charge Voltage Low AB00KE Alternator Defective charge
E11 E924 Eng. Oil Press. Low B@BAZG Engine oil Lowering of oil pressure
— None Eng. Oil Level Low B@BAZK Engine oil Lowering of level
— None Eng. Water Overheat B@BCNS Cooling water Overheating
— None Eng. Water Lvl Low B@BCZK Cooling water Lowering of level
— None Hydr. Oil Overheat B@HANS Hydraulic oil Overheating
— None Auto. Lub. Abnormal. DA80MA Auto grease controller Malfunction
a The items in this list are arranged in the order of the error codes.
a The error codes having no numbers in the user code column and the failure codes having no numbers in
the 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 sys-
tem or mechanical system).
a The history division column shows in which division each failure is classified, the electrical system or
mechanical system, when it is recorded in the failure history.
a In "Error code: E924/Failure code: B@BAZG", the error code is displayed only when the user code is
turned ON and the failure code is recorded in only the mechanical system of 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.
2) Switch operation
Operate the switch as instructed below.
• Switch operation: [ ] + [1] o [2] o [3]
(Enter a figure, depressing [ ])
1) Selection of menu
Select "01 Monitoring" in the initial display of
Service Menu and depress [ ] switch.
3) Monitoring operation
Call the monitoring information display and
confirm the monitored information, while
operating the machine.
a As the unit of display, one of "SI unit system", "Metric unit system", and "Inch unit system" can be selected.
a The unit of display can be changed with "Selection of unit" in the "AAAA/ Default" function of the service
menu.
a "CA" of the unit of display denotes the crankshaft angle.
Note 1: The momentary fuel consumption ratio shown above is the theoretical fuel consumption ratio (Since it is
a theoretical value, it is a little different from the actual fuel consumption ratio).
Note 2: The fuel consumption amount is the theoretical fuel consumption amount after the engine is started until
the engine is stopped (Since it is a theoretical value, it is a little different from the actual fuel consump-
tion amount).
1) Selection of menu
Select 02 Abnormality Record in the initial
display of Service Menu and depress [ ]
switch.
2) Selection of Submenu
Select an appropriate item from Submenu in
the Abnormality Record display and depress
[ ] switch.
No. Abnormality Record Submenu
Return
00
(termination of Abnormality Record)
01 Electrical Systems
02 Mechanical Systems
1) Selection of menu
Select 03 Maintenance Record in Service
Menu and depress [ ] switch.
2) Information to be displayed
[1]: Name of oils and filters
[2]: Times of replacement to date
[3]: Service meter reading at the latest
replacement
1) Selection of menu
Select 04 Maintenance Mode Change in the
initial display of Service Menu, and depress
[ ] switch.
1) Selection of menu
Select 05 Phone Number Entry menu in the
display of Service Menu, and depress [ ]
switch.
1) Selection of menu
Select 06 "AAAA/Default menu" in the ini-
tial display of Service Menu, and depress
[ ] switch.
2) Selection of submenu
Select an item to change from the submenu,
and depress [ ] switch.
No. AAAA/Default submenu
00 Return (termination of AAAA/Default)
01 Key-on Mode
02 AA/Language
03 Unit
04 Wiper Select
1) Selection of menu
Select "07 Adjustment" on the service menu
and press the [ ] switch.
1) Selection of menu
Select "08 Cylinder cut out" on the initial
screen of the service menu and press the
[ ] switch.
PREPARATION WORK
a When troubleshooting an electric circuit related 2. Engine controller
to the monitor panel, engine controller, or pump 1) Slide the operator's seat and seat stand for-
controller, expose the related connectors ward to the stroke end.
according to the following procedure. 2) Insert or connect T-adapters for trouble-
shooting to connectors E11, E12, and E13
1. Monitor panel of engine controller (3).
1) Remove cover (1). a Since the connectors are secured with
a The cover is secured with 2 clips at the screws, loosen those screws before dis-
top and bottom. Those clips can be re- connecting them.
moved by pulling them up. a After returning the connectors, tighten
3. Pump controller
2) Remove the 3 mounting screws and discon- a The pump controller is installed in the cover
nect monitor panel (2) from the mount. at the rear of the operator's seat.
a Take care not to drop the mounting 1) Remove 3 caps (4) and 3 mounting bolts.
screws in the console. a Remove the caps with a thin flat-head
3) Insert or connect T-adapters for trouble- screwdriver.
shooting to connectors P01, P02, and P70 2) Remove cover (5).
of the monitor panel.
Specification of machine
Positions to install measuring devices (Related to relief pressure and OLSS oil pressure)
What is maximum level of coolant temperature? What is maximum level of hydraulic oil temperature?
(During work) (During work) Outside temperature
Max.: °C
Min.: °C
Height: m
0.34 – 0.54
SAE30 {3.5 – 5.5}
0.21 {2.1}
High idle
0.29 – 0.49
SAE10W 0.18 {1.8}
MPa {3.0 – 5.0}
3. Engine oil pressure
{kg/cm2} Min. 0.12
SAE30 0.08 {0.8}
{Min. 1.2}
Low idle
Min. 0.10
SAE10W 0.07 {0.7}
{Min. 1.0}
High idle
kPa Min. 147
4. Boost pressure Turn heavy lift switch ON 117 {880}
{mmHg} {Min. 1100}
Raise boom to relieve
Exhaust
High idle Max. 700 750
5. Exhaust temperature
A-mode °C
temperature Turn heavy lift switch ON
Outside
Raise boom to relieve — —
temperature
*1: Turn swing lock switch ON and operate swing control lever finely (Do not relieve).
* PC750LC-7: 52 – 64
Oil temperature:
45 – 55°C Backhoe Max. 900 Max. 1000
Hydraulic drift of Bucket Hydraulic spec.
6 work equipment • Backhoe spec.: drift of mm/15 min.
Empty tooth tip Loading
• Loading shovel spec.: shovel spec. Max. 1500 Max. 1800
Rated load on bucket
Memo
UNDERCARRIAGE INSPECTION
(Program form No.: ***************)
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 5) Other maintenance items can be checked
to disassemble the components. externally, so check any item that is consid-
If components are disassembled immediately ered to be necessary.
any failure occurs:
• Parts that have no connection with the failure 4. Confirming failure
or other unnecessary parts will be disassem- • Confirm the extent of the failure yourself, and
bled. judge whether to handle it as a real failure or
• It will become impossible to find the cause of as a problem with the method of operation,
the failure. etc.
It will also cause a waste of manhours, parts, or a When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in 5. Troubleshooting
accordance with the fixed procedure. • Use the results of the investigation and in-
spection in Items 2 – 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart ing flowchart to locate the position of the fail-
from the problem that has been reported? ure exactly.
2) Was there anything strange about the a The basic procedure for troubleshooting
machine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or
4) Under what conditions did the failure occur? information.
5) Had any repairs been carried out before the
failure? 6. Measures to remove root cause of failure
When were these repairs carried out? • Even if the failure is repaired, if the root
6) Has the same kind of failure occurred cause of the failure is not repaired, the same
before? failure will occur again.
To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
4) Check the stroke of the control valve spool.
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.
• 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, press
down the stopper with your thumb and pull
the connectors apart.
a Never pull with one hand.
• 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 to
the 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.
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.
6) Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit.
Normally, flushing is carried out twice: primary
flushing is carried out with flushing oil, and sec-
ondary flushing is carried out with the specified
hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil 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.
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.
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Action to be taken concerning Error Code, User Code and Failure Code
1 Display User Code in monitor panel
Accord-
2 Display Error Code in electrical system after checking failure historying to
displayed
Display Failure Code in mechanical system after checking failure his-
3 code
tory
Engine-related failure
4 Starting performance is poor (starting always takes time) S-1
5 Engine does not turn E-1 S-2 a)
Engine turns but no exhaust smoke
6 S-2 b)
Engine does not start comes out
Exhaust smoke comes out but engine
7 S-2 c)
does not start (Fuel is being injected)
8 Engine does not pick up smoothly (follow-up is poor) S-3
9 Engine stops during operations S-4
10 Engine does not rotate smoothly (hunting) S-5
11 Engine lacks output (or lacks power) S-6
12 Exhaust smoke is black (incomplete combustion) S-7
13 Oil consumption is excessive (or exhaust smoke is blue) S-8
14 Oil becomes contaminated quickly S-9
15 Fuel consumption is excessive S-10
16 Oil is in coolant (or coolant spurts back, or coolant level goes down) S-11
17 Oil pressure caution lamp lights up (drop in oil pressure) S-12
18 Oil level rises (water, fuel in oil) S-13
19 Water temperature becomes too high (overheating) S-14
20 Abnormal noise is made S-15
21 Vibration is excessive S-16
22 Preheater does not operate E-2
23 Auto engine warm-up device does not work E-3
24 Auto-decelerator does not operate E-4
Failure related to work equipment, swing and travel
25 Speed or power of all work equipment, travel, and swing is low H-1
26 Engine speed lowers remarkably or engine stalls H-2
27 All work equipment, travel, and swing systems do not work E-5 H-3
28 Abnormal sound is heard from around pump H-4
Work equipment-related failure
29 Boom speed or power is low H-5
30 Speed or power of arm is low H-6
31 Speed or power of bucket is low H-7
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
32 Boom does not move H-8
33 Arm does not move H-9
34 Bucket does not move H-10
35 Hydraulic drift of work equipment is large H-11
36 Time lag of work equipment is large H-12
37 Heavy lift function does not operate or stop H-13
38 Machine push-up function does not operate or stop E-6 H-14
39 Boom shockless function cannot be turned ON or OFF E-7 H-15
Travel-related failure
40 Machine deviates in one direction H-16
41 Machine deviates largely at start H-17
42 Machine deviates largely during compound operation H-18
43 Travel speed or power is low H-19
44 Machine does not travel (only one track) H-20
45 Travel speed does not change H-21
46 Travel alarm does not sound or does not stop sounding E-32
Swing-related falure
47 Upper structure does not swing H-22
48 Swing speed or acceleration is low H-23
Swing speed or acceleration is low during compound operation of
49 H-24
swing and work equipment
50 Upper structure overruns excessively when it stops swinging H-25
51 Large shock is made when upper structure stops swinging H-26
52 Large abnormal sound is made when upper structure stops swinging H-27
53 Hydraulic drift of swing is large H-28
Monitor panel-related failure (Operator’s Menu: ordinary Display)
54 Any item is not displayed on monitor panel E-8
55 Part of display on monitor panel is missing E-9
56 Monitor panel displays contents irrelevant to the model E-10
57 Fuel level monitor red lamp lights up while engine is running E-11
58 Engine coolant thermometer does not display normally E-12
59 Hydraulic oil temperature gauge does not display correctly E-13
60 Fuel gauge does not display correctly E-14
61 Swing lock monitor does not display correctly E-15
62 When monitor switch is operated, nothing is displayed E-16
63 Windshield wiper and window washer do not work E-17
64 Alarming buzzer cannot be cancelled E-18
Troubleshooting
No. Failure-looking phenomenon Code
E mode H mode S mode
display
Monitor panel-related failure (Service Menu: Special Function Display)
65 "Boom RAISE" is not correctly displayed in monitor function E-19
66 "Boom LOWER" is not correctly displayed in monitor function E-20
67 "Arm IN" is not correctly displayed in monitor function E-21
68 "Arm OUT" is not correctly displayed in monitor function E-22
69 "Bucket CURL" is not correctly displayed in monitor function E-23
70 "Bucket DUMP" is not correctly displayed in monitor function E-24
71 "SWING" is not correctly displayed in monitor function E-25
72 "Left travel" is not displayed normally in monitoring function E-26
73 "Right travel" is not displayed normally in monitoring function E-27
74 "Service" is not correctly displayed in monitor function E-28
Other failure
75 Air conditioner does not work E-29
76 Step light does not light up or go off E-30
77 Electric grease gun does not operate E-31
a The addresses roughly show the places of the connectors in the 3-dimensional connectors arrangement
drawing and the electric circuit diagram of each system.
Address
Connector Connector No. of
Place of use Stereo- M E P
No. Type pin
gram circuit circuit circuit
D01 SWP 8 Assembled-type diode W-7 E-9 A-4
D02 SWP 8 Assembled-type diode W-7 F-9 A-3
D03 SWP 8 Assembled-type diode R-1 A-3
D04 SWP 8 Assembled-type diode Q-1 A-3
D05 SWP 8 Assembled-type diode Q-1 F-9 A-2
D06 SWP 8 Assembled-type diode Q-1 F-9
D07 KES1 2 Diode S-9 E-9
D08 KES1 2 Diode S-9 E-9
E Terminal 1 Battery relay terminal E A-7 J-7 H-2 L-7
E06 M 3 Fuel control dial O-8 K-8
E09 S 8 Model selection connector (for engine controller) W-5 A-1
E11 DRC 24 Engine controller V-1 K-2 A-7 F-4
E12 DRC 40 Engine controller V-1 K-1 A-6 F-3
E13 DRC 40 Engine controller V-1 A-4
E21 HD30 31 Intermediate connector AJ-4 I-4
E22 HD30 31 Intermediate connector AJ-3 J-4 I-7 K-6
ENE DT 2 Engine speed sensor AJ-6 L-6
F01 X 2 Travel alarm L-8 L-5
F02 YAZAKI 2 Intermediate connector AA-9
FB1 — — Fuse box W-3 H-7 G-8
G YAZAKI 2 Engine G sensor AH-2 K-5
G11 X 2 Electric grease gun A-5
G12 X 2 Electric grease gun remote switch A-3
H08 M 8 Intermediate connector W-4 D-7
H09 S 8 Intermediate connector W-4 D-7 D-1
B-1
H10 S 16 Intermediate connector T-9 J-8 E-2
D-6
B-1
H11 S 16 Intermediate connector T-9 E-2
D-5
H12 S 12 Intermediate connector U-9 D-4 J-7 E-2
H15 S090 20 Intermediate connector N-7 D-3 I-9 A-2
HT Terminal 3 Heater relay AJ-5 K-2
J01 J 20 Joint connector (Black) W-8 C-9 G-9 A-9
J02 J 20 Joint connector (Black) W-8 C-9 G-9 A-9
J03 J 20 Joint connector (Pink) W-8 D-9 B-9
J04 J 20 Joint connector (Green) W-7 D-9 B-9
J05 J 20 Joint connector (Pink) W-6 E-9 C-9
J06 J 20 Joint connector (Orange) W-6 C-9
J07 J 20 Joint connector (Green) V-9 E-9 D-9
J08 J 20 Joint connector (Pink) U-9 G-9 D-9
J09 J 20 Joint connector (Black) X-2 D-9
J11 DT 8 Joint connector L-8 H-9
J12 DT 8 Joint connector L-6 H-9
J13 DT 8 Joint connector K-2 I-9
J14 DT 8 Joint connector L-5 I-9 H-9 I-9
J15 DT 8 Joint connector J-9 I-9
J16 DT 8 Joint connector J-9 H-9
J17 DT 8 Joint connector K-9 I-9
J18 DT 6 Joint connector F-9 I-9 I-9
Address
Connector Connector No. of
Place of use Stereo- M E P
No. Type pin
gram circuit circuit circuit
J19 DT 6 Joint connector H-1 J-9
J20 DT 6 Joint connector L-7 I-9 J-9
J21 DT 6 Joint connector I-9 J-9 J-9
J22 DT 8 Joint connector D-1 J-9 J-9
K19 M 2 Pump resistor (for driving pump in emergency) U-2 B-1
K30 DT 3 CAN terminal resistor W-2 K-1 A-1 F-3
K31 DT 3 CAN terminal resistor N-4 A-4 K-7 E-1
M Terminal 1 Battery relay terminal M C-9 J-7 I-2 L-7
M07 M 3 Light switch P-8 D-1
M08 M 1 Working lamp (Boom) B-9 H-1
M09 M 1 Working lamp (Boom) A-9 H-1
M10 X 1 Intermediate connector E-9 H-2
M13 KES0 2 Speaker (Right) AC-8
M16 Terminal 1 Horn (High tone) C-1 G-9
M17 Terminal 1 Horn (Low tone) B-1 H-9
M19 YAZAKI 2 Cigarette lighter N-3
M21 PA 9 Radio U-2
M22 Y090 2 Horn switch N-7 B-1
M26 S 12 Air conditioner unit W-5
M28 SWP 2 Windshield washer motor I-1 K-8
M31 M 2 Optional power supply (2) U-2
M32 M 2 Optional power supply (1) S-9
M33 M 2 Optional power supply (3) W-3
M34 X 1 Air conditioner compressor electromagnetic clutch AG-2
M37 Terminal 1 Horn (High tone) D-1 G-9
M38 Terminal 1 Horn (Low tone) C-1
M38 M 2 Machine push-up switch R-9 A-1
M39 M 3 Boom shockless control switch W-4 F-1
M40 YAZAKI 2 Headlamp Z-8 A-8
M41 YAZAKI 2 Headlamp Y-7 A-8
M42 M 1 Right headlamp A-3 I-1
M45 DT 12 Intermediate connector U-2
M46 X 4 RS232C junction connector N-3 A-4
M71 M 2 Room lamp Z-8
M72 M 4 DC/DC converter U-2
M73 KES0 2 Speaker (Left) AD-8
M75 YAZAKI 2 Step light AB-1 D-1
M79 YAZAKI 2 12-V accessory socket V-9
M80 X 1 Intermediate connector E-1 G-9
M81 M 2 Step light switch AD-2 F-1
M82 M 1 Flash light E-1 G-9
M95 X 4 Intermediate connector D-1 G-9
NE YAZAKI 2 Engine Ne sensor AJ-4 K-5
OL DT 2 Engine oil level sensor AH-2 K-3
A-7
P01 070 12 Monitor panel N-6 K-8 E-1
A-1
A-6
P02 040 20 Monitor panel N-5 K-8 E-1
A-1
P03 M 2 Alarm buzzer stop switch P-9 D-1
P05 M 2 Rotary lamp switch W-4
P06 DT 2 Fuel level sensor C-9 K-4
Address
Connector Connector No. of
Place of use Stereo- M E P
No. Type pin
gram circuit circuit circuit
P08 X 2 Radiator coolant level switch L-7 K-5
P10 DT 2 Hydraulic oil temperature sensor L-5 K-6
P11 DT 2 Air cleaner clogging switch I-9 K-5
P15 Y050 2 Air conditioner sunlight sensor N-6
P16 YAZAKI 2 Air conditioner outside temperature sensor H-9
P20 X 2 Radiator coolant level switch L-8 K-5
P30 DT 3 Front pump pressure sensor H-9 L-5
P31 DT 3 Rear pump pressure sensor J-9 L-5
P70 040 16 Monitor panel N-4 A-5 K-7 E-1
PCV1 SUMI 2 Fuel supply pump PCV1 AG-2 K-3
PCV2 SUMI 2 Fuel supply pump PCV2 AH-2 K-2
PFUEL AMP 3 Common rail pressure sensor AH-3 K-7
PIM SUMI 3 Boost pressure sensor AG-7 K-6
PSH Terminal 1 Engine oil pressure switch (High pressure) AI-3 L-5
PSL Terminal 1 Engine oil pressure switch (Low pressure) AI-3 L-6
R10 R 5 Light relay O-8 G-1
R11 R 5 Starting motor cut-out relay (PPC lock) P-8 G-1
R13 R 5 Starting motor cut-out relay (Personal cord) Q-9 H-1
R14 R 5 Step light power supply drive relay W-5 F-9
R15 R 5 Step light relay W-5 E-9
R20 R 5 Horn relay W-6 E-9
R21 R 5 Flash light relay W-7 E-9
R22 R 5 Engine controller power supply relay W-5 B-9
S01 X 2 Right travel forward PPC oil pressure switch G-1 K-3
S02 X 2 Boom RAISE PPC oil pressure switch K-2 K-2
S03 X 2 Arm OUT PPC oil pressure switch L-3 K-2
S04 X 2 Boom LOWER PPC oil pressure switch K-2 K-2
S05 X 2 Arm IN PPC oil pressure switch L-3 K-2
S06 X 2 Bucket CURL PPC oil pressure switch L-2 K-2
S07 X 2 Bucket DUMP PPC oil pressure switch L-2 K-2
S08 X 2 Swing RIGHT PPC oil pressure switch L-4 K-2
Service PPC oil pressure switch
S09 X 2 J-1 K-1
(Intermediate connector)
S10 X 2 Swing LEFT PPC oil pressure switch L-3 K-1
S11 X 2 Right travel reverse PPC oil pressure switch H-1 K-1
S12 X 2 Left travel forward PPC oil pressure switch H-1 K-1
S13 X 2 Left travel reverse PPC oil pressure switch I-1 K-1
S14 M 3 Lock lever switch S-1 F-2 F-9
S21 Terminal 6 Emergency pump drive switch R-9 C-1
S22 Terminal 6 Swing holding brake release switch R-9 D-1
S25 S090 16 Intermediate connector Q-9
ST DT 2 Starting motor AH-8 K-4 K-6
T02 Terminal 1 Revolving frame ground A-6 K-6 K-8
T03 Terminal 1 Revolving frame ground A-6 K-6 K-8
T04 Terminal 1 Revolving frame ground A-4 G-1
T05 Terminal 1 Floor frame ground W-3 F-7 D-2
T06 Terminal 1 Radio body ground T-2
T06A M 1 Intermediate connector T-1
T08 Terminal 1 Engine controller ground V-1 A-1
T09 Terminal 2 Revolving frame ground A-4 L-6 K-8
T10 Terminal 1 Revolving frame ground F-1 H-8
Address
Connector Connector No. of
Place of use Stereo- M E P
No. Type pin
gram circuit circuit circuit
T11 Terminal 1 Cab ground AD-3
T12 Terminal 1 Revolving frame ground A-4 L-6 K-8
T14 Terminal 2 Revolving frame ground A-4 G-1
THL DT 3 Spill fuel temperature sensor AI-3 K-4
TWH DT 2 Engine coolant temperature sensor (High temperature) AE-7 K-6
TWL DT 3 Engine coolant temperature sensor (Low temperature) AF-7 K-6
V01 DT 2 Swing priority solenoid valve G-1 G-2
V02 DT 2 2-stage relief solenoid valve L-8 G-2
V03 DT 2 Travel junction solenoid valve L-5 G-2
V04 DT 2 Swing holding brake solenoid valve F-9 G-2
V05 DT 2 Machine push-up solenoid valve G-9 G-2
V06 DT 2 Travel speed selector solenoid valve G-9 G-2
V07 DT 2 CO cancel solenoid valve L-4 G-1
V08 DT 2 PPC oil pressure lock solenoid valve G-1 G-1
V09 DT 2 Boom shockless control solenoid valve (Raise) J-1 G-1
V10 DT 2 Boom shockless control solenoid valve (Lower) J-1 G-1
W03 X 2 Window rear limit switch [Single-wiper specification] AB-9 A-9
B-2
W04 M 6 Wiper motor Y-4
B-7
W05 M 6 Lower wiper motor [Double-wiper specification] E-1 G-9
W06 M 2 Lower wiper switch [Double-wiper specification] W-4 E-1
X05 M 4 Swing lock switch Q-9 E-1 A-1
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.
a This circuit diagram is made by extracting the engine controller system from the general electric circuit dia-
gram.
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.
X type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
1 Part No.: 08055-00181 Part No.: 08055-00191 799-601-7010
2 799-601-7020
3 799-601-7030
4 799-601-7040
6 799-601-7050
8 799-601-7060
12 799-601-7310
14 799-601-7070
16 799-601-7320
M type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
1 Part No.: 08056-00171 Part No.: 08056-00181 799-601-7080
2 799-601-7090
3 799-601-7110
4 799-601-7120
6 799-601-7130
8 799-601-7340
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
8 799-601-7140
10
799-601-7150
(White)
12
799-601-7350
(White)
16
799-601-7330
(White)
S type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
10
—
(Blue)
— —
12
799-601-7160
(Blue)
16
799-601-7170
(Blue)
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)
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 Terminal part No.: 79A-222-2760
—
(Q’ty: 50) (Q’ty: 50)
8 799-601-7180
12 799-601-7190
16 799-601-7210
20 799-601-7220
10 799-601-7510
12 799-601-7520
14 799-601-7530
18 799-601-7540
20 799-601-7550
L type connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
2 —
— —
Connector for PA
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
9 —
— —
Bendix MS connector
No.of
pins T-adapter Part
Male (female housing) Female (male housing)
No.
10 799-601-3460
— —
2 —
Part No.: 08027-10210 (Natural color) Part No.: 08027-10260 (Natural color)
08027-10220 (Black) 08027-10270 (Black)
3 —
4 —
Part No.: 08027-10410 (Natural color) Part No.: 08027-10460 (Natural color)
08027-10420 (Black) 08027-10470 (Black)
6 —
Part No.: 08027-10610 (Natural color) Part No.: 08027-10660 (Natural color)
08027-10620 (Black) 08027-10670 (Black)
8 —
Part No.: 08027-10810 (Natural color) Part No.: 08027-10860 (Natural color)
08027-10820 (Black) 08027-10870 (Black)
5 799-601-7360
— —
6 799-601-7370
— —
F type connector
No.of
pins T-adapter
Male (female housing) Female (male housing)
Part No.
4 —
— —
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9210
799-601-9210
799-601-9220
799-601-9220
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9230
799-601-9230
799-601-9240
799-601-9240
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9250
799-601-9250
799-601-9260
799-601-9260
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9270
799-601-9270
799-601-9280
799-601-9280
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9290
799-601-9290
[The pin No. is also marked on the connector (electric wire insertion end)]
DT Series connector
No.of
pins Body (receptacle) T-adapter
Body (plug)
Part No.
