SM Pw170es-6k-962

UEBM000500
Shop
Manual
HYDRAULIC EXCAVATOR
SERIAL NUMBERS PIN1 70ES-6 -K30001 andup
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or
disclosed except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication.
It is recommended that customers contact their distributor for information on the latest revision.
July 1999 Copyright 1999 Komatsu America International Company

10 STRUCTURE AND FUNCTION
Engine related parts ..................................... 1O-2

Radiator, oil cooler, aftercooler.. ................... 1O-3
Power train ................................................... 1O-4
Swing circle .................................................. 1O-5
Swing machinery.. ........................................ 1O-6
Undercarriage .............................................. 1O-8
Transmission ................................................ 1O-9
Axle 1O-l 0
Suspension Lock Cylinder.. .......................... 1O-l 4
Braking train ................................................. 1O-l 6
Break pedal .................................................. 1O-l 7
Break valve.. ................................................. 1O-l 8
Accumulator For Brake System .................... 1O-l 9
Steering train ................................................ 1O-20
Steering column ........................................... 1O-22
Hydraulic circuit diagram .............................. lo-23
Hydraulic tank .............................................. 1O-24
Hydraulic pump ............................................ 1O-25
Control valve ................................................ 1O-32
CLSS ............................................................ 1O-38
Swing motor ................................................. 1O-73
Center swivel joint ........................................ 1O-75
Travel motor (Front, Rear) ............................ 1O-76
Work equipment, swing PPC valve 1 O-78
Travel PPC valve .......................................... 1O-82
Service PPC valve ....................................... 1O-83
Safety lock valve.. ......................................... 1O-86
PPC accumulator ......................................... 1O-86
PPC shuttle, travel joint valve ....................... 1O-87
EPC, solenoid valve ..................................... 1O-91
Additional filter for breaker ........................... 1O-l 00
Boom holding valve ...................................... 1O-l 01
Hydraulic cylinder ......................................... 1O-l 07
Work equipment ........................................... 1O-l 1 1
Electrical wiring diagram .............................. 1O-l 12A
.............................................................. IO-1 12B
.............................................................. IO-1 12c
Engine control system .................................. 1O-l 13
Electronic control system ............................. 1O-l 19
Machine monitor system .............................. 1O-l 45
10-I
STRUCTURE AND FUNCTION ENGINE RELATED PARTS
ENGINE RELATED PARTS
6 7 10 i4 8 9
D-D
A-A H-H
B-B c-c
1. Drive plate OUTLINE

2. Torsion spring . The damper assembly is a dry type.
3. Stopper pin
4. Friction plate
5. Damper assembly
6. Air cleaner
7. Intake connector
8. Muffler
9. Rear engine mount
IO. Front engine mount
1o-2
STRUCTURE AND FUNCTION RADIATOR. COOLER. AFTERCOOLER
RADIATOR l OIL COOLER
/
6
1. Reservoir tank SPECIFICATIONS

2. Oil cooler Radiator: CWX-4
3. Radiator Oil cooler: SF-3
4. Fan
5. Radiator inlet hose
6. Radiator outlet hose
7. Radiator cap
8. Net
9. Shroud
1o-3
STRUCTURE AND FUNCTION POWER TRAIN
1 2 3 4 5 6
1. Front axle 11. Swing machinery

2. Center swivel joint 12. Swing circle
3. Swing motor 13. Transmission
4. Control valve 14. Rear axle
5. Swing brake solenoid valve 15. Gear pump
6. Travel speed solenoid valve 16. Priority valve
7. Travel motor 17. Power brake valve
8. Propshaft 18. Pressure reducing valve
9. Hydraulic pump 19. Clutch control valve
IO. Engine 20. Clutch
IO-4
STRUCTURE AND FUNCTION SWING CIRCLE
SWING CIRCLE
1. Swing circle inner race (No. of teeth: 94) SPECIFICATIONS

2. Ball
3. Swing circle outer race reduction ratio: g = 7,833
a. Inner race soft zone S position

b. Outer race soft zone S position amount of grease: 8/(G2-LI)
1o-5
STRUCTURE AND FUNCTION SWING MACHINERY
SWING MACHINERY
1. Swing pinion (No. of teeth: 12)

2. Cover
3. Case
4. No. 2 of planetary carrier
5. No. 2 sun gear (No. of teeth: 24)
6. No. 2 ring gear (No. of teeth: 78)
7. Case
8. No. 1 ring gear (No. of teeth: 78)
9. No. 1 sun gear (No. of teeth: 18)
IO. Retainer
11. Oil level gauge
12. Cover
13. No. 1 planetary gear (No. of teeth: 29)
14. No. 1 planetary carrier
15. Coupling
16. No. 2 planetary gear (No. of teeth: 26)
17. Drain plug
18. Breather
19. Parking brake piston
20. Parking brake spring
21. Parking brake disc
22. Parking brake plate
23.
23. Gauge rod
SPECIFICATIONS
reduction ratio: 24+78 x 7 = 22.667

24
1O-6
STRUCTURE AND FUNCTION SWING MACHINERY
SWING HOLDING BRAKE
OPERATION
From brake valve return
1) When swing brake solenoid valve is
deactivated
When the swing brake solenoid is deactivated,
the pressurized oil from the PPC pressure re-
ducing valve is shut off and port B is connected
to the tank circuit.
Because of this, brake piston (2) is pushed
down in the direction of the arrow by brake
spring (I), so disc (3) and plate (4) are pushed
together and the brake is applied.
2) When swing brake solenoid valve is excited From brake valve return
When the swing solenoid valve is excited, the
valve is switched, and the pressurized oil from
the PPC pressure reducing valve enters port B
and flows to brake chamber “a”.
The pressurized oil entering chamber “a” over-
comes the force of brake spring (I), and brake
piston (2) is pushed up in the direction of the
arrow. Because of this, disc (3) and plate (4)
separate, and the brake is released.
1. Brake spring
2. Brake piston
3. Disc
4. Plate
1o-7
STRUCTURE AND FUNCTION UNDERCARRIAGE
UNDERCARRIAGE
KW13OP6002 KW13OP6003
1. Undercarriage 6. Propshaft
2. Step 7. Travel motor
3. Wheel chock 8. Transmission
4. Front oscillating steering axle 9. Double wheel ass’y
5. Rear axle 10. Single wheel ass’y
1O-8
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION CLUTCH ASS’Y
1. Screw-fork to shaft 7. Gear 1. Casing 7. Plug

2. Flange 8. Cover 2. Drive shaft 8. Plug
3. Brake cylinder 9. Output shaft 3. Friction plates
4. Brake drum 10. Bearing 4. Spring discs
5. Friction disk 11. Gear 5. Gear
6. Flange 12. Clutch ass’y 6. Clutch control gear pump
1o-9
STRUCTURE AND FUNCTION CLUTCH
CLUTCH CONTROL CIRCUIT
STRUCTURE
TRANSMISSION
SWIVEL P --
Bar
FRONT REAR
TRAVEL TRAVEL
MOTOR TRANSMISSION MOTOR
1. Clutch control pump

2. Pressure relief valve ass’y
3. Pressure reducing valve
4. Clutch control valve
1O-9A
STRUCTURE AND FUNCTION CLUTCH
FUNCTION
The clutch is a device which automatically disen-

gages the drive between the 200 cc (rear) travel
motor and the transmission. This occurs when the
machine is accelerating and the disengagement oc-
curs at 11 Kph. The transmission system becomes
more efficient (by reducing losses caused by the
unnecessary rotation of the rear travel motor) pro-
viding better acceleration and enabling a maximum
speed of 30 Kph.
When the machine decelerates from a high speed
the clutch will re-engage automatically at 9 Kph and
will remain engaged until the speed is increased
above 11 Kph again.
1O-9B
STRUCTURE AND FUNCTION AXLE
AXLE
OUTLINE
. Each axle consists of an axle housing support-
ing the chassis weight, a differential set in the
axle housing, a final drive, and a brake provided
at each and.
. A trunnion-type axle shaft with a king pin at the

final drive end is used to enable the direction of
travel of the machine to be changed.
FRONT AXLE
Kw13OP6005
IO-IO
REAR AXLE
x KW13OP6006
IO-I 1
FRONT AXLE
Kw13OP6007
2
Axle reduction ratio = 17, 73:i
1. Planetary carrier 16. Roller bearing

2. Washer 17. Roller bearing
3. Brake drum 18. Hexagon head screw
4. Pin 19. Shaft
5. Seal ring 20. Joint
6. Grease nipple 21. Bushing
7. Seal ring 22. Brease nipple
8. Seal ring 23. Seal ring
9. Bushing 24. Cylinder head screw
IO. Axle tube 25. Roller bearing
Il. Ring nut 26. Washer
12. Ball bearing 27. Ring
13. Ring nut 28. Hexagon head screw
14. Ball bearing 29. Sun gear
15. Seal ring
IO-12
REAR AXLE
1. Planetary gear 16. Seal ring

2. Bolt 17. Roller bearing
3. Planetary carrier 18. Roller bearing
4. Stud 19. Bevel gear
5. Wheel Hub 20. Cylinder head screw
6. Bushing 21. Bearing
7. Socket 22. Ring gear plate
8. Shaft 23. Sun gear
9. Axle tube
10. Ring nut
11. Roller bearing
12. Roller bearing
13. Shim
14. Bolt
15. Cover
IO-13
STRUCTURE AND FUNCTION SUSPENSION LOCK CYLINDER
SUSPENSION LOCK CYLINDER
KW13OP6009
1. Barrel Specifications
2. Plunger
Piston: 01 OOmm
Stroke: 155mm
Operating pressure: 40.0 MPa (408 Kg/cm’)
Pilot pressure: 3.0 MPa (30.6 Kg/cm”)
Max 5.0 MPa (51 .O Kg/cm*)
IO-14
SUSPENSION LOCK CYLINDER
CIRCUIT
Purpose Function
The undercarriage of wheeled hydraulic excavators The oscillating axle (3) is mounted in bearing (2) in
have one of the two driven axles oscillating the middle of the excavator. The two rams (1) which
mounted. This makes it possible to fully utilize the are full of hydraulic oil are connected through pipe-
excavator’s rimpull in rough terrain - all of the wheels lines to the oscillation lock solenoid valve (4).
being constantly in contact with the ground. When the excavator is being moved, the oscillation
An oscillating blocking ram is fitted on each side of lock solenoid valve should be de-energized so that
the undercarriage to block the axle during digging or the hydraulic oil in the ram can be returned to tank
lifting work. as the axle is oscillating up and down. Before com-
Blocking the axle increases the excavator’s stability. mencing excavating operations, the oscillation lock
solenoid valve should be energized to pressurize
1. Ram the oil in the rams. This will lock the axle in the posi-
2. Axle oscillating point tion it is in.
3. Oscillating axle
4. Oscillation lock solenoid valve
5. PPC pressure reducing valve
6. Hydraulic tank
7. Swivel joint
---
IO-15
STRUCTURE AND FUNCTION BRAKING TRAIN
BRAKING TRAIN
Brake valve
Priority valve
I
Gear pump
Engine
Accumulator
Diesel
P
Tank
Filter
, Brake pedal (latching)
\
Linkage
IO-16
STRUCTURE AND FUNCTION
BRAKE PEDAL
BRAKE PEDAL
KW13OP6012
Actuation force at ‘A’ = 300 - 350 N

(30.6 - 35.7 kg)
When installed in machine
IO-17
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
DS2
DSI P N
/ DS3
‘DS2
s2 DS2
DS2
Kw13OP6013
P = Pump Sl = Accumulator service brake

N = Secondary circuit S2 = Accumulator service brake
T = Tank S3 = Accumulator parking brake
Bl = Service brake DSl = Pressure switch stop light
B2 = Service brake DS2 = Pressure switch acculator-pressure
B3 = Parking brake DS3 = Pressure switch parking brake
IO-18
STRUCTURE AND FUNCTION ACCUMULATOR FOR BRAKE SYSTEM
ACCUMULATOR FOR BRAKE SYSTEM
Seal ins Surface Kw130P6014
Specifications
Volume: 0.75 G * Remove before installation

Max working pressure: 210 bar
Precharge pressure: 50 bar
IO-19
STRUCTURE AND FUNCTION STEERING TRAIN
‘EERING TRAIN
SHARED WITH BRAKE CIRCUIT
d
P
/-L.---L
L,s! q
-.
I
;
rr -IL :--
b
\ .._-- --
d‘ ‘i :
4 I’--
I
5 :\7--
- - i

The steering is fully hydraulic. The oil sent by
steering pump (2) mounted on the steering
PTO at the front of the engine (1) flows to steer-
ing valve (4). From here is passed through
swivel joint (6) and is sent to steering cylinder
(7). The steering cylinder then extends or re-
tracts to move tie-rod and steer the machine.
The hydraulic power from steering pump (2) is

sent to the steering cylinder and converted
back to mechanical power to operate the steer-
ing.
1 O-20
STRUCTURE AND FUNCTION STEERING TRAIN
ITEM
POSITIONS
1. HYDRAULIC OIL FILTER
2. HYDRAULIC OIL PUMP (SHARED WITH BRAKING CIRCUIT) l&x/REV
3. PRIORITY VALVE
CONTROL SPRING PRESSURE 7 bar
4. STEERING VALVE OSPD 70/l 95 LS DYN.
5. STEERING CILINDER D=090, d=050, STROKE=1 7OP,

STEERING CILINDER VOLUME = (9 -5 ) x TC x 17 = 748 cmm~
4
6. STEERING WHEEL ... 0352
QUANTITIY OF STEERING TURNS
NORMAL
I= CYL.VOL = 748 cm3 = 3.8 TURNS
PUMPVOL 195 cm3
EMERGENCY
I= CYL.VOL = 748 cm3 = 10.7 TURNS
PUMP.VOL 70 cm3
IO-21
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Gaiter
4. Pedal
5. Hose
6. Orbitroll valve
7. Mounting bracket
1o-22
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
, I 4-OUTRIGGER
c------_
IJ J
1 1 I ’
I I
,qDR__:‘:_J I
REAR DOZER
,r - - - - - - J
I I
2-OUThGGER
Z-OUTRIGGER
-I-,DR'
i '
1O-23
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM

p
002
mA5_ - - - . - 4~--------~
/
---
Al
Al
-
TI
a! _
----/<----
_ - - - ,‘OC
r02
ro2
- - - -
F-I-
_I
_ _ _p,q
1
I’
I
------ ------___
------ 5,0; - - - - - - _ , l-l ;i
A3
AA__----_/_------__h r02 II ,I
1’ I’ LL
!! II ,’
,_-_._.. I, L-_-e--I-d-----
;,A_ - ~ ro2
‘-S ; (Mlu vu*)
II
II
warl
& ’
T
~lo,Go,yD, _.I pq_
P,, - 1
_ I r - - - - - I-3 -+
r-
- 8
44
-‘mr’m I I
-lmmlpP, ,,
Il
II
~ ;I ~
; _
1 O-23A
STRUCTURE AND FUNCTION HYDRAULICTANK
HYDR AULICTANK
7 6 3
/, Fl
5
1. Hydraulic tank Specifications
2. Bypass valve Tank capacity:
3. Oil filter cap Amount of oil inside tank:
4. Sight gauge Pressure valve
5. Suction strainer Relief cracking pressure: 0.038 f 0.015 MPa
6. Filter element (0.39 f 0.15 kg/cm’)
7. Bypass strainer Suction cracking pressure: 0 - 0.0045 MPa
(0 - 0.046 kg/cm”)
Bypass valve set pressure: 0.103 f 0.02 MPa
(1.05 f 0.2 kg/cm’)
1O-24
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
,e
a b
a. Pump drain port PD 1. Main pump

b. Pump delivery port PA 2. TVC*LS valve
c. Pump LS pressure port PLS
d. LS control EPC pressure port PSIG
e. Main pump suction port PS
1O-25
OPERATION
1. Operation of pump
1) cylinder block (7) rotates together with
shaft (l), and shoe (5) slides on flat surface
A.
When this happens, rocker cam (4) moves
along cylindrical surface B, so angle a be-
tween center line X of rocker cam (4) and
the axial direction of cylinder block (7)
changes. (Angle a is called the swash plate
angle.)
2) Center line X of rocker cam (4) maintains

swash plate angle a in relation to the axial
direction of cylinder block (7), and flat sur-
face A moves as a cam in relation to shoe
(5).
In this way, piston (6) slides on the inside of
cylinder block (7), so a difference between
volume E and F is created inside cylinder
block (7). The suction and discharge is car-
ried out by this difference F - E.
In other words, when cylinder block (7) ro-
tates and the volume of chamber E be-
comes smaller, the oil is discharged during
that stroke. On the other hand, the volume 7 E
of chamber F becomes larger, and as the
volume becomes bigger, the oil is sucked
in.
3) If center line X of rocker cam (4) is in line

with the axial direction of cylinder block (7)
(swash plate angle = 0), the difference be-
tween volumes E’ and F’ inside cylinder
block (7) becomes 0, so the pump does not
carry out any suction or discharge of oil. (In
actual fact, the swash plate angle never
becomes 0.)
1 O-26
2. CONTROL OF DISCHARGE AMOUNT
PP
If swash plate angle a becomes larger, the dif- . Piston (14) moves in a reciprocal movement
ference in volumes E and F becomes larger and (t+) according to the command from the
discharge volume Q increases. TVC*LS valve and the spring force.
Swash plate angle a is changed by positioning . Main pump discharge pressure (self-pressure)
piston (12) and return piston (14). PP is always connected to the chamber receiv-
Servo piston (12) moves in a reciprocal move- ing the pressure on piston (12) end. (the self-
ment (-) according to the spring force and pressure is brought in).
pump output pressure. . Output pressure PEN of the LS valve is brought
This straight line movement is transmitted to the chamber receiving the pressure at piston
through rod (13) and (15) to rocker cam (4), and (14) end.
rocker cam (4), which is supported by the cylin- . The relationship between piston (12) and piston
drical surface to cradle (2), moves in a swinging (14) controls swash plate (4) angle.
movement on the cylindrical surface in (direc-
tion).
1 O-27
1. Shaft 9. End cap

2. Cradle 10. Spring
3. Case 11. Spring
4. Rocker cam 12. Positioning piston
5. Shoe 13. Rod
6. Piston 14. Return piston
7. Cylinder block 15. Rod
8. Valve plate 16. Stopper
1 O-28
FUNCTION . Piston (6) carries out relative movement in the

. The engine rotation and torque transmitted to axial direction inside each cylinder chamber of
the pump shaft is converted into hydraulic en- cylinder block (7).
ergy, and pressurized oil is discharged accord- l The cylinder block seals the pressure oil to
ing to the load. valve plate (8) and carries out relative rotation.
. It is possible to change the delivery amount by This surface is disigned so that the oil pressure
changing the swash plate angle. balance is maintained at a suitable level.
The oil inside each cylinder chamber of cylinder
STRUCTURE block (7) is sucked in and discharged through
. Cylinder block (7) is supported to shaft (1) by a valve plate (8).
spline, and shaft (1) is supported by the front
and rear bearings.
. The tip of piston (6) is a convex ball, and shoe
(5) is caulked to it to form one unit. Piston (6)
and shoe (5) form a spherical bearing.
. Rocker cam (4) has flat surface A, and shoe (5)
is always pressed agaist this surface while slid-
ing in a circular movement.
. Rocker cam (4) brings high pressure oil at cylin-
drical surface B with cradle (2), which is se-
cured to the case, and forms a static pressure
bearing when it slides.
1o-29
2. TVC. LS valve
I I \
: 654 ;A i
LS VALVE TVC VALVE

1. Locknut 9. Solenoid
2. Plug 10. Piston
3. Spring 11. Spring
4. Spool 12. Spring
5. Sleeve 13. Piston
6. Piston 14 Lever
7. Sleeve 15 Valve body
8. Spring
IO-30
FUNCTION
1. LS VALUE
. The LS valve detects the load and controls the a
E PSIG = 2.94 MPa (30 kg/m-+)
discharge amount. Lz
This valve controls main pump discharge s
amount Q according to differential pressure &
APLS (=PP - PLS) (the difference between ;
z
main pump pressure PP and control valve out- ::
5
let port pressure PLS) (called the LS differential
2
pressure). I? I ’
. Main pump pressure PP, pressure PLS (called 0.64 (6.5) 2.55 (26) UvlPa (kg/cm91
the LS pressure) coming from the control valve LS differential pressure PLS
output, and pressure PSIG (called the LS se-
lection pressure) from the proportional solenoid
vlve enter this valve. The reletionship between
discharge amount Q and differential pressure
APLS, (the difference between main pump
pressure PP and LS pressure PLS) (=PP -
PLS) changes as shown in the diagram on the
right according to LS selector pressure PSIG.
. When PSIG changes between 0 and 2.94 MPa
(0 and 30 kg/ cm”), the spool load changes ac-
cording to this, and the selector point for the
pump discharge amount changes at the rated
central value between 0.64 and 2.55 MPa (6.5
and 26 kg/cm”).
2. TUC VALUE
. When the pump discharge pressure PP
(selfpressure) is high, the TVC valve controls
the pump so that no more oil than the constant
flow (in accordance with the discharge pres-
sure) flows even if the stroke of the control valve
becomes larger. In this way it carries out equal
horsepower control so that the horsepower ab-
sorbed by the pump does not exceed the en-
gine horsepower.
. In other words, if the load during the operation
becomes larger and the pump discharge pres-
sure rises, it reduces the discharge amount
from the pump; and if the pump discharge pres-
sure drops, it increases the discharge amount
from the pump. The relation between the pump Pump discharge pressure PP
discharge pressure PP and pump discharge
amount Q is shown on the right, with the current
given to the TVC valve solenoid shown as a pa-
rameter. However, in the heavy-duty operation
mode, there are cases where it is given the
function of sensing the actual speed of the en-
gine, and if the speed drops because of an in-
crease in the load, it reduces the pump dis-
charge amount to allow the speed to recover. In to the TVC valve solenoid from the controller in-
other words, when the load increases and the creases according to the drop in the engine
engine drops below the set value, the command speed to reduce the pump swash plate angle.
1o-31
OPERATION
! T-
,2
Minimum direction 202FO6033
1. LS valve this point, spool (4) is pushed to the left, and

1) When control valve is at “NEUTRAL” port d and port C are connected. Pump pres-
position sure Pp enters the large diameter end of the
The LS valve is a three-way selector valve, with piston from port h, and the same pump pres-
pressure PLs (LS pressure) from the outlet port sure Pp also enters the small diameter end of
of the control valve brought to spring chamber i, the piston, so the swash plate is moved to the
and main pump discharge pressure PP brought minimum angle by the difference in area of pis-
to chamber j of plug (6). The size of this LS ton (1).
pressure PLs + force F of spring (3) and the
main pump pressure (self pressure) Pp deter-
mines the position of spool (4). However, the
size of the output pressure Psig (the LS selecti-
on pressure) of the EPC valve for the LS valve
entering port e also changes the position of
spool (4). (The set pressure of the spring
changes.)
Before the engine is started, servo piston (1) is
pushed to the right by spring (7) installed to rod
(2). (See the diagram on the right.)
When the engine is started and the control lever
is at the “NEUTRAL” position, LS pressure PLs
is 0 MPa (0 kg/cm”). (It is interconected with the
drain circuit through the control valve spool.) At
IO-31A
PLS
Maximum direction
202FO6035
2) Operation in maximum direction for pump

discharge amount
. When the difference between main pump pres- . For this reason, the pressure at the large piston
sure Pp and LS pressure PLs, in other words, diameter end of servo piston (1) becomes drain
LS differential pressure PLs, becomes smaller pressure Pt, and pump pressure Pp enters the
(for example, when the area of opening of the small diameter end, so servo piston (1) is
control valve becomes larger and pump pres- pushed to the right. Therefore, rod (2) moves to
sure Pp drops), spool (4) is pushed to the right the right and moves the swash plate in the di-
by the combined force of LS pressure PLs and rection to make the discharge amount larger.
the force of spring (3). . If the output pressure of the EPC valve for the
. When spool (4) moves, port b and port c are LS valve enters port e, this pressure creates a
joined and connected to the TVC valve. When force to move piston (5) to the left. If piston (5) is
this happens, the TVC valve is connected to the pushed to the left, it acts to make the set pres-
drain port, so cicuit c - h becomes drain pressure of spring (3) weaker, and the difference
sure Pt. (The operation of the TVC valve is ex- between PLs and Pp changes when ports b
plained later.) and c of spool (4) are connected.
IO-31B
PLS PSIC
b. \
j
r--L
6
Minimum direction
202FO6036
3) Operation in minimum direction for pump

discharge amount
. The following explains the situation if servo pis- . Main pump pressure Pp also enters the small
ton (1) moves to the left (the discharge amount piston diameter end, but because of the differ-
becomes smaller). When LS pressure APLs ence in area between the large piston diameter
becomes larger (for example, when the area of end of servo piston (1) and the small piston di-
opening of the control valve becomes smaller ameter end of servo piston (1) is pushed to the
and pump pressure Pp rises), pump pressure left. As a result, rod (2) moves in the direction to
Pp pushes spool (4) to the left. make the swash plate angle smaller.
. When spool (4) moves, main pump pressure Pp . If LS selection pressure Psig enters port e, it
flows from port d to port c, and from port h, it acts to make the set pressure of spring (3)
enters the large piston diameter end. weaker.
lo-31c
NC valve
PLS
-%i 8
202FO6037
4) When servo piston is balanced
. Let us take the area receiving the pressure at At this point, the relationship between the area
the large piston diameter end as Al, the area receiving the pressure at both ends of piston (1)
receiving the pressure at the small diameter is AO:Al = 1:2, so the pressure applied to both
end as AO, and the pressure flowing into the ends of the piston when it is balanced becomes
large piston diameter end as Pen. If the main Pp: Pen = 2:l.
pump pressure Pp of the LS valve and the corn- The position where spool (4) is balanced and
bined force of force F of spring (3) and LS pres- stopped is the standard center, and the force of
sure PLs are balanced, and the relationship is spring (3) is adjusted so that it is determined
A0 x Pp = Al x Pen, servo piston (1) will stop in when Pp - PLs = 2.11 MPa (21.5 kg/cm’). How-
that position, and the swash plate will be kept at ever, if Psig (the output pressure of 0 - 2.94
an intermediate position. (It will stop at a posi- MPa (0 - 30 kg/cm’) of the EPC valve of the LS
tion where the opening from port b to port c and valve) is applied to port e, the balance stop po-
from port d to port c of spool (4) is approxi- sition will change in proportion to pressure Psig
mately the same.) between Pp - Pls = 2.11 t+ 0.637 MPa (21.5
t+ 6.5 kg/cm’).
IO-31D
STRUCTURE AND FUNCTION CIRCUIT DIAGRAM
202FO6038 202FO6139
2. TVC valve
1) When pump controller is normal
a. When the load on the actuator is small and l The size of command current X is determined
pump pressure Pp is low by the nature of the operation (lever operation),
(1) Movement of solenoid (1) the selection of the working mode, and the set
. The command current from the pump controller value and actual value for the engine speed.
flows to solenoid (1). This command current
changes the internal force pushing solenoid
push pin (11).
. On the opposite site to the force pushing this
solenoid push pin (11) is the spring set pres-
sure of springs (3) and (4) and pump pressure
Pp. Piston (2) stops at a position where the
combined force pushing piston (2) is balanced,
and the pressure (pressure of port c) output
from the TVC valve changes according to this
piston.
IO-31E
(2) Movement of spring

. The spring load of springs (3) and (4) in the
TVC valve is determined by the swash plate po-
sition.
. When servo piston (9) moves, cam (7), which is
connected to rod (8), also moves. When this
happens, Lever (6) is rotated by the angle of
cam (7), and piston (5) moves to the right and
left.
. If piston (5) moves to the right, spring (3) is
compressed, and if it moves further to the right,
spring (4) contacts seat (lo), so both spring (3)
and spring (4) function. In other words, the
spring load is changed by piston (5) extending
or contracting springs (3) and (4).
. If the command current input to solenoid (1)
changes further, the force pushing solenoid
push pin (11) changes, and the spring load of
springs (3) and (4) also changes according to
the value of the solenoid command current.
. Port c of the TVC valve is connected to port e of
the LS valve (see 1. LS valve). Self pressure Pp
enters port b, the small piston diameter end of
servo piston (9), and port a.
. When pump pressure Pp is small, piston (2) is
on the right. At this point, port c and port d are
connected, and the pressure entering the LS
valve becomes drain pressure Pt. If port h and
port e of the LS valve are connected (see 1. LS
valve), the pressure entering the large piston
diameter end from port f becomes drain pres-
sure Pt, and servo piston (9) moves to the right.
In this way, the pump discharge amount moves
in the direction of the increase.
. As servo piston (9) moves further, piston (5) is
moved to the left by rod (8), cam (7), and lever
(6). Springs (3) and (4) expand and the spring
force becomes weaker. When the spring force
becomes weaker, piston (2) moves to the left,
so the connection between port c and port d is
cut, and the pump discharge pressure is con-
nected to port b. As a result, the pressure at
port c rises, and the pressure at the large piston
diameter end also rises, so the movement of
piston (9) to the right is stopped. In other words,
the stop position for piston (9) (= pump dis-
charge amount) is decided at the point where
for the force of springs (3) and (4) and the push-
ing force from the solenoid and the pushing
force created by pressure Pp acting on piston
(2) are in balance.
IO-31F
Minimum direction
I NC
202FO6039 202FO6139
b. When load on actuator is small and pump . If main pressure Pp increases further and pis-
discharge pressure is high ton (2) moves further to the left, main pump
. When the load is large and pump discharge pressure Pp flows to port c and acts to make
pressure Pp is high, the force pushing piston the discharge amount the minimum. When pis-
(2) to the left becomes larger and piston (2) ton (9) moves to the left, piston (5) is moved to
moves to the position shown in the diagram the right by cam (7) and lever (6). For this rea-
above. When this happens, as shown in the dia- son, springs 3 and 4 are compressed and push
gram above, part of the pressurized oil from back piston (2). Because of this force, piston (2)
port b flows out to port d and the pressure oil cuts off the connection from port b to port c,
flowing from port c to the LS valve becomes ap- and and port c and port d are connected. As a
proximately half of main pump pressure Pp. result, the pressure at port c (=f) drops, and pis-
. When port h and port e of the LS valve are con- ton (9) stops moving to the left. The position in
nected (see 1. LS valve), the pressure from port which piston (9) stops when this happens is fur-
f enters the large piston diameter end of servo ther to the left than the position when pump
piston (9), and servo piston (9) stops. pressure Pp is low.
lo-31G
. The relation of pump pressure Pp and the posi-

tion of servo piston (9) forms a bent line be-
0
cause of the double-spring effect of springs 3 E
and 4.The relationship between pump pressure
Pp and pump discharge amount Q is shown in
the figure on the right.
Pump discharge pressura Pp
202Fo6040
. If command current X sent to solenoid (1) in-

creases further, the relationship between pump
pressure Pp and pump discharge amount Q is
proportional to the pushing force of the solenoid
and moves in parallel. In other words, if the
pushing force of solenoid (1) is added to the
force pushing to the left because of the pump
pressure applied to the piston (2), the relation-
ship between Pp and Q moves from a to b in
accordance with the increase.
I
Pump discharge pressure PP
202FO6041
IO-31H
(Maximum direction)
202FO6042 202FO6139
2) When pump controller is abnormal and TVC . If main pump pressure Pp is low, the combined
prolix swiych is “ON” force of the pump pressure and the force of so-
a. When load on main pump is light lenoid (1) is weaker than the spring set force, so
. If there is a failure in the pump controller, turn piston (2) is balanced at a position to the rigft.
TVC prolix switch “ON” to switch to the resistor . At this point, port c is connected to the drain
side. In this case, the power source is taken di- pressure of port d, and the large piston diam-
rectly from the battery. But if the current is used eter end of servo piston (9) also becomes the
as it is, it is too large, so use the resistor to con- drain pressure Pt through the LS valve. When
trol the current flowing to solenoid (1). this happens, the pressure at the small piston
. When this is done, the current becomes con- diameter end is large, so servo piston (9)
stant, so the force pushing solenoid push pin moves in the direction to make the discharge
(11) is also constant. amount larger.
10-311
.,
tJhT
LS valve
A...
/b
-
(Minimum direction)
202FO6043 202FO6139
b. When main pump load is heavy

. In the same way as in the previous item, when
the TVC prolix switch is “ON”, the command
current sent to solenoid (1) becomes constant.
For this reason, the force of solenoid push pin E
m
(11) pushing piston (2) is constant.
If main pump pressure Pp increases, piston (2)
moves further to the left when the main pump
load is light, and is balanced at the position
shown in the diagram above.
In this case, the pressure from port b flows to
port c, so servo piston (9) moves to the left (to Pump discharge pressure PP
make the discharge amount smaller) by the
same mechanism as explained in Item 2)-b. In
other words, even when the TVC prolix switch is
“ON”, the curve for the pump pressure Pp and
discharge amount Q is determined as shown in
the diagram for the value of the current sent to
the solenoid through the resistor. The curve
when the TVC prolix switch is “ON” is curve b,
which is to the left of curve a for when the pump
controller is normal.
IO-31J
STRUCTURE AND FUNCTION PPC PUMPLESS SYSTEM
PPC PUMPLESS SYSTEM

STRUCTURE
a I ves
35-$ba r A
A T P
- 7 4-.
4 b L -I
n
To orbitroll valve
-A N Sl s3
. .
Q
+ DS2
t-1’ 1
;-_ p _%&&--A III
I -
1
81’
From orbitrol I valve I

_---- +-----_I
(load sensing signal)
82
1. Gear Pump.
2. Steering/Braking Priority Valve.
3. Power Brake Valve.
4. Pressure Reducing Valve.
FUNCTION
. The PPC Pumpless system discharges pressu-
rized oil to operate the PPC circuit and solenoid
valve assemblies.
IO-31K
STRUCTURE AND FUNCTION PPC PUMPLESS SYSTEM
OPERATION
. The PPC pumpless system utilises the return
line oil from the power brake valve. Oil is sup-
plied to the steering/braking circuits from a
gear pump driven by the engine. Oil flow is
prioritised to the steering circuit via a priority
valve with the remaining oil flow feeding the
power brake valve.
. The return line from the brake valve passes
through a pressure reducing valve where the oil
pressure is maintained at 35-O/3 bar.This pres-
sure is utilised to charge the PPC circuit.
IO-31L
STRUCTURE AND FUNCTION CONTROL VALVE
CONTROL VALVE
Outline
The following control valve is standard: Pf. Port P6 (from travel REVERSE PPC valve)
. 8-spool valve (includes 2 service valves) Pg. Port P7 (from boom lift cylinder RAISE PPC
valve)
The cross sections shown are for the 6-spool valve Ph. Port P8 (from boom lift cylinder LOWER PPC
(sub assembly) valve)
* The cross-sectional structure of the service Pi. Port P9 (from arm OUT PPC valve)
valve is the same as the structure for the bucket Pj. Port PlO (from arm IN PPC valve)
valve, so refer to the bucket valve for details. Pk. Port Pll (from bucket DUMP PPC valve)
PI. Port P12 (from bucket CURL PPC valve)
General locations and names of ports (common Pm. Port P-l (from boom adjust EXTEND PPC
for each external view diagram) valve)
1. 6-spool valve sub assembly Pn. Port P-2 (from boom adjust RETRACT PPC
2. Cover A (main relief valve) valve)
3. Cover B (unload valve) PO. Port P-3 (from service PPC valve)
4. Arm counterbalance valve Pp. Port P-4 (from service PPC valve)
5. No. 1 service valve
6. No. 2 service valve
Port Pp (from main pump)

:: Port Al (to swing motor MB)
Port Bl (to swing motor MA)
:: Port A2 (to stabilizer cylinder head)
Port B2 (to stabilizer cylinder bottom)
F’ Port A3 (to travel motor A)
g. Port B3 (to travel motor B)
h. Port A4 (to boom lift cylinder bottom)
i. Port B4 (to boom adjust cylinder head)
j. Port A5 (to arm cylinder head)
k. Port B5 (to arm cylinder bottom)
I. Port A6 (to bucket cylinder head)
m. Port B6 (to bucket cylinder bottom)
n. Port A7 (to boom adjust cylinder bottom)
0. Port B7 (to boom adjust cylinder head)
P. Port A8 (to attachment)
o. Port B8 (to attachment)
t. Port Tsw (to swing motor)
U. Port Tc (to oil cooler)
V. Port T (to tank)
aa. Port Pls (to pump LS valve)

bb. Port Pxl (from 2-stage relief solenoid valve)
dd. Port Bp (from PPC shuttle valve)
ee. Pressure sensor port (pressure sensor in-
stalled)
W. Port T (to tank)
Pa. Port Pl (from swing LEFT PPC valve)
Pb. Port P2 (from swing RIGHT PPC valve)
PC. Port P3 (from stabilizer EXTEND PPC valve)
Pd. Port P4 (from stabilizer RETRACT PPC valve)
Pe. Port P5 (from travel FORWARD PPC valve)
1 O-32
EXTERNAL VIEW
8-spool valve (includes 2 service valves)
PP PO
Pm
pk
Pi
Pi
Pj
Pg
Ph
Pe
Pf PC
Pd P*
pb bb
a
1
4
ee
6
1o-33
Cross-sectional drawing
* The cross section is given only for the 6-spool valve (STANDARD). The cross-sectional structure of the
service valves in an 8-spool valve is the same as the structure of the bucket valve, so refer to the bucket
valve for details.
(1 Mark)
(1 Mark)
(2 Marks)
(4 Marks)
Side by Side
(1 Mark)
(4 Marks)
(2 Marks) (2 Marks)
Separated Seoarated
(1 Mark)
(1 Mark)
(3 Marks)
(3 Marks)
A-A Kw13OP6018
1. Pressure compensation valve (swing left) 7. Pressure compensation valve (bucket CURL)
2. Pressure compensation valve 8. Pressure compensation valve (arm IN)
(stabilizer EXTEND) 9. Pressure compensation valve (boom LOWER)
3. Pressure compensation valve 10. Pressure compensation valve
(travel FORWARD) (travel REVERSE)
4. Pressure compensation valve (boom RAISE) 11. Pressure compensation valve
5. Pressure compensation valve (arm OUT) (stabilizer RETRACT)
6. Pressure compensation valve (bucket DUMP) 12. Pressure compensation valve (swing RIGHT)
Note: Pressure compensation valves are identi-

fied by markings on the valve assembly.
(See disassembly and assembly section
30-l 00 for details.)
1o-34
10
B-B
202rn6051
1. Spool (swing) 6. Spool (bucket)

2. Spool (stabilizer) 7. LS bypass plug
3. spool (travel) 8. Unload valve
4. Spool (boom) 9. Spool return spring
5. Spool (arm) IO. Main relief valve
1 O-34A
202FO6052
1. Suction valve (stabilizer head) 6. Safety-suction valve (bucket bottom)

2. Suction valve (travel motor A) 7. Safety-suction valve (arm bottom)
3. Suction valve (boom lift cylinder bottom) 8. Safety-suction valve (boom lift cylinder head)
4. Safety-suction valve (arm head) 9. Suction valve (travel motor B)
5. Safety-suction valve (bucket head) 10 Suction valve (stabilizer bottom)
1 O-34B
CONTROL VALVE
(1 Mark)
(1 Mark)
(1 Mark)
(3 Marks)
(1 Mark)
202FO6053
1. LS shuttle valve (bucket)

2. LS shuttle valve (arm)
3. LS shuttle valve (boom)
4. LS shuttle valve (travel)
5. LS shuttle valve (stabilizer)
6. LS select valve
Note: LS shuttle valves are identified by mark-

ings on the valve assembly. (See disas-
sembly and assembly section 39-99 for de-
tails.)
IO-35
E-E
F-F 8
12 Kw13OP6019
1. Cooler bypass valve Swing valve Stabilizer valve

3. Main relief valve 5. Pressure compensation valve 9. Pressure compensation valve
4. Lift check valve (LEFT) (EXTEND)
6. LS select valve 10. LS shuttle valve
7. Pressure compensation valve 11. Pressure compensation valve
(RIGHT) (RETRACT)
8. Spool 12. Suction valve
13. Spool
14. Suction valve
1 O-36
6’ H-H ‘5 ‘4
16’ K-K
\
18
\
17
202FO6055
Boom valve Arm valve Bucket valve (service valve)

1. Pressure compensation valve 7. Pressure compensation valve 14. Pressure compensation valve
(RAISE) (OUT) (DUMP)
2. LS shuttle valve 8. LS shuttle valve 15. LS shuttle valve
3. Pressure compensation valve 9. Pressure compensation valve 16. Pressure compensation valve
(LOWER) (IN) (CURL)
4. Safety-suction valve 10. Safety-suction valve 17. Safety-suction valve
5. Spool 11. Spool 18. Spool
6. Suction valve 12. Counterbalance valve 19. Safety-suction valve
13. Safety-suction valve
1 O-36A
202F06056
1. Arm counterbalance valve

2. LS bypass plug
3. Unload valve
1 O-36B
SAFETY-SUCTION VALVE FOR SERVICE VALVE
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve
8. Sleeve
9. Adjustment screw
IO. Locknut
202FO6057
SPECIFICATIONS
Model code Part No. (reference) Set pressure Use
17.15 MPa (175 kg/cm’)

W24800 709-70-74700 Clam shell/Breaker
(at 5 dlmin)
35.79 MPa (365 kg/cm’) 2 piece/Breaker

709-70-74302
(at 5 dlmin) (Boom adjust cylinder)
24.5 MPa (250 kg/cm’)

709-70-74600 For crusher (Okada)
(at 5 Blmin)
1o-37
STRUCTURE AND FUNCTION CLSS
CLSS
OUTLINE OF CLSS
Actuators
r------!‘j Contrr
NC valve
Y ! I
I
Return
piston
_
I
I
Tank
Features Structure
. CLSS stands for Closed center Load Sensing l The CLSS consists of a main pump control
System, and has the following features. valve, and actuators for the work equipment.
. The main pump body consists of the pump it-
1) Fine control not influenced by load. self, the TVC valve and the LS valve.
2) Control enabling digging even with fine control.
3) Ease of compound operation ensured by flow
divider function using area of opening of spool
during compound operations. Energy saving
using variable pump control.
1 O-38
BASIC PRINCIPLE
1) Control of pump swash plate angle
. The pump swash plate angle (pump discharge amount) is controlled so that LS differential pressure APLS
is constant. LS differential pressure APLS, which is the differential pressure between pump discharge
pressure PP and LS pressure PLS (actuator load pressure) at the outlet port of the control valve (LS
differential pressure APLS = Pump discharge pressure PP - LS pressure PLS).
. If LS differential pressure APLS becomes lower than the set differential pressure of the LS valve, the pump
swash plate angle becomes greater, and if it becomes higher, the pump swash plate angle becomes
smaller.
Actuator
APLS I 1
P 1
I .---- L--- :I
I I pressure
I , small(Low) !1
Small current + 1Large current :1
II
T T
I ’ I- Y" I I
llil
TVC valve -I 11 I I
I I I I
I I I I
I I I I
._c I I
I I
,, ,‘-
I I
II--
---I I I
I I I I
II I I
II I I
II I I
I I
Q max. Q min.
7+qy7-~~~?J
Piston
positioning
1o-39
2) Pressure compensation control

. A valve (pressure compensation valve) is installed to the outlet port side of the control valve to balance the
load. When there is compound operation of the actuators, this valve acts to make pressure difference AP
constant for the upstream flow (inlet port) and downstream flow (outlet port) of the spool of each valve.ln
this way, the flow of oil from the pump is divided in proportion to area of opening Sl and S2 of each valve.
Load
1O-40
OPERATION FOR EACH FUNCTION OF CLSS

Hydraulic circuit diagram for system
PUMP PRESSURE CHECK PORT
I
1
: wo2 Ps
I _ <-_____ _
_a-__P,
to2 __L
1 ’
1 :
A
V
IO-41
1. Unload valve
(LS pressure + 3.92 MPa (40 kg/cm’))
2. Safety-suction valve
(33.77 MPa (365 kg/cm’) - Arm,
Bucket, Second Boom)
(33.32 MPa (340 kg/cm’) - Boom)
3. Pressure compensation valve
4. LS shuttle valve
5. Suction valve
6. Main relief valve
(normal: 31.85 MPa (325 kg/cm’),
When pressure rises:
34.79 MPa (355 kg/cm’))
7. Lift check valve
8. Bypass check valve
9. LS select valve
1 O-42
1) Unload valve
Function
1. When the control valve is at neutral, pump discharge amount Q discharged by the minimum swash plate
angle is eleased to the tank circuit. When this happens, pump discharge pressure Pp is set at 3.92 MPa (40
kg/cm’) by spring (3) inside the valve. (LS pressure PLS: 0 MPa (0 kg/cm”).
PLS
202FOf3.363
Operation
When control valve is at neutral

. Pnmp discharge pressure Pp is acting on the 1. Unload valve
left end of spool (4) and LS pressure Pls is act- 2. Sleeve
ing on the right end. 3. Spring
. When the control valve is at neutral, LS pres- 4. Spool
sure PLs is 0, so only pump discharge pressure
Pp has any effect, and Pp is set only by the load Pp: Pump circuit (pressure)
of spring (3). PLs: LS circuit (pressure)
. As pump discharge pressure Pp rises and T: Tank circuit (pressure)
reaches the load of spring (3) (3.92 MPa (40 kg/
cm2)), spool (4) is moved to the right in the di-
rection of the arrow. Pump discharge pressure
Pp then passes through the drill hole in sleeve
(2) and is connected to the tank circuit T.
. In this way, pump discharge pressure Pp is set
to 3.92 MPa (40 kg/cm”).
1o-43
2. During fine control of the control valve, when the demand flow for the actuator is within the amount dis-
charged by the minimum swash plate angle of the pump, pump discharge pressure Pp is set to LS pressure
Pls + 3.92 MPa (40 kg/cm”). When the differential pressure between pump discharge pressure Pp and LS
pressure Pls reaches the load of spring (3) 3.92 MPa (40 kg/cm’), the unload valve opens, so LS differential
pressure APls becomes 3.92 MPa (40 kg/cm”).
PLS
\
pp.
202FO6064
Operation
Fine control of control valve

When fine control is carried out on the control 1. Unload valve
valve, LS pressure Pls is generated and acts on 2. Sleeve
the right end of spool (4). 3. Spring
When this happens, the area of the opening of 4. Spool
the control valve is small, so there is a big differ-
ence between LS pressure Pls and pump dis- Pp: Pump circuit (pressure)
charge pressure Pp. Pls: LS circuit (pressure)
When the diffferential pressure between pump T: Tank circuit (pressure)
discharge pressure Pp and LS pressure Pls
reaches the load of spring (3) 3.92 MPa (40 kg/
cm”), spool (4) moves tot he right in the direc-
tion of the arrow, and pump circuit Pp and tank
circuit T are connected.
In other words, pump discharge pressure Pp is
set to a pressure equal to the spring force 3.92
MPa (40 kg/cm’) + LS pressure Pls, and LS dif-
ferential pressure Pls becomes 3.92 MPa (40
kg/cm”).
1o-44
3. When the control valve is being operated and the demand flow for the actuator becomes greater than the
pump discharge from the minimum swash plate angle, the flow of the oil out to tank circuit T is cut off, and
all of pump discharge Q flows to the actuator circuit.
PLS.
PP.
202FO6065
Operation
Control valve operated

. When the control valve is operated to a bigger 1. Unload valve
stroke, LS pressure Pls is generated and acts 2. Sleeve
on the right end of spool (4). When this hap- 3. Spring
pens, the area of the opening of the control 4. Spool
valve spool is large, so the difference between
LS pressure Pls and pump discharge pressure Pp: Pump circuit (pressure)
Pp is small. Pls: LS circuit (pressure)
. For this reason, the differential pressure be- T: Tank circuit (pressure)
tween pump discharge pressure Pp and LS
pressure Pls does not reach the load of spring
(3) (3.92 MPa (40 kg/cm”)), so spool (4) is
pushed to the left by spring (3).
. As a result, pump circuit Pp and tank circuit T
are shut off, and all the pump discharge amount
Q flows to the actuator circuit.
1o-45
2) Introduction of LS pressure
+ The diagram shows the condition for arm IN.
7.
Upstream pressure of pressure

compensation valve
(for spool meter-in downstream)
SLPOO210
1. Main pump Function

2. Main spool . The upstream pressure (=spool meter-in down-
3. Pressure compensation valve stream pressure) of pressure compensation
4. Valve valve (3) is introduced and goes to shuttle valve
5. Ball valve (7) as the LS pressure. When this happens, it is
6. LS circuit connected to port B of the actuator through
7. LS shuttle valve valve (4), and LS pressure = actuator load pres-
sure. Introduction hole a inside the spool has a
small diameter, so it also acts as a throttle.
Operation
. When spool (2) is operated, the pump pressure
passes through introduction hole a, enters port
and is taken to the LS circuit. When the pump
pressure rises and reaches the load pressure
of port B, ball valve (5) opens.
1 O-46
3) LS bypass plug
Outline
1. This releases the residual pressure of LS pressure Pk.
2. This make the speed of the rise in pressure of LS pressure Pls more gentle. In addition, with this discarded
throttled flow, it creates a pressure loss in the throttled amount of the spool or shuttle valve, and increases
the stability by lowering the effective LS differential pressure.
202FO6067
Operation
. The pressurized oil for LS circuit Pls passes 1. LS bypass plug
from clearance filter a (formed by the clearance
between LS bypass plug (1) and the valve Pls: LS circuit (pressure)
body) through through orifice b and flows to the T: Tank circuit (pressure)
tank circuit.
1o-47
4) Pressure compensation valve
.6
/
SLPOO212
1. Main pump 4. Piston

2. Valve 5. Spring
3. Shuttle valve 6. LS shuttle valve
On this machine, this is employed for the bucket

Function valve (at the cylinder bottom) and service valve.
1. During independent operation and at maxi- With the integrated compensation valve, as a
mum load pressure (during compound op- basic rule, port C and chamber E are not inter-
erations, when load pressure is higher than connected, so even if a high peak pressure is
other work equipment). generated at port C, valve (7) does not hit the
. The pressure compensation valve acts as a valve chamber.(However, the system is de-
load check valve. signed so that port C and spring chamber E are
interconnected just before the bucket valve is
Operations seated.)
. If the pump pressure (LS pressure) is lower
than the load pressure at port C, shuttle valve
(3) inside pressure compensation valve piston
(4) moves to interconnect spring chamber E
and port C. From this condition, the force of
spring (5) acts to move piston (4) and valve (2)
in the direction of closing.
Reference: Intergrated pressure compensation

valve
. When high peak pressure is generated in the
actuator circuit or when peak pressure is gener-
ated repeatedly over a continuous period (such
as when using a breaker), valve (2) may hit
valva chamber seat s and generate a high
SAP00387
stress. To prevent this, an integrated pressure
compensation valve (2) and piston (4) is used.
1 O-48
- 6
From LS shuttle valve for other work equipment
.B
Upstream pressure of pressure compensation valve

m (for spool meter-in downstream)
Spool meter-in upstream press&e )c/ ’

SLPoo213
2. When receiving compensation (during com- Operation

pound operations, when load pressure is . Spring chamber E is interconnected with port D.
lower than other work equipment) Piston (4) and valve (2) are actuated by the LS
. The pressure compensation valve is closed by circuit pressure from the other work equipment
The LS pressure of port D, and the spool meter- at port F in the direction of closing (to the right).
in downstream pressure of port B becomes the In other words, the valve upstream pressure of
same as the maximum pressure of the other port B (= spool meter-in downstream pressure)
work equipment. The spool meter-in upstream is controlled by the LS pressure.
pressure of port A is the pump pressure, so
spool meter-in differential pressure (upstream
pressure (pressure of port A) - downstream
pressure (pressure of port B)) becomes the
same for all spools that are being operated. In
this way, the pump flow is divided in proportion
to the area of the meter-in opening.
1o-49
5) Shuttle valve inside pressure compensation valve
3C4 B
SLPOOZ14

2. Valve When holding pressure at port A > LS pressure
3. Shuttle valve inside pressure compensation in spring chamber B.
valve . Shuttle valve (3) is pushed to the right by the
4. Piston pressure of port A, and the circuit between
ports A and C is shut off. In this condition, the
holding pressure at port A is taken to spring
chamber B, and pushes piston (4) to the left to
prevent piston (4) and valve (2) from
seperating.
1O-50
SLPOO215
<For travel>
. No holding pressure is generated at port A in
the travel circuit, so a pressure compensation
valve without a shuttle valve is used.
SBPOO216
LS pressure
Reference: When there is no shuttle valve Holding pressure

. If there is no shuttle valve, piston (4) and valve
(2) will seperate. In this condition, if another ac- w
tuator is opened, the piston acts as an accumu- Time
lator, so there is a time lag.
1o-51
6) Surface area ratio of pressure compensation valve
Function
. The pressure compensation valve determines the compensation characteristics by carrying out fine adjust-
ment of the area ratio (A2/Al) between area A2 of piston (3) and area Al of valve (4) to match the charac-
teristics of each actuator.
202FO6076
. Area ratio (A2/Al) and compensation characteristics