2 799-601-9020
Part No.: 08192-12200 (normal type) Part No.: 08192-12100 (normal type)
08192-22200 (fine wire type) 08192-22100 (fine wire type)
3 799-601-9030
Part No.: 08192-13200 (normal type) Part No.: 08192-13100 (normal type)
08192-23200 (fine wire type) 08192-23100 (fine wire type)
4 799-601-9040
Part No.: 08192-14200 (normal type) Part No.: 08192-14100 (normal type)
08192-24200 (fine wire type) 08192-24100 (fine wire type)
6 799-601-9050
Part No.: 08192-16200 (normal type) Part No.: 08192-16100 (normal type)
08192-26200 (fine wire type) 08192-26100 (fine wire type)
[The pin No. is also marked on the connector (electric wire insertion end)]
8GR: 799-601-9060
8B: 799-601-9070
8
8G: 799-601-9080
8BR: 799-601-9090
Part No.: 08192-1820 (normal type) Part No.: 08192-1810 (normal type)
08192-2820 (fine wire type) 08192-2810 (fine wire type)
12GR: 799-601-9110
12B: 799-601-9120
12
12G: 799-601-9130
12BR: 799-601-9140
Part No.: 08192-1920 (normal type) Part No.: 08192-1910 (normal type)
08192-2920 (fine wire type) 08192-2910 (fine wire type)
[The pin No. is also marked on the connector (electric wire insertion end)]
799-601-9010
2
[The pin No. is also marked on the connector (electric wire insertion end)]
1 —
Part No.: 08192-31200 (Contact size#12) Part No.: 08192-31100 (Contact size#12)
08192-41200 (Contact size #8) 08192-41100 (Contact size #8)
08192-51200 (Contact size #4) 08192-51100 (Contact size #4)
[The pin No. is also marked on the connector (electric wire insertion end)]
24 799-601-9360
— Part No.:7821-93-3110
40
799-601-9350
(A)
— Part No.:7821-93-3120
40
799-601-9350
(B)
— Part No.:7821-93-3130
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-2500
799-601-2700
799-601-2800
799-601-2900
799-601-3000
799-601-5500
799-601-6000
799-601-6500
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
Connector type or
Part No. No. of pins
—
part name
799-601-7140 S 8P
799-601-7150 S 10P-White
799-601-7160 S 12P-Blue
799-601-7170 S 16P-Blue
799-601-7330 S 16P-White
799-601-7350 S 12P-White
799-601-7180 AMP040 8P
799-601-7190 AMP040 12P
799-601-7210 AMP040 16P
799-601-7220 AMP040 20P
799-601-7230 Short connector X-2
799-601-7240 Case
799-601-7270 Case
799-601-7510 070 10P
799-601-7520 070 12P
799-601-7530 070 14P
799-601-7540 070 18P
799-601-7550 070 20P
799-601-7360 Relay connector 5P
799-601-7370 Relay connector 6P
799-601-7380 JFC connector 2P
799-601-9010 DTM 2P
799-601-9020 DT 2P
799-601-9030 DT 3P
799-601-9040 DT 4P
799-601-9050 DT 6P
799-601-9060 DT 8P-Gray
799-601-9070 DT 8P-Black
799-601-9080 DT 8P-Green
799-601-9090 DT 8P-Brown
799-601-9110 DT 12P-Gray
799-601-9120 DT 12P-Black
799-601-9130 DT 12P-Green
799-601-9140 DT 12P-Brown
799-601-9210 HD30 18-8
799-601-9220 HD30 18-14
799-601-9230 HD30 18-20
799-601-9240 HD30 18-21
799-601-9250 HD24 24-9
799-601-9260 HD30 24-16
799-601-9270 HD30 24-21
799-601-9280 HD30 24-23
799-601-9290 HD30 24-31
799-601-9310 Plate For HD30
799-601-9320 Measurement box For DT, HD
799-601-9330 Case
799-601-9340 Case
799-601-9350 DRC26 40P
799-601-9360 DRC26 24P
799-601-9410 For NE, G sensor 2P
For fuel, boost
799-601-9420 3P
press.
799-601-9430 PVC socket 2P
Error Code in Electrical System E93D (Engine fuel temp. sensor error) .................................................... 20-394
Error Code in Electrical System E953 (Engine Comm. Abnormality).......................................................... 20-396
Error Code in Electrical System E954 (Short engine starter sw.)................................................................ 20-398
Error Code in Electrical System E955 (Engine S-NET error) ...................................................................... 20-400
Error Code in Electrical System E956 (Engine power failure (1)) ............................................................... 20-402
Error Code in Electrical System E957 (Engine power failure (2)) ............................................................... 20-404
Error Code in Electrical System E95A (Engine Q-adj. sw. signal error) ...................................................... 20-406
Error Code in Electrical System E96A (Engine coolant sensor Lo error).................................................... 20-408
Error Code in Electrical System E970 (PCV1 over current)........................................................................ 20-410
Error Code in Electrical System E971 (PCV2 over current)........................................................................ 20-412
Error Code in Electrical System E974 (PCV1 line cut)................................................................................ 20-414
Error Code in Electrical System E975 (PCV2 line cut)................................................................................ 20-416
Error Code in Electrical System E977 (Rail press. sensor error) ................................................................ 20-418
Error Code in Electrical System E979 (Rail press. high)............................................................................. 20-420
Error Code in Electrical System E97A (Rail press. abnormal) .................................................................... 20-420
Error Code in Electrical System E97B (No-pressure fuel feed by supply pump 1) ..................................... 20-421
Error Code in Electrical System E97C (Rail press. too low) ....................................................................... 20-423
Error Code in Electrical System E97D (Rail press. out of control) .............................................................. 20-423
Error Code in Electrical System E980 (Eng. Controller Abnormality) ......................................................... 20-424
Error Code in Electrical System E981 (Fuel Injector 1 Disc.)...................................................................... 20-426
Error Code in Electrical System E982 (Fuel Injector 2 Disc.)...................................................................... 20-427
Error Code in Electrical System E983 (Fuel Injector 3 Disc.)...................................................................... 20-428
Error Code in Electrical System E984 (Fuel Injector 4 Disc.)...................................................................... 20-429
Error Code in Electrical System E985 (Fuel Injector 5 Disc.)...................................................................... 20-430
Error Code in Electrical System E986 (Fuel Injector 6 Disc.)...................................................................... 20-431
Error Code in Electrical System E98A (Fuel Injector 1 – 3 S/C) ................................................................. 20-432
Error Code in Electrical System E98B (Fuel Injector 4 – 6 S/C) ................................................................. 20-434
Failure Code in Mechanical System A000N1 (Eng. Hi Out of Std) ............................................................. 20-437
Failure Code in Mechanical System AA10NX (Aircleaner Clogging) .......................................................... 20-438
Failure Code in Mechanical System AB00KE (Charge Voltage Low) ......................................................... 20-440
Failure Code in Mechanical System B@BAZG (Eng. Oil Press. Low)........................................................ 20-442
Failure Code in Mechanical System B@BAZK (Eng. Oil Level Low).......................................................... 20-444
Failure Code in Mechanical System B@BCNS (Eng. Coolant Overheat)................................................... 20-445
Failure Code in Mechanical System B@BCZK (Eng. Coolant Lvl Low)...................................................... 20-446
Failure Code in Mechanical System B@HANS (Hydr. Oil Overheat).......................................................... 20-448
Failure Code in Mechanical System DA80MA (Auto. Lub Abnormal.) ........................................................ 20-450
Type of power
Fuse No. Fuse capacity Destination of power
supply
TVC solenoid (for emergency pump drive)
1 10A
Swing holding brake solenoid (for swing brake release)
Starting motor cut-out relay
2 10A Machine push-up solenoid
Switch power supply Boom shockless solenoid
(Circuit breaker 1) 3 10A PPC lock solenoid
Cigarette lighter
4 20A
Windshield washer motor
Horn
5 10A
Flash light
6 10A (Spare)
7 10A Rotary lamp
Switch power supply
8 10A (Spare)
(Circuit breaker 1)
9 10A Radio
10 20A Monitor panel
11 25A Air conditioner unit
12 20A (Spare)
Switch power supply
13 20A (Spare)
(Circuit breaker 1)
14 10A Service power supply (M32 connector)
15 10A DC/DC converter
16 10A Radio
17 10A —
Constant power 18 10A (Engine compartment lamp)
supply 19 10A Room lamp
(Circuit breaker 9) Step light
20 10A Pump controller power source (for step light)
Step light switch
• Short-circuiting
Cause that presumably
A wiring harness that is not connected with a 24 V electric circuit has a contact
triggered failure
with the electric circuit.
in question
3
(The assigned No. is for
<Precaution for Troubleshooting>
filing purpose only. It
1) Connector No. display method and handling of T-adapter
does not stand for any
Insert or connect T-adapters in the following manner before starting troubleshoot-
priority)
ing unless otherwise instructed.
• If there is no indication of "male" or "female" in a specific connector No., discon-
4 nect 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., discon-
nect the connector and connect the T-adepter with only one side of either "male"
or "female".
2) Entry sequence of pin No. and handling of circuit tester lead
Connect the positive (+) lead and the negative (–) lead OFF a circuit tester in the
following manner unless otherwise instructed.
5 • Connect the positive (+) lead with the pin No. indicated at the front or the wiring
harness.
• Connect the negative (–) lead with the pin No. indicated at the front or the wiring
harness.
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
Double-wiper specification
User Code Error Code Failure Code Failure Wiper Drive (For) S/C
— E112 DY2DKB phenomenon (Monitor panel system)
• Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor forward rotation circuit is switched OFF.
monitor panel
Phenomenon
occurring on • The wiper stops.
machine
Relative
information
NOTE: When the upper wiper and lower wiper are operated simultaneously: Below 3 V 20 – 30 V (at regu-
lar intervals)
Single-wiper specification
User Code Error Code Failure Code Failure Wiper Drive (For) S/C
— E112 DY2DKB phenomenon (Monitor panel system)
• Abnormal current flowed in the wiper motor forward rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor forward rotation circuit is switched OFF.
monitor panel
Phenomenon
occurring on • The wiper stops.
machine
Relative
information
Electric Circuit Diagram for Windshield Wiper Motor (Single wiper spec.)
Single-wiper specification
User Code Error Code Failure Code Failure Wiper Drive (Rev) S/C
— E113 DY2EKB phenomenon (Monitor panel system)
• Abnormal current flowed in the wiper motor reverse rotation circuit, when power is supplied to the cir-
Failure content
cuit.
Response from
• Power to the wiper motor reverse rotation circuit is switched OFF.
monitor panel
Phenomenon
occurring on • The wiper stops.
machine
Relative
information
Electric Circuit Diagram for Windshield Wiper Motor (Single wiper spec.)
User Code Error Code Failure Code Failure Washer Drive S/C
— E114 DY2CKB phenomenon (Monitor Panel system)
• Abnormal current flew to the window washer drive circuit, when the circuit was grounded and power
Failure content
was switched ON.
Response from
• Power supply to the grounding in the window washer motor circuit was switched OFF.
Monitor Panel
Phenomenon
occurring on • The window washer stopped moving.
machine
Relative
information
(Internal short-circuiting)
Between (1) and (2) 5 – 20 z
Presumed cause and
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
harness
2 Between wiring harness from P01 (female) (3) and M28
(Contact with 24 V
circuit) (female) (2), or between wiring harness between P01 Voltage Below 1 V
(female) (3) and D05 (female) (7) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
3 Monitor panel defective P01 Window washer switch Voltage
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
Single-wiper specification
User Code Error Code Failure Code Failure Wiper Working Abnormality
— E115 DY20KA phenomenon (Monitor Panel system)
Failure content • A W signal is not inputted at both ends of movement, when it is in motion.
Response from
• Power to the windshield wiper motor is turned OFF.
Monitor Panel
Phenomenon
occurring on • The windshield wiper motor does not work.
machine
Relative • Input of W signal at both ends of movement (ON or OFF) can be confirmed in the monitor function.
information (Code No.: 04502 Monitor input 3)
Above 1 Mz
operation range
Presumed cause and
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness Wiring harness between P01 (female) (5) and W04 Resistance
2 Below 1 z
(Disconnection or faulty (male) (6) value
contact with connector) Resistance
Wiring harness between W04 (male) (5) and grounding Below 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
P01 Windshield wiper blade Voltage
3 Monitor panel defective At upper end of
Below 1 V
operation range
Between (5) and grounding
Outside upper end of
20 – 30 V
operation range
Double-wiper specification
User Code Error Code Failure Code Failure Wiper Parking Abnormality
— E116 DY20MA phenomenon (Monitor Panel system)
Failure content • P signal on the retraction range is not inputted, when the wiper is retracted.
Response from
• Power supply to the windshield wiper motor is switched OFF, when the wiper is retracted.
Monitor Panel
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No.: 04502 Monitor input 3)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
Single-wiper specification
User Code Error Code Failure Code Failure Wiper Parking Abnormality
— E116 DY20MA phenomenon (Monitor Panel system)
Failure content • P signal in the retraction range is not inputted, when the wiper is retracted.
Response from • Power supply to the windshield wiper motor is switched OFF, when the wiper is
Monitor Panel retracted.
Phenomenon
occurring on • The windshield wiper cannot be retracted completely.
machine
Relative • It can be checked in the monitoring function whether P signal (ON or OFF) in the retraction operation
information range is inputted or not. (Code No.: 04502 Monitor Input 3)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between P01 (female) (12) and W04 Resistance
2 (Disconnection or defec- Below 1 z
(male) (4) value
tive contact with connec-
tor) Resistance
Between wiring harness W04 (male) (5) and grounding Below 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
3 Monitor panel defective P01 Windshield wiper blade Voltage
Between (12) and Retraction range Below 1V
grounding Operation range 20 – 30 V
Error Code in Electrical System E117 (Eng. Controller S-NET Comm Err.)
User Code Error Code Failure Code Failure Eng. Controller S-NET Comm Err.
— E117 DAC0KR phenomenon (Monitor Panel System)
• The monitor panel detected communication failure in the S-NET communication circuit to the engine
Failure content
controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%.
monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative • Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
information (Code No. 05100: Connection of S-NET)
(Contact with grounding and E12 (female) (21), (31) or between P02 (female) Resistance
circuit) Above 1 Mz
Presumed cause and
(9), (10) and C02 (female) (21) and related circuits and value
grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Short-circuiting of wiring
3 harness Between wiring harness between P02 (female) (9), (10)
(Contact with 24 V circuit) and E12 (female) (21), (31) or between P02 (female) Voltage Below 1 V
(9), (10) and C02 (female) (21) and related circuits and
grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Engine controller position during the troubleshooting.
4
defective E12 Voltage
Between (21), (31) and (11) 6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
5 Monitor panel defective
P02 Voltage
Between (9), (10) and (20) 6–9V
Error Code in Electrical System E118 (Pump Controller S-NET Comm Err.)
User Code Error Code Failure Code Failure Pump Controller S-NET Comm Err.
— E118 DAB0KR phenomenon (Monitor panel System)
• The monitor panel detected communication failure in the S-NET communication circuit to the pump
Failure content
controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%.
monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative • Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
information (Code No. 05100: Connection of S-NET)
(Contact with grounding and E12 (female) (21), (31) or between P02 (female) Resistance
circuit) Above 1 Mz
Presumed cause and
(9), (10) and C02 (female) (21) and related circuits and value
grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Short-circuiting of wiring
3 harness Between wiring harness between P02 (female) (9), (10)
(Contact with 24 V circuit) and E12 (female) (21), (31) or between P02 (female) Voltage Below 1 V
(9), (10) and C02 (female) (21) and related circuits and
grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Pump controller position during the troubleshooting.
4
defective C02 Voltage
Between (21) and (31) 6–9V
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
5 Monitor panel defective
P02 Voltage
Between (9), (10) and (20) 6–9V
User Code Error Code Failure Code Failure Monitor Comm. Abnormality
E0E E128 DAF0MC phenomenon (Monitor panel system)
• The monitor panel detected communication failure in the CAN communication circuit to the engine con-
Failure content
troller or pump controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%.
monitor panel • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative
information
User Code Error Code Failure Code Failure CO Cancel Sol. S/C
— E201 DW48KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the CO cancel circuit, when power was supplied to the circuit.
• Power supply to the CO cancel circuit is switched OFF.
Response from
• Even if the failure cause disappears of itself, the solenoid circuit does not return to normalcy, unless the
controller
engine starting switch is once turned OFF.
Phenomenon
• When the boom is raised (in the heavy lift mode) and the machine travels, power is low (The pump CO
occurring on
function cannot be cancelled).
machine
Relative • Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)
2 D03 defective
D03 (male) Resistance value (Continuitiy)
(Internal short-circuiting)
Between (1) and (5) Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Grounding fault of wiring position during the troubleshooting.
harness
3 Between wiring harness between C03 (female) (17),
(Contact with grounding Resistance
circuit) J06, and V07 (female) (2) or between C03 (female) (17) Min. 1 Mz
value
and D03 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
Working mode
Pump controller C03 Voltage
4 Control lever
defective
At E mode +
Between (17) and Max. 1 V
all levers in neutral
grounding
At A mode (Note) 20 – 30 V
Note: You may carry out troubleshooting while the working mode is at E-mode and the travel lever is operated
or while the working mode is at E-mode and the heavy lift switch is turned ON.
User Code Error Code Failure Code Failure Travel Junction Sol. S/C
— E202 DW91KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the travel junction solenoid circuit, when power is supplied to the circuit.
• Power to the travel junction solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• When the right and left travel motors and work equipment are operated simultaneously, the machine
occurring on
deviates (The right and left travel circuits are not connected to each other).
machine
Relative • Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)
User Code Error Code Failure Code Failure Swing Brake Sol. S/C
E03 E203 DW45KB phenomenon (Pump controller system)
• Abnormal current flowed in the swing holding brake solenoid circuit, when power is supplied to the cir-
Failure content
cuit.
• Power to the swing holding brake solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The machine cannot swing (The swing holding brake cannot be released).
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Relative
• If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding
information
brake release switch in the RELEASE position (The parking brake does not operate when the machine
stops, however).
User Code Error Code Failure Code Failure 2-stage Relief Sol. S/C
— E204 DWK0KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the 2-stage relief solenoid circuit, when power was supplied to the circuit.
• Power supply to the 2-stage relief solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• The heavy-lift function does not work.
occurring on
• Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
machine
Relative • Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
User Code Error Code Failure Code Failure Swing Priority Sol. S/C
— E205 DW41KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the swing priority solenoid, when power was supplied to the circuit.
• Power supply to the swing priority solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the swing
occurring on
speed is low (the oil flow in the swing circuit is kept low).
machine
Relative • Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.
information (Code No. 02300: Solenoid 1)
2 D04 defective
D04 (male) Resistance value (Continuitiy)
Presumed cause and
(Internal short-circuiting)
Between (3) and (7) Min. 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Grounding fault of wiring position during the troubleshooting.
harness
3 Between wiring harness between C03 (female) (38),
(Contact with grounding Resistance
circuit) J06, and V01 (female) (2) or between C03 (female) (38) Min. 1 Mz
value
and D04 (female) (3) and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
Swing priority switch
C03 Left work equipment Voltage
Pump controller control lever
4
defective
OFF + NEUTRAL Max. 1 V
Between (38) and Swing priority mode
grounding + 20 – 30 V
Swing operation
User Code Error Code Failure Code Failure Travel Speed Sol. S/C
— E206 DW43KB phenomenon (Pump controller system)
Failure content • Abnormal current flew to the travel speed solenoid, when power was supplied to the circuit.
• Power supply to the travel speed solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• The travel speed does not turn to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized.)
machine
• The travel speed shifting solenoid is not turned ON when the engine speed is below 1,200 rpm.
Relative
• Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function.
information
(Code No. 02300: Solenoid 1)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
User Code Error Code Failure Code Failure Flash Light Relay S/C
— E207 D163KB phenomenon (Pump controller system)
• Abnormal current flowed in the flash light relay circuit (the primary circuit of the relay), when power is
Failure content
supplied to the circuit.
• The controller turns OFF the output to the coil circuit of the flash light relay.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The flash light does not flash.
machine
• Operation of the flash light relay circuit (the primary side of the relay) (ON or OFF) can be checked in
Relative the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the flash light relay and cannot detect
abnormality on the secondary (contact) side.
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
2
(Contact with grounding Between wiring harness between C03 (female) (25) and Resistance
circuit) Min. 1 Mz
R21 (female) (1) and grounding valve
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
C03 Horn switch Voltage
Pump controller
3 20 – 30 V Max. 1 V
defective
Between (25) and ON (at constant cycle,
grounding 5 seconds)
OFF Max. 1 V
User Code Error Code Failure Code Failure CO Cancel Sol. Disc.
— E211 DW48KA phenomenon (Pump controller system)
Failure content • No current flows to the CO cancel solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• When the boom is raised (in the heavy lift mode) and the machine travels, power is low (The pump CO
occurring on
function cannot be cancelled).
machine
• Operation of the CO cancel solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Relative
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under Error Code [E201].)
harness
Wiring harness from C03 (female) (17) to J06 and V07 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (2) value
tive contact with connec-
tor) Wiring harness between V07 (female) (1) to J15 and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
3 harness Between wiring harness between C03 (female) (17),
(Contact with 24 V circuit) J06, and V07 (female) (2) or between C03 (female) (17) Voltage Max. 1 V
and D03 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Pump controller position during the troubleshooting.
4
defective C03 (female) Resistance value
Between (17) and grounding 20 – 60 z
User Code Error Code Failure Code Failure Travel Junction Sol. Disc.
— E212 DW91KA phenomenon (Pump controller system)
Failure content • No current flows to the travel junction solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it).
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• When the right and left travel motors and work equipment are operated simultaneously, the machine
occurring on
deviates (The right and left travel circuits are not connected to each other).
machine
• Operation of the travel junction solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Relative
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under Error code [E202].)
harness
Wiring harness between C03 (female) (7), J06, and V03 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (2) value
tive contact with connec-
tor) Wiring harness between V03 (female) (1), J15, and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
3 harness
(Contact with 24 V circuit) Between wiring harness between C03 (female) (7), J06, Voltage Below 1 V
V03 (female) (2), and D03 (female) (3) and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
4 Pump controller defective
C03 (female) Resistance value
Between (7) and grounding 20 – 60 z
User Code Error Code Failure Code Failure Swing Brake Sol. Disc.
E03 E213 DW45KA phenomenon (Pump controller system)
Failure content • No current flows in the swing holding brake solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it).
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The machine cannot swing (The swing holding brake cannot be released).
machine
• Operation of the swing holding brake solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
• If the solenoid and wiring harness are normal, the machine can swing by setting the swing holding
brake release switch in the RELEASE position (The parking brake does not operate when the machine
Relative stops, however).
information • Keep the swing lock switch in the OFF position and the swing holding brake release switch in the
RELEASE position during troubleshooting.
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under Error code [E203].)
OFF Max. 1 z
Between (3) and (4)
Presumed cause and
LOCK Min. 1 Mz
a Turn 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 Resistance
Disconnection of wiring Max. 1 z
(female) (7) value
harness
Wiring harness between D01 (female) (3), J02, and X05 Resistance
4 (Disconnection or defec- Max. 1 z
(male) (3) value
tive contact with connec-
tor) Wiring harness between X05 (male) (4), J06, and V04 Resistance
Max. 1 z
(female) (2) value
Wiring harness between V04 (female) (1), J15, and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
5 harness
(Contact with 24 V circuit) Between wiring harness between C03 (female) (37) and Voltage Max. 1 V
D01 (female) (7)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
6 Pump controller defective C03 (female) Disconnect D01 and Resistance value
Between (37) and directly connect pins (3)
and (7) on the female side. 20 – 60 z
grounding
User Code Error Code Failure Code Failure 2-stage Relief Sol. Disc.
— E214 DWK0KA phenomenon (Pump controller system)
Failure content • No current flows to the 2-stage relief solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The heavy-lift function does not work.
occurring on
• Travel power is low (The main relief valve is not set in the HIGH PRESSURE position).
machine
• Operation of the 2-stage relief solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Relative
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under Error Code [E204].)
harness
Wiring harness from C03 (female) (28) to J06 and V02 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (2) value
tive contact with connec-
tor) Wiring harness between V02 (female) (1) to J15 and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
3 harness Between wiring harness between C03 (female) (28),
(Contact with 24 V circuit) J06, and V02 (female) (2) or between C03 (female) (28) Voltage Max. 1 V
and D03 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
4 Pump controller defective
C03 (female) Resistance value
Between (28) and grounding 20 – 60 z
User Code Error Code Failure Code Failure Swing Priority Sol. Disc.
— E215 DW41KA phenomenon (Pump controller system)
Failure content • No current flows to the swing priority solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• When the boom is raised and the machine is swung simultaneously in the swing priority mode, the
occurring on
swing speed is low (the oil flow in the swing circuit is kept low).
machine
• Operation of the swing priority solenoid (ON or OFF) can be checked in the monitoring function.
(Code No. 02300: Solenoid 1)
Relative
• Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
information
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under Error Code [E205].)
harness
Wiring harness from C03 (female) (38) to J06 and V01 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (2) value
tive contact with connec-
tor) Wiring harness between V01 (female) (1) to J15 and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
3 harness Between wiring harness between C03 (female) (38),
(Contact with 24 V circuit) J06, and V01 (female) (2) or between C03 (female) (38) Voltage Max. 1 V
and D04 (female) (3) and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
Pump controller running during the troubleshooting.
4
defective C03 (female) Resistance value
Between (38) and grounding 20 – 60 z
User Code Error Code Failure Code Failure Travel Speed Sol. Disc.
— E216 DW43KA phenomenon (Pump controller system)
Failure content • No current flows to the travel speed solenoid circuit, when power is supplied to the circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it)
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The travel speed does not shift to Hi.
occurring on
(The swash plate angle of the travel motor is not minimized.)
machine
• The travel speed shifting solenoid is not turned ON when the engine speed is below 1,200 rpm.
• Operation of the travel speed solenoid (ON or OFF) can be checked in the monitoring function.