When ratio is 1 .OO: spool meter-in downstream pressure Ppb = Max. load pressure B, and oil
flow is divided in proportion to area of opening of spool.
When ratio is more than 1 .OO: spool meter-in downstream pressure Ppb > Max. load pressure B, and oil
flow is divided in a proportion less than area of opening of spool.
When ratio is less than 1 .OO: spool meter-in downstream pressure Ppb < Max. load pressure B, and oil
flow is divided in a proportion more than area of opening spool.
* Spool meter-in downstream pressure Ppb acts on area Al of valve (4), and max. load pressure B(= LS
pressure Pls) acts on area A2 of piston (3).
. Area ratio of each pressure compensation valve
Valve 1 Port A I Port B I Remarks 1. Pressure compensation valve

Service 1 11.001 Il.001 2. Spring
3. Piston
Bucket DUMP 1 .oo CURL 1 .oo
4. Valve
Arm OUT 0.96 IN 1 .oo 5. Spool
Boom RAISE 0.96 LOWER 1.00
Al: Cross-sectional area of valve
Travel FORWARD 1 .OO REVERSE 1 .OO with~u~f~ut~“,‘~;lve A2: Cross-sectional area of piston
B: Actuator circuit (pressure)
Stabilizer 1 RAISE 11.OO1 LOWER Il.001
Pp: Pump circuit (pressure)
Swing LEFT 0.98 RIGHT 0.98 Throttle 00.6 Ppb: Spool meter-in upstream pressure
IO-52
7. Boom regeneration circuit
/ \
48 8 4A
SLPOO220

2. Main spool 1) Culinder head pressure < culinder bottom
3A. Pressure compensation valve pressure (free fall, etc.)
3B. Pressure compensation valve . A return flow circuit is provided from the cylin-
4A. Suction valve (with safety) der bottom to the cylinder head so that when
4B. Suction valve the boom is lowered, the return flow can be
5. Check valve used to increase the flow of oil from the pump to
6. LS shuttle valve the cylinder bottom.
7. Drain circuit
8. Regeneration circuit Operation
. When the cylinder head pressure < cylinder
bottom pressure, part from the pressurized oil
from the cylinder bottom passes through the
notch in spool (2), goes through port B, and en-
ters drain circuit (7). The rest of the oil goes
from port C, enters regeneration circuit (8),
opens check valve (5), and passes through port
C and D to flow back to the cylinder head.
1o-53
CLSS
s LPOO221
2) Cylinder head pressure > Cylinder bottom

pressure (digging operations etc.)
. Check valve (5) in regeneration circuit (8) acts
to shut off the flow from the cylinder head to the
cylinder bottom.
1o-54
8. Arm regeneration circuit
38
11 t
4B-
205FO6O60

2. Main spool 1) Cylinder head pressure > cylinder bottom
3A. Pressure compensation valve pressure
3B. Pressure compensation valve . A return flow circuit is provided from the cylin-
4A. Safety valve der head to the cylinder bottom so that when
4B. Safety valve the arm is moved in, the flow of oil to the cylin-
5. Arm counterbalance valve der becomes the pump discharge amount + the
6. Piston return flow, and this increases the cylinder
7. Spool speed.
8. Check valve
9. LS shuttle valve Operation
10. Drain circuit . When the cylinder head pressure > cylinder
11. Regeneration circuit bottom pressure, the pressurized oil from the
cylinder head passes through the notch in spool
(2), enters port C and opens check valve (8),
then passes through ports D and E to flow back
to the cylinder bottom.
1o-55
10
d i
205FO6061
2) When load is large 3) Cylinder bottom pressure > Cylinder head

. During arm IN operations, if the load increases pressure
and the cylinder bottom pressure exceeds 16.6 l When the cylinder bottom pressure > cylinder
MPa (170 kg/cm2), counterbalance valve (5) is head pressure, check valve (8) is closed by the
actuated to increase the meter-out opening at cylinder bottom pressure and prevents any oil
the cylinder head. This reduces the pressure flowing back from the cylinder bottom to the
loss between the cylinder head and the hydrau- head end.
lit tank, and ensures the digging force.
Operation
. The cylinder bottom pressure enters port F and
pushes piston (6) to the left. Spool (7) moves
fully to the left and interconnects port C of re-
generation circuit (11) and tank drain circuit
(10). As a result, the pressure loss in the drain
circuit is reduced.
1 O-56
9. Arm counterbalance valve
cylinder bonom
205FO6062
1. Piston Operation
2. Spool . During arm IN operations, if the actuating pres-
3. Spring sure at the arm cylinder bottom rises, the pres-
4. Check valve sure at port A also rises. When the force re-
5. Regeneration circuit ceived by piston (1) from the pressure at port A
6. Tank drain circuit becomes greater than the force of spring (3),
piston (1) moves to the left.
. Spool (2) is pushed by piston (1) and also
moves to the left, so ports B and C are intercon-
nected. When this happens, the pressurized oil
from the cylinder head passes through ports B
and C, and flows directly to drain circuit (6).
(The pressure loss is removed when draining.)
. When this happens, check valve (4) is closed by
the pressure at port A, so it shuts off regenera-
tion circuit (5), and prevents the oil from flowing
back from the cylinder bottom to the head end.
1o-57
10) LS select valve
Function
. When the swing + boom RAISE, or swing + travel are operated together, this valva prevents the high
pressure which is generated when driving the swing, and prevents swing LS pressure a from flowing into LS
circuit Pls.
202FO6081
Operation 1. LS select valve

Normal operation 2. Valve
. Normally, when the swing is operated alone, or 3. Spring
when it is operated together with any other 4. Piston
movement except boom RAISE or the travel,
the pilot pressure does not act on on pilot port a: Swing LS circuit (pressure)
BP. Pls: LS circuit (pressure)
. In this condition, swing LS pressure pushes Bp: PPC pilot circuit (pressure)
valve (2) open, and flows to LS circuit Pls. T: Tank circuit (pressure)
1 O-58
202FO6082
Swing + boom RAISE, or swing + travel operated

together
. When the swing + boom RAISE, or swing + 1. LS select valve
travel are operated, the pilot pressure from the 2. Valve
PPC shuttle valve flows into pilot port Bp. 3. Spring
. When pilot pressure Bp becomes stronger than 4. Piston
spring (3), piston (4) is pushed to the right in the
direction of the arrow, valve (2) closes, and a: Swing LS circuit (pressure)
swing LS pressure a does not flow into LS cir- Pls: LS circuit (pressure)
cuit Pk. Bp: PPC pilot circuit (pressure)
. The size of pilot pressure Bp is determined by T: Tank circuit (pressure)
the amount the control lever is operated.
1o-59
11) Cut-off function
Function
. This function uses the TVC valve, pump controller, and pump pressure sensor, and if pump discharge
pressure Pp exceeds the set pressure, it makes pump discharge amount Q the minimum.
ctuator
-E&O
Control valvf
LS passage
/
Pump passage
Mir
l+q--j ============b
Piston
positioning
A: Cut off
B: Cut off cancel
Operation ISwing lock switch

. If the pump pressure sensor detects that the
pump discharge pressure Pp has gone above IOn IOff (Brake off)
the set pressure, it sends this information to the (Brake on)
Power max.
pump controller.
. When the pump controller receives this signal,
it increases the signal current to TVC valve (l),
and makes the pump discharge amount (swash
plate angle) Q the minimum.
HO I B I B I B
GOI B 1 A 1 B
1. TVC valve FO B A A
2. Solenoid
BO B A A
LO B B B
Travel B B B
1 O-60
12) Variable type pressure compensation valve (for service valve
From sewice Cylinder 6 Lax pressure from other 6 h

valve
spool port work equipment SDPOlIJ1
1. Valve Function
2. Spring . It is possible to adjust the division of the oil flow
3. Sleeve to the service valve when the service valve (for
4. Poppet attachment) is operated together with the main
5. Spring control valve (boom RAISE, etc.). (Variable in
6. Screw proportion to surface area).
7. Locknut . The pump pressure leaving the service valve
8. Plastic cap spool acts on the left end of valve (I), and at the
same time passes through throttle a and enters
chamber g.
The maximum LS pressure passes through
throttle d and enters chamber e. At the same
time, the cylinder port pressure passes through
passage c and throttle f, and goes to chamber
h.
In addition, the force of spring (2) acts on valve
(l), and the force spring (5) acts on poppet (4).
The force of spring (5) can be adjusted with
screw (6).
IO-61
Operation
Simultaneous operation with work equipment

under heavy load (boom RAISE etc.)
1. The pump pressure and LS pressure are deter-
mined by the pressure of the other work equip-
ment, but the cylinder port pressure becomes
the actuating pressure of the attachment. When
the difference between the pnmp pressure and
the cylinder pressure is less than the force of
spring (5), the balance of the force acting on
valve (1) is as follows.
PxA:=PxA+LS(A2-Al)+F. SOP01 132
Al : Cross-sectional area of diameter Dl
A2: Cross-sectional area of diameter D2.
F: Force of spring.
2. If the difference between pump pressure P and

the cylinder pressure becomes greater than the
force of spring (5), poppet (4) is pushed to the
right and the passage opens, so the pump pas-
sage is connected to the cylinder port through
throttle a, chamber g, and passage b and c,
r
and the oil flows to the cylinder port. When this
happens, a differential pressure is formed be- r%l
tween the upstream and downstream sides of tP
Vroa rervice CrliaOr _
throttle a, and the pressure in chamber g goes velre SDODI Dart
down, so the force pushing valve (1) to the left is SDPOI I33
reduced. In other words, the area ratio be-
comes smaller, so valve (1) moves to the right
and increases the flow from the pump to the
cylinder.
1 O-62
4. OPERATION OF SYSTEM AS A WHOLE 1. Hydraulic tank

1) When all control valves are at neutral
Hydraulic pnmp
. Pump discharge amount Q all flows from un-
2. Main pump
load valve (6) to tank (1).
3. TVC valve
. Non of the spools (7A to 12A) is being oper-
4. LS valve
ated, so the LS pressure Pls is not generated.
At the same time, the LS pressure Pls is con- Control valve
netted to the tank circuit by LS bypass plug (5), 5. LS bypass plug
so it is the tank pressure. 6. Unload valve
. In this condition, LS differential pressure APls 7. Bucket valve
becomes the unload pressure -- tank pressure, 7A. Spool
and becomes higher than the LS set pressure 7B. Pressure compensation valve (DUMP)
of LS valve (4), so main pump (2) is set to the 7c. Pressure compensation valve (CURL)
minimum swash plate angle. 7D. LS shuttle valve
8. Arm valve
8A. Spool
8B. Pressure compensation valve (OUT)
8C. Pressure compensation valve (IN)
8D. LS shuttle valve
9. Boom valve
9A. Spool
9B. Pressure compensation valve (RAISE)
9c. Pressure compensation valve (LOWER)
9E. Check valve
IO. Travel valve
10A. Spool
1 OB. Pressure compensation valve
(FORWARD)
1 OC. Pressure compensation valve
(REVERSE)
1 OD. LS shuttle valve
11. Stabilizer valve
11A. Spool
11B. Pressure compensation valve
(EXTEND)
11c. Pressure compensation valve
(RETRACT)
11 D. LS shuttle valve
12. Swing valve
12A. Spool
12B. Pressure compensation valve (LEFT)
12C. Pressure compensation valve (RIGHT)
13. LS select valve
14. LS bypass plug
16. Cooler bypass valve
17. Lift check valve
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor
* The arm counterbalance valve, safety-suction

valve, and suction valve are not shown.
IO-63
1
f I I I
1
r KW13OP6021
1 O-64
CLSS
2) When boom RAISE is operated independ- 1. Hydraulic tank

ently
Hydraulic pump
. When boom spool (A9) is operated to the
2. Main pump.
RAISE position, pump discharge amount Q
3. TVC valve
flows to the bottom end of of boom cylinder
4. LS valve
(20), and at the same time, LS pressure Pls is
generated and unload valve (6) closes. Control valve
. LS pressure Pls becomes the boom holding 5. LS bypass plug
pressure, and the area of the opening of boom 6. Unload valve
spool (A9) is larger than the other spools (over- 7. Bucket valve
size opening), so the difference between pump 7A. Spool
discharge pressure Pp and LS pressure Pls 7B. Pressure compensation valve (DUMP)
(LS differential pressure APls) becomes 7c. Pressure compensation valve (CURL)
smaller. 7D. LS shuttle valve
. This LS differential pressure APls is lower than 8. Arm valve
the LS set pressure of LS valve (4), so main 8A. Spool
pump (2) is held at the maximum swash plate 8B. Pressure compensation valve (OUT)
angle. 8C. Pressure compensation valve (IN)
9. Boom valve
9A. Spool
9E. Check valve
IO. Travel valve
10A. Spool
(FORWARD)
(REVERSE)
11A. Spool
11 B. Pressure compensation valve
(EXTEND)
11 C. Pressure compensation valve
(RETRACT)
12. Swing valve
12A. Spool
13. LS select valve
14. LS bypass plug
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor

1 O-65
STRUCTURE CLSS
AND FUNCTION
I
c
PLS
KW13DP6022
1O-66
When swing is operated independently 1. Hydraulic tank

When swing-spoof (12A) is operated, pump dis-
Hydraulic pump
charge amount Q flows to swing motor (23)
2. Main pump
and, at the same time, LS pressure Pls is gen-
3. TVC valve
erated and unload valve (4) closes. LS pressure
4. LS valve
Pls becomes the load pressure of swing motor
(23). Control valve
In the swing circuit, the difference between LS bypass plug
pump discharge pressure Pp and LS pressure Unload valve
Pls (LS differential pressure APls) becomes Bucket valve
the same pressure as the LS set pressure of LS 7A. Spool
valve (4). 7B. Pressure compensation valve (DUMP)
As a result, the swash plate of main pump (2) is 7c. Pressure compensation valve (CURL)
kept at a position midway between the mini- 7D. LS shuttle valve
mum and maximum swash plate angle, and the Arm valve
main pump discharges the demand flow 8A. Spool
(approx. 50%) for the swing circuit. 8B. Pressure compensation valve (OUT)
When the swing is operated independently, 8C. Pressure compensation valve (IN)
pump discharge amount Q does not become 8D. LS shuttle valve
100%. 9. Boom valve
9A. Spool
9E. Check valve
IO. Travel valve
10A. Spool
(FORWARD)
(REVERSE)
11A. Spool
(EXTEND)
(RETRACT)
12. Swing valve
12A. Spool
12B. Pressure compensation valve(LEFT)
13. LS select valve
14. LS bypass plug
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor
* The arm counterbalance valve,safety-suction

1 O-67
I-
-
18
KW13OP6023
I I
1O-68
When boom and arm are operated simulta- 1. Hydraulic tank
neously
Hydraulic pump
If boom spool (A9) is operated to the RAISE
2. Main pump
position and arm spool (8A) is operated to the
3. TVC valve
OUT position, pump discharge amount Q flows
4. LS valve
to cylinders (20) and (19).
When this happens, the load pressure of boom Control valve
cylinder (20) is greater than the load pressure 5. LS bypass plug
of arm cylinder (19), where the load pressure is 6. Unload valve
lower. However, the pressure at the down- 7. Bucket valve
stream side of arm spool (8A) is compensated 7A. Spool
by pressure compensation valve (7B), which 7B. Pressure compensation valve (DUMP)
receives the load pressure (=max. LS pressure 7c. Pressure compensation valve (CURL)
Pls) of the boom. 7D. LS shuttle valve
As a result, the upstream pressure and down- 8. Arm valve
stream pressure of boom spool (9A) and arm 8A. Spool
spool (8A) become equal, so the oil flow from 8B. Pressure compensation valve (OUT)
main pump (2) is divided in proportion to the 8C. Pressure compensation valve (IN)
area of opening of each spool. 8D. LS shuttle valve
In the same way as when the boom is operated 9. Boom valve
independently, the area of the opening of boom 9A. Spool
spool (9A) is a large oversize opening, so the 9B. Pressure compensation valve (RAISE)
difference between pump discharge pressure 8C. Pressure compensation valve (LOWER)
Pp and LS pressure Pls (LS differential pres- 9D. LS shuttle valve
sure PLS) becomes smaller. 9E. Check valve
This LS differential pressure PLS is lower than IO. Travel valve
the LS pressure of LS valve (4), so main pump 10A. Spool
(2) is held at the maximum swash plate angle. 1 OB. Pressure compensation valve
(FORWARD)
(REVERSE)
11A. Spool
(EXTRACT)
(RETRACT)
12. Swing valve
12A. Spool
12C. Pressure compensation valve (RIGHT
13. LS select valve
14. LS bypass plug
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor

1O-69
1
I a
KW13OP6024
::: I
I 1 1
1O-70
When circuit is relieved at end of boom 1. Hydraulic tank

stroke
Hydraulic Pump
When boom cylinder (20) reaches the end of its
2. Main pump
stroke, main relief valve (15) opens and pump
3. TVC valve
discharge amount Q is relieved to tank (1).
4. LS valve
When pump discharge pressure Pp comes
close to the relief pressure, the pump controller Control valve
sends a signal to the solenoid of TVC valve (3) 5. LS bypass plug
to carry out the cut-off function to make pump 6. Unload valve
discharge amount Q the minimum. 7. Bucket valve
The cylinder is at the end of its stroke, so no oil 7A. Spool
flows to the upstream or downstream side of 7B. Pressure compensation valve (DUMP)
boom spool (9A). Pump discharge pressure Pp 7c. Pressure compensation valve (CURL)
and LS pressure Pls are the same pressure, 7D. LS shuttle valve
and Ls differential pressure APls becomes 0. 8. Arm valve
LS differential pressure APls is lower than the 8A. Spool
LS set pressure of LS valve (4), so LS valve (4) 8B. Pressure compensation valve (OUT)
acts to make the pump swash plate angle the 8C. Pressure compensation valve (IN)
maximum. However, because of the mecha- 8D. LS shuttle valve
nism, the operation of TVC valve (3) is given 9. Boom valve
priority over the operation of LS valve (4), so the 9A. Spool
pump is kept at the minimum swash plate angle 9B. Pressure compensation valve (RAISE)
by the cut-off function of TVC valve (3). 9c. Pressure compensation valve (LOWER)
9E. Check valve
IO. Travel valve
10A. Spool
(FORWARD)
(REVERSE)
11A. Spool
(EXTRACT)
(RETRACT)
12. Swing valve
12A. Spool
13. LS select valve
14. LS bypass plug
Actuator
18. Bucket cylinder
19. Arm cylinder
20. Boom cylinder
21. Travel motor
22. Dozer cylinder
23. Swing motor

IO-71
I I
PLS
I
KW13OP6025
,:.:
I
I
i.
I I
1 O-72
STRUCTURE AND FUNCTION SWING MOTOR
SWING MOTOR
RIGHT SWING
-------
1
a. Port G (to control valve TSW port) SPECIFICATIONS

b. Port MB (from control valve)
c. Port MA (from control valve) Type 1 F12-060-MF-CV-C-509
d. Port T (to tank)
Theoretical delivery 59.8 cc/rev
e. Port L (plugged)
Safety valve set 31.36 MPa
pressure (320 kg/cm’)
Rated speed 2250 rpm
1o-73
SUCTION-SAFETY VALVE
Function
When the swing is stopped, the outlet port cir-
cuit of the motor is closed by the control valve,
but the motor continues to be turned by the iner-
tia of the swing. As a result, the pressure at the
outlet port of the motor becomes abnormally
high and there is danger that the motor will be
damaged.
The safety valve is installed to prevent this
problem. It acts to release the abnormally high
pressure oil from the outlet port of the motor to
port G and also functions as a swing brake.
The suction valve supplies an amount of oil
equivalent to the amount of oil released by the
safety valve. It sends this oil from port G to the
inlet port of the motor to prevent any cavitation.
Operation
When starting swing
If the swing control lever is operated to swing to
the right, the pressurized oil from the pump
passes through the control valve and it supplies
to port MA.
When this happens, the pressure at port MA
rises and the starting force is generated in the
motor, so the motor starts to turn.
The oil from the outlet port of the motor flows
from port MB through the control valve and re-
turns to the tank.
When stopping swing
When the swing control lever is returned to the
neutral position, no more pressurized oil is sup-
plied from the pump to port MA.
At the same time, the oil from the outlet port of
the motor returns from the control valve to the
tank, and the circuit is closed.
The pressure at port MB rises, and rotating re-
sistance to the motor is generated, so the brake
starts to take effect.
If the pressure at port MB rises to the set pres-
sure of safety valve (l), safety valve (1) opens
and releases the pressurized oil at port MB to
port G.
No pressurized oil is supplied at port MA, but
the swing continues, so negative force is gener-
ated.
When this negative pressure to the set pres-
sure of suction valve (2), suction valve (2)
opens and oil is supplied fromport G to prevent
cavitation.
1 O-73A
1. Barrel housing
2. Valve plate
3. Cylinder barrel
4. Piston with piston rings
.lO 5. Timing gear
6. Roller bearings
7. Bearing housing
8. Shaft seal
9. Output/input shaft
10. Needle bearings

d i i 4 321
Section A-A 11. Safety valve with check valve
12. Check valve
13. Check valve spring
/ 13
12
/
Section C-C
Section B-B
IO-74
STRUCTURE AND FUNCTION CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
To tank
From steering
orbitrol valve R
From control
valve 83
From steering
orbitrol valve L
From control /
valve AZ bA
_ From brake
From suspensoin valve BI
lock solenoid
valve ass’y AI
From travel
speed solenoid
valve ass’y A2
From brake -
valve 83
n
To travel
A-A
~W13OP6026
1. Cover
3
L. Housing
3. Sealing ring
4. Lip seal
5. Rotor
1o-75
STRUCTURE AND FUNCTION FRONTTRAVEL MOTOR
FRONT TRAVEL MOTOR
d h
\
-J,
C ~\i --
b
F---l a
MA GT
Hydraulic Schematic Diagram SPECIFICATIONS
Motor inlet (A) Type: Variable displacement

i: Motor outlet (B)
Overide pressure port (X) Theoretical delivery: Min. 26 cc/rev
:: Drain port (V) Max. 80 cc/rev
Drain port (T)
F’ Pressure test port (MB) Hi-Lo switching-pressure: 2.94 MPa (30 kg/cm”)
cl. Pressure test port (MA) Rated speed: 5240 rpm (Max)
h. Pressure test port (Ml)
i. Pressure test port (G)
1 O-76
STRUCTURE AND FUNCTION REAR TRAVEL MOTOR
REAR TRAVEL MOTOR
Hydraulic Schematic Diagram
a. Motor inlet (A)

b. Motor outlet (B)
c. Drain port (T)
d. Drain port (T)
e. Overide pressure port (X)
f. Pressure test port (Ml)
g. Pressure test port (G)
SPECIFICATON
Type: variable displacement
Theoretical delivery: Min 0

Max 200 cc/rev
Rated speed: 5240 rpm Hydraulic Schematic Diagram
1o-77
STRUCTURE AND FUNCTION WORK EQUIPMENT. SWING PPC VALVE
WORK EQUIPMENT l SWING PPC VALVE
2OUFO2032
a. Port P (from PPC Pressure Reducing Valve)

b. Port T (to tank)
c. Port P2 (L.H.: Arm IN/R.H.: Boom RAISE)
d. Port P4 (L.H.: Swing LEFT/R.H.: Bucket DUMP)
e. Port Pl (L.H.: Arm OUT/R.H.: Boom LOWER)
f. Port P3 (L.H.: Swing RIGHT/R.H.: Bucket CURL)
1 O-78
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
A-A
D-D
B-B
E-E 2OUFO2033
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston 10. Body
5. Disc 11. Filter
6. Nut (for connecting lever)
1o-79
WORK EQUIPMENT l SWING PPC VALVE
OPERATION
1. At neutral
Ports A and B of the control valve and ports Pl
and P2 of the PPC valve are connected to drain
chamber D through fine control hole “f” in spool
(I). (Fig 1)
2. During fine control (neutral fine control)

When piston (4) starts to be pushed by disc (5),
retainer (9) is pushed; spool (1) is also pushed
by metering spring (2) and moves down.
When this happens, fine control hole “f” is shut
off from drain chamber D, and at almost the
same time it is connected to pump pressure
chamber Pp, so pilot pressure oil from the con-
trol pump passes through fine control hole “f”
and goes from port Pl to port A.
Whe the pressure at port Pl becomes higher,
spool (1) is pushed back and fine control hole
“f” is shut off from pump pressure chamber Pp.
At almost the same time, it is connected to drain
chamber D to release the pressure at port Pl.
When this happens, spool (1) moves up or
down so that the force of metering spring (2) is
balanced with the pressure at port Pl The rela-
tionship in the position of spool (1) and body
(10) (fine control hole “f” is at a point midway
between drain hole D and pump pressure
chamber Pp) does not change until retainer (9)
contacts spool (1).
Therefore, metering spring (2) is compressed
proportionally to the amount on movement of
the control lever, so the pressure at port Pl also
rises in proportion to the travel of the control le-
ver.
In this way, the control valve spool moves to a
position where the pressure in chamber A (the
same as the pressure at port Pl) and the force
of the control valve spool return spring are bal-
anced. (Fig. 2)
PPC
l-l
Pressure
Reducing
Valve
1 O-80
STRUCTURE AND FUNCTION WORK EQUIPMENT l SWING PPC VALVE
3. During fine control

(When control lever is returned)
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port Pl.
When this happens, fine control hole “f” is con-
nected to drain chamber D and the pressure oil
at port Pl is released.
If the pressure at port Pl drops too far, spool (1)
is pushed down by metering spring (2) and fine
control hole “f” is shut off from drain chamber D.
At almost the same time, it is connected to
pump pressure chamber Pp, and the pump
pressure is supplied until the pressure at port
Pl recovers to a pressure that corresponds to
the lever position. When the spool of the control
valve returns, oil in drain chamber D flows in
from fine control hole “f” in the valve on the side PPC
that is not working. Pressure
Reducing
The oil passes through port P2 and enters
Valve
chamber B to fill the chamber with oil. (Fig. 3)
I
4. At full stroke
When disc (5) pushes down piston (4), and re-
tainer (9) pushes down spool (l), fine control
hole “f” is shut off from drain chamber D, and is
connected with pump pressure chamber Pp.
Therefore, the pilot pressure oil from the control
pump passes through fine control hole “f” and
flows to chamber A from port Pl, and pushes
the control valve spool. 9
The oil returning from chamber B passes from
port P2 through fine control hole “f” and flows to f. 77 ii
drain chamber D. (Fig. 4)
IPPC I I
1Reducingl I
IO-81
STRUCTURE AND FUNCTION TRAVEL PPC PEDAL
TRAVEL PPC PEDAL
0 @> 0 0
0 B
SPECIFICATIONS
Kw13OP6031
Inlet pressure: 50 bar (max).
Back pressure at port T: 3 bar
Operating curve: (35).
1 O-82
SERVICE PPC VALVE
SERVICE PPC VALVE
1
?\
\
2
4
-
\
\
1. Pin
2. Cam
3. Ball
4. Piston
5. Cover
6. Sleeve
7. Centering spring
8. Metering spring
9. Spool
10. Body
a. Port T (to tank)

b. Port P (from PPC pressure reducing valve)
c. Port A (to service valve Pl)
d. Port I3 (to service valve P2)
1 O-83
STRUCTURE AND FUNCTION SERVICE PPC VALVE
OPERATION
At neutral
. The pressurized oil from the control pump en-
ters from port P and is blocked by spool (9).
. Port A and B of the control valve and port “a”
and “b” of the PPC valve are connected to drain
port T through fine control hole X of spool (9).
When operated
. When cam (2) is moved, metering spring (8) is
pushed by ball (3), piston (4) and sleeve (6),
and spool (9) is also pushed down by this.
. As a result, fine control hole X is shut off from
the drain circuit. At almost the same time, fine
control portion Y is connected with port “a”, and
the pressurized oil from port P flows from port
“a” to port A of the control valve.
1 O-84
STRUCTURE AND FUNCTION SERVICE PPC VALVE
When the pressure at port “a” becomes higher,

spool (9) is pushed back by the force acting on
the end of the spool. When fine control portion Y
closes, fine control hole X is connected to the
drain circuit at almost the same time.
As a result, spool (9) moves up and down to
balance the force at port “a”and the force at me-
tering spring (8).
Therefore, metering spring (8) is compressed in
proportion to the amount the control lever is
moved. The spring force becomes larger,so the
pressure at port “a” also increases in proportion
to the amount the control lever is operated.
In this way, the control valve spool moves to a
position where the pressure of port A (the same
as the pressure at port “a”) is balanced with the
force of the return spring of the control valve
spool.
1 O-85
STRUCTURE AND FUNCTION SAFETY LOCKVALVE PPC ACCUMULATOR
SAFETY LOCK VALVE

Y--l. 1. Lever
2. Body
3. Seat
4. Ball
5. End cap
2 $
F205CXI I8
PPC ACCUMULATOR
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
SPECIFICATIONS
Gas capacity: 400 cc
1O-86
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE
PPC SHUTTLE VALVE
Pi2 P22
P42
P62
A2
A2
P62
P62
AP
PO2
P72 A4
P62
PA2
Pa2
Kw13OP6032
1. PPC shuttle valve

2. Clam shell controlflravel EPC manifold block
Function
This sends the PPC valve output pressure to the
control valve. It is provided with a mount port for the
pressure switch for detecting the pilot pressure.
1 O-87
STRUCTURE AND FUNCTION PPC SHUTTLE VALVE
a. Port Pll (to control valve [swing])

b. Port P21 (to control valve [swing])
c. Port P31 (to control valve [bucket])
d. Port P41 (to control valve [bucket])
e. Port P51 (to control valve [boom])
f. Port P61 (to control valve [arm])
g. Port PLS (to LS select valve)
h. Port P71 (to control valve [arm])
i. Port P81 (to control valve [boom])
]. Port PA1 (to control valve [stabiliser])
k. Port PBl (to control valve [stabiliser])
I. Port PC1 (to control valve [2nd boom])
m. Port P91 (to control valve [2nd boom])
n. Port P12 (from swing PPC valve)
0. Port P22 (from swing PPC valve)
p. Port P32 (from bucket PPC valve)
q. Port P42 (from bucket PPC valve)
r. Port P52 (from boom/stabiliser solenoid valve)
s. Port P62 (from arm PPC valve)
t. Port P72 (from arm PPC valve)
u. Port P82 (from boom/stabiliser solenoid valve)
V. Port PA2 (from boom/stabiliser solenoid valve)
w. Port PB2 (from boom/stabiliser solenoid valve)
x. Port PC2 (from 2 piece boom PPC valve)
Y. Port P92 (from 2 piece boom PPC valve)
aa. Port Al (mount port for swing oil pressure switch)

ba. Port A8 (mount port for bucket DUMP oil pressure switch)
bb. Port A2 (mount port for bucket CURL oil pressure switch)
ca. Port A4 (mount port for arm OUT oil pressure switch)
cb. Port A3 (mount port for arm IN oil pressure switch)
da. Port A5 (mount port for boom RAISE oil pressure switch)
db. Port A7 (mount port for boom LOWER oil pressure switch)
ee. Port A6 (mount port for 2 piece boom/stabiliser switch)
1O-88
PPC SHUTTLE VALVE
1
,2
2
F-F A-A
G-G B-B
N-N
L- -4
K-K D-D
(ZPLACES) M-M
L-L E-E
PPC shuttle valve

1. Ball
2. Plug
3. Blind plug
4. Valve body
1O-89
STRUCTURE AND FUNCTION EPC, SOLENOID VALVE
EPC, SOLENOID VALVE
i h g f e
a. Port A5 (to pump LS valve) 1. LS control EPC valve

b. Port T2 (to main pump) 2. 2 stage relief solenoid valve
c. Port Tl (to main valve) 3. Swing brake solenoid valve
d. Port TO (plugged) 4. Travel speed solenoid valve
e. Port Al (to main relief valve) 5. Suspension lock solenoid valve
f. Port A2 (to swing motor) 6. Valve block
g. Port A3 (to travel motor)
h. Port A4 (to suspension lock cylinder)
i. Port Pl (to PPC valve)
j. Port PO (from PPC pressure reducing valve)
1o-91
STRUCTURE AND FUNCTION EPC. SOLENOID VALVE
LS CONTROL EPC VALVE
A-A
202FO6124
a. Port C (to LS valve) 1. Body

b. Port T (to tank) 2. Spool
c. Port P (from PPC pressure reducing valve) 3. Spring
4. Push pin
5. Coil
6. Plunger
7. Connector
1o-92
Function
. 2.94_
The EPC valve consists of the proportional so- (30)
lenoid portion and the hydraulic valve portion.
. When it receivers signal current i from the pump Z 2.45_
controller, it generates EPC output pressure P E (251
eIYJ
in proportion to the size of the signal, and out- Y
puts it to the control valve. m X96_
2 (20)
a
E 1.47_
i (15)
h
2 0.98
,a (101
5
0.49_
(5)
I I
I I I 1 I 1 I I
0 200 400 600 800 1000
Current i (mA)
202FO6113
Operation
1. When signal current is 0 (coil deactivated)
. There is no signal current flowing from the con-
troller to coil (5), coil (5) is deactivated.
. For this reason, spool (2) is pushed to the right
in the direction of the arrow by spring (3).
. As a result, port P closes and the pressurized
oil from the control pump does not flow to the
LS valve.
At the same time, the pressurized oil from the
LS valve passes from port C through port T and
is drained to the tank.
1o-93
2. When signal current is very small (coil ex-
c73
cited) LSvalve
. When a very small signal current flows to coil
(5), coil (5) is excited, and a propulsion force is
generated, which pushes plunger (6) to the left
in the direction of the arrow.
. Push pin (4) pushes spool (2) to the left in the
direction of the arrow and pressurized oil flows
from port P to port C.
. When the pressure at port C rises and the load
of spring (3) + the force acting on surface a of
spool (2) becomes greater than the proportion
force of plunger (6), spool (2) is pushed to the
right in the direction of the arrow. The circuit
between port P and port C is shut off, and at the
same time, port C and port T are connected.
. As a result, spool (2) is moved tot the left or
right until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pressure
of port C.
. Therefore, the circuit pressure between the
EPC valve and the LS valve is controlled in pro-
portion to the size of the signal current.
3. When signal current is maximum (coil ex-

cited)
. When the signal current flows to coil (5), coil (5)
is excited.
. When this happens, the signal current is at its
maximum, so the propulsion force of plunger
. (6) is also at its maximum.
For this reason, spool (1) is pushed to the left in
the direction of the arrow by push pin (4).
. As a result, the maximum flow of pressurized oil
from port P flows at its maximum to port C, and
the circuit pressure between EPC valve and LS
valve becomes the maximum.
At the same time, port T closes and stops the oil
from flowing to the tank.
1o-94
TRAVEL SPEED GOVERNOR EPC VALVE
A-A
202FO6124
a. Port C (to travel pedal PPC valve) 1. Body

b. Port T (to tank) 2. Spool
c. Port P (from PPC pressure recuding valve) 3. Spring
4. Push pin
5. Coil
6. Plunger
7. Connector
1o-95
Function
2.94_
. The EPC valve consists of the proportional so- (30)
lenoid portion and the hydraulic valve portion.
. When it receivers signal current i from the
pump controller, it generates EPC output pres- $ :;“:-
sure P in proportion to the size of the signal, g
m 1.96_
and outputs it to the control valve. 2 (20)
a
!J 1.47
$ (151
h
5 0.98
,a (10)
S
I , , ; , , , , , , ,
0 200 400 600 800 1000
Current i (mA)
202FO6113
Operation
1. When signal current is 0 (coil deactivated)
. There is no signal current flowing from the con-
troller to coil (5), coil (5) is deactivated.
in the direction of the arrow by spring (3).
. As a result, port P closes and the pressurized
oil from the control pump does not flow to the
travel pedal PPC valve.
travel pedal PPC valve passes from port C
through port T and is drained to the tank.
PPC Pressure
Reducing Valve
1O-96
When signal current is very small (coil ex-

cited)
When a very small signal current flows to coil
(5), coil (5) is excited, and a propulsion force is
generated, which pushes plunger (6) to the left
in the direction of the arrow.
Push pin (4) pushes spool (2) to the left in the
direction of the arrow and pressurized oil flows
from port P to port C.
When the pressure at port C rises and the load
of spring (3) + the force acting on surface a of
spool (2) becomes greater than the proportion
force of plunger (6), spool (2) is pushed to the
right in the direction of the arrow. The circuit be-
tween port P and port C is shut off, and at the
same time, port C and port T are connected.
As a result, spool (2) is moved tot the left or
right until the propulsion force of plunger (6) is
balanced with the load of spring (3) + pressure
of port C.
Therefore, the circuit pressure between the
EPC valve and the travel pedal PPC valve is
controlled in proportion to the size of the signal
current.
3. When signal current is maximum (coil ex-

cited)
When the signal current flows to coil (5), coil (5)
is excited.
When this happens, the signal current is at its
maximum, so the propulsion force of plunger
(6) is also at its maximum.
For this reason, spool (1) is pushed to the left in
the direction of the arrow by push pin (4).
As a result, the maximum flow of pressurized oil
from port P flows at its maximum to port C, and
the circuit pressure between EPC valve and
travel pedal PPC valve becomes the maximum.
At the same time, port T closes and stops the oil
from flowing to the tank.
1o-97
TRAVE SPEED, SWING BRAKE, 2-STAGE RELIEF SUSPENSION LOCK

SOLENOID VALVE
Nut
Plunger
Coil
Connector
1 II 5. Push pin
6. Spring
7. Spool
8. Block
202FO6131
Operation
When solenoid is deactiviated f4
. The signal current does not flow from the con-
troller, so coil (3) is deactivated.
. For this reason, spool (7) is pushed to the left in
the direction of the arrow by spring (6).
. As a result, port A closes the pressurized oil
from the control pump does not flow to the ac-
tuator.
actuator flows from port B to port C, and is then
PPC Pressure
drained to the tank.
When solenoid is excited

. When the signal current flowsfromthe controller
to coil (3), coil (3) is excited and a propulsion
force is generated in plunger (2) to the right in
the direction of the arrow.
in the direction of the arrow by push pin (5).
. As a result, the pressurized oil from the control
pump flows from port A to port B, and then
flows to the actuator.
At the same time, port C is closed, and this
stops the oil from flowing to the tank.
1O-98
STRUCTURE AND FUNCTION TRAVEL/BOOM/STABILISER SOLENOID VALVE
TRAVEL, BOOM, STABILISER SOLENOID VALVE ASSEMBLY

a bed ef g
k I In
a. Port PI (from PPC Pressure reducing valve) 1. Valve block

b. Port A3 (to main control valve) 2. Travel forward/reverse solenoid valve
c. Port B3 (to main control valve) 3. Boom/stabiliser lower solenoid valve
d. Port A2 (to shuttle valve) 4. Boom/stabiliser raise solenoid valve
e. Port B2 (to shuttle valve)
f. Port Al (to shuttle valve)
g. Port A2 (to shuttle valve)
h. Port C3 (from travel PPC valve)
i. Port P3 (to travel PPC valve)
j. Port Tl (to tank)
k. Port P2 (from travel EPC solenoid valve)
I. Port C2 (from wrist control PPC valve)
m. Port Cl (from wrist control PPC valve)
1O-99A
STRUCTURE AND FUNCTION BOOM SAFETY VALVE
BOOM SAFETY VALVE
High pressure from

1 2 control valve (v port)
To tank (T port)
Overload caution
signal I I
To cylinder port
0 port)
IO-106A
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
OPERATION
BOOM RAISE
. During boom raising the pilot signal from wrist V port
control operates control valve spool to direct
high pressure oil to port V of hose burst valve.
. This pressure lifts check valve (4) from seat &
high pressure oil flows in the bottom of the cyl-
inder raising the room.
Cylinder
BOOM LOWER
. During boom lowering the pilot signal reverses
T port
the flow through the control valve spool. High
pressure oil flows to the head side of the cylin- /
der. Oil in the bottom side of the cylinder flows
2e To tank
through the port Cy of the valve but cannot flow
past the check valve. The pilot signal also
opens the spool (2) of the hose burst valve and
allows oil to flow back to tank.
1Reducing Valve1
IO-106B
STRUCTURE AND FUNCTION BOOM HOLDING VALVE
When hose burst occurs v port

(Operation to lower safety)
. The sudden loss of pressure at port V will
\
cause check valve (4) to re-seat and so
the valve is locked.
. The boom can be lowerd in a controlled
way by operating the wirst control in the
normal way.
IO-106C
STRUCTURE AND FUNCTION HYDRAULIC CYLINDERS (Boom & Arm)
HYDRAULIC CYLINDERS (Boom & Arm)
BOOM LIFT CYLINDER

1 2 3 4 5 6 7 9 y !l
1. Rod side bushing 6. Wear ring 11. Piston

2. Piston rod 7. Cylinder 12. Set screws
3. Cylinder head 8. Casting ring 13. Bottom side bushing
4. Rod packing 9. Wear ring
5. Buffer ring 10. Piston ring
ARM CYLINDER
7 e 9 IO 12 13 14 I5
1. Rod side bushing 7. Cylinder 13. Set screw

2. Piston rod 8. Head side cushion plunger 14. Bottom side cushion plunger
6. Wear ring 12. Piston
BUCKET CYLINDER
P
f

2. Piston rod 7. Cylinder 12. Set screw
5. Buffer ring IO. Piston ring
IO-107
STRUCTURE AND FUNCTION HYDRAULIC CYLINDERS
BOOM ADJUST CYLINDER
FK203P5021

2. Piston rod 7. Cylinder 12. Set screw
Specifications
Unit: mm
Cylinder I Boom lift I Arm I Bucket 1 Boom adjust
Inside diameter of cylinder I 120 I 120 I 110 I 160
Outside diameter of cylinder I 85 I 85 I 75 I 100

Stroke 1352 I 1013 I
Max. stroke I 2522 I 3285 I 2560 I 1962
Min. stroke I 1527 I 1933 I 1547 I 1275
1 O-l 08
STRUCTURE AND FUNCTION OUTRIGGER CYLINDER
OUTRIGGER CYLINDER
1. Cylinder 11. O-ring 21. Backup ring

2. Piston rod with bearing eye 12. Backup ring 22. Relief valve spring
3. Piston 13. O-ring 23. Plut
4. Cylinder head 14. Piston ring 24. Nut
5. Check valve 15. O-ring 25. Grub screw
6. Valve seat 16. Backup ring 26. Bush
7. Valve cone 17. Piston guide ring 27. Circlip
8. Wiper (Dust seal) 18. O-ring 28. Grease nipple
9. Seal 19. Backup ring
10. Rod guide ring 20. O-ring
Cylinder head (4) guides the piston rod (2) which is Important
sealed by seal (9). Seal (9) is protected against dirt Depressurizing the cylinder
by wiper (8). The check valve built into the cylinder prevents any
cylinder movement due to oil leakage within the con-
When oil flows through port I tot he piston side of the trol block or sudden loss of hydraulic pressure due
cylinder the piston rod (2) extends out of the cylinder to a hose burst.
(1). The built in check valve also holds hydraulic pres-
sure within the cylinder when the hydraulic hoses
The piston is guided in the cylinder (1) by the piston are removed from the cylinder.
guide ring (7). It is sealed by the piston ring (14).The
cylinder head is sealed against the cylinder by O- a Depressurize the cylinder before opening
ring (13).
To depressurize the cylinder, loosen the plug (23)
When oil fows through port II to the rod side of the carefully using an Allen key and wait until the pres-
cylinder the piston rod retracts. sure has been released. To be absolutely sure the
plug can be completely removed.
IO-109
STRUCTURE AND FUNCTION DOZER BLADE CYLINDER
DOZER BLADE CYLINDER
25-l_
tl--
1
I
I-
+--; i
‘7 ,8
1 27 i- I I
29 30
1. Cylinder 11. Seal 21. Backup ring

2. Piston rod with bearing eye 12. Rod guide ring 22. O-ring
3. Piston 13. Seal 23. Backup ring
4. Cylinder head 14. O-ring 24. O-ring
5. Valve seal 15. Piston ring 25. O-ring
6. Check valve 16. O-ring 26. Grub screw
7. Valve cone 17. Backup ring 27. Nut
8. Plug 18. Piston guide ring 28. Relief valve spring
9. Backup ring 19. O-ring 29. Nipple
10. Wiper (dust seal) 20. O-ring 30. Bush
Cylinder head (4) guides the piston rod (2) which is Important
sealed by seal (11). Seal (11) is protected against Depressurizing the cylinder
dirt by wiper (10). The check valve built into the cylinder prevents any
cylinder movement due to oil leakage within the con-
When oil flows through port I tot he piston side of the trol block or sudden loss of hydraulic pressure due
cylinder the piston rod (2) extends out of the cylinder to a hose burst.
(1). The built in check valve also holds hydraulic pres-
sure within the cylinder when the hydraulic hoses
The piston is guided in the cylinder (1) by the piston are removed from the cylinder.
guide ring (18). It is sealed by the piston ring (16).
The cylinder head is sealed against the cylinder by A Depressurize the cylinder before opening
O-ring (20).
To depressurize the cylinder, loosen the plug (8)
When oil fows through port II to the rod side of the carefully using an Allen key and wait until the pres-
cylinder the piston rod retracts. sure has been released. To be absolutely sure the
plug can be completely removed.
10-110
WORK EQUIPMENT -TWO PIECE BOOM
WORK EQUIPMENT - ONE PIECE BOOM
1. Arm
2. Bucket cylinder
3. Arm cylinder
4. Boom
5. Boom cylinder
6. Bucket
7. Boom lift cylinder
a. First boom
9. Second boom
10. Boom adjust cylinder
10-111
0
“A*AK I “L” TYPE.
DOBO56-XXXXX
m
7*,?*1(1
"X" i"'"E.
D00055-XXXXX
$iiGg]) mm TPlZPlKI ‘SW”

00R055~XXXXX
ClPE.
c%.u @Z!JKES DOR027-OXXXX

9 .'
CZuKES D08027-'XXXX
PYIIO-6 CONNECT AK
LENOIO
cam cmlRMa PLV cmI?aL‘II
1 O-l 12A
J \
\ * /
RH WRIST CONTROL LH WRIST CONTROL
LEVER SWITCHES LEVER SWITCHES 10-I 12B
iiG
$
___
j;
--
--
--
--
--
li’
f
~1
10-I 12c
STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
202Foe148
1. Starting motor FUNCTION

2. Fuel control dial
3. Pump and engine throttle controller . The engine can be started and stopped simply
4. Governor motor
by using the starting switch.
5. Loose spring . A dial type engine control is used to control the
6. Battery relay
engine speed. The engine throttle controller re-
7. Battery
ceives the control signal from the fuel control
8. Fuel injection pump
dial, sends a drive signal to the governor motor
and controls the angle of the governor lever in
the fuel injection pump.
. At the same time, the engine throttle controller
also receives signals from other controllers to
control the engine speed.
IO-113
1. OPERATION OF SYSTEM
Stat*ting engine
. When the starting switch is turned to the START
position, the starting signal flows to the starting
motor, and the starting motor turns to start the
engine.
When this happens, the engine throttle control-
ler checks the signal from the fuel control dial
and sets the engine speed to the speed set by
the fuel control dial.
Engine speed control

. The fuel control dial sends a signal to the en-
gine throttle controller according to the position
of the dial. The engine throttle controller calcu-
lates the angle of the governor motor according
to this signal, and sends a signal to rave the
governor motor so that it is at that angle.
When this happens, the operating angle of the
governor motor is detected by the
potentiometer, and feedback is sent to the en-
gine throttle controller, so that it can observe
the operation of the governor motor.
Stopping engine
. When the starting switch is placed at the OFF
position, the shut off valve is closed so the sup-
ply of fuel to the engine is shut off and the en-
gine stops.
IO-114
2. COMPONENTS OF SYSTEM
1. FUEL CONTROL DIAL
HIGH 1. Knob
2. Dial
3. Spring
4. Ball
5. Potentiometer
Front of-machine
6. Connector
A-A
3a3
z,‘, w
B
Composition
u
:
of circuit
205FO5 I I3
FUNCTION (%I *,
. 100
The fuel control dial is installed at the bottom of
the monitor panel. A potentiometer is installed
2
under the knob, and when the knob is turned, it
rotates the potentiometer shaft. ?z
b
When the shaft rotates, the resistance of the ;;i
variable resistor inside the potentiometer $
Z
changes, and the desired throttle signal is sent
2
to the engine throttle controller.
The shaded area in the graph on the right is the 0 0.25 1 4 4.75 5 Voltage
abnormality detection area and the engine Characteristics of throttle VOkage

speed is set at low idling. 205FO51 14
IO-115
2. GOVERNOR MOTOR
1. Potentiometer
2. Cover
3. Shaft
4. Dust seal
5. Bearing
6. Motor
7. Gear
8. Connector
-.
L
Composition of circuit
I I
202FO6149
FUNCTION OPERATION
. The motor is rotated and the governor lever of Motor stationary
the fuel injection pump is controlled by the drive . Both A phase and B phase of the motor a con-
signal from the engine throttle controller. tinuous, and a holding torque is generated in
. A stepping motor is used for the motor which the motor.
provides the motive power. Motor rotating
. In addition, a potentiometer for giving feedback . A pulse current is applied to the A phase and B
is installed to allow observation of the operation phase from the engine throttle controller to geve
of the motor. synchronous rotation with the pulse.
The rotation of the motor is transmitted to the
potentiometer through a gear.
IO-116
STRUCTURE AND FUNCTION ENGINE CONTROL
Governor, pump controller
CN3 CN5
CNI CN2
IO-117
STRUCTURE AND FUNCTION ENGINE CONTROL
Input and output signals
CN-1 CN-3
‘in. Input/ ‘in. Input/
Name of signal Name of signal
I
VO. output 10. I 0uttJut I
1 Battery relay drive output output
2 NC
3 Swing holding brake

solenoid
output
3 S-NET (-)
I Input/
output I
4 INC I I 4 IGND I Input I
5 INC I I 5 I Swing pressure switch I InputI
6 IGND I InputI 6 Service valve pressure
switch I
Input
I
7 I Power source (+24V) I InputI 7 Engine oil pressure sensor
Input
8 INC H I I
9 I Travel selector solenoid I outputI 8 I Radiator water level sensor I Input I
I 0 I 2-stage relief solenoid I outputI 9 INC I I

11 INC I I IO INC I I
12 IGND
I
II Input I
13 Power source (+24V) Input
CN-2 13 I Travel pressure switch I InputI

‘in.
Name of signal
Input/ 14 I Park brake I InputI
VO. I output I
,5 Engine oil pressure
, Solenoid power source Input
Input sensor L I I
(+24V) II
2 IGovernor motor phase A (+)I Output I
16 I Engine oil level sensor I InputI
17 I Air cleaner clogging sensor I Input I
3 IGovernor motor phase A (-) I Output I
4 IGovernor motor phase B (+)I Output I
CN-17
5 IGovernor motor phase B (-) I Output I
I I
7 1LS-EPC solenoid (+) I output I
8 ITVC solenoid 1 (+) I output I
9 ITravel EPC solenoid (+) I output I I I2 Boom RAISE pressure
switch I
Input
I
I I I 3 IArm IN pressure switch I Input I

I InputI
II IPGND
I I4 S-NET(+)
I Input,
output I
I
, 2 Solenoid power source
(+24V) I
Input
I
I 5 IModel selection I InputI
13 INC I I I 6 IModel selection 3 I InputI
14 NC I 7 IModel selection 5 I InputI
15 NC I 8 ISwing prolix switch I InputI
16 NC I 9 IOverload sensor I InputI
17 LS-EPC solenoid (-)
18 TVC solenoid 1 (-)
output
output
I I
,.
I ii
Boom LOWER pressure
switch
IArm OUT pressure switch
I
Input
I
I Input I
19 Travel EPC solenoid (-) output
20 NC
I I
12 S-NET(+)
I Input,
output I
21 PGND Input I 13 IModel selection 2 I InputI
I 14 IModel selection 4 I InputI
I 15 ISpeed select I InputI
I 16 ISwing lock switch I InputI
IO-118
STRUCTURE AND FUNCTION ELECTRONIC CONTROL SYSTEM
ELECTRONIC CONTROL SYSTEM

CONTROL FUNCTION
Pump & Engine Mutual control function

I ,
I
I 2
I I I
Pump and valve control function
I 3
I I I
Power maximizing function
I 3
Electronic control system Auto deceleration function
Engine automatic warming-up, overheat

prevention function
I I
I
I 6
I I I
Swing control function
Travel control function
I 8
I I I
Components of system
* For details of the self-diagnostic function, see TROUBLESHOOTING
IO-119
1) Pump & Engine Mutual control system
Work equipment levers
Engine Knob switch
Travel pedal
Y&
Hydraulic
switch
Fuel control 1
dial s s-
Hi 5 .s
(Travel pedal signal)
1 Governor, pump controller A
(Network signal)
FUNCTION
There are five modes available for selection l The pump controller detects the actual engine
with the working mode switch on the monitor speed and the speed set by the engine gover-
panel. These modes are the heavy-duty opera- nor through the fuel control dial matches the
tion (H/O) mode, general operation (G/O) pump absorption torque set for each mode, and
mode, lifting operation (L/O) mode, and the carries out control so that the pump absorbs all
breaker operation (B/O) mode. It is possible to of the torque at each output point of the engine.
select the most suitable engine torque and
pump absorption torque to match the nature of
the work
Engine torque curve . Engine horsepower curve . Pump output curve
H/O (Travel)
UO B/O
P
I I . ,
HI0 (Travel) v) t
z
0
E
a
b
;
fj
t
I I Ill 2
Engine speed N Engine speed N Pump discharge amount 0.
IO-120
1. Control method in each mode Heavy-duty travel operation (H/O) travel mode
. Matching point in heavy-duty operation mode: Rated output point
. When the load on the pump rises and the pressure rises, the engine speed goes down.
When this happens, the pump dischrge amount is reduced, and the engine speed is controlled so that it
becomes the rated speed. Just the cut-off at relief is cancelled and the oil flow at relief is increased.
. If the reverse happens and the pressure goes down, the system is controlled so that the pump discharge
amount is increased until the engine speed reaches the rated speed.
by repeating this control, the engine can always be used at near the rated output point
Heavy-duty travel operation (H/O) travel 85 kW 116 PS 2150 rpm
Heavy Duty working (H/O work) mode
iU”l/(’
Engine speed N Engme speed N ump discharge amount (1
202FO6157 2cmc$158 202Fo6154
. Matching point in Heavyt Duty working 90% partial output point.

. When the load on the pump rises and the pressure rises, the engine speed goes down. When this happens,
mutual control of the engine and pump is used to control the system so that the pump absorption torque
follows the equal horsepower curve of the engine,1 and the engine speed is lowered while keeping the
torque constant.
. In this way, the engine is used in a range which provides good fuel efficiency.
I Heavy Duty Working operation (HO work) 1 76 kW 103 PS 2100 rpm I
General operaton (G/O), finishing operation

(F/O) mode
Engine spsed N Engine sped N Pump discharge amount Q

.
. Matching point in general operation and finishing operation modes: 75 % partial output point.
. When the load on the pump rises and the pressure rises, the engine speed goes down. When this happens,
mutual control of the engine and pump is used to control the system so that the pump absorption torque
follows the equal horsepower curve of the engine,1 and the engine speed is lowered while keeping the
torque constant.
. In this way, the engine is used in a range which provides good fuel efficiency.
General operation (G/O), 60 kW (82 ps)

Finishing operation (F/O) 1,910 rpm
IO-121
Lifting operation (L/O) mode

Matching point in iifting operation mode: 60 %
Lifting operation (L/O) 53 kW 71 PS 1,780 rpm
partial output point
When the lifting operation mode is selected, the
engine speed is automatically lowered to the
partial postion.
The cut-off function is cancelled and also the
relief pressure is increased.
In this condition, control is carried out in the
same way as for the general operation and fin-
ishing operation modes to match the load on
the pump.
In this way, the fuel consumption is reduced and
the fine control ability is improved.
I-
--w
2
o-
?
\
5 \
I
.-e \
F
w \
I
\
Engine speed N Pump discharge amount 0
Engine speed N
202FO6163 202FO6164 202FO6165
Breaker operation (B/O) mode Breaker operation (B/O) 160kW (82 PS) 1,910 rpm
Matching point in lifting operation mode: 70 %
partial output point
The pump absorption torque in the breaker op-
eration mode is the same as for the general op-
eration and finishing operation modes, and is
controlled to become an even lower speed.
As a result, the pump absorption torque needed
to ensure the breaker drive is ensured, and
theengine is used in a range that provides a
much better fuel comsumption ration than for
the general operation mode or finishing mode.
Engine speed N Engine speed N Pump discharge amount Q
202FO6166 202FO6166
202FO6167
IO-122
Power max. mode
, Pump discharge amount Q

Engine speed N Engine speed N SAP00344
SAP00342 SAP00343
. Matching point in power max. mode:

Rated output point
. When the pump load increases, the engine
1x1 Power max

PW170ES-6k
76 kW (103 PS) 2100 rpm

speed drops.
When this happens, the pump discharge is re-
duced to prevent the engine speed from going
down and to ensure that the engine is used at
near the rated output point.
The cut-off at relief is cancelled and the oil flow
at relief is increased. And also the relief pres-
sure is increased.
IO-124
2. Pump control function when travelling

. If the travel is operated in any working mode
other than the heavy-duty operation (H/O)
mode, the working mode and engine speed are
kept as they are, and the pump absorption
torque is increased to the maximum horse-
power at that speed.
I I I I
Engine speed N
202FO6169
Pump discharge amount Q
202FO6170
3. control function TVC prolix switch is ON

. Even if any abnormality should occur in the
controller or sensor, the TVC prolix switch can
be turned ON to provide an absorption torque
more or less equivalent to the general operation
(G/O) mode, thereby allowing the machine to
maintain its functions.
. In this case, it is designed to allow a constant
current to flow from the battery to the TVC
valve, so oil pressure sensing is carried out only
by the TVC valve.
202FO6171
Pump discharge amount 0
202FO6172
IO-125
2) Pump and valve control function
r----1
j ’
$I
31
JJ
>I
Control Valve ?j j
r------
I ‘1 !=II
‘5
r Hi
!-stage relief I_______________,L____________--A
Engine
Electric
Fuel injection governor
Fuel control dial

J Speed
sensor
Hi -- ---I
I
LS
i___ control
EPC
valve
TVC valve A
FUNCTION
. The following functions are available to provide

the optimum matching under various working
conditions: a cut-off function which reduces the
relief loss; a function which cancels the cut-off
function and prevents the speed from dropping;
a 2-stage relief function which increases the
digging power; and a fine control mode function
which improves the ease of fine control.
IO-126
1. LS control function EPC pressure Psig at

. 2.94MPa (30 kg/cmz)
The switching point (LS set differential
pressure) for the pump discharge amount
inside the LS valve is changed by changing
the output pressure from the LS control
EPC valve to the LS valve according to the
engine speed and operating condition of
the actuator.
. Because of this, the timing for starting the
discharge amount from the pump can be LS set differential pressure
optimized, to give excellent ease of 202FO6174
compount operation and fine control
* For details of the operation, see HYDRAU-
LIC PUMP
2. Cut-off function
. If the load becomes larger during opera-
tion, and the pump discharge pressure
rises to close to the relief pressure, the
pump pressure sensor detects this and the
controller sends a signal to the TVC valve
to reduce the relief loss.
* For detalis of the operation, see CLSS Pump discharge amount Q
3. Cut-off cancel function 202FO6175
. the cut-off cancel function acts to stop the
operation of the cut-off function in order to I Cut-off canceled
ensure the pump flow when close to the
relief pressure, thereby preventing any
drop in speed.
. The relief pressure when the cut-off is op-
erated is 31.85 MPa (325 kg/cm’), and
when the cut-off cancel function is oper-
ated, the relief pressure becomes approx.
34.8 MPa (355 kg/cm’).
. Actuation conditions for cut-off cancel
function
202FO6176
Swing
Working mode switch Knob switch
lock
H/O Travel ON ON OFF ON OFF
Cut-off function Canceled Canceled Canceled Actuated Canceled Actuated

+
2-stage relief Actuated at
Actuated Actuated
function H/O, G/O
* Quick warming up for hydraulic oil when

swing lock switch is ON:
When the swing lock switch is turned ON,
the cut-off function is cancelled, and the 2-
stage relief function is actuated.
If the work equipment is relieved in this
condition, the temperature of the hydraulic
oil can be raised more quickly to reduce the
warming up time.
IO-127
4. 2-stage relief function

. The relief pressure for normal operations is
31.85 MPa (325 kg/cm2), but when the 2-
stage relief function is actuated,the relief
pressure rises to approx. 34.79 MPa (355
kg/cm2).
Because of this, the hydraulic pressure is
increased by one stage.
. When the 2-stage relief function is actu-
ated, the cut-off cancel function is also ac-
tuated automatically.
. Actuating conditions for 2-stage relief func-
tion
Conditions Relief pressure
l When traveling 31.85 MPa

l When swing lock switch is ON (325kg/cm”)
l In lifting operation (L/O) mode
l When power max. fucntion or a
swift slow-down function are 34.79 MPa
actuated (355kg/cm”)
5. Fine control mode function . Relationship between working mode and pump
. When the finishing operation (F/O) mode is discharge amount (for independent operation)
selected from the-working mode, the pump (%)-
LS valve is controlled, and the pump dis-
charge amount is reduced to improve the
ease of fine control and the precision when
finishing.
Arm
T
-E bucket Swing
Actuator RAISE LOWER OUT
Heavy-duty
operation
(H/O)
100 50 100 50 50
General
operation
(G/O)
Finlshlng
operation 80 40 60 80 40 40
(F/O)
Lifting
operation 100 50 100 100 50 50
mode (L/O)
6. LS bypass function Breaker
. When the travel is operated at the same operation 100 50 100 100 50 50
time as the work e-quipment or swing, the (a/o)

pressure compensation function in the
CLSS circuit is weakened to reduce the
drop in the travel speed to the minimum.
. With this mechanism, the pressure is con-
trolled so that the LS pressure in the CLSS
circuit is made lower than the actual pres-
sure when the travel is operated together
with the work equipment or swing. In this
way the pressure compensation function is
weakened.
* For details of the operation, see CLSS.
IO-128
3) Power max. function, swift slow-down function
Control valve
Work
equipement
lever knob
switch
FUNCTION
. This function provides an increase in the dig-

ging power for a certain time or switches the
working mode to the lifting operation (L/O) and
reduced the speed. It is operated using the L.H.
knob switch to momentarily match the operat-
ing conditions.
+ The power max. function and swift slow-down
function are operated with the same switch.
Only one of these functions can be selected at
any time; they cannot both be operated to-
gether.
IO-129
1. Power max. function

. During digging operations, when that extra
bit of digging power is needed (for exam-
ple, when digging up boulders), the L.H.
knob switch can be pressed to raise the
hydraulic pressure by approx. 10 % and in-
crease the digging force.
. If the L.H. knob switch is pressed ON when
the working mode is at H/O or G/O, each
function is automatically set as follows
Working mode Cut-off function 2-stage relief function Actuating time
Actuated
Heavy-duty working Automatically canceled
Canceled (31.85 34.79 MPa)
operation (H/O work) after 8.5 set
(325 355 kg/cm’)
2. Swift slow-down function

. During normal operations, if it is desired to
carry out lifting operations or finishing op-
erations for a moment, the working mode
can be switched to lifting operation (l/O)
mode by operating the L.H. knob switch p.
. If the L.H. knob switch is pressed ON when
the working mode is at H/O or G/O, each
function is automatically set as follows
I Working mode
I
Actuating time
1 Lifting operation (L/O) 1 While switch is kept pressed
IO-130
4) Auto-deceleration function
Boom Bucket
n n
Engine
Fuel injection
Main pump , I
ww (
M
@
Fuel control dial
Monitor panel
‘F
Governor,
pump controller
Function
. If all the control levers are at neutral when wait-
ing for work or waiting for a dump truck, the en-
gine speed is automatically recuded to a
midrange speed to reduce fuel consumption
and noise.
. If any lever is operated, the engine speed re-
turns immediately to the set speed.
IO-131
Operation
Control levers at neutral When control lever is operated
If the engine is running at above the decelera- l If any control lever is-operated when the engine
tion actuation speed (approx. 1,400 rpm), and speed is at No. 2 deceleration, the engine
all the control levers are returned to neutral, the speed will immediately rise to the speed set by
engine speed drops immediately to approx. 100 the fuel control dial.
rpm below the set speed to the No. 1 decelera-
tion position.
If another 4 seconds pass, the engine speed is
reduced to the No. 2 deceleration position
(approx. 1,400 rpm), and is kept at that speed
until a lever is operated.
speed (rpm)
No. 1 deceleration
No. 2 deceleration ( 1400)

II
I,
4 Less than 1
4
-
Time (set)
Levers at neutral
Lever operated
IO-132
5. Automatic warming up and engine overheat prevention function
I Control valve
Governor,
pump controller
FUNCTION
. If the coolant temperature is low, this automati-
cally raises the engine speed to warm up the
engine after it is started. (Automatic warming up
function).
In addition, if the coolant temperature rises too
high during operations, it reduces the load of
the pump to prevent overheating. (Engine over-
heat prevention function).
IO-133
1. Engine automatic warming-up function

. After the engine is started, if the engine
coolant temperature is low, the engine
speed is automatically raised to warm up
the engine.
Conditions for actuation (both are necessary)

Coolant temperature: Less than 30°C
Enoine speed: Less than 1,400 rum
Conditions for cancellation (any one) I

Coolant temperature: 30°C or above
Automatic Automatic warming-up time:
10 minutes or more
1 Fuel control dial: Held at more than 1

Manual
70% of full throttle for mor than
1 3 seconds I
IO-134
2. Engine overheat prevention function

. This function protects the engine by lowering
the pump load and engine speed to prevent
overheating when the engine coolant tempera-
ture has risen too far.
. This system is actuated in two stages. The first
stage is when the coolant temperature is be-
tween 102°C and 105X, and the second stage
is when the coolant temperature is 105°C and
above.
Normal operation
(coolant temperture below 102°C)
Actuation condition
Coolant tempera-
ture: Below 102%
7 i!
(Coolant tempera-
ture gauge:
Green ranae)
-0
1 st stage (Coolant temperature between 102°C and 105%) u
Actuation condition Actuation, remedy Cancel condition

I
Working mode ) PC1 8O/PC160K Coolant temperature: Below
Coolant tempera-
102°C
ture: Between 102% z&
and 105 c S When the above condition is
‘Grzreaker 1 gz:: 10 0-J
(Coolant tempera- met, the system returns to the
: condition before the overheat
ture gauge: cu
prevention function was actu-
Red range
I I ated (automatic reset).
2nd stage (coolant tem-

perature 105°C and above)
Actuation condition 1 Actuation. remedv I Cancel condition

Working mode ( In any mode ( Coolant temperature:
Coolant tempera-
Below 102%
ture: Engine speed Low idling Fuel control dial: Return tem-
14
105°C and above % porarily to low idling postion
Monitor caution Lights up V S
(Coolant tempera- lamp 4 When the above conditions are
ture gauge: met, the system returns to the
G
Caution buzzer Sounds condition before the overheat
Red range) I prevention function was actu-
ated (manual reset).
IO-137
6) Swing control function
Swing motor
i
I
I Swing brake
1solenoid valve
Control valve
Engine e
.i OiiT;rre
Monitor panel
il Pump controller
Function
. The system is provided with a swing lock and
swing holding brake function.
IO-138
1. Swing lock, swing holding brake function . Swing lock switch and swing lock, holding brake
. The swing lock (manual) can be locked at any
desired positon, and the swing holding brake
(automatic) is interconnected with the swing, so
Operation
it prevents any hydraulic drift after the swing is
stopped. When swing lever is placed at
neutral, swing brake is applied
after approx. 4 set; when swing
lever is operated, brake is
canceled and swing can be
operated freely.
Swing lock is actuated and swing
is held in position. Even when
Swing
ON
I I
ON
lock
swing lever is operated, swing
lock is not canceld and swing
does not move.
% Operation of swing lock prolix switch

OFF (when controller
. If any abnormality should occur in the control- is normal)
ler, and the swing holding brake is not actuated
noramlly and the swing cannot be operated, the
ON OFF
swing lock prolix switch can be operated to can-
cel the swing lock and allow the swing to be op- Swing
erated. Swing Swing lock Swing lock Swing lock holding
* Even when the swing lock prolix switch is brake applied canceled applied brake
I I applied
turned ON, the swing lock switch stays ON and
the swing brake is not cancelled.
* When the swing brake is cancelled, the swing
has only a hydraulic brake operated by the
safety valve, so if the swing is stopped on a
slope, there may be hydraulic drift.
2 Hydraulic oil quick warm-up function when

swing lock switch is ON
+ For details, see PUMP AND VALVE CONTROL
FUNCTION
202FO6182
IO-139
7) Travel control function
Travel
Motor
Control valve
Pump pressure
sensor
Monitor panel
Fuel control dial
Q
c4
t
t
Engine throttle
controller
Function
. When travelling, the pump copntrol is carried

out, and the travel speed can be selected
manually or automatically to give a travel per-
formance that suits the nature of the work or the
jobsite.
IO-140
1. Pump control function when traveling

. If the travel is operated in any working mode
other than the heavy-duty operation (H/O)
mode, this increases the pump absorption
torque while keeping the working mode and en-
gine speed as they are.
+ For details, see PUMP & ENGINE MUTUAL
CONTROL FUNCTION
2. Travel speed selection function Lo Mi Hi

Travel speed switch (Low (Midrange (High
. Manual selection using travel speed switch speed) speed) speed)
If the travel speed switch is set to Lo, Mi or Hi, Pump flow (%) 30 100 100
the pump controller controls the pump flow and Motor volume Max. Max. Min.
motor volume at each speed range as follows to Travel speed (km/h) 2.7 1.o 30
switch the travel speed.
IO-141
8) Components of system
1. Engine speed sensor
0
gtz-p
202FO6185
1. Wire Function
2. Magnet . The engine speed sensor is installed to the ring
3. Terminal gear portion of the engine flywheel. It counts
4. Housing electrically the number of gear teeth that pass
5. Connector in front of the sensor, and sends the result to
the pump controller.
. This detection is carried out by a magnet, and
an electric current is generated every time the
gear tooth passes in front of the magnet.
2. PPC oil pressure switch
1. Plut
2. Switch
3. Connector
1 2 3
SPECIFICATONS
Composition of points: N.O. points
Actuation (ON) pressure:
___ 0.49 f 0.1 MPa (5.0 f 1 .O kb/cm’)
_-_
Reset (OFF) pressure:
k!I+ 0.29 f 0.05 MPa (3.0 f 0.5 kg/cm’)
Function
. There are 8 switches installed to the PPC shut-
tle valve.The operating condition of each actua-
tor is detected from the PPC pressure, and this
is sent to the pump controller.
@q---J PzjzJ
202FO6186
IO-142
3. Pump pressure sensor
1. Plug
2. Sensor
3. Connector
ffJ=pqJ
202FO6187
Function
. This sensor is installed to the inlet port circuit of
the control valve. It converts the pump dis- Insulation layer
charge pressure to a voltage and sends this to
the controller.
Operation
When the pressurized oil entering from the
pressure introduction portion pressurized the
diaphragm of the pressure detection portion,
the diaphragm deflects and changes shape.
A gauge layer is installed to the face opposite
the diaphragm, and the resistance of the gauge
layer converts the deflection of the diaphragm
into an output voltage and sends it to the amp
(voltage amplifier).
the voltage is further amplified by the amplifier
and is sent to the pump controller.
Relationship between P (kg/cm’) and output
voltage (v)
V = 0.008 x P + 1 .O
+ 1 kg/cm2 = 0.098 MPa
0
100 400 500
Pressure P (kg/crrS)
202FO6163
IO-143
4. TVC prolix resistor
202FO6216
1. Resistor Function
2. Connector . This resistor acts to allow a suitable current to
flow to the TVC solenoid when the TVC prolix
SPECIFICATION switch is ON.
Resistance: 30 !A . No currect flows when the TVC prolix switch is
OFF
5. Fuel control dial, governor motor, engine 8. LS control epc valve

throttle controller Suspension lock solenoid valve
* See ENGINE CONTROL SYSTEM Travel speed solenoid valve
Swing brake solenoid valve
6. Monitor panel 2-stage relief solenoid valve
+ See MONITORING SYSTEM + See EPC, solenoid valve
7. TVC valve
+ See HYDRAULIC PUMP
IO-144
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM

Monitor panel
Switch signal
Caution. water
temperature, fuel
level signal Governor,
pump controller
I
Sensor signal
SWlSOrS
w
BUZZW
signal
I
Buzzer
Function . The monitor panel also has various built-in

. the machine monitor system uses the sensors mode slector switches, and functions as the
installed to all parts of the machine to observe control panel for the machine control system.
the conditon of the machine. It processes this
information swiftly, and displays it on a panel to
inform the operator of the conditon of the ma-
chine.
The content of the information displayed on the
machine can broadly be devided as follows.
1. Monitor portion
This gives an alarm if any abnormality oc-
curs in the machine
2. Gauge portion
This always displays the conditon of the
machine (coolant temperature, fuel level).
IO-145
1. Monitor panel
CN-PO2
CN-PO1
Outline Input and output signals

. The monitor panel consists of the switchesfor
CN-PO1 CN-PO2
the monitor display functions, mode selector,
and electrical components.
It has a built-in CPU (Central Processing Unit),
and processes, displays and outputs the infor-
mation.
The monitor display panel uses a liquid crystal
display (LCD). the mode switches are flat sheet
switches. Input and output signals.
IO-146
DISPLAY MONITOR
1. Clock (displays error code when error occurs)
2. Service meter
3. Coolant temperature gauge
4. Fuel gauge
5. Engine oil level caution lamp
3 4
6. Preheating pilot lamp
7. Swing holding brake pilot lamp
13 14
8. Charge level caution lamp
9. air cleaner clogging caution lamp
5
10. Overload caution lamp
11
11. Coolant level caution lamp
10 6
12. Engine oil pressure caution lamp
13. Fuel level caution lamp
12 9 8 15 7 14. Coolant temperature caution lamp
Content of display 15. Oil maintenance caution lamp
When engine is
Symbol Display item Display range When engine is running
stopped
Flashes and buzzer
fG Coolant level Below low level Flashes when abnormal
SAP00519 sounds when abnormal
Below 1,500 rpm:
Lights up when normal
Engine oil below 0.05 MPa (0.5 kg/cm’) Flashes and buzzer
(goes out when engine
pressure Above 1,500 rpm: sounds when abnormal
SAW0520 starts)
below 0.15 MPa (1.5 kg/cm’)
Air cleaner
When clogged OFF Flashes when abnormal
clogging
Lights up when normal

I
Charge level When charging is defective (goes out when engine Flashes when abnormal
SAP00522 starts)
04
SAP00523
Engine oil
level
Below low level Flashes when abnormal OFF
!.s Over load Above high level OFF Flashes when abnormal
SDPOO688
Lights up when swing lock switch is ON, flashes

Parking When swing is locked
when swing lock prolix switch is ON
SDF‘O0582
Lights up for 30 seconds when starting switch is

Preheating During preheating at HEAT, then flashes for 10 seconds to indicate
iiFW526 that preheating is completed
30t 102t 1059:

Coolant Flashes when above 102”C, flashes and buzzer
temperature sounds when above 105°C
SAP00703 SAP00529
Fuel level Flashes when below low level

SAP00530
Oil
maintenance
IO-147
MODE SELECTION SWITCHES
(II m II 1.
2.
Working mode switch
Auto deceleration switch
3. Travel speed switch
4. Power max./Swift slow-down switch
. The switch portion consists of five mode selec-

tion switches, and the condition of the machine
changes each time that nay switchis pressed.
The LED above the switch lights up to display
the present condition of the machine.
Switch actuation table
Switch Item Action
WORKING MODE H/O - G/O - F/O - L/O - B/O

SDP00692
(SET) KNOB BUTTON

(POWER UPI (SPEED DOWN)
SDP00693 SDP00694
d” SDP00695
AUTO DECEL ON - OFF
aa 69SDP00696
TRAVEL SPEED Hi ++ Mi ++ Lo
IO-148
2. Sensors
. The signals from the sensor are input directly to
the monitor panel.
The contact type sensors are always con-
nected at one end to the chassis GND.
Name of sensor Type of sensor
Coolant level Contact type
Engine oil level Contact type
Engine oil
Contact type
pressure
Coolant
Resistance type
temperature
Fuel level Resistance type

I .
Air cleaner
Contact type
clogging
Cooland level sensor
1. Sub-tank
2. Float
3. Sensor
4. Connector
SAP00375
IO-149
Engine oil level sensor
1. Connector
2. Bracket
3. Float
4. Switch
Composition of
circuit
SSPOO376
Engine oil pressure sensor (both Lo and Hi)
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
1 2 3 4 5 6
5. Spring
6. Terminal
0 69 @ Composition of circuit
?.SP00379
Coolant temperatur sensor
swoo379
IO-150
Fuel level sensor
1. Float
2. Connector
FULL 3. Cover
4. Variable resistor
EMPTY
Air cleaner clogging sensor
f!L
IO-151
AND FUNCTION OVERLOAD WARNING DEVICE
STRUCTURE
OVERLOAD WARNING DEVICE

1) OUTLINE
Function
. This device is installed to prevent the machine
from tipping over when it lifts an excessive
weight while being used as a crane.
Structure
. When an excessive weight is lifted, the oil pres-
sure goes up at the bottom side of the boom
cylinders. When this happens, the pressure
switch senses the rising pressure, turns the
pressure switch on, and lights the monitor lamp
to warn the operator. When the monitor lamp
lights, immediately lower the weight to the
ground or bring the arm closer in the operator to
prevent the machine from tipping over.
Overload warning
monitor lamp
.
IO-152
STRUCTURE AND FUNCTION OVERLOAD WARNING DEVICE
2) OPERATION
1. Boom cylinder safety valve

2. Boom cylinder
3. Hose
4. Pressure switch
The overload caution system is operated by pres-

sure alone (it does not take into account the position
of the boom).
Hose (3) directs oil from the boom lift cylinder safety
valve (1) to the pressure switch (A). The pressure
switch will activate when excessive weight is lifted
by the boom and the oil pressure at the bottom of the
boom cylinders (2) exceeds 155 kg/cm2.
NOTE: the overload caution system can only be ac-
tivated when the L/O mode (lifting) is activated on
the monitor panel.
IO-153
STRUCTURE AND FUNCTION BREAKER MODE HYDRAULIC PERFORMANCE
BREAKER MODE HYDRAULIC PERFORMANCE

(MAIN VALVE BYPASSED)
Pa
Main
valve
Attachment
Bypass
valve
The performance of the hydraulic system when

used in the B.O. mode for attachment operation, is
shown below.
The pressure Pa is that which is observed at the in-

let to the Attachment.
The pressure Pb is the pressure observed on the

return line or tank line (back pressure).
The figure below shows the pressures at points A

and B for varying flow through the attachment.
Max. back
pressure
29.5 bar
0 20 40 60 60 100 120 140 160 160
Flow lLitras/minutel
IO-154
STRUCTURE AND FUNCTION BREAKER MODE HYDRAULIC PERFORMANCE
BREAKER MODE HYDRAULIC PERFORMANCE

(VIA MAIN VALVE)
Pa
I
The figure below shows the pressures at points A

and B for varying flow through the attachment.
The performance of the hydraulic system when

used in the B.O. mode for attachment operation, is
shown below.
The pressure Pa is that which is observed at the in-

let to the Attachment.
The pressure Pb is the pressure observed on the

return line or tank line (back pressure).
Max. back
pressure
50 bar
0 20 40 60 80 100 120 140 160 180 200 220
flow ~Litrdminutel
20 TESTING AND ADJUSTING
Table of judgement standard value 20- 2 Testing and adjusting PPC pressure 20- 33
Standard value table for electrical parts . . . ....20- 12 Testing EPC valve, solenoid valve output
Checking and adjusting belt tension for pressure 20- 35
air conditioner compression 20- 20 Measuring PPC valve output pressure
Adjusting engine speed sensor 20- 21 and testing PPC shuttle valve 20- 37
Testing and adjusting governor motor Adjusting work equipment
lever strong 20- 22 l swing PPC valve 20- 39
Testing clearance of swing circle bearing .. ...20 -24 Testing locations causing hydraulic
Testing and adjusting hydraulic pressure drift of working equipment 20- 40
in work equipment, swing, travel circuit . . . . ....20- 25 Measuring oil leakage 20- 42
Testing and adjusting TVC valve output Releasing remaining pressure in
pressure (servo piston input pressure).........20- 28 hydraulic circuit 20- 43
Testing and adjusting LS valve output Bleeding air 20- 44
pressure (servo piston input pressure) and Accumulators 20- 46
LS differential 20- 30 Troubleshooting 20- 50
a When carruing out testing, adjusting, or troubleshooting,

safety pins and blocks to prevent the machine from moving.
park the machine on level ground and use the
a When carrying out work together with other workers, always use signals and do not let unauthorized
people near the machine.
a When checking the water level, always wait for the water to cool down. If the radiator cap is removed
when the water is still hot, the water will spurt out and cause burns.
a Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-I
TESTING AND ADJUSTING TABLE OF JUDGEMENT STANDARD VALUE
TABLE OF JUDGEMENT STANDARD VALUE

l FOR ENGINE
Machine model PWI 70-6k
Engine SA4Dl02E
Item Measurement conditions Unit Standard value Permissible value
Travel 2545 2545 f 50

High idling rpm
Working 2340 2340 f 20
Engine speed
Low idling rpm 900 f 50 900 f 50
Rated speed 2200 2200 f 100

I rpm I I
20-2
. FOR CHASSIS
+ The standard values and permissible values shown in this table are all values for H/O (heavy-duty opera-
tion) mode.
Machine model PWI 70-6k
Cate-
Item Measurement conditions Unit Standard value Permissible value
gory
Hydraulic oil temperature
At pump relief (LS relief) Min. 2,100 2,100 * 50
45 - 55°C
Coolant temperature:
At pump relief (power whithin operating range
max)
rpm Min. 2,100 2,100 * 50
Pump relief: Arm relief
Speed when auto Fuel control dial at MAX.
1,400 * 200 1,400 * 200
deceleration is operated Control lever at neutral
1st boom control valve I a b I a b
Arm control valve
Service valve
Bucket control valve

mm
2nd Boom control valve 53 * 0.5 12 * 0.5 8 * 0.5 53 * 0.5 12 * 0.5 8 * 0.5
Swing control valve
Stabiliser control valve
Travel control valve
Boom control lever Center of lever knob so* 10 8Ok 10

Read max. value to end of travel
Arm control lever Engine stopped ao* 10 80? 10
Excluding neutral play
Bucket control lever mm so* 10 8Ok 10
Swing control lever so* 10 8Ok 10
Play of control lever IOk5 iOk5
15.7 * 2.9 Max. 24.5

Engine at high idling (1.6 * 0.3) (Max. 2.5)
Hydraulic oil temperature
15.7 * 2.9 Max. 24.5
Armj control lever 45 - 55°C
(1.6 ? 0.3) (Max. 2.5)
Fit push-pull seal to center of
control lever knob to measure 12.7 * 2.9 Max 21.6
bucket control lever ) Measure max. value to end of (1.3 * 0.3) (Max 2.2)
travel
Swing control lever
)Tip of pedal 12.7 ? 2.9 Max 21.6
(1.3 * 0.3) (Max 2.2)
) Engine at high idling
) Hydraulic oil temperature
45 - 55°C
) Measure max. value to end of Wd
travel 1
325 ? 25 Max. 488

Brake pedal
(33 * 2.5) (Max. 50)
w KW13OP6012
20-3
Machine model
T PWI 70-6k
Item Measurement conditions Unit Standard value ‘ermissible value

) Hydraulic oil temperature:
45 - 55°C
) Measure max. value to end of travel
337.5klO7.5 Max. 506

-ravel control pedal VW (34.5?11) (Max. 52)
Kw13OP6044
31.85kl.47 31.85k2.45
Normal
(325?15) (325?25)
RAISE
Power 34.79k1.47 34.79k2.45
t max. (355ki 5) (355*25)
soom
31.85kl.47 31.85k2.45
(325?15) (325?25)
33.8kl.47 33.8lk2.45
(345?15) (345?25)
31.85?1.47 31.85k2.45
Normal
(325*15) (325*25)
Power 34.79kl.47 34.79k2.45
max. (355ki 5) (355*25)
) Hydraulic oil temperature 31.85kl.47 31.85k2.45
45 _550c Normal (325?15) (325?25)
3ucket ) Relief pressure with engine at ~
MPa
Power kg/cm2) 34.79k1.47 34.79k2.45
high idling (Relieve only circuit
max. (355k15) (355*25)
) to be measured)
) In H/O mode 31.85?1.47 31.85k2.45
swing
(325*15) (325*25)
-ravel
34.79k0.98 34.79k1.96
(355ki 0) (355*20)
;tabiliser
Levers at neutral
.S differential pressure ) Hydraulic oil Controllevers at
temperature neutral 3.9*1 .o 3.0*1 .o
45 - 55°C
(4Oki 0) (4Oki 0)
rvc valve output pressure ) Engine at high idling
servo piston input ) In H/O mode
jressure)
20-4
Machine model
T PWI70-6k
Cate Measurement conditions Unit Standard value Permissable value

gory
-
Work equipment posture
Max. reach
90” 3.1kO.3 max 4.0
rime taken to start

swing
-
Kw13OP6046
. Engine at high idling

. Hydraulic oil tempera- 180
ture: 45 - 55°C 4.9kO.5 Max 6.0
. In H/O mode
. time taken to swing 90 Set
and 180” from starting
position 180” -
.-P
Work equipment posture
rz
Max. reach
rime taken to swing 25&i .5 Max 30

Kw13OP6047

) Hydraulic oil temperature:
45 - 55°C
. In H/O mode
n Swing one turn, and measure
time taken to swing next 5
turns
20-5
Machine model
T PWI 70-6k
Cate Measurement Unit Standard value Permissible value

gory conditions
KW13OP6048
Hydraulic drift of Engine stopped 0 0

swing Hydraulic oil temperature:
.-F 45 - 55°C
5 Set machine on 15” slope, and set
upper structure at 90” to the side
Make match marks on swing circle
outer race and track frame
Measure distance that match marks
move apart after 15 minutes
Leakage from l Engine at high idling

swing motor l Hydraulic oil temperature:
45 - 55°C “/mm 3 6
l Swing lock switch ON
l Relieve swing circuit
Lo 36 30-42
sec.
KW13OP6049
Mi
Travel speed l Engine at high idling 18 15-21
l Hydraulic oil temperature:
45 - 55°C
l In H/O mode !O kph
l Run up for at least 200 m, set 9 8.6 - 9.4
and measure time taken to Hi
travel next 50 m on flat 10 kph
ground. set 6 5.8 - 6.2
mm 0 0
Hydraulic drift of
travel
l Engine stopped
45 - 55°C
l Stop machine on 12” slope
l Apply park brake
l Measure the distance the
machine moves in 5 minutes
20-6
?-
m
Applicable model
- 1 PWI70-6k
catt Measurement conditions Unii Standard value Permissible value

w Y
/mil 30
Leakage of travel
motor(s)
l Engine at high idling

45 - 55°C
l Apply park brake and relieve travel
circuit
Total work Posture for measurement

equipment
Max. 265 Max. 400
(hydraulic drift at
tip of bucket teeth)
Boom cylinder
(amount of
Max. 5 Max. 7.5
retraction of
cylinder)
Place in above posture and
2nd Boom measure extension or retraction of
cylinder (amount each cylinder and downward
movement at tip of bucket teeth nm Max. 5 Max. 7.5
of extension of
cylinder) Bucket: Rated load
Horizontal, flat ground
Arm cylinder Levers at neutral
(amount of Engine stopped
Hydraulic oil temperature: Max. 30 Max. 45
extension of
45 - 55°C
cylinder)
Start measuring immediately after
Bucket cylinder setting
(amount of Measure hydraulic drift every 5
minutes, and judge from results for 0 0
retraction of
cylinder) 15 minutes _
3.7kO.4 Max. 4.5

Boom
Bucket teeth in
contact with KW13OP6053
;ec.
ground
Cylinder fully
l Engine at high idling 2.8kO.3 Max. 3.2
extended
45 - 55°C
-
20-7
Cate
T
Applicable model
Measurement conditions Unit

r Standard value
PWI 70-6k
Permissible value
gorl
Z
- 3.7kO.4 Max. 4.6
Arm cylinder fully
retracted
1
fully extended
Kw13OP6054
l Engine at high idling 2 3.OkO.3 Max. 3.6

0
45 - 55°C
3.6kO.4 Max. 4.3

Bucket cylinder
fully retracted
& Kw13OP6055
fully extended
l Engine at high idling 2.2kO.3 Max. 2.6
45 - 55°C
set
!a
Kw13OP6056/
Max. 2.0 Max. 3.0
l Lower boom and measrue time
taken from point where bucket
contact ground to point where
chassis rises from ground
l Engine at low idling
45 - 55°C
Arm
Kw13OP6057 Max. 1 .O Max. 2.6
l Stop arm suddenly and measure

time taken for arm to stop
45 - 55°C
20-8
Cate
T
Applicable model
Measurement conditions Unit

r Standard value
PWI 70-6k
Permissible value
Item
gorl
Bucket
Cylinders
Center swivel joint
sec. Max. 2.0 Max. 3.0
Kw13OP6058
l Stop bucket and measure time taken
for bucket to stop at bottom and then
start again
45 - 55°C
l Engine at high idling Max. 3.5 15

45 - 55°C clmir
l Relieve circuit to be measured IO 50
20-9
Cate
PWI 70-6K (H.0 WORK TRAVEL)
gory
I I I
I
I
-------- .---
-r-------- 1-- -
I
I
I
I
I
.___;----.---_I_____
I I
0 100 200 277 300
Pump Q (I/min)
pump speed: At 2.200 rpm, TVC current 330 mA
Test pump Standard value Judgement

discharge for discharge standard lower
Check point
pressure amount limit
(MPa (kg/cm’) Q(l/min) Q(l/min)
As desired P See graph See graph
As far as possible, bring pump discharge pressures P as close as possible to the average pres-
sure when measuring.
The error is large near the point where the graph curves, so avoid measuring at this point.
When measuring with the pump mounted on the machine, if it is impossible to set the engine
speed to the specified speed with the fuel control dial, take the pump discharge amount and the
engine speed at the point of measurement, and use them as a base for calculating the pump
discharge amount at the specified speed.
20-I 0
Flow control characteristics of TVC valve (STD)

+ The values in this table are used as reference values when carrying out troubleshooting.
Item Measurement Unit PWI 70-6K

conditions
Time taken for

swing for boom
RAISE + starting Set 4.2kO.2
swing
Kw13OP6059
Engine at high idling

Hydraulic oil temperature: 45 - 55°C
In H/O mode
Load the bucket with the rated load and
measure the time taken from the position
of starting the swing to the point of
passing the 90” position..
20-I 1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS

sys Name of Connector spectior Judgement table Measurement
ten- component No. nethod conditions
If the condition is within the range shown in the 1) Turn starting

table below, it is normal switch OFF.
2) Disconnect
Fuel control dial E06 (male) 1 Between (l)-(2) 1 0.25 - 7 kR
connector.
1 Between (2) - (3) 1 0.25 - 7 kR I
Between (1) - (3) 4-6kR

2) Disconnect
1 Between (1) - (2) 1 0.25 - 7 kn I
Potentiometer E04 (male) connector.
1 Between (2) - (3) 1 0.25 - 7 kn I
1 Between (1) - (3) 1 4-6kCI
If the condition is as shown in the table below, it is 1) Turn starting

normal switch OFF.
1 Between (1) - (2) 1 2.5 - 7.5 n 2) Disconnect
connector.
E05 (male)
I Between (3) - (4) 1 2.5 - 7.5 n I
I Between (1) - (3) 1 No continuity I
Between (1) - chassis No continuity
Between (3) - chassis No continuity

2) Disconnect
Between(male) (1) - (2) 500 - 1,000n
connector.
Engine speed E07 Between(male) (2)-chassis Min. 1 MCI
sensor
Measure with AC range 1) Start engine.
2) Insert T-adapter.
1 Between (l)-(2) 1 0.5 - 3.0 V
1) Screw in rotation sensor until it contacts ring

gear, then turn back 1 * l/6 turns.
2) It must work normally when adjusted as
above.
iavel(Auto\decel) If the condition is as shown in the table below, it is 1) Start engine (or
i75
normal with engine
‘ravel(Parkbrake
When boom, arm, and bucket levers are oper- stopped and
nzzer)G156
‘ravel(Auto’susp’ ated accumulator
PPC oil pressure xk) Gi32 charged)
!pieceboom/ 2) Disconnect
switch
G66
itabiliser connectors SO1 -
;erviceSO9
SO8
;erviceG72
loomRAISES02 Between (male)
Min. 1MR
IrmOUTSO3 (l), (2) - chassis
loomLOWERS04
lrmINSO5
lucketCURLSO6
lucketDUMP SO7
iwingSO8
If the condition is within the range shown in the

table below, it is normal 1) Turn starting
Fuel shut-off valve !09 (male) switch OFF
Between (A) - (C) 46.5 - 56.9 kn 2) Disconnect
connector
Between (B) - (C) 0.87 - 1.07 kn
20-I 2
ispectior
SYS Name of Connector Judgement table Measurement
method
ten- component No. conditions
If the condition is as shown in the table 1) Start engine.

below, it is normal 2) Turn fuel
Pump pressure CO8 control dial to
Between (2) - (1) I%-26V
sensor (male) MAX position
(front) Between All levers at neutral 0.5 - 1.5 V 3) Insert T -
adapter
(3) - (1) At arm IN relief 3.1 - 4.5 v
It the condition is as shown in the table 1) Turn starting

below. it is normal switch OFF
Swing lock switch x05 2) Disconnect
(female) connector
co2
If the condition is as shown in the table 1) TurnTVC

below, it is normal prolix switch
TVC solenoid OFF.
Between (1) - (2) 1 IO-220
valve Cl3 2) Turn starting
(male) 1 Between (I), (2) - chassis 1 Min. 1 MCI switch OFF
3) Disconnect
connector
Cl3
Swing holding If the condition is within the range shown in 1) Turn starting
brake solenoid the table below, it is normal switch OFF
valve vo4 2) Disconnect
1 Between (I) - (2) I 20 -60 f-l
(male) connector
I Between (I), (2) - chassls
I Min. 1 M.Q V06
If the condition is within the range shown in 1) Turn starting

Travel speed the table below, it is normal switch OFF
solenoid valve V06 2) Disconnect
Between (1) - (2) 20 -60 f-l
(male) connector
Between (I), (2) - chassis Min. 1 M.Q vo4

Suspension lock the table below, it is normal switch OFF
solenoid valve G25 2) Disconnect
Between (1) - (2) 20 -60 0
(male) connector
Between (I), (2) - chassis Min. 1 MCI vo5.

the table below, it is normal switch OFF
2 step relief vo5 2) Disconnect
Between (1) - (2) 20 -60 f-l
solenoid valve (male) connector
Between (I), (2) - chassis Min. 1 M.Q V25
20-13
spectior Judgement table Measurement

SYS Name of Connector
nethod conditions
terr component No.

Cl0 the table below, it is normal switch OFF
LS-EPC solenoid (male) 2) Disconnect
Between (1) - (2) 1 7-140
connector
Between (I), (2) - chassis Min. 1 MCI ClO.

the table below, it is normal switch ON.
Power source co1 2) Insert
voltage co2 T - adapter
If the condition is as shown in the table 1) Turn starting

below. it is normal switch ON.
Fuel control co3 2) Insert
dial T - adapter
II
I
Between (4) - (17) 0.25 - 1.o v

(high idling)
If the condition is as shown in the table 1) Turn starting

below, it is normal switch ON.
2) Insert
Governor co3 T - adapter
potentiometer
E Between (7) - (17)

4.75 - 5.25 V
-r
bower source)
2
b If the condition is as shown in the table be- 1) Turn starting
E
low, it is normal switch OFF
9
s Coolant PO7
Normal temperature
(25”Cl
Aprrox. 37 - 50 kfl
2) Disconnect
connector
temperature (male) 100°C Aprrox. 3.5 - 4.0 k.Q PO7
sensor 3) Insert T -
adapter into
connector at
sensor end.
If the condition is as shown in the table be- 1) Turn starting

low, it is normal switch ON.
Governor co2 2) Insert
Between (2) - (3) 1.8- 4.6 V
motor T - adapter.
Between (4) - (5) 1.8- 4.6 V

the table below, it is normal switch ON.
Battery relay co1 2) Insert
Between (1) - (6) 20 - 30 v
T - adapter.
*This is only for 2.5 set after the starting
switch is operated ON + OFF; at other
times it must be 0 V.
20-I 4
Name of
component T
Connector
No.
ispectiol
method
Judgement table Measurement
conditions
1) Start engine.
f the condition is as shown in the table be-
ow, it is normal 2) Turn swing
lock switch
When either swing or OFF.
work equipment control 3) Turn swing
lever is operated o-3v lock prolix
Swing holding (solenoid ON, swing switch OFF.
xake sole- co1 holding brake canceled) 4) Insert T -
Between
ioid adapter.
Approx. 5 set after (3) -
swing lever and work + The lever can
(6h (12) be operated
equipment control
levers are placed at 20 - 30 v slightly
neutral (solenoid OFF, (without
swing holding brake moving the
applied) equipment).
f the condition is as shown in the table be- 1) Start engine.

ow, it is normal 2) Insert T -
adapter.
With travel speed 3) Turn fuel
switch at Hi or Mi control dial to
(solenoid ON, travel o-3v MAX position.
motor swash plate 4) Operate the
angel MIN) Between
lever slightly
Travel speed co1 (9) - not enough to
When travel speed
solenoid (61, (12) move the
switch is at lo (solenoid
OFF travel motor 20 - 30 v machine.
swash plate angle To check that the
MAX) solenoid is OFF,
measure with the
fuel control dial at
LOW (1200 rpm or
below)
f the condition is as shown in the table be- 1) Turn starting

ow, it is normal switch ON.
:-I
2) IsertT-
When swing lock switch
adapter.
is OFF, and swing +
+ The lever can
travel levers are opera-
o-3v be operated
Suspension co1 ted simultaneously Between slightly
ock (solenoid ON, LS not
(2) - (without
divided)
(6h (12) moving the
When sing lock switch equipment).
is ON (solenoid OFF, 20 - 30 v
LS not divided)
f the condition is as shown in the table be- 1) Turn starting

ow, it is normal. switch ON.
2) Insert T -
When travel is operated adapter.
Z-stage relief independently (solenoid o-3v * The lever can
solenoid co1 ON) Between
be operated
(10) - slightly
When levers and (6h (12)
20 - 30 v (without
pedals are at neutral
moving the
(solenoid OFF)
equipment).
20-15
-
sys Name of Connector lspectiol Judgement table Measurement
ten component No. method conditions

normal switch ON.
TVC solenoid co2 l G/O mode ( Hi-idle, swing lock off 2) Turn fuel
valve (default lever neutral control dial to
value) MAX positon
Between front (8) - (18) 410k40mA
3) Turn prolix
switch OFF.
If the condition is as shown in the table below, it is

1) Turn starting
normal
LS-EPC co2 switch ON.
l G/O mode
solenoid valve 2) Turn fuel
(default value) control dial to
Between (7) - (17) 800 k 80 mA
MAX position
3) All levers at
neutral.

co3 normal switch ON.
RH and LH When switch is ON 20 - 28 V 2) Insert
Between
lever switches T - adapter.
(9) - GND
When switch is OFF o-1 v

Cl7 normal switch ON.
S-NET 2) Insert T -
Between (4), (12) - GND 4-8V
adapter
If the condition is as shown in the table below, it 1) Start engine.

is normal 2) Set monitoring
High idling (rpm) code to 10 or
16 (command
H/O Approx. 2450 value).
3) Operate
No. 2 throttle Monitoring G/O Approx. 2030 working mode
signal code 16 switch and L.H.
F/O Approx. 2030
knob switch.
UO Approx. 1890
Power max. (H/O) (G/O) Approx. 2450
Swift slow-down (H/O) (G/O) Approx. 1890
If the condition is as shown in the table below, it 1) Turn starting

is normal switch OFF.
2) Disconnect
Between selection 1 Cl7 (5) CO2 (11) No continuity connector.
Model selection C17- CO2
Between selection 2 Cl7 (13) CO2 (11) Continuity 3) Connect
T - adapter to
Between selectlon 3 Cl7 (6) - CO2 (11) No contlnulty wiring harness
end.
Between selectlon 4 Cl7 (14) - CO2 (11) No continuity
Between selectlon 5 Cl 7 (7) - CO2 (11) No continuity
20-I 6
-
SYS Name of Connector lspectiot Judgement table Measurement
method
ten component No. conditions
-
the table below, it is switch OFF
3) Disconnect
!_
Between (1) - (2) 500- iooon
connector.
1Between (2) - chassis 1 Min. 1 M.Q
Measure with AC range 1) Start engine.

Engine speed E07 2) Insert T -
sensor
Between (1) - (2) 0.5 - 3.0 v
I adapter.
1) Screw in rotation sensor until it contacts

ring gear, then turn back 1 f l/6 turns
2) It must work normally when adjusted as
above.

2) Disconnect
Above LOW level in
Coolant level PO8 Max. ICI connecter PO6
sub-tank
sensor (male) 3) Insert T -
Below LOW level in
Min. 1MO adapter into
sub-tank I
connector at
sensor end.

2) Disconnect
Engine oil level PO5 connector PO5
Raise float Max. Ifl
sensor (male) 3) Drain oil, then
BLPOOOOZ
remove sensor.
v ’ Lower float Min. 1MfI

BLP00003
20-17
spectior Judgement table Measurement

SYS Name of Connector
nethod conditions
ter-r component No.
f the condition is as shown in the table be- 1) Install oil

ow, it is normal. pressure
_ow pressure sensor measuring
gauge.
2) Remove
Engine oil pres- wiring har-
sure sensor PlO (Continuity) (0.85 * 0.14 kg/cm2) ness termi-
nal.
Sensor connector
3) Start engine.
4) Put tester in
H
contact
a between
sensor
A Cl
terminals
A & C.

ow, it is normal switch OFF.
2) Disconnect
connector
P06.
3) Drain fuel,
Fuel level sensor PO6 then remove
(male) sensor.
$) Insert T -
adapter into
sensor.
k Connect the
T - adapter to
the connector
and sensor
flange.
f the condition is as shown in the table be- 1) Start engine.

ow, it is normal 2) Disconnect
Air cleaner normal Continuity Pll, P12.
3) Put tester in
Air cleaner clogged I No continuity I
Air cleaner PI1 contact with
clogging sensor PI2 connector at
sensor end to
measure.
20-I 8
Name of C onnector ispectio Judgement table Measurement

component method
No. conditions
-
B‘etween When engine is running (l/2 throttle or 1) Start engine
a lternator above) below, the sensor is defective.
Alternator tczrminal + 27.5 - 29.5 V
RI and + If the battery is old, or after starting in
Clhassis cold areas, the voltage may not rise for
some time.
-
Position of gauge Display level resistance Insert a dummy

display kC (Monitor panel input
1)
resistance with
resistance)
the starting
Starting switch ON Starting switch OFF switch OFF, or
measure the
Right Min. - Max. resistance of
Measure side the sensor.
resistance
2) Check the
between coolant
temperature
E display with the
gauge CO3 starting switch
t
(female) (1) - I 3.512 - 3.900 I ON.
CO3 (female)
(16)
I 8.502 - 10.774 I
Left side 1 1 1 I 9.946 - 36.535 I

33.725 -
Gauges 1: Levels 13 and 14 flash

-
Position of gauge Display level resistance

1) Insert a dummy
display kC (Monitor panel input
resistance with
resistance)
the starting
Starting switch ON Starting switch OFF OFF, or meas-
ure the resist-
Min. - Max. ance of the
sensor.
I 12 I E 2) Check the
I 11 I display with the
Measure 18.90 - 25.05 starting switch
resistance 22.59 - 28.45 ON.
between fuel 25.82 - 31.85
level gauge CO3 29.18 - 35.22
(female) (2) - 32.45 - 39.91
chassis
37.00 - 44.60
41.77 - 48.72
45.52 - 55.14
t 50.42 - 64.35
60.61 - 77.07
_eft side 1ALLOFF
to)1 72.98 - 69.15
638.00 - 69.15
r Level 1 flashes.
20-I 9
CHECKING AND ADJUSTING BELTTENSION FOR AIR
TESTING AND ADJUSTING CONDITONER COMPRESSOR
CHECKING AND ADJUSTING

BELT TENSION FOR AIR
CONDITIONER COMPRESSOR
CHECKING
1. Remove belt guard 0.
2. Press compressor drive belt midway between fan pul-
ley and compressor pulley. The belt should normally
deflect by about 15-18 mm (0.60-0.70 inch) when
pressed with the finger (with a force of approx. 6kg (13
1 b.)
ADJUSTING
1. Loosen two nuts and bolts 0.
2. Carefully lever compressor housing as shown to
tighten belt to tightness criteria. Tighten lower bolt to
hold in position.
3. Tighten upper bolt.
4. Check each pulley for damage, wear of the V-groove
and wear of the V-belt. In particular, be sure to check
the V-belt is not touching the bottom of the V-groove.
5. Replace belt if it has streched, leaving no allowance
for adjustment, or if there is a cut or crack on belt.
6. Refit belt guard.
7. When the new belt is set, readjust it after operating for
one hour.
20-20
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED

SENSOR
Screw in until the tip of sensor 91) contact gear (2).
When gear (2) contact sensor (l), turn back one turn.
Tighten locknut (3).
Be particularly careful when securing the sensor wir-
ing to ensure that no excessive force is brought to
bear on the wiring.
Be careful not to let the tip of the sensor be scratched
or to let any iron particles stick to the sensor tip. L
20-21
TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
TESTING AND ADJUSTING

GOVERNOR MOTOR LEVER
STROKE
TESTING
1. Check engine speed at high idling in H/O work mode
(ref: 20.2). If outside tolerance adjust as below
2. Check engine speed in H/O travelmode (lightly de-
press travel pedal unti engine speed rises without ma-
chine moving) and at low idling.
3. If within tolerance checkis OK (ref 20.2)
ADJUSTMENT
Set engine speed at high idling in H/O work mode to stand-

ard value by adjusting linkage (ref: 20.2)
20-22
TESTING AND ADJUSTING TESTING AND ADJUSTING GOVERNOR MOTOR LEVER STROKE
5. Confirm engine speeds are within tolerance according

to:
No load engine speeds
+ To check travel condition,ensure H.O. working mode is

selected then move travel pedal that auto decel is can-
celled but machine does not move.
20-23
TESTING AND ADJUSTING TESTING CLEARANCE OF SWING CIRCLE BEARING
TESTING CLEARANCE OF
Revolving framel
SWING CIRCLE BEARING
Method of testing clearance of swing circle bearing
when mounted on machine
1. Fix a magnet-type dial gauge to the outer circle (or

inner circle) of the swing circle, and put the tip of the
probe in contact with the inner circle (or outer circle).
Set the dial gauge at the front or rear.
I F20505395
2. Extend the work equipment to the maximum reach,

and set the tip of the bucket to the same height as the
bottom of the revolving frame.
When this is done, the upper structure will tilt forward,
so the front will go down and the rear will rise.
3. Set the dial gauge to the zero point.
Kw130P6060
4. Set the arm more or less at right angles to the ground

surface, then lower the boom until the front of the ma-
chine comes off the ground.
When this is done, the upper structure will tilt back, so
the front will rise and the rear will go down.
5. Read the value on the dial gauge at this point. The

value on the dial gauge is the clearance of the swing
circle bearing.
a When carrying out the measurement, do not put

your hand or feet under the undercarriage. Kw13OP6061
6. Return to the condition in Step 2, and check that the

dial gauge has returned to zero point. If it has not re-
turned to zero point, repeat Steps 2 to 5.
20-24
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING,TRAVEL CIRCUIT
TESTING AND ADJUSTING

HYDRAULIC PRESSURE IN
WORK EQUIPMENT, SWING,
TRAVEL CIRCUIT
MEASURING
+ Hydraulic oil temperature when measuring: 45 - 55°C
A Lower the work equipment to the ground and stop the 202FO6339
engine. Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank. Then put the safety
lock lever in LOCK position.
Remove pressure pick-up plug (1) (Thread dia = 10

pitch = 1.25 mm) from the circuit to be measured, then
install oil pressure gauge Cl (58.8 MPa (600 kg/cm*)).
Measuring unload pressure

Measure the oil pressure in H/O mode with the engine
at high idling and the control levers at neutral.
Measuring pump relief pressure

Oil pressure when main pressure is at low pressure 202FO6340
(31 .gkg/cm*).
1) Measure the pressure when each actuator axcept
the travel is relieved in G/O mode with the engine
at high idling.
* Note that the set pressure of the safety valve for
the swing motor is lower than the main relief pres-
sure, so the value measured will be the relief
pressure of the safety valve.
If the swing lock switch is turned ON, the pressure
will rise, so always keep the lock switch OFF
when measuring.
20-25
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN WORK
TESTING AND ADJUSTING EQUIPMENT, SWING, TRAVEL CIRCUIT
2. When main relief pressure is raised (34.8 MPa

(355kg/cm”)).
1) When travel is operated
Measure the oil pressure in H/O mode with the
engine at high idling.
+ To relieve the travel circuit, apply the service
brake.
2) Whe power max. function is actuated
When measuring the oil pressure in G/O or H/O
mode with the engine at high idling and the power
max. function actuated, relieve on of the boom,
arm, or bucket circuits, and measure the oil pres-
sure.
20-26
TESTING AND ADJUSTING HYDRAULIC PRESSURE IN
TESTING AND ADJUSTING WORK EQUIPMENT, SWING,TRAVEL CIRCUIT
ADJUSTING

. Adjusting high set pressure end
1) Loosen locknut (5)
+ Check that elbow (6) can move.
2) Loosen locknut (3), then turn holder (4) to
adjust.
+ Turn the holder to adjust as follows.
. To INCREASE pressure, turn
CLOCKWISE.
. To DECREASE pressure, turn
COUNTERCLOCKWISE.
* Amount of adjustment for one turn of adjust-
ment screw: 12.6 MPa (128kg/cm2).
$B Locknut:
58.8 f 4.9 Nm (6 f 0.5 kgm)
* When the high pressure end is adjusted, the

low pressure end also changes, so adjust the
low pressure end also.
. Adjusting low set pressure end
1) Loosen locknut (5).
* Check that elbow (6) can move.
2) Loosen locknut (7), then turn holder (8) to
adjust. 202FO6343
* Turn the holder to adjust as follows.