Relative (Code No. 02300: Solenoid 1)
information • Since the controller detects disconnection while the solenoid output is turned ON, be sure to turn the
solenoid output ON when checking the solenoid again after repairing it. (For how to turn power ON or
OFF, refer to the troubleshooting under Error Code [E206].)
harness
Wiring harness from C03 (female) (27) to J06 and V06 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (2) value
tive contact with connec-
tor) Wiring harness between V06 (female) (1) to J15 and Resistance
Max. 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
3 harness Between wiring harness between C03 (female) (27),
(Contact with 24 V circuit) J06, and V06 (female) (2) or between C03 (female) (27) Voltage Max. 1 V
and D04 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
4 Pump controller defective
C03 (female) Resistance value
Between (27) and grounding 20 – 60 z
User Code Error Code Failure Code Failure Model selection Abnormality
— E217 DA2SKQ phenomenon (Pump controller system)
Failure content • A model code signal was inputted which indicates another model that is not registered in the controller.
• The controller treats it as a default-set model (PC750).
Response from
• Even if the failure cause disappears of itself, the machine operation does not return to normalcy, unless
controller
the engine starting switch is once turned OFF.
Phenomenon
occurring on • None in particular with PC750 • 800 model
machine
• Model names (expressed in number) that the controller recognizes can be confirmed in the monitoring
Relative function. (Code No. 00200: Controller Model Code)
information a Input of model selecting signals (ON or OFF) can be confirmed in the monitoring function.
(Code No. 02201: Switch Input 2)
Electric circuit diagram related to model selection connector (for pump controller)
User Code Error Code Failure Code Failure S-Net Comm. Disc.
E0E E218 DA2SKA phenomenon (Pump controller system)
• The pump controller detected communication failure in the S-NET communication circuit to the monitor
Failure content
panel or engine controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative • Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
information (Code No. 05100: Connection of S-NET)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Presumed cause and
User Code Error Code Failure Code Failure Travel Alarm S/C
— E221 DV20KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the travel alarm circuit, when power is supplied to the circuit.
• Power to the travel alarm circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • The travel alarm does not sound.
machine
Relative • Operation of the travel alarm (ON or OFF) can be checked in the monitoring function.
information (Code No. 03701: Controller output 2)
If the above voltage is normal but the travel alarm does not operate, the travel alarm
is defective.
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
2
(Contact with grounding Between wiring harness between C03 (female) (8) and Resistance
circuit) Min. 1 Mz
F01 (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
3 Pump controller defective C03 Travel lever Voltage
Neutral Max. 1 V
Between (8) and grounding
Operated 20 – 30 V
User Code Error Code Failure Code Failure F Pump P. Sensor Abnormality
— E224 DHPAMA phenomenon (Pump controller system)
Failure content • Signal voltage from the front pump pressure sensor is below 0.3 V or above 4.42 V.
Response from
• When the failure cause disappears of itself, the machine operation returns to normalcy.
controller
Phenomenon
occurring on • The front pump pressure cannot be monitored (Special function of monitor panel).
machine
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
Relative sensor will be broken. Accordingly, take extreme care when checking.
information • Input from the front pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 01100: Front pump pressure)
Disconnection of wiring Wiring harness between C01 (female) (22), J21, and Resistance
harness Max. 1 z
Presumed cause and
User Code Error Code Failure Code Failure R Pump P. Sensor Abnormality
— E225 DHPBMA phenomenon (Pump controller system)
Failure content • Signal voltage from the rear pump pressure sensor is below 0.3 V or above 4.42 V.
Response from
• When the failure cause disappears of itself, the machine operation returns to normalcy.
controller
Phenomenon
occurring on • The rear pump pressure cannot be monitored (Special function of monitor panel).
machine
a If the 5-V circuit (B) and GND circuit (A) of the pressure sensor are connected inversely, the pressure
Relative sensor will be broken. Accordingly, take extreme care when checking.
information • Input from the rear pump pressure sensor (pressure) can be checked in the monitoring function.
(Code No. 01101: Rear pump pressure)
Disconnection of wiring Wiring harness between C01 (female) (22), J21, and Resistance
harness Max. 1 z
Presumed cause and
User Code Error Code Failure Code Failure Press. Sensor Power Abnormality
— E226 DA25KP phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the pressure sensor power supply (5 V) circuit.
• Power to the power supply (5 V) circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• The pressure sensor signal is not input normally.
occurring on
• The error code of abnormality in the pressure sensor is displayed, too.
machine
Relative
information
defective.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Grounding fault of wiring Between wiring harness between C01 (female) (22),
Resistance
harness J21, and P30 (female) (B) and grounding Min. 1 Mz
2 value
(Contact with grounding [Front pump pressure sensor system]
circuit) Between wiring harness between C01 (female) (22),
Resistance
J21, and P31 (female) (B) and grounding Min. 1 Mz
value
[Rear pump pressure sensor system]
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
3 Pump controller defective
C01 Voltage
Between (22) and (10) 4.5 – 5.5 V
User Code Error Code Failure Code Failure Engine Speed Sensor Abnormality
— E227 DLE2MA phenomenon (Pump controller system)
Failure content • Normal pulse signal is not input to the signal circuit of the engine speed sensor.
Response from • Control is carried out as in the E-mode.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• Power is a little low (Engine speed cannot be sensed).
occurring on
• The monitor panel cannot monitor the engine speed (pump controller system).
machine
Relative • Input from the engine speed sensor (rpm) can be checked in the monitoring function.
information (Code No. 01006: Engine speed)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
User Code Error Code Failure Code Failure TVC Sol. S/C
E02 E232 DXA0KB phenomenon (Pump controller system)
Failure content • Abnormal current flowed in the TVC solenoid circuit.
• Power to the TVC solenoid circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
• If the pump load increases, the engine speed lowers extremely and the engine may stall. (The pump
occurring on
absorption torque cannot be controlled.)
machine
• Output to the TVC solenoid (current) can be checked in the monitoring function.
(Code No. 01300: TVC solenoid current)
Relative • If the solenoid and wiring harness are normal, the machine can be operated with the output equivalent
information to the E-mode by setting the emergency pump drive switch in the EMERGENCY position (Error code
[E233] is displayed at this time, but it does not indicate a failure).
• Keep the emergency pump drive switch in the normal position during troubleshooting.
User Code Error Code Failure Code Failure TVC Sol. Disc.
E02 E233 DXA0KA phenomenon (Pump controller system)
Failure content • No current flows in the TVC solenoid circuit.
Response from • None in particular (The solenoid does not function as there is no current flowing to it).
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• If the pump load increases, the engine speed lowers extremely and the engine may stall.
occurring on
(The pump absorption torque cannot be controlled.)
machine
• Output to the TVC solenoid (current) can be checked in the monitoring function.
Relative (Code No. 01300: TVC solenoid current)
information • If the solenoid and wiring harness are normal, the machine can be operated with the output equivalent
to the E-mode by setting the emergency pump drive switch in the EMERGENCY position.
a Turn 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 Resistance
Disconnection of wiring Below 1 z
(female) (3) value
harness
Wiring harness between S25 (female) (2) and C13 Resistance
3 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between C03 (female) (3) and S25 Resistance
Below 1 z
(female) (6) value
Wiring harness between S25 (female) (5) and C13 Resistance
Below 1 z
(female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Short-circuiting of wiring
Between wiring harness between C03 (female) (16) and
4 harness Voltage Below 1 V
S25 (female) (3) and grounding
(Contact with 24 V circuit)
Between wiring harness between S25 (female) (2) and
Voltage Below 1 V
C13 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
5 Pump controller defective
C03 (female) Resistance value
Between (16) and (3) 10 – 22 z
User Code Error Code Failure Code Failure Pump Comm. Abnormality
E0E E257 DA2RMC phenomenon (Pump controller system)
• The pump controller detected communication failure in the CAN communication circuit to the monitor
Failure content
panel or engine controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative
information
User Code Error Code Failure Code Failure Step Light Relay S/C
— E302 D195KB phenomenon (Pump controller system)
• Abnormal current flowed in the step light relay circuit (the primary circuit of the relay), when power is
Failure content
supplied to the circuit.
• Power to the step light relay circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • Step light does not light up.
machine
• Operation of the step light relay circuit (the primary side of the relay) (ON or OFF) can be checked in
Relative the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the step light relay and cannot detect
abnormality on the secondary (contact) side.
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
2
(Contact with grounding Between wiring harness between C03 (female) (15) and Resistance
circuit) Above 1 Mz
R15 (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 Step light switch Voltage
3 Pump controller defective
20 – 30 V
Between (15) and ON
(Kept for 60 sec)
grounding
OFF Below 1 V
Error Code in Electrical System E304 (Step Light Power Hold Relay S/C)
User Code Error Code Failure Code Failure Step Light Power Hold Relay S/C
— E304 D194KB phenomenon (Pump controller system)
• Abnormal current flowed in the step light power hold relay circuit (the primary circuit of the relay), when
Failure content
power is supplied to the circuit.
• Power to the step light power hold relay circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
unless the engine starting switch is once turned OFF.
Phenomenon
occurring on • Step light does not light up.
machine
• Operation of the step light power hold relay circuit (the primary side of the relay) (ON or OFF) can be
Relative checked in the monitoring function. (Code No. 03701: Controller output 2)
information • This error code detects abnormality on the primary (coil) side of the step light power hold relay and can-
not detect abnormality on the secondary (contact) side.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Grounding fault of wiring position during the troubleshooting.
harness
2 Between wiring harness between C03 (female) (5), D02,
(Contact with grounding Resistance
circuit) and R14 (female) (1) or between C03 (female) (5) and Above 1 Mz
value
D04 (female) (4) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
C03 Step light switch Voltage
3 Pump controller defective
20 – 30 V
ON
Between (5) and grounding (Kept for 60 sec)
OFF Below 1 V
User Code Error Code Failure Code Failure Battery Relay Drive S/C
— E315 D110KB phenomenon (Pump controller system)
Failure content • When a signal is output to the battery relay drive circuit, abnormal current flowed.
Response from • The controller turns OFF the output to the battery relay drive circuit.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • There may be a trouble in writing data into the ROM (non-volatile memory) of each controller.
machine
Relative • Operation of the battery relay (ON or OFF) can be checked in the monitoring function.
information (Code No. 03700: Controller output 1)
User Code Error Code Failure Code Failure Engine Ne sensor problem
E11 E91B DLE3LC phenomenon (Engine controller system)
Failure content • Cranking angle cannot be judged from the engine Ne speed sensor signal.
Response from • The machine is driven with limited output.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
• Input from the engine Ne speed sensor (rpm) can be checked in the monitoring function.
Relative
(Code No. 01002: Engine speed)
information
• Special adapter (799-601-9410) is necessary for troubleshooting for the engine Ne speed sensor.
harness
Wiring harness between E12 (female) (36) and NE Resistance
Presumed cause and
User Code Error Code Failure Code Failure Engine G sensor problem
E11 E91C DLH1LC phenomenon (Engine controller system)
Failure content • Cylinder cannot be judged from the engine G speed sensor signal.
• The machine is driven with limited output.
Response from
• Control is carried out with the Ne speed sensor signal.
controller
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
Relative
• Special adapter (799-601-9410) is necessary for troubleshooting for the engine G speed sensor.
information
harness
Wiring harness between E12 (female) (35) and G Resistance
Presumed cause and
User Code Error Code Failure Code Failure Engine type selection error
E11 E920 DB29KQ phenomenon (Engine controller system)
• The model selection signal directly taken by the engine controller does not conform to the model in the
Failure content
controller or it is not confirmed.
• Control is carried out with the default model (PC750).
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
• The model name (figure) recognized by the controller can be checked in the monitoring function.
Relative (Code No. 00201: Controller model code)
information • Input of the model selection signal (ON or OFF) can be checked in the monitoring function.
(Code No. 17400: Engine controller input state)
harness
Wiring harness between E11 (female) (23) and E09 Resistance
Presumed cause and
User Code Error Code Failure Code Failure Engine type mismatch
E11 E921 DB20KQ phenomenon (Engine controller system)
• The model information taken by the engine controller through the model selection connector does not
Failure content
conform to the model information taken from the pump controller by communication.
• The normal operation is continued.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
• The model name (figure) recognized by the engine controller can be checked in the monitoring func-
Relative tion. (Code No. 00201: Controller model code)
information • The model name (figure) recognized by the pump controller can be checked in the monitoring function.
(Code No. 00200: Controller model code)
Engine controller Engine controller may be defective. (Since trouble is in the controller, troubleshoot-
2
defective ing cannot be carried out.)
User Code Error Code Failure Code Failure Fuel dial sys. error
E14 E931 DK10KX phenomenon (Engine controller system)
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
100% after the engine is started.
Response from
• If the abnormality is detected while the engine is running, the fuel control dial signal just before the
controller
abnormality is detected is kept.
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The engine speed cannot be controlled.
machine
Relative • Input from the fuel control dial (voltage) can be checked in the monitoring function.
information (Code No. 03000: Fuel control dial voltage)
User Code Error Code Failure Code Failure Engine coolant sensor Hi error
E15 E934 DGE2KX phenomenon (Engine controller system)
Failure content • The signal voltage from the engine coolant high temperature sensor is below 0.5 V or above 4.5 V.
Response from • The signal of the engine coolant high temperature sensor is kept at 90°C.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The engine does not start easily when temperature is low.
occurring on • The overheat protection function does not operate.
machine • If the controller is also defective, the engine does not stop.
• Input from the engine coolant high temperature sensor (voltage and coolant temperature) can be
Relative checked in the monitoring function.
information (Code No. 04106: Engine coolant temperature sensor Hi, 04102: Engine coolant temperature (High
temperature))
harness
Wiring harness between E12 (female) (27) and TWH Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between E12 (female) (39), J09, and Resistance
Below 1 z
TWH (female) (2) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3
(Contact with grounding Between wiring harness between E12 (female) (27) and Resistance
circuit) Above 1 Mz
TWH (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Engine controller E12 Resistance value
4
defective
Between (27) and (39) 3.5 k – 90 kz
Between (27), (39) and grounding Above 1 Mz
Circuit diagram related to engine coolant temperature sensor (for low temperature and high temperature)
Error Code in Electrical System E936 (Engine oil press. sw. error)
User Code Error Code Failure Code Failure Engine oil press. sw. error
E15 E936 DDE2L6 phenomenon (Engine controller system)
• The signal circuit of the low-pressure switch is closed (connected to grounding) and the signal circuit of
the high-pressure switch is opened (disconnected from grounding) while the engine is running.
• The signal circuit of the low-pressure switch is opened (disconnected from grounding) while the engine
Failure content
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 • None in particular.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The engine does not start easily when temperature is low.
occurring on • The overheat protection function does not operate.
machine • If the controller is also defective, the engine does not stop.
Relative • Input from the engine oil pressure switch (Lo or Hi) (ON or OFF) can be checked in the monitoring func-
information tion. (Code No. 17400: Engine controller input)
Resistance
3 (Disconnection or defec- Wiring harness between E11 (female) (21) and PSL Below 1 z
value
tive contact with connec-
tor) Resistance
Wiring harness between E11 (female) (15) and PSH Below 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Grounding fault of wiring position during the troubleshooting.
harness Between wiring harness between E11 (female) (21) and Resistance
4 Above 1 Mz
(Contact with grounding PSL and grounding value
circuit) Between wiring harness between E11 (female) (15) and Resistance
Above 1 Mz
PSH and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position and start the engine during the troubleshooting.
E11 Engine Voltage
Between (21) and ground- Stopped Below 1 V
ing (Low-pressure switch
Engine controller signal) Low idle 20 – 30 V
5
defective
Between (15) and ground- Stopped Below 1 V
ing (High-pressure switch Running at 1,300 rpm
signal) 20 – 30 V
or higher
Carry out troubleshooting while the engine is running 15 seconds after the engine is
started.
Circuit diagram related to engine coolant temperature sensor (for low pressure and high pressure)
User Code Error Code Failure Code Failure Engine boost sensor error
E11 E93C DH30KX phenomenon (Engine controller system)
Failure content • The signal voltage from the boost pressure sensor is below 0.3 V or above 4.7 V.
Response from • None in particular.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
• Input from the boost pressure sensor (voltage and pressure) can be checked in the monitoring function.
Relative
(Code No. 36501: Boost pressure sensor voltage, 36500: Boost pressure)
information
• Special adapter (799-601-9420) is necessary for troubleshooting for the engine boost pressure sensor.
tive contact with connec- Wiring harness between E12 (female) (39), J09, and Resistance
Below 1 z
Presumed cause and
Error Code in Electrical System E93D (Engine fuel temp. sensor error)
User Code Error Code Failure Code Failure Engine fuel temp. sensor error
E15 E93D DGE4KX phenomenon (Engine controller system)
Failure content • The signal voltage from the fuel temperature sensor is above 4.5 V.
Response from • None in particular.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The engine does not start easily when temperature is low.
occurring on • The overheat protection function does not operate.
machine • If the controller is also defective, the engine does not stop.
Relative • Input from the fuel temperature sensor (voltage) can be checked in the monitoring function.
information (Code No. 14201: Fuel temperature sensor voltage)
harness
Wiring harness between E12 (female) (17) and THL Resistance
2 (Disconnection or defec- Below 1 z
(female) (A) value
tive contact with connec-
tor) Wiring harness between E12 (female) (29) and THL Resistance
Below 1 z
(female) (B) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3
(Contact with grounding Between wiring harness between E12 (female) (17) and Resistance
circuit) Above 1 Mz
THL (female) (A) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Engine controller E12 Resistance value
4
defective
Between (17) and (29) 0.3 k – 9 kz
Between (17), (29) and grounding Above 1 Mz
User Code Error Code Failure Code Failure Engine Comm. Abnormality
E0E E953 DB2RMC phenomenon (Engine controller system)
• The engine controller detected communication failure in the CAN communication circuit to the monitor
Failure content
panel or pump controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative
information
User Code Error Code Failure Code Failure Short engine starter sw.
— E954 DD11KB phenomenon (Engine controller system)
Failure content • Starting switch signal C (starting signal) is detected while the engine is running (at 500 rpm or higher).
Response from • Starting switch signal is recognized to be OFF.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • The machine operates normally.
machine
Relative • Input of starting switch signal C (ON or OFF) can be checked in the monitoring function.
information (Code No. 17400: Engine controller input)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Presumed cause and
User Code Error Code Failure Code Failure Engine S-NET error
E0E E955 DB2SMC phenomenon (Engine controller system)
• The engine controller detected communication failure in the S-NET communication circuit to the moni-
Failure content
tor panel or pump controller.
Response from • The engine output is fixed to the E-mode and the pump absorption torque is limited to about 80%.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The output lowers (The pump absorption torque is reduced).
occurring on
• If the working load increases, the engine may stall.
machine
Relative • Connection of the S-NET (ON or OFF) can be checked in the monitoring function.
information (Code No. 05100: Connection of S-NET)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Presumed cause and
User Code Error Code Failure Code Failure Engine power failure (1)
E10 E956 DB22KK phenomenon (Engine controller system)
Failure content • When the starting switch is turned ON, the source voltage of the controller is below 10 V.
Response from • None in particular.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
• The engine stalls.
occurring on
• The engine cannot be started.
machine
Relative
information
3 (Disconnection or defec-
Wiring harness between B17 and battery relay B termi- Resistance
Presumed cause and
User Code Error Code Failure Code Failure Engine power failure (2)
E15 E957 D1D0KB phenomenon (Engine controller system)
Failure content • When the starting switch is turned OFF, the source voltage of the controller is above 10 V.
Response from • None in particular.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The engine does not start easily when temperature is low.
occurring on • The overheat protection function does not operate.
machine • If the controller is also defective, the engine does not stop.
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Presumed cause and
Error Code in Electrical System E95A (Engine Q-adj. sw. signal error)
User Code Error Code Failure Code Failure Engine Q-adj. sw. signal error
— E95A DB2AMA phenomenon (Engine controller system)
Failure content • The fuel injection amount adjustment switch of the controller is not set to the correct position.
Response from • None in particular.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon
occurring on • Setting of the fuel injection amount adjustment switch cannot be changed.
machine
• Setting (Set position) of the fuel injection amount adjustment switch can be checked in the monitoring
Relative
function. (Code No. 36800: Right fuel injection amount adjustment switch, 36801: Left fuel injection
information
amount adjustment switch)
Engine controller
2 If the cause is not detected, engine controller may be defective.
defective
User Code Error Code Failure Code Failure Engine coolant sensor Lo error
E15 E96A DGE3L6 phenomenon (Engine controller system)
Failure content • The signal voltage from the engine coolant low temperature sensor is above 4.5 V.
• The signal of the engine coolant low temperature sensor is kept at 20°C (If the signal of the high tem-
Response from
perature sensor is effective, it is used as a substitute).
controller
• When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The engine does not start easily when temperature is low.
occurring on • The overheat protection function does not operate.
machine • If the controller is also defective, the engine does not stop.
• Input from the engine coolant low temperature sensor (voltage and coolant temperature) can be
Relative
checked in the monitoring function. (Code No. 04105: Engine coolant temperature sensor voltage Lo,
information
04107: Engine coolant temperature (Low temperature))
harness
Wiring harness between E12 (female) (37) and TWL Resistance
2 (Disconnection or defec- Below 1 z
(female) (A) value
tive contact with connec-
tor) Wiring harness between E12 (female) (39), J09, and Resistance
Below 1 z
TWL (female) (B) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3
(Contact with grounding Between wiring harness between E12 (female) (37) and Resistance
circuit) Above 1 Mz
TWL (female) (A) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Engine controller E12 Resistance value
4
defective
Between (37) and (39) 0.3 k – 9 kz
Between (37), (39) and grounding Above 1 Mz
Circuit diagram related to engine coolant temperature sensor (for low temperature and high temperature)
User Code Error Code Failure Code Failure PCV1 over current
E11 E970 AD11KB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel supply pump PCV1 circuit.
• Power to the fuel supply pump PCV1 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
information
2
(Contact with grounding Between wiring harness between E13 (female) (12) and Resistance
circuit) Above 1 Mz
PCV1 (female) (1) value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Short-circuiting of wiring
Between wiring harness between E13 (female) (12) and
3 harness Voltage Below 1 V
PCV1 (female) (1)
(Contact with 24 V circuit)
Between wiring harness between E13 (female) (22) and
Voltage Below 1 V
PCV1 (female) (2)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Engine controller E13 (female) Resistance value
4
defective
Between (12) and (22) 2.3 – 5.3 z
Between (12), (22) and grounding Above 1 Mz
User Code Error Code Failure Code Failure PCV2 over current
E11 E971 AD51KB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel supply pump PCV2 circuit.
• Power to the fuel supply pump PCV2 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
information
2
(Contact with grounding Between wiring harness between E13 (female) (13) and Resistance
circuit) Above 1 Mz
PCV2 (female) (1) value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Short-circuiting of wiring
Between wiring harness between E13 (female) (13) and
3 harness Voltage Below 1 V
PCV2 (female) (1)
(Contact with 24 V circuit)
Between wiring harness between E13 (female) (23) and
Voltage Below 1 V
PCV2 (female) (2)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Engine controller E13 (female) Resistance value
4
defective
Between (13) and (23) 2.3 – 5.3 z
Between (13), (23) and grounding Above 1 Mz
User Code Error Code Failure Code Failure PCV1 line cut
E11 E974 AD11KA phenomenon (Engine controller system)
Failure content • Fuel supply pump PCV1 circuit is disconnected.
• Power to the fuel supply pump PCV1 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV1.
information
harness
Between wiring harness between E13 (female) (12) and Resistance
2 (Disconnection or defec- Below 1 z
PCV1 (female) (1) value
tive contact with connec-
tor) Between wiring harness between E13 (female) (22) and Resistance
Below 1 z
PCV1 (female) (2) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3
(Contact with grounding Between wiring harness between E13 (female) (22) and Resistance
circuit) Above 1 Mz
PCV1 (female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Engine controller E13 (female) Resistance value
4
defective
Between (12) and (22) 2.3 – 5.3 z
Between (12), (22) and grounding Above 1 Mz
User Code Error Code Failure Code Failure PCV2 line cut
E11 E975 AD51KA phenomenon (Engine controller system)
Failure content • Fuel supply pump PCV2 circuit is disconnected.
• Power to the fuel supply pump PCV2 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
• Special adapter (799-601-9430) is necessary for troubleshooting for fuel supply pump PCV2.
information
harness
Between wiring harness between E13 (female) (13) and Resistance
2 (Disconnection or defec- Below 1 z
PCV2 (female) (1) value
tive contact with connec-
tor) Between wiring harness between E13 (female) (23) and Resistance
Below 1 z
PCV2 (female) (2) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3
(Contact with grounding Between wiring harness between E13 (female) (23) and Resistance
circuit) Above 1 Mz
PCV2 (female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Engine controller E13 (female) Resistance value
4
defective
Between (13) and (23) 2.3 – 5.3 z
Between (13), (23) and grounding Above 1 Mz
User Code Error Code Failure Code Failure Rail press. sensor error
E11 E977 DH40KX phenomenon (Engine controller system)
Failure content • The signal voltage from the common rail fuel pressure sensor is below 0.7 V or above 4.5 V.
Response from • The machine is driven with limited output.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
• Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
Relative
function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
information
• Special adapter (799-601-9420) is necessary for troubleshooting for common rail fuel pressure sensor.
tive contact with connec- Wiring harness between E12 (female) (39), J09, and Resistance
Below 1 z
Presumed cause and
User Code Error Code Failure Code Failure Rail press. high
E11 E979 AD00L2 phenomenon (Engine controller system)
Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 1).
Response from • The machine is driven with limited output.
controller • When the failure cause disappears of itself, the machine operation returns to normalcy.
Phenomenon • The output lowers (The engine output lowers about 20% and the pump absorption torque is reduced).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
Relative • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
information function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Electric system of
3 common rail fuel Carry out troubleshooting for error code [E977].
pressure sensor defective
Mechanical system of
The common rail fuel pressure sensor may have a mechanical defect. Check it
4 common rail fuel
directly.
pressure sensor defective
The overflow valve may have trouble of breakage of spring, wear of seat, or fixing of
5 Overflow valve defective
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 Rail press. abnormal
E11 E97A AD00MA phenomenon (Engine controller system)
Failure content • The signal circuit of the common rail fuel pressure sensor detected high pressure (level 2).