. To INCREASE pressure, turn
CLOCKWISE.
. To DECREASE pressure turn
COUNTERCLOCKWISE.
+ Amount of adjustment for one turn of adjust-
ment screw: 12.6 MPa (128 kg/cm’).
cm Locknut:
44.1 f 4.9 Nm (4.5 f 0.5 kgm)
+ Normally, there is a pressure of approx. 1.27

MPa (13 kg/cm”) or less applied to port Pr,
but at the high pressure setting the pressure
is approx. 2.94 MPa (30 kg/cm’).
20-27
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
TESTING AND ADJUSTING TVC

VALVE OUTPUT PRESSURE
(SERVO PISTON INPUT
PRESSURE)
MEASURING
* Hydraulic oil temperature when measuring: 45 - 55°C
. Measure the oil pressure when the circuit is relieved in
the pressure rise mode.
1. Remove pressure measurement plugs (1) and (2) and
install oil pressure gauge Cl.
* Install a 39.2 MPa (400 kg/cm*) gauge to the
servo end, and a 58.8 MPa (600 kg/cm*) gauge to
the pump outlet port end.
2. Set the swing lock switch ON.
3. Set the working mode to H/O mode.
4. Run the engine at high idling, push the L.H. knob
switch ON, and measure the oil pressure when the
arm IN circuit is relieved.
. Check that the servo piston input pressure is
APPROX. l/3 of the pump discharge pressure.
[Reference]
If there is any abnormality in the LS valve or servo
piston, the servo piston input pressure will be almost
the same or 0 of the pump discharge pressure.
+ (2) Thread dia. = 1Omm, Pitch = 1.25mm

(1) Thread dia. = 12mm, Pitch = 1.5mm
202FO6340
20-28
TESTING AND ADJUSTING TVC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING (SERVO PISTON INPUT PRESSURE)
ADJUSTING
+ If the load becomes larger, the engine speed will drop.
Or if the engine speed remains normal, the work
equipment speed will drop. In such cases, if the pump
discharge pressure and LS differential pressure are
normal, adjust the TVC valve as follows.
1. Loosen locknut (3), and if the speed is slow, turn
screw (4) to the left; if the engine speed drops, turn the
screw to the right.
+ If the screw is turned to clockwise the pump ab-
sorption torque will be increased, and if it is
turned to anticlockwise pump absorption torque
will be reduced.
2. After completing the adjustment, tighten thr locknut.
CW Locknut:Nm (kgm)
* Before the screw is adjusted please mark there to

make clear the original position of the screw.
(TCV valve of main pump)
20-29
TESTING AND ADJUSTING LS VALVE OUTPUT PRESSURE (SERVO
TESTING AND ADJUSTING PISTON INPUT PRESSURE) AND LS DIFFERENTIAL PRESSURE
TESTING AND ADJUSTING LS

(SERVO PISTON INPUT
PRESSURE) AND LS
DIFFERENTIAL PRESSURE
+ Hydraulic oil temperature when measuring: 45 - 55°C
MEASURING
1. Measuring LS valve output pressure (servo piston in-
put pressure).
1) Remove pressure measurements plugs (1) and
(2) and install oil pressure gauge Cl.
* Install a 39.2 MPa (400 kg/cm’) gauge to the
servo end, and a 58.8 (600 kg/cm’)
gauge to the pump outlet port end.
. Oil pressure when travel is rotating under no load
(wheels OFF the ground).
i) Set the working mode tp H/O mode, and turn the
travel speed switch to HI.
ii) Use the work equipment and/or undercarriage at-
tachment to raise the wheels OFF the ground.
iii) Measure the oil pressure with the engine at high
idling and the travel pedal operated to the end of
its stroke to rotate the wheels under no load. Run
the engine at high idling, operate the travel pedal
to the end of its stroke, and measure the oil pres-
sure when the working mode and travel speed
are switched as shown in Table 1.
Table 1
202FO6340
* (2) Thread dia = IOmm

(1) Thread dia = 12mm
20-30
2. Measuring LS differential pressure

1) Measuring with a differential pressure gauge
I) Remove oil pressure measurement plug (1)
(Thread dia. = 12 mm, Pitch = 1.5 mm), and
instll differential pressure gauge C4.
II) Set tot the conditions in Table 2 and measure
the LS differential pressure.
Table 2
Note: When all control levers are at neutral, the LS dif-

ferential pres-sure is the same as the unload
pressure
2) Measuring with oil pressure gauge

* The maximum differential pressure is 3.9 MPa
(40kg/cm’), so measure with the same gauge.
1) Remove oil pressure measurement plug (1)
(thread dia. = 12mm, pitch = 1.5 mm), and installe
the plug inside hydraulic tester Cl.
11) Install oil pressure gauge Cl (58.8 MPa (600kb/
cm2)) to the measurement plug for the pump dis-
charge pressure.
* Use a gaugewith a scale in units of 0.98MPa
(1 Okg/cm*).
If no 58.8 MPa (600kg/cm*) pressure gauge
is available, a 39.2 MPa (400kg/cm*) pres-
sure gauge can be used.
Ill) Set to the conditions in Table 2 and measure the
pump discharge pressure.
* Stand directly in front of the indicator and be
sure to read it correctly.
IV) Remove oil pressure gauge Cl, then install the
LS pressure measurement plug.
V) Set to the conditions in Table 2 and measure the
LS pressure.
* Stand directly in front of the indicator and be
sure to read it correctly. (Pump discharge
pressure) - (LS pressure) = differential pres-
sure.
// 202FO6354
20-31
ADJUSTING
1. Adjusting LS valve
When the differential pressure is measured under the
conditions above, and the results show that the differ-
ential pressure is not within the standard value, adjust
as follows.
1) Loosen locknut (4) and turn screw (5) to adjust
the differential pressure.
+ Turn the screw to adjust the differential pressure
as follows.
. To INCREASE pressure, turn CLOCKWISE
. To DECREASE pressure, turn COUNTER-
CLOCKWISE
2) After adjusting, tighten locknut (4)
cm Locknut:
29.4 f 4.9 Nm (3.0 f 0.5kgm)
Note: Always measure the differential pressure while

adjusting. While adjusting as the wheels are rotat-
ing, care should be taken when leaning into the
pump compartment. No loose clothing.
20-32
TESTING AND ADJUSTING TESTING AND ADJUSTING CONTROL PUMP CIRCUIT OIL PRESSURE
TESTING AND ADJUSTING PPC

PRESSURE REDUCING VALVE
CIRCUIT OIL PRESSURE
MEASURING
* Hydraulic oil temperature when measuring:
45 - 55°C
1. Remove pressure pick-up plug (1) (Thread dia. = 10

mm, Pitch = 1.25 mm), and install oil pressure gauge
Cl (5.88 MPa (60kg/cm’)).
2. Start the engine and measure with the engine at high
idling.
+ When testing for internal leakage of the equip-
ment in the control circuit, use the parts given be-
low to shut off the circuit for the following sections
when measuring the relief pressure.
* Item no. 2 and below can be checked if the equip-

ment in the previous number is normal
* Use the following parts to shut off the circuit.
. For elbow
Sleeve nut: 07221-20210, 07221-20315
Plug: 07222-00210, 07222-00315
. For hose
Plug: 07376-50210,07376-50315
Solenoid valve
202F06358A-K
20-33
TESTING AND ADJUSTING TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE
TESTING EPC VALVE SOLENOID

MEASURING
* Hydraulic oil temperature when measuring 45 - 55°C
1. Measuring output pressure of LS control EPC sole-

noid valve
1) Disconnect output hose (1) of the LS control EPC
valve, then use adampter C3 in the oil pressure
gauge kit to install oil pressure gauge Cl (59MPa
(60kg/cm’)).
2. Measure the output pressure under the conditons
in Table 1
Table 1
output
Engine (Reference)
Operation pressure
speed (rpm) Current (A)
MPa (kg/cm2)
2.5
Min. 1100 800 * 80
(2’3
0.2 * 0.2
Max. 1900 0
(2 * 2)
+ Monitoring code 10 or 40 for engine speed

Monitoring code 15 for LS control EPC current
20-35
TESTING AND ADJUSTING TESTING EPC VALVE SOLENOID VALVE OUTPUT PRESSURE
2. Measuring output pressure of ON/OFF solenoid valve

1) Disconnect outlet hose (2) of the solenoid valve,
then use adapter C3 in the oil pressure gauge kit
to install oil pressure gauge Cl (5.9 MPa (60kg/
cm2)).
2) Measure the output pressure under the condi-
tions in Table 2.
Table 2
Condition of Oil pressure

Name of solenoid Measurement conditions Operating condition Remarks
solenoid (MPa (kg/cm2))
Swing or work equipment lever 2.94*0.49
Brake cancelled ON
operated I (306)
Swing brake
All levers except travel at neutral (5
Brake actuated OFF 0
set after returning to neutral) I I
Travel speed switch at Hi Motor swash
2.94kO.49
Engine speed 1500 rpm or above Travel speed Hi ON plate angle at
(3rX5)
Travel pedal operated I I minimum
Travel speed
Motor swash
Travel speed selector switch at Lo or
Trave speed Lo plate angle at
engine speed 1500 rpm or below
maximum
Swing lock switch ON + work 2.94*0.49
Pressure rise ON
equipment lever operated (3Ok5)
2-stage relief
All levers at neutral Normal pressure OFF 0
I
2.94kO.49
Suspension lock switch ON Sus lock actuated ON
Suspension (30?5)
4
lock
Suspension lock switch OFF Sus lock cancelled OFF 0
I
Operation of solenoid valve
ON: Continuous (oil pressure generated)

OFF: Not continuous (oil pressure: 0)
Cl 202FO6362
20-36
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND TESTING PPC SHUTTLE VALVE
MEASURING PPC VALVE

OUTPUT PRESSURE AND
TESTING PPC SHUTTLE VALVE
* Hydraulic oil temperature when measuring:
45 - 55°C
1. Measuring PPC valve output pressure

1) Disconnect the hose of the circuit to be measured
(see next page).
2) Install adapter C3 between the hose and elbow.
3) Install oil pressure gauge Cl (5.9 MPa (60kg/
cm2)) to adapter C3
4) Run the engine at high idling, operate the control
lever of the circuit to be measured, and measure
the oil pressure.
2. Checking PPC shuttle valve

If the output pressure at the control valve end is low,
check for leakage of oil from the PPC shuttle valve as
follows.
1) Disconnect the hose between the PPC valve and
the shuttle block at the block end.
2) Install an adapter for measuring the oil pressure
to the tip of the hose, then install blind plugs to the
tip and shuttle block end.
3) Operate the control lever and measure the output
pressure.
+ If the output pressure becomes normal, there
is leakage from the PPC shuttle valve; if
there is no change, the PPC valve is defec-
tive.
3. Checking defective operatio of PPC shuttle valve

1) Remove the oil pressure switch, fit adapter C5,
then install oil pressure gauge Cl (5.9 MPa
(60 kg/cm’)).
2) Operate the applicable lever.
* If no oil pressure is generated or if oil pres-
sure is generated when another lever is op-
erated, the operation of the PPC shuttle
valve is defective.
PPC
/
c5
Blind pl& 202F06366
20-37
MEASURING PPC VALVE OUTPUT PRESSURE
TESTING AND ADJUSTING AND TESTING PPC SHUTTLE VALVE
Pressure switch location diagram

Shuttle block seen from rear of machine
Swing
Bucket DUMP (SO8)
‘(507)
w&t CURL
Arm IN
(505)
Boom LOWER
(SO41
Arm OUT
(503)
Boom RAISE
2-Piece boom (502)
stabiI\ser
(G66)
Control valve
0 Bucket DUMP
b
------A
0 Arm
_----~
-,---(*
(Swing RIGHT)
---_1-
L. H. PPC valvel
---
(see from tool
(Extend) KWKiOP6062
1. Swing PPC shuttle valve 4. Stabiliser / 2 piece boom PPC shuttle valve
2. PPC shuttle valve for LS select 5. 2 Piece boom PPC shuttle valve
3. Stabiliser PPC shuttle valve
20-38
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT, SWING PPC VALVE
ADJUSTING WORK EQUIPMENT,

SWING PPC VALVE
* If there is excessive play in the work equipment of
swing lever, adjust as follows.
A Lower the work equipment to the ground and stop the
engine. Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.Then set the safety
lock llever to the LOCK position.
1. Remove the PPC valve
2. Remove boot (1)
3. Loosen locknut (2), then screw in disc (3) until it con-

tacts the 4 heads of piston (4).
. When doing this do not move the piston.
4. Secure disc (3) in position, then tighten locknut (2) to

the specified torque.
5-1 Locknut:
112.7?14.7Nm (1191.5kgm) L
5. Install boot (1).
* With the above adjustment, the clearance between

disc (3) and piston (4) becomes 0.
20-39
TESTING LOCATIONS CAUSING HYDRAULIC
TESTING AND ADJUSTING DRIFT OF WORK EQUIPMENT
TESTING LOCATIONS CAUSING

HYDRAULIC DRIFT OF WORK
EQUIPMENT
* If there is any hydraulic drift in the work equipment
(cylinders), check as follows to determine if the cause
is in the cylinder packing or in the control valve.
1. Checking for defective cylinder packing

* For machine equipped with accumulator Kw13OP6063
1) Checking boom and bucket cylinders

I) Set in the same posture as when measuring
hydraulic drift, and stop the engine.
II) Operate the boom control lever to RAISE or
the bucket control lever to CURL.
. If the lowering speed increases, the
packing is defective.
. If there is no change, the boom holding
valve (boom) or the control valve
(bucket) is defective.
2) Checking arm cylinder
I) Operate the arm cylinder to move the arm in
fully, then stop the engine.
II) Operate the control lever to arm IN.
. KW13OP6064
If the lowering speed increases, the
packing is defective.
. If there is no change, the control valve is
defective.
+ If the pressure in the accumulator has
dropped, run the engine for approx. 10
seconds to charge the accumulator
again before operating.
[Reference]
If the cause of the hydraulic drift is in the packing, and
the above operation is carried out, the downward
movement becomes faster for the following reasons.
1) If the work equipment is set to the above posture 3) When the pressure is balanced, the down-
(holding pressure applied to the bottom end), the ward movement becomes slower. If the lever
oil at the bottom end leaks to the head end. How- is then operated according to the procedure
ever, the volume at the head end is smaller than given above, the circuit at the head end is
the volume at the bottom end by the volume of the opened to the drain circuit (the bottom end is
rod, so the internal pressure at the head end in- closed by the check valve), so the oil at the
creases because of the oil flowing in from the bot- head end flows to the drain circuit and the
tom end. downward movement becomes faster.
2) When the internal pressure at the head end in-
creases, the pressure at the bottom end also rises
in proportion to this. the balance is maintained at a
certain pressure (this differs according to the
amount of leakage) by repeating this procedure.
20-40
TESTING LOCATIONS CAUSING HYDRAULIC
TESTING AND ADJUSTING DRIFT OF WORK EQUIPMENT
2. Checking PPC valve

If the hydraulic drift differs when the safety lock lever is
in the LOCK or FREE position, (engine running), the
PPC valve is defective.
20-41
TESTING AND ADJUSTING MEASURING OIL LEAKAGE
MEASURING OIL LEAKAGE Posture for measuring boom cylinder
+ Hydraulic oil temperature when measuring:

45 - 55°C
1. Work equipment cylinder

+ If the hydraulic drift of the work equipment is out-
side the standard value, measure the leakage in-
side the cylinder as follows, and judge if the
cause of the hydraulic drift is in the cylinder or in
the control valve.
. If the leakage is within the standard value,
the problem is in the control valve.
. If the leakage is greater than the standard
value, the problem is in the cylinder. Posture for measuring arm, bucket cylinder
1) Fully extend the rod of the cylinder to be meas-
ured, then stop the engine.
2) Disconnect piping (1) at the head end, then block
the piping at the chassis end with a blind plug.
A Be careful not to disconnect piping at the bot-

tom end.
3) Start engine and apply relief pressure to the bot-

tom end of the cylinder with the engine at high
idling. KW13OP6066
4) Continue this condition for 30 seconds, then
measure the oil leakage for the next one minute.
Disconnect hose
End of stroke &pd
I F201 C6006
Arm cylinder
I 202FO6376 I 202FO6375 1
20-42
TESTING AND ADJUSTING RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
2. Swing motor
1) Disconnect drain hose (1) from the swing motor,
then fit a blind plug at the tank end.
2) Turn the swing lock switch ON.
3) Start the engine and operate the swing relief with
the engine at high idling.
+ After measuring, swing 180” and measure
again.
3. Travel motor
1) Disconnect drain hose (2) from the travel motor,
then fit a blind plug at the tank end.
2) Apply park brakes
3) Start the engine and operate the travel relief with
the engine at high idling.
a When measuring the oil leakage from the travel

motor, mistaken operation of the control lever
may lead to a serious accident, so always use sig-
nals and check when carrying out this operation.

* When measuring move the motor slightly (to
change the position between the valve plate
and cylinder, and piston and cylinder), and
measure several times.
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
* No accumulator is installed, so the pressure remain-
ing in the piping between the control valve and the
hydralic cylinder or swing motor cannot be released by
operating the control levers. Therefore, when remov-
ing the above piping, be careful of the following points.
1. Run the engine at low idling, operate the hydraulic cyl-

inders so that they are not relieved at the end of the
stroke, lower the work equipment to the ground, then
stop the engine.
* If the engine is stopped with the cylinder relieved
at the end of the stroke, wait for 5 - 10 minutes
before starting the operation.
2. When removing the piping, gradually loosen the
sleeve nut of the piping to slowly release the pressure
remaining in the piping. Remove the piping when the
oil stops spurting out.
20-43
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
Order for operations and procedure for bleeding air
l Replace cylinder
0 -+ 0 ’ 0
l Remove cylinder piping
l Replace swing motor
0 ’ 0 ’ 0
l Remove swing motor piping
l Replace travel motor
0 ’ 0 0
l Remove travel motor, swivel piping
Note 1: Bleed the air from the swing and travel motors only when the oil inside the motor case has been drained.
1. Bleeding air from pump

1) Loosen air bleed plug (1)
2) When oil oozes out tighten plug (1)
QK-I Plug:
17.15f2.45Nm (1.75f0.25kgm)
+ Precautions when starting the engine

After completing the above procedure and start-
ing the engine, run the engine at low idling for 10
minutes.
* If the coolant temperature is low and automatic
warming-up is carried out, cancel it by using the
fuel control dial after starting the engine.
20-44
TESTING AND ADJUSTING BLEEDING AIR
2. Bleeding air from hydraulic cylinders

1) Start the engine and run at idling for approx. 5
minutes.
2) Run the engine at low idling, then raise and lower
the boom 4 - 5 times in succession.
+ Operate the piston rod to approx. 100 mm
before the end of its stroke. Do not releive the
circuit under any circumstances.
3) Run the engine at high idling and repeat Step 2).
After that, run the engine at low idling, and oper-
ate the piston rod to the end of its stroke to relieve
the circuit.
4) Repeat Steps 2) and 3) to bleed the air from the
arm and bucket cylinders.
* When the cylinder has been replaced, bleed
the air before connecting the piston rod.
Be particularly careful not to operate the cyl-
inder to the end of its stroke when the piston
rod has been connected to the LOWER end
of the boom cylinder.
4. Bleeding air from travel motor

1) Disconnect motor drain hose (2).
2) Run the engine at low idling and check that oil
oozes out from the nipple.
3) If oil oozes out, connect hose (2).
20-45
TESTING AND ADJUSTING ACCUMULATORS
ACCUMULATORS
CHARACTERISTIC DETAILS
1. Model code
Charging and testing Unit ii’ K loo

for piston and diaphragm accumulators
Gauge Indication Range

0-lOObar 0-1450psi 100 100
Charging hose 1 _
with cap screw Gl
(fem. thread W 24.32 x l/14” - DIN 477) suitable for
direct connection with nitrogen bottles in Germany,
Netherlands, Switzerland, Sweden, Finnland, Russia,
Belgium (see point 4.3).
Length of Charging Hose

2.5 m
4.0 M 2:: I
other lengths on request
Adapter to Cap Screw Gl

(see point 4.4) for nitrogen bottles in
Great Britain, Australia G2
France G3
USA G4
Italy G5
Japan G6
Japan G7
Brazil G8
China G9
Russia GlO
other adapters on request
Case I
Accessories
full details required when ordering
Gas safety valve with intermediate piece (see point 4.5)
Pressure release valve with connector (see point 4.5)
Adapter for cap screw D (see point 4.1)
2. Weight
2.2 kg with case
1 .O kg without case
3. Mounting position
Optional
20-46
OPERATING INSTRUCTIONS
1. Gas charging pressures

The ciritical value of gas pre-charge for accumulator
20E-60K1150 is as follows.
(Ratio between maximum working pressure and gas
pre-charge pressure.)
20E-60-K1150
Max. working pressure (~2) = 210 bar
Gas pre-charge (PO) = 50 bar
Permissable pressure ratio PZ : PO = 8 : 1

If gas pre-charge falls below this ratio then it becomes
“Critical”.
Charging and testing unit
2. Temperature effect to be taken into account
piston and iaphragm accumulators
In order not to exceed the stated temperatures, the
pre-charge pressure p0 has to be determined at
charging temperature:
po, to = pO.t2 z
t0 = pre-charge temperature (“C)

t2 = max. operating temperature (“C)
3. PREPARATION
Prior to each testing, charging or topping-up of
nitorgen, the accumulator has to be separated from
the pressurised system by means of the shut-off valve
and the fluid has to be released. The protective cap S
has to be unscrewed. Slightly loosen the int.hex.
screw by means of an Allen key GW 0, DIN 911
(approx l/2 turn). Screw cap nut D by hand onto accu-
mulator gas valve. Turn charging unit to a position
where the gauge can be easily read.
4. TESTING
Valve V is opened by loosening the int.hex. screw with
spindle A. After the pointer of the gauge begins to
deflect unscrew the spindle by a further full turn.
The gauge now shows the charging pressure in de ac-
cumulator. The check valve prevents any escape of ni- Piston and diaphragm accumulators
trogen. (gas valve)
5. PRESSURERELEASE
By carefully opening relief valve B, the nitrogen es-
capes into the atmosphere.
6. PRESSURE INCREASE (CHARGING)

Use only nitrogen for charging accumulators.
Never use oxygen! Danger of explosion! If the gas
pressure in the nitrogen bottle is higher than the
max. operating pressure of the accumulator, a
Charging hose for FPS and FPK
pressure release valve and a gas safety valve
1) not for diaphragm accumulators
must be fitted.
20-47
The flexible charging hose is connected to the pres-

sure release valve on the commercially available nitro-
gen bottle by means of the cap nut Gl. (For nitrogen
bottle connections from other countries the appropri-
ate adapter is required).
Cap nut M of the charging hose is for the connection
with nipple C of the charging and testing unit. By open-
ing the shut-off valve on the nitrogen bottle, with spin-
dle A screwed in, slowly release nitrogen into accumu-
lator, to ensure better pressrue compensation and to
prevent damage to the gas valve insert. Close shut-off
valve of the nitrogen bottle and check charging pres-
sure on the gauge.
Repeat this project until the required pre-charge pres-

sure is reached. After a period of approx. 5 minutes,
during which time temperature compensation takes
place (for higher charging quantities a longer period
has to be allowed), recheck pressure (see point 3.3);
adjust if necessary.
When the required pre-charge pressure is reached,

the int.hex screw P is tightened which closes gas
valve V. Now the charging and testing unit is un-
screwed and the int.hex. screw P is retightened
(torque 25 Nm). Check the gas valve on the accumula-
tor for leakages by means of sealing spray or soapy
water.
Screw protective cap S onto the gas valve of the accu-

mulator and tighten. The seal ring U and the int.hex
screw P are always in the gas valve V and are only
loosened when the charging and testing unit is used.
Length 2.5 m (part no. 236514)

Length 4.0 m (partno. 236515)
20-48
G2 (part no. 23637) G5 (part no. 236373)
G3 (part no. 2103421) G6 (part no. 2103423)
G4 (part no. 236374)
20-49
TROUBLESHOOTING
Points to remember when troubleshooting ............................................................................................. 20- 51

Sequence of events in troubleshooting .................................................................................................. 20- 52
Precautions when carrying out maintenance ......................................................................................... 20- 53
Checks before troubleshooting.. ............................................................................................................. 20- 60
Connector types ..................................................................................................................................... 20- 61
Connection table for connector pin numbers.. ........................................................................................ 20- 64
Explanation of control mechanism of electrical system ......................................................................... 20- 77
Display method and special functions of monitor panel ......................................................................... 20- 78
Method of using judgement table ........................................................................................................... 20- 86
Method of using troubleshooting charts ................................................................................................. 20- 88
Details of troubleshooting and troubleshooting procedure ..................................................................... 20- 90
Service code table ................................................................................................................................. 20- 95
Troubleshooting of communication abnormality system (N mode). ........................................................ 20- 97
Troubleshooting of governor, pump controller [governor control system] (E mode) ............................... 20- 100
Troubleshooting of engine (S mode) ...................................................................................................... 20- 129
Troubleshooting of governor, pump controller system [pump control system] (C mode) ....................... 20- 152
Troubleshooting of governor, pump controller [input signal system] (F mode) ....................................... 20- 183
Troubleshooting of hydraulic, mechanical system (H mode) .................................................................. 20- 197
Troubleshooting of monitor panel system (M mode) .............................................................................. 20- 229
20-50
TROUBLESHOOTING POINTSTO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely
fitted.
A When carrying out the operation with two or more workers, keep strictly to the agreed signal, and do not
allow any unauthorized person to come near.
A If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A When removing the plug or cap from a location which is under pressure from oil, water, or air, always
release the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, an important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible cusses of the failure that would produce the reported symptoms.
1. When carrying out thoubleshooting, do not 5) Other maintenance items can be checked
hurry to disassemble the components. If com- externally, so check any item that is consid-
ponents are disassembled immediately any fail- ered to be necessary.
ure occurs: 4. Confirming failure
. Parts that have no connection with the fail- . Confirm the extent of the failure yourself,
ure or other unnecessary parts will be dis- and judge whether to handle it as a real
assembled. failure or as a problem with the method of
. It will become impossible to find the cause operation etc.
of the failure. + When operating the machine to
It will also cause a waste of manhours, parts, or reenact the troubleshooting symp-
oil or grease, and at the same time, will also toms, do not carry out any investiga-
loose the confidence of the user or operator. tion or measurement that may make
For this reason, when carrying out trouble- the problem worse.
shooting, it is necessary to carry out thorough 5. Troubleshooting
priorinvestigation and to carry out troubleshoot- . Use the results of the investigation and in-
ing in accordance with the fixed procedure. spection in items 2-4 to narrow down the
2. Points to ask user or operator causes of failure, then use the trouble-
1) Have any other problems occurred apart shooting flowchart to locate the position of
from the problem that has been reported? the failure exactly.
2) Was there anything strange about the ma- + The basic procedure for troubleshoot-
chine before the failure occurred? ing is as follows.
3) Did the failure occur suddenly, or were 1) Start from the simple points
there problems with the machine condition 2) Start from the most likely points
before this? 3) Investigate other related parts or
4) Under what conditions did the failure oc- information.
cur? 6. Measures to remove root cause of failure
5) Had any repairs been carried out before . Even if the failure is repaired, if the root
the failure? cause of the failure is not repaired, the
When were these repairs carried out? same failure will occur again.
6) Has the same kind of failure occurred be- To prevent this, always investigate why the
fore? problem occurred. Then, remove the root
3. Check before troubleshooting cause.
1) Check the oil level
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers
4) Check the stroke of the control valve spool
20-51
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop an Jobsite

1;“9, TEW00180 m TEW00181
Step 1
IExamination, confirmation of symptoms1 _
_
l) When a request for repairs is received,
\r-
first ask the following points.
. Name of customer
. Type, serial numer of machine
. Details of lobsite, etc.
2) Ask questions to gain an outline of the
problem.
. Condition of failure
. Work being carried out at the time
of the failure
. Operating environment TEW00182
. Past history, details of marnte-
nance. etc.
\
TEW00183
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of

the shop manual to find locations of
possible causes.
TEW00184
i
Step 3
I
1Preparation of troubleshooting tools 1 zzzr TEW00185
1) Look at the table of troubleshooting dKJ

tools in the shop manual and prepare
the necessary tools.
Gep7 I
. T adapter . Pinpoint locations of failure (carry out
. Hydraulic pressure gauge kit. etc.
troubleshootrng)
2) Look in the parts book and prepare the . Decide action to take
necessary replacement parts.
TEWOOt88 1) Before starting troubleshootrng, locate
/
/ and repair simple failures.
. Check before starting Items
. Other check items
2) See the Troubleshooting Section of the
shop manual, select a troubleshooting
flowchart that matches the symptoms,
\ and carry out troubleshootina.
. Drive and operate the machine to con-
w \
firm
really
the condition
a failure.
and judge if there IS
TEWOOl88
Step 4
IGo Ask operator questions to confirm details
. Was there anything strange about the

machine before the failure occurred?
. Drd the failure occur suddenly?
. Had any repairs been carned out before
the failure?
TEWWl90
TEW00189
20-52
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
PRECAUTIONS WHEN
CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long
period, and to prevent failures or other troubles before they
occur, correct operation, maintenance and inspection,
troubleshooting, and repairs must be carried out. This sec-
tion deals particularly with correct repair procedures for
mechatronics and is aimed at improving the quality of re-
pairs. For this purpose, it gives sections on “Handling elec-
tric equipment” and “Handling hydraulic equipment” (par-
ticularly hydraulic oil).
1. PRECAUTIONS WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting one
component to another component, connectors used
for connecting and disconnecting one wire from an-
other wire, and protector or tubes used for protecting
the wiring. Compared with other electrical compo-
nents fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during inspec- TEW00191
tion and repair operations they are frequently removed

and installed again, so they are likely to suffer defor-
mation or damage. For this reason, it is necessary to
be extremely careful when handling wiring harnesses.
Main failures occurring in wiring harnesses

improper insertion
(1) Defective contact of connectors (defective con-
tact between male and female) Problems with de-
fective contact are likely not properly inserted into
the female connector, or because one or both of
the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or
oxidization of the contact surfaces.
I TEW00192
20-53
(2) Defective compression or soldering of connec-

tors. The pins of the male and female connectors
are in contact at the compressed terminal or
solered portion, but there is excessive force on
the wiring, and the plating peels to cause im-
proper correction or breakage.
(3) Disconnection 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 compression of the connector may
I TEW00193
be lost, or the soldering may be damaged, or the

wiring may be broken.
(4) High pressure water entering connector

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

If oil or grease are stuck to the connector and an
oil film is formed on the mating surface between
the male and female pins, the oil will not let the
electricity pass, so there will be defective contact.
If there is oil or grease or dirt stuck to the connec-
tor, wipe it off with a dry cloth or blow dry with air,
and spray it with a contact restorer.
+ When wiping the mating portion of the con-
nector, be careful not to use excessive force
or deform the pins.
+ If there is water or oil in the air, it will increase I TEW00195
the contamination of the points, so clean with

air from which all the water and oil has been
removed.
20-54
2) Removing, installing, and drying connectors and

wiring harness
Disconnecting connectors
(1) Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
when removing
connectors and not the wires.
For connectors held by a screw, loosen the screw
fully, then hold the male and female connectors in
each hand an pull apart. For connectors which
have a lock stopper, press down the stopper with
your thumb and pull the connectors apart. v TEW00197
(2) Action to take after removing connectors

After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil, or water from
getting in the connector portion.
Connecting connectors
(1) Check the connector visually
a. Check that there is no oil, dirt or water stuck to the
connector pins (mating portion).
b. Check that there is no deformation, defective con-
tact, corrosion, or damage to the connector pins.
c. Check that there is no damage or breakage to the
outside of the connector.
* If there is any oil, water, or dirt stuck to the con- TEW00199
nector, wipe it off with a dry cloth. If any water has

got inside the connector, warm the inside of the
wiring with a dryer, but be earful no to make it too
hot as this will cause short circuits.
+ If there is any damage or breakage, replace the
connector.
20-55
(2) Fix the connector securely.

Align the position of the connector correctly, then
insert it securely. For connectors with lock stop-
per, push in the connector until the stopper clicks
into position.
Clicks into position
II TEWOOlSS
(3) Correct any protrusion of the boot and any mis-

alignment of the wiring harness. For connectors
fitted with boots, correct any protrusion of the
boot. In addition, if the wiring harness is mis-
aligned, or the clamp is out of position, adjust it to
its correct position.
* When blowing with dry air, there is danger
that the oil in the air may cause improper
contact, so clean with air from which all the
water and oil has been removed.
Drying wiring harness II

TEW00200
If there is any oil or dirt on the wiring harness, wipe it
off with a dry cloth. Avoid washing it in water or using
steam. If the connector must be washed in water, do
not use high pressure water or steam directly on the
wiring harness. If water gets directly on the connector,
do as follows.
(1) Disconnect the connector and wipe off the water
with a dry cloth.
+ If the connector is blown dry with air, there is
the risk that oil in the air may cause defective
contact, so avoid blowing with air.
(2) Dry the inside of the connector with a dryer.

If water gets inside the connector, use a dryer to
dry the connector. TEW00196
+ Hot air from the dryer can be used, but be

careful not to make the connector or related
parts too hot, as this will cause deformation
or damage to the connector.
TEW00202
20-56
(3) Carry out a continuity test on the connector. After

drying, leave the wiring harness disconnected
and carry out a continuity test to check for any
short circuits between pins caused by water.
+ After completely drying the connector, blow it
with contact restorer and reassemble.
T-adapter
3) Handling control box

(1) The control box contains a microcomputer and
electronic control circuits. These control all of the
electronic circuits onthe machine, so be ex-
tremely careful when handling the control box.
(2) Do not open the cover of the control box unless
necessary.
(3) Do not place objects on top of the control box.
(4) Cover the control connectors with tape or a vinyl
bag.
(5) During rainy weather, do not leave the control box
in a place where it is exposed to rain.
(6) Do not place the control box on oil, water, or soil,
or in any hot place, even for a short time. (Place it I TEW00204
on a suitable dry stand)

(7) Precautions when carrying out arc welding on the
body, disconnect all wiring harness connectors
connected to the control box. Fit an arc welding
ground close to the welding point.
I1 TEW00206
2. POINTSTO REMEMBER WHEN

HANDLING HYDRAULIC
EQUIPMENT
With the increase in pressure and precision of hydraulic

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

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

If disassembly or maintenance work is carried out on
hydraulic equipment in the field, there is danger of
dust entering the equipment. It is also difficult to con-
firm the performance after repairs, so it is desirable to
use unit exchange. Disassembly and maintenance of
hydraulic equipment should be carried out in a spe-
cially prepared dustproof workshop, and the perform-
ance should be confirmed with special test equip-
ment.
TEW00207
3) Sealing openings
After any piping or equipment is removed, the open-
ings should be sealed with caps, tapes, or vinyl bags
to prevent any dirt or dust from entering. If the opening
is left open or is blocked with a rag, there is danger of
dirt entering or of the surrounding area being made
dirty by leaking oil so never do this. Do not simply drain
oil out on to the ground, collect it and ask the customer
to dispose of it, or take it back with you for disposal.
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when refilling
with hydraulic oil. Always keep the oil filler and the
I TEW00208
area around it clean, and also use clean pumps and oil
containers. If an oil cleaning device is used, it is possi-
ble to filter out the dirt that has collected during stor-
age, so this is an even more effective method.
I TEW00209
20-58
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows easily.
In addition, the sludge can also be drained out easily
from the circuit together with the oil, so it is best to
change the oil when it is still warm. When changing the
oil, as much as possible of the old hydraulic oil must
be drained out. (Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from the drain
plug in the circuit.) If any old oil is left, the contami-
nants and sludge in it will mix with the new oil and will
shorten the life of the hydraulic oil.
6) Flushing operations
After disassembling and assembling the equipment,
or changing the oil, use flushing oil to remove the con-
taminants, sludge and old oil from the hydraulic circuit.
Normally flushing is carried out twice: primary flushing
is carried out with flushing oil, and secondary flushing
is carried out with the specified hydraulic oil.
7) Cleaning operations
After repairing the hydraulic equipment (pump, control
valve, etc.) or when running the machine, carry out oil TEWOO210
cleaning toi remove the sludge or contaminants in the
hydraulic oil circuit.
The oil cleaning equipment is used to remove the
ultrafine (about 3 u) particles that the filter built into the
hydraulic equipment cannot remove, so it is an ex-
tremely effective device.
I TEW00211
20-59
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Judgement
Item Action
standard
1. Check fuel level Add fuel
2. Check for dirt or water in fuel Clean, drain
3. Check hydraulic oil lever Add oil
4. Check hydraulic oil strainer Clean, drain
5. Check swing machinery oil level Add oil
6. Check engine oil level (Level of oil in oil pan) Add oil
7. Check cooling water level Add water
8. Check condition of dust indicator Clean or replace
9. Check hydraulic oil filter Replace
1. Check for loose or corroded battery terminals Tighten or replace
2. Check for loose or corroded alternator terminals Tighten or replace
3. Check for loose or corroded straight motor terminals Tighten or replace
1. Check for abnormal noise or smell Repaire
2. Check for oil leakage Repaire
3. Bleed air from system Bleed air
1. Check battery voltage (engine stopped) 20 - 30 V Replace
2. Check level of battery electrolyte Add or replace
3. Check for discolored, burnt, or bare wiring Replace
4. Check for missing wiring clamps, hanging wires Repair

5 Check for getting wet onto wiring (check carefully getting Disconnect connector
’ wet at connectors and terminals) and dry connection
6. Check for broken or corroded fuses Replace
7, Check alternator voltage (engine running at over half
27.5 - 29.6 V Replace
throttle)
8, Noise when battery relay is operated (switch starting
Replace
switch from ON to OFF)
20-60
TROUBLESHOOTING CONNECTOR TYPES
CONNECTORTYPES
A02 KESI 2 Swing park brake solenoid
A03 1 KESI 2 1Diode

A04 1 KESI 2 I2-stages relief solenoid circuit
A05 1 KESI 2 I Swing brake solenoid cicuit
A07 KESI 2 I Travel speed solenoid circuit
A08 KESI 2 Heater circuit

t
All KESI 2 Alarm buzzer circuit
A13 1KESIX 2 I Battery relay drive circuit

A14 1 KESI 2 I Battery relay drive circuit
Al6 1 KESI 2 I Fuel shut off circuit
2 I Horn
17 Pump controller
20 Pump controller
16 Pump controller
IO TVC prolix switch
2 TVC prolix resistor
3 Pump pressure sensor
2 I LS control EPC solenoid valve
2 Pump TVC solenoid valve
Cl7 040 16 Governor, pump controller Park brake switch
17 Governor, pump controller Brake light switch
3 Governor potentiometer
4 Governor motor
3 Fuel control dial
2 Engine speed sensor
14 Intermediate connector
E09 3 Fuel shut off valve
SIMPLE
Eli L 1 Heater relay G51 CONN- 1 ENG room lamp
ECTOR
El2 1 3 ALTERNATOR G52 KESO 4 Lower wiper
El3 I 2 STARTER G53 HELLA 6 Flasher unit
SIMPLE
FOI X 2 Travel alarm G54 CONN- 1 SUS lock switch
ECTOR
Con- Con- No.

nector nectar of Electrical component
No. type pins
G55 Horn relay
G62 ForwarcVreversesol
G63 EPC flow
G68 2 PC boom/stabiliser switch
G69 M 2 Lower wiper
G70 M 4 LH wrist control
G71 M 4 RH wrist control
G72 X 2 Service sol
G75 X 2 Travel switch
Simple
G76 tonne- 1 Sidelight
%ctor
Simple
G77 tonne- 1 Sidelight Travel (Park brake buzzer)
ctor
Simple
G90 tonne- 1 Park brake switch
ctor
Simple
G91 tonne- 1 Brake light switch SUS lock switch
ctor
G92 Britax 1 5 Roadlights switch
G93 AMP 1 Fuseholder
G94 AMP 1 1
G95 Britax 1 9 Hazard switch
G96 Britax 1 6 SUS lock switch
G97 _ I 3 Indicator switch
G98 Britax I 6 Outriggers UR switch
G99 Britax I 9 Park brake switch
GIOO Britax I 2 Worklights pilot
G101 Britax I 2 Indicators pilot
G102 Britax I 2 Low brake press pilot
G103 Britax I 2 Main beam pilot
G104
G105 Diode L.H. stand switches
G106 M 11 Rear W/lamp

Simple
G130 connec- 1 Service brake
tor
Simple
G131 tonne- 1 Service brake
ctor
G132 x 12 Travel switch (auto SUS lock)
G133 KESI 1 Diode IV124 1 PA 4 1 vvork equrpmenr ramp
20-62
No. of
Electrical component Electrical component
pins
M26 1 X 6 1Heater Boom LOWER oi pressure switch
M28 1 - 2 1Window washer motor Arm IN oil pressure switch
M30 l - Ill Work lights (option) SO6 X Bucket CURL oil pressure switch
Electromagnetic clutch for air
M34 1 M so7 x Bucket DUMP oil pressure switch
conditioner compressor
M38 1 M 3 I Light switch t SO8 X Swing oil pressure switch
M39 1 M 1 IOPT LOWER wiper Swing oil pressure switch

M40 1 M 1 I Right working light Swing redundancy switch
M41 1 M 1 I Left working light Staeter switch
M42 KESI 2 I Rear working light TO3 GRD (Revo frame)
M45 I 040 3 I Network bus TO4 GRD (safety relay)
M46 1 M 3 I Check * vo4 x Swing brake solenoid valve
Boom lamp (LH) 2 2-stage relief solenoid valve
2 Travel speed solenoid valve

6 Wiper motor
WOS M 18 Wiper motor controller
Cab light 4 Rear limit switch
Wiper, indicator switch

Intermediate connector
Swing lock switch
Intermediate connector
20-63
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
No.
of
pins
r Male (female housing)
X type connector
Female (male housing)
205FO53 IO
205FO5309
205FO5.3 I I 205FO53 I2
2 2
205FO53 I3 205FO53 I4
1 3
\
4 2
205FO53 I5 205FO53 I6
20-64
No.
of
T M type connector
pin: Male (female housing) Female (male housing)
205FO53 I7 205FO53 I8
1
1
205FO53 I9
205FO5320
2
\ ;3
-
3
,2&F
1
20560532 I 205FO5322
1 3
\ I
!
2 4
205FO5323 205FO5324
20-65
No. M type connector

of
pins Male (female housing) Female (male housing)
4 1
ES
/ \
3 s 6 3
205FO5325 205FO5326
20-66
No.
of
T S type connector
5 1
8 4 8 4
205FO5327 205FO5329
1 6 6 1
/
IO
/ \
10 5
205FO5329 205FO5330
8 1
16
8 i
16 7
205FO5333 205FO5334
20-67
No.
of
r AMP040 type connector
16
1 9
205FO5335
10 20 20 10
/
‘\
\ i
20
205FO5337
1 11 ri 1 205FO5338
20-68
No.
of
T AMP070 type connector
14
205FO6364 205FO6365
18
k.4
205FO6366 205FO6367
20-69
No. AMP250 type connector

of
Y
3
a 3
1
205FO6366
205FO6369
20-70
No.
of
T SWP type connector
118 4 1
/
14
/ I \ \
14 10 7 3
3 7 10 14
F56103067 F56103086
20-71
No. MIC connector

of
17
I I
142F414 142F415
11
1
21 12
21
142F416 - 142F417
20-72
No. Relay connector

of
6 5 6
No. Simple connector

of
pins Male (male housing) Female (female housing)
195FO5 128 195FO5129
No.
of Ring connector
pins
20-73
No.
of
r L type connector
2OTFOl 150
20TF01149
No. PA type connector

of
205FO6370 205FO637 I
20-74
No.
of
T Automobile conector (KESI)
pin: Female (male housing) Male (female housing)
E3
205FO6373
205FO6372
20-75
No. Automobile conector (KESI)

of
pins Female (male housing) Male (female housing)
PE 423F350
423F349
I 1
B
I I 1
2 3 3 2
I
423F351 423F 352
423F354
423F353
20-76
TROUBLESHOOTING EXPLANATION OF CONTROL MACHANISM FOR ELECTRICAL SYSTEM
EXPLANATION OF CONTROL MACHANISM FOR ELECTRICAL

SYSTEM
1. Explanation of machine control functions
The control mechanism for the electrical system consists of the monitor panel and governor and pump
controller. The monitor panel and the governor and pump controller input the signals that are necessary,
and together with the signals selected by the monitor panel, the governor and pump controller outputs or
inputs the necessary signals and control the pump absorption torque and engine output.
TVC output power sourc
Each solenoid control

Network tKtlVv
Work equipment oil

Boom Raise/Lower
press. switch
Arm In/Out
Bucket Curl/Dump
Press. switch swing
8 Swing lock signal 1 Travel oil press. switch

c
Engine oil level sensor

Gover, pump F pump press. sensor
c
controller
Engine oil press.
_ Star-signal 0
Air cleaner clogging

Air cleaner sensor signal Battery relay drive a
c
clogging sensor
Coolant level sensor signal
Fuel level sensor signal
20-77
TROUBLESHOOTING DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
DISPLAY METHOD AND SPECIAL FUNCTIONS OF MONITOR PANEL
1. Display on machine monitor

When the starting switch is turned on, all the monitor and gauge lamps light up for approx. 3 seconds, and
the buzzer sounds for approx. 1 second. During this time, the monitor itself carries out self diagnosis, and
after it has finished, it returns to the normal display.
2. Recording of service codes and user code display function

1) All the abnormality data for the governor and pump controller is sent to the monitor panel. When the
monitor panel receives this data, it records the abnormality data, and at the same time, depending on
the nature of the abnormality, it displays the user code on the time display panel to advice the operator
of the action to take. However, in cases of abnormalities which are not urgent and do not require the
user code to be displayed, only the content of the abnormality is recorded, and no display is given.
2) Types of user codes and system

E02 (TVC system)
E03 (Swing holding brake system)
E05 (Governor motor system)
* For details of the service codes included in the user code, see the action taken by the controller
when an abnormality occurs, the symptoms on the machine or the judgement table.
3) Displaying user code

If it becomes necesarry to display the user code, the time displayed panel is automatically switched to
advice the operator to take the necesarry action.
. Actual display (Example: Disconnection in the cancel solenoid system for the swing holding brake)
OFF OFF
WVM/-v
OFF OFF User code OFF OFF OFF
EKP00077
20-78
4) Display of trouble data

The monitor panel records both service codes which are included in the user code, and service codes
which are not included. This data can be displayed on the time display as follows.
+ For details of the service codes that are not included in the user code, see ACTION TAKEN BY CON-
TROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE or the JUDGEMENT
TABLE.
Time display Service

I
Time
Working
mode _
function
Monitor panel rear
0 Method of displaying trouble data
Operation Display
1. To set to the trouble data display mode. 1. On the tme display and service meter display, the service
Keep the TIME switch + L.H. travel code and number of hours (service meter hours) that
speed switch pressed for 2.5 seconds. have elapsed since the occurrense of the abnormality are
Note: It is possible to call it up at the fol- displayed.
lowing times. . Example of display : When E212 has occured 12
1) In the normal mode hours before (service meter)
2) In the user code display mode 1) Display of service code 2) Display of elapsed time
3) In the machine data monitoring
mode
4) In the time adjustment mode
2. To go to the next service code display,

press the time switch + R.H. woking
mode switch. i--‘-w 4J-uv
OFF OFF Service code OFF OFF Elapsed ON
3. To go back to the previous service code time data
display, press the time switch + L.H. BKP00079
woking mode switch.
3) If any abnormality exists at this time, the E mark is dis-
played
0,FF
OFF
OiF Servick code OFF OFF Elapsed ON

time data
L If there is an abnormality, or the controller is carrying out
self diagnosis, the output is shut off, and E is displayed.
BKP00080
20-79
Operation I Display
4. To finish with the trouble data display 4. If there is no abnormality code in memory
mode, keep the TIME switch + L.H.
travel speed switch pressed for 2.5 sec-
onds. OFF OFF
5. To erase the memory, keep the time
switch pressed, turn the starting switch
from OFF to ON, and keep the time
switch pressed for 5 seconds.
wwh-Jwv
OFF - is displayed OFF - is displayed OFF
3. Machine data monitoring function

The input signals from the sensors and the output signals to drive the solenoid are displayed on the time
display and service meter display.
Time display
meter
Til
switch
\
Travel speed e
switch \ e
Monitor panel rear
1) Method of displaying monitoring code
Operation Display
1. To set the machine data monitoring 1. On the time display and service meter display, the moni-
mode, do as follows. toring code and data are displayed.
Keep the time switch + knob button func- . Example of display
tion switch pressed for 2.5 seconds. 1) When engine speed is monitoring (monitoring code
Note: this is possible at the following 10)
times.
OFF OFF
1) During the normal code
2) During the user code display
3) During the time adjustment mode
4) During the trouble data display
mode v-- uvvw-v-v
OFF OFF Monitoring OFF OFF Monitoring OFF OFF
code code data
(example of 1950 rpm)
BKP00083
20-80
Operation Display
2. To go to the next monitoring code dis- 2) When displaying bit pattern

play, press the time switch + R.H. work- . For monitoring codes 08,20 - 24,36,37,47 - 49,4A,
ing mode switch. display the bit pattern.
3. To go back to the previous monitoring . Example of monitoring code 20
code display, press the time switch + OFF - Displays OFF
L.H. working mode switch.
i
4. To finish with the machine data monitor-
ing code mode, keep the time switch + a &@$#B a
knob button function switch pressed for
WUWV
2.5 seconds. OFF OFF Displays OFF Displays bit OFF OFF
monitoring pattern
code BKP00084
. The code no. is displayed in the monitoring code por-

tion, and the display lights up to display bit patterns
(1) - (6).
2) Table of machine data monitoring codes

* For detalis of the B in the Unit column, see the bit pattern chart in the next section.
No. Item I Unit Name of component
01 Monitor model code I - I Monitor panel
02 Governor, pump controller model code I - I Governor, pump controller
03 Governor, pump controller model code I - I Governor, pump controller
08 S-NET component condition display I B I Governor, pump controller
10 Engine speed I 1Orpm Governor, pump controller
11 Pump discharge pressure input MPa (kg/cm2) Governor, pump controller
13 TVC current output I IOmA Governor, pump controller
14 Travel EPC current I - I EPC
15 LS-EPC current output IOmA Governor, pump controller
16 No. 2 throttle command IOmA Governor, pump controller
20 Governor, pump controller PPC oil pressure switch input signal (1) B Governor, pump controller
23 Governor, pump controller solenoid actuation B Governor, pump controller
24 Input condition of sensor for governor, pump controller monitor warning 1 B Governor, pump controller
30 Fuel control dial input value IOmV Governor, pump controller
31 Potentiometer voltage IOmV Governor, pump controller
32 VBB voltage (battery voltage) 1OOmV
25 Input condition of sensor for governor, pump controller monitor warning 2 B Governor, pump controller
20-81
+ For detalis of the B in the Unit column, see the bit pattern chart in the next section.
No. 1 Item I Unit Name of component
33 IG overnor motor A phase current I 1OmV Governor, pump controller
34 IG overnor motor B phase current I 1OmV Governor, pump controller
35 1Battery relay output voltage I 1OOMV Governor, pump controller
36 IG overnor governor input condition I B IGovernor, pump cotnroller
37 IG overnor governor output condition I B IGovernor, pump controller
40 I Engine speed I 1Orpm Governor, pump controller
41 I Coolant temperature sensor voltage I 1OmV Governor, pump controller
42 I Fuel sensor input voltage I 1OmV Governor, pump controller
43 I Battery charge input voltage I 1OOmV Governor, pump controller
47 I Monitor panel output condition I I B IGovernor, pump controller
48 I Monitor panel input condition 1 I B IGovernor, pump controller
49 I Monitor panel input condition 2 I B IGovernor, pump conroller
4A Monitor panel input condition 3 B Governor, pump controller
4C Monitor panel output condition 2 B Governor, pump controller
20-82
3) Bit pattern chart

As shown in the diagram below, the time display has bit numbers light up to show that the signal is being
transmitted. (For details, see METHOD OF DISPLAY MONITORING CODE.)
OFF OFF
OFF OFF Code portion OFF OFF OFF
BKPO0085
Code Content Bit Details (condition when lighted up)
(1) Governor, pump controller connected (ID=2)
(2) Governor, pump controller connected (ID=3)
(3)
08 Connection of S-NET components
(4)
(5)
(6)
(1) Swing switch ON
(2) Travel switch ON
Input condition of governor, pump controller (3) Boom LOWER switch ON

20
PPC switches Boom RAISE switch ON
(4)
(5) Arm IN switch ON
(6) Arm OUT switch ON
(1) Bucket CURL switch ON
(2) Bucket DUMP switch ON
Input condition of governor, pump controller (3) Swing lock switch ON

21
PPC switches and other switches Service switch ON
(4)
(5) Model selection 5
(6) Swing prolix switch ON
(1) Model selection 1 GND connected
(2) Model selection 2 GND connected

Input condition of governor, pump controller Model selection 3 GNC connected
(3)
22 model selection and other switches
Drive condition of governor, (4) Model selection 4 GND connected
(5) Kerosene mode input GND connected
(6) Knob switch ON
(1)
(2) Overload sensor Open
Input condition 2 of sensor for governor, pump (3)

25
controller monitor warning
(4)
(5)
(6)
20-83
Code Content Bit Details (condition when lighted up)

(1) Above engine oil pressure sensor Lo set pressure
(2) Above engine oil pressure sensor Hi set pressure
Input condition 1 of sensor for governor, (3) Radiator water level sensor abnormal
24
pump controller monitor warning (4) Engine oil level sensor abnormal
(5) Hydraulic oil level sensor abnormal

(6) Air cleaner clogging sensor abnormal
(1)
(2)
Input condition of governor, pump (3)
36
controller (4)
(5) Starting switch ON
(6)
(1) Battery relay: Actuated
(2)
Output condition of governor, pump (3)
37
controller (4)
(5)
(6)
(1)
(2) Alarm buzzer: when operated machine
(3)
47 Monitor panel output condition 1 (4)
(5)
(6)
(1) KEY ON SW OFF
(2) Terminal BR Voltage Hi
(3) LIGHT SW OFF

49 Monitor panel input condition 2
(4) Preheating switch OFF
(5) START C Sometimes turns ON
-(6)
20-84
Code Content 1 Bit Details (condition when lighted up)
(1) Time switch OFF

PPC oil pressure selector
(2) OFF
switch
4A Monitor panel INPUT condition 3 (3) Overload selector switch OFF
(4) STD/DLX selection STD
(5) Swing lock switch OFF
(6) Buzzer cancel switch OFF
4. Governor motor adjustment mode

This is used when adjusting the linkage between the governor motor and the injection pump. (For details of
the procedure, see TESTING AND ADJUSTING.)
Operation Display
4
1. To set the governor motor adjustment I.
OFF
mode, press the time switch + R.H. OFF
working mode switch.
---J-w-v
OFF Displays “g-SET” OFF OFF OFF
BKP00086
2. To return to the time display mode use 2. Buzzer sounds once a second
the same procedure as in step 1.
5. Time adjustment mode

To adjust the time do as follows.
Operation Display
1. To set the time adjustment mode, keep 1. The time mark portion flashes
the time switch depressed for 2.5
seconds.
OFF OFF
2. Use the L.H. working mode switch to

advance the hour.
h
3. Use the R.H. working mode switch to w--+-J-v
Flashes Hour Minute ON Normal display ON
advance the minute. (24-hour clock)
BKP00087
4. To return to the time display mode use

the same procedure as in Step 1. + The example shows the situation when setting to 12:34.
20-85
TROUBLESHOOTING METHOD OF USING JUDGEMENTTABLE
METHOD OF USING JUDGEMENTTABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the
electrical system or by an abnormality in the hydraulic or mechanical system. the symptoms are then used to
decide which troubleshooting table (E-00, S-00, C-00, F-00, H-00, M-00) matches the symptoms.
The judgement table is designed so that it is easy to determine from the user code and service code which trou-
bleshooting table to go to.
+ The abnormality display (warning) given by the monitor panel leads directly to troublehsooting of the ma-
chine monitor (M-00). (See troubleshooting of the machine monitor system).
1. When using judgement table for governor, pump controller (governor control system) and engine
related parts
. If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of the
judgement table (E-00).
(A l Mark is put at the places where the failure mode and service code match).
. If a problem has appeared but no service code is displayed on the monitor panel, go to the point where
the failure mode matches the troubleshooting code on the right of the judgement table (E- or S-).
<Example> Failure mode “Engine does not start”.
Procedure: Check if the service code is being displayed on the monitor panel
[Judgement]
1) If a service code is being displayed on the monitor panel.. .go to troubleshooting [E3:00 ] for the governor,
pump controller (governor control system).
2) If no service code is displayed on the monitor panel, and the engine does not start:
Starting motor rotates Go to troubleshooting S-2 of

. Check that starting mechanical system
motor rotates
Starting motor does not rotate Go to troubleshooting E-8 of
electical system
20-86
TROUBLESHOOTING METHOD OF USING JUDGEMENTTABLE
2. When using judgement table for governor, pump controller (governor control sustem) and hydraulic related
parts.
. If a service code is displayed on the monitor panel, go to the troubleshooting code at the bottom of the
judgement table (C-00).
(A l mark is put at the places where the failure mode and service code match.)
. If a problem has appeared but no service code is displayed on the monitor panel, go to the point where
the failure mode matches the input signal, and check the display for the input signal (the display at the
place with a mark).
. If it is displayed normally, go to the troubleshooting code on the right of the judgement table
(H-00).
. If the input signal is not displayed on the monitor panel, go to the troubleshooting code at the
bottom of the judgement table (F-00).
<Example> Failure mode “Upper structure does not swing”.
Procedure: check if the service code is being displayed on the monitor panel.
[Judgement]
1) If a service code is being displayed on the monitor panel...go to troubleshooting [E2: ] for the governor,
pump controller (pump controller system).
2) If no service code is displayed on the monitor panel, and the upper structure does not swing:
. Check governor, pump controller

input signal (Check in monitoring mode)
c There is a signal
There is no signal
Go to troubleshooting
mechanical system
Go to troubleshooting
of governor,
H-25 of
F-00
pump controller
input signal system (F mode
for applicable system)
20-87
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. 1 Component Service code
N-00 Troubleshooting of communication abnormality system E218 group
Troubleshooting of electrical system for governor, pump

E-00 controller (governor control system)
E3-00 group
s-00 Troubleshooting of engine related parts
Troubleshooting of electrical system for governor, pump

c-00 controller (pump control system)
E2- 00 group
Troubleshooting of governor, pump controller (input signal

F-00 system)
H-00 Troubleshooting of hydraulic, mechanical system
M-00 Troubleshooting of machine monitor El -00 group
2. Method of using troubleshooting table for each troubleshooting mode

1) Troubleshooting code number and problem. The title of the troubleshooting chart gives the trouble-
shooting code, and failure mode (problem with the machine). (See Example (1)).
2) Distinguishing conditions. Even with the same failure mode (problem), the method of troubleshooting
may differ according to the model, component, or problem. In such cases, the failure mode (problem) is
further divided into sections marked with small letters (for example a), so go to the appropriate section
to carry out troubleshooting. (See Example (2)). If the troubleshooting table is not divided into sections,
start troubleshooting from the first check item in the failure mode.
3) Method of following troubleshooting chart
. Check or measure the item inside 4 and according to the answer follow either theYES line
or the NO line to go to the next I. (Note: The number written at the top right corner of the I is
an index number; it does not indicate the order to follow).
. Following the YES or NO lines according to the results of the check or measurement will lead
finally to the Cause column. Check the cause and take the action given in the Remedy column on
the right. (See Example (3)).
. Below the I there are the methods for inspection or measurement, and the judgement values. If
the judgement values below the I are correct or the answer to the question inside the I is
YES, follow theYES line; if the judgement value is not correct, or the answer to the question is NO,
follow the NO line.
. Below the I is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling is
mistaken, there is danger that it may cause mistaken judgement, or the equipment may be dam-
aged. Therefore, before starting inspection or measurement, always read the instructions care-
fully, and start the work in order from item (1).
4) General precautions. When carrying out troubleshooting for the failure mode (problem), precautions
that apply to all items are given at the top of the page and marked with + (See Example (4)). The
precautions marked + are not given in the I, but must always be followed when carrying out the
check inside the I.
5) Troubleshooting tools. When carrying out the troubleshooting, prepare the necesarry troubleshooting
tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
20-88
6) Installation position, pin number

A diagram or chart is given for the connector type, installation position, and connector pin number connec-
tion. When carrying out troubleshooting, see this chart for details of the connector pin number and location
for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart
for each failure mode (problem).
<Example>
(1) M-9 When starting switch is turned ON (engine stopped), check item for previous trouble-
shooting flashes
(4) + Before carrying out troubleshooting, check that all the related connectors are properly in-
serted.
* Always connect any disconnected connectors before going on the next step.
* Check that the coolant is at the specifies level before carrying out troubleshooting.
(2) a) G (coolant level) light flashes

sApoo51gDevidedinto sections a) and b)
b) @ (en g’me oil level) light flashes
SAP00523
(3)
Cause
YES Defective coolant level

sensor system (see M-26)
4YES Defective governor, pump Replace

when short connec- Ir controller
tor IS connected to YES Is bit (3) of
_ monitoring code 24 _
3
~ lighted up?
* Disconnect P08. Is contlnulty between
. Turn starting switch YES Cl6 (female) (8) and ~ - Defective monitor panel Replace
ON. _ * Turn starting switch NO
chassis as shown in
ON.
2 table? Defective contact, or
* Set to monitoring
~ code24. disconnection in wiring Repair or
Is there continuity * Turn starting switch
harness between Cl 6 replace
- between PO8 (female) - OFF. NO
* disconnect C16, P08. (female) (8) -PO8
NO (2) and chassis?
* Connect ++ disconnect (female) (1)
I I short connector to PO8
. Turn starting switch (female)
OFF. Defective contact, or
. Disconnect PO8 NO disconnection in wiring Repair or
harness between PO8 replace
(female) (2) - chassis ground
Table
Short connector Continuity
Connected I Yes I
Disconnected No
I
20-89
TROUBLESHOOTING DETAILS OFTROUBLESHOOTING ANDTROUBLESHOOTING PROCEDURE
DETAILS OFTROUBLESHOOTING AND TROUBLESHOOTING

PROCEDURE
If any abnormality should occur, it is necessary to go to the correct troubleshooting chart in accordance with the
judgement table for that type of failure (governor, pump controller (governor control system) and governor, pump
controller (pump control system). For details of the troubleshooting and troubleshooting procedure, refer to this
flow chart.
When carrying out troubleshooting, ask the operator as much as possible about the condition of the machine,
and check the following items before starting.
(1) Condition of controller connection (check with monitoring codes 02 - 03 )
(2) Blown fuses
(3) Battery voltage (monitoring mode 32)
(4) Electricity generation (charge input) voltage (monitoring code 43)
The procedure for carrying out check items No. 3 and 4 in the flow chart below is given on the following pages.
E
E02 (TVC system)
YE
E03 (Swing holding brake system)
Go to Item 2
E05 (Governor motor system) I
- E2 00 group. Troubleshooting for governor,

Carry out troubleshootlng m applicable mode (Note, For
YE pump controller (pump control system) (C mode)
E216, carry out troubleshooting of the communication ab-
E3 00 group. Troubleshooting for governor,
normality system (N mode.)
- pump controller (governor control system)
(E mode)
Engine system
1
2 5
Is problem in engine
IS Selvlce code YE system of hydraulic NO chart ior
displayed on monitor * Go to flow chart for Ilems where
(mechanical)
panel? sectlo” where there IS ,,,ere ,s ,,o
system? dIsp,ayj (El 1
no abnormality display
on judgment table E15)
. Operate and check * After adlustIng 011
1Hydraulic Carry out trouble-
Selvlce code. pressure, judge from
(mechani- shooting for hydraulic
engine speed. ^
YE controller Input and tial) system (mechanical) system
* Is all workequlpment
(H mode)
slow and does
engine speed drop
* Check wng under heavy load?
1
3 monitoring code.
. Governor controller:
-Carry out troubleshooting for
30,31,33,34 IO
NC Input slgnal system (F mode).
Are monitor codes * Pump controller.
02, 03, 06 normal? 10-24
* Valve controller.
50 69
* Check ConnectIon - Carry out troubleshootlng
condltlon of S-NET I” NO for communication
monitoring codes abnormality system
02,03,08 (N comde).
+ For details, see governor, pump controller (governor control system) (pump control system) in the JUDGE-
MENT TABLE.
20-90
If there is no abnormality display in the communications system transmitted in S-NET, it can be taken that the
output signal from the monitor panel has been transmitted. However, even if there is no abnormality display, if the
operation is defective, use the following procedure when checking directly. If any abnormality occurs in the S-
NET system, the system is automatically switched to the following default mode, so be careful when carrying out
troubleshooting.
Default Mode when communications cannot be carried out for the monitor and governor, pump controller
Set mode Pump Control Governor control

1 Working mode G/O mode H/O mode
2 Throttle signal FULL FULL
3 Auto-deceleration ON (deceleration mode) ON (deceleration mode)
4 Coolant temperature signal OFF
6 Power max. mode ON (power max. possible)
7 Travel speed Lo
8 Automatic warming up _ ON (automatic warming-up mode)
1. Procedure for checking monitor panel output signal

* For details of operating the monitoring mode, see MONITOR PANEL DISPLAY AND SPECIAL FUNC-
TIONS.
1. Connnection condition of components
1) Set to the monitoring mode and display monitoring code 08.
2) The time display (bits) will light up to display the components that are connected.
* Governor, pump controller (pump control system) (1) and governor, pump controller (governor
control system) (2) will light up.
2. Checking working mode signal (check No. 2 throttle signal monitoring code 16) at the same time)
2) Switch the working mode as shown in Table 1 and check that the engine speed changes.
Table 1
High idling speed (rpm)

Working mode
[The figures in ( ) are the rated speed]
I H/O I Approx. 2340 (2100) I

Approx. 2140 (2050) l
I G/O I % I
L/O Approx. 2050 (1780)
0% 1 Swing Lock ON
20-91
3. Checking travel speed selection signal

2) Change the speed selector switch to Hi or Mi and run the engine at 1500 rpm or above. Check that
bit (6) lights up when traveling at Hi or Mi pump oil pressure: 21.6 - 32.3 MPa (220 - 330 kg/cm2).
2 Checking input signal of governor, pump controller

+ Check the input signals for each controller as follows.
. Pump control system
1. Checking input signal
1) Check hydraulic switch
i) Set to the monitoring mode, and display monitoring code 20 and 21.
ii) Operate each work equipment lever, and check how the bit pattern lights up.
* For details of the bit pattern chart, see MONITOR PANEL DISPLAY AND SPECIAL
FUNCTIONS.
2) Check speed sensor (check engine speed)
i) Set to the monitoring mode, and display monitoring code IO.
ii) Use the fuel control dial to change the speed, and measure the speed when this is done.
3) Check pump discharge pressure sensor
i) Set to the monitoring mode, and display monitoring code Il.
20-92
TROUBLESHOOTING DETAILS OF TROUBLESHOOTING AND TROUBLESHOOTING PROCEDURE
4) Check kerosene mode input signal

i) Set to the monitoring mode, and display monitoring code 22.
ii) Connect the CN-M36 connector and check that bit (5) lights up.
5) Check knob switch input signal
ii) Turn the knob switch ON and check that bit (6) lights up.
2. Check output signals

i) Check LS-EPC solenoid output current.
ii) Run the engine at high idling with all the levers at neutral and in the G/O or H/O mode, and
measure the current.
* All levers at neutral: 900 f 80 mA. Engine at high idling, any lever operated (other than
travel):0 A
2) No. 2 throttle signal
ii) Use the procedure in item 2 for checking the monitor panel output signal, and measure the engine
speed.
3) Checking ON --- OFF solenoid condition
ii) Refer to Table 3 and check that the applicabel bit light up.
Table 3 Types of solenoid and conditions for actuation
Name of solenoid Actuation condition Bit that lights up
Swing holding brake Swing or work equipment lever operated (3)

I
2-stage relief ON release Travel operated independently (5)

I I
Travel speed selector Travel speed selector switch Hi or Lo (6)

I
* Operate the lever slightly not enough to move the machine.
4) Check TVC solenoid output current

i) Set to the monitoring mode, and display monitoring code 13
ii) With the starting switch kept at the ON position (G/O mode), measure the current when the fuel
control dial is turned to the MAX position.
. Current with starting switch ON (G/O mode) and the fuel control dial at MAX 410 f 80 (mA).
20-93
. Governor control sustem

1. Check input signal
1) Check fuel control dial input voltage
ii) Measure the voltage when the fuel control dial is turned from low idling to high idling.
+ Voltage: 0.25 - 4.75 V
2) Check governor potentiometer voltage
ii) Measure the potentiometer voltage when the fuel control dial is turned from low idling to high
idling.
+ Voltage: 0.5 - 3.3 V
2. Check outout signal

1) Check governor moter drive current
i) Set to the monitorong mode, and display monitoring codes 33 and 34.
* Code 33 is the A phase (engine speed acceleration direction) and code 34 is the B phase
(engine speed deceleration direction)
ii) Measure the governor motor drive current when the fuel control dial is turned in the accelera-
tion direction and deceleration direction.
* Current: 700 f 70 (mA)
2) Measure battery relay drive output voltage

ii) Measure the battery relay drive output voltage when the starting switch is turned from ON to
OFF or
iii) Set to the monitoring mode, and display monitoring code 37.
iv) Check that bit (1) lights up when the starting switch is turned from ON to OFF
20-94
TROUBLESHOOTING SERVICE CODE TABLE
SERVICE CODE TABLE

Service User Service User
Abnormal system Abnormal system
code code code code
El01 Abnormality in error history data El12 Short circuit in relay drive R
El02 Abnormality in time data El13 Short circuit in relay drive L
El03 Short circuit in buzzer output, contact with 24 V

El14 Short circuit in window washer drive
wiring harness for buzzer drive
El04 Air cleaner clogging detected
El06 Abnormality in engine oil pressure sensor (Hi)

detected I I
El08 1Water temperature over 105*C I I
E201 1Short circuit in suspension lock solenoid system I I
E203 Short circuit in swing holding brake solenoid E03
system I I
E206 I Short circuit in 2-stage relief solenoid system I I
E206 1Short circuit in travel speed solenoid system I I
E21 I I Disconnection in LS bypass solenoid system
E213 Disconnection in swing holding brake solenoid
system I I
E2f5 I Disconnection in 2-stage relief solenoid system I E03 I
E216 I Disconnection in travel speed solenoid system I I
E217 IE rror in model selection input
I I
E218 I Network response overtime error I I
E222 I Short circuit in LS-EPC solenoid system I
E223 Disconnect in LS-EPC solenoid system
E224 Abnormality in pump pressure sensor system
E226 Abnormality in pressure sensor system power

source I I
E227 Abnormality in engine speed sensor
E232 I Short circuit in pump TVC solenoid system I E02I

E233 Disconnection in pump TVC solenoid system E02
E306 Abnormality in feedback potentiometer system
E308 I Abnormality in fuel control dial input value I EmI

E315 Short circuit in battery relay output system
E316 Step-out in governor motor
E317 I Disconnection in governor motor system I E05I

E318 Short circuit in governor motor system E05
20-95
TROUBLESHOOTING OF COMMUNICATION
ABNORMALITY SYSTEM
(N MODE)
N-l [E218] Communication abnormality 20-98
20-97
TROUBLESHOOTING N-l
N-l [E218] Communication abnormality
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the service code E is not displayed, the problem has been removed.
* If the starting switch was turned off after the abnormality occurred, turn the starting switch on and check that
the service code displays E. (If it is not displayed, the problem has been removed.)
* Before carrying out troubleshooting, check that all the related
connectors are properly inserted. Remedy
* Always connect any disconnected connectors before going on
the next step.
Has been reset Replace
4 YES
Is monitoring code Defective monitor panel Repair
02,03 display normal?
and PO1 (14) normal? Disconnection is between

* Disconnect Cl7
. Turn starting switch POl(4) (11) and PO1 (14) or Replace
On. Cl 7. POl, and install
chassis
. See Table 1 T-adapter to PO1
monltorlng code 08?
I I * Min. 10
Do bitts (1) and (2) * Disconnect
I Defective governor, pump Replace
light up an monltonng connector Cl7 NO controller
* Turn starting switch
ON
- See Table 2
YES Defective governor, pump Replace
ON. controller
Is voltage between
Cl7 (4) (12) and
chassis normal? Defevtive monitor panel Replace
Is reslstance between
- Turn starting PO1(4), (11) andC17
switch ON.
. Mln 75V Disconnection in wiring
* Disconnect Cl7 harnees between PO1(4), Replace
and measure (11) and Cl7 (4) (12)
voltage at c17.
harnees end. * Max. 10
Table 1
When each controller is connected to the
” ” is displayed. If the correct
Governor, pump controller model code

Governor, pump controller model code
1rable 2
. Light up when connected . Note: Checks can be carried out with code 08 only
(1) Governor, pump controller when there is a disconnection. The display does not
(2) Governor, pump controller change when there is a short circuit.
Therefore, checks when there is a short circuit
should be carried out basically using Table 1
20-98
TROUBLESHOOTING N-l
N-l Related electric circuit diagram
Governor, pump controller Monitor panel

C16(MIC17) PO1 (04020)
\ I
S-NET(+)
4
S-N ET(-)
S-NET(+)
\
C17(04016)
20-99
TROUBLESHOOTING OF GOVERNOR,
PUMP CONTROLLER
(GOVERNOR CONTROL SYSTEM)
(E MODE)
Points to remember when carrying out troubleshooting of governor, pump controller system.. ............... 20-101
Action taken by controller and condition of machine when abnormality occurs ....................................... 20-I 02
Judgement table for governor, pump controller (governor control system)
and engine related parts .......................................................................................................................... 20-l 06
Electrical circuit diagram of governor, pump controller (governor control system). .................................. 20-l 08
E- 1 Abnormality in governor, pump controller power sosurce (controller LED is OFF). ............ 20-I IO
E-2 [E308] Abnormality in fuel control dial input value is displayed.. ........................................ 20-l 11
E-3 [E317] Abnormality (disconnection) in governor motor drive system is displayed .............. 20-l 12
E-4 [E318] Abnormality (short circuit) in governor motor drive system is displayed ................. 20-I 13
E-5 [E306] Abnormality in feedback potentiometer system is displayed.. ................................. 20-I 14
E-6 [E315] Abnormality (short circuit) in battery relay output system is displayed.. .................. 20-l 15
E-7 [E316] Abnormality (step-out) in motor is displayed.. ......................................................... 20-l 16
E-8 Engine does not start.. ........................................................................................................ 20-I 18
E-9 Engine speed is irregular.. .................................................................................................. 20-120
a) Idling speed is irregular.. .............................................................................................. 20-120
b) There is hunting.. ......................................................................................................... 20-122
E-l 0 Lack of output (engine high idling speed is to low). ............................................................ 20-124
E-l 1 Engine does not stop.. ........................................................................................................ 20-l 26
E-12 Defective operation of battery relay system (engine does not stop). .................................. 20-l 28
20-I 00
POINTSTO REMEMBER WHEN CARRYING OUTTROUBLESHOOTING OF
TROUBLESHOOTING GOVERNOR, PUMP CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN CARRYING OUTTROUBLE-

SHOOTING OF GOVER-NOR, PUMP CONTROLLER SYSTEM
1. Points to remember when there is abnormality which is not displayed by user code. The engine is controlled
by the governor and pump controller. The problem that may occur with this system include the following.
1. Idling speed is too high (too low)
2. High idling speed is too low
3. Auto-deceleration speed is too high (too low)
4. Engine speed for automatic warming-up operation is too high (too low)
5. There is hunting
6. Engine does not stop
If any abnormality occurs, and the abnormality is displayed on the time display portion of the monitor panel,
use the troubleshooting table to determine the appropriate troubleshooting flow chart form E-l to E-12.
However, if there is any abnormality in the machine and no abnormality display is given, it is necessary to
determine whether the problem is in the mechanical system or in the electrical system. If the linkage be-
tween the governor motor and the injectionpump is not properly adjusted, problems 1 to 6 listed above may
occur. Therefore, if there is no abnormality display, but one of problems 1 to above has occured, carry out
troubleshooting as follows.
Defective adjustment of governor motor

1 likage SeeTESTING AND ADJUSTING.
governor motor and

InJectIon pump IS dIS-
Go to troubleshooting E-9 - E-l 2 of elec-
connected and pump trical system
lever IS operated by
hand or is fixed with
we, does condition Go to troubleshooting S-l - S-16 of en-
return to normal?
NO
gine system
* If engine does not
stop, push governor
lever to STOP
posltlon and check If
engine stops.
Disconnect the linkage as explained above, or check the adjustment and go to the troubleshooting flow
chart for the mechanidal system or electrical system. For details of the procedure for adjusting the linkage,
see TESTING AND ADJUSTING.
2. Points to remember if abnormality returns to normal by itself

In the following cases, there is a high probability that the same problem will occur again, so it is desirable to
follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adepter is inserted, or the T-adepter is removed and the
connector is returned to its original position when carrying out troubleshooting of the failure, and the
service code is no longer displayed, or if the monitor disolay returns to normal.
3) After completing troubleshooting, always erase the service code from memory.
3. User code memory retention function

When displaying the abnormality code in memory and carrying out troubleshooting, note down the content
of the display, then erase the display. After trying to re-enact the problem, carry out troubleshooting accord-
ing to the failure code that is displayed. (There are cases where mistaken operation or abnormalities that
occur when the connector is disconnected are recorded by the memory retention function. Erasing the data
in this way saves any wasted work).
20-I 01
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY
TROUBLESHOOTING OCCURS AND PRO-BLEMS ON MACHINE

OCCURS AND PROBLEMS ON MACHINE
User Service Abnormal system Nature of abnormality
:ode code
1. Short circuit in wiring harness between CO3 (7) - (14), (7) -

(17) (14) - (17)
2. Short circuit in wiring harness between E04 (1) - (2), (1) - (3),
(2) - (3)
(2) - (3)
E308 Abnormality in fuel con- 4. Short circuit in wiring harness between CO3 (7) - (4), (4) - (17)
trol dial input valvue 5. Disconnection in wiring harness between CO3 (7) - X07 (6) -
E06 (1)
6. Disconnection in wiring harness between CO3 (4) - X07 (5) -
E06 (2)
7. Disconnection in wiring harness between CO3 (17) - X07 (4) -
E06 (3)
8. Defective fuel control dial
9. Defective contact of C03, X07, E06 connectors
E05
1. Disconnection inside governor motor

2. Sisconnection in wiring harness between CO2 (2) - E05 (1)
E317 Abnormality (disconnec- 3. Disconnection in wiring harness between CO2 (4) - E05 (3)
tion) in motor drive sys- 4. Disconnection in wiring harness between CO2 (3) - E05 (2)
tern 5. Disconnection in wiring harness between CO2 (5) - E05 (4)
6. Defective contact of E05 connector
1. Short circuit inside governor motor

2. Wiring harness between CO2 (2) - E05 (1) and between CO2
(4) - E05 (3) short circuiting with wiring harness between CO2
E318 Abnormality (short circuit) (3) - E05 (2)
in motor drive system 3. Wiring harness between CO2 (4) - E05 (3) and between CO2
(2) - E05 (1) short circuiting with wiring harness between CO2
(5) - E05 (4)
4. Wiring harness in Items 2 and 3 short circuiting with ground
20-I 02
TROUBLESHOOTING OCCURS AND PROBLEMS ON MACHINE
when there is abnormalit
1. Does not become partial speed

when set at MAX position
1. When there is a disconnection in

both the A phase and B pahse at
the same time, the problem is
the same as for a short circuit in
the governor motor system
2. When there is a disconnection in
Takes no particular action only one of A phase or B phase
1) Engine does not stop
2) Stops moving at position im-
mediately before failure, so
engine speed cannot be
controlled
3) There are cases of hunting
1. If during operation
1) Set to low idling
2) Engine does not stop
1) Engine starts, but stays at
2) Engine does not stop after

Motor drive current: Hold: 0.7 A
Start: 0.84 A
20-103

:ode code
1. Short circuit in wiring harness between CO3 (7) - (14), (7) -

(17) (14) - (17)
(2) - (3)
3. Short circuit in wiring harness between E06 (1) - (2), (10 - (3),
E306 Abnormality in feedback (2) - (3)
potentiometer system 4. Short circuit in wiring harness between CO3 (7) - (4), (4) - (17)
5. Disconnection in wiring harness between CO3 (7) - E04 (1)
8. Defective governor motor potentiometer
9. Defective contact of C03, E04 connectors
Abnormality (short circuit) If excess current flows between CO3 (1) and battery relay
E315 in battery relay output + This occurs only when turning starting switch to OFF and
system stopping engine
1. Defective adjustment of rod or scuffing of loose spring
E316 Abnormality (step-out) in 2. Abnormality in governor motor

motor
3. Abnormality in govenor, pump controller
20-I 04
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. Precision of engine speed con-

trol may be reduced.
For example:
1) Engine does not rise to high
idling speed (a little too low)
2) Engine does not go down to
Calculates position of motor low idling speed (a little too
and carries out control from high)
value of voltage immediately 3) Defective engine speed for
befor abnormality occurred autodeceleration or auto-
matic warming-up
4) Engine may not stop
+ The governor motor mo-
ves in the direction to stop
the engine, but the motor
may not move completely
to the position to stop the
engine.
Between CO3 (1) and chassis: 20 - 30 V

* Holds with the motor in the stop
position for 2 - 2.5 set, returns to Sets battery relay drive cur- Engine does not stop
the low idling position, the turns rent to 0
then battery relay OFF.
1. Linkage adjustment correct 1. Displays when returning

from high idling to low
idling Engine speed cannot be controlled
2. Must move lightly when connector is * Starts again (repeats (particularly at high idling), so there
removed step-out) is hunting
2. In some cases it may not
display when returning
3. Normal from partial speed to low
idling
20-105
JUDGEMENTTABLE FOR GOVERNOR, PUMP GOVERNOR
TROUBLESHOOTING fGOVERNOR CONTROL SYSTEM) AAND ENGINE RELATED PARTS

(GOVERNOR CONTROL SYSTEM) AND ENGINE RELATED
PARTS
_
Governor, pump controller,engine
E related parts (E3’syslem)
FJ
Self-dlagnostlc display
5
8
5
s:
z
g
a
2
2
E
8
E
2
i
e
z
s
OY
s
x
_ _
Failure mode _ _
301 31!
_ _
1 1Enaine does not start easilv
_ _
2 Engine does not start
3 Engine speed stays at low idling, and does not follow accelerator; or engine pickup is poor 5
- 5
-
4 Engine stops during operation
- -
5 Engine rotation is irregular
When idling speed is irregular
-
When there is huntino
-
6 Lack of output (engine high idling speed is too low) _
7 1Auto-deceleration does not work
8 1Enaine does not stoo 5
_
9 1Warming-up operation is defective
_
10 1Exhaust gas is black
- -
11 1Oil consumotion is excessive. or exhaust aas is blue
- -
12 1Oil becomes dirty prematurely
- -
13 1Fuel consumption is excessive, or exhaust qas is blue
- -
14 Oil is mixed in coolant
- -
15 1Engine oil pressure caution lamp lights up _ _
16 I Oil level rises
_ _
17 Coolant temperature rises too high (overheating)
_ _
18 IAbnormal noise is generated
_ _
19 1There is excessive vibration
- -
20 Engine speed does not change even when working mode is switched
- -
- -
Troubleshooting code when service code is displayed i_-
- i_!
-
5 I
Troubleshooting code when there is abnormality in monitoring or machine monitor check - - -

. : This shows applicable item for service code
+ : This shows item that needs only checking with monitoring
20-I 06
TROUBLESHOOTING (GOVERNOR CONTROL SYSTEM) AAND ENGINE RELATED PARTS
Checking mon,tor,ng,
check items
7
z
0
5
a,
2
6
mz
5
2
a,
s
n
_
xutorlng code
-s.
- S-l
- s-2
_ s-3
_ s-4
_ E-9A), S-5
_ E-9A), S-5
_ E-l 0, S-6
E-3. E-4
=Y
-’
-
-
_
_
_
_
_
-
-
-
-
_
_
_
-1;
_
0: This shows item to check with monitoring or

machine monitor
20407
FUEL I
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE l/2 q

QI-EOE
PW70-6 CDNNECT
PNlM-6 DlmNNECl
.5El+&
CN-Gl53
20-I 08
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR E MODE 2/2
-f-o
OArrm
4
408 -
40R
/
r--_-_--_- --__,I
20- 109
TROUBLESHOOTING E-l
E-l Abnormality in governor, pump controller power source

(controller LED is OFF)
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT-adapter, or when removing theT_adapter and returning the connector
to its original position, if the service code E is not displayed, the problem has been removed.
+ Check that fuse 1 is not blown.
+ Before carrying out troubleshooting, check that all the related connecotrs are properly inserted.
+ Always connect any disconnected connectors before going on the next step.
+ When the starting motor rotates correctly. (If the starting motor also does not rotate, go to E-8.)
Cause Remedy

1 controller
Is voltage between
CO1 (7) (13) and CO2 _
Defective contact, or
(111 1211 normal? 2 YES disconnection in wiring Repair or
harness between fuse 1 and replace
Is voltage between CO1 (female) (7) (13)
. Turn starting swtch
fuse 1 and chassis
ON.
. 20.30V Defective contact, or
disconnection in wiring Repair or
NO
ON. harness between fuse I- replace
. 20.30V HI5 (2)-Ml4 (2) (I)-battery
relay M
E-l Related electric circuit diagram

COl(MIC13)
H14(M6) Fuse H15(L2)
04 0
PGND \ d-_? Fusible link
0 @ M14(L2)
C02(MIC21)
Battery
I/-lj BKPOWS6
20-I IO
TROUBLESHOOTING E-2
E-2 [E308] Abnormality in fuel control dial input value is

displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
connector and inserting theT_adapter, or when removing theT-adapter and returning the connector
Before carrying out troubleshooting, check that all the related
Cause Remedy
connectors are properly inserted.
Always connect any disconnected connectors before going
on the next step.
2 YES Defective governor, pump Replace

controller
~
Defective wiring harness in
system with defective Replace
resistance

OFF. Defective fuel control dial Replace
NO
. Disconnect E06
+ If E306 also occurs at the same time, check the wiring harness below.
. Wiring harness between CO3 (female) (7) - E04 (female) (1) short circuiting with groud, or contact with
other wiring harness
Table 1
Resistance
CO3 (female) E04 (male)
value
1 (7)-(4) 1 (l)-(2) 1 0.25-7kC
1 (4) - (17) 1 (2) - (3) 1 0.25 - 7kC
I (7) - (17) I I 2 - 3kR

1 (l)-(3) 1 4-6kC
Between each
Min. 1 MC
pin and chassis
E-2 Related electric circuit diagram
Governor, pump controller X07(MIC17)
CO3(04020) Kil
Fuel control
Throttle
dial
command
Throttle power
source (+I Governor
potentiometer
Feedback
Throttle power
source (-1 BKPOOO97
20-I 11
TROUBLESHOOTING E-3
E-3 [E317] Abnormality (disconnection) in motor drive

system is displayed
connecotr and inserting theT-adapter, or when removing theT_adapter and returning the connector
* During operation, if there is
1) a simultaneous disconnection in A phase and B phase:
1) the engine will run at low idling
2) the engine will not stop
2) a disconnection in either A phase or B phase, the engine speed will remain the same as before the
abnormality occurred
If the problem occurs when the engine is stopped,
1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
; Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION
position).
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connected any disconnected connectors before going on the next step.
Cause Remedy

controller
(female), or between
,. ,,
Defective wiring harness in Replace
system with defective
(male), or between * Turn starting switch No
resistance
each p,n and chassis OFF
as shown ,n Table I? * Disconnect ~02.
OFF. Defective governor motor Replace
NO
. Disconnect E05.
Table 1

C02(MIC21) E05(X4)
Governor motor
A(+)
40
‘a 3
AH @ 3
B(+) @. 3
i%-1 @ gl
I BKPOOO98
20-I 12
TROUBLESHOOTING E-4
E-4 [E318] Abnormality (short circuit) in moter drive system

is displayed
to its original postion, if the service code E is not displayed, the problem has been removed.
If the abnormality occurs during operation, because of the force of the spring,
1) the engine will run at low idling
2) the engine will not stop
If the problem occurs when the engine is stopped,
1) the engine can be started, but it stays in low idling, or 2) it will not stop after it is started.
Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION
position).
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ Always connect any disconnected connertors before going on the next step.
Cause Remedy

Is resistance between controller

resistance
Defective governor motor Replace
Table 1
Resistance
E05 (male) CO2 (female)
value
91) - (2) (2) - (3) 2.5 - 7.5 kR
(3) - (4) (4) - (5) 2.5 - 7.5 kn
(1) - (3) (2) - (4) Min. 1 M!LI
(1) - (4) (2) - (5) Min. 1 MCI
Between Between
chassis and chassis and
pins (1) (2) (3) pins (2) (3) (4) Min’ ’ Mn
(4) (5)

C02(MIC21) E05(X4)
I Governor motor
ji;(+)
40
@ 3
AH @ .a
B(+) @ 3
BH @ -8 -
20-I 13
TROUBLESHOOTING E-5
E-5 [E306] Abnormality in feedback potentiometer system is

displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
Cause Remedy
Defective governor, pump Replace

controller

resistance
+ If E308 also occurs at the same time, check the wiring harness below.
. Wiring harness between CO3 (female) (7) - x07 (6) - E06 (female) (1) short circuiting with ground, or
contact with other wiring harness
Table 1
Resistance
CO3 (female) E04 (male)
value
(7) - (4) (1) - (2) 0.25 - 7k!J
(14) - (17) (2) - (3) 0.25 - 7kC
(7) - (17) - 2 - 3kR
(1) - (3) 4 - 6kC

Between each
Min. 1 MR
pin and chassis -
Governor, pump controller X07(MICl7) E06(M3)

CO3(0*
Throttle
command
Throttle power
source (+I
Feedback
Throttle power
source (-1
20-I 14
TROUBLESHOOTING E-6
E-6 [E315] Abnormality (short circuit) in battery relay output

system is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its oringinal
Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION
position.
+ This only occurs when the engine is stopped and the starting switch is turned OFF.
Cause Remedy

I controller
1
Is resistance
between CO1
(female) (1) and
2 YES
chassis normal? Defective battery relay Replace
~ Is WSlStance between
co, (female) (1) and bat-
* Between co1
NE tery relay telmlnal BR. - Contact between other
(female) (1) and and between w,r,ng har-
chassis.Approx. ne** and chassis normal? wiring harness and wiring
lion harness between CO1 (fe- Replace
* Turn starting switch * Between CO1 NO
male) (I)-battery
OFF (female) (1) and
* Disconnect COl. battery relay BR: relay BR.
Max ln When light is connected
. Between Waring
harness and chassis.
Min. 1 MO
* Turn starting swtch
OFF.
* Disconnect CO1 and
battery relay BR.

Sarting switch X07(MIC17) H14(SlO) Fuse H14(SlO) Ml1 (L2)
II I
3 -m--
g)
@- Fusiblelink
I I

COl(MIC13)
/ gz$i;;Nitch &
CO3(04020)
20-I 15
TROUBLESHOOTING E-7
E-7 [E316] Abnormality (step-out) in motor is displayed

connector and inserting theT_adapter, or when removing theT_adapter and returning the connector
If any other service code [E306] - [E318] has occured at the same time, start troubleshooting from the code
exept code [E316].
Check that the fuse is normal.
Read the precautions given in TESTING AND ADJUSTING, “Adjusting travel of governor motor lever”
before carrying out the troubleshooting.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
I Cause Remedy
YES Defective governor, pump 3eplace

3 controller
Are E306, E317, and
Operate fuel control
YES dial 0 MAX and turn
- starting swtch OFF - 4 YES 1) Defective linkage Adjust or
Is operation normal? ~ -
2) Defective injection pump
~ Is there any scuffing
eplace
2
ON.
* Turn starting switch when spring rod IS
ON NO moved to injection
* Turn auto decelera- pump end?
tion OFF. Defective governor motor
* Disconnect E05
NO 3eplace
* Disconnect llnkage at
* Turn starting swtch governor motor end.
ON.
. Turn i
N0
Defective governor linkage Adjust (For
autodeceleration
OFF. jetails, see
* settogo”ernor rESTlNG
motor adjustment AND
mode.
ZDJUSTINC
. See TESTING AND
ADJUSTING.
20-I 16
TROUBLESHOOTING E-8
E-8 Engine does not start

+ When starting motor does not rotate.
+ Check that fuse No. 14 is not blown before
starting troubleshooting.
+ Before carrying out troubleshooting, check YE
that all the related connectors are properly

inserted.
+ Always connect any disconnected connec-
tors before going on the next step.
YE
YES
El-
N
. Approx24” NO
YEiS
YE
, ‘“, ,YES
L
NO
MOZ(X2)
Safety relay
4
S B
n Fusible link -
Starting motor
C
Shut-off vdve
E09
20-I 18
L L
TROUBLESHOOTING E-9
E-9 Engine speed is irregular
a) Idling speed is irregular

YES
2 4 YES
VI -- ”
and pump IS adys-

ted, does condition
become normal?
Turn starting switch . SeeTESTING AND No

ON. ADJUSTING.
Starting mOtOr SIgnal 7 YES
lever is placed at po-
Is controller model YE ~
code as shown I”
. Turn starting switch
ON.
Table 1?
Fuel control dial 5
I
Is voltage between
ON. NO
CO3 (4) and (17)
- Set to monltorlng
normal and stable?
code03or02.
. At MIN : 4.0 - 4.75V NO
Table 1
* The diagram shows monitoring

code 03.
20-I 20
TROUBLESHOOTING E-9
I Cause Remedy
See N mode
Defective adjustment of Adjust

linkage
Defective injection pump See S mode
Defective contact of wiring

harness between starting Repair or
switch ACC-X07 (17)-CO3 replace
(femal) (8), or defective
starting switch
See E-5
See E-2
See C-14
H08(M6)
I I I

Startins switch I I

CO3(04020) X07(MIC17) E06(M3)
Fuel control dia
Governor
Feedback potentiometer
20-I 21
TROUBLESHOOTING E-9
b) There is hunting
2 4 YES
When linkage be-

tween governor motor
Yl ES Is E218
and pump is adjus- -
dIsplayed? ted, does condition
I
I
become normal?
* Turn starting switch NO

ON
3 Startinq motor Signal 7 YES

When llnkage IS dls-
lr
connected and motor
lever IS placed at po- CO3 (8) and chassis
Potentiometer
NO sItIon engine low
idling?
I normal and stable?
Is controller model YE
code as shown in
ON.
Table 17
* Turn fuel control dial
Fuel control dial 5 I I
from MIN to MAX
. At MIN
* Turn starting switch and stop also at
:2.9 3.3v
ON. midway position. NO
. At MAX
* Set to monitoring
code 03 or 02 NO :0.5 - 0.9v
. At MIN
: -
4.0 4.75v NO
. At MAX
:0.25 -
1 .OV
Table 1
I Controller model code I

code 03.
20-I 22
TROUBLESHOOTING E-9
I Cause Remedy
See N mode

linkage
Defective contact of wiring

harness between starting Repair or
switch ACC-X07 (17)-CO3 replace
(femal) (8), or defective
starting switch
See E-5
See E-2
See C-14
E-9 Related electric circuit diagram H08(M6)
P5
Fuse
14
Governor, pump controller tz+

CO3(04020) E06(M3)
1
Fuel control dia
E04(X3)
rnr0ttlepowerSOURCE
(+) Q)
Governor
Feedback @ a potentiometer
Throttle
powerSOUICB
f-)
20-123
TROUBLESHOOTING E-l 0
E-IO Lack of output (engine high idling speed is too low)
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted
YIIS
YE Is E218
dIsplayed?