• The machine is driven with limited output.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
Relative • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
information function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
Error Code in Electrical System E97B (No-pressure fuel feed by supply pump 1)
User Code Error Code Failure Code Failure No-pressure fuel feed by supply pump 1
E15 E97B AD10L3 phenomenon (Engine controller system)
Contents of
• The fuel pump does not supply fuel (Level 1).
trouble
Action of • Operates by normal control method.
controller • Even if cause of failure disappears, system does not reset itself until engine is stopped.
Problem that • Engine does not start easily.
appears on • Engine output and speed lower.
machine • Black smoke is produced.
Relative
information
pump PCV
Presumed cause and
Defective common rail Since common rail pressure sensor may be defective, check wiring harness for
6
pressure sensor breakage.
a See TESTING AND ADJUSTING (Testing leakage through pressure limiter and
7 Defective pressure limiter return rate from injector).
Leakage through pressure limiter Max. 10 cc/min (at 1,600 rpm)
a See TESTING AND ADJUSTING (Testing leakage through pressure limiter and
return rate from injector).
Relief speed (rpm) Return (Spill) rate limit (cc/min)
1,600 960
8 Defective injector
1,700 1,020
1,800 1,080
1,900 1,140
2,000 1,200
Defective fuel supply If none of causes 1 – 8 is the cause of the trouble, the fuel supply pump may be
9
pump defective.
NOTE 1: Check the low-pressure circuit parts for the following items.
1) Fuel level
2) Clogging of fuel tank breather
3) Sticking and wear of feed pump and clogging of filter
4) Leakage through and clogging of low-pressure fuel piping
5) Malfunction of bypass valve and installation of wrong part (See Fig. 1)
6) Clogging of fuel filter
7) Fuel in oil pan (Fuel leakage inside head cover)
Fig. 1: Locations of overflow valve (1), bypass valve (2), and fuel inlet joint (3)
• Overflow valve (1): Spring is seen through both holes.
• Bypass valve (2): Spring is seen through hole on nut side.
• Fuel inlet joint (3): Gauze filter is seen through both holes.
NOTE 2: Check, clean, and replace the filters and strainers according to the following procedure.
1) Gauze filter: Disassemble and check. If clogged, clean.
2) Upstream strainer of gauze filter: If the gauze filter is clogged, clean the upstream filter, too.
3) Fuel filter: If the trouble is not solved by performing 1) and 2) above, replace the fuel filter.
B. Check with monitor panel (Failure history function, monitoring function, and reduced cylinder mode operation function)
Good NG
3 Check of error code / / / /
Check of monitoring information (Working mode: A mode)
Standard value
Code Displayed item Checking condition Unit Measured value Good NG
(Reference value)
Low idle rpm 800 – 850
01002 Engine speed High idle rpm 1,930 – 2,030
Boom raise relief rpm Min. 1,700
Low idle % 0
31701 Throttle position
High idle % 100
36100 Fuel delivery command Boom raise relief mm3 —
Common rail pressure com-
36200 Boom raise relief MPa 110 – 120
mand
4
Common rail fuel
36400 Boom raise relief MPa 110 – 120
pressure
Low idle CA —
36300 Fuel injection timing command High idle CA —
Boom raise relief CA —
36500 Boost pressure Boom raise relief kPa —
Engine coolant temperature
04102 Low idle °C —
(High temperature)
Engine coolant temperature
04107 Low idle °C —
(Low temperature)
14200 Fuel temperature Low idle °C —
Check of reduced cylinder mode operation (Engine speed)
Standard value
Function Reduced cylinder Checking condition Unit Measured value Good NG
(Reference value)
No. 1 cylinder Low idle rpm —
5 No. 2 cylinder Low idle rpm —
Cylinder No. 3 cylinder Low idle rpm —
cut-out No. 4 cylinder Low idle rpm —
No. 5 cylinder Low idle rpm —
No. 6 cylinder Low idle rpm —
Standard value
C. Check of fuel circuit pressure Checking condition Unit Measured value Good NG
(Reference value)
MPa 0.15 – 0.3
6 Fuel low-pressure circuit pressure High idle
{kg/cm2} {1.5 – 3.0}
Standard value
E. Check of leakage and return rate Checking condition Unit Measured value Good NG
(Reference value)
11 Leakage through pressure limiter No load, 1,600 rpm cc/min Max. 10
Boom raise relief, 1,600 rpm cc/min 960
Speed:
Boom raise reliefl, 1,700 rpm cc/min 1,020
12 Return rate from injector Boom raise relief, 1,800 rpm cc/min 1,080
Leakage:
Boom raise relief, 1,900 rpm cc/min 1,140
Boom raise relief, 2,000 rpm cc/min 1,200
User Code Error Code Failure Code Failure Rail press. too low
E11 E97C AD10MB phenomenon (Engine controller system)
Failure content • No-pressure feed by fuel supply pump (level 2) occurred.
• The machine is driven with limited output and speed.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
Relative • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
information function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
User Code Error Code Failure Code Failure Rail press. out of control
E11 E97D AD10MA phenomenon (Engine controller system)
Failure content • Abnormal fuel pressure was generated in the common rail.
• The machine is driven under the normal control.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
occurring on • The output lowers (Only the pump absorption torque is reduced).
machine • The engine speed does not rise above low idle.
Relative • Input from the common rail pressure sensor (voltage and pressure) can be checked in the monitoring
information function. (Code No. 36401: Common rail pressure sensor voltage, 36400: Common rail fuel pressure)
User Code Error Code Failure Code Failure Eng. Controller Abnormality
E10 or E11 E980 DB20KT phenomenon (Engine controller system)
Failure content • The controller has abnormality in it.
• The machine is driven with limited output or all output is turned OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stop and it cannot be started (when user code [E10] is displayed).
Relative
information
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
1 (Disconnection or defec-
tive contact with connec- Wiring harness between E13 (female) (11), (31), (32) Resistance
Below 1 z
tor) and grounding value
Engine controller If cause 1 is not detected, the engine controller may be defective.
2
defective (Since trouble is in the engine controller, troubleshooting cannot be carried out.)
User Code Error Code Failure Code Failure Fuel Injector 1 Disc.
E11 E981 ADA1KA phenomenon (Engine controller system)
Failure content • Fuel injector 1 circuit is disconnected.
• Power to the fuel injector 1 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between E13 (female) (14) and CN1 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between E13 (female) (24) and CN1 Resistance
Below 1 z
(female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Engine controller position during the troubleshooting.
3
defective E13 (female) Resistance value
Between (14) and (24) 0.4 – 1.1 z
User Code Error Code Failure Code Failure Fuel Injector 2 Disc.
E11 E982 ADB1KA phenomenon (Engine controller system)
Failure content • Fuel injector 2 circuit is disconnected.
• Power to the fuel injector 2 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between E13 (female) (6) and CN2 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between E13 (female) (16) and CN2 Resistance
Below 1 z
(female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Engine controller position during the troubleshooting.
3
defective E13 (female) Resistance value
Between (6) and (16) 0.4 – 1.1 z
User Code Error Code Failure Code Failure Fuel Injector 3 Disc.
E11 E983 ADC1KA phenomenon (Engine controller system)
Failure content • Fuel injector 3 circuit is disconnected.
• Power to the fuel injector 3 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between E13 (female) (5) and CN3 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between E13 (female) (15) and CN3 Resistance
Below 1 z
(female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Engine controller position during the troubleshooting.
3
defective E13 (female) Resistance value
Between (5) and (15) 0.4 – 1.1 z
User Code Error Code Failure Code Failure Fuel Injector 4 Disc.
E11 E984 ADD1KA phenomenon (Engine controller system)
Failure content • Fuel injector 4 circuit is disconnected.
• Power to the fuel injector 4 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between E13 (female) (26) and CN4 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between E13 (female) (36) and CN4 Resistance
Below 1 z
(female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Engine controller position during the troubleshooting.
3
defective E13 (female) Resistance value
Between (26) and (36) 0.4 – 1.1 z
User Code Error Code Failure Code Failure Fuel Injector 5 Disc.
E11 E985 ADF1KA phenomenon (Engine controller system)
Failure content • Fuel injector 5 circuit is disconnected.
• Power to the fuel injector 5 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between E13 (female) (33) and CN5 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between E13 (female) (34) and CN5 Resistance
Below 1 z
(female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Engine controller position during the troubleshooting.
3
defective E13 (female) Resistance value
Between (34) and (33) 0.4 – 1.1 z
User Code Error Code Failure Code Failure Fuel Injector 6 Disc.
E11 E986 ADF1KA phenomenon (Engine controller system)
Failure content • Fuel injector 6 circuit is disconnected.
• Power to the fuel injector 6 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between E13 (female) (25) and CN6 Resistance
2 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between E13 (female) (35) and CN6 Resistance
Below 1 z
(female) (2) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Engine controller position during the troubleshooting.
3
defective E13 (female) Resistance value
Between (25) and (35) 0.4 – 1.1 z
User Code Error Code Failure Code Failure Fuel Injector 1 – 3 S/C
E11 E98A ADAZKB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit.
• Power to the fuel injector 1 circuit, fuel injector 2 circuit, and fuel injector 3 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
User Code Error Code Failure Code Failure Fuel Injector 4 – 6 S/C
E11 E98B ADDZKB phenomenon (Engine controller system)
Failure content • Abnormal current flowed in the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit.
• Power to the fuel injector 4 circuit, fuel injector 5 circuit, and fuel injector 6 circuit is switched OFF.
Response from
• Even after the failure cause disappears of itself, the machine operation does not return to normalcy,
controller
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).
Phenomenon
• The output lowers (Only the pump absorption torque is reduced).
occurring on
• The engine speed does not rise above low idle.
machine
• The engine stops and it cannot be started (when user code [E10] is displayed).
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
User Code Error Code Failure Code Failure Eng. Hi Out of Std
— — A000N1 phenomenon (Mechanical system)
Failure content • Engine speed higher than 2,500 rpm is detected while the engine is running.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the engine may be damaged.
machine
Relative • Input from the engine speed sensor (rpm) can be checked in the monitoring function.
information (Code No. 01002: Engine speed)
(While system is normal) speed, then carry out troubleshooting for the mechanical system of the engine.
Presumed cause and
User Code Error Code Failure Code Failure Charge Voltage Low
— — AB00KE phenomenon (Mechanical system)
Failure content • Signal voltage from alternator is below 20 V while the engine is running.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the battery may not be charged.
machine
• If the charge level monitor on the monitor panel lights up in red while the engine is running, this failure
Relative code is recorded.
information • Input from the alternator (Voltage, ON or OFF) can be checked in the monitoring function.
(Code No. 04300: Charge voltage, 04501: Monitor input 2)
2 (Disconnection or defec-
tive contact with connec- Wiring harness between P02 (female) (11), J02, and Resistance
Below 1 z
tor) alternator terminal R value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Grounding fault of wiring
harness Between wiring harness between P02 (female) (11),
3 J02, and alternator terminal R, or between P02 (female)
(Contact with grounding Resistance
circuit) (11), D01, J01, and starting switch terminal BR, or Above 1 Mz
value
between P02 (female) (11), battery relay terminal BR
and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
4 Monitor panel defective P02 Engine Voltage
Between (11) and
Above low idle Above 20 V
grounding
User Code Error Code Failure Code Failure Eng. Oil Press. Low
E11 E924 B@BAZG phenomenon (Mechanical system)
• 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.
Failure content • 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
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the engine may be damaged.
machine
• 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.
Relative • If the engine oil pressure monitor on the monitor panel lights up in red while the engine is running, this
information 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)
Circuit diagram related to engine oil pressure sensors (for low pressure and high pressure)
User Code Error Code Failure Code Failure Eng. Oil Level Low
— — B@BAZK phenomenon (Mechanical system)
• The signal circuit of the engine oil level switch is opened (disconnected from grounding) while the
Failure content
engine is stopped.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the engine may be damaged.
machine
• If the engine oil level monitor on the monitor panel lights up in red while the engine is running, this fail-
Relative ure code is recorded.
information • Input from the engine oil level switch (ON or OFF) can be checked in the monitoring function.
(Code No. 04501: Monitor input 2)
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
4 Monitor panel defective P02 Engine oil level Voltage
Normal level Below 1 V
Between (8) and grounding
Below normal level 20 – 30 V
User Code Error Code Failure Code Failure Eng. Coolant Overheat
— — B@BCNS phenomenon (Mechanical system)
Failure content • The signal circuit of the engine coolant high temperature sensor detected temperature above 105°C.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the engine may be damaged.
machine
• If the engine coolant temperature monitor on the monitor panel lights up in red while the engine is run-
ning, this failure code is recorded.
Relative
• Input from the engine coolant high temperature sensor (coolant temperature and voltage) can be
information
checked in the monitoring function. (Code No. 04102: Engine coolant temperature (High), 04106:
Engine coolant temperature sensor voltage Hi)
Engine overheated Check the engine for overheating. If it has been overheated, find out the cause and
1
Presumed cause and
(While system is normal) check the engine for damage, then repair.
Engine coolant high
Carry out troubleshooting for "Display of engine coolant temperature gauge on moni-
2 temperature sensor
tor panel is abnormal" in E-mode.
system defective
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Engine controller position during the troubleshooting.
3
defective E12 (female) Engine coolant temperature Resistance value
Between (27) and (39) 105°C 3.28 kz
Circuit diagram related to engine coolant temperature sensor (for low temperature and high temperature)
User Code Error Code Failure Code Failure Eng. Coolant Lvl Low
— — B@BCZK phenomenon (Mechanical system)
• The signal circuit of the radiator coolant level switch is opened (disconnected from grounding) while the
Failure content
engine is running.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the engine will overheat.
machine
• If the radiator coolant level monitor on the monitor panel lights up in red while the engine is stopped
Relative (the starting switch is at the ON position), this failure code is recorded.
information • Input from the radiator coolant level switch (ON or OFF) can be checked in the monitoring function.
(Code No. 04500: Monitor input 1)
User Code Error Code Failure Code Failure Hydr. Oil Overheat
— — B@HANS phenomenon (Mechanical system)
Failure content • The signal of the hydraulic oil temperature sensor rises above 102°C while the engine is running.
Response from
• None in particular.
controller
Phenomenon
occurring on • If the machine is used as it is, the hydraulic equipment may be damaged.
machine
• If the hydraulic oil temperature monitor on the monitor panel lights up in red while the engine is running,
Relative this failure code is recorded.
information • Input from the hydraulic oil temperature sensor (temperature) can be checked in the monitoring func-
tion. (Code No. 04401: Hydraulic oil temperature)
a This failure code is applicable only when the auto grease device is installed.
Type of power
Fuse No. Fuse capacity Destination of power
supply
TVC solenoid (for emergency pump drive)
1 10A
Swing holding brake solenoid (for swing brake release)
Starting motor cut-out relay
2 10A Machine push-up solenoid
Switch power supply Boom shockless solenoid
(Circuit breaker 1) 3 10A PPC lock solenoid
Cigarette lighter
4 20A
Windshield washer motor
Horn
5 10A
Flash light
6 10A (Spare)
7 10A Rotary lamp
Switch power supply
8 10A (Spare)
(Circuit breaker 1)
9 10A Radio
10 20A Monitor panel
11 25A Air conditioner unit
12 20A (Spare)
Switch power supply
13 20A (Spare)
(Circuit breaker 1)
14 10A Service power supply (M32 connector)
15 10A DC/DC converter
16 10A Radio
17 10A —
Constant power 18 10A (Engine compartment lamp)
supply 19 10A Room lamp
(Circuit breaker 9) Step light
20 10A Pump controller power source (for step light)
Step light switch
Failure
Phenomena occurring on machine
information
Relative
Information on occurred failures and troubleshooting
information
<Contents>
• The standard values in normalcy by which to judge "good" or "no good" about pre-
1 sumed causes.
• References for making judgement of "good" or "no good"
A wiring harness that is not originally connected with a grounding circuit is in contact
Presumed cause and
with it.
Cause for presumed • Failure due to short-circuiting
failure A wiring harness that is not originally connected with a power source circuit (24 V)
(The attached No. for is in contact with it.
3
filing and reference
purpose only. It does not <Points to remember in troubleshooting>
stand for any priority) 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 con-
4
nector 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 fol-
5 lowing 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.
This is part of the electrical circuit diagram which shows the portion where the failure occurred.
Failure
• The engine does not start. (Engine does not rotate)
information
Relative
• The engine starting circuit is equipped with the start lock mechanism of lock lever type.
information
LOCK Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Starting motor cut-out R11 (female) and R13 (female) Resistance value
5 relay defective
Between (1) and (2) 100 – 500 z
(Internal defect)
Between (3) and (5) Above 1 Mz
Between (3) and (6) Below 1 z
a Turn the engine starting switch OFF for the preparations (with the wiring harness
connected), and start the engine for troubleshooting.
Starting motor Voltage
B (Power
Between B and grounding 20 – 30 V
supply)
Starting motor defective
6 Between ST (1)
(Internal defect) S (Start) 20 – 30 V
and grounding
Between ST (2)
R (Charge) Below 1 V
and grounding
If the above voltages are normal and the starting motor does not rotate, the starting
motor has a defect in it or the engine is defective.
a Turn the engine starting switch OFF for the preparations (with only wiring harness
Alternator defective R disconnected), and hold it in the ON position during the troubleshooting.
7
(Internal short-circuiting) Alternator Voltage
Between terminal R and grounding Below 1 V
Wiring harness between R13 (female) (3), J04, J22, and Resistance
Below 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Between wiring harness between B26, J14, and H15 Resistance
Above 1 Mz
(female) (1) and grounding value
Between wiring harness between H15 (female) (4), J01, Resistance
Above 1 Mz
and R11 (female) (5) and grounding value
Grounding fault of wiring Between wiring harness between R11 (female) (3) and Resistance
Above 1 Mz
harness ST (female) (1) and grounding value
9
(Contact with grounding Between wiring harness between FB1-3 and S14 (male) Resistance
circuit) Above 1 Mz
(1) and grounding value
Between wiring harness between S14 (male) (3) and Resistance
Above 1 Mz
R11 (female) (1) and grounding value
Between wiring harness between R11 (female) (2) and Resistance
Above 1 Mz
R13 (female) (6) and grounding value
Between wiring harness between R13 (female) (2) and Resistance
Above 1 Mz
P02 (female) (14) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Short-circuiting of wiring
10 harness Between wiring harness between ST (female) (2) and
(Contact with 24 V circuit) alternator terminal R or between ST (female) (2), J02 Voltage Below 1 V
and D01 (female) (6) or between ST (female) (2) and
P02 (female) (11) and grounding
Electrical Circuit Diagram for Engine Preheat, Start and Battery Charging
Failure (1) When the starting switch is turned to the HEAT posi-
• The preheater does not operate.
information tion, the preheating monitor does not light up.
• The preheating monitor starts lighting when the starting switch is turned to the HEAT position. After about
Relative 30 seconds, it start flashing to notify that preheating is finished (It stops flashing in about 10 seconds).
information • Input of the preheating signal (ON or OFF) can be checked in the monitoring function.
(Code No. 04500: Monitor input 1)
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
a Turn the engine starting switch OFF for the preparations , and hold it in the OFF or
HEAT position during troubleshooting.
3 Monitor panel defective P02 Starting switch Voltage
Between (18) and OFF Below 1 V
grounding HEAT 20 – 30 V
(Internal disconnection)
Between coil terminal
OFF Continued
and grounding
Between contact terminals HEAT Below 1 z
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Intake air heater position during the troubleshooting.
3 defective
Intake air heater Continuity
(Internal disconnection)
Between terminals Continued
Wiring harness between H15 (female) (3), J02, and Resistance
Below 1 z
heater relay terminal value
Disconnection of wiring Wiring harness between starting motor terminal B and Resistance
harness Below 1 z
heater relay value
4 (Disconnection or defec-
tive contact with connec- Wiring harness between heater relay and intake air Resistance
Below 1 z
tor) heater value
Resistance
Wiring harness between intake air heater and engine Below 1 z
value
Electrical Circuit Diagram for Engine Preheat, Start and Battery Charging
Failure
• The auto engine warm-up device does not work.
information
• The auto engine warm-up device is activated, when the engine coolant temperature is below 30°C, and
raise the engine rotation up to 1,200 rpm.
Relative • The auto engine warm-up device is released by keeping the fuel dial opening at above 70% for more
information than 3 seconds, when the engine starting switch is in the ON position or after the engine is started.
• If the engine coolant 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.
Failure
• The auto-decelerator does not operate.
information
• Since the auto-decelerator is set to 1,400 rpm, it does not operate if the fuel control dial is not set above
this level.
Relative
• Check the display on the monitor panel while the engine is running.
information
• If the display on the monitor panel is abnormal, carry out troubleshooting in "*** is not displayed nor-
mally in monitoring function".
Failure
• All the work equipment, swing and travel do not move.
information
Relative
—
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Assembled-type diode position during the troubleshooting.
4 D01 fault
D01 (male) Resistance value (Continuitiy)
(Internal short-circuiting)
Between (4) and (8) Above 1 Mz (No continuitiy)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Disconnection of wiring Wiring harness between FB1-3 outlet and S14 (male) Resistance
harness Below 1 z
(1) value
5 (Disconnection or defec-
tive contact with connec- Wiring harness from S14 (male) (2) and V08 (female) Resistance
Below 1 z
tor) (2) value
Wiring harness between V08 (female) (1) to J14 and Resistance
Below 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Grounding fault of wiring
Between wiring harness between FB1-3 outlet and S14 Resistance
harness Above 1 Mz
6 (male) (1) and grounding value
(Contact with grounding
(GND) circuit) Wiring harness from S14 (male) (2) to V08 (female) (2),
Resistance
or between wiring harness between S14 (male) (2) and Above 1 Mz
value
D01 (female) (4) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
Failure • Any item is not displayed on the monitor When the starting switch is turned ON, any item is not
information panel. displayed on the monitor panel.
Relative
information
tor) value
Presumed cause and
If all the LCD (Liquid Crystal Display) in the monitor panel light up (i.e. the screen
1 Monitor panel LCD fault
becomes totally white) by the following switching operation, then the monitor panel is
normal.
• Switching operation: [ ] + [ A ] (push swiches simultaneously.)
Monitor panel If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in
2
defective the monitor panel, troubleshooting cannot be carried out.)
Failure
• The monitor panels displays contents that have nothing to do with the model on which it is installed.
information
Relative
—
information
If the display on the monitor panel is normal, troubleshoot Error Code [E217].
Monitor panel If cause 1 is not detected, the monitor panel may be defective. (Since trouble is in
2
defective the monitor panel, troubleshooting cannot be carried out.)
E-11 Fuel level monitor red lamp lights up while engine is running
Failure
• The fuel level monitor red lamp lighted up while the engine was running.
information
Relative
• If the fuel gauge shows in a red range on the monitor panel, the fuel level monitor lamp lights up red.
information
Fuel level sensor fault P06 (male) Fuel level Resistance value
2
Presumed cause and
(Internal disconnection)
FULL (Upper limit) Approx. 12 z
Between (1) and grounding
EMPTY (Lower limit) 85 – 110 z
Disconnection of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3 (Disconnection or defec-
tive contact with connec- Wiring harness between P02 (female) (2) and P06 Resistance
Max. 1 z
tor) (female) (1) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
4 Monitor panel defective P02 (female) Fuel level Resistance value
FULL (Upper limit) Approx. 12 z
Between (2) and grounding
EMPTY (Lower limit) 85 – 110 z
tor) Below 1 z
TWH (female) (2) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3
(Contact with grounding Between wiring harness between E12 (female) (27) and Resistance
circuit) Above 1 Mz
TWH (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
4 harness
(Contact with 24 V circuit) Between wiring harness between E12 (female) (27) and Voltage Below 1 V
TWH (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Engine controller E12 (female) Resistance value
5
defective
Between (27) and (39) 3.5 k – 90 kz
Between (27), (39) and grounding Above 1 Mz
If causes 1 – 5 are not detected, the monitor panel may be defective. (Since trouble
6 Monitor panel defective
is in the monitor panel, troubleshooting cannot be carried out.)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between P02 (female) (12) and P10 Resistance
2 (Disconnection or defec- Max. 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between P02 (female) (13) and P10 Resistance
Max. 1 z
(female) (2) value
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3
(Contact with grounding Between wiring harness between P02 (female) (12) and Resistance
(GND) circuit) Min. 1 Mz
P10 (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
4 harness
(Contact with 24 V circuit) Between wiring harness between P02 (female) (12) and Voltage Max. 1 V
P10 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
P02 (female) Hydraulic oil temperature Resistance value
5 Monitor panel defective
Between (12) and (13) 90 – 3.5 kz
Between (12) and 10 – 100°C
Min. 1 Mz
grounding
2 (Disconnection or defec-
Wiring harness between P02 (female) (2) and P06 Resistance
Presumed cause and
Grounding fault of wiring a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
harness position during the troubleshooting.
3
(Contact with grounding Between wiring harness between P02 (female) (2) and Resistance
(GND) circuit) Min. 1 Mz
P06 (female) (1) and grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
4 harness
(Contact with 24 V circuit) Between wiring harness between P02 (female) (2) and
Voltage Max. 1 V
P06 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
5 Monitor panel defective P02 (female) Fuel level Resistance value
FULL (Upper limit) Approx. 12 z
Between (2) and grounding
EMPTY (Lower limit) 85 – 110 z
(1) Though the swing lock switch was turned ON, the
Failure swing lock monitor does not light up.
• Swing lock monitor does not display correctly
information (2) Though the swing lock switch was turned OFF, the
swing lock monitor lights up.