ON YES
Potentiometer 6
‘I
Does injection pump normal and stable?
lever contact FULL
Fuel control dial
NO stopper?
. At MIN
,2 9 3.3v
I
* Start engine. . At MAX
NO
- Set fuel control dial normal and stable?
,05-09v
to MAX
* H/O mode.
4 . At MIN
ll
ON. 4 0 4.75v
Is adjustment of . At MAX
* Set to monitoring
llnkage between ‘025. l.OV
code 03 0102
NO governor motor and
pump normal? 8 YES
NO
- See TESTING AND
ADJUSTING.
Table 1
Controller model code

code 03.
20-I 24
I Cause Remedy
See N mode
Starting motor signal 7 YES

Is voltage between
- CO3 (8) and chassis - Defective contact of wiring
normal and stable? harness between starting Repair or
switch ACC - X07 (17) - CO3 replace
* During operation?
(female) (8), or defective
20 3ov
starting switch
See E-5
See E-2
Defective adjustment of
governor motor linkage
See S mode Adjust
See C-14
HOS(M6)
E-l 0 Related electric circuit diagram
Starting switch
SlaRlng switch ON signal
Throttle command Fuel control dia
Governor
potentiometer
20-125
E-l 1 Engine does not stop
a Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION
position).
* Always connect any disconnected connectors before goning on the next step.
* Read the precautions given in TESTING AND ADJUSTING, “Adjusting travel of governor motor lever”
before carrying out the troubleshooting.
”
lever contact STOP
3
Turn starting switch
Potentiometer 6 YES
ON-OFF
. When llnkage IS
When starting switch
YES ISOFF, ISVOltage
condition become
Relay drwe slgnal 5 - between CO3 (14) -
~ and (17) normal?
* Does loose spring When starting swtch
YES is OFF, does voltage ~ -
. When engine IS NO
Is controller model - between CO1 (1) and -
(6) (12) change as stopped
code as shown in . See TESTING AND Starting motor signal 4
~ shown in Table 2? * 29.33v
Table 17 ADJUSTING.
When stating swtch ~
t * 20 3ov
is OFF, is voltage
: between CO3 (8) and - NO
* Turn starting switch N0
chassis normal?
ON.
* Set to monitoring
* Max.lV
code 03 or 02
NO
Table 1
~~
+ The diagram shows monitoring code 03.
Table 2
Voltage from When ON (Approx. 24V)

starting switch (CO3 (8)) 1
- To battery relay (BR)

OFF
Voltage output from controller when starting switch is OFF
See Note 1
_ __ __ _ __
When ON
(Approx. 24Vl
Condition of actuation
of controller circuit OFF_ 1 _ Min. 4.0;a- re’av (BR’
co1 (1)
Drive time Max. 7sec. (when it is impossible to sat to
NO IINJECTION because of failure in motor)
BKP00206
Note 1: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is always
flowing from starting switch BR, so if the voltage is measured at CO1 (I), there is a voltage of 20 -30V
20-I 26
I Cause Remedy
Defective wiring harness

between starting switch
, YES
Terminal ACC-X07 (11) -E08
When shut-off vlave (12, 13) -shut-off valve
connector E09 is connecter E09 (A)
disconnected, does -
Engine stop?
Defective shut-off valve See S mode

linkage
Defective governor motor
See E-5

controller
Contact with 24V wiring
harness of wiring harness
between starting switch Replace
ACC-X07 (17)- CO3 (female)
(8), or defective starting
switch
See C-14
E-l 1 Related electric circuit diagram

Shut - off valve
E09 E08(SWP16)
Battery relaydrive
CO1(MIC13)
20-127
TROUBLESHOOTING E-12
E-12 Defective operation of battery relay system (engine does not stop)
This only occurs when the engine is stopped and the starting switch is turned OFF.
2L Check with the engine stopped (push the fuel control lever of the fuel injection pump to the NO INJECTION
** position).
Cause Remedy
YES
See E-6
Is E315 displayed? _ YES Defective governor, pump Replace

Relaydrwe slgnal 2 controller
* Turn starting switch Is display of monitor-

ON. - ing code 35 as shown -
NO 2 YES
I” Table 17 Defective battery relay Replace
Is WSlStance between
. Turn starting swtch CO1 (female) (1) and bat-
OFF. - tery relay tenlxna, BR, -
NO and between w,rrq har- 1) Disconnection in wiring
* 20 3ov
neSSand chass,s normals
harness between CO1 Replace
* Between CO1 (fe- NO (female) (1) - battery
male) (1) and battery
relay BR
relay BR: MAX 1 0
* Between wiring har-
ness and chasw 2) When light is connected
Max. 1 MO
OFF.
battery relay BR.
Table 1
Voltage from When ON (Approx. 24V)
starting switch (CO3 18)) -1 To banery relay ,BR)
OFF
Voltage output from controller when starting swirch is OFF
See Note 1
1When ON
(Approx. 24V)
Condition of actuation
of controller circuit OFF I; j _ Min, 4,0z;anerv re’av (BR)
co1 (1)
Drive time Max. 7sec. (when it is impossible to set to
NO IINJECTION because of failure in motor)
ElKP00206
Note 1: When the starting switch is ON, the controller end is OFF, but a voltage of approx. 20 - 30V is always
from starting switch BR, so if the voltage is measured at CO1 (l), there is a voltage of 20 - 30V.
20-I 28
TROUBLESHOOTING OF
ENGINE SYSTEM (S MODE)
Method of using troubleshooting charts 20-l 30

s- 1 Starting performance is poor (starting always takes time) ....................................................... 20-l 34
s- 2 Engine does not start.. ............................................................................................................. 20-l 35
(1) Engine does not run ......................................................................................................... 20-l 35
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) ...................... 20-l 36
(3) Exhaust smoke comes out, but engine does not start (fuel is being injected) .................. 20-l 37
s- 3 Engine does not pick up smoothly ........................................................................................... 20-l 38
s- 4 Engine stops during operations ............................................................................................... 20-l 39
s- 5 Engine does not rotates smoothly (hunting) ............................................................................ 20-l 40
S- 6 Engine lacks output (no power) ............................................................................................... 20-l 41
s- 7 Exhaust smoke is black ........................................................................................................... 20-l 42
S- 8 Oil consumption is excessive, or exhaust gas is blue .............................................................. 20-l 43
s- 9 Oil becomes contaminated quickly .......................................................................................... 20-l 44
s-10 Fuel consumption is excessive ................................................................................................ 20-l 45
S-l 1 Oil is in cooling water.. ............................................................................................................. 20-146
s-12 Oil pressure caution lamp lights up (drop in oil pressure). ....................................................... 20-147
s-13 Oil level rises (water, fuel in oil.. ............................................................................................... 20-148
s-14 Water temperature becomes too high (overheating). ............................................................... 20-l 49
s-15 Abnormal noise is made .......................................................................................................... 20-l 50
S-16 Vibration is excessive .............................................................................................................. 20-l 51
20-I 29
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sec-
tions: questions, check items, and troubleshooting. The
questions and check items are used to pinpoint high pro-
bability causes that can be located from the failure symp-
toms or simple inspection without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final
confirmation.
[Questions]
Sections @ + @ in the chart on the right corresponds
to the items where answers can be obtained from the
user. The items in @ are items that can be obtained
from the user, depending on the user’s level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under 0 in the chart
on the right correspond to this.
The serviceman narrows down the causes from infor-
mation @ that he has obtained from the user and the
results of 0 that he has obtained from his own inspec-
tion.
[Troubleshooting]
Troubleshooting is carried out in the order of probabil-
ity, starting with the causes that have been marked as
having the highest probability from information gained
from [Questions] and [Check items].
20-I 30
The basic method of using the troubleshooting chart is as

follows.
Items listed for [questions] and [check items] that have a
relationship with the Cause items are marked with o, and
of these, causes that thave a high probability are marked
with @I
check each of the [Questions] and [Check items] in turn,
and marked the o or 0 in the chart for items where the
problem appeared. The vertical column (Causes) that has
the highest number of points is the most probable cause,
so start troubleshooting for that item to make final confir-
mation of the cause.
For [Confirm recent repair history] in the
[Questions] section, ask the user, and mark
the Cause column with A to use as reference
for locating the cause of the failure. However,
do not use this when making calculations to
narrow down the causes.
Use the A in the Cause column as reference
for [degree of use (Operated for long pe-
riod)] in the [Questions] section as refer-
ence.
As a rule, do not use it when calculating the
points for locating the cause, but it can be in-
cluded if necessary to determine the order
for troubleshooting.
20431
. Example of troubleshooting when exhaust gas is black

Let us assume that [clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have
causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and
[dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship
with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
S-7 Exhaust gas is black (incomplete combustion)

General causes why ezhaust gas is black
. Insufficient intake of air
. Improper condition of fuel injection
. Excessive injection of fuel
20-I 32
Five causes
Step 1
Clarify the relationship between the three

symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
t ’ ’
II Step 2
Add up the total of Oand 8 marks where the

horizontal lines for the three symptoms and the
vertical columns for the causes intersect.
(1)Clogged air cleaner element: 00
(2) Air leakage between turbocharger
and head: 00
(3) Clogged, seized injection nozzle: 0
(4) Defective contact of valve, valve seat: 0
(5) Worn piston ring, cylinder: 0
Step 3
The calculation in Step 2 show that the closest

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
20-133
TROUBLESHOOTING S-l
S-l Starting performance is poor (starting always takes time)

+ Check that the monitor panel does not display any abnormality in the governor control sustem. General
causes why exhaust smoke comes out but engine takes time to start
. Defective electrical system
. Insufficient supply of fuel
. Improper selection of fuel (At ambient temperature of 10°C or below, use ASTM D975 No. 1)
7t Battery charging rate
t
\ Charging1 1 1 1 1
Amb\rate 1 100% 1 90% 1 80% 1 75% 1 70%
. The specific gravity should exceed the value for the charging rate of
70% in the above table.
. In cold areas the specific gravety must exceed the value for the
chargi ing rate of 75% in the above table.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
a : Possible causes due to length of use (used for a long period)
nut is loosened
2) Little fuel comes out even when fuel filter air bleed
, . . ._ __. . . _ __.. ,;shed, it is found to be heavy or does

not return (when bind cover at rear of pump is removed, it 0
can be seen that plunger control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged
88tXI-Bt;
or: c=cooSEsqrjak2
% It is not permitted to replace only the regulator. Remedy 1 t 9. m 1ZE P o.- a
.olll.co..umb~
oE”“““EC#xEE<LUO
20-I 34
TROUBLESHOOTING s-2
S-2 Engine does not start

(1) Engine does not run I Causes I
General causes why engine does not turn

. Internal parts of engine seized
+ If internal parts of the engine are seized, carry out
troubleshooting for “Engine stops during opera-
tions”.
. Defective electrical system
Legend
0 : Most probable causes (judgingfrom Questionsand Check items)
A: Possible causes due to length of use (used for a long period)
0: Items to confirm the cause. d
!
1 Confirm recent repair history
-
Degree of use of machine 1Operated for long period
Condition of horn when 1Horn sounds -6

-
starting switch is turned ON 1Horndoesnot soundor volumeis low
-
When starting switch is Makes grating noise
-
turned to START, pinion Soon disengages again
moves out, but Makesrattlingnoisaand does notturn z

-
When starting switch is turned to START, pinion does not move out
-
When starting switch is turned to ON, there is no clicking sound
-
Battery terminal is loose
-
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low I l

For the following conditions 1) - 5). turn the starting switch
OFF, connect the cord, and carry out troubleshooting at ON

I
1) When terminal B and terminal C of starting switch are
connected, engine starts
2) When terminal B and terminal C of starting motor are

0
connected, engine starts ~ I I I 1 I
3) When terminal B and terminal C of safety relay are
connected, engine starts
4) When terminal of safety switch and terminal B of

I I I@II
I I I I I
starting motor are connected, engine starts I

a
5) There is no 24V between battery relay terminal M and
0
terminal E ttttt
When ring gear is inspected directly, tooth surface is
Found to be chipped
I-L Remedy -
20-I 35
TROUBLESHOOTING s-2
(2) Engine turns but no exhaust smoke comes out

(fuel is not been injected)
+ check that the monitor panel does not display any ab-
normality in the governor control system.
General causes why engine turns but no exhaust smoke
comes out.
. Supply of fuel impossible
. Supply of fuel is extremely small
. Improper selection of fuel (particulary in winter)
* Standard for use of fuel .

I Causes
Ambient temperature
Type of fuel -22 -4 14 32 50 68 86 104°F
-30 -20 -10 0 IO 20 30 40°C
Diesel fuel
Legen
0: Possible causes (judging from Questions and check items)

0 : Most probable causes (judging from Questions and Check items)
n : Possible ceuses due to length of use (used for a long period)
l : Items to confirm the cause.
U n engine is cranked with starting motor,

E 0
m 1) Injection pump coupling does not turn
C
P 2) No fuel comes out even when fuel filter air bleed plug is loosened 0 00 0
6 3) No fuel spurts out even when injection pipe sleeve nut is loosened 0 0 0
Rust and water are found when fuel tank is drained 00
20-I 36
TROUBLESHOOTING s-2
(3) Exhaust smoke comes out but engine does not

start (Fuel is being injected)
+ General causes why exhaust smoke comes out but

engine does not start
. Lack of rotating force due to defective electrical sys-
tem Causes
. Improper selection of fuel and oil
ions and check items)

astions and Check items)
(used for a long period)
1) Little fuel comes out even when injection pump
When fuel filter is drained, no fuel comes out I I I I I I I I I I
20-137
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly (follow-up is poor)

+ Check that the monitor panel does not display any ab-
normality in the governor control system.
General causes why engine does not pick up smoothly
. Improper fuel used
estions and check item

Questions and Check ite
se bed for a long pe
Color of exhaust gas
20-I 38
TROUBLESHOOTING S-A
S-4 Engine stops during operations

+ Check that the monitor panel fuel level display shows
that there is still fuel remaining.
General causes why engine stops during operations
. Seized rarts inside engine
. Overheating
+ If there is overheating and the engine stops, carry out
troubleshooting for overheating.
. Failure in main piston pump
+ If the engine stops because of a failure in the main
piston pump, carry out troubleshooting for the hydrau-
lic system (H mode)
Legend
n : Possible causes due to length of use (used for a long period)
Condition when
engine stopped
Rust and water are found when fuel tank is drained
Metal particles are found when oil is drained
they are found to be clogged

TROUBLESHOOTING s-5
S-5 Engine does not rotate smoothly (hunting)

+ Check that the monitor panel does not display any
abnormality in the governor control system.
General causes why engine does not rotate smoothly
. Air in fuel system Causes I
. Defective governor mechanism
. Defective electric governor mechanism
+ If hunting does not occur when the rod between the
governor motor and the injection pump is discon-
nected, troubleshoot by using the electrical system
troubleshooting (E mode).
Legend
0 : Most probable causes (judgingfrom Questions and Chedc items)
Condition of hunting
en tnjectton pump Is
20-140
TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

+ Check that the monitor panel does not display any
abnormality in the governor control system. Measure
the engine speed and judge if the cause is in the en-
gine or in the chassis. Causes
General causes why engine lacks output
. Improper fuel used (if non-specified fuel is used, out-
put drops)
. Lack of output due to overheating
+ If there is overheating and insufficient output, carry
out troubleshooting for overheating.
Legend
Q : Mostprobable causes (judging from Questions and Check items)
A : Possible causes due to length of use fused for a long period)
r
suddenly drops when load is applied
I 1 Whenturbocharaer is rotated bv hand, it isfoundto be heavy
When fuel filter, strainer are inspected directly, they are found to be clogged
.-z When feed pump strainer is inspected directly, it is found to be clogged 1 1 1 1 10 1 1
A I
Speed does not change when oparation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy, or does not return
Whenvalve clearanceis checkeddirsctly, it is found to bs outside standardvalue
I I When lever is olaced at FULL position, it does not contact stopper I I I I I Il l I I
20-141
TROUBLESHOOTING s-7
S-7 Exhaust smoke is black

(incomplete combustion)
General causes why exhaust smoke is black
. excessive injection of fuel
Legend
n : Possible causes due to length of use (used for a long period)
1 Confirm recent repair history I I I I I I I I I I I
/ Degree of use of machine 1 Operated for long period I lalnlnl I I I I Inl
Color of exhaust gas
Power was lost
-
When turbocharger is rotated by hand, it is found to be heavy
When air cleaner is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
Speed does not change when operation of certain cylinders is stopped
When cheek is made using delivery method, injection timing is found to be incorrect
injection pump test shows that injection amount is incorrect
When valve clearance is checked directly il is found to be outside standard value
When muffler is removed, exhaust color returns to normal
Remedy
20-I 42
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

+ Do not run the engine at idking for more than 20 min-
utes continuously. (Both low and high idling)
General causes why oil consumption is excessive
. Abnormal combustion of oil
. Eternal leakage of oil
. Wear of lubrication system
firm the cause.
20-143
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper fuel
. Improper oil used
. Operation under excessive load
Causes
ing from Questions and check items)

judging from Ouestionsand Check kerns)
o length of use fused for a long period)
When compression pressure is measured, it is found to be low @
When breather element is inspected directly, hose is broken
or is found to be clogged with dirty oil
When oil filter is inspected directly, it is found to be clogged
Turbocharger drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to
be catching or broken I
20-I 44
TROUBLESHOOTING S-l 0
S-IO Fuel consumption is excessive

General causes why fuel consumption is excessive
. Leakage of fuel
. Excessive injection of fuel
Condition of fuel
Exhaust smoke
Remove feed pump and inspect directly
When engine speed is measured, low idling speed is found to be high a
$ pt;g’;‘;u
Remedy $_ * B .z L E 2 3
% :;a
Pna”%Soua
I
20-145
S-l 1 Oil is in cooling water, or water spurts back, or water

level goes down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
Pressure-tightness test of oil cooler shows there is leakage
Pressure-tightness test of cylinder head shows there is leakage
Remove oil pan and inspect directly
20-I 46
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

+ Check that the monitor panel engine oil level lamp is
not lighted up.
+ When the oil pressure sensor is normal (see M
mode).
General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubrication system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
+ Standards for engine oil selection
Ambient temperature
Type of fuel -22 -4 14 32 50 68 86 104°F
Diesel fuel
Legend
a : Possible causes due to length of use (used for a long period)
a : hems to confirm the cause.
Confirm recent repair history

-
-
-
Non-soecified oil is beina used
-
t-
Condition when oil
pressure lamp lights up -

-
There is clogging, leakage from hydraulic piping (external)
-
Metal particles are found when oil is drained
-
1 Metal particles are stuck to oil filter element
r
1 Oil is cloudy white or smells of diesel oil c
7
I
When oil filter is inspected directly, it is found to be clogged ‘Z
P
._ 1
.a
5 Remove oil pan and inspect directly
e Oil pump rotation is heavy, there is play $
$
o
.g
There is catching of relief valve or regulator valve, spring or B
a P
; valve guide is broken %
B
When oil pressure is measured, it is found to be within 1a
standard value s
Remedy -
i
20-147
TROUBLESHOOTING s-13
S-13 Oil level rises

(water, fuel in oil)
* If there is oil in the cooling water, carry out trouble-
shooting for “Oil is in cooling water”.
Causes
General causes why oil level rises
. Water in oil
. Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
Legend
Confirm recent repair histon/
f
es appear, or water spurts back
Engine oil smells of diesel fuel
Fuel must be added more frequently
20-I 48
S-14 Water temperature becomes too high (overheating)

* Check that the monitor panel coolant level caution
lamp is not lighted up. Causes
* When the monitor panel water temperature gauge is

normal, go to troubleshooting of machine monitor
system (M mode).
GE!neral causes why water temperature becomes too
high
. Lack of cooling air (deformation, damage of fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
* Carry out troubleshooting for chassis
Legend
0 : Most probable causas (judgingfrom Questionsand Check items)
1 Confirm recent repair history
1 Degree of use of machine 1 Operated for long period
Condition of overheating
I-
Water temperature gauge

I-
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive eir bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white
C There is play when fan pulley is rotated

:: Radiator shroud, inside of underguard are clogged with dirt or mud
0
6
When light bulb is held behind radiator. no light passes through
r~-----~
Water is leaking because of cracks in hose or loose clamps
I When belt tension is inspected, it is found to be loose I I I I

Temperature difference between top and bottom radiator
pressure is found to be low
When compression pressure is measur-ed, it is found to be low
Remove oil pan and inspect directly
Remedy
20- 149
TROUBLESHOOTING s-15
S-15 Abnormal noise is made

+ Judge if the noise is an internal noise or an external
noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion
. Air sucked in from intake system
ions and check items)

estions and Check items)
(used for a long period1
When compression pressure is measured, it is found to be low a

When turbocharger is rotated by hand, it is found to be heavy a
Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is stopped
Injection pump test shows that injection amount is incorrect

D
: Fan is deformed, belt is loose
C
When valve clearance is checked, it is found to be outside standard value
1 Remove cvlinder head cover and inspect directly I I I I I I I I I.1 I I I

When muffler is removed, abnormal noise disappears I I I I I I I I I I I I.1
20-I 50
S-l 6 Vibration is excessive

+ If there is abnormal noise together with the vibration,
carry out troubleshooting for “Abnormal noise is
made”.
General causes why noise is excessive
. Defective parts (abnormal wear, breakage)
. Improper alignment
. Abnormal combustion
I Causes I
Legend
0: Most probable causes (judgingfrom Questions and Check items)
A: Possible causes due to length of use (used for a long period1
Degree of use of machine Operated for long period nna

I
2 Suddenly increased 0 0
I Condition of vibration
Gradually increased 000
4
Non-specified oil is being used 00
20-151
TROUBLESHOOTING OF GOVERNOR,
PUMP CONTROLLER
(PUMP CONTROL SYSTEM) (C MODE)
Points to remember when carrying out troubleshooting of pump controller system 20-l 53
Action taken by controller and condition of machine when abnormality occurs 20-l 54
Judgement table for governor, pump controller and hydraulic related parts.. 20-I 60
Electrical circuit diagram of C mode systems 20-l 62
c- 1 Abnormality in controller power source (controller LED is OFF). .............................................. 20-164
c- 2 [E232] Short circuit in pump TVC solenoid system is displayed ............................................... 20-I 65
c- 3 [E233] Disconnection pump TVC solenoid system is displayed ............................................... 20-I 67
c- 8 [E203] Short circuit in swing holding brake solenoid system is displayed.. ............................... 20-169
c- 9 [E213] Disconnection in swing holding brake solenoid system is displayed ............................. 20-l 71
c-10 [E205] Short circuit in 2-stage relief solenoid system is displayed ........................................... 20-I 73
C-l 1 [E215] Disconnection in 2-stage relief solenoid system is displayed ........................................ 20-l 74
c-12 [E206] Short circuit in travel speed solenoid system is displayed ............................................. 20-l 75
c-13 [E216] Disconnection in travel speed solenoid system is displayed ......................................... 20-I 76
c-14 [E217] Model selection input error is displayed ........................................................................ 20-I 77
c-15 [E222] Short circuit in LS-EPc solenoid system is displayed .................................................... 20-178
C-16 [E223] Disconnection in LS-EPc solenoid system is displayed ................................................ 20-l 79
c-17 [E224] Abnormality in pump pressure sensor system is displayed ........................................... 20-I 80
c-19 [E226] Abnormality in pressure sensor power source is displayed ........................................... 20-I 81
c-20 [E227] Abnormality in engine speed sensor system is displayed ............................................. 20-l 82
20-I 52
POINTS TO REMEMBER WHEN TROUBLESKOOTING PUMP
TROUBLESHOOTING CONTROLLER SYSTEM
POINTS TO REMEMBER WHEN TROUBLESHOOTING PUMP

CONTROLLER SYSTEM
1. Points to remember if abnormality returns to normal by itself
In the followinf two cases, there is a high probability that the same problem will occur again, so it is desirable
to follow up this problem carefully.
1) If any abnormality returns to normal by itself, or
2) If the connector is disconnected and the T-adepter is inserted, or if the T-adepter is removed and the
connector is returned to its original position when carrying out troubleshooting of the failure, and the
service code is no longer displayed, or if the monitor display returns to normal.
3) After completing troubleshooting, always erase the user code from memory.
2. User code memory retention function

When displaying the abnormality code in memory and carrying out troubleshooting, note down the content
of the display, then erase the display. After trying to re-enact the problem, carry out troubleshooting accord-
ing to the failure code that is displayed. (There are cases where mistaken operation or abnormalities that
occur when the connector is disconnected sre recorded by the memory retention function. Erasing the data
in this way saves any wasted work).
20- 153

User ;ervice Abnormal system Nature of abnormality
code code
1. Short circuit with ground, short circuit inside pump TVC solenoid
2. Short circuit with power source, short circuit with ground in wiring
harness between controller CO2 (8) and TVC solenoid Cl3 (1) ((+)
E232 Short circuit in pump side)
TVC solenoid system 3. Short circuit with power source in wiring harness between control-
ler CO2 (18) and TVC solenoid Cl 3 (2) ((-) side)
4. Defective governor, pump controller
E02
1. Disconnection, defective contact inside pump TVC solenoid
2. Disconnection, defective contact in wiring harness between con-
troller CO2 (8) and TVC solenoid Cl 3 (1) ((+) side)
Disconnection in 3. Disconnection, defective contact, short circuit with ground in wiring
E233 pump TVC solenoid harness between controllerC02 (18) and TVC solenoidC13 (2) ((-)
sytem side)
1. Short circuit with ground, short circuit inside swing holding brake
solenoid
Short circuit in swing 2. Short circuit with ground in wiring harness between controller CO1
E203 holding brake sole- (3) and solenoid V04 (2) ((+) side)
noid system 3. Defective governor, pump controller
E03
1. Disconnection, defective contact inside swing holding brake sole-
noid
Disconnection in 2. Disconnection, defective contact, short circuit with power source in
E213 swing holding brake wiring harness between controller CO1 (3) and solenoid V04 (2)
solenoid system ((+) side)
3. Disconnection, defective contact in wiring harness between sole-
noid V04 (1) and chassis ground ((-) side)
20-I 54
Condition when normal Action by controller when abnormality ‘roblem that appears on machine
(voltage, current, resistance) is detected when there is abnormality
1. Make output to TVC solenoid 0. 1. No current flows to the pump

2. Displays user code E02 on monitor TVC solenoid.
panel. Therefore, when the load is
. Resistance of solenoid: * If the abnormality is restored by the large, there is a big drop in the
IO-22D vibration of the machine, it resets the engin speed which may result
power source to restore to the proper in the engine stalling.
condition. (However, the service code 2. The swing acceleration is poor
display does not go out.)
The current stops flowing to the TVC 1. In the case of 1, it is the same
solenoid, so no particular action is as E232.
. Resistance of solenoid: taken. 2. In the case of 2, the current
IO-22D If there is a short circuit with the (min. 1A) continues to flow to
. Current: 1000 mA (H/O ground at the (-) end, the current (min. the pump TVC solenoid, so the
mode, auto-deceleration IA) continues to flow to the TVC sole- output of the pump TVC valve
ON, levers at neutral, fuel noid. increases and the overall
control dial at MAX.) It displayes user code E02 on the speed becomes slower.
monitor panel.
If the abnormality is restored by the
vibration of the machine, it resets the
power source to restore to the proper
condition. (However, the service code
1. Makes output to TVC solenoid 0.

2. displays user code E03 on monitor
panel.
. Resistance of solenoid: + If the abnormality is restored by the When the swing is operated, the
20 - 6Ofl vibration of the machine, it resets the motor brake is not released, so
power source to restore to the proper the upper structure does not
condition. (However, the service code swing.
1. The current stops flowing to the sole-

noid, so no particular action is taken.
. Resistance of solenoid: 2. Displays user code E03 on monitor
20 - 60 fl panel. Same as display for E203
+ If the abnormality is restored by the
vibration of the machine, it resets the
20- 155
User jervice Abnormal system Nature of abnormality

code code
Short circuit in LS 1. Short circuit with ground, short circuit inside LS bypass solenoid
E201 bypass solenoid 2. Short circuit with ground in wiring harness between controller co1
system (2) and solenoid V05 (2) ((+) side)
Short circuit in 2- 1. Short circuit with ground, short circuit inside 2-stage relief solenoid
stage relief solenoid 2. Short circuit with ground in wiring harness between controller ~01
E205 system (IO) and solenoid V05 (2) ((+) side)
1. Short circuit with ground, short circuit inside travel speed solenoid
Short circuit in travel 2. Short circuit with ground in wiring harness between controller CO1
E206 speed solenoid (9) and solenoid V06 (2) ((+) side)
system 3. Defective governor, pump controller
E215 Disconnection in 2- 1. Disconnection, defective contact inside 2-stage relief solenoid

stage relief solenoid 2. Disconnection, defective contact, short circuit with power source in
system wiring harness between controller CO1 (10) and solenoid V05 (2)
((+) side)
noid V05 (1) and chassis ground ((-) side)
E216 Disconnection in 1. Disconnection, defective contact inside travel speed solenoid

travel speed solenoid 2. Disconnection, defective contact, short circuit with power source in
system wiring harness between controller CO1 (9) and solenoid V06 (2)
((+) side)
noid V06 -(l) and chassis ground ((-) side)
E217 Model selection input 1. Disconnection, defective contact, short circuit with ground in model
error selection wiring harness Cl7 (5) (6) (7) (13) (14)
20-I 56
Condition when normal Action by controller when abnormality Problem that appears on machine
1. Makes output to solenoid 0. 1. With swing + boom RAISE, the

* If the abnormality is restored by the boom is slow.
vibration of the machine, it resets the 2. With swing + arm IN, the arm IN
l Resistance of solenoid: power source to restore to the proper movement is slow.
20 - 6OD condition. (However, the service code 3. With swing + arm OUT, the arm
display does not go out.) OUT movement is slow.
4. With swing+ travel, there is a big
drop in the travel speed.
1. Makes output to solenoid 0. 1. In the L/O and F/O modes, the

* If the abnormality is restored by the work equipment and swing
l Resistance of solenoid: vibration of the machine, it resets the speeds become faster.
20 - 60 D power source to restore to the proper 2. The steering is difficult to turn.1
1. Makes output to solenoid 0. Even if the travel speed is

+ If the abnormality is restored by the switched, the travel speed does
l Resistance of solenoid: vibration of the machine, it resets the not change (remains at Lo)
20 - 60R power source to restore to the proper
1. The current stops flowing to the sole- Same content as display for E201
+ If the abnormality is restored by the
l Resistance of solenoid: vibration of the machine, it resets the
20 - 60R power source to restore to the proper
l Resistance of solenoid: + If the abnormality is restored by the
20 - 60 R vibration of the machine, it resets the
l Resistance of solenoid: * If the abnormality is restored by the
20 - 60 D vibration of the machine, it resets the
l Between Cl 7 (13) and chas- Detect abnormality in input 1. Engine stalls, or

sis: Max. 1 Cl 1) Retains data when starting switch is 2. Work equipment, swing, travel
Between Cl7 (5), (7), (14) ON speeds are all slow, and there is
(6) and chassis: Min. 1 MX no power
20- 157

code code
1. Disconnection, short circuit, short circuit with ground in network wi-

Network response ring harness
E218 overtime error 2. Abnormality in governor, pump controller
3. Abnormality in monitor
1. Short circuit with ground, short circuit inside LS-EPC solenoid

2. Short circuit with power source, short circuit with ground in wiring
E222 Short circuit in LS- harness between controller CO2 (7) and solenoid Cl 0 (1) ((+) side)
EPC solenoid system 3. Short circuit with power source in wiring harness between controller
CO2 (17) and solenoid Cl 0 (2) ((-) side)
1. Disconnection, defective contact inside LS-EPC sollenoid

2. Disconnection, defective contact in wiring harness between control-
E223 Disconnection in LS- ler CO2 (7) and solenoid Cl0 (1) ((+) side)
EPC solenoid system 3. Disconnection, defective contact, short circuit with ground in wiring
harness between controller CO2 (17) and solenoid Cl 0 (2) ((-) side)
1. Disconnection, defective contact, short circuit, short circuit with

ground inside pump pressure sensor
2. Disconnection, defective contact, short circuit in wiring harness be-
E224 Abnormality in pump tween controller CO3 (6) and pressure sensor CO8 (2) ((+) side) and
pressure sensor between CO3 (16) and CO8 (1) ((-) side)
system 3. Disconnection, defective contact, short circuit with power source,
short circuit with ground in wiring harness between controller CO3
(3) and pressure sensor CO8 (3) (SIG side)
Abnormality in 1. Short circuit, short circuit with ground inside pump pressure sensor
E226 pressure sensor 2. Short circuit, short circuit with ground in wiring harness between
power source system controller CO3 (6) and fron pressure sensor CO8 (2)
1. Disconnection defective contact, short circuit inside engine speed

sensor
E227 Abnormality in speed 2. Disconnection, defective contact, short circuit with ground in wiring
sensor system harness between controller Cl 6 (1) and speed sensor E07 (2) ((-)
side) and between Cl 6 (2) and E07 (1) (SIG side)
20-I 58
Condition when normal Action by controller when abnormality Problem that appears on machine
1. When communications are impossible 1. @ Even when travel is operated,

with the monitor, control is carried out with the power max. function does
the following settings. not work
@Working mode: G/O 0 The swift speed-down func-
@ Priority mode: OFF tion does not wor
@ Travel speed: Lo 0 The auto-deceleration cannot
@ Auto-deceleration: ON be canceled
@ Power max. : ON (others are as usual) 0 The travel speed does not in-
crease
0 The priority mode has no ef-
fect
@ the automatic mode has no
effect
1. Makes output to LS-EPC solenoid 0. 1. The Lo travel speed is too fast.

+ If the abnormality is restored by the vibra- 2. In L/O and F/O modes, the work
l Resistance of solenoid: 7 - 14 0 tion of the machine, it resets the power equipment speed is too fast.
source to restore to the proper condition. 3 When the engine is running at low
(However, the service code display does idling, the swing speed is too fast.
not go out.)
1. The current stops flowing to the LS-EPC In the case of 1, it is the same as
solenoid, so no particular action is taken. E222
2. If there is a short circuit with the ground at In the case of 2, electric current
Current: Approx. 705 mA (Le- the (-) end, the current (min. 1A) conti- (min. 1A) continues to flow to the
vers at neutral, low idling) nues to flow to the LS-EPC solenoid. LS-EPC solenoid, so the work
t If the abnormality is restored by the vibra- equipment, travel, and swing
tion of the machine, it resets the power speeds are slow
source to restore to the proper condition.
(However, the service code display does
not go out.)
_
Between CO3 (3) and (16): 0.5 - 1 Takes pump pressure as 0 MPa (0 kg/ The travel speed does not auto-
4.5 V cm2)when actuating. matically shift (it does not change
Between CO3 (6) and (16): 18 - * If the abnormality is restored by the vibra- from Hi to Lo).
28V tion of the machine, it resets the power + If the button is operated
Between CO3 (female) (3) and source to restore to the proper condition. manually, the panel display is
(16), (3) and chassis (However, the service code display does switched.
Resistance: Min. 1 MG (Discon- not go out.)
nect connectors CO3 and C08.)
1. Takes front pump and rear pump pressure 1. The travel speed dos not auto-
as 0 MPa (0 kg/cm”) when actuating. matically shift (it does not change
l Voltage between CO3 (6) and 2. When abnormality is detected, it switches form Hi to Lo).
(16): 18 - 28V the output OFF, and when all levers are t If the button is operated
returned to neutral, it outputs again. manually, the panel display is
* This automatic resetting is repeated up to switched.
3 times.
l Resistance: 500 - 1000 CI 1. It functions in the equivalent of the G/O It operated about the same as G/O
l Voltage (AC range) : 0.5 - 3.0 V mode (the speed rises) mode (prolix) (the power is slightly
(engine started) lower)
20-I 59
JUDGEMENTTABLE FOR GOVERNOR, PUMP CONTROLLER
TROUBLESHOOTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS

(PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
Failure mode
. .Thls shows applicable ,tem for servce code

* .Thls shows ,tem that needs only checlmg with mmtmng
o This shows Itern to check with mmtmng or machlne monitor
20-I 60
TROUBLESHOOTING (PUMP CONTROL SYSTEM) AND HYDRAULIC RELATED PARTS
* If service code E218 (abnormality in network system) is displayed, go to troubleshooting for N mode.
Go”elnOl
pump
cmltrder
(E2
xx Check items in monitoring mode
4yzlem)
20-161
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE 2/2
a I I I
II
_
_
_
r
20-I 62
ELECTRICAL CIRCUIT DIAGRAM FOR C MODE 2/2
J
5
-
_
_
-
_
_
_
20-I 63
TROUBLESHOOTING C-l
C-l Abnormality in controller power source system

(controller LED is OFF)
to its original position, if an E service code is not displayed, the problem has been removed.
Check that fuse 1 is not blown.
When the starting motor rotates normally. (If the starting motor also does not rotate, go to E-8.)
Cause Remedy
YES
1 , Defective governor, pump controller Replace
Isvoltage between
CO1 (7) (13) and ~02 - Defective contact or disconnection in Repair or
(11) (21) normal? 2 YES wwng harness between fuse and 1 replace
CO1 (female) (7) (13)
~ Is voltage between
_ fuse 1 and chassis _
ON.
No normal?
. 20.30V Defective contact, or disconnection in
I I I
wwng harness between fuse 1 Hi5
* Turn StartlnC] swtch NO (2) Ml4 (2) (1) battery relay M
ON.
* 20 - 3ov
C-l Related electric circuit diagram

,COl(MIC13), ,
H14(SlO) Fuse H15(L2)
1
gI a-
PGND
f-l Fusible link
12
C02(MIC21)
II-II
-!3 M14iL2)
20-I 64
TROUBLESHOOTING c-2
C-2 [E232] Short circuit in pumpTVC solenoid system is

displayed
connector and inserting theT-adapter, or when removing theT-adapter and returning the connector
If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an
E service code is displayed. (If it is not displayed, the problem has been removed.)
Always turn the TVC prolix switch OFF.
Cause Remedy
3 YES Defective governor, pump controller Replace

Is resistance
1L-
bet-
YES ween CO2 (female)
- (8) and (18), (8) and
2
~ chassis as shown in
Is rexstance Table l?
between Cl3 (male) ~ GotoA
* Turn starting swtch NO
(1) and (2), (1) and -
OFF.
chassis as shown in
* Disconnect CO2
Table l?
OFF NO
* Disconnect Cl3
Defective pump NC solenoid Replace

:Internal short wcut or short clrcult
Nith ground)
Short circuit with around or short

:,rcu,t with power-source ,n w,r,ng
5 YES wness between CO2 (female) (8) Repair or
ii2 (5) CO5 (female) (I), or short replace
:ircuit with power sow% in wiring
YE :s wrness between CO2 (female) (18)
mHP
4 ii2 (7) -CO5 (female) (2)
I
Defective TVC prolix switch (Internal
* Turn Starting swtch NO short circuit with ground or short Replace
A- OFF. :ircuit with power source)
* Disconnect CO5
. Turn TVC prolix Short c,rcu,t with ground or short
* Turn starting wtch switch OFF. :,rcu,t with power source ,n w,r,ng
wness between CO5 (female) (3) Repalr or
OFF.
* Disconnect C05.
IO -112 ,
(3) Cl3 (female) (1) orshort replace
:ircuit with power sow% in wiring
wness between CO5 (female) (4)
ii2 (4) -Cl3 (female) (2)
Table 1
I Troubleshooting No.2 I Troubleshooting No. 3 I Troubleshooting No.4 Resistance value
1Between Cl3 (male) (1) - (2) 1Between CO2 (female) (8) - (18) 1Between CO5 (female) (3) - (4) 1 IO-22f-l I
Between Cl3 (male) (1) - chassis Between CO2 (female) (8) - chassis Between CO5 (female) (3) - chassis Min. 1 MCI I
Table 2
Troubleshooting No.5 I Resistance value I

I Between ~05 (male) (I) -(31,
(2)-(4) I Max. 10
Between CO5 (male) (1) (2) (3) (4) - chassis Min. 1 M.Q
20-I 65
TROUBLESHOOTING c-2
C-2 Related electric circuit diagram
TVC prolix switch
20-I 66
TROUBLESHOOTING c-3
C-3 [E233] Disconnection in pumpTVC solenoid system is

displayed
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch On and check if an
+ If there is a disconnection in the solenoid or wiring harness, no current flows to the solenoid. If the No. 2 pin
of the solenoid is short circuiting with the ground, the current (approx. 1 A) continues to flow to the solenoid.
+ Always turn the TVC prolix switch OFF.
Cause Remedy
3 YFS
Defective governor, pump controller Replace
IS resistance
l-
YES between ~02
- (female) (8) and (1 S),
2
~ (18) and chassis as
Is rexstance shown in Table l?
between Cl3 (male) ~ GotoA
(1) and (Z), (2) and -
OFF.
chassis as shown in
* Disconnect ~02.
Table l?
OFF.
NO
* Disconnect C13.
Defective pump NC solenoid Replace

:intemal disconnection or defective
xntact)
Defective contact or dIsconnectIon in

Niring harness between CO2 (female)
5 YES
‘81 Hi2 151 CO5 ifemalei iii. 01 Repair or
Is resistance between jefectlve &tact, short arklt’wlth replace
YES CO5 (male) (1) and (3), grand, or dIsconnectIon I” w,r,ng
(2) and (4L (1) (2) (3) - wness between CO2 (female) (18)
4 (4) and chassis as
-112 (7) CO5 (female) (2)
Is resistance
A r
I- between CO5
(female) (3) and
(4),(4) and chassis
as shown m Table 17
Iurn starting wtcn
OFF.
* Disconnect C05.
NO
Defective TVC prolix switch (internal
jlsconnectlon, defective contact, or
short c,rcu,t with ground)
Defective contact or disconnection in

Nirina harness between CO5 (female)
:3) Hi2 (3) Cl3 (female) (I), or
Replace
Repair or
replace
jlsconnectlon in wwng harness
,etween CO5 (female) (4) Hi2 (4)
313 (female) (2)
Table 1
I Troubleshooting No.2 I Troubleshooting No. 3 I Troubleshooting No.4 Resistance value
Between Cl3 (male) (1) - (2) Between CO2 (female) (8) - (18) Between CO5 (female) (3) - (4) IO-220
Between Cl3 (male) (2) - chassis Between CO2 (female) (18) - chassis Between CO5 (female) (4) - chassis Min. 1 MCI
Table 2
Troubleshooting No.5 Resistance value
Between CO5 (male ) (1) - (3), (2) - (4) Max. 10

1Between CO5 (male) (1) (2) (3) (4) - chassis 1 Min. 1 M.Q
20-167
TROUBLESHOOTING c-3
TVC prolix switch

C02fMIC21) H12(S16)
m&-- da---
l!f!_k
I
I’
I I -
5
-
7
C13(X2)
L-kg-1
20-I 68
TROUBLESHOOTING C-8
C-8 [E203] Short circuit in swing brake solenoid system is

displayed
connector and inserting
theT-adapter, or when removing theT-adapter and returning the connector
+ If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an
E service code is displayed. (If it is not displayed, the probem has been removed.)
+ Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
Cause Remedy
3 YES
YI
2 /zjzzq.,,,,
YES between V04 (male) - Turn starting switch NO

(1) and (2), (2) and OFF.
* Disconnect COI.
1 I chassis normal?
- Turn sw,ng lock switch
OFF.
Turn starting switch
connector wth other - 20 60 0
OFF
solenoid Is [E203]
Disconnect V04
0
* Turn starting switch I

OFF. I 1 Defective swing holding brake
solenoid (Internal short wcult or short
* Interchange V04 with NO
c,rcu,t with ground)
Replace
other connector.
* Start engine.
- Operate swng lever. Short circuit with chassis ground in
5 YES
wiring harness between CO1 (female) Repair or
H
II (3).A26(1)(2)-H13(1)-X01 (7). replace
Is resistance between
X05 (male) (3)
chassis normal? Short circuit with chassis around in

wiring harness between Xb5 (male)
* Turn starting switch (4) -X01 (7) Hi3 (7) V04 (female)
* Disconnect X05.
- 20 60 0
Defective swing lock sitch (internal Replace
OFF
NO short c,rcu,t with ground)
- Disconnect X05
* Turn swing lock
swtch OFF
. Mln 1 MO
Table 1
1Between V04 (male) (1) - 92) 1 20 -60 CI 1

1Between V04 (male) (2) - chassis 1Min. 1 MCI1
20- 169
TROUBLESHOOTING C-8
Swing prolix swtich Swing lock switch
Fuse
I I
A26
CO1(MlC13)
H13(S16) X01 (MIC21) X05(M4)
brake solenoid
VO4(X2)
A05
@ Swing holding
I- brake solenoid
valve
20-170
TROUBLESHOOTING c-9
C-9 [E213] Disconnection in swing brake solenoid system

is displayed
to its orginal position, if an E service code is not displayed, the problem has been removed.
Always turn the swing lock prolix switch OFF, then turn the swing lock switch OFF before checking.
Cause Remedy
3 YES
YI ~~-‘GotoA
2
Replace
Is resistance
yES_ between V04 (male)
ON.
(1) and (2) normal?
1 * Disconnect 601.
I
Interchange
connector wth other AC=
solenoid. Is [E213]
* Disconnect V04 NO
dIsplayed?

OFF. I
* 20 -60 n
I
t
Defective swing holding brake
solenoid (internal disconnection
short c,rcu,t with power source)
or Replace

other connector.
* Turn startino switch Defective contact or disconnection in Repair or
ON. 4 6YES
Niring harness between VO4 (female) replace
:I) and chassis ground
Is voltage between
:‘” V04 (female) (2) and _
Short c,rcu,t with powersource,
chassis as shown in
zlefective contact, or disconnection in Repair or
~ Table 17
Is resistance Niring harness between X05 (male) replace
YES between X05 NC i;;-X01 (6) H13 (7) -‘JO4 (female)
_ (female] (3] and (4] - * Turn starting .wch
ON
4 normal?
* Disconnect V.
I I
* Turn starting switch Defective swing lock switch (internal
Wxnnection or short circuit with Replace
OFF.
NO 3ower source)
- Disconnect X05
* Min. 10
short circuit with powersource,
- Turn starting swtch zlefective contact, or disconnection in Repair or
ON. Niring harness between CO1 (female) replace
* Disconnect X05. NO
:3) A26 (1) (2) H13 (1) -X01
:7)-X05 (male) (3)
Table 1
Troubleshooting No. 3 Troubleshooting No. 4 Troubleshooting No. 6 Voltage Measurement condition
Between CO1 (male) Between X05 (male) Between V04 (male) 0 - 3V 5 seconds after all levers are returned to neutral
(3) - chassis (3) - chassis (2) - chassis 20 - 30V Swing lever operated
20-171
TROUBLESHOOTING c-9
Fuse
I I

CO1(MIC13)
H13(S16) X01 (MIC21) X05(M4)
brake solenoid
rE
-
VO4(X2)
A05
g Swing holding
l- brake solenoid
@ valve
TTT
20-I 72
TROUBLESHOOTING C-l 0
C-IO [E205] Short circuit in 2-stage relief solenoid system

is displayed
* This troubleshooting is caried out when there is still an abnormality, so when disconnecting the
E service code is displayed. (If it is not displyed, the problem has been removed.)
Cause Remedy
3 YES
IS resistance
YES between CO1
2 (female) (10) and
Short c,rcu,t with chassis ground I” Repalr or
~ Is resistance chassis normal?
wwng harness between CO1 (female x replace
YES between V25 (male) *~ Turn starting swtch ~NO IO) and V25 (female) (2)
- (1) and (2)> (2) and - OFF.
1 chassis as shown in * Disconnect CO1
~ Table l? * 20 - 60n
Interchange * Turn starting switch
connector with other
OFF
solenoid. Is [E205] - NO
* Disconnect V25
dlsplayed?
* Turn starting wtch

v Defective P-stage relief solenoid
OFF.
(internal short circuit or short circuit ReDlaGs
* lnterchangeV25 with NO
with ground)
other connector.
* Start engine
* Operated travel
Independently
Table 1
Between V25 (male) (1) - (2) 20 - 60 0

Between ~25 (male) (2) - chassis Min. 1 MCI
Governor, pump controller V25(X2)

CO1(MIC13)
@ 2 -stage
relief
@--- solenoid valve
20-I 73
C-l 1 [E215] Disconnection in 2-stage relief solenoid system

is displayed
This troubleshooting is carried out when there is still an abnormlaity, so when disconnecting the
to its original position, if an E service code is not displyed, the problem has been removed.
Cause Remedy
4 YEE
Defective contact or dIsconnectIon m
awng harness between V25 (female)
(1) and chassis ground
chassis as shown in
Short circuit with power source,
defective contact, or dlsconnectlon in Repair or
awng harness between CO1 (female) replace
(10) -V25 (female) (2)
* Disconnect V25
chaws as shown m
Defective governor, pump controller

NO
displayed? . . . 20 - 60 n
* Turn starting switch Defective Z-stage relief solenoid
OFF. I (Internal dIsconnectIon or short wcut
* Interchange V25 with NO alth power source)
other connector
- Turn starting swtch
ON.
Table 1
Troubleshooting No. 3 I Troubleshooting No. 4 1 Voltage 1 Measurement condition
Between CO1 (male) (10) - Between V25 (female) (2) - 0 - 3V All levers at neutral
chassis chassis 20 - 30V 1Travel operated independently
C-l 1 Related electric circuit diagram

Governor, pump controller V25(X2)
CO1(MIC13)
@- 2 -stage
2-stage relief
relief @ - @- solenoid valve
solenoid
/777
A04
, II I
20-I 74
TROUBLESHOOTING c-12
C-12 [E206] Short circuit in travel speed solenoid system

is displayed
Cause Remedy
3 YES
Replace
IS resistance
YES between CO1
2 (female) (9) and
Short circuit with chassis ground in Repair or
~ chassis normal?
Is resistance wwng harness between CO1 (female) replace
YES between V04 (male) *~ Turn starting switch ~NO (8) and V04 (female) (2)
- (1) and (21, (2) and - OFF.
1 chassis as shown in * Disconnect 601.
~ ~Table l? * 20-6on
Interchange * Turn starting wtch
connector with other OFF.
solenoid Is [E206] - NO
* Disconnect V04
displayed?

OFF. . Defective travel speed solenoid
(Internal short wcut or short clrcult Replace
with ground)
other connector.
* Start engine.
* Travel speed swtch
at MI or HI
* Operate the lever
slightly not enough to
move the machine
Table 1
1Between V04 (male) (1) - (2) 1 20 - 60 0 1

1Between vO4 (male) (2) - chassis I Min. 1 MCI I

Governor, pumpcontroller VO4(X2)
co1 (MIC13)
Travel speed
solenoid valve
I
20-175
C-13 [E216] Disconnection in travel speed selector solenoid

system is displayed
Before carryuing out troubleshooting, check that all the related connectors are properly inserted.
Cause Remedy
4 YE
Defective contact or disconnection in Repair or
wwng harness between VO6 (female) replace
YE (1) and chassis ground
F[
Short circuit with power source,

3 defective contact, or disconnection in Repair or
. Turn starting wtch N( wwng harness between CO1 (female) replace
Is voltage
between (9) V06 (female) (2)
ON.
. Disconnect V
chaws as shown m
Is resistance Defective governor, pump controller Replace

YES * Turn starting switch
between V06 (male)
(1) and (2) normal?
’ I * Disconnect 601.
Defective travel speed solenoid

OFF. I (internal disconnection or short circuit Replace
* lnterchangeV06 with NO with power source)
other connector
ON.
Table 1
Troubleshooting No. 3 I Troubleshooting No. 4 1 Voltage 1 Measurement condition I
0 - 3v Travel speed switch at Lo
Between CO1 (male) (10) - Between V06 (female) (2) - Travel speed switch at Mi or Hi
chassis chassis
2o - 3ov Operate the lever slightly not enough to move the
machine
Governor, pump controller VO6(X2)

CO1(MIC13)
Travel speed
solenoid valve
20-I 76
C-16 [E223] Disconnection in LS-EPC solenoid system

displays
Before carrying out troubleshooting,check that all the related connectors are properly inserted.
Cause Remedy
2 YES
IS resistance
between CO2 Defect contact or short circuit with
(female) (7) and (17), Ii chassis ground in wiring harness
1
11171 and chassis as 11 between CO2 (female) (7) and Cl0
IS resistance shown in Table 17 (female) (I), or defective contact, Repalr or
between Cl0 (male) * Turn starting switch NO short c,rcu,t with ground, or replace
(1) and (2), (2) and -.
OFF dIsconnectIon in wwng harness
chassis as shown in * Disconnect C02. between CO2 (female) (17) Cl 0
Table l? (female) (2)
- Turn startlnq wtch
OFF. Defective LS-EPS solenoid (Internal
NO dIsconnectIon, defective contact, or Replace
- Disconnect Cl0
short circuit with ground)
Table 1
Troubleshooting No. 1 I Troubleshooting No. 2 1 Resistance value

Between Cl0 (male) (1) - (2) 1Between CO2 (female) (7) - (17) 1 7-140
Between Cl0 (male) (1) - chassis I Between CO2 (female) (7) - chassis I Min. 1 MCI

C02(MIC21)
20- 179
C-17 [E224] Abnormality in pump pressure sensor system

is displayed
E service code is displayed. (If it is not displayed, the problem hs been removed.)
Before carrying out troubleshooting, check that all the related connecotrds are properly inserted.
Cause Remedy
2 YES
17
- 1
H’
defective contact,‘or dIsconnectIon in RepaIr or
Is voltage
between wwng harness between CO3 (female)
CO8 (2) and (1)
Engine at high ldllng NO (3) CO8 (female) (3)
replace
* Operate repeatedly
normal?
arm IN relief H
Short clrcut with ground, defective
contact, or dlsconnctlon I” w,r,ng RepaIr or
harness between CO3 (female) (6) replace
and CO8 (female) (1)
Short clrcut with ground, defective

I I I contact, or dlsconkctlon I” w,r,ng RepaIr or
- Disconnect C08. NO harness between CO3 (female) (6) reDlaCe
* Turn starting switch and CO8 (female) (2)
ON.
* 18.28V

Governor, pump controller CO3 COEqX3)
Pump pressure sensor

SIG @ g
Pressure sensor Pump pressure
power source (g @ sensor
Pressure sensor GND @ I @
20-I 80
C-19 [E226] Abnormality in pressure sensor power source

system is displayed
If the starting switch is turned OFF after an abnormaltiy occurs, turn the starting switch ON and check if an
Cause Remedy
2 YES
iJefect1ve front pump pressure sensor Replace
(Internal short c,rcu,t or short c,rcu,t
Is voltage between
with ground)
YES CO3 (6) and (16)
* Disconnect 608.
normal? . 18.28V
. Turn starting switch Short c,rcu,t or short c,rcu,t with Repalr or
OFF. ground in wwng harness of system replace
. Disconnect C03, and where resistance value is defective
cot3
. Mln 1 MO
Governor, pump controller CO3 COA(X.?)

\ I I I I I I
)$=J+i
Pump pressure sensor
H
1
~EzT~,,, 2
Pump pressure
sensor
3
1 I 1 1 I I I
20-I 81
C-20 [E227] Abnormality in engine speed sensor system is

displayed
+ always connect any disconnected connectors before going on the next step.
Cause Remedy
2 YES
Defective govenror, pump controller Replace
IS resistance
YES between Cl6 Short circuit with ground, defective
1 contact, 01 disconnection in wiring
(female) (1) and (2)
harness between Cl6 (female) (1) RepaIr or
nC#tllal?
E08 (10) E07 replace
Is resistance (female) (2), or between Cl6
between E07 (male) - (female) (2) E08 (9) E07
OFF.
(1) and (2) normal? (female) (1)
* Disconnect 616.
* 500. iooon
* Turn starting swtch Defective englne speed sensor
OFF. (Internal dIsconnectIon, defective Replace
NO contact, or short circuit with ground)
. Disconnect E07.
-
* 500 1ooon

C16(MIC17) E08(SWP14) E07(X2)
B-- - a Engine
speed
f3 Q sensor
(SIG \Y I” I I
BKPOO255
20-I 82
TROUBLESHOOTING OF GOVERNOR, PUMP CONTROLLER
(INPUT SIGNAL SYSTEM) (F MODE)
Electrical circuit diagram for F mode ... ..................................................................................................... 20-l 84

F- 1 Bit pattern 20-(l) Swing oil pressure switch does not light up ................................................... 20-l 86
F- 2 Bit pattern 20-(2) Travel oil pressure switch does not light up .................................................... 20-l 87
F- 3 Bit pattern 20-(3) Boom LOWER oil pressure switch does not light up ...................................... 20-l 88
F- 4 Bit pattern 20-(4) Boom RAISE oil pressure switch does not light up ........................................ 20-l 89
F- 5 Bit pattern 20-(5) Arm IN oil pressure switch does not light up .................................................. 20-190
F- 6 Bit pattern 20-(6) Arm OUT oil pressure switch does not light up .............................................. 20-l 91
F- 7 Bit pattern 21-(l) Bucket CURL oil pressure switch does not light up ....................................... 20-192
F- 8 Bit pattern 21-(2) Bucket DUMP oil pressure switch does not light up ....................................... 20-l 93
F- 9 Bit pattern 21-(3) Swing lock switch does not light up ............................................................... 20-194
F- 11 Bit pattern 22-(6) L.H. knob switch does not light up ................................................................. 20-l 95
20-I 83
TROUBLESHOOTING
_.
r--
Slyi RmlmAlx sl.
PUP REDUNDANCYCIRCUIT SWITCH
CU-FRE E 1
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE l/2 RESISTER
Sllffi LOCK SlITCH

I
I
I -
r -
I
I
I
r-
k-
I
t:r
20-184
ELECTRICAL CIRCUIT DIAGRAM FOR F MODE 2/2
20-I 85
TROUBLESHOOTING F-l
F-l Bit pattern 2041) Swing oil pressure switch does not
light up
to its original position, if the monitor code display returns to normal, the problem has been re-
moved.
Turn the swing lock switch ON before operating the swing lever.
If there is no display when the lever is operated on one side, the PPC shuttle valve is defective. (See H-5)
(When measuring with the engine stopped, charge the accumulator first.)
Cause Remedy
YES
1 I
Defective contact or dIsconnectIon m RepaIr or
Is voltage between 3 YES wiring harness between SO8 (female) replace
Cl6 (5) and chassis Is resistance between (1) and chassis ground
Klrtllal? YES C16 (female) (5) and
_ SO8 (female) (2) nor- _
v Start engine. 2 mal, and IS c,rcu,t ,nsu- Defective contact, short clrcut with
’ Swig lever at Is reskance between lated from chassis? ground, or dlsconnectlon in wlrlng RepaIr or
neutral .20- 30 v - SO8 (male) (1) and * Turn starting switch NO
harness between C16 (female) (5) replace
) Swing lever N
’
(2) normal,and IS - OFF.
and SO8 (female) (2)
operated circuit insulated from * Disconnect Cl6 and SO8.
:
Max. 1V chassU * Between Cl6 and 508: Max. 1 0 Defective swung 011pressure wtch (If
* Disconnect SO8. * Between wirinq harness and chassis: Min. 1 Mn the condition does not return to Replace
* Start enalne ..^ normal even when the switch is
NV
* Swing lever at replaced, go the H-5
neutral: Min. 1 MfI
* Swing lever
operated: Max 10
* See Note 1.
Note 1: It is also possible to fit a short connector and

judge the condition. In this case, check the volt-
age between Cl 6 (5) and the chassis.
. If it is 20 - 30 V: Go to Yes
. If it is less than 1 V: Go to No
F-l Related electric circuit diagram
Governor, pump controller SO8(X2)

C16(MIC17)
Swing oil
Swing oil pressure switch
pressure 5 -
switch
I I
I
T/r
20-I 86
TROUBLESHOOTING F-2
F-2 Bit pattern 2042)Travel oil pressure switch does not

light up
* This troubleshooting is carried out when there is still an abnormality, so when the connector and
inserting or when removing the T-adapter and returning the connector to its original
the T-adapter,
position, if the monitor code display returns to normal, the problem has been removed.
a Before operating the travel lever, check that the surrounding area is safe.
+ If there is no display when the travel lever is operated on one side, the PPC shuttle valve is defective. (See
H-5)
Cause Remedy
Defective contact, or dIsconnectIon m Repalr or

3 YES wiring harness between SO1 (female) replace
Cl6 (13) and chaws Is res,stance between (1) and chassis ground
YES Cl6 (female) (13) and
* Start engine. 2 mal, and IS c~rcut msu- Defective contact, short clrcult with
- Travel lever at neutral Is reslstance lated form chassis? ground, or dIsconnectIon I” w,r,ng Repalr or
20 -30 v harness between Cl6 (female) (13) replace
between SO1 (male) ~
* Turn starting switch ~
NO
* Travel lever oDeratedN SO1 (female) (2) and A27 (1) (2)
(1) and (2) normal, - oFF
Max. 1 V and is circuit insu- * Disconnect Cl 6 and Sol.
L lated from chaws? * Between Cl6 and Sol’ Max 1 II Defective travel 011pressure switch (If
. Disconnect SO1 * Between wirinq harness and chassis. Min. 1 M n the condition does not return to Replace
* Start engine. hlP normal even when the switch is
. Travel lever at neutral ‘“” replaced, go to H-5.)
:Min. 1MfI
. Travel lever operated
:Max, 1 n
* See Note 1

. If it is 20 - 30 V: Go to YES
. If it is less than 1 V: Go to NO
F-2 Related electric circuit diagram
Governor, pumpcontroller
. I
:16(MIC17)
20-I 87
TROUBLESHOOTING F-3
F-3 Bit pattern 20-(3) Boom LOWER oil pressure switch

does not light up
connector and inserting the T-adpate, or when removing the T-adapter and returning the connector
moved.
When measuring with the engine running, operate the lever slightly and make sure that the work equipment
does not move.
Before carrying out troubelshooting, check that all the related connectors are properly inserted.
Cause Remedy
Defective contact, or dlsconnectlon in RepaIr or

nortllal? YES C17 (female) (10) and
v Start engine. 2 mal, and IS c,rcu,t IF,“- Defective contact, short clrcut with
) Boom lever at Is resistance lated from chassis? ground, or dlsconnectlon anwlrlng RepaIr or
-
neutral. 20 30 v between SO4 (male) ~
* Turn starting switch ~NO
B Boom lever operatedN (1) and (2) normal, - oFF.
H13 (11) SO4 (female) (2)
to LOWER: Max. 1V and is circuit insu- * Disconnect Cl7 and 504.
lated from chaswP . Between Cl 7 and 504: Max. 1II Defective boom LOWER 011pressure
* Disconnect 504. * Between wirinq harness and chassis : Min. 1 MO switch (if the conditiion does not Replace
* Start eqne return to normal even when the switch
NO
* Boom lever at is replaced, go to H-5)
neutral: Min. 1 MfI
* Boom lever operated
to LOWER, Max 1 n
* See Note 1.