Relative • Input from the swing lock switch (ON or OFF) can be confirmed in the monitor function.
information (Code No.: 04502 Monitor input 3)
tor) Wiring harness from X05 (male) (2) to J08 and ground- Resistance
Below 1 z
ing value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Grounding fault of wiring position during the troubleshooting.
harness
3 Between wiring harness from P02 (female) (17) to J07
(Contact with grounding Resistance
(GND) circuit) and X05 (male) (1), or between P02 (female) (17) to Above 1 Mz
value
C02 (female) (38) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
4 harness Between wiring harness from P02 (female) (17) to J07
(Contact with 24 V circuit) and X05 (male) (1), or between P02 (female) (17) to Voltage Below 1 V
C02 (female) (38) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
5 Monitor panel defective P02 Swing lock switch Voltage
Between (17) and OFF 20 – 30 V
grounding ON Below 1 V
Failure • When monitor switch is operated, nothing is (1) When mode selector switch is operated, working
information displayed. mode monitor is not displayed.
Relative
—
information
Failure • When monitor switch is operated, nothing is (2) When LCD monitor adjustment switch is operated,
information displayed. mode selection screen is not displayed.
Relative
—
information
Failure • When monitor switch is operated, nothing is (3) When maintenance switch is operated, item selec-
information displayed. tion screen is not displayed.
Relative
—
information
Failure • When monitor switch is operated, nothing is (4) When automatic deceleration switch is operated,
information displayed. automatic deceleration monitor is not displayed.
Relative • When the automatic decelerator does not operate either, conduct the troubleshooting for "Auto-deceler-
information tor does not operate".
Failure • When monitor switch is operated, nothing is (5) When travel speed selector switch is operated,
information displayed. travel speed monitor is not displayed.
Relative
information
Failure • When monitor switch is operated, nothing is (6) When wiper switch is operated, wiper monitor is not
information displayed. displayed.
Relative • When the wiper does not operate either, conduct the troubleshooting for "Windshield wiper and window
information washer do not work".
Double-wiper specification
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between P01 (female) (9) and W04 Resistance
2 (Disconnection or defec- Below 1 z
(male) (3) value
tive contact with connec-
tor) Resistance
Wiring harness between W04 (male) (1) and grounding Below 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
3 Monitor panel defective P01 Wiper switch Voltage
OFF Below 3 V
Between (9) and grounding
ON 20 – 30 V (Note)
Note: When the upper wiper and lower wiper are operated simultaneously: Below 3 V 20 – 30 V (at regular
intervals)
Double-wiper specification
Note: When the upper wiper and lower wiper are operated simultaneously: Below 3 V 20 – 30 V (at regular
intervals)
harness
Wiring harness between P01 (male) (9) and W04 Resistance
Presumed cause and
Electrical Circuit Diagram for Windshield Wiper Motor (Single windshield wiper spec.)
harness
Wiring harness from FB1-4 outlet to J04 and M28 Resistance
3 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness from M28 (female) (2) and P01 (female) Resistance
Below 1 z
(3) value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Grounding fault of wiring position during the troubleshooting.
harness
4 Between wiring harness from FB1-4 outlet to J04 and
(Contact with grounding Resistance
circuit) M28 (female) (1), or FB1-4 outlet to D05 (female) (3), Above 1 Mz
value
and to other relative circuits and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Monitor panel P01 Windshield washer switch Voltage
5
defective
OFF 20 – 30 V
Between (3) and grounding
ON Below 1 V
Failure
• The alarming buzzer cannot be cancelled.
information
Relative • Input from the alarming buzzer stop switch (ON or OFF) can be confirmed in the monitor function.
information (Code No.: 04502 Monitor input 3)
harness
Wiring harness between P02 (female) (16) and P03 Resistance
2 (Disconnection or defec- Below 1 z
(male) (1) value
tive contact with connec-
tor) Resistance
Wiring harness from P03 (male) (2) to J08 to grounding Below 1 z
value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
3 harness
(Contact with 24 V circuit) Between wiring harness between P02 (female) (16) and
Voltage Below 1 V
P03 (male) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
position during the troubleshooting.
Alarming buzzer stop
4 Monitor panel fault P02 Voltage
switch
Between (16) and Release 20 – 30 V
grounding Depress Below 1 V
Failure • "Boom RAISE" is not correctly displayed in mon- "Boom RAISE" is not correctly displayed in the moni-
information itor function tor function on the monitor panel.
Relative
—
information
Failure • "Boom LOWER" is not correctly displayed in "Boom LOWER" is not correctly displayed in the
information monitor function monitor function on the monitor panel.
Relative
—
information
Failure • "Arm IN" is not correctly displayed in monitor "Arm IN" is not correctly displayed in the monitor
information function function (special function) on the monitor panel.
Relative
—
information
Failure • "Arm OUT" is not correctly displayed in monitor "Arm OUT" is not correctly displayed in the monitor
information function function (special function) on the monitor panel.
Relative
—
information
Failure • "Bucket CURL" is not correctly displayed in "Bucket CURL" is not correctly displayed in the mon-
information monitor function itor function (special function) on the monitor panel.
Relative
—
information
Failure "Bucket DUMP" is not correctly displayed in moni- "Bucket DUMP" is not correctly displayed in the mon-
information tor function itor function (special function) on the monitor panel.
Relative
—
information
Failure • "SWING" is not correctly displayed in monitor "SWING" is not correctly displayed in the monitor
information function function (special function) on the monitor panel.
Relative
—
information
Electrical Circuit Diagram for Right and Left Swing PPC hydraulic Switches
Failure • "Left travel" is not displayed normally in the "Left travel" is not displayed normally in the monitor-
information monitoring function. ing function (special function) of the monitor panel.
Relative
information
Disconnection of wiring Wiring harness between C02 (female) (16), J19, and
Resistance
Presumed cause and
harness S12 (female) (2) or between C02 (female) (16) and S13 Below 1 z
value
3 (Disconnection or defec- (female) (2)
tive contact with connec- Wiring harness between S12 (female) (1), J13, J11, and Resistance
tor) Below 1 z
grounding value
Wiring harness between S13 (female) (1), J13, J11, and Resistance
Below 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Grounding fault of wiring position during the troubleshooting.
harness
4 Between wiring harness between C02 (female) (16),
(Contact with grounding Resistance
circuit) J19, and S12 (female) (2) or between C02 (female) (16) Above 1 Mz
value
and S13 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
5 harness Between wiring harness between C02 (female) (16),
(Contact with 24 V circuit) J19, and S12 (female) (2) or between C02 (female) (16) Voltage Below 1 V
and S13 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
6 Pump controller defective C02 Left travel lever Voltage
Between (16) and Neutral 20 – 30 V
grounding Forward or reverse Below 1 V
Circuit diagram related to left travel forward PPC oil pressure switch and left travel reverse
PPC oil pressure switch
Failure • "Right travel" is not displayed normally in moni- "Right travel" is not displayed normally in the moni-
information toring function toring function (special function) of the monitor panel.
Relative
information
Disconnection of wiring Wiring harness between C03 (female) (39), J19, and
Resistance
Presumed cause and
harness S01 (female) (2) or between C03 (female) (39) and S11 Below 1 z
value
3 (Disconnection or defec- (female) (2)
tive contact with connec- Wiring harness between S01 (female) (1), J13, J11, and Resistance
tor) Below 1 z
grounding value
Wiring harness between S11 (female) (1), J13, J11, and Resistance
Below 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Grounding fault of wiring position during the troubleshooting.
harness
4 Between wiring harness between C03 (female) (39),
(Contact with grounding Resistance
circuit) J19, and S01 (female) (2) or between C03 (female) (39) Above 1 Mz
value
and S11 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
5 harness Between wiring harness between C03 (female) (39),
(Contact with 24 V circuit) J19, and S01 (female) (2) or between C03 (female) (39) Voltage Below 1 V
and S11 (female) (2) and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
6 Pump controller defective C02 Right travel lever Voltage
Between (39) and Neutral 20 – 30 V
grounding Forward or reverse Below 1 V
Circuit diagram related to right travel forward PPC oil pressure switch and right travel reverse
PPC oil pressure switch
Failure • "Service" is not correctly displayed in monitor "Service" is not correctly displayed in the monitor func-
information function tion (special function) on the monitor panel.
Relative
—
information
Failure
• The air conditioner does not work.
information
Relative
information
Failure (1) When the switch is pressed, the light does not keep
• The step light does not light up or go off.
information lighting up for 1 minute.
Relative
information
R15
relay is defective.
Presumed cause and
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Wiring harness between FB1-20 outlet and M81
Resistance
(female) (2) or between FB1-20 outlet and R14 (female) Below 1 z
value
(3) or between FB1-20 outlet and R15 (female) (3)
Wiring harness between M81 (female) (1), J07, and C01
Resistance
(female) (24) or between M81 (female) (1), D04 and Below 1 z
value
R14 (female) (1)
Wiring harness between C03 (female) (5), D02, and Resistance
Below 1 z
Disconnection of wiring R14 (female) (1) value
harness Wiring harness between R14 (female) (2), J04, J22, and Resistance
6 (Disconnection or defec- Below 1 z
grounding value
tive contact with connec-
tor) Wiring harness between R14 (female) (5), J07, and C03 Resistance
Below 1 z
(female) (1), (2), (11), (12), (14), and (24) value
Wiring harness between C03 (female) (15) and R15 Resistance
Below 1 z
(female) (1) value
Wiring harness between R15 (female) (2), J04, J22, and Resistance
Below 1 z
grounding value
Wiring harness between R15 (female) (5) and M75 Resistance
Below 1 z
(female) (1) value
Wiring harness between M75 (female) (2) and ground- Resistance
Below 1 z
ing value
Failure
• The step light does not light up or go off. (2) While the switch is not pressed, the light lights up.
information
Relative
information
Short-circuiting of wiring and C01 (female) (24) or between M81 (female) (1), Voltage Below 1 V
4 harness D04, and R14 (female) (1) and grounding
(Contact with 24 V circuit) Between wiring harness between C03 (female) (5), D02,
Voltage Below 1 V
and R14 (female) (1) and grounding
Between wiring harness between C03 (female) (15) and
Voltage Below 1 V
R15 (female) (1)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Pump controller defective
(Step light switch input C01 Step light switch Voltage
system) Between (24) and Released Below 1 V
grounding Pressed 20 – 30 V
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Pump controller defective
(Step light power source C03 Step light switch Voltage
5 holding relay output Released Below 1 V
system) Between (5) and grounding 20 – 30 V
Pressed
(60 seconds)
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
position during the troubleshooting.
Pump controller defective C03 Step light switch Voltage
(Step light relay output
system) Released Below 1 V
Between (15) and
grounding 20 – 30 V
Pressed
(60 seconds)
Failure
• The electric grease gun does not operate.
information
Relative
information
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Presumed cause and
E-32 Travel alarm does not sound or does not stop sounding
(1) The alarm does not sound while the machine is trav-
Failure • The travel alarm does not sound or does not
eling.
information stop sounding.
(2) The alarm sounds while the machine is stopped.
Relative
information
2 Neutral Below 1 V
(Internal defect) Between (1) and (2)
Operated 20 – 30 V
If the above voltages are normal and the travel alarm does not sound, the travel
alarm is defective.
a Turn the engine starting switch OFF for the preparations, and hold it in the OFF
Disconnection of wiring position during the troubleshooting.
harness
Wiring harness between C03 (female) (8) and F01 Resistance
3 (Disconnection or defec- Below 1 z
(female) (1) value
tive contact with connec-
tor) Wiring harness between F01 (female) (2), J21, and Resistance
Below 1 z
grounding value
a Turn the engine starting switch OFF for the preparations, and hold it in the ON
Short-circuiting of wiring position during the troubleshooting.
4 harness
(Contact with 24 V circuit) Between wiring harness between C03 (female) (8) and Voltage Below 1 V
F01 (female) (1) and grounding
a Turn the engine starting switch OFF for the preparations, and keep the engine
running during the troubleshooting.
5 Pump controller defective C03 Travel lever Voltage
Neutral Below 1 V
Between (8) and grounding
Operated 20 – 30 V
1. Combination and operation of hydraulic 2. Finding cause of trouble that "work equip-
pumps ment speed is low and machine deviates to
• For the work equipment, travel, and swing left"
circuits, 2 tandem pumps (4 pump units) of • The possible causes of this trouble are as
the No. 1 pump (HPV95+95) and the No. 2 follows:
pump (HPV95+95) are used. 1) The main relief valve of the left 5-spool
• The oil from the No. 1 front pump and that valve is defective.
from the No. 2 front pump merge together 2) The jet sensor of the left 5-spool valve is
and flow in the left 5-spool valve. The oil defective.
from the No. 1 rear pump and that from the 3) The CO-NC valve of the No. 1 front
No. 2 rear pump merge together and flow in pump is defective.
the right 4-spool valve. 4) The servo valve of the No. 1 front pump
• The TVC valve installed on the No. 1 rear is defective.
pump carries out the TVC control of the No. 5) The No. 1 front pump is defective.
1 pump and No. 2 pump similarly. 6) The servo valve of the No. 2 front pump
• The CO-NC valve installed on the No. 1 front is defective.
pump and the jet sensor installed to the left 7) The No. 2 front pump is defective.
5-spool valve carry out the CO-NC control of • Whether the main relief valve, jet sensor,
the No. 1 front pump and No. 2 front pump and CO-NC valve are good or not can be
similarly. judged by measuring the relief pressure, dif-
• The CO-NC valve installed on the No. 1 rear ferential pressure, and output pressure re-
pump and the jet sensor installed to the right spectively.
4-spool valve carry out the CO-NC control of • Since the oil from the No. 1 front pump and
the No. 1 rear pump and No. 2 rear pump that from the No. 2 front pump merge togeth-
similarly. er as explained in 1 above, exchange the
outlet hoses of the No. 2 front and rear
pumps and check the phenomenon of the
machine to find out a defective system in the
servo valves and pump units of the No. 1 and
No. 2 front pumps.
1) If the machine still deviates to the left (If
deviation does not change), the No. 1
front pump system is defective.
2) If the machine deviates to the right (If
deviation changes), the No. 2 front
pump system is defective.
3) If the travel speed lowers, the jet sensor
or the CO-NC valve is defective (when
the right and left relief pressures are
normal).
• To judge the condition of the servo valve and
pump unit, remove the servo valve and test it
or measure the stroke of the servo piston.
a Actually, judge the condition according "4.
Judgment matrix for trouble that work equip-
ment speed is low and machine deviates".
3. Finding cause of trouble that "work equip- 4. Judgment matrix for trouble that work equip-
ment speed is low and machine deviates to ment speed is low and machine deviates (on
right" the next page)
• The possible causes of this trouble are as a Carry out diagnosis in order from the top line
follows: and judge the factor having the most black
1) The main relief valve of the right 4-spool points (q) to be the cause of the trouble.
valve is defective. 1) To judge the servo valve, remove it and test
2) The jet sensor of the right 4-spool valve it or measure the stroke of the servo piston.
is defective. a Perform the test on the servo piston unit
3) The CO-NC valve of the No. 1 rear in the specified maintenance shop.
pump is defective. 2) If the speed lowers extremely and the pump
4) The servo valve of the No. 1 rear pump seems to be abnormal, check the line filter
is defective. too.
5) The No. 1 rear pump is defective. 3) If the speed lowers little but cannot be set to
6) The servo valve of the No. 2 rear pump the normal level by adjusting each device,
is defective. check the line filter too.
7) The No. 2 rear pump is defective. 4) To check the operation of the servo piston,
• Whether the main relief valve, jet sensor, remove the caps from both sides of it and
and CO-NC valve are good or not can be move the servo piston with the hand.
judged by measuring the relief pressure, dif-
ferential pressure, and output pressure re-
spectively.
• Since the oil from the No. 1 rear pump and
that from the No. 2 rear pump merge togeth-
er as explained in 1 above, exchange the
outlet hoses of the No. 2 front and rear
pumps and check the phenomenon of the
machine to find out a defective system in the
servo valves and pump units of the No. 1 and
No. 2 rear pumps.
1) If the machine still deviates to the left (If
deviation does not change), the No. 1
rear pump system is defective.
2) If the machine deviates to the right (If
deviation changes), the No. 2 rear pump
system is defective.
3) If the travel speed lowers, the jet sensor
or the CO-NC valve is defective (when
the right and left relief pressures are
normal).
• To judge the condition of the servo valve and
pump unit, remove the servo valve and test it
or measure the stroke of the servo piston.
a Actually, judge the condition according "4.
Judgment matrix for trouble that work equip-
ment speed is low and machine deviates".
Causes
Left Right
No. 1 pump No. 2 pump 5-spool 4-spool
valve valve
Front Rear
Front pump Rear pump
pump pump
Remedy
A A A A A A
No.
X X X X X X X X X X X X X X X X
Diagnosis
Machine "deviates to left" and work equipment speed
1
and swing speed are low.
q q q q q q q
Machine "deviates to left" and single swing speed is
2
particularly low.
q q q q q q
Machine "deviates to left" and single swing speed is
3
normal.
q
4 Travel relief pressure of front pump circuit is low. q
Machine "deviates to left"
How to exchange outlet hoses of No. 2 pump and hydraulic circuit diagram after they are exchanged
Failure
Phenomena on machine
Phenomenon
Related
Information concerning to failure or troubleshooting.
Information
1
standard value in normalcy
Presumed cause and
2
Possible causes of
failure <Contents>
(The sequence number is • Standard values for judgement of possible causes.
only for reference and • Remarks for judgement
does not state priority.)
3
H-1 Speed or power of all work equipment, travel, and swing is low
Failure
• Speed or power of all work equipment, travel, and swing is low
information
• Measure the speed of the work equipment, travel, and swing speed and check that all of them are slow
(or their power is low).
• Check that abnormal sound is not heard from around the pump.
Relative
(If abnormal sound is heard, carry out the related troubleshooting.)
information
• Check that the machine does not deviate.
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode A.
0
4 malfunction of control All levers in neutral
Presumed cause and
+5
relief valve {34 0 kg/cm2}
If the oil pressure is still abnormal after adjustment, check cause 5. If cause 5 is not
detected, the control relief valve operation may be defective. Check the control relief
valve directly.
a Stop the engine and block (1) – (9) in Fig. 1 in order. Run the engine at high idle
and check.
Leakage in control Control levers Control relief pressure
5
system devices +0.49
3.33 0 MPa
All levers in neutral +5
{34 0 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
7 {Min. 18 kg/cm2}
malfunction of TVC valve
Heavy lift switch OFF + 1.18 ± 0.2 MPa
Boom RAISE relief {12 ± 2 kg/cm2}
1.14 ± 0.2 MPa
Heavy lift switch ON + Boom RAISE relief
{11.6 ± 2 kg/cm2}
If the oil pressure is still abnormal after adjustment, the TVC valve may be defective.
Check the TVC valve directly.
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
Malfunction of CO Working mode Solenoid valve outlet pressure
8
cancel solenoid valve Min. 2.74 MPa
A-mode
{Min. 28 kg/cm2}
E-mode 0 MPa {0 kg/cm2}
Failure
• Engine speed lowers remarkably or engine stalls
Phenomenon
Related
• Carry out all the troubleshooting in working mode A.
Information
H-3 All work equipment, travel, and swing systems do not work
Failure
• All work equipment, travel, and swing systems do not work
information
Relative
• Carry out all the troubleshooting in working mode A.
information
Failure
• Abnormal sound is heard from around pump
Phenomenon
Related
Information
1 Low hydraulic oil level Since the hydraulic oil level may be low, check it directly.
Since a piping clamp between the hydraulic tank and hydraulic pump may be loos-
value in normalcy
2
priority solenoid valve Swing priority switch OFF +
Presumed cause and
0 MPa {0 kg/cm2}
Lever in neutral
Swing priority switch ON + Min. 2.74 MPa
Boom RAISE operation {Min. 28 kg/cm2}
Malfunction of boom
3 The spool of the boom control valve (Lo, Hi) may malfunction. Check it directly.
control valve (spool)
The safety-suction valve of the boom control valve (Lo) may malfunction. Check it
Malfunction of boom directly. (When checking the safety-suction valve by exchanging it with a valve of
4 control valve another work equipment circuit, stop the hose of the machine push-up solenoid
(Safety-suction valve) securely. After finishing check, be sure to return the safety-suction valve since its set
pressure and structure are different from others.)
Boom control valve
The control valve unit of the boom control valve (Lo, Hi) may be defective. Check it
5 (control valve unit)
directly.
defective
a Keep the engine stopped for the preparations, and run it at high idle during
Boom cylinder seal troubleshooting.
6
defective Right work equipment control lever Leakage from cylinder
Boom RAISE relief Max. 20 cc/min
Failure (2) The boom raise speed or power is low in the heavy
• Boom speed or power is low
information lift mode.
• The heavy lift mode is the state that the heavy lift switch is turned ON.
• Check that the other work equipment, travel, and swing are normal. (If any of them is abnormal, carry
Relative
out troubleshooting related to it.)
information
• Check that the machine does not deviate. (If it deviates, carry out troubleshooting related to deviation.)
• When carrying out the following troubleshooting, set the working mode in the A-mode.
a Keep the engine stopped for the preparations, and run it at high idle during
Presumed cause and
troubleshooting.
Malfunction of 2-stage Right work equipment control lever Solenoid valve outlet pressure
2
relief solenoid valve Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Single boom RAISE operation
{Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
Right work equipment control lever Main relief pressure
Wrong adjustment or +1.0
3 malfunction of main relief 33.8 –2.0 MPa
valve Single boom RAISE operation +10
{345 –20 kg/cm2}
If the main relief valve is still abnormal after adjustment, its operation (on the high
pressure set side) may be defective. Check it directly.
a Keep the engine stopped for the preparations, and run it at high idle during
Presumed cause and
troubleshooting.
Malfunction of machine Machine push-up switch Solenoid valve outlet pressure
1
push-up solenoid valve Min. 2.74 MPa
OFF
{Min. 28 kg/cm2}
ON 0 MPa {0 kg/cm2}
Malfunction of boom
The safety-suction valve of the boom control valve (Lo) (on the high pressure set side
2 control valve
on the head side) may malfunction. Check it directly.
(Safety-suction valve)
Failure
• Speed or power of arm is low
Phenomenon
• Check that the speeds of the other work equipment, travel, and swing are normal.
(If they are abnormal, carry out the related troubleshooting.)
Related
• Check that the machine does not deviate.
Information
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode A.
Malfunction of arm Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
2
control valve (spool) directly.
The safety-suction valve of the arm control valve (Lo, Hi) may malfunction. Check it
Malfunction of arm
directly. (After checking the safety-suction valve by exchanging it with a valve of
3 control valve
another work equipment circuit, be sure to return it since its set pressure is different
(safety & suction valve)
from others.)
Defective arm control Since the body of the arm control valve (Lo, Hi) may have a malfunction, check it
4
valve (body) directly.
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
Defective seal of arm high idle.
5
cylinder L.H. work equipment control lever Leakage from cylinder
Relieved in arm IN position Max. 20 cc/min
Failure
• Speed or power of bucket is low
Phenomenon
• Check that the speeds of the other work equipment, travel, and swing are normal.
(If they are abnormal, carry out the related troubleshooting.)
Related
• Check that the machine does not deviate.
Information
(If the machine deviates, carry out the related troubleshooting.)
• Carry out all the troubleshooting in working mode A.
Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
2
control valve (spool) directly.
Since the safety & suction valve of the bucket control valve (Lo, Hi) may have a mal-
Malfunction of bucket function, check it directly. (The safety & suction valve may be checked by replacing it
3 control valve with one of another work equipment circuit. After checking, however, be sure to
(safety & suction valve) return the safety & suction valve since its set pressure and structure are different
from the others.)
Defective bucket control Since the body of the bucket control valve (Lo, Hi) may have a malfunction, check it
4
valve (body) directly.
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
Defective seal of bucket
5 R.H. work equipment control lever
cylinder Leakage from cylinder
(bucket)
Relieved in bucket CURL position Max. 20 cc/min
Failure
• Boom does not move
Phenomenon
• Check that operations of the other work equipment, travel, and swing are normal.
Related
(If they are abnormal, carry out the related troubleshooting.)
Information
• Carry out all the troubleshooting in working mode A.
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
value in normalcy
Malfunction of boom Since the spool of the boom control valve (Lo, Hi) may have a malfunction, check it
2
control valve (spool) directly.
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
value in normalcy
Malfunction of arm Since the spool of the arm control valve (Lo, Hi) may have a malfunction, check it
2
control valve (spool) directly.
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
value in normalcy
Malfunction of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
2
control valve (spool) directly.
Failure
• Hydraulic drift of work equipment is large (1) Hydraulic drift of boom is large
Phenomenon
Related
Information
1 Since the spool of the boom control valve (Lo) may have a malfunction, check it directly.
control valve (spool)
Since the safety & suction valve (bottom side) of the boom control valve (Lo) may have
value in normalcy
Malfunction of boom con- a malfunction, check it directly. (The safety & suction valve may be checked by replac-
2 trol valve (safety & suc- ing it with one of another work equipment circuit. After checking, however, be sure to
tion valve) return the safety & suction valve since its set pressure and structure are different from
the others.)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at high
Defective seal of boom idle.
3
cylinder R.H. work equipment control lever Leakage from cylinder
Relieved in boom RAISE position Max. 20 cc/min
Failure
• Hydraulic drift of work equipment is large (2) Hydraulic drift of arm is large
Phenomenon
Related
Information
1
control valve (spool) directly.
Since the safety & suction valve (head side) of the arm control valve (Lo) may have a
value in normalcy
Malfunction of arm malfunction, check it directly. (The safety & suction valve may be checked by replac-
2 control valve ing it with one of another work equipment circuit. After checking, however, be sure to
(safety & suction valve) return the safety & suction valve since its set pressure and structure are different
from the others.)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
Defective seal of arm high idle.
3
cylinder L.H. work equipment control lever Leakage from cylinder
Relieved in arm IN position Max. 20 cc/min
Failure
• Hydraulic drift of work equipment is large (3) Hydraulic drift of bucket is large
Phenomenon
Related
Information
Defective seal of bucket Since the spool of the bucket control valve (Lo, Hi) may have a malfunction, check it
1
control valve (spool) directly.
Since the safety & suction valve (bottom side) of the bucket control valve (Lo, Hi)
value in normalcy
Malfunction of bucket may have a malfunction, check it directly. (The safety & suction valve may be
2 control valve checked by replacing it with one of another work equipment circuit. After checking,
(safety & suction valve) however, be sure to return the safety & suction valve since its set pressure and struc-
ture are different from the others.)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
Defective seal of bucket high idle.
3
cylinder R.H. work equipment control lever Leakage from cylinder
Relieved in bucket CURL position Max. 20 cc/min
Failure
• Time lag of work equipment is large (1) Time lag of boom is large
Phenomenon
Related
Information
Presumed Since the safety & suction valve (head side) of the boom control valve (Lo)
cause and may have a malfunction, check it directly. (When checking by replacing the
Malfunction of boom
standard value safety & suction valve with one of another work equipment circuit, stop the oil
1 control valve (safety
in normalcy in the machine pushup solenoid hose securely. After checking, be sure to
& suction valve)
return the safety & suction valve since its set pressure and structure are differ-
ent from the others.)
Failure
• Time lag of work equipment is large (2) Time lag of arm is large
Phenomenon
Related
Information
Failure
• Time lag of work equipment is large (3) Time lag of bucket is large
Phenomenon
Related
Information
Failure
• Heavy lift function does not operate or stop
Phenomenon
Related
Information
Failure
• Machine push-up function does not operate or stop
Phenomenon
Related
Information
Failure
• Boom shockless function cannot be turned ON or OFF
Phenomenon
Related
Information
high idle.
Malfunction of travel PPC
3 Travel lever PPC valve output pressure
valve
FORWARD, REVERSE 2.74 MPa
Full stroke {28 kg/cm2}
Malfunction of travel
4 Since the spool of the travel control valve may have a malfunction, check it directly.
control valve (spool)
Defective travel control
5 Since the body of the travel control valve may have a malfunction, check it directly.
valve (body)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
Defective seal of center Travel lever Leakage from swivel joint
6
swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 1.
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
7 Leakage in travel motor
Travel lever Leakage from travel motor
Relieved on one side Max. 40 l/min
8 Defective travel motor Since the travel motor may be defective, check it directly.
Internal defect of final Since the final drive may have a defect in it, check it directly. (The defect can be
9
drive judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Malfunction of travel
Presumed cause and
2 Since the spool of the travel control valve may have a malfunction, check it directly.
control valve (spool)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
Defective seal of center Travel lever Leakage from swivel joint
3
swivel joint
Relieved on one side Max. 100 cc/min
If seal is defective, the machine deviates as shown in Fig. 1.
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
Low set pressure of Travel lever Travel relief pressure
4
travel motor safety valve +1.0
34.3 –2.0 MPa
Relieved on one side +10
{350 –20 kg/cm2}
Fig. 1 Defective seals in center swivel joint and travel deviation directions
Failure (1) Machine deviates only when started with travel lever
• Machine deviates largely at start
Phenomenon at full stroke
• Check that the machine does not deviate during constant-speed travel.
Related
(If the machine deviates even during constant-speed travel, carry out the related troubleshooting.)
Information
• Carry out all the troubleshooting in working mode A.
Malfunction of main Since the servo-valve of main pumps (No. 1 & No. 2) may have a malfunction, check
1
pump servo-valve it directly. (Test the servo-valve unit or measure its stroke.)
value in normalcy
Malfunction of travel
2 Since the spool of the travel control valve may have a malfunction, check it directly.
control valve (spool)
a Keep the engine stopped for the preparations, and run it at high idle during
Defective seal of center troubleshooting.
3
swivel joint Travel lever Leakage from swivel joint
Either side relief Max. 100 cc/min
Internal defect of travel
4 Since the travel motor may have a defect in it, check it directly.
motor (body)
{Min. 17 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the CO • NC valve may have
a malfunction or may be adjusted defectively. Check the CO • NC valve directly.
Malfunction of main Since the servo-valve of main pump may have a malfunction, check it directly.
2
pump servo-valve (Test the servo-valve unit or measure its stroke.)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
Travel lever Differential pressure of jet sensor
Min. 1.14 MPa
Defective adjustment or Neutral
3 {Min. 11.6 kg/cm2}
malfunction of jet sensor
Max. 0.15 MPa
Full stroke on one side (Idle travel)
{Max. 1.5 kg/cm2}
If the oil pressure cannot be set normally by adjustment, the relief valve may have a
malfunction or the orifice may be defective. Check the relief valve and orifice directly.
Failure
• Machine deviates largely during compound operation
Phenomenon
• Check that the machine does not deviate when the work equipment is not operated.
Related
(If the machine deviates under that condition, carry out the related troubleshooting.)
Information
• Carry out all the troubleshooting in working mode A.
Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
value in normalcy
Malfunction of travel Since the travel junction valve of the travel control valve may have a malfunction,
2
junction valve check it directly.
Failure
• Machine does not travel (only one track) (1) Machine does not travel in either direction.
Phenomenon
Related
Information
Malfunction of travel
1 Since the parking brake of the travel motor may have a malfunction, check it directly.
motor (parking brake)
Internal defect of travel
2 Since the travel motor may have a defect in it, check it directly.
motor (body)
Internal defect of final Since the final drive may have a defect in it, check it directly. (The defect can be
3
drive judged by abnormal sound, abnormal heat, metal chips in drained oil, etc.)
Failure
• Machine does not travel (only one track) (2) Machine does not travel forward or in reverse
Phenomenon
Related
• Carry out all the troubleshooting in working mode A.
Information
Malfunction of travel
2 Since the spool of the travel control valve may have a malfunction, check it directly.
control valve (spool)
Defective travel control Since the suction valve of the travel control valve may have a malfunction, check it
3
valve (suction valve) directly. (The suction valve can be checked by replacing it with normal one.)
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
high idle.
Malfunction of travel Travel levers Travel relief pressure
4
motor (safety valve) +1.0
Relieved on one side 34.3 –2.0 MPa
(Direction in which machine does not travel) +10
{350 –20 kg/cm2}
Malfunction of travel
Since the counterbalance valve of the travel motor may have a malfunction, check it
5 motor
directly.
(counterbalance valve)
Failure
• Travel speed does not change
Phenomenon
• Check that the Lo and Hi travel speeds are normal.
(If they are abnormal, carry out the related troubleshooting.)
Related • The travel speed selection system has the automatic speed changing function. If the oil pressure rises
Information above 22.6 MPa {230 kg/cm2} during travel, the travel speed is changed to Lo even while the machine
is traveling at Hi (Hi is still displayed on the monitor panel).
• Carry out all the troubleshooting in working mode A.
a Prepare with the engine stopped, then carry out troubleshooting with the engine at
Presumed cause and
high idle.
Malfunction of travel Travel speed selection switch Solenoid valve outlet pressure
1
speed solenoid valve Lo 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Hi
{Min.28 kg/cm2}
Malfunction of travel Since the servo mechanism of the travel motor may have a malfunction, check it
2
motor (servo mechanism) directly.
Failure
• Upper structure does not swing (1) The upper structure swings in neither direction.
Phenomenon
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out
Related troubleshooting related to it.)
Information • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the A-mode.
Malfunction of swing
2 The parking brake of the swing motor may malfunction. Check it directly.
motor (parking brake)
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
Left work equipment control lever Swing relief pressure
Wrong adjustment or +2.5
3 malfunction of swing Swing relief 28.4 –0.5 MPa
motor (safety valve) (in either direction) +25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction.
check the safety valve directly.
Swing motor (motor unit)
4 The motor unit of the swing motor may have a defect in it. Check it directly.
defective internally
Swing machinery Swing machinery may have a defect in it. Check it directly. (The swing machinery can
5
defective internally be checked by abnormal sound, abnormal heating, metal dust in the drained oil, etc.)
Failure
• Upper structure does not swing (2) The upper structure does not swing in only 1 direction.
Phenomenon
• Check that the other work equipment and travel are normal. (If either of them is abnormal, carry out
Related troubleshooting related to it.)
Information • When carrying out the following troubleshooting, set the swing lock switch in OFF and the working
mode in the A-mode.
{Min.28 kg/cm2}
Malfunction of swing
2 The spool of the swing control valve may malfunction. Check it directly.
control valve (spool)
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly.
3 control valve (The suction valves of the right and left swing control valves can be checked by
(suction valve) exchanging them with each other and seeing the change of the phenomenon.)
The suction valve of the swing motor may malfunction. Check it directly.
Malfunction of swing
4 (The suction valves of the right and left swing motors can be checked by exchanging
motor (suction valve)
them with each other and seeing the change of the phenomenon.)
The check valve of the swing motor may malfunction. Check it directly.
Malfunction of swing
5 (The check valves of the right and left swing motors can be checked by exchanging
motor (check valve)
them with each other and seeing the change of the phenomenon.)
2 The parking brake of the swing motor may malfunction. Check it directly.
motor (parking brake)
Presumed cause and
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
Left work equipment control lever Swing relief pressure
Wrong adjustment or +2.5
3 malfunction of swing Swing relief 28.4 –0.5 MPa
motor (safety valve) (in either direction) +25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction.
check the safety valve directly.
Swing motor (motor unit)
4 The motor unit of the swing motor may have a defect in it. Check it directly.
defective internally
Swing machinery may have a defect in it. Check it directly. (The swing machinery
Swing machinery
5 can be checked by abnormal sound, abnormal heating, metal dust in the drained oil,
defective internally
etc.)
{Min. 28 kg/cm2}
Malfunction of swing
2 The spool of the swing control valve may malfunction. Check it directly.
control valve (spool)
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly. (The
3 control valve suction valves of the right and left swing control valves can be checked by exchang-
(suction valve) ing them with each other and seeing the change of the phenomenon.)
The suction valve of the swing motor may malfunction. Check it directly.
Malfunction of swing
4 (The suction valves of the right and left swing motors can be checked by exchanging
motor (suction valve)
them with each other and seeing the change of the phenomenon.)
The check valve of the swing motor may malfunction. Check it directly.
Malfunction of swing
5 (The check valves of the right and left swing motors can be checked by exchanging
motor (check valve)
them with each other and seeing the change of the phenomenon.)
H-24 Swing speed or acceleration is low during compound operation of swing and
work equipment
• Swing speed or acceleration is low during (1) The swing speed or acceleration is low during com-
Failure
compound operation of swing and work pound operation of swing and work equipment with
Phenomenon
equipment the swing priority mode OFF.
Related • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the
Information swing lock switch OFF.
a Keep the engine stopped for the preparations, and run it at high idle during
Presumed cause and
troubleshooting.
Malfunction of swing
2 Right work equipment control lever Swing PPC shuttle valve outlet pressure
PPC shuttle valve
Min. 2.74 MPa
Swing RIGHT/LEFT stroke end
{Min. 28 kg/cm2}
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
Malfunction of swing Swing priority selector valve
3 Right work equipment control lever
priority selector valve outlet pressure (Port A2)
Neutral 0 Pa {0 kg/cm2}
Swing RIGHT/LEFT stroke end Same as main pump pressure
Malfunction of arm
4 control valve The throttle valve of the arm control valve (Lo) may malfunction. Check it directly.
(throttle valve)
Malfunction of bucket
5 control valve The throttle valve of the bucket control valve (Hi) may malfunction. Check it directly.
(throttle valve)
• Swing speed or acceleration is low during (2) The swing speed or acceleration is low during com-
Failure
compound operation of swing and work pound operation of swing and work equipment with
Phenomenon
equipment the swing priority mode ON.
• Before carry out the following troubleshooting, check that the swing speed is normal when the swing
Related priority switch is turned OFF.
Information • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the
swing lock switch OFF.
priority solenoid valve Swing priority switch OFF + Min. 2.35 MPa
Presumed cause and
Failure • Upper structure overruns excessively when it (1) The upper structure overruns excessively when it
Phenomenon stops swinging stops swinging in both directions.
Related
Information
Failure • Upper structure overruns excessively when it (2) The upper structure overruns excessively when it
Phenomenon stops swinging stops swinging in only 1 direction.
Related
Information
{Min. 28 kg/cm2}
Malfunction of swing
2 The spool of the swing control valve may malfunction. Check it directly.
control valve (spool)
The suction valve of the swing control valve may malfunction. Check it directly.
Malfunction of swing con-
3 (The suction valves of the right and left swing control valves can be checked by
trol valve (suction valve)
exchanging them with each other and seeing the change of the phenomenon.)
The suction valve of the swing motor may malfunction. Check it directly.
Malfunction of swing
4 (The suction valves of the right and left swing motors can be checked by exchanging
motor (suction valve)
them with each other and seeing the change of the phenomenon.)
The check valve of the swing motor may malfunction. Check it directly.
Malfunction of swing
5 (The check valves of the right and left swing motors can be checked by exchanging
motor (check valve)
them with each other and seeing the change of the phenomenon.)
Failure • Large shock is made when upper structure (1) Large shock is made when the upper structure stops
Phenomenon stops swinging swinging in both directions.
Related • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the
Information swing lock switch OFF.
Malfunction of swing
Presumed cause and
2 The parking brake of the swing motor may malfunction. Check it directly.
motor (parking brake)
a Keep the engine stopped for the preparations, and run it at high idle during
troubleshooting.
Left work equipment control lever Swing relief pressure
Wrong adjustment or +2.5
3 malfunction of swing 28.4 –0.5 MPa
motor (safety valve) Swing relief (in either direction) +25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction.
Check the safety valve directly.
Swing motor (motor unit)
4 The motor unit of the swing motor may have a defect in it. Check it directly.
defective internally
Swing machinery may have a defect in it. Check it directly. (The swing machinery
Swing machinery
5 can be checked by abnormal sound, abnormal heating, metal dust in the drained oil,
defective internally
etc.)
Failure • Large shock is made when the upper struc- (2) Large shock is made when the upper structure stops
Phenomenon ture stops swinging. swinging in only 1 direction.
Related • When carrying out the following troubleshooting, set the working mode in the A-mode and turn the
Information swing lock switch OFF.
troubleshooting.
Presumed cause and
Malfunction of left PPC Left work equipment control lever PPC valve output pressure
1
valve (swing circuit) Neutral 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Swing RIGHT/LEFT stroke end
{Min. 28 kg/cm2}
Malfunction of swing
2 The spool of the swing control valve may malfunction. Check it directly.
control valve (spool)
The suction valve of the swing motor may malfunction. Check it directly.
Malfunction of swing
3 (The suction valves of the right and left swing motors can be checked by exchanging
motor (suction valve)
them with each other and seeing the change of the phenomenon.)
H-27 Large abnormal sound is made when upper structure stops swinging
Failure • Large abnormal sound is made when upper (1) Large abnormal sound is made when the upper
Phenomenon structure stops swinging structure stops swinging in both directions.
Related
Information
a Keep the engine stopped for the preparations, and run it at high idle during
Presumed cause and
troubleshooting.
Left work equipment control lever Swing relief pressure
Wrong adjustment or +2.5
2 malfunction of swing 28.4 –0.5 MPa
motor (safety valve) Swing relief (in either direction) +25
{290 –5 kg/cm2}
If the oil pressure is still abnormal after adjustment, the safety valve may malfunction.
Check the safety valve directly.
Swing machinery may have a defect in it. Check it directly. (The swing machinery
Swing machinery
3 can be checked by abnormal sound, abnormal heating, metal dust in the drained oil,
defective internally
etc.)
Failure • Large abnormal sound is made when upper (2) Large abnormal sound is made when the upper
Phenomenon structure stops swinging structure stops swinging in only 1 direction.
Related
Information
Malfunction of swing The suction valve of the swing control valve may malfunction. Check it directly.
1 control valve (The suction valves of the right and left swing control valves can be checked by
(suction valve) exchanging them with each other and seeing the change of the phenomenon.)
The suction valve of the swing motor may malfunction. Check it directly.
Malfunction of swing
2 (The suction valves of the right and left swing motors can be checked by exchanging
motor (suction valve)
them with each other and seeing the change of the phenomenon.)
Failure
• Hydraulic drift of swing is large (1) While the swing holding brake is applied.
Phenomenon
Related
Information
a Keep the engine stopped for the preparations, and run it at high idle during
Presumed cause and
troubleshooting.
Malfunction of swing Left work equipment control lever Solenoid valve outlet pressure
1 holding brake solenoid
valve Neutral (After 5 seconds or more) 0 MPa {0 kg/cm2}
Min. 2.74 MPa
Operated to swing (in either direction)
{Min. 28 kg/cm2}
Malfunction of swing
2 The parking brake of the swing motor may malfunction. Check it directly.
motor (parking brake)
Failure
• Hydraulic drift of swing is large (2) While the swing holding brake is released.
Phenomenon
Related
Information
Malfunction of swing
2 control valve The suction valve of the swing control valve may malfunction. Check it directly.
(suction valve)
Malfunction of swing
3 The safety valve of the swing motor may malfunction. Check it directly.
motor (safety valve)
Malfunction of swing
4 The suction valve of the swing motor may malfunction. Check it directly.
motor (suction valve)
Malfunction of swing
5 The check valve of the swing motor may malfunction. Check it directly.
motor (check valve)
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 function. 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.
[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
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].
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)
k
available, can be substituted with com-
mercially available tools. This mark indicates safety-related pre-
cautions which must be followed when
2) Distinction of new and existing special tools doing the work.
N: Tools with new part numbers, newly a This mark gives guidance or precau-
developed for this model.
2 This mark stands for a specific coating
tions when doing the procedure.
R: Tools with upgraded part numbers,
remodeled from already available tools
3 This mark indicates the specified
agent to be used.
for other models.
Blank: Tools already available for other mod-
5
torque.
els, used without any modification. This mark indicates an amount of oil or
3) Circle mark (Q) in sketch column: water to be added.
A circle mark means that a sketch of the
special tool is presented in the section of
Sketches for Special Tools. SKETCHES OF SPECIAL TOOLS
a Part No. of special tools starting with 79*T means • Various special tools are illustrated for the con-
that they are locally made parts and as such not venience of local manufacture.
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
1) Necessity
t: Special tools which cannot be substi- This mark indicates safety-related pre-
tuted, should always be used. cautions which must be followed when
q: Special tools which are very useful if doing the work.
available, can be substituted with com- a This mark gives guidance or precau-
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.
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Dimensions
Nominal number Part Number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
Taper 1/8
12 07049-01215 12 10 15
øD
ød
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22 L
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28 DEW00401
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hy-
draulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idling.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cyl-
inder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
a Tools marked Q in the Sketch column are tools introduced in the sketches of the special tools (See SKETCH-
ES OF SPECIAL TOOLS).
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
795-471-1700 Remover t 1
Removal and instal- 795-471-1520 • Block 1
lation of fuel supply A Pulling out of drive gear
pump assembly 795-471-1530 • Bolt 1
01435-01085 • Bolt 2
Removal and instal-
B 795T-471-1550 Wrench t 1 Q Fixing of injector assembly
lation of nozzle tip
795-521-1110 Push tool t 1
Removal and 790-101-5221 Grip t 1
installation of engine C Press fitting of oil seal
front seal 01010-51225 Bolt t 1
01050-31640 Bolt t 3
1 795-931-1100 Seal puller t 1 Pulling out of oil seal
795-521-1131 Push tool t 1
790-101-5421 Grip t 1 Press fitting of oil seal
2
01010-51240 Bolt t 1 (Standard type)
Removal and 01050-31625 Bolt t 3
installation of engine D
rear seal 795-931-1210 Sleeve jig t 1
795-931-1220 Sleeve jig t 1 Press fitting of oil seal
3
01050-31625 Bolt t 3 (Sleeve type)
01050-31645 Bolt t 3
4 790-331-1110 Wrench q 1 Tightening of flywheel bolt
Removal and instal-
lation of cylinder E 790-331-1110 Wrench q 1 Tightening of cylinder head bolt
head assembly
790-101-5401 Push tool kit t 1
• 790-101-5541 • Plate t 1
Disassembly, 1 Press fitting of oil seal
• 790-101-5421 • Grip t 1
assembly of swing
F • 01010-81240 • Bolt t 1
machinery
assembly 790-201-2780 Spacer t 1 Press fitting of main bearing
2
790-201-2880 Spacer t 1 Press fitting of main bearing
3 796T-626-1120 Push tool t 1 N Q Press fitting of sub bearing
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
791-685-9540 Rod t 1
4
791-685-9550 Nut t 3
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9550 Nut t 1
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
791-680-5520 Guide t 1
5
791-126-0140 Pusher t 1
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
04530-12030 Eyebolt t 1
791-685-9620 Extension t 1 Removal, press fitting of master
790-101-1102 Pump t 1 pin and regular pin
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
Disassembly, 790-101-1102 Pump t 1
assembly of 1 link N 6
at field 790-101-4200 Pulley t 1 294 kN {30 ton}
791-680-5542 Adapter t 1
7
791-632-1110 Adapter t 1
8 791-680-5580 Guide t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
9 791-126-0150 Adapter t 1
01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-680-5542 Adapter t 1
791-680-5560 Guide t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
791-126-0150 Adapter t 1
10
01010-51030 Bolt t 1
791-685-9620 Extension t 1
791-680-5560 Guide t 1
791-632-1110 Adapter t 1
791-680-9630 Adapter t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
11 791-680-1520 Guide t 1
791-685-9510 Frame t 1
Disassembly, 791-685-9520 Frame t 1 Removal, press fitting of master
assembly of 1 link N
791-685-9530 Rod t 1 pin and regular pin
at field
791-685-9540 Rod t 1
791-685-9550 Nut t 3
791-685-9560 Bolt t 4
12 791-126-0150 Adapter t 1
791-680-5560 Guide t 1
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
791-680-1520 Guide t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
790-101-1102 Pump t 1
13
790-101-4200 Pulley t 1 294 kN {30 ton}
791-680-9501 Remover, installer t 1
790-101-1102 Pump t 1
14
790-101-4200 Pulley t 1 294 kN {30 ton}
790-101-4300 Cylinder t 1 1,471 kN {150 ton}
Removal, installation of
1 796-770-1301 Oil stopper t 1
hydraulic pump
Disassembly,
assembly of 790-101-5001 Push tool kit t 1
S
hydraulic pump • 790-101-5151 • Plate t 1 Press fitting of oil seal (hydraulic
assembly 2
• 790-101-5021 • Grip t 1 pump shaft)
01010-50816 • Bolt t 1
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
790-101-2501 Push-puller t 1
• 790-101-2510 • Block t 1
• 790-101-2520 • Screw t 1
Disassembly, • 791-112-1180 • Nut t 1
assembly of Disassembly of center swivel
T • 790-101-2540 • Washer t 1
center swivel joint joint
assembly • 790-101-2630 • Leg t 2
• 790-101-2570 • Plate t 2
• 790-101-2560 • Nut t 2
• 790-101-2660 • Adapter t 2
Cylinder repair Disassembly, assembly of
1 790-502-1003 t 2
stand hydraulic cylinder
2 790-720-1000 Expander t 1 N Q Installation of piston ring
796-720-1690 Ring t 1 Boom, arm cylinder
796-720-1720 Ring t 1 Bucket cylinder (for SE)
07281-02169 Clamp t 1 Boom, arm cylinder
3
796-720-1690 Ring t 1
Bucket cylinder
07281-01919 Clamp t 1
07281-02429 Clamp t 1 Bucket cylinder (for SE)
790-201-1702 Push tool kit t 1 Press fitting of coil bushing
Boom,
• 790-201-1881 • Push tool t 1
arm cylinder
Arm cylinder (for
• 790-201-1871 • Push tool t 1
SE), bucket cylinder
Disassembly, 4 • 791-863-1110 • Push tool
assembly of t 1
U Bucket cylinder
hydraulic cylinder • 790-101-5421 • Grip t 1
(for SE)
assembly • 01010-51240 • Bolt t 1
• 790-101-5021 • Grip t 1
All cylinders
• 01010-50816 • Bolt t 1
790-201-1500 Push tool kit t 1 Press fitting of dust seal
Boom,
• 790-201-1690 • Plate t 1
arm cylinder
• 790-201-1680 • Plate t 1 Bucket cylinder
5 • 792-715-1400 • Push tool t 1
Bucket cylinder
• 790-101-5421 • Grip t 1
(for SE)
• 01010-51240 • Bolt t 1
• 790-101-5021 • Grip t 1 Press fitting of dust seal
• 01010-51240 • Bolt t 1 All cylinders
790-102-4300 Wrench t 1
6
790-102-4310 Pin t 2
New/remodel
Necessity
Symbol
Sketch
Q'ty
Component Part No. Part Name Nature of work, remarks
B Wrench
F3 Push tool
J3 Push tool
L4 Push tool
L5 Adapter
REMOVAL AND
INSTALLATION OF FUEL
SUPPLY PUMP ASSEMBLY
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
795-471-1700 Remover t 1
795-471-1520 • Block 1
A 10. Remove cover (16) on the timing gear case
795-471-1530 • Bolt 1
side.
01435-01085 • Bolt 2
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
3 Sleeve nut:
manently.
11. Remove holder (16) and push connector (15) 3 Cylinder head cover mounting bolt:
inward to remove. 29.4 – 34.3 Nm {3.0 – 3.5 kgm}
3 Mounting bolt:
securely to the socket of the push rod.
a Check that there is not dirt in the injector 1) Take out wiring harness connector (22)
sleeve. through the connector insertion opening
a Procedure for installing fuel injector with O-ring (23) removed.
1) Fit the gasket and O-ring to the fuel injector 2) Fit O-ring (23) and apply engine oil (SAE30)
and apply engine oil (SAE No. 30) to them. to its periphery.
2) Insert holder (18) in fuel injector assembly 3) Install connector holder (24) and push it in.
(11). Direct the injector connector toward 4) Secure connector holder (24) with mounting
the fuel high-pressure pipe insertion hole bolt (17).
and insert the fuel injector assembly and
holder together.
3 Terminal nut:
through the fuel high-pressure pipe insertion the injector body.
part and tighten it with your fingers, match-
ing it to injection connector (21). 1.8 – 2.2 Nm {0.18 – 0.22 kgm}
5) Tighten bolt (19) of holder (18) permanently.
a Apply engine oil to the spherical part of
the ball washer (to fit the ball washer).
a After tightening the holder permanently,
remove the high-pressure pipe sleeve
and install the other injectors similarly in
SPECIAL TOOLS
New/remodel
Necessity
Symbol
Sketch
4. Remove retaining nut (4) from injector assembly
Q’ty
New/remodel
shaft and seal lip with oil or grease. Wipe off
Necessity
Symbol
Sketch
all oil from the shaft.