. If it is 20 - 30 V: Go to YES
. If it is less than 1 V: Go to NO
Govermor, pump controller SO4(X2)

I
C17(04016)
H13(S16) Boom LOWER
(iJ
oil pressure switch
0 @ ;
TTT
BKPOO259
20-I 88
TROUBLESHOOTING F-4
F-4 Bit pattern 20-(4) Boom RAISE oil pressure switch does
not light up
moved.
does not move.
Cause Remedy
Defective contact, or dIsconnectIon I” RepaIr or

Cl7 (2) and chassis - Is resistance between (1) and chassis ground
normal? YES Cl7 (female) (2) and
* Start engine. 2 mal, and IS c~rcut msu- Defective contact, short c,rcu,t with RepaIr or
* Boom lever at lated from chassis? ground, or dIsconnectIon I” w,r,ng replace
IS resistance
-
neutral: 20 3ov - between SO2 (male) ~
* Turn starting switch ~
NO
harness between Cl7 (female) (2)
* Boom lever operatedNO (1) and (2) normal, - HI3 (9) SO2 (female) (2)
OFF
to RAISE. Max. 1 V and is circuit insu- * Disconnect Cl 7 and 502.
lated from chaws? . Between Cl7 and SO2, Max 1 O Defective boom RAISE 011pressure Replace
* Disconnect 502. * Between wirinq harness and chassis Min. 1 MO switch
* Start engine. (If the condition does not return to
NO
. Boom lever at normal even when the switch is
neutral, Mln 1 MO replaced, go to H-5.)
. Boom lever operated
to RAISE : Max 1 O
* See Note 1

. If it is 20 - 30V : Go toYES
. If it is less than 1V: Go to NO
Governor, pump controller SO2(X2)
($ Boom RAISE oil

pressure switch
a
n-T
20- 189
TROUBLESHOOTING F-5
F-5 Bit pattern 20-(5) Arm IN oil pressure switch does not
light up
moved.
does not move.
Cause Remedy
Defective contact, or dlsconnectlon in RepaIr or

Klrtllal? YES C17 (female) (3) and
v Start engine. 2 mal, and IS c,rcu,t IF,“-
) Arm lever at neutrals Is resistance be- lated from chassis? Defective contact. short clrcut with
ground, or disconnection in wiring Repair or
-
20 3ov tween SO5 (male) (1) ~
* Turn starting switch ~NO
B Arm lever operated N and (2) normal, and - oFF.
H13 (10) SO5 (female) (2)
:
to IN Max. 1 V is circuit isulated * Disconnect Cl7 and 505.
from chaswP . Between Cl 7 and 505: Max. 1II Defective arm IN 011pressure switch
* Disconnect 505. * Between wirinq harness and chassis : Min. 1 MO (If the condition does not return to Replace
* Start enalne ..^ normal even when the switch is
. Arm lever at neutral ‘” replaced, go to H-5.)
Mln 1 MO
. Arm lever operated
to IN, Max. 1 n
* See Note 1.
Note 1: It is also possible to fit a short connecotr and

. If it is 20 - 30V: Go to YES
. If it is less than IV: Go to NO

SO5(X2)
C17(04016) I I 1
H13(S16)
a Arm IN oil
@I pressure switch
@
20-I 90
TROUBLESHOOTING F-7
F-6 Bit pattern 20-6 Arm Out oil pressure switch does not
light up
moved.
A When measuring with the engine running, operate the lever slightly and make sure that the work equipment
does not move.
Cause Remedy
Defective contact, or dIsconnectIon m Repalr or

wiring harness between SO3 (female) replace
Cl7 (11) and chaws (1) and chassis ground
* Start engine. Defective contact, short clrcult with Repalr or

- Arm lever at neutrals ground. or dIsconnectIon in Waring replace
-
20 3ov harness between Cl7 (female) (11)
- Arm lever operated N HI3 (12) SO3 (female) (2)
to OUT: Max. 1 V
Defective arm OUT 011pressure switch Replace

(If the condition does not return to
normal even when the switch is
* Arm la& at neutral: ‘” replaced, go to H-5.)
Min. 1 Mn
. arm lever operated to
OUT, Max. 1 n
- See Note 1

. If it is 20 - 30V: Go toYES

C17(04016)
I \ I H13(S16)
Arm OUT oil
pressure switch
@-
BKW0262
20-I 91
TROUBLESHOOTING F-7
F-7 Bit pattern 2141) Bucket CURL oil pressure switch does
not light up
a moved.
does not move.
Cause Remedy
YES
11
Is voltage between 3 YES Defective contact, or disconnection in Repair or

Cl6 (11) and chassis - Is resistance between wiring harness between SO6 (female) replace
nClrtllal? YES C16 (female) (1) and (1) and chassis ground
* Start engine. 2 mal, and IS c,rcu,t IF,“-
. Bucket lever at Is resistance bet- lated from chassis?
-
neutral. 20 3ov N6 ween SO6 (male) (1) * Turn starting switch NO
* Bucket lever harness between C16 (female) (11) replace
and (2) normal, and - oFF.
and SO6 (female) (2)
operated to CURL. is circuit insulated * Disconnect Cl6 and S06.
Max. 1 V from chassis? * Between Cl6 and S06: Max. 1 II Defective bucket CURL 011pressure
* Disconnect SO6. * Between wirinq harness and chassis : Min. 1 MO switch
* Start eqne (If the condition does not return to Replace
NO
. Bucket lever at normal even when the switch is
neutral: Min. 1 MfI replaced, go to H-5.)
. Bucket lever
operated to CURL,
Max 10
. See Note 1.

age between Cl6 (11) and the chassis.
. If it is 20 - 30V: Go to YES

SO6(X2 )
C16(MIC17) I/ I -I I -
I \ -
Bucket CURL oil

pressure switch
BKPW263
20-I 92
TROUBLESHOOTING F-8
F-8 Bit pattern 2142) Bucket DUMP oil pressure switch does
not light up
moved.
does not move.
Cause Remedy
Defective contact or dIsconnectIon in Repalr or

Is voltage
between 3 YES wiring harness between SO7 (female) replace
Cl6 (12) and chaws Is res,stance between (2) and chassis ground
YES Cl6 (female) (12) and
SO7 (female) (2) nor-
* Start engine. Defective contact, short clrcult with Repalr or
. Bucket lever at ground, or dIsconnectIon I” w,r,ng replace
Is resistance bet-
-
neutral: 20 3ov ween so7 (male) (1) * Turn starting switch NO
harness between Cl6 (female) (12)
N and SO7 (female) (2)
. Bucket lever and (2) normal, and OFF
operated to DUMP: is circuit insulated * Disconnect Cl 6 and 507.
Max 1 V
- Between Cl6 and SO7, Max 1 II Defective bucket DUMP 011pressure
* Disconnect 507. * Between wirinq harness and chassis. Min. 1 Mn switch
- Start enalne. .^ (If the condition does not return to
N”
. Bucket lever at normal even when the switch is
neutral Mln 1 MO replaced, go to H-5.)
. Bucket lever
operated to DUMP,
Max. 1 n
* See Note 1.

. If it is 20 - 30V: Go toYES
F-8 Related electric circuit digram

SO7(X2)
C16(MIC17)
Bucket c Bucket DUMP oil
DUMP oil pressure switch
@ a
pressure
switch
m
20- 193
TROUBLESHOOTING F-9
F-9 Bit pattern 21-(3) Swing lock switch does not light up
+ This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
moved.
+ If the panel display is normal. (If the swing lock lamp does not light up, go to M-21 .)
Cause Remedy
Defective contact, short c,rcu,t with

Is voltage between 3 YES ground, 01 disconnection in wiring Repair or
Cl7 (16) and chassis - Is resistance between harness between X05 (female) (2) replace
Klrtllal? YES C17 (female) (16) and X01 (5) -HO8 (6) -chassis ground
_ X05 (female) (1) nor- _
* Turn starting switch 2 mal, and IS c,rcu,t ,nsu-
ON. lated from chassis? Defective contact. short c,rcu,t with
Is resistance bet-
* Swing lock switch - ween x05 (female) * Turn starting switch NO harness between C17 (female) (16) replace
ON: Max. 1V No (1) and (2) normal, -
-
OFF: 20 30V and is circuit insu-
OFF. x01 (4) -x05 (male) (1)
* Disconnect Cl7 and X05.
lated from chaswP . Between Cl7 and X05: Max. 1 O
* Turn starting switch * Between wirinq harness and chassis : Min. 1 MO
Defective sw,ng lock switch ReDlaCe
OFF
NO
* Disconnect X05.
. Swng lock switch
ON. Max. 1O OFF:
Mln 1 MO

h
20-I 94
TROUBLESHOOTING F-l 1
F-II Bit pattern 22-(6) L.H. knob switch does not light up
moved.
When fuse No. 5 is not blown.
Cause Remedy
Defecltve contact, or dIsconnectIon I”

w,r,ng harness between knob switch
3 YES outlet M23 (4) G30(4) CO3
CO3 (9) and chassis II (female) (9)

ON.
* Knob switch Defective L H. knob switch
ON: 20 -30V N
OFF. Max. 1 V
~
Defective contact, or dIsconnectIon I”
wiring harness between fuse No. 5
ON HI2 (16) G30(3) M23(3) knob
NO
switch inlet
-
* 20 3ov
F-l 1 Related electric circuit diagram
H12(S16)
A L.H Knob switch

Governor, pump controller G30(M4) M23(M4) I I
CO3(040) n
@ @ Lo-
@ @ >I I+-
Y
20- 195
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM (H MODE)
Tabel of failure modes and causes.. 20-l 98

All work equipment, travel, swing
H- 1 Speeds of all work equipment, swing, travel are slow or lack power.. 20-202
H- 2 There is excessive drop in engine speed, or engine stalls.. 20-204
H- 3 No work equipment, travel, swing move.. 20-205
H- 4 Abnormal noise generated (around pump).. 20-205
H- 5 Auto-deceleration does not work.. 20-206
H- 6 Fine control ability is poor or response is poor.. 20-206
Work equipment
H- 7 Boom is slow or lacks power ..................................................................................................... 20-208
H- 8 Arm is slow or lacks power ........................................................................................................ 20-210
H- 9 Bucket is slow or lacks power ................................................................................................... 20-212
H- 10 Work equipment (boom, arm, bucket) does not move .............................................................. 20-213
H- 11 Excessive hydraulic drift (boom, arm bucket) ........................................................................... 20-213
H- 12 Excessive time lag (engine at low idling) .................................................................................. 20-214
H- 13 Other equipment moves when single circuit is relieved .......................................................... 20-214
H- 14 In F/O modes, work equipment speed is faster than set speed ................................................ 20-215
H- 15 Lack of power when pressure rises ........................................................................................ 20-215
Compound operations
H- 16 In compound operations, work equipment with larger load is slow ........................................... 20-215
H- 17 In swing + boom RAISE, boom RAISE is slow .......................................................................... 20-216
Travel system
H- 21 Travel speed is slow ................................................................................................................ 20-218
H- 23 Travel speed does not switch or is faster than set speed .......................................................... 20-220
Swing system
H- 25 Does not swing (both left and right, one direction only) ............................................................ 20-221
H- 26 Swing acceleration is poor or swing speed is slow (both left and right, one direction only) ...... 20-222
H- 27 Excessive overrun when stopping swing (both left and right, one direction only) ..................... 20-224
H- 28 Excessive shock when stopping swing (one direction only) ...................................................... 20-225
H- 29 Excessive abnormal noise when stopping swing ...................................................................... 20-225
H- 30 Excessive hydraulic drift of swing (when brake is ON, when brake is OFF) ............................. 20-226
H- 31 Swing speed is faster than specified speed .............................................................................. 20-227
20- 197
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES (l/2)

_ _ _
Parts causing failure P
Piston pump
z
2
5
>
- - - - -
s t E
T 5 8 2
ii
9 I” ‘n
P iiL lil
Failure mode
(
2 z [2E
9 8 E E E 5E
i- -Y - WI
-
s- ij- 2 n
- -
Speeds of all work equipment, swing, travel are slow or lack power 0
- -
0
- -
0
-
0
- - -
There is excessive drop in engine speed, or engine stalls 0
_
0
_ _ _ _
No work equipment, travel, swing move _
0
_
0
_ _0 _
Abnormal noise generated (around pump) - - -
0
- -
0
- - -
Auto-deceleration does not work - - - - - - - -
Fine control ability is poor or response is poor _
0 0 0
_ _ _ _
Boom is slow or lacks power _ _ _ _ 0
_
Arm is slow or lacks power - - - - - - - -
0
Bucket is slow or lacks power - - - - - - - -

0
Boom does not move _ _ _ _ 0

_
Arm does not move _ _ _ _ 0

_
Bucket does not move - - - - - - - -

0
Excessive hydraulic drift - - - - - - - -

Escessive time lag (engine at low idling) _ _ _ _ _
Other equipment moves when single circuit is relieved _ _ _ _ _
In F/O modes, work equipment speed is faster than specified speed - -
0
- - - - - -
Lack of power when pressure rises - - - - - - - -
In compound operations, work equipment with larger load is slow _ _ _ _ _
In swing + boom (RAISE), boom is slow _ _ _ _ 0
_
In swing +travel, travel speed drops excessively - - - - - - - -
In work equipment boom raise + travel, travel speed drops excessively - - - - - - - -
Travel soeed is slow - - - - - - - -

0
Travel soeed does not switch or is faster than soecified soeed _ _ _ _ _

Both left and right - - -
Does not swing - - - - -
One direction onlv, - - - - - - - -
0
Swing acceleration is pour Both left and right _ _ _ _ _

or swing speed is slow One direction only _ _ _ _ 0
_
Excessive overrun when Both left and right _ _ _ _ _

stopping swing One direction only - - - - - - - -
0
Excessive shock when stopping swing(one direction only) - - - - - - - -

Excessive abnormal noise when stopping swing _ _ _ _ _
Exessive hydraulic drift When brake ON - - - - - - - -
of swing When brake OFF - - - - - - - -
0
Swing speed is faster than specified swing speed

_
0
_ _ _ _
+ In the failure modes, modes for compound operations are used when inde
20-I 98
- - - - - - -
Control
-
valve
- T
L I”
9 1” 9
s
.- F E
-5 L g
3
E
2 s a, %I
I” x s Y 3
9 1” 9 9 _c lil
E
5
z
1” E
2 E a,
m
5
E z
0
75 s
8
5 9 t!? C Ea, 5 C E L E 5 0 ‘5
_o E .- 6
a,
P 2 5a
.E s
a, a :
3 5 E z7 9
2
z ,x
iz
‘5
a
.E
5
2
Troubleshooting
code
: 2 2
r”
- -3 -ct 2- -Y -2 2- -< - a
- -a $
a - -c?l15
-
-
0
- - - - -
-
0
- - - - - - - H-i
0 H-2
0 H-3
- - - - - - - - - - - - H-4
-
- -
- - - - - - - - - -
C
- - - H-5
0 H-6
0 0 0 H-7
0
- -
0
- - 0
- -
0
- - - - - H-8
-
- - -
- - -
0
- - - - - -
0
- - - - H-9
0
0 H-10
- - - - - -
0
- - - - -
-
- - -
- - -
0
- - - - - - - - - - H-i 1
0 H-12
0 H-13
- - - - - - - - - - - - H-14
-
- -
-
0
- - - - - - - - - - - - H-15
H-16
0 C H-17
- - - -
0
- - - -
c
- -- - H-18
--
- -
H-19
- - - - - - - - - -
--
- -
H-21
- - -
0
- -
0
- - - -
0
-
C
- -
H-23
- - - - - - - - - -- - H-25
--
- -
- - - - - - - - -
0
- - -
C
H-26
0 0 <
H-27
- - - - - - - - -
0
- - -
0
- -
- - - - - - - - -
0
- - -
0
- - H-28
H-29
- - - - - - - - - - - - - - H-30
- - -
0
- - - - - - - - - - -
H-31
20-I 99
TABLE OF FAILURE MODES AND CAUSES (2/2)

_
Parts causing failure
s
;P lenoid valve Swing
motor
22 5
a
9 $ L9
2 5
F
5 0 P .- 5
5
2 ,” 4 &2
Failure mode
W 5 .-F 5is .I!?
5
\ 5 &I 2 c cz
; Speeds of all work equipment, swing, travel are slow or lack power 0 0
6
E F There is excessive drop in engine speed, or engine stalls - - - - -
%2
P Y
No work equipment, travel, swing move - - - - -
L>
a, Abnormal noise generated (around pump) - - - - -
g 2 Auto-deceleration does not work
i Fine control ability is poor or response is poor
Boom is slow or lacks power - - - - -
Arm is slow or lacks power
Bucket OS slow or lacks power
2 Boom does not move
Arm does not move - - - - -
Bucket does not move
- - - - -
Excessive hydraulic drift
Escessive time lag (engine at low idling) 0
Other equipment moves when single circuit is relieved

0
- - - -
In F/O modes. work eauioment soeed is faster than soecified soeed
1 Lack of Dower when oressure rises 0
F 2 In compound operations, work equipment with larger load is slow

2 .s In swing + boom (RAISE), boom is slow - - - - -
E & In swing + travel. Travel speed drops excessively - - - - -
5 g Iln work eauioment boom raise + travel. travel soeed droos excessivelv
E Travel soeed is slow 0
2%
q Z Travel soeed does not switch or is faster than soecified soeed -
0
- - -
0
-
1 Both left and riaht
Does not swing - - - -
1 One direction onlv 0
Swing acceleration is poor Both left and right
or swing speed is slow One direction only 0
- - - - -
5 Excessive overrun when Both left and right
5 - - - -
2 stopping swing One direction only 0
.-P Excessive shock when stopping swing(one direction only)
2 Excessive abnormal noise when stoppinq swinq 0
- - - -
Exessive hydraulic drift When brake ON - -

0
- -
of swing When brake OFF 0
1 Swing speed is faster than specified swing speed 0
* In the failure modes, modes for compound operations are used when independ
20-200
-
Travel motor
- - -
s
ST
.G
lil
Pressure switch
- T
73
.- _c
a
2
9 E
I” i .-F
9 5 L
5 b 9 5
g a, u
1”
c $ .G
3 9
s
.- d
L E I” 2 Y 5 9
9 9 .-9 .o s .-5
I) Troubleshooting code
lil ti 6 7 F
,x F 5a, 5 3 u
e E 5 -0 a,
$2 5 5
2 2 i 8 5
2
- -0 -6 -c - -I’ -m -* -I -+
H-l
- - - - - - - - - -
H-2
H-3
- - - - - - - - - - - H-4
- - - - - - - - - - 0000000
-
0 H-5
H-6
0 0 H-7
- - - - - -
0
- - - - -
H-8
- - - - - -
0
- - - - -
H-9
H-10
- - - - - - - - - - -
- - - - - -
0
-
0
- - - -
H-i 1
H-12
H-13
- - - - - - - - - - -
H-14
- - - - - - - - - - -
H-15
H-16
H-17
- - - - - - - - - - -
H-18
- - - - - - - - - - -
H-19
H-21
- - - - - - - - -0 - -
0 H-23
- - - - - - - - - -
0
-
- - - - - - - - - - -
- - - - - - - - - - -
- - - - - - - - - - -
0
- - - - - - - - - -
0
-
- - - - - - - - - - -
20-20 1
TROUBLESHOOTING H-l
H-l Speeds of all work equipment, swing, travel are slow or

lack power
* Carry out troubleshooting in the H/O mode.
* Check that no abnormal noise is being generated from the main pump before carrying out troubleshooting.
(If there is any abnormal noise, carry out troubleshooting for H-4.)
3 YES
LS cd& EPC valve

normal?
- 0 2? 0.2 MPa NO
(2 f 2 kg/cm2)
- Eqne at high ldllng
2 * Arm relief
,‘ES Is main pump relief

pressure normal?
1
* 31.4 -34.8 MPa

(320.355kg/cmz)
* Engine at high idling
1
- Arm relief
* Turn swing lock
IS Control pump
swtch OFF.
circuit pressure
normal?
. Check and measure

Clrcult 011pressure
For details, see
TESTING AND
ADJUSTING.
I
NI3
20-202
TROUBLESHOOTING H-l
I Cause Remedy
Defective piston pump assy Replace
Defective operation OS LS Replace

control EPC solenoid valve
Defective operation of Repair or

unload valve replace
Defective hydraulic equip- Adjust or

ment in control pump circuit replace
(See TESTING AND
ADJUSTING)
20-203
TROUBLESHOOTING H-2
H-2 There is excessive drop in engine speed, or engine stalls

+ Carry out troubleshooting in the H/O mode.
+ Check that the main relief pressure is normal.
Cause Remedy
Clogged throttle inside servo Clean
Is throttle inside
sewo clogged?
2 YES
Defective piston pump Assy Replace
Is engine speed at
NC arm IN relief normal? -
See troubleshooting for

- See Note 1 NO engine (S mode)
Note 1:
* Engine speed (reference) at arm IN relief when engine and pump are normal
ingine speed at arm IN relief Conditions
. Engine at high idling

. Power max.mode
. Swing lock switch ON
2.100 f 50 rpm . Measure the speed at the
point where the drop in en-
gine speed is greatest
when the arm cylinder is at
the end of stroke and the
lever is operated slowly to
the full position.
20-204
TROUBLESHOOTING H-3,H-4
H-3 No work equipment, travel, swing move
I Cause Remedy
Defective control pump,

2 YES
defective control relief vlave,
defective control circuit, or Replace
When main pump
defective main piston pump
YE pressure plckup plug
IS removed, does 011
come out?
Defective damper Replace
Is safety lockvalve l Crank with starting NO
working properly? motor.
Defective operation of safety Adjust

, lock valve or safety linkage
H-4 Abnormal noise generated (around Pump)
Cause Remedy
3 YES
I I Goto
mproper hydraulic oil Change

iydraulic oil
YE Are there bubbles
inside hydraulic tank? Zlogged by external object
YES
Remove
4
:cloth, etc.)
IS suction strainer
Is hydraulic tank oil
- clogged by external -
level normal? 5 YES
NO oblect? Defect inside pump Repair or
Is suction strainer
~
. External oblect, clogged with metal replace
Cloth, etc. _ particles or are metal -
NO particles stuck to Operate for a short time and Inspect agai
drain plug?
watch for any change in (depending
NC)
symptoms on changes
in symptoms
Lack of hydraulic oil Add hydrauli

NO
oil
20-205
TROUBLESHOOTING H-5. H-6
H-5 Auto-deceleration does not work (when PPC shuttle

valve is cause)
+ The control pressure for the travel and swing passes through the PPC shuttle valve and is supplied to the
pressure switch.
Cause Remedy
1 YES
Defective pressure switch Replace
Does condition
become normal when
pressure switch is
E!plLX6d?
Defective operation of PPC Repair OI
shuttle valve in applicable replace
NO system (swing or travel)
H-6 Fine control ability is poor or response is poor
I Cause Remedy
1 YES
Cloggd throttle in LS circuit Clean
Replace
20-206
TROUBLESHOOTING H-7
H-7 Boom is slow or lacks power

* When travel and swing speeds are normal.
YES
YE
valve move
smoothly?
n
YES
Is relief pressure of
pump normal when
Check LS shuttle for
arm and bucket
‘L
NO
boom RAISE circuit
IS relieved?
I
- 31 4 34 8 MPa
-
(320 355 kg/cm2) L
- Engine at high ldllng NO
8 YES
4
r 1
Is operating pressure
IS pressure normal when boom
IES
compensation valve for
boom normal, or does I F~0 LOWER is being
operated?
- 4 9? 2.9 MPa NO
* It is also possible to (50 ? 30 kg/cm2)
mterchange wth - Engine at high ldllng
Does control valve
IES other compensation
spool for boom move
valve I
smoothly?
. See Note 2. N0
IS outputpressure of
PPCvalve normal?
NO
1:
H
I
Is pressure switch for
boom RAISE,
LOWER normal?
* See Judgement
Table. (Bit pattern 20
(3) (4))
I
. Mln 30MPa
(31 kg/cm2)
- Eqne at high ldllng j
* Operate boom.
N(
. See Note 1. NO
Note 1: If auto-deceleration is canceled when boom RAISE or boom LOWER is operated, system is normal.
Note 2: After inspection, do not forget to return the interchanged valves to the original position.
20-208
TROUBLESHOOTING H-7
I Cause
I
Remedy
7 YES
Defective operation of boom Correct or
lock valve replace
Defective boom cylinder Correct or

. 14.9 f 2.5 MPa NO
(150 k 25 kg/cm*)
piston packing replace
. At mm reach, no
load Defective operation of LS Correct or
shuttle valve (LS shuttle for replace
arm or bucket)
Replace

lock valve replace

regeneration valve replace

pressure compensation replace
valve or pressure compen-
sation piston (for boom
RAISE end)
Defective operation of Correct or

control valve spool (for replace
boom RAISE end)
Defective PPC valve Replace
Defective boom RAISE or Replace

boom LOWER pressure
switch
20-209
TROUBLESHOOTING H-8
H-8 Arm is slow or lacks power
+ When travel and swing speeds are normal.

r
YES
YES
. Check LS shuttle for

‘I
bucket
normal when arm NO
circuit is relieved?
t10n valve for arm nor-

YE :s
mal, or does pressure
’ I
* Engine at high idling NO
compensation piston
Interchange wth
other compensation NO
valve.
. See Note 2.
YES ls output pressure of _ [

PPC valve normal? NO
1
- Mln 30MPa
Is pressure switch for
(31 kg/cm*)
arm IN. OUT r.:.. _I L.-L ._I,..
normal? g NO
I
* see Judgement
Table. (Bit pattern 20
(5)z (‘31) NO
- See Table 1
Note 1: If the auto-decleration is canceled when arm IN or arm OUT is operated, the system is normal.
20-210
TROUBLESHOOTING H-8
I Cause Remedy
7 YES
Defective operation of arm Correct or
regeneration valve or arm replace
_ Is leakage from arm _ counterbalance valve.
cylinder normal?
Defective arm cylinder Correct or

- Max. 20 ccimln NO piston packing replace
Defective operation of LS Correct or

shuttle valve (LS shuttle for replace
bucket)
Defective safety-suction Replace

valve for arm
Defective operation of arm Corrrect or

valve or pressure compen-
sation piston

control valve spool replace
Defective arm IN or arm Replace

OUT pressure switch
20-211
TROUBLESHOOTING H-9
H-9 Bucket is slow or lacks power

+ When travel and swing speeds are normal.
Cause Remedy
H
3 v ‘ES
I\
GotoA

r
.
ri
control valve spool for replace
YE3 bucket
Min. 3.0 MPa I Defective PPC valve Replace

(31 kg/cm*) NO
I *. Engine at high idling
Owrate bucket
Defective bucket CURL or
* See Judgement
bucket DUMP pressure Repalce
Table. (Bit pattern 21 L
Cl), (21) NO switch
. See Note 1

5 YE!
safety-suction valve for replace
YES IS leakage from

bucket
4 - bucket cylinder Repair or
~ normal?
Defective bucket cylinder replace
IS pressure
compensation valve for
* Max. 20 cclmin NC
piston packing
From A - bucket normal, or does -
. Engine at high ldllng
pressure compensation
piston move smoothly?
* It IS also powble to
interchange with
NO
other compensation valve for bucket or pressure
valve. compensation piston
* See Note 2
Note 1: If the auto-deceleration is canceled when bucket CURL or bucket DUMP is operated, the system is
normal.
20-212
TROUBLESHOOTING H-l 0, H-l 1
H-IO Work equipment (boom, arm, bucket) does not move

(but travel and swing are normal)
* When boom, arm, and bucket are each operated independently. Cause Remedy
1 YES
Defective control valve spool Correct or
replace
Is output pressure of
PPC valve normal?

. Min. 3.0 MPa NO
(31 kg/cm*)
H-l 1 Excessive hydraulic drift (boom, arm, bucket)

1) Excessive hydraulic drift of boom
Cause Remedy
1 YES
Defective hydraulic cylinder Replace
Does speed of piston packing
downward movement
become faster when
lever IS operated? 2 YES
Defective operation of Replace
- See TESTING AND Does condition satety-suction valve
ADJUSTING. become normal when
* It IS alsopowble to NO safety-suction valve
measure leakage of IS Interchanged?
cylinder. Defective operation of boom Correct or
* Max. 20 cclmin NO lock valve replace
- At relief
2) Excessive hydraulic drift of arm or bucket

c Cause Remedy
Defective hydraulic cylinder Replace

1
piston packing
1
Does speed of
downward movement
become faster when YES Defective operation of Replace
lever IS operated? safety-suction valve
- See TESTING AND

ADJUSTING.
- It IS also powble to N Defective control valve spool Replace
measure leakage of
cylinder.
* Max. 20 cclmin ve damaged? Or does
* At relief NO pressure compensation Damaged slipper seal of
- Eqne at high ldllng piston move smoothly? pressure compensation Correct or
- It IS also oosslble to NO valve, or defective operation replace
interchange with of pressure compensation
other compensation
piston
valve.
- See Note 1.
20-213
TROUBLESHOOTING H-12, H-13
H-12 Excessive time lag (engine at low idling)
Cause Remedy
Boom, Defective safety-suction

valve, or defective regenera- Replace
:A- arm tion valve
IS pressure Defective safety-suction Replace
1
compensation valve I Bucket
YES valve
_ normal, or does
1
~ piston move smoothly?
IS output pressure of . It IS also powble to pressure compensation replace
LS-EPC solenoid - interchange with NO valve or pressure compen-
valve normal? other compensation sation piston
valve.
* See Note 1. - See Note 2
Defective operation of LS- Correct or
NO EPC sloenoid valve replace
Note 1: Output pressure of LS-EPC solenoid

. Approx 2.5 MPa (Approx 26 kg/cm”) is output from the LS-EPC solenoid when the engine is at low
idling (approx. 1100 rpm or below) regardless of the working mode.
Note 2: After inspection, do not forget to return the interchanged valves to the original postition.
H-13 Other equipment moves when single circuit is relieved
Cause Remedy
Defective operation of
valve slipper seal (The
slipper seal in the pressure Replace
compensation valve of the
circuit that moved is
defective.)
20-214
TROUBLESHOOTING H-14, H-15, H-16
H-14 In F/O modes, work equipment speed is faster than

specified speed
Cause Remedy
1 YES
II
Defective LS valve Correct or
replace
IS output pressure of
LS-EPC solenoid
Defective operation of LS- Correct or

. See Note 1. NO EPC solenoid valve replace
+ Output pressure of LS control EPC solenoid (travel OFF)

Approx 2.5 MPa (Approx 26 kg/cm”) is output from the LS control EPC solenoid when the engine speed is
approx. 1100 rmp or less in the F/O mode. (In the F/O mode, the engine speed is set at 1900 rpm when the
fuel control dial is at the MAX position.)
H-15 Lack of power when pressure rises

Cause Remedy
2 YES
I Defective main relief valve Replace
Defective operation of 2- Repair or

- Mln 3.0 Mpa (31 kg/c@ NO
Is 011pressure wtch stage relief solenoid valve replace
* H/O or GIO mode
normal?
- Power max. mode
* L H. knob switch ON
” ,s,..,...
* Operate each control Defective oil pressure switch Replace
lever, and If auto- NO
deceleration is
canceled, condltlon IS
normal.
H-16 In compound operations, work equipment with larger

load is slow
Cause Remedy
Defective operation of pressure Replace (replace pressure compensa-
compensation valve tion valve on side where load is lower)
1Combination of compound operation 1 Side where load is larger
1 IBoom RAISE + arm IN I Boom RAISE
2 IBoom RAISE + arm OUT Arm OUT
3 IBoom RAISE + bucket CURL Boom RAISE
4 IArm OUT + bucket CURL Arm OUT

5 Boom LOWER + arm OUT Arm OUT
20-215
TROUBLESHOOTING H-17. H-18. H-19
H-17 In swing + boom RAISE, boom RAISE is slow

* If swing and boom RAISE work normally when operated independently.
Cause Remedy
1 YES
Defective operation of LS Correct or
select valve replace
IS output pressure of
LS select solenoid -
valve normal?
Defective operation of PPC Correct or
* Min. 3.0 MPa NO shuttle valve for LS select replace
(31 kg/cm2)
* Operate boom
circuit
RAISE (operate lever
slightly)
H-18 In swing + travel, travel speed drops excessively

Cause Remedy
* If swing and travel work normally when operated independently.
3 YES Defective operation of LS Repair or

select valve replace
YES IS pressure of LS
- select valve circuit -
2
_ normal?
Defective operation of PPC Repair or
shuttle valve (PPC shuttle replace
YES Does LS bypass * Min. 2.7 MPa NO for LS select)
valve move - (28 kg/cm2)
‘I I smoothly?
_
* Operate travel lever
Defective operation of LS Repair or
IS pressure of LS fully.
bypass solenoid
NO bypass valve replace
valve clrwt normal?
H

bypass solenoid valve replace
* Operate swing and
travel simultaneously
H-19 In work equipment boom RAISE + travel, travel speed

drops excessively
* If work equipment (boom RAISE) and travel work normally when operated independently.
Cause Remedy
1 YES
II bypass valve replace
Is pressure of LS
bypass solenoid -
valve circuit normal?
* 0.2 f 0.2 MPa NO bypass solenoid valve
(2 ? 2 kg/cm2)
* Operate boom
RAISE and travel
simultaneously
20-216
TROUBLESHOOTING H-21
H-21 TRAVEL SPEED IS SLOW

+ When work equipment speed is normal.
+ Check operating condition of oil pressure switch with monitoring code before carrying out troubleshooting.
3 YES
II
YES IS output pressure of
LS control EPC
solenoid valve
2, r
Is traveloilpressure L n0rtXl?
wtch normal? NO
. See Table 1
,H
FOkWARD and Note:
H
REVERSE, or is it If auto-deceleration IS NO
slow I” one dIrectIon canceled when travel is
only? operated, system IS
normal. (When travel
PPC shuttle IS normal).
Table 1 Output pressure of LS control EPC solenoid
Lo Mi Hi
I 2f0.2 MPa 1 0.6f0.2 MPa 1 0.2f0.2 MPa 1

(20f2 kg/cm’) (6f2 kg/cm’) (2f2 kg/cm’)
l Travel lever at fine control position (auto deceleration canceled)
20-218
Cause Remedy

shuttle valve (for boom, arm, replace
bucket)
Defective operation of LS Replace

control EPC solenoid valve
Defective oil pressure switch Replace
Go to H-20
20-219
TROUBLESHOOTING H-23. H-24
H-23 Travel speed does not switch or is faster than specified

speed
I Cause Remedy
;ES 1 Defective operation of travel

speed selector servo piston Replace
YE S
2
Defective operation of travel Correct or
‘&‘!+ ~~~1% solenoid replace
LS-EPC solenoid valve
switch: Mi, Hi
- See Table 1.
- Turn travel wtch ON. Defective operation of LS- Correct or
Is travel pressure
wtch normal?
NO EPC solenoid valve replace
* See Judgement
Table. Defective travel pressure Replace
(Bit pattern 20 (2)) hln switch
* If autodeceleratlon IS ‘.-
canceled when travel
IS operated, system
IS normal.
Table 1. Output pressure of LS-EPC solenoid

Unit: MPa (kg/cm’)
Travel speed
I
2.0 f 0.2 2.2 f 0.2 0.2 f 0.2
LS-EPC output pressure (20.0 f 2.0) (22.7 f 2.0) (2.0 f 2.0)
Remarks
l Operate travel lever slightly (auto-deceleration cancel position)
H-24 Travel does not move (one side only)
Cause Remedy
Defective final drive Repair OI

replace
Is any foreign 3 YES Defective operation of Replace

material found in 011
suction valve of control valve
drained from final
drwe? YE s
m_I-
2
Defective operation of
Is drain amount of NO counterbalance valve or Replace
travel motor safety valve
- Max :
30 //mln
* Engine at high idling ho Defective travel motor Replace
- At travel relief
20-220
H-25 Does not swing

a) Does not swing to either left or right
Cause Remedy
3 YES
Defective swing machinery Repair or
replace
Defective swing holding Repair or
YES brake or swing motor replace

IS swng pressure
switch normal?
t
*Operate swing lever
(or operate work
holding brake solenoid valve replace
equipment lever).
- See Judgement Defective swing pressure Replace
Table. (Bit pattern 20 i
switch
NO
(1))
* If autodeceleration is
canceled when swng
is operated, system
IS normal
b) Does not swing in one direction
Cause Remedy
2 YES Defective swing motor safety Replace

valve or suction valve
>
control valve spool for swing replace
. Mln 2 7 MPa I Defective PPC valve Replace

(28 kg/cm2) NO
- Operate wng lever
(or operate work
equipment lever)
20-22 1
H-26 Swing acceleration is poor or swing speed is slow

+ If condition is normal when work equipment is operated independently.
a) Swing acceleration is poor
4 YES
1
YES
I 1 ,
2 * Travel operated
mdependengly NO
Both left and Does LS shuttle * Min. 2.7 MPa
right Both valve move (28 kg/cm*)
dIrectIon smoothly?
1-I
1
- LS shuttle for boom, NO
arm, bucket, R.H.
travel, L H. travel
YES
1 8
I IS pressure compen-
IS svmlg acceleration
sation valve normal, or
poor in both
does pressure
dIrectIons or I” one compensationvalve
direction only? o~ston move smoothlv?
I I
- It IS also possible to
YE Does control valve interchange with other
-
NO
compensation valve
:
* Note After inspection,
do not forget to return
to the orIgInal posltlon.
PPc valve normal? NO
5
I I
- Same condltlons as
One dIrectIon Is output pressure of for Item 5
only - RemOVe PPC shuttle NO
PPC valve normal?
block inlet hose, fit
1-I t
adapter, and block
- Mln 3 0 MPa tip. (Note).
(31 kg/cm*)
* Engine at high idling IO
. Turn sw,ng lock
switch ON (lock).
Note: If the adapter for blocking the circuit is not availabel, interchange PPC hose of swing with one of bucket
(CURL, DUMP), boom (LOWER), or arm (IN).
20-222
I Cause Remedy
Defective swing motor 3epair or

assembly eplace
Defective operation of LS 3epair or

shuttle valve (all LS shuttles) eplace
Defective swing motor safety 3eplace

7 YES
Does condition valve
become normal when
- left and right safety -
valves of motor are
Defective swing motor 3eplace
Werchanged?
suction valve
* It is also possibele to NO
measure relief pressure of motor.
-
* Relief pressure: 30,4 33.8 MPa (310 - 345 kg/cm>)
Defective operation of 3epair or
pressure compensation eplace
valve or compensation valve
piston
Defective operation of 3epair or

control valve spool eplace
Defective operation of PPC 3epair or

shuttle valve (for swing) eplace
Defective PPC valve 3eplace
20-223
H-27 Excessive overrun when stopping swing

a) One direction only
I Cause Remedy
3 YFS I Defective swing PPC slow Correct or

return valve replace
Defective swing motor safety Replace

valve
Correct or
replace
b) Both directions
I Cause I Remedy I
1 Defective swing motor 1 Repair or replace
20-224
TROUBLESHOOTING H-28, H-29
H-28 Excessive shock when stopping swing

(one direction only)
Cause Remedy
1 YES
Defective swing PPC slow Correct or
Does condltlon be-
come normal when left return valve (check valve) replace
and right swing PPC -
slow return valves are
Interchanged?
NO
H-29 Excessive abnormal noise when stopping swing
Cause Remedy
Does
3 Defective operation of swing Clean
motor safety-suction valve
1
1
condltlon be-
come normal when Defective swing motor Replace
swing motor safety- YES
suction valve is 2 safety-suction valve
cleaned?
Does condlbon
become normal when
swing motor safety- -
N 3 YES
suction valve is Defective swing machinery Repair or
replaced?
Is foreign material replace
- found I” swng
NO machinery?
Defective back pressure Correct or

NO
valve
20-225
H-30 Excessive hydraulic drift of swing

a) When swing holding brake is released
I Cause Remedy
2 YES Defective swing motor Correct or

ISpressurecompensa- safety-suction valve replace
t,onvalveondefective
One d~rect~on only ~ side normal, or does -
pressure compensation Defective pressure compen-
1 piston move smoothly? sation valve for swing, or Correct or
NO defective operation of replace
Is hydraulic drift
~XC~SSI”~ I” both pressure compensation
dIrectIons or one piston
direction only?
3 YES
I I Defective control valve so001 Replace
H
7 I
1 One direction only Is dram amount

motor normal?
from
for swing
I Defective swing motor Repair or

- 11 //mln NO
replace
. At sw,ng relief
‘I
b) When swing holding brake is applied
I Cause Remedy
1 YES
Defective operation of swing Repair of
Is output pressure of
holding brake replace
swrngholdmg brake
solenoid valve
normal?
Defective operation of swing Correct or
. 0.2 f 0.2 MPa NO
(2 ? 2 kg/cm2) holding brake solenoid valve replace
. When 5 seconds
have passed after all
swing and work
equipment control
levers have been
returned to neutral
20-226
H-31 Swing speed is faster than specified swing speed
I Cause Remedy
1 YES
Defective operation of LS Replace
Is outputpressureof valve servo
LS-EPC solenoid - assembly
valve normal?
Defective LS-EPC solenoid Correct or
. See Table 1. NO
replace
Table 1. Output pressure of LS-EPC solenoid valve
unit: MPa (kg/cm”)
H/O mode G/O mode F/O mode L/O mode

0.2 f 0.2 0.2 f 0.2 1.2 f 0.2 0.2 f 0.2
(2.0 f 2.0) (2.0 f 2.0) (12 f 2.0) (2.0 f 2.0)
l Travel OFF
l Swing lock switch OFF
20-227
TROUBLESHOOTING OF MACHINE
MONITOR SYSTEM (M MODE)
Action taken by panel and condition of machine when abnormality occurs... 20-230
Electrical circuit diagram for monitor system 20-232
M- 1 [El011 Abnormality in error data is displayed [El021 Error in clock data is displayed ............. 20-234
M- 2 [El031 Short circuit in buzzer output or contact of 24 V wiring harness with buzzer
drive harness is displayed.. ...................................................................................................... 20-235
M- 3 [El 041 Air cleaner clogging detected is displayed ................................................................... 20-236
M- 4 [El 061 Drop in engine oil pressure Hi detected is displayed .................................................... 20-236
M- 5 [El 081 Engine water temperature 105°C detected is displayed ............................................... 20-237
M- 6 When starting switch is turned ON, none of lamps on monitor panel light up
for three seconds ..................................................................................................................... 20-238
M- 7 When starting switch is turned ON, monitor panel lamps all stay lighted up
and do not go out.. ................................................................................................................... 20-240
M- 8 When starting switch is turned ON, items lighted up on monitor panel are different
from actual machine (model) ................................................................................................... 20-240
M- 9 When starting switch is turned ON (engine stopped), basic check items flash ....................... 20-241
M- 10 Preheating is not being used but preheating monitor lights up ................................................ 20-243
M- 11 When starting switch is turned ON and engine is started, basic check items flash.. ............... 20-244
M- 12 When starting switch is turned ON (engine stopped), caution items,
emergency stop items flash ..................................................................................................... 20-246
M- 13 When starting switch is turned ON and engine is started, caution items,
emergency stop items flash ..................................................................................................... 20-248
M- 14 When starting switch is turned ON (engine stopped), buzzer does
not sound for 1 second. Caution item flashes but buzzer does not sound ............................... 20-251
M- 15 No abnormality is displayed on monitor but buzzer sounds ..................................................... 20-251
M- 16 Night lighting on monitor panel does not light up (liquid crystal display is normal ................... 20-252
M- 17 Coolant temperature gauge does not rise ............................................................................... 20-253
M- 18 Coolant temperature gauge does not give any display ............................................................ 20-253
M- 19 Fuel level gauge always displays FULL ................................................................................... 20-254
M- 20 Fuel level gauge does not give any display ............................................................................. 20-254
M- 21 Swing lock switch is turned ON (LOCK) but swing lock monitor does not light up.. ................. 20-255
M- 22 Swing prolix switch is turned ON (prolix), but swing lock monitor does not flash.. ................... 20-255
M- 23 Service meter does not advance while engine is running.. ...................................................... 20-256
M- 24 When starting switch is at OFF and time switch is pressed, time and
service meter are not displayed ............................................................................................... 20-256
M- 25 Defective fuel level sensor system ........................................................................................... 20-257
M- 26 Defective coolant temperature sensor system ......................................................................... 20-258
M- 27 Defective engine oil level sensor system ................................................................................. 20-259
M- 28 Defective coolant level sensor system ..................................................................................... 20-260
M- 30 Wiper does not work or switch is not being used but wiper is actuated ................................... 20-261
20-229
ACTION TAKEN BY MONITOR PANEL WHEN ABNORMALITY

code code
1. Abnormality in internal memory

El 01 Abnormality in error 2. Excess voltage (more than 36V) has occurred
data 3. Low voltage (less than 12V) has occurred
4. Connector has separated
1. Abnormality in internal clock function

El 02 Abnormality in clock 2. Excess voltage (more than 36V) has occurred
data 3. Low voltage (less than 12V) has occurred
4. Connector has separated
1. Short circuit inside buzzer

El03 Short circuit in 2. Power line in contact with wiring harness between monitor (PO1
buzzer output system (7) pin) and buzzer
3. Abnormality in monitor panel
El 04 Air cleaner clogging 1. Air cleaner clogging sensor has detected clogging
detected is displayed
Drop in engine oil Hi

El 06 pressure detected is 1. Engine oil pressure Hi sensor has detected drop in oil pressure
displayed
Engine water tem-

El 08 perature 105°C 1. Coolant temperature gauge has detected water temperature of
detected is displayed 105°C
20-230
Condition when normal Action by controller when Problem that appears on machine
(voltage, current, resistance) abnormality is detected when there is abnormality
1. Service code cannot be cleared

l When starting switch is 2. Time becomes 0O:OO
turned ON, keep time
switch pressed for 5
seconds to actuated 1. Service code cannot be cleared
clear function 2. Time becomes 0O:OO
3. Clock does not advance.
l Voltage between PO1 (7)

- chassis
Buzzer On: Max. IV
Buzzer OFF: 20 - 30V 1. Buzzer does not sound
* When there is a discon-
nection, El03 is not
displayed and the buzzer
does not sound
l Resistance between PI 1 1. If abnormality detection continues, air

(male) - P12 (male): cleaner clogging caution lamp flashes and
Min 1 f2 (engine started) buzzer sounds
l Resistance between 1. If abnoramlity detection continues, engine

sensor terminal and oil pressure caution lamp flashes and
chassis: Min. 1 Mf2 buzzer sounds
(engine at mid-range
speed or above)
l Resistance between PO7 1. If anbormality detection continues, coolant

(1) - (2): Min. 3.156 R temperature caution lamp flashes and
(engine started) buzzer sounds
2. If abnormality detection continues, engine
speed is reduced to low idling
20-231
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE 112
20-232
ELECTRICAL CIRCUIT DIAGRAM FOR M MODE 2/2
20-233
TROUBLESHOOTING M-l
M-l [EIOI] Abnormality in error data is displayed

[El021 Error in clock data is displayed
This is not an abnormality. It occurs during troubleshooting when disconnecting and connecting connector
PO2 (for the monitor panel electrical system), fuse No. 13, connector H14, connector Ml 1, battery relay
treminal B, or the battery terminal.
(When the monitor panel power source circuit is shut off with the starting switch turned OFF.)
If the service code display appears again after the system has been reset, carry out troubleshooting as
follows.
Cause Remedy
2 YES
Defective monitor panel Replace
Disconnecton, defective contact,

short circuit with ground in wiring
harness between battery - Repair or
~ battery relay B - Ml 1 (1) (2) - replace
H14 (1) -fuseNo. 13 - PO2
(female) (8) (14)
. After resetting Normal

system, carry out
NO
normal operations for
a short time and
wanted the condltlon
(See Note 1.)
Note 1: Resetting operation:

Turn the starting switch OFF. Then keep the time switch at the back of the monitor panel depressed,
switch the starting switch ON again, and keep the time switch depressed for 5 seconds to return the
system to normal.
(With this operation, all the service codes in the internal memory are erased.)
M-l Related electric circuit diagram

Monitor panel PO2(04016)
H14(M6) Ml1 (L2)

GND g Fuse
Power source
(g 8. @
(+24V)
GND (3J @ g
Power source
(+24V) 63 Fusible link
20-234
TROUBLESHOOTING M-2
M-2 [El031 Short circuit in buzzer output or contact of 24V

wiring harness with buzzer drive harness is displayed
* If the starting switch is turned OFF after an abnormality occurs, turn the starting switch ON and check if an
E service code is displayed. (If it is not displayed, the sytem has been reset.)
Cause Remedy
YES
Short circuit with power sowe

in wiring harness between PO1 Repair or
(female) (7) and PO4 (female) (2) replace
or short clrcult in wiring harness
between PO4 (1) and (2)
Defective buzzer Reolace

OFF. d
NO
* Disconnect P04.
Table
M-2 Related electric circuit diagram
P04(M2)
-Ii=@= Buzzer
All
20-235
TROUBLESHOOTING M-3.4
M-3 [El041 Air clogging detected is displayed
Cause Remedy
YES (See M-l 3 f)
IS a,r cleanerclogging
caution lamp on
monitor flashing? 2 YES
Defective monltor panel Replace
- Is “E” sewce code _

NO dlsplayed ?
Failure in engine system

* Turn starting switch NO (See Note 1)
ON.
Note 1: The monitor panel display has returned to normal, but the air cleaner clogging sensor has detected
symptoms of clogging in the past, so carry out troubleshooting of the engine to remove the problem
M-4 [El061 Drop in engine oil pressure detected is displayd
Cause Remedy
YES (See M-l 3 a)

1
Is engine oil pressure

caution lamp on
monitor flashing? 2 YES
_ Is “E” service code _

NO displayed ?