Q’ty
Part No. Part Name
a Do not remove internal plastic tube (6) from
the standard seal until the seal is assembled.
795-521-1110 Push tool t 1
790-101-5221 Grip t 1
C
01010-51225 Bolt t 1
01010-31640 Bolt t 3
REMOVAL
1. Removal the radiator and oil cooler assembly.
For details, see REMOVAL OF RADIATOR AND
OIL COOLER ASSEMBLY.
2) Hold metal ring of seal (2) with both hands 2. Installation of damper assembly
and push in with sudden force until it feels Fit damper assembly (1) and tighten with mount-
3 Mounting bolt:
that it has gone over large diameter of inter- ing bolts.
nal plastic tube (6).
3) After pushing seal in, remove internal plastic 245 – 308.7 Nm {25 – 31.5 kgm}
tube (6).
a When removing, be particularly careful
not to damage the seal lip.
New/remodel
to pull out.
Necessity
Symbol
Sketch
a Before pulling out, knock the oil seal in
Q’ty
Part No. Part Name
slightly. This separates the seal from the
housing and makes it easier to pull out
1 795-931-1100 Seal puller t 1 the seal.
a Do not use a drill. The metal powder will
795-521-1131 Push tool t 1
get inside the engine.
790-101-5421 Grip t 1
2
01010-51240 Bolt t 1
01050-31625 Bolt t 3
D
795-931-1210 Sleeve t 1
795-931-1220 Sleeve t 1
3
01050-31625 Bolt t 3
01050-31645 Bolt t 3
4 790-331-1110 Wrench q 1
REMOVAL
1. Remove PTO assembly.
For details, see REMOVAL OF PTO ASSEM-
BLY.
4 Flywheel: 60 kg
1. Procedure for assembling standard seal 2) Hold metal ring of seal (2) with both hands
a Before assembling the seal, check that there and push in with sudden force.
are no scratches, burrs, flashes, or rust on 3) After pushing seal in, remove internal plastic
the housing, lip sliding surface, or at the cor- tube (6).
ner of the end face of crankshaft (5). a When removing, be particularly careful
a When assembling the seal, do not coat the not to damage the seal lip.
shaft and seal lip "a" with oil or grease. Wipe
off all oil from the shaft.
a Do not remove internal plastic tube (6) from
the standard seal until the seal is assembled.
1) Put large inside diameter end "c" of internal
plastic tube (6) in contact with end of crank-
shaft (5).
a Be particularly careful to assemble fac-
ing in the correct direction.
2. Assembly procedure for seal with sleeve 2) Put sleeve of seal in contact with end face of
a Before assembling the seal, check that there crankshaft (5), then tighten 3 bolts uniformly
are no scratches, burrs, flashes, or rust on until end face of tool D3 contacts end face of
the housing, lip sliding surface, or at the cor- crankshaft (5) to press fit sleeve/seal (7).
ner of the end face of the crankshaft. a First, tighten tool D3 (for press fitting
a When assembling the seal, do not coat the seal with sleeve) until bolt (45 mm)
shaft and the area between sleeve (3) and comes into contact, then tighten with bolt
seal lip "a" with oil or grease. Wipe off all oil (25 mm).
from the crankshaft.
a Always handle the seal and sleeve as a set.
Never disassemble it.
1) Set sleeve/seal (7) to tool D3 (for press fit-
1st step:
Tighten to
112.7 – 122.5 Nm {11.5 – 12.5 kgm}
2nd step: 1) When using tool D4
Using an angle tightening
wrench (tool D4), tighten
bol ts a further 90 ° +30° 0 in
order (1) to (6).
2) When not using tool D4
Make marks on bolt and fly- a After installing the flywheel, use dial gauge
w h e e l w i t h pa i n t , t h e n [1] to measure the face runout and radial ru-
ti g h te n b o lts a f ur th e r nout.
90° +30° in order (1) to (6). a Face runout: Max. 0.30 mm
0
a Radial runout: Max. 0.30 mm
REMOVAL AND 4. Remove air intake hose (5), and hose (6) and
connector (7) between the turbocharger and
INSTALLATION OF CYLINDER aftercooler.
HEAD ASSEMBLY
5. Disconnect turbocharger lubricating oil drain
SPECIAL TOOLS tube (8) and remove inlet tube (9).
New/remodel
6. Remove bracket (10).
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
7. Lift off turbocharger and exhaust manifold
assembly (12).
E 790-331-1110 Wrench q 1
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
3. Remove heat insulation covers (2), (3), and (4). 12. Disconnect hose (20) between aftercooler and
air intake manifold from the connector.
13. Disconnect boost pressure sensor connector 18. Disconnect 5 high-pressure tube clamps (29).
(21).
16. Disconnect 6 high-pressure tube clamps (27). 21. Remove head cover (34).
k Check high pressure pipe as following items. a Before tightening the cylinder head mounting
If there is any of those defects, it can cause bolts, check the following matter.
fuel leakage. In this case, replace the high- 1) Measure stem length "e" of each mounting
pressure pipe. bolt.
• Check the taper seal of its joint (Part "a": 2) Using limit of bolt
Part of 2 mm from the end) for visible • Short bolt: Must be shorter than 170.8 mm
lengthwise slit "b" and spot "c". • Long bolt: Must be shorter than 205.8 mm
• Check part "d" (End of taper seal: Part at 3) If the mounting bolts are longer than the
2 mm from the end) for stepped-type above using limits or they have been tight-
wear caused by fatigue which your nail ened 5 times (there are 5 punch marks on
can feel. them), do not reuse them but replace them.
2 Mounting bolt:
head bolts.
REMOVAL INSTALLATION
1. Lift off radiator grille (1). • Carry out installation in the reverse order to
removal.
2. Lift off radiator top cover (2).
New/Remodel
4. Loosen 2 bolts of the radiator grille (2) and open
Necessity
the grille.
Symbol
Sketch
Q’ty
Part No. Part Name a Remove the air conditioner condenser, the
fuel cooler and the after cooler referring to
the paragraph of Removal of Air Conditioner
Condenser, Fuel Cooler and After Cooler.
799-703-1200 Service tool kit t 1
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 799-703-1110 t 1
(220V)
Vacuum pump
799-703-1120 t 1
(240V)
799-703-1401 Gas leak detector t 1
REMOVAL
k Disconnect the (–) terminal of the battery in ad-
vance.
k Lower the work equipment completely to the 5. Remove the brackets (5) of the air conditioner
ground and stop the engine. Loosen the oil filler condenser and the fuel cooler.
cap of the hydraulic tank slowly to release the in-
ternal pressure.
a Collect air conditioner gas (R134a) from air con-
ditioner circuit.
8. Remove 3 pieces of the hose clamp (9) of the air 14. Lift the fan guard, radiator and hydraulic oil
conditioner condenser. cooler assembly temporarily and remove the
mounting bolts (17).
9. Remove 2 pieces of the plate (10).
15. Remove the fan guard, radiator and hydraulic oil
cooler assembly (18).
10. Disconnect the air intake hose (11) and the air
intake tube (12).
INSTALLATION
• To install this assembly, reverse the removing
procedures.
• Coolant Filling
a Fill coolant up to the specified level through
the coolant filler port, start the engine to cir-
culate coolant and check the coolant level
again.
New/Remodel
4. Disconnect the fuel cooler hose quick coupler
Necessity
(4) and (5).
Symbol
Sketch
Q’ty
Part No. Part Name
5. Loosen 4 pieces of the fuel cooler mounting bolt
(6) and remove the fuel cooler (7).
799-703-1200 Service tool kit t 1
Vacuum pump
799-703-1100 t 1
(100V)
Vacuum pump
X 799-703-1110 t 1
(220V)
Vacuum pump
799-703-1120 t 1
(240V)
799-703-1401 Gas leak detector t 1
REMOVAL
k Lower the work equipment completely to the 6. Disconnect the air conditioner condenser hoses
ground and stop the engine. Loosen the cap of (8) and (9).
the hydraulic tank slowly to release the internal
pressure of the hydraulic tank. 7. Loosen 4 pieces of the air conditioner con-
a Collect air compressor gas (R134a) from air con- denser mounting bolt (10) and remove the air
ditioner circuit. conditioner condenser (11).
INSTALLATION
2. Open the radiator grille (2). • To install this assembly, reverse the removing
procedures.
• Fill air conditioner gas (R134a).
a Using tool X, charge air conditioner gas
(R134a) to air conditioner circuit.
6 Fuel tank:
880 l (when the tank is fully filled)
INSTALLATION
• To install this assembly, reverse the removing
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
REMOVAL
k Lower the work equipment completely to the
ground and stop the engine. Loosen the cap of
the hydraulic tank slowly to release internal
4. Remove the radiator cover (4).
pressure of the hydraulic tank.
k Drain engine oil.
k Disconnect the (–) terminal of the battery.
5. Remove the engine hood (5).
a Put counter marks on each hose and tube, and
6. Remove the main pump cover (6).
attach oil stopper plugs to the disconnected hos-
es and tubes.
2. Drain coolant.
Engine Left Side 14. Disconnect the air cleaner dust indicator hose
8. Remove the air compressor cover (8) and (19) and remove the wiring connector (20).
loosen the belt adjustment bolt to remove the
belt.
11. Remove the fuel cooler hose (11), the fuel hose
(12), the hose clamp (13), the engine breather
hose (14) and the clamp of the muffler drain
hose (15).
19. Reduce the tension of the tension pulley (27) 24. Disconnect the servo valve hose (36) and the
and remove the fan belt (28). safety valve hose (37).
20. Disconnect the starter wiring (29) and the 25. Disconnect the control pump outlet hose (38).
ground cable (30).
26. Disconnect the outlet hoses (39) and (40) of No.
1 and No. 2 pumps and the drain hoses (41) and
(42).
INSTALLATION
• To install this assembly, reverse the removing
3 Mounting bolt:
procedures.
• Oil Filling
a Fill oil up to the specified level, start the en-
gine to circulate oil throughout the pipe and
check the oil level.
• Coolant Filling
a Fill coolant up to the specified level, start the
engine to circulate coolant throughout the
pipe and check the coolant level.
29. Lift the engine, PTO and pump assembly (48)
and remove it. • Air Bleeding
a Lift the assembly a little to prevent the fan Bleed air from the main pump referring to the
pulley from interfering, take out the front paragraph of "Bleeding Air from Main Pump" in
mount, slide it backward and lift the assem- Testing and Adjusting.
bly.
3 Bolt:
277.05 ± 31.85 Nm {28.25 ± 3.25 kgm}
ASSEMBLY
a Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
2. Gear assembly oil before installing.
Remove gear assemblies (5), (6), and (7).
a If the gear assembly will not come out, re- 1. Bearings
move nipple (8), then use a puller to remove Install bearings (9), (10), (11), (12), and (13) to
the gear assembly from the case. gears (5), (6), and (7).
0 0.12 1 1 0.3
New/Remodel
Remove drain plug and drain oil from final drive
Necessity
Symbol
case.
Sketch
Q’ty
Part No. Part Name
6 Final drive case: Approx. 20 l
3 • 02215-11622 • Nut t 2
791-181-1010 Adapter t 2
796T-627-1340 Push tool t 1 N Q
Puller (294kN
790-101-2102 t 1
{30 ton})
790-101-1102 Pump t 1
Wrench
4 790-627-1200 t 1 N
assembly 4. No. 3 carrier assembly
J 796-627-1070 Spacer t 1 N 1) Remove thrust washer (50).
2) Using eyebolts , remove No. 3 carrier
5 01017-52450 Bolt t 1 assembly (2).
01580-12419 Nut t 1
790-201-2830 Spacer t 1
6
790-101-5151 Plate t 1
Push tool kit
790-101-5401 t 1
(C)
• 790-101-5441 • Plate t 1
7
• 790-101-5421 • Grip t 1
• 01010-51240 • Bolt t 1
Push tool kit
790-101-5001 t 1
(A)
• 790-101-5151 • Plate t 1
8
• 790-101-5061 • Plate t 1
• 790-101-5021 • Grip t 1
iii) Turn over carrier assembly (2) and set 6. No. 3 ring gear
to press, then using tool J6, pull out Using eyebolts , remove No. 3 ring gear (12).
shaft (5) and remove gear assembly (6).
7. Hub assembly
iv) Remove bearing (7) and spacer (8) from 1) Remove lock plate (13).
gear (6). 2) Using tool J4, remove nut (14).
a If the parts are to be used again,
make match marks to prevent any
change in the combination with the
outer race.
v) Remove outer race (9) from gear (6).
3) Using eyebolts , remove hub assembly iii) Pull out gear (23) from carrier (27), and
(15) together with bearing (16) from shaft remove thrust washer (24) and bearing
(41). (25).
4) Remove bearing (16) from hub (49). iv) Remove thrust assembly (26) from car-
rier (27).
2) Using eyebolts , install No. 1 carrier a There are the remains of the caulking
assembly (32). when the pin is inserted at the end face
of hole h at the side of the carrier, so re-
move the caulked metal from the inside
diameter of the hole before starting to
assemble.
iii) Assemble bearing (25) to gear (23), put
thrust washer (24) in contact with both
ends, then set to carrier (27).
iv) Align position of pin holes of carrier and
shaft, then tap with a plastic hammer to
install shaft (22).
a When installing the shaft, rotate the
planetary gear, and be careful not to
damage the thrust washer.
6. No. 2 sun gear
1) Press fit thrust washer (29) to No. 2 sun
gear (28).
2) Install No. 2 sun gear (28).
6) Outside bearing
Install bearing (16).
8) Install lock plate (13). ii) Assemble bearing (7) and spacer (8) to
a Install the lock plate as shown in the dia- gear (46), and set to carrier (47).
3 Mounting bolt:
Thread tightener (LT-2)
3 Bolt:
12. No. 3 carrier assembly
1) Assemble No. 3 carrier assembly as follows.
i) Using tool J7, press fit outer race (9) to 927 ± 103 Nm {94.5 ± 10.5 kgm}
gear (46). vi) Install thrust washer (50).
14. Cover
2 Mounting surface:
Using eyebolts , install cover (1).
INSTALLATION
• Carry out installation in the reverse order to
removal.
3 Mounting bolt:
to the paragraph of "Removal of Swing Motor procedures.
Assembly".
926.7 ± 102.9 Nm {94.5 ± 10.5 kgm}
• Oil Filling
a Fill oil up to the specified level through the oil
filler port.
New/Remodel
2) Remove No. 1 sun gear (3).
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
3 2
DISASSEMBLY
1. Draining oil
Loosen drain plug and drain oil from swing
machinery case.
2. Cover CEP00207
CEP00205
19 22 17
20
21
23
18
CEP00213
4) Remove the thrust washer (16).
a Remove No. 2 carrier assembly (17) be-
fore removing the washer. 9. Pinion shaft assembly
1) Remove bolt (24), then remove holder (25).
2) Remove gear (26).
24
26
25
CEP00214
35 34
27
28
CEP00215 CEP00220
35
CEP00223
2 Mounting bolt:
using push tool , press fit bearing inner tighten bolt (24).
race portion.
3 Mounting bolt:
a When setting the case assembly to the Thread tightener (LT-2)
shaft, be extremely careful not to dam-
age the oil seal. 385 ± 42 Nm {39.25 ± 4.25 kgm}
24
26
25
CEP00214
22 17
20
21
23
6. No. 2 sun gear
1) Set the thrust washer (16).
h a Be sure to set the washer before installing
CEP00226
No. 2 carrier assembly (17).
18
CEP00227
CEP00207
3 2
CEP00206
11. Cover
3 Mounting bolt:
Gasket sealant (LG-6)
CEP00205
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
Remover,
791-680-9501 t 1
installer
Cylinder (1,471
790-101-4300 t 1
1 kN {150 ton})
M Puller (294 kN
790-101-4200 t
{30 ton})
790-101-1102 Pump t 4. Fit block or hydraulic jack (10 ton) under shoe
at idler end, then remove guide pin .
2 790-331-1100 Wrench t
REMOVAL
1. Positioning master pin
a Move the master pin so that it is midway be-
tween the idler and the carrier roller. The
track shoe is opened to the rear, so be sure
that there is enough space.
INSTALLATION
• Carry out installation in the reverse order to
removal.
3 Lubricator:
ING, Adjusting track shoe tension.
New/Remodel
New/Remodel
Symbol
Symbol
Sketch
Sketch
Necessity
Necessity
Q’ty
Q’ty
Part No. Part Name Part No. Part Name
DISASSEMBLY
1. Using two bolts (2), install tool N1 (adapter,
New/Remodel
guide, bolt) to link (1).
a It is also possible to use two track bolts for
Symbol
Sketch
Necessity
Q’ty
Part No. Part Name bolt (2).
790-101-1102 Pump t 1
10
790-101-4300 Cylinder (*1) t 1
11 790-680-1520 Guide t 1
791-685-9510 Frame t 1
791-685-9520 Frame t 1
791-685-9530 Rod t 1
791-685-9540 Rod t 1
791-685-9550 Nut t 3 2. Assemble tool N2 (pump, cylinder 1471 kN
{150t}) and tool N3 (frame, rod, adapter, bolt x 1,
791-685-9560 Bolt t 4 eyebolt), then raise chassis and set on track.
12 791-126-0150 Adapter t 1
791-680-5560 Guide t 1
N
791-680-9570 Adapter t 1
01010-51030 Bolt t 1
791-680-1520 Guide t 1
790-101-1102 Pump t 1
790-101-4300 Cylinder (*1) t 1
790-101-1102 Pump t 1
13
790-101-4200 Pulley (*2) t 1 3. Insert rod of tool N4 from cylinder end, and
Remover (kit), install with two nuts.
791-680-9501 t 1 a Pass the rod through the hole in link (1) to in-
installer
stall.
790-101-1102 Pump t 1
14
790-101-4200 Pulley (*2) t 1
790-101-4300 Cylinder (*1) t 1
5. Set tool N6 (294 kN {30 ton} puller) and spacer 2. Set link sub-assembly (3) on link to be con-
to center of roller tread of link to be disassem- nected.
bled, then apply hydraulic pressure to puller and
open link 5 – 6 mm.
4. Set tools N9 and N10 in same way as for opera- 7. Set tool N9 at pin (7) end, then use tool N12
tion to remove pin, then use tool N9 (adapter, (adapter, bolt, and guide) to press fit pin (7).
INSTALLATION
• Carry out installation in the reverse order to
removal.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
1 790-201-2680 Plate t 1
L
2 796-675-1510 Instaler t 1
DISASSEMBLY
1. Remove plug and drain oil.
6. Remove floating seal (4) from idler (7).
6 Idler : Approx. 550 – 630 cc
4. Turn over idler and using tool L2, assemble 8. Turn over idler, and assemble support (3) to
floating seal (4). shaft.
a Align the groove in the support with the
groove in the shaft when assembling.
5
3 Plug: 210.7 ± 29.4 Nm {21.5 ± 3 kgm}
Idler: 550 – 630 cc (GO140B)
2. Remove snap ring (3), then remove packing (4), 2. Assemble backup ring (5) and packing (4) to
backup ring (5), and wear ring (6) from plunger plunger (2), and install snap ring (3).
(2).
3. Fill inside with grease (G2-LI), then assemble
3. Remove dust seal (7). plunger assembly (1) in piston.
REMOVAL INSTALLATION
a The coil portion of the recoil spring assembly is • Carry out installation in the reverse order to
hooked on the rib inside the track frame, so pre- removal.
pare a special tool for disassembly. a To check that the spring is securely fitted in-
side the track frame, check through the side
1. Remove track shoe assembly. hole on the inside (at the 5th track roller from
For details, see REMOVAL OF TRACK SHOE the front).
ASSEMBLY.
New/Remodel
(2).
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
791-685-8501 Compressor t 1
791-635-3160 Extension t 1
796-630-1110 Plate t 1
01010-51640 Bolt t 2
M 3
791-630-1120 Spacer t 1
Cylinder (686
790-101-1600 t 1
kN {70 ton}) 3. Release hydraulic pressure gradually to relieve
790-010-1102 Pump t 1 tension of spring, then remove recoil spring
assembly (1) from tool M3.
796-630-1110 Plate t 1
4. Remove rear pilot (4) and rod (5) from spring
(3).
DISASSEMBLY
1. Set recoil spring assembly (1) to tool M3.
k The recoil spring is under large installed
load, so be sure to set the tool properly.
Failure to do this is dangerous.
a Installed load of spring: 490 kN {50 ton}
ASSEMBLY
1. Install tool D1 to tip of rod (5).
a Tool M3 is to prevent damage to the thread
when inserting the rear pilot.
REMOVAL INSTALLATION
1. Loosen the track shoe a bit referring to the para- • To install this assembly, reverse the removing
New/Remodel
Necessity
6. Remove the floating seal (5) from the support
Symbol
Sketch
Q’ty
Part No. Part Name (2).
DISASSEMBLY
2. Set the carrier roller assembly (1) on the press 9. Remove the bearing (6) from the shaft (3) by
base. using the tool L3.
a Since the assembly will drop if the support
(2), the shaft (3) and the roller (4) are re-
moved from the roller (1), set a pedestal be-
low the roller.
ASSEMBLY 10. Press fit the roller, in which the floating seal (5)
1. Press fit the bearing outer race (7) in the both was assembled, in the shaft (3).
sides of the support (2) by using the tool L3. a Press fit the roller (4) to the shaft end face
and press fit the roller finally by using the tool
2. Press fit the bearing (6) in the shaft (3) by using L5.
the tool L3. a Secure more than 18 ton of press fitting force
between the shaft and each roller.
5
1 mm.
a Clean the O-ring and the O-ring contacting Lubricating oil: 300 – 350cc (GO140)
surface to degrease them completely and
New/Remodel
Track roller assembly (S flange):
Necessity
140 kg
Symbol
Sketch
Q’ty
Part No. Part Name
REMOVAL
1. Loosen track shoe tension.
For details, see REMOVAL OF TRACK SHOE
ASSEMBLY. INSTALLATION
• Carry out installation in the reverse order to
2. Remove track roller guard (1). removal.
New/Remodel
the oil at this point or lay a cloth to prevent
Necessity
the area from becoming dirty.
Symbol
Sketch
Q’ty
Part No. Part Name
5. Remove floating seal (6) on opposite side from
roller (4) and collar (8).
8 791-580-1520 Installer t 1
9 790-201-2670 Plate t 1 5
6
791-601-1000 Oil pump t 1
L
or 4
10 4
791-646-8002 Oil lubricator t 1
790-701-3000 Seal checker t 1
CEP00087 CEP00088
DISASSEMBLY
1. Remove plug and drain oil.
6. Remove pin (7), then remove collar (8) from
a Rotate the shaft while draining the oil.
shaft (5).
6 Track roller: Approx. 420 – 480 cc
7. Remove bushings (9) and (10) from roller (4).
2. Remove pin (1), then remove collar (2).
9, 10
5
4
7 CEP00089 CEP00090
1
2 CEP00085 CEP00086
ASSEMBLY 4. Using tool L9, install floating seals (6) and (3) to
1. Using tool L10, press fit bushings (9) and (10) to roller (4).
roller (4). a For details of the precautions when installing
floating seals (6b) and (6d), and (3b) and
2. Assemble collar (8) to shaft (5), and install pin (3d), see the precautions marked a for Step
(7). 3.
3. Using tool L9, install floating seal (6) to shaft (5). 5. Assemble shaft (5) to roller (4).
CEP00096
a When assembling the floating seal, clean the 6. Turn over roller (4) and shaft (5) assembly.
contact surface of O-ring (6c) and floating
seal (6a), remove all grease and oil, and dry 7. Using tool L9, install floating seal (3) to collar
it. Make sure that no dirt or dust sticks to the (2).
contact surface of the floating seal. a For details of the precautions when installing
a After inserting the floating seal, check that floating seals (3a) and (3c), see the precau-
the angle of the seal is less than 1 mm and tions marked a for Step 3.
that the protrusion of the seal is within a
range of 5 – 7 mm.
CEP00097
5
CEP00099
10. Using tool L10, fill track roller assembly with oil,
then tighten plug (11).
11
CEP00202
8. Disconnect the return filter inlet hose (8) and the 12. Lift the hydraulic tank assembly (14) and
outlet hose (9) from the control valve. remove it.
• Air Bleeding
Bleed air referring to the paragraph of "Bleeding
Air from Each Part" in Testing and Adjusting.
11. Disconnect the suction tube (13) below the
hydraulic tank.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
REMOVAL
k Lower the work equipment completely to the
ground and stop the engine. Loosen the cap of
the hydraulic tank slowly to release internal
pressure of the hydraulic tank.
k Disconnect the (–) terminal of the battery.
a Attach a tag to each hose so that it can be con-
nected to the correct position.
2. Open the engine hood and the pump rear cover 7. Disconnect the hoses (9), (10), (11), (13) and
and remove the pump upper cover. (14).
3. Remove the TVC solenoid connector (1). 8. Disconnect the suction tube (12).
INSTALLATION
• To install this assembly, reverse the removing
procedures.
• Bleeding Air
a Bleed air from each part referring to the par-
agraph of "Testing and Adjusting".
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
REMOVAL
k Lower the work equipment to touch the ground
completely and stop the engine. After that, slow-
ly loosen the cap of the hydraulic oil tank to re-
lease the inside pressure of the hydraulic oil
tank.
k Separate the (–) terminal of the battery.
a Put tags, etc. to each piping so that the mounting
position may not be mistaken.
6 Hydraulic oil tank: Approx. 500 l 4. Separate the hoses (5) and (6) and suction tube
(7).
2. Open the engine hood and the rear cover of the
pump. After that, remove the upper cover of the
pump.
INSTALLATION
• Installation shall be made in the reversed proce-
dure of the removal procedure.
• Air Bleeding
a Carry out air bleeding of each section refer-
ring to the section "Testing and adjusting".
New/Remodel
removal.
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
2 Lip of oil seal: Grease (G2-LI)
2 Coat the outside circumference of the
790-101-5001 Push tool kit t 1 oil seal thinly with grease (G2-LI), then
press fit.
• 790-101-5151 • Plate t 1 a Using tool S2, press fit oil seal (4).
S 2
• 790-101-5021 • Grip t 1
01010-50816 Bolt t 1
REMOVAL
1. Remove main pump assembly.
For details, see REMOVAL OF MAIN PUMP
ASSEMBLY.
New/Remodel
dure of the removal procedure.
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name • Filling the oil (Hydraulic oil tank)
a Fill the oil to the stipulated level from the oil
filler port, start the engine to circulate the oil
S 1 796-770-1301 Oil stopper t 1 inside the piping and, after that, re-check the
oil level.
• Air Bleeding
REMOVAL a Carry out air bleeding of each section refer-
k Lower the work equipment to touch the ground ring to the section "Testing and adjusting".
completely and stop the engine. After that, slow-
ly loosen the cap of the hydraulic oil tank to re-
lease the inside pressure of the hydraulic oil
tank.
k Separate the (–) terminal of the battery.
a Put tags, etc. to each piping so that the mounting
position may not be mistaken.
4 Pump assembly: 35 kg
ASSEMBLY
1. Assembly of sleeve assembly (1)
a Set sleeves (12) and (9) to the protrusion
measured when disassembling. After install-
ing to the control valve, adjust the relief pres-
sure.
For details, see TESTING AND ADJUST-
ING.
1) Assemble piston (14) and spring (13) to
sleeve (15), then screw in sleeve (12) and
3 Locknut:
tighten locknut (11).
3 Locknut:
sleeve (12), and tighten locknut (8).
6. Separate each tube of the travel (10), boom 10. Separate the RH swing motor hose (18).
(11), bucket (12) and arm (13).
11. Remove the tube clamp (19) and tube (20).
7. Separating the lower side back pressure com-
pensation valve hose. 12. Remove the piping brackets (21) and (22).
Separate the tube (14) between the 5-spool
control valve.
4
Separate the sensor (7).
4-spool control valve assembly, RH: Separate the tube (28) between the 4-spool
250 kg control valve.
15. Separate the 16 pcs. of the PPC hoses (29).
4 5-spool control valve assembly, RH: a Install the tube (1) and adjust the mounting posi-
250 kg tion of the valve. After that, fasten the valve as-
3 Suction valve:
3. Fit O-ring and install suction valve (35).
3 Suction-safety valve:
and (33).
3 Orifice:
186.2 ± 9.8 Nm {19 ± 1 kgm}
3. Remove the U-bolt (7) of the oil gauge tube, 3. Separate the swivel joint section hose (14).
remove the bolt (8) and remove the bracket (9).
INSTALLATION
• Installation shall be made in the reversed proce-
INSTALLATION
• Installation shall be made in the reversed proce-
dure of the removal procedure.
3. Pull out the pin (9) and shift the link (10) to the • Filling the oil
direction of the frame side. a Fill the oil to the stipulated level from the oil
a Separate the hose (12) between the swing filler port and circulate the oil inside the pip-
motor. ing. After that, re-check the oil level.
a Fill the quantity of the oil which leaked when
4. Temporarily hang the swivel joint assembly. the swivel joint assembly was removed.
a Use the hole of the split flange bolt.
New/Remodel
1
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
2
3
790-101-2501 Push-puller t 1
• 790-101-2510 • Block t 1
• 790-101-2520 • Screw t 1 4
• 791-112-1180 • Nut t 1
T • 790-101-2540 • Washer t 1
7
• 790-101-2630 • Leg t 2
• 790-101-2570 • Plate t 2
6
• 790-101-2560 • Nut t 2
• 790-101-2660 • Adapter t 2
5
DISASSEMBLY
1. Remove cover (1).
CEP00381
2. Remove snap ring (2).
ASSEMBLY
1. Assemble slipper seal (7) and O-ring (6) to
swivel rotor.
Grease (G2-LI)
a When installing the rotor, be extremely care-
ful not to damage the slipper seal and O-ring.
3 Mounting bolt:
4. Fit O-ring and install cover (1).
New/Remodel
Necessity
4. Remove remaining mounting bolts, then pull out
Symbol
Sketch
Q’ty
Part No. Part Name travel motor assembly (6) and sling.
4
K 796-660-1560 Guide-bolt t 2 N
Travel motor assembly: 140 kg
REMOVAL
k Swing the work equipment 90°, then lower it
completely to the ground.
k Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
4 Cover: 120 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
3 Mounting bolt:
2. Disconnect hoses (2), (3), (4), and (5).
384.7 ± 41.65 Nm {39.25 ± 4.25 kgm}
a Fit plugs into the hoses.
2. Assemble shim (12) and spring (11) to valve Thread tightener (LT-2)
(13). a Coat two places on the female thread with
a When assembling spring (11), set the end one drop of Loctite each as shown in the di-
a When assembling piston (8), coat the out- 7. Assemble boot (3) and disc (2), and tighten with
3 Mounting bolt:
5. Install plate (5).
ASSEMBLY
1. Assemble valve (18) to body (19).
3 Mounting bolt:
4.41 ± 0.49 Nm {0.45 ± 0.05 kgm}
3 Mounting bolt:
by 0.39°.
3 Mounting bolt:
lever and piston: Grease (G2-LI)
REMOVAL
k Retract the arm and bucket cylinder piston rods,
lower the work equipment completely to the
ground, then set the lock lever to the LOCK po- 7 6
sition. 5
INSTALLATION
• Carry out installation in the reverse order to
removal.
Grease (LM-G)
k When aligning the position of the pin hole,
3. Start engine, and retract piston rod, then tie pis- never insert your fingers in the hole.
ton rod with wire to prevent it from coming out. a Adjust with shims (4) so that the clearance a
k Stop the engine and release the remaining between link (7) and cover (2) is less than 1
pressure in the circuit. For details, see mm.
TESTING AND ADJUSTING, Releasing • Shim thickness: 0.8 mm (STD)
pressure in hydraulic circuit. 1.0 mm (SE)
Grease (LM-G)
k When aligning the position of the pin hole, never
insert your fingers in the hole.
a Adjust with shims (9) so that the clearance b
between bracket (8) and the end face of of
bottom of cylinder (5) is less than 1 mm.
• Shim thickness: 0.8 mm (STD)
1.0 mm (SE)
• Bleeding air
a Bleed the air.
For details, see TESTING AND ADJUST-
ING, Bleeding air.
4 Pin: 35 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
SPECIAL TOOLS a If the pin does not come out, use tool V2 and
remove the pin from the head end.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
791-650-1610 Bracket t 1
790-445-4130 Screw t 1
791-112-1180 Nut t 1
V 2
01643-32780 Washer t 1
Puller (294 kN
790-101-2102 t 1
{30 ton})
4. Start engine, and retract piston rod, then tie pis-
790-101-1102 Pump t 1 ton rod with wire to prevent it from coming out.
k Stop the engine and release the remaining
pressure in the circuit. For details, see
REMOVAL TESTING AND ADJUSTING, Releasing
k Extend the arm cylinder piston rod to a point ap- pressure in hydraulic circuit.
prox. 200 mm before the end of the IN stroke,
lower the work equipment completely to the 5. Disconnect hose (4) and grease hose (5).
ground, then set the lock lever to the LOCK po- a Fit plugs in the hoses to prevent dust or dirt
sition. from entering.
1. Set block between arm cylinder and boom. 6. Sling arm cylinder assembly (6), then remove
plate (7) and pull out bottom pin (8).
2. Disconnect grease hose (1). a If the pin does not come out, use tool V2 and
remove the pin from the bottom end.
3. Remove plate (2), and pull out head pin (3). a There are shims installed, so check the
number, thickness, and position, and keep in
a safe place.
4
7. Remove arm cylinder assembly (6).
8 7 5
CEP00522
CEP00523
• Bleeding air
a Bleed the air.
For details, see TESTING AND ADJUST-
ING, Bleeding air.
INSTALLATION
• Carry out installation in the reverse order to
removal.
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
a Adjust with shims (10) so that the clearance
a between bracket (9) and the bottom end
face of cylinder (6) is less than 1 mm.
• Shim thickness: 0.8 mm
4
pressure inside the hydraulic tank.
a Fit blind plugs in the hoses after disconnecting Pin: 60 kg
them, to prevent dirt or dust from entering.
4 Pin: 60 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
New/Remodel
4. Using tool V3, pull out head pin (3), then discon-
Necessity
nect piston rod from boom.
Symbol
Sketch
Q’ty
Part No. Part Name
790-445-4100 Remover t 1
Puller (294 kN
1 790-101-4200 t 1
{30 ton})
790-101-1102 Pump t 1
790-445-4120 Sleeve t 1
791-520-4140 Screw t 1
V
796-775-1110 Adapter t 1
t 1 5. Start engine, and retract piston rod, then tie pis-
3 791-112-1180 Nut ton rod with wire to prevent it from coming out.
01643-32780 Washer t 1 k Stop the engine and release the remaining
Puller (294 kN pressure in the circuit. For details, see
790-101-2102 t 1 TESTING AND ADJUSTING, Releasing
{30 ton})
pressure in hydraulic circuit.
790-101-1102 Sleeve t 1
6. Lower boom cylinder assembly on stand, then
disconnect hose (4).
REMOVAL
k Retract the arm and bucket cylinder piston rods 7. Disconnect grease hose (5).
fully, lower the work equipment completely to the
ground, then put the lock lever in the LOCK po- 8. Sling boom cylinder assembly and remove plate
sition. (6).
a Fit plugs in the hoses to prevent dust or dirt from
entering.
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
a Adjust with shims (10) so that the clearance
a between bracket (9) and the bottom end
face of boom cylinder (8) is less than 1 mm.
• Shim thickness: 1.0, 1.5 mm
• Bleeding air
a Bleed the air.
For details, see TESTING AND ADJUST-
ING, Bleeding air.
INSTALLATION
• Carry out installation in the reverse order to
removal.
4
ing pin of the bottom dump cylinder can be
removed. Then fit a block under the bucket, low- Pin: 35 kg
er the work equipment completely to the ground
and stop the engine. 6. Lift off bottom dump cylinder assembly (5).
4
a Fit plugs in the hoses after disconnecting them,
to prevent dirt or dust from entering. Bottom dump cylinder assembly:
140 kg
1. Remove cover (1).
INSTALLATION
• Carry out installation in the reverse order to
removal.
3. Start engine and retract piston rod fully. k When aligning the mounting position of the
k After stopping the engine, release the pres- pin, do not insert your fingers in the pin hole.
sure inside the piping.
For details, see TESTING AND ADJUST-
ING, Releasing pressure in PPC circuit. k When aligning the mounting position of the
pin, do not insert your fingers in the pin hole.
4. Remove hose (3).
a Bleed the air from the work equipment circuit.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
New/Remodel
catch the oil.
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
Cylinder repair
1 790-502-1003 t 2
stand
2 790-720-1000 Expander t 1 N Q
796-720-1690 Ring t 1
796-720-1720 Ring t 1
07281-02169 Clamp t 1
3
796-720-1690 Ring t 1 4) Disassemble piston rod assembly as fol-
07281-01919 Clamp t 1 lows.
i) Set piston rod assembly (2) to tool U1.
07281-02429 Clamp t 1
790-201-1702 Push took kit t 1
• 790-201-1881 • Push tool t 1
• 790-201-1871 • Push tool t 1
• 791-863-1110 • Push tool t 1
4
• 790-101-5421 • Grip t 1
U
• 01010-51240 • Blot t 1
• 790-101-5021 • Grip t 1
• 01010-50816 • Bolt t 1
ii) Remove piston assembly stopper screw
790-201-1500 Push tool kit t 1 (3).
• Applicable to:
• 790-201-1690 • Plate t 1
Boom and arm cylinder for standard
• 790-201-1680 • Plate t 1 and SE specifications.
Bucket cylinder for standard specifi-
• 792-715-1400 • Push tool t 1 cation.
5
• 790-101-5421 • Grip t 1 Screw size: M12 x pitch 1.75
• 01010-51240 • Bolt t 1
• 790-101-5021 • Grip t 1
• 01010-51240 • Blot t 1
790-102-4300 Wrench t 1
6
790-102-4300 Pin t 2
DISASSEMBLY
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts, and disconnect
head assembly (1).
a If screw (3) has been caulked iv) Remove 6 screws (21), then remove
strongly and cannot be removed, spacer (22), and remove piston ass’y
screw it in fully, then fit a tap to the (4) and O-ring, back-up ring (23).
thread and pull it out. • Applicable to bucket cylinder for SE
specification.
• Arm cylinder
• Arm cylinder
6) Assemble piston assembly (4) as follows. a. Screw in until piston assembly (4)
i) When using rod and piston assembly contacts end face of rod, then use
3 Screw (3):
b. Tighten screw (3). between piston (4) and thread-
ed part of rod (2), and make a
58.9 – 73.6 Nm {6 – 7.5 kgm} hole horizontally.
c. Caulk thread at 2 places with a For the cylinder with bottom
punch. cushion (arm cylinder), avoid
the cushion plug position when
machining.
• Screw machining dimension
(mm)
3 Screw:
262 or equivalent) sert.
a After inserting, check that the ring is not
58.9 – 73.6 Nm {6 – 7.5 kgm} broken and has not come out, then push
e. Caulk thread at 4 places with in fully.
punch.
3 Mounting bolt :
7) Install O-ring, back-up ring (23), piston ass’y bolts.
(4) and spacer (22), then retighten them
4
then set the lock lever to the LOCK position.
Bucket assembly:
1. Remove 3 pin lock bolts (1), then remove stop- 2,960 kg (PC750STD)
per (2). 3,560 kg (PC800STD)
3,435 kg (PC750SE)
3,870 kg (PC800SE)
INSTALLATION
• Carry out installation in the reverse order to
removal.
Grease (LM-G)
2. Using forcing screws, remove connecting pin of k When aligning the position of the pin hole,
link and bucket. never insert your fingers in the hole.
4
in the hydraulic piping.
k Loosen the oil filler cap slowly to release the Pin: 55 kg
pressure inside the hydraulic tank.
a Fit plugs in the hoses after disconnecting them,
to prevent dirt or dust from entering.
4
5. Lift off bucket assembly (5).
Pin: 37 kg
4 Bucket assembly: 6,800 kg
k After stopping the engine, release the residual
pressure in the piping. For details, see TEST-
ING AND ADJUSTING, Releasing residual pres-
sure in PPC valve hydraulic circuit.
INSTALLATION
• Carry out installation in the reverse order to
removal.
SPECIAL TOOLS
New/Remodel
Necessity
Symbol
Sketch
5
Q’ty
Part No. Part Name 6
2
3
4
791-650-1610 Bracket t 1
790-445-4130 Screw t 1 1
791-112-1180 Nut t 1
2
01643-32780 Washer t 1 CEP00525
Puller (294 kN
790-101-2102 t 1 a If the pin does not come out, use tool V2 and
{30 ton})
remove the pin from the head end.
790-101-1102 Pump t 1
V 790-445-4120 Sleeve t 1
791-520-4140 Screw t 1
796-775-1110 Adapter t 1
3 791-112-1180 Nut t 1
01643-32780 Washer t 1
Puller (294 kN
790-101-2102 t 1
{30 ton})
790-101-1102 Sleeve t 1
8. Remove plate (5), then using tool V3, pull out INSTALLATION
boom top pin (6). • Carry out installation in the reverse order to
a There are shims installed, so check the removal.
number, thickness, and position, and keep in
a safe place.
2 Inside surface of bushing when assem-
bling pin: Anti-friction compound
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
9. Start engine, then raise boom and remove arm Grease (LM-G)
assembly (7). k When aligning the position of the pin hole,
4
never insert your fingers in the hole.
Arm assembly: a Adjust with shims so that the clearance a be-
3,960 kg (PC750STD) tween boom (8) and the bottom end face of
4,530 kg (PC800STD) arm (7) is less than 1 mm.
4,930 kg (PC750SE, PC800SE) • Shim thickness : 1.0 mm
CEP00526
• Bleeding air
a Bleed the air.
For details, see TESTING AND ADJUST-
ING, Bleeding air.
4
ASSEMBLY.
a Secure the arm cylinder assembly to the Arm assembly: 3,100 kg
boom with lever block [1].
k After stopping the engine, release the resid-
ual pressure in the piping. For details, see
TESTING AND ADJUSTING, Releasing re-
sidual pressure in PPC valve hydraulic cir-
cuit..
INSTALLATION
• Carry out installation in the reverse order to
removal.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
790-445-4100 Remover t 1
Puller (294 kN
V 1 790-101-4200 t 1
{30 ton})
10
790-101-1102 Pump t 1
CEP00299
REMOVAL 6. Using tool V1, remove 2 boom foot pins (7), then
1. Remove bucket and arm assembly. remove boom assembly.
For details, see REMOVAL OF BUCKET, ARM a There are shims installed, so check the
ASSEMBLY. number, thickness, and position, and keep in
k Lower the boom assembly completely to the
a safe place.
4
ground, then set the lock lever to LOCK po-
sition. Boom assembly:
8,360 kg (PC750 STD)
2. Disconnect boom cylinder assembly from boom. 8,790 kg (PC800 STD)
For details, see REMOVAL OF BOOM CYLIN- 7,970 kg (PC750SE, PC800SE)
DER ASSEMBLY.
INSTALLATION
• Carry out installation in the reverse order to
removal.
Grease (LM-G)
k When aligning the position of the pin hole,
never insert your fingers in the hole.
a Adjust with shims so that the clearance a be-
tween bracket (4) and the end face of the
foot of boom (3) is less than 1 mm.
• Shim thickness : 1.0, 1.5 mm
• Bleeding air
a Bleed the air.
For details, see TESTING AND ADJUST-
ING, Bleeding air.
4 Pin: 35 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
New/Remodel
Necessity
Symbol
Sketch
Q’ty
Part No. Part Name
790-445-4100 Remover t 1
Puller (294 kN
V 1 790-101-4200 t 1
{30 ton})
790-101-1102 Pump t 1
INSTALLATION
• Installation shall be made in the reversed proce-
dure of the removal procedure.
Grease (LM-G)
k When matching the position of the pin hole,
never insert finger into the pin hole.
a Make adjustment so that the clearance a be-
tween the end face of the foot of the boom
(3) and the bracket (4) may become 1 mm or
less, using the shim (5).
• Shim thickness: 1.0 and 1.5 mm
• Air Bleeding
a Carry out air bleeding referring to the section
"Air bleeding of each section" in the "Testing
and adjusting".
INSTALLATION
• Carry out installation in the reverse order to
removal.
CEP00438
11
10
CEP00443
10. Remove the 4 pcs. of the mounting nuts and the INSTALLATION
6 pcs. of the mounting bolts and hang the opera- • Installation shall be made in the reversed proce-
tor’s cab assembly to remove the operator’s dure of the removal procedure.
cab.
CEP00445
a Among the panes of window glass on the 4 sides (1) : Right side window glass
of the operator's cab, 4 panes (1) – (4) are stuck. (2) : Left side rear window glass
In this section, the procedure for replacing the (3) : Door lower window glass
stuck glass is explained. (4) : Front window glass
When replacing front window glass (4), remove (5) : Front window assembly
front window assembly (5). (It is impossible to (Front window glass + Front frame)
replace only the front window glass while the (6) : Both-sided adhesive tape
front window assembly is installed to the opera- (16): Center trim seal
tor's cab.)
For the procedure for replacing the front window
assembly, see REMOVAL AND INSTALLATION
OF FRONT WINDOW ASSEMBLY.
New/Remodel
Necessity
Symbol
Sketch
Q'ty
Part No. Part name
Lifter
1 793-498-1210 t 2
Y (Suction cup)
2 20Y-54-13180 Adapter t 2
REMOVAL
a Remove the window glass to be replaced ac-
cording to the following procedure.
a If the window glass is broken finely, it may be
removed with knife [4] and a screwdriver.
1. Using seal cutter [1], cut the adhesive between
a Widening the cut with a screwdriver, cut the
broken window glass (7) and operator's cab
adhesive and both-sided adhesive tape with
(metal sheet) (8).
knife [4].
3) Evenly apply paint primer to the surfaces to a In addition to the above parts, apply the
stick both-sided adhesive tapes and the sur- primer to right side window glass (1) and
faces out of those surfaces on operator's door lower window glass (3).
cab (8) which will be coated with the adhe- • Range to apply primer additionally for
2 Paint primer:
sive. right side window glass (1): (b)
• Range to apply primer additionally for
SUNSTAR PAINT PRIMER door lower window glass (3): (c)
580 SUPER or equivalent a After applying the primer, leave it for at
a Do not apply the primer more than 2 least 5 minutes (within 8 hours) to dry.
times. (If it is applied more than 2 times,
its performance will be lowered.)
4) Evenly apply glass primer to the sticking 4. Stick both-sided adhesive tape (6) along the
2 Glass primer:
surfaces of window glass (9). inside edge of the glass sticking section.
a Do not remove the release tape of the both-
SUNSTAR GLASS PRIMER sided adhesive tape on the glass sticking
580 SUPER or equivalent side before sticking the glass.
a Do not apply the primer more than 2 a When sticking the both-sided adhesive tape,
times. (If it is applied more than 2 times, do not touch the cleaned surface as long as
its performance will be lowered.) possible.
a Take that the both-sided adhesive tape will
not float at each corner of the window frame.
a Stick both-sided adhesive tape (6a) addition- a Stick both-sided adhesive tape (6b) ad-
ally for right side window glass (1). ditionally for door lower window glass
• Positions to stick additional both-sided adhe- (3).
sive tape for right side window glass: a Positions to stick additional both-sided
(f) : 50 mm adhesive tape for door lower window
(g) : 90 mm glass:
(h) : 250 mm (j) : 110 mm
(k) : 90 mm
(m) : 200 mm
5. Position the new window glass. a When positioning front window glass (4),
1) Check the clearance between the window set its horizontal position to the frame
glass and the operator's cab on the right, width and set its vertical position so that
left, upper, and lower sides, and then adjust height difference (p) between it and the
it evenly. frame top will be 3 mm.
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.
6. Apply adhesive.
2 Adhesive (Summer):
a Use either of the 2 types of the adhesive.
SUNSTAR PENGUINE
2 Adhesive (Winter):
SEAL 580 SUPER "S"
SUNSTAR PENGUINE
SEAL 580 SUPER "W"
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use the
adhesive after this limit.
a Keep the adhesive in a dark place where the
temperature is below 25°C.
a Never heat the adhesive higher than 30°C.
a When reusing the adhesive, remove the all
hardened part from the nozzle tip.
1) Break aluminum seal (13) of the outlet of
adhesive cartridge (12) and install the noz-
zle.
2) Cut the tip of the adhesive nozzle (14) so a Apply adhesive (15) to dimensions (s)
that dimensions (q) and (r) will be as fol- and (t) of both-sided adhesive tape (6) of
lows. operator's cab (8).
• Dimension (q): 10 mm • Dimension (s) : 10 mm
• Dimension (r) : 15 mm • Dimension (t) : 15 mm
a Apply adhesive (15) higher than both-
sided adhesive tape (6).
a Apply the adhesive evenly.
7. Install the window glass. a After installing front window glass (4), fill
1) Install window glass (9), matching it to the the clearances between it and center
lines of the positioning tapes drawn in step trim seal (16) with caulking material in
5. range (s) to dimensions (t) and (u).
a Since the window glass cannot be re- After applying the primer to glass (4) of
moved and stuck again, stick it very section A – A, apply adhesive as caulk-
carefully. ing material.
a Stick the glass within 5 minutes after ap- • Caulking dimension (t) : 2 mm
plying the adhesive. • Caulking dimension (u) : 5 mm
2) After sticking window glass (9), press all a When caulking, mask the glass side and
around it until it is stuck to the both-sided form the adhesive with a rubber spatula
adhesive tape. as shown in the figure.
2 Glass primer:
a Press the corners of the window glass a Wipe off projected adhesive.
firmly.
SUNSTAR GLASS
2 Adhesive:
PRIMER 580 SUPER
SUNSTAR PENGUINE
SEAL 580 SUPER "S" or "W"
8. Fix the window glass. 9. After installing the window glass, remove the
1) After installing right window glass (1) to the primer and adhesive from the operator's cab
operator's cab, insert stopper rubbers Y2 to and window glass.
2 places (v) at the bottom of the glass to fix a Using white gasoline, wipe off the adhesive
the glass. before it is dried up.
a When cleaning the glass, do not give an im-
pact to it.
8. Remove left lower pin (10). 10. Lower front window assembly (13) completely.
a If left lower pin (10) is removed, plate (12) at a Do not let the front window assembly touch
the end of pull-up assist cable (11) comes the monitor.
off.
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).
INSTALLATION
3. Raise the front window assembly and fix it with 5. Install left corner blocks (1) and (2) and secure
the rear locks (on both sides). left corner bracket (6) with left striker bolt (4).
a Check that the locks in the rear of the opera- a Tighten the striker bolt securely after adjust-
tor's cab are applied securely. ing it in step 6.
a Install the left corner blocks so that there will
4. Install right corner block (3) and fix right corner be no level difference at 2 part (d).
block bracket (7) with right striker bolt (5). a Secure roller clearance (e).
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.
6. Tighten left striker bolt (4) and right striker bolt 7. Open and close the front window assembly and
(5) at roughly right positions so that front window check the working condition of both locks (20)
glass (18) will be fitted to cab-side trim seal (19). and (21).
1) If both locks do not work normally, move the
striker bolts toward the rear of the cab and
tighten them again.
2) After moving the striker bolts, check the fit-
ness of the front window glass and cab-side
trim seal which was checked in step 6.
3) Repeat the work in 1) and 2) until the fitness
of the front window and the working condi-
tion of both locks (20) and (21) are accepta-
ble, and then tighten the striker bolts.
4 Counterweight assembly:
12,000 kg (PC800)
9,800 kg (PC750)