. Turn starting swtch NO
(See Note 1)
ON.
Note 1: The monitor panel display has returned to normal, but the engine oil pressure sensor has detected
symptoms of a drop in the oil pressure in the past, so carry out throubleshooting of the engine to
remove the problem.
20-236
TROUBLESHOOTING M-5
M-5 [El081 Engine water temperature 105°C detected is

displayed
Cause Remedy
YES (See M-13 d)

1
Does coolant
temperaturegauge on
monitor panel display
red range and is 2 YES RepkSe
Defective monitor panel
caution lamp flashing? t
Is “E” service code
N dIsplayed?
(See Note 1)
ON
Note 1: The monitor panel display has returned to normal, but the coolant temperature sensor has detected
symptoms of the coolant temperature reaching 105°C in the past, so carry out troubleshooting of the
engine to remove the problem.
20-237
TROUBLESHOOTING M-6
M-6 When starting switch is turned ON, none of the lamps on

the monitor panel light up for 3 seconds
* Check that fuses No. 10 and 13 are not blown.

a) None of lamps on monitor panel light up

Cause Remedy
YES
2
HIs voltage between

PO1 (9) and chassis
normal?
II
3 YES
Disconnetion, defective contact, short
circuit with ground in wiring harness
between PO1 (female) (9) and fuse
No. 10
Disconnection, defeictive contact,

Repair or
replace
Is voltage between short circuit with ground in wiring Repair or

PO2 (8) (14) (1)(9) NO harness between fuse No. 10 HO5 replace
normal? ON. (2) Ml4 (2) (1) battery relay M
.CN:e[i
- Turn starting swtch Disconnection, defective contact,
short c,rcu,t with ground I” w,r,ng
harness between PO2 (female) (8)
(14)andfuseNo.i3
Disconnection, defective contact,

RepaIr or
replace
short circuit with ground in wiring RepaIr or

- Turn starting swtch NO harness between fuse No. 13 Hi4 replace
ON.
1
(2) Ml (2) (1) battery relay B
. 20.30V
b) Some of lamps on monitor panel do not light up
Cause Remedy
20-238
TROUBLESHOOTING M-6
M-6 a) Related electric circuit diagram
Monitor panel PO1(04020) M14(L2)
Starting switch ON
H14(M6) Mll(L2)
GND
Power source (. a a
GND
Power source
PO2(04016)
mP @
Battery relay
20-239
TROUBLESHOOTING M-7, M-8
M-7 When starting switch is turned ON, monitor panel lamps

all stay lighted up and do not go out
Cause Remedy
M-8 When starting switch is turned ON, items lighted up on

monitor panel are different from actual machine (model)
* Immediately after replacing the monitor panel, turn the starting switch OFF, then turn it On again
Cause Remedy
1 YES
Is display of
monltorlng code 01 -
as shown in table?
Go to troubleshooting for C
. Turn starting swtch NO
ON.
* Set to monltorlng
code 01.
Table
20-240
TROUBLESHOOTING M-9
M-9 When starting switch is turned ON (engine stopped), ba-

sic check items flashes
* Before carrying out troubleshoting, check that all the related connectors are properly inserted.
a) 0- (coolant level) flashes

SAP0051 9
+ Check that the coolant is at the specified level before carrying out troubleshooting.
Cause Remedy
Defective coolant level sensor system

(See M-26)
4 YES
-r
when short connec- Defective monitor panel

YE ~
tor IS connected to
. Disconnect P08. Defective contact, or dIsconnectIon m

2
* Turn starting switch wiring harness between Cl6 (female)
ON. Is there contlnulty switch OFF. NO (8) PO8 (female) (1)
* Disconnect 616, P08.
. Connect- dwxnnect short
I connector to PO8 (female).
Defective contact, or dIsconnectIon m
wiring harness between PO8 (female)
- Turn starting swtch (2)-chassis ground
OFF.
. Disconnect PO8
Table
Short connector Continuity

1 Connected 1 Yes I
1 Disconnected 1 No I

lonitor panel C16(MIC17)
PO8(X2)
\
@
I Coolant
level sensor
BKP00277
20-241
TROUBLESHOOTING M-9
b) 04 (coolant level) flashes

SAP00523
+ Chek that the engine oil is at the specified level before carrying out troubleshooting.
Cause Remedy
YES Defective engine oil level sensor

system (see M-27)
41
I
3 YES
when PO5 (female)
(1) is connected to Is bit (4) of
chassis ground? YES monltormg code 24
2 lighted up?
. Disconnect P05.
* Turn starting switch Is continuity between
Defective mon~tor panel
ON. Cl6 (female) (16) NO
_ - Turn starting
NO and chassis as
switch ON.
shown in table?
- Set to monltormg
* Turn starting code 24.
Defective contact, or dIsconnectIon in
wwng harness between Cl6 (female)
. k%%?e%l6,PO5. No (16) E08 (5) PO5 (female) (1)
* Connect-dwxnnect short connector to
PO5 (female) (1).
Table
1 Chassis ground 1 Continuity 1

1 Connected I Yes I
1 Disconnected I No I
M-9 b) Related electric circuit diagram
Governor, pump controller Engine oil level sensor
Monitor panel C16(MIC17)
EOB(SWPl4) PO5(Xl)
Network 3
20-242
TROUBLESHOOTING M-10
M-IO Preheating is not being used but!$$(preheating monitor)

lights up
Cause Remedy
2 YES Defective monitor panel Replace
Short circuit with power source

in wiring harness between Repair or
starting switch RI X07 (3) replace
~ Hi3 (6) PO1 (female) (18) or
heater relay- H13 (female) (6)
Defective starting switch Replace

Rl. NO
ON.
. Max 1V
Starting switch
Fuse H08(M6)
A- @. BR
I I
Monitor panel
PO1 (04020)
H13(S16)
20-243
M-II When starting switch is turned ON and engine is started,

basic check items flash
+ Before carrying out troubleshooting, check that all the related connectors sare properly inserted.
+ Check both the alternator system and the engine oil pressure system.
a) Alternator system
Cause Remedy

controller
YE PI-

* Start engine and run NO
at ml&range or
above.
- Set to monltonng
code 43. Defective contact, or disconnec-
tion in wiring harness between Repair or
0 alternator terminal D- E08 (2) - replace
CO3 (female) (12)
I I
* startengine
and run
at mid-range or
above. Defective alternator
NO
. 20.30V
M-l la) Related electric circuit diagram

Monitor panel CO3(04020) Alterntor
EOI(SWP14)
Battery
Network
charge
20-244
TROUBLESHOOTING M-l 1
b) Engine oil pressure system

* When engine oil pressure is normal.
Cause Remedy
“I Defective oil pressure sensor Replace
1
1
When engine IS running
at low idling and wiring Contact of chassis ground with Repair or
harness of oil pressure YES wiring harness between Cl 6 rep&e
sensor IS removed.
Does display go out?
2 I (female) (15) E08 (8) Pi0 (c)
or Pi0 (A) E08 (11) CO3 (16)
* Engine at low idling
Defective governor, pump Repalce

controller
Defective monitor panel Repalce

* Engine at low idling
- Set to monltormg
code 24.
M-l 1b) Related electric circuit diagram

Monitor panel C16(04017) E08(SWP14)
Engine oil
pressure Hi 3
Network
Engine oil 8
pressure Lo
i
I PlO
Engine oil
pressure sensor
20-245
M-12 When starting switch is turned ON (engine stopped),

caution items, emergency items flash (battery, engine oil
pressure lamps do not light up)
* Check both the alternator system and the engine oil pressure system.
a) Alternator system
Cause Remedy

controller
Does monltorlng
YE code 43 show a
value of greater than
2 1007
Defective monitor panel Repalce
Is voltage
between . startengineandrun No
yES_ CO3 (female) (12) atmid-range speed
and chassis normal? or above
1
* Set to monitoring Short clrcult with power source Repair or
Is voltage between . Disconnect C03. code 43 in wiring harness between CO3 replace
alternator terminal R * Turn starting switch (female) (12) - E08 (2) -
and chassis normal? ON UO alternator D
. Max. 1V
Defective alternator Replace

Monitor panel CO3(04020) Alterntor
EOI(SWP14)
Battery
Network
charge
20-246
b) Engine oil pressure sensor system

+ When engine oil pressure is normal.
I Cause Remedy

controller
Is bit (1) or
YEK monitoring code 24 _
llghted up?
2
Is there contlnulty ~ Defective monitor panel Replace
YES between Cl6 * Engine at low idling NO
- (female) (15) and - * Set to monltorlng
sensor wiring code 24.
1
~ harness? Defective contact, or dlsconnec-
Is there continuity * Turn starting switch tion in wiring harness between Repair or
between sensor OFF. Cl6 (female) (15) - E08 (8) - replace
terminal and * Disconnect Cl6 and NO sensor or PI0 (A) E08 (11)
chassis? sensor wiring
CO3(16).
harness
* Turn starting wtch
OFF.
Defective oil pressure sensor Replace
* Remove sensor NO
wiring harness.
M-12b) Related electric circuit diagram

Monitor panel C16(04017) E08(SWP14)
Engine oil
pressure Hi 3
Network
Engine oil 8
pressure Lo
8 PlO
CO3(04020) Engine oil
GND pressure sensor
for pressure @-
sensor
20-247
M-13 When starting switch is turned ON and engine is started,

caution items, emergency items flash (when there is no
abnormality in engine or items to check before
troubleshooting)
a) 0 6 (engine oil pressure) flashes

SAP00520
* Check that the engine oil pressure is normal before Cause Remedy
carrying out troubleshooting.
See M-l 1 b)
(coolant level) flashes
+ Check that the coolant level is normal before carrying

Cause Remedy
out troubleshooting.
See M-9 a)
(battery charge) flashes

SAP00522
Cause Remedy
See M-l 1 a)
20-248
d) u -
SAP00527
(coolant
.
temperature) flashes
I
Remedy
+ Check that the coolant temperature is normal before
carrying out troubleshooting
YES Defective coolant tempera-
2 ture sensor system (see M-
When PO7 IS d~scon- 26)
netted, does only
YE
level 1 (left end) of -
gauge display light
up? Is resistance controller
* Start engine. between CO3
No- -
(female) (1) (16) - - Short circuit of Waring harness
chassis normal? between, CO3 (female) (A) - E08 Repair or
(6) - PO7 (female) (1) and wiring
Is coolant tempera- * Turn starting swtch NO replace
ture in red range? harness between CO3 (female)
OFF.
(16) E08 (11) PO7 (female)
t * Disconnect CO3 and
I
PO7. (B)
Start engine and run
. Max. 1 Mn
at ml&range or Replace
above NO
M-l 3 d) Related electric circuit diagram
Governor, pump controller Coolant

Monitor panel CO3(04020) EOB(SWP141 PO7(X2) temperature sensor
Coolant @
(-g
work 2 temperature
I/ GND @ (g
BKPOO284
4 (fuel level) flashes

SAP00528
* Check that there is fuel before carrying out troubleshooting.

Cause Remedy
YES Defective fuel level sensor

system (see M-25)

~~ controller
r
Defective contact or
level may vary, so the 1 I I
H
Is fuel gauge in red
display IS given a * Connect PO6 (female) N~ harness between CO3 replace
range? (female) (2) and PO6
time delay.) (1) to chassis ground.
* Turn starting switch ON. (feamle) (1)
* Max 03V
* Start engine.
NO
M-l 3 e) Related electric circuit diagram

Monitor panel CO3(04020)
Fuel level sensor

Network 2 Fuel level
EKPOOZ85
20-249
s+
f1 c--4 a
SAP00521
(air cleaner clogging) flashes
+ Check that the air cleaner is not clogged before

Cause Remedy
carrying out troubleshooting
Defective air cleaner Replace

clogging sensor
4 YE: Defective governor, pump Replace

controller
YES IS bit (6) Of
when Pi 1 (female) IS - monltorlng code 24 -
connected to P12 3
~ lighted up?
Is continuity between Defective monitor panel Replace
YE Cl6 (female) (17) * Start engine NC
and chassis as - Set to monltonng
2 shown in table?
Defective contact or
code 24
* Turn starting harness between Cl6 replace
switch OFF.
between P12 (male) NO (female) (17) and Pi 1
* Disconnect 616,
Pi 1 and P12.
(female)
* Connect H disconnect Pll
* Turn starting switch (female) to Pi2 (male) Defective contact or
OFF L disconnectrion in wiring Repair or
* Disconnect P12
harness between PI 2 replace
(male) and chassis ground
M-l 3 f) Related electric circuit diagram

Monitor panel C16(MIC17)
PI1
Air cleaner
Network clogging Air cleaner
PI2 clogging sensor
BKP00266
20-250
M-14 When starting switch is turned ON (engine stopped),

buzzer does not sound for 1 second
Caution item flashes but buzzer does not sound
* Of the caution items, the buzzer will not sound even if there is
an abnormality in the battery charge or fuel level.
Remedy
* Always connect any disconnected connectors before going
on the next step. YES I Defective monitor panel Replace
2 I
When PO1 (female) Defective contact or disconnec- Repair or

YE (7) and chassis are tion in wiring harness between replace
connected does 3 YES
PO1 (female) (7) and PO4
buzzer sound?
(female) (2)
~ Is voltage between
* Disconnect POl. - PO4 (female) (1) and -
Disconnection, defective contact, Repair or
* z;; Starting switch NO chassis normal?
short circuit with ground in wiring replace
harness between PO4 (female)
* Disconnect P04.
NO (1) and fuse No. 13
* Turn startlnq swtch
ON.
I I
. Turn startlngwtch . 20.30V
OFF. I
. Disconnect PO4 Defective buzzer Repalce
NO
-
* 200 300 n
M-15 No abnormality is displayed on monitor but buzzer

sounds
* When the buzzer sounds continuously.
If the buzzer sounds intermittently, carry out troubleshooting
M-14.)
on the next step.
I
Contact of chassis ground with
~1~~~~
Repair or
replace
Replace
M-14, 15 Related electric circuit diagram
P04(M2)
Monitor panel POl(O4020)
a
Buzzer
Buzzer a a.
I
20-251
M-16 Night lighting on monitor panel does not light up

(liquid crystal display is normal)
* When the front lamp and working lamp light up normally.
Cause Remedy
Blown bulb or defective contact Replace bulb,

of bulb or clean
(defective
contact)
there defective YES Defective monitor panel Replace

COtltElCt? 2 I
. Remove bulb
-I
. Check visually for
blown bulb Nq.;z;l;h 1, 3 YES
L Gjj$5--1-
ON. _
- Setto monltorlng NO Defective contact, or disconnec- Repair or
tion in wiring hanress between replace
code 49.
PO1 (female) (8) -X01 (1) M38
(female) (1)
ON.
* Turn light switch ON.
* 20.3ov

Monitor panel
PO1(04020) Light switch
XOl(MIC21) M30
Light @ @ 3
@- 3
@ .a
Fuse
I
I
‘I
20-252
M-17 Coolant temperature gauge does not rise

+ If the coolant temperature actually does not rise, check the
engine system.
+ Before carrying out troubleshooting, check that all the related
connectors are properly inserted. Cause Remedy
+ Always connect any disconnected connectors before going
on the next step.
YES Defective coolant temperature
1 3 YES
When short connector Does momtonng
is connected to PO7 YES code 41 show a
(female), do level - value of less than -
lamps on guage go up
,n turn and then all 50? Defective governor, pump
lamps go out?
2 Replace
controller
~ Is there continuity bet- . Connect ~hortc~nnector NO
* Disconnect P07. ween CO3 (female) (1) to PO7 (female).
* Turn starting switch _ and (1s) when short _ . Turn starting swtch ON
ON. NO connector IS connected . set to monltorlng code Defective contact, or d~sconnec- Repair or
to PO7 (female)?
YES tion in wiring harness between replace
1
. Turn starting swtch CO3 (female) (16) - E08 (11) -
OFF. PO7 (female) (6)
between CO3
* Disconnect CO3 and II
Y
PO7. Defective contact or disconnec-
Repair or
tion in wiring harness between
replace
* Turn starting switch NO CO3 (female) (1) E08 (6) PO7
OFF. (female) (A)
PO7
M-18 Coolant temperature gauge does ndt give any display

(none of gauge lamps light up during operation)
connectors are properly inserted. Cause Remedy
on the next step.
YES Defective coolant temperature
1
1
When PO7 IS d~scon-
Contact of chassis ground with Repair or
netted, does coolant
YES wiring harness between CO3 replace
temperature gauge n (female) (1) E08 (6) PO7
display appear?
(female) (A)
* Disconnect P07.
* Turn starting wtch ,
ON. Defective governor, pump Replace
controller
* Turn starting switch code 41 show a
* Disconnect C03,
PO7. Defective monitor panel Replace
ON.
* Set to monitoring
code 41.
M-17, 18 Related electric circuit diagram

Governor, pump controller Coolant
Monitor panel c03(04020) EOB(SWP14) PO7(X2) temperature sensor
I 1 I I 1 I \I
Coolant @
a
/Network 2 temperature
L/ GND @ @
BKPW284
20-253
M-19 Fuel level gauge always displays FULL

+ Check if the taqnk is actually full before carrying out
troubleshooting.
+ Before carrying out troubleshooting, check that all the
related connectors are properly inserted.
+ Always connect any disconnected connectors before
Cause Remedy
going on the next step.
YES Defective fuel level senor

system (see M-25)
Contact of chassis ground Repair or

YES with wiring harness between replace
down in turn and then 2 CO3 (female) (2) and PO6
(female) (1)
* Turn starting switch Is there continuity
ON. - between CO2 (female) -
* Wait for approx. 2 NO (2) and chassis? 3 YES
minutes. (The fuel
~ Does monltormg
level may vary, SO the
. Turn starting switch code 42 show a
display is given a
OFF. NO Value Of greater than
time delay)
* Disconnect C02, 40? Defective governor, pump Replace
PO6.
* Turn startina switch NO controller
ON. -
* Set to monitoring
code 42
M-20 Fuel level gauge does not give display

+ Check that there is actually no fuel before carrying out
troubleshooting.
+ Before carrying out troubleshooting, check that all the
related connectors are properly inserted.
+ Always connect any disconnected connectors before Cause Remedy
going on the next step.
YES Defective fuel level sensor

system (see M-25)
Defective governor, pump qeplace

controller
- Disconnect F
. Turn starting Defective monitor panel Replace
ON. NO
Defective contact, or
harness between CO3 replace
OFF. NO
* Disconnect C03, PO6 (female) (2) and PO6
(female) (1)
M-l 9,20 Related electric circuit diagram

Fuel level sensor
BKP00285
20-254
TROUBLESHOOTING M-21. M-22
M-21 Swing lock switch is turned ON (LOCK) but 0

(swing lock monitor) does not light up 6SAT00098
* Carry out this troubleshooting only if the swing lock is actually being actuated.
on the next step.
*I
1 YES
Is voltagebetween
PO5 and chassis as _
shown I” table? Defective contact or
NO
* Turn starting switch harness between PO1 replace
ON. (female) (5) - X01 (4) - X05
(male)

Swing lock switch
Table
Swing lock switch ON Max. 1 V

Swing lock switch OFF 20 - 30 V
0
M-22 Swing prolix switch is turned ON (prolix), but
(swing lock monitor) does not flash SA%OO98
+ Carry out this troubleshooting only if the swing prolix is actually beir actuated.
Cause Remedy
on the next step.
2 YES
Is bit (6) of
yES_ monltorlng code 21 _
1 lighted up?
Is voltage between
- Turn starting swtch NO controller
Cl7 (8) and chassis _
as shown in table? UP.
* Set to monitoring Defective contact or
code 21
ON. harness between Cl7 replace
NO
(female) (8) and prolix
switch (4)
M-22 Related electric circuit diagram _

swung prolix switch

Monitor panel
~
C17104016) I
Swing
prolix @-
switch
Table
1 Swing prolix switch ON 1Max. 1 V 1

1 Swing prolix switch OFF 120 - 30 V 1
20-255
M-23 Service meter does not advance while engine is running
Cause Remedy
YES
1 I See M-13 d)

* Start engine and run
controller
at ml&range or
above.
- Set to monltorlng
code 43.
M-24 When starting switch is at OFF and time switch is

pressed, time and service meter are not displayed
Cause Remedy
2 YES
I I Defective monitor panel Replace
When starting switch
.
IS ON, IS panel
display normal?
See M-6
Turnstarting swtch NO
ON.
20-256
M-25 Defective fuel level sensor system

+ Remove the fuel level sensor when carrying out thetroubleshooting
Cause Remedy
3 YES Interference with sensor Replace

II inside tank (See Note 2
YES Is there any large
- crack, chip, or
2
~ damage to float?
Defective contact of Clean
YES Does arm move NO connector connector 01
- smoothly? replace
1
Defective sensor Replace
When float is moved
NO (See Note 2)
up and down, IS res,s-
tance betwen connec- -
tar (1) and flange as
Disconnection in wiring Replace
shown in table?
4 YES harness (See Note 3) sensor
(defective clamp) (external
Checkwrmg harness force applied)
- visually.
No Is it broken?

NO
Table
I Top (FULL) stopper postion 1 Approx. 12D or below 1

1 Bottom (EMPTY) stopper position 1 Approx.85-110R 1
Bottom (EMPTY)
BLPOO290
Note 1: Difference between fuel level an gauge display. For gaugedisplay position 14 (FULL), the amount of
fuel is 78-l 00%; and for display position 1 (EMPTY) it is below 145%. If the chassis is at an angle, the
displayed amount of fuel will be different from the actual amount. Therefore when checking, stop the
machine at a horizontal place and wait for at least 2 minutes before checking the gauge. (The display is
given a time delay so that the gauge can deal with sudden changes in the fuel level).
Note 2: There is the possibility of defective installation or interference with the sensor inside the tank, so be
carefyul when installing
Note 3: Check for vibration at the connector mount. If there is excessive vibration, take the appropriate action.
20-257
M-26 Defective coolant temperature sensor system
I
ES
Cause
Defective contact of
I
Remedy
Zlean con-
iector or re-
1 connector (See Note 1)
Aace sensor
between temperature
sensor connector Disconnection in wiring Replace
(male) (1) and (2) as 2 YES harness (See Note 2) sensor
show in table? (defective clamp)
Check wiring harness
_ visually (external force applied)
Is it broken?

NO
Table
Normal temperature (20°C) Approx. 70 c 78 kR

1oo”c Approx. 3C
Note 1: If the problem occurs again, the connector (female) at the chassis end is probably defective, so check
the connector and wiring harness at the chassis end.
20-258
M-27 Defective engine oil level sensor system

+ Remove the engine oil level sensor when carrying out troubleshooting
Cause Remedy
YFS Defective movement of float due Clean

2 to dirt
Is any foreign
YE material (dirt) stuck Replace
to mwng part of 3 YES Resonance of mount (See Note sensor (See
float?
2) Note 4)
Is ther any large
- crack, chip, or
When float is moved No damage to float? Clean
up and down,is resis- Defective contact of connector connector or
tance betweenconnec- NO (See Note 2) replace
tor (I) and flanqe as
4 YES Disconnection in wiring harness Replace

(See Note 3) (defective clamp) sensor
Checkwrmg (external force applied)
L harnessvisually. -
No Is It broken?
NO
Table
BLPoo292
Note 1: Variations in oil level. The oil level may change according to the angle of the machine, the engine
speed, or the temperature of the oil, so if there is any display, check the oil level again with the machine
at a horizontal place.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again,
check for vibration at the connector mount, and if there is excessive vibration, take the appropriate
action.
20-259
M-28 Defective coolant level sensor system

+ Remove the coolant level sensor when carrying out troubleshooting.
I Cause Remedy
YES Defective movement of float Clean

2 due to dirt
Is any foreign
YE material (dirt) stuck
to moving part of 3 YES Resonance of mount Replace
float? (SeeNote 2) sensor (Set
Is there any large Note 4)
1 - crack, chip or
No damage to float?
Defective contact of Clean
up and down, is
resistance between NO connector (See Note 2) connector c
connector (1) and (2) replace
as shown ,n Table I?
4 YES
Disconnection in wiring Replace
I I harness (Se Note 3) sensor
1Check Waring harness 11 1 (defective clamp) (external
Replace
Table
Note 1: Variations in coolant level. The coolant level may change according to the angle of the machine, or the
swaying of the machine, so if there is any display, check the coolant level again with the machine at a
horizontal place.
Note 4: Defective installation is a possible cause, so be careful when installing. If the problem occurs again,
check for vibration at the connector mount, and if there is excessive vibration, take the appropriate
action.
20-260
M-30 Wiper does not work or switch is not being used but
wiper is actuated
a) Wiper does not work
* Check that fuse No. 7 is normal. Cause Remedy
4 YEE
GotoA
Is resistancebet-
YES wean Ml 8 (female)
3 (1) (4 (1) (4) as
~ shown in Table l? Defective wiper washer Replace
YES Is voltage between * Turn starting switch NC switch
- M46 (2) and (1) - OFF.
2 normal? * Disconnect Ml& Defective contact, or discon- Replace
I I nection in winng harness bet- wiring
. 20.30V ween fuse (7) and W08 (female)
YES between WlO (male) harness
* Turn starting swtch NO (5), or WOE (female) (l), (8) and
(3) (4) WO8
(4) (18) ON.
GND
1
* Max. 1 CI
Defective contact, or disconnec-
Replace
* Turn starting swtch tion in wiring harness between
between WlO wiring
(female) (3) and (4) OFF. NO Ml0 (male) (3) (4) and WOE
* Disconnect WlO, (male) (3) (4) and W08 (female) harness
WOK (4) (8)
* Front window closed l Replace
position. Min. 1 M 0 i l Defective rear limit switch
l Set window
* Turn starting wtch Ni0 l Front window is open
OFF.
in posistion
* Disconnect WlO. correctly.
YES Defective wiper motor Replace

6
7 YES Defective wiper motor Replace

controller
FromA-m
W04 (male) W08
ON. N Contact between wiring Replace
(female) as shown m
harnesses of system with wiring
* Turn starting switch NC defective resistance harness
ON.
* Turn starting switch * Disconnect W04,
Short circuit in wiring Replace
OFF. W08.
* Disconnect M18, harness between Ml8 wiring
W08. NO (male) (1) (2) (4) -X01 (21) harness
(11) (20) - W08 (female) (12)
(14) (15)
Table 1 Table 2
Actuation mode Ml8 (female) W08 (female) Between W04 (female) (1) W08 (female) (7)
Between W04 female) (3) W08 (female) (6)
INTmode m Between W04 (female) (4) ~08 (female) (11) Max. 1 n
Between W04 (female) (5) W08 (female) (9)
Between (1) (2) Between (12) Between W04 (female) (6) -WOE
(female) (10)
OFF mode Between (1) (4) Between (12) Between ~04 (female) (1) (3) (4) (5) (6) GND Min. 1MCI
Between (2) (4) Between (14)
Max. 1 0
ON mode w
Max. 1 MCI
20-261
Table 3
Timing chart (when wiper is ON)
Set time
Length of pause until next

Tla 0.13 set
actuation
Safety c,rcu,t during operatlon of

w,per[safety function (I)]
10 set
1.5 set
Safety circuit during stowing of

10 set
w,per [safety function (2)]
Timing chart (for wiper INT)
I Item
I
Symbol
I
Set time
Length of pause until next

actuation
( Tla ( 4 set
1
Safety circuit during operation of
Safety circuit during stowing of

Tsp 10 set
wiper [safety function (2)l
I I
M-30 Ralated electric circuit diagram G163
W04(M6) H15(L2)
Connector for
Rear lock
20-262
b) Wiper switch is not being used but wiper is actuated
Cause Remedy
3 YES
YEIS
!
Defective wiper washer Replace
Is resistance NO switch
YE
between Ml8 (male)
(3) and (4) normal?
Defective contact. or
1
disconnection in wiring Replace
Is resistance . Max. 1 Mn
harness between Ml0 wiring
between WlO * Turn startino switch
(female) (3) and (4) OFF. _I NIO (male) (3) (4) - W08 (female) harness
normal? * Disconnect WlO, (4) (18)
WO8.
. Front window closed
l Defective rear limit switch l Replace
posistion: Min. 1 MO
. Turn starting switch NO l Front window is open l Set window
OFF. in position
. Disconnect WlO. correctly.
Defective wiper motor Replace

6 1
YE
Defective wiper motor Replace

controller
Is resistance bet-
ween W08 (female) Contact between wiring Replace
From A P
-
(12) (14L (141. (15) harnesses of system with wiring
as shown m Table l? - Max 1 MX NC
defective resistance harness
OFF.
- Disconnect W04. Short circuit of wiring
harness between Ml8 Replace
NO (male) (1) (2) (4) -X01 (21) wiring
(11) (20) - W08 (female) (12) harness
(14) (15)
Table 1
1Actuation mode 1 Ml8 (female) 1 W08 (female) 1Resistance (0) 1

Between (1) (4) Between (12) (15) Max. 1 0
INT mode Between (1) (2) Between (12) (14)

Max. 1 MO
Between (2) (4) Between (14) (15)
OFF mode Between (1) (4) Between (12) (15) Max 1MD
20-263
Table 3
Timing chart (when wiper is ON)
I Item Symbol Set time
Tla 0.13 set
Safety c,rcu,t during qeratlon of

Tsa 10 set
wiper [safety function (I)]
Length of pause when stowing

w,per blade TIP 1.5set
Safety c,rcu,t during stowq ot

Tsp 10 set
w,per [safety function (2)]
Timing chart (for wiper INT)
INTSWO ;pF 1
Switch
wsw @ ;F”F
,,:
R. limit Switch@ ,“,“,
Safety circuit during operation of
M-30 Ralated electric circuit diagram

G163
W04(M6) H15(L2)
Connector for I
troubleshooting
M46(M3)
Wiper motor
controller
WO8(07(
Wl O(M4)
Rear lock
20-264
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL .................. .30-3 SWING MOTOR

PRECAUTIONS WHEN CARRYING Disassembly and Assembly ................. .30-24
OUT OPERATION ....................................... .30-5 REVOLVING FRAME ASSEMBLY
SPECIAL TOOL LIST.. ................................ .30-7 Removal ............................................... .30-31
GOVERNOR MOTOR ASSEMBLY Installation ............................................ .30-33
Removal and Installation ...................... .30-l 0 SWING CIRCLE ASSEMBLY
HYDRAULIC COOLER ASSEMBLY Removal and Installation ...................... .30-34
Removal ............................................... .30-l 1 HYDRAULIC TANK ASSEMBLY
RADIATOR, HYDRAULIC COOLER Removal ............................................... .30-36
ASSEMBLY Installation ............................................ .30-37
Removal ............................................... .30-l 2 MAIN PUMP ASSEMBLY
Installation ............................................ .30-l 3 Removal ............................................... .30-38
ENGINE, MAIN PUMP ASSEMBLY Installation ............................................ .30-39
Removal ............................................... .30-l 4 CONTROL VALVE ASSEMBLY
Installation ............................................ .30-l 7 Removal ............................................... .30-40
DAMPER ASSEMBLY Installation ............................................ .30-41
Removal and Installation ...................... .30-l 8 Disassembly and Assembly ................. .30-42
FUEL TANK ASSEMBLY LS SELECT VALVE ASSEMBLY
Removal and Installation ...................... .30-l 9 Disassembly and Assembly ................. .30-46
CENTER SWIVEL JOINT ASSEMBLY LS SHUTTLE VALVE
Removal and Installation ...................... .30-20 Disassembly and Assembly ................. .30-47
Disassembly and Assembly ................. .30-21 PRESSURE COMPENSATION VALVE ASSEMBLY
SWING MOTOR ASSEMBLY Disassembly and Assembly ................. .30-48
Removal and Installation ...................... .30-21 MAIN RELIEF VALVE ASSEMBLY
SWING MACHINERY ASSEMBLY Disassembly.. ....................................... .30-50
Removal and Installation ...................... .30-22 Assembly ............................................. .30-51
30-I
LS CONTROL EPC VALVE ASSEMBLY ARM ASSEMBLY
Removal and installation ...................... .30-52 Removal ............................................... .30-73
EPC SOLENOID VALVE ASSEMBLY Installation ............................................ .30-73
Removal and Installation ...................... .30-53 BUCKET, ARM ASSEMBLY
PPC SHUTTLE VALVE ASSEMBLY Removal ............................................... .30-75
Removal ............................................... .30-54 Installation ............................................ .30-75
Installation ............................................ .30-55 BOOM ASSEMBLY
Disassembly.. ....................................... .30-56 Removal ............................................... .30-77
Assembly ............................................. .30-57 Installation ............................................ .30-78
WORK EQUIPMENT PPC VALVE ASSEMBLY OPERATOR’S CAB ASSEMBLY
Removal and Installation ...................... .30-58 Removal ............................................... .30-79
TRAVEL PPC VALVE ASSEMBLY Installation ............................................ .30-81
Removal and Installation ...................... .30-59 COUNTERWEIGHT ASSEMBLY
Disassembly.. ....................................... .30-59 Removal and Installation ...................... .30-82
Assembly ............................................. .30-59 GOVERNOR, PUMP CONTROLLER ASSEMBLY
BOOM CYLINDER ASSEMBLY Removal and Installation ...................... .30-83
Removal ............................................... .30-60 MONITOR PANEL ASSEMBLY
Installation ............................................ .30-61 Removal and Installation ...................... .30-84
ARM CYLINDER ASSEMBLY SWING MACHINERY ASSEMBLY
Removal ............................................... .30-62 Disassembly.. ....................................... .30-85
lnstalltion .............................................. .30-63 Assembly ............................................. .30-l 01
BUCKET CYLINDER ASSEMBLY (Special tools) ..................................... ..30-12 1
Removal ............................................... .30-64 TRANSMISSION ........................................ ..30-12 3
Installation ............................................ .30-65 FRONT AXLE.. ............................................ .30-l 30
HYDRAULIC CYLINDER ASSEMBLY REAR AXLE ................................................ .30-l 48
Disassembly.. ....................................... .30-66 BUCKET ADAPTOR
Assembly ............................................. .30-68 Welding instructions ................................... ..30-16 2
WORK EQUIPMENT ASSEMBLY OUTRIGGER + BLADE
Removal ............................................... .30-71 Cyl ............................................................. .30-l 65
Installation ............................................ .30-72
BUCKET ASSEMBLY
Removal ............................................... .30-73
Installation ............................................ .30-73
30-2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
@) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
@ Any special techniques applying only to the installation procedure are marked q , and the same mark
is placed after the relevant step in the removal procedure to indicate which step in the installation
procedure it applies to.
(Example)
REMOVAL OF 0 0 0 0 ASSEMBLY . . . . . ..Title of operation
a Precautions related to safety when carrying out the operation
1. XXXX(1) Step in operation
+ Technique or important point to remember when removing
xxxx (1).
2. A A A A (2): m Indicates that a technique is listed for use during instal-
lation
3. 0 0 0 0 assembly (3)
:
u Quantity of oil or water drained
INSTALLATION OF 0 0 0 0 ASSEMBLY . . . . ..Title of operation

. Carry out installation in the reverse order to removal.
m Technique used during installation
* Technique or important point to remember when installing
A A A A (2).
. Adding water, oil Step in operation
* Point to remember when adding water or oil
Quantity when filling with oil and water
&
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
3. Listing of special tools

@ For details of the description, part number, and quantity of any tols (Al, etc.) that appear in the opera-
tion procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
4. General tightening torque table (when using torque wrench)

* In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flats
mm mm kgm Nm
6 IO 1.35 f 0.15 13.2 f 1.4
8 13 3.2 f 0.3 31.4 f 2.9
IO 17 6.7 f 0.7 65.7 f 6.8
12 19 11.5 f 1 .o 112 f 9.8
14 22 18.0 f 2.0 177 f 19
16 24 28.5 f 3 279 f 29
18 27 39 f 4 383 f 39
20 30 56 f 6 549 f 58
22 32 76 f 8 745 f 78
24 36 94.5 f 10 927 f 98
27 41 135 f 15 1320 f 140
30 46 175f20 1720 f 190
33 50 225 f 25 2210 f 240
36 55 280 f 30 2750 f 290
39 60 335 f 35 3280 f 340
,Sealing surface
5. Table of tightening torques for flared nuts

* In the case of flared nuts for which there is no special instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque

mm mm kgm Nm
14 19 2.5 f 0.5 24.5 f 4.9
18 24 5f2 49 f 19.6
22 27 8f2 78.5 f 19.6
24 32 14f3 137.3 f 29.4
30 36 18f3 176.5 f 29.4
33 41 20 f 5 196.1 f 49
36 46 25 f 5 245.2 f 49
42 55 30 f 5 294.2 f 49
6. Table of tightening torques for split flange bolts
+ In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
Thread diameter Width across flats Tightening torque
mm mm Kgm Nm
IO 14 6.7 f 0.7 65.7 f 6.8
12 17 11.5f 1 112 f 9.8
16 22 28.5 f 3 279 f 29
30-4
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
+ Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal number Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
02 0737650210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes
Nominal number I Flange (hose end) 1 Sleeve head (tube end) 1 Split flange
04 07379-00400 07378-I 0400 07371-30400
05 07379-00500 07378-i 0500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D 1 d 1 L
06 1 07049-00608
DEW00401
30-5
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
2. Precautions when carrying out installation work

. Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
. Install the hoses without twisting or interference.
. Replace all gaskets, O-rings, cotter pins, and lock plated with new parts.
. Bend the cotter pins and lock plates securely.
. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
. When caoting with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
. Clean all parts, and correct any damage, dents, burrs, or rust.
. Coat rotating parts and sliding parts with engine oil.
. When press fitting parts, coat the surface with anti-friction compound (LM-P).
. After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
. When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
. When tightening split flanges, tighten uniformly in turn to prevent excessive tighenting on one side.
* When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the
cylinder 100 mm form the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
* When using the machine for the first time after repair or long storage, follow the same procedure.
3 Precautions when completing the operation

. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reas-
sembling the parts.
+ For details, see TESTING AND ADJUSTING, Bleeding air.
. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST
Nature of work symbol Part No. Part Name Q’ty Remarks
l Engine l hydraulic pump

assembly
l Radiator l hydraulic oil
cooler assembly
l Control pump assembly

B 796-460-1210 3il stopper 1
l Hydraulic pump assembly
l Removal, installation of TVC

l LS valve assembly
l Revolving frame
Disassembly of center swivel

D 790-l 01-2501 ‘ush-puller 1
joint assembly
Removal installation of swing Tightening of circle
E 790-331-l 110 Wench 1
circle bolt
30-7
-
Nature of work Symbol Part No. Part Name a’ty Remarks
Cylinder repair
790-502-l 003 1
stand
1
790-l 01-l 102 Pump 1
Socket
790-l 02-l 330 (wdth across flats: 1
75 mm)
2
7
Socket
790-302-l 430 (width across flats: 1
Disassembly, assembly of
0 85 mm)
hydraulic cylinder
3 790-720-I 000 Expander 1 Expansion of piston ring
796-720-I 670 Ring 1
4
07281-01279
796-720-l
07281-01159
660
Clamp
Ring
Clamp
-
1
1
I
30-8
Nature of work Symbol Part No. Part Name Q’ty Remarks
792-785-I 100 Remover 1

l Removal, installation of
Removal of boom foot
work equipment assembly P 790-I 01-3800 Puller (50 ton long) 1
pin
l Boom assembly
790-I 01-I 102 Pump (30 ton) 1
30-9
DISASSEMBLY AND ASSEMBLY GOVERNOR MOTOR
REMOVAL OF GOVERNOR
MOTOR ASSEMBLY
a. Drsconnect the cable from the negative (-) terminal of
the battery.
1. Open engine hood and disconnect governor motor

connector.
2. Remove motor rod (1).
3. Remove governor motor assembly (2).

+ Rotate the shaft of the governor motor and do not
stop it suddenly.
INSTALLATION OF GOVERNOR
MOTOR ASSEMBLY
Ig
+ Adjust the rod. For details, see TESTING AND
ADJUSTING, Testing and adjusting of governor
motor lever stroke.
30-I 0
DISASSEMBLY AND ASSEMBLY HYDRAULIC OIL COOLER
REMOVAL OF HYDRAULIC OIL

COOLER ASSEMBLY
a Lower the work equipment completely to the ground
and stop the engine. Then loosen the oil filler cap
slowly to release the pressure inside the hydraulic
tank.
. Remove the hydraulic tank strainer, and using tool B,
stop the oil.
. When not using tool B, remove the drain plug,
and drain the oil from the hydraulic tank and in-
side the system.
b
& Hydraulic tank: Approx. 120 B
1. Remove battery and set oil container under chassis.
2. Disconnect hoses (4) and (5).

+ Disconnect hose (4) at the cooler end, and hose
(5) at the chassis end.
+ Put blind plugs in the places that have been dis-
connected.
3. Remove mounting bolts (6) at side of hydraulic oil

cooler assembly. IJ
205FO6451
4. Sling hydraulic oil cooler assembly (7), remove 2

mounting bolts each on left and right, then lift off hy-
draulic oil cooler assembly (7).
& kg
1
Hydraulic oil cooler assembly: 60 kg
INSTALLATION OF HYDRAULIC 6
OIL COOLER ASSEMBLY

. Refilling with oil (hydraulic tank) 205FO6452

* Add oil through the oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
30-I 1
DISASSEMBLY AND ASSEMBLY RADIATOR l HYDRAULIC OIL COOLER
REMOVAL OF RADIATOR l
-
HYDRAULIC OIL COOLER
ASSEMBLY
tank.
stop the oil.
side the system.
:
u Hydraulic tank: Approx. 120 B
. Drain engine coolant.
1. Remove undercover under radiator.
2. Disconnect small diameter from radiator (near cap) to

reservoir tank.
3. Disconnect cooler hoses (4) and (5).
205FO6458
4. Disconnect radiator upper hose (g), and remove

clamps of heater hose (;O) from right’side of radiator
assembly.
5. Remove fan guard (11).
30-I 2
DISASSEMBLY AND ASSEMBLY RADIATOR l HYDRAULIC OIL COOLER
6. Disconnect radiator support rods (12) and (13).

+ Loosen the mounting bolts, then remove the top
mounting bolts and move the rods towards the
rear of the engine.
7. Disconnect radiator lower hose (14) and heater hose

(15).
* The radiator lower hose is fixed by a clamp to the
radiator, so always disonnect the clamp.
8. Sling radiator and hydraulic oil cooler assembly, re-

move 4 bottom mounting bolts, then lift off radiator and
hydraulic oil cooler assembly.
* When raising the radiator and hydraulic oil cooler
assembly, check the position carefully and do not
let it hit the fan when removing it.
Radiator l hydraulic oil cooler assembly :

115 kg
INSTALLATION OF RADIATOR l
HYDRAULIC OIL COOLER

ASSEMBLY
. Refilling with water

* Add water through the water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
again.
. Refilling with oil (hydraulic tank)

30-I 3
DISASSEMBLY AND ASSEMBLY ENGINE l HYDRAULIC PUMP
REMOVAL OF ENGINE l
HYDRAULIC PUMP ASSEMBLY
a. Disconnect the cable from the negative (-) terminal of
the battery.

tank. I
- 202FO6609
stop the oil.
. when not using tool B, remove the drain plug, and

drain the oil from the hydraulic tank and inside the
system.
b
,). Hydraulic tank: Approx. 120 B
. Drain engine coolant.
1. Remove pump bottom cover and engine bottom cover.
2. Open engine hood and remove pump top cover.
3. Remove engine step, control valve top cover, parti-

tion, and exhaust muffler cover
4. Disconnect alternator wiring (5).

* Mark the wiring with tags to show the connection
position.
5. Disconnect engine oil pressure sensor wiring.
6. Disconnect intake hose (7).
7. Remove radiator inlet hose (8).
8. Remove fan guard (9) and belt guards.
9. Loosen fan belt, remove connecting bolt at pulley and

spacer, then remove fan.
m
30-I 4
10. Disconnect heater hose (12).
11. Disconnect water pump inlet hose (13).
13. Disconnect coolant temperature sensor wiring con-

nector (14).
14. Disconnect electrical intake air heater wiring (15).
15. Disconnect governor motor wiring connector (16)
16. Disconnect TVC l LS valve wiring connector (17).
17. Remove clamp (18), and remove spill hose (19).
18. Disconnect fuel hose (20)

* When the hose is disconnected, fuel will flow out,
so insert a wooden plug into the hose to prevent
the fuel from leaking out.
19. Disconnect starter motor wiring (21).
20. Disconnect engine oil level sensor wiring connector

(22).
21. Disconnect starting motor wiring connector (23).
30-I 5
23. Disconnect main pump suction tube (25).
25. Disconnect main pump outlet hose (27).
26. Disconnect main pump drain hose (28).
27. Disconnect TVC l LS valve inlet hoses at side of main

pump.
28. Disconnect engine speed wiring connector.

29. Disconnect earth wiring.
31. Remove mount bolt, then lift off engine and hydraulic
pump assembly (36) slowly. m
* When removing the engine and hydraulic pump
asembly, check that all wiring and piping has
been disconnected, and be careful not to hit any
part when removing.
Engine l hydraulic pump assembly: 600 kg
30-16
INSTALLATION OF ENGINE l
HYDRAULIC PUMP ASSEMBLY
m
* Adjust the fan belt tension.
For details, see TESTING AND ADJUSTING,
Testing and adjusting fan belt tension.
m
+ Check that the O-ring is not damaged or deterio-
rated, then connect the hoses.
+ Set the engine mount rubber as shown in the dia-

gram, then install the engine and hydraulic pump
assembly.
gm Engine mount mounting bolt:

276.9 f 31.9 Nm(28.25 f 3.25 kgm)
Refilling with water

I i
+ Add water through the water filler to the specified
level. (Mountat main pump end)
Run the engine to circulate the water through the (Mount at fan end)
202FO6610
system. Then check the water level again.
Refilling with oil (hydraulic tank)

* Add oil throught the oil filler to the specified level.
Bleeding air
* Bleed the air from the hydraulic pump.
Bleeding air.
Fill with refrigerant (R-l 34a).
30-I 7
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
1. Remove main pump assembly. For details, see RE-
MOVAL OF MAIN PUMP ASSEMBLY.
2. Remove damper assembly (1).

m
INSTALLATION OF DAMPER
ASSEMBLY
Damper mounting bolt;

171.05 f 7.35 Nm (7.25 f 0.75 kgm)
Thread of Damper mounting bolt;
Thread tightener (LT-2)
30-I 8
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUELTANK
ASSEMBLY
Ah Drsconnect the cable from the negative (-) terminal of
the battery.
1. Loosen drain valve (1) of fuel tank and drain fuel.
u : Fuel tank: Approx. 250 G (when tank is full)
2. Disconnect fuel supply hose (2) and return hose (3). 205FO6484
3. Remove handrail (4), battery case (5), and cover (6).
4. Remove connector (7) from holder, and disconnect it.

+ Remove the wiring from the clamp, then discon-
nect from the fuel tank.
5. If refueling pump is fitted disconnect hose from tank

tube.
6. Remove mounting bolts, and lift off fuel tank assembly

(8) m
Fuel tank assembly: 100 kg
INSTALLATION OF FUEL TANK

ASSEMBLY
cm Fuel tank mounting bolt:

276.9 f 31.9 Nm (28.25 f 3.25 kgm)
. Refilling with oil (fuel tank)

Add fuel.
202FO6470
I 202FO6473
DISASSEMBLY AND ASSEMBLY CENTER SWIVEL JOINT
REMOVAL OF CENTER SWIVEL

JOINT ASSEMBLY
and stop the engine. Then loosen the oil filter cap
tank.
Mark all the piping with tags to prevent mistakes in the

mounting position when installing.
4’ L ' KW13OP6091
1. Disconnect hoses (1) and (2) between travel motor
swivel joint.
2. Disconnect pilot hosees (3), (4) and (5) and brake
pipes (6) and (7).
3. Disconnect drain hoses (8) and steering hoses (9) and
(10).
4. Disconnect hoses (11) (12) (13) & (14) between con-

trol valve and swivel joint.
5. Disconnect steering hoses (15) and (16) and drain
hose (17).
6. Disconnect brake hoses (18) (19) and (20).
7. Disconnect travel speed selector hose (21), and sus-
pension lock hose (22).
8. Remove center swivel joint assembly (23).
Center swivel joint assembly: 83 kg
INSTALLATION OF CENTER
SWIVEL JOINT ASSEMBLY
=&T rea df o swivel joint mounting bolt:

Tread tightener (LT-2)
c- Swivel joint mounting bolt:
277f32 Nm (28.25k3.25 kgm)
View A KWt30P6093
* Add oil through the oil filter to the specified level.
. Bleeding air
* Bleed the air from the travel motor.
Bleeding air.
KW13OP6094
30-20
DISASSEMBLY AND ASSEMBLY SWING MOTOR
REMOVAL OF SWING
MOTOR ASSEMBLY
and stop the engine. Loosen the oil filler cap slowly to
release the pressure inside the hydraulic tank. Then
set the safety lock lever to the LOCK position.
1. Disconnect hoses (l), (2), (3), and (4), and tubes (5)
and (6), then remove filter and bracket assembly.
+ Machines equipped with additional attachment
circuit
2. Remove hose clamps (7) and (8).
3. Disconnect swing motor inlet and outlet hoses (9),

(lo), and (11). -
Remove bracket (12).
Disconnect drain hoses (13) and (14).
Disconnect pilot hose (15).
Remove swing motor assembly (16). m
Swing motor assembly 30 kg
INSTALLATION OF SWING
MOTOR ASSEMBLY

+ Add oil through the oil filler to the specified level.
+ Bleeding air
* Bleed the air from the swing motor. For details,
see TESTING AND ADJUSTING, Bleeding air.
m
cxl Swing motor mounting bolt:
277 f 32 Nm (28.3 f 3.3 kgm)
DISASSEMBLY AND ASSEMBLY SWING MACHINERY
REMOVAL OF SWING
MACHINERY ASSEMBLY
1. Remove swing motor assembly. For details, see RE-
MOVAL OF SWING MOTOR ASSEMBLY.
2. Using eyebolts 0, remove swing machinery assembly

(1). m
+ When removing the swing machinery assembly,
lift off slowly and be careful not to damage the
hoses.
Swing machinery assembly: 120 kg
MACHINERY ASSEMBLY
Carry out installation in the reverse order to removal.
h
SmSwing machinery mounting bolt:
548.8 f 49 Nm (56 f 5 kgm)

. Bleeding air
+ Bleed the air from the swing motor. For details,
see TESTING AND ADJUSTING, Bleeding air.
30-22
FITTING OFTHE HYDRAULIC MOTOR

Clean the mating area and the pilot diameter of the gear-
box where the motor is to be mounted.
After mounting the motor, verify, through of a depth slide
gauge, the axial dimension of the gearbox measured from
input side of the motor adaptor flange to the brake shaft:
Axial dimension = 93 - 94,5 mm.
Place the hydraulic motor and tighten the 2 hexagonal

head screws Ml 6 x 40, grade 8.8, by a torque wrench at a
torque of 21,5 daNm.
Dwg. Verify the axial dimension of the
INSTALLATION OF THE SLEW DRIVE TO THE MA-

CHINE
a) Clean the mating surfaces from oils or paint and fit the
gearbox to the undercarriage.
b) Fix the slew drive to the frame with 10 screws M20

minimum grade 8.8, tightened by a torque wrench at a
torque of 41,5 daNm.
Dwg. - Gearbox installation scheme
30-23
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR
1 F12 NmflO 1
60
6o ‘\ 60 11 138.0 13894185
I I I
\
mm
F12 1Thread 1Tool I

60 1M24 x 1.5 13793077
NOT KEY TYPE

I- -
SPLINE TYPE
30-24
Dissasem bly
Put the unit in a bench with a hole or place it on a fixture

for assembly Loosen the 4 bolts.
Lift off the housing
Lift out the pistons

l p5tons
Turn the bearing housing upside down and loosen the

retaining ring holding the seal ring carrier.
Loosen the seal carrier using two screwdrivers.
Loosen the retaining ring holding the bearing and bearing

play adjustment washers.
Push out the shaft with a press or a plastic mallet.
If it is necessary to remove the bearing races, use a drift

or a press.
30-26
For disassembly the valve plate has got a thread in the

centre. Use the special tool to pull it out.
Thread specification:
F12 Thread Tool
60 M24x1.5 3793077
Assembly
Push the shaft into the bearings in the housing. Use as

many washers as needed to just allow the retaining ring
on the shaft to enter into its groove.
30-27
Install pistons, cylinder barrel support and cylinder barrel.

Note: The shaft has got one tooth marked with a
punchmark and the barrel has got one space marked.
It is absolutely necessary that these are mating to ensure
correct alignment for the pistons in the cylinders. Also
choose correct adjustment shim to ensure correct back-
lash.
Install the barrel housing and tighten the screws.
Backlash and correct timing can be checked through the

drainhole.
Correct tightening torque is:
30-28
Item Title
110 BARREL HOUSING ASSY

121 VALVE PLATE
131 BLEEDER PLUG
132 SEAL WASHER
211 BEARING HOUSING
221 O-RING
225 O-RING
229 O-RING
231 SEAL CARRIER
233 SHAFT SEAL
237 RETAINING RING

256 PLUG
257 SEAL WASHER
311 SHAFT TYPE
411 CYLINDER BARREL
415 NEEDLE BEARING

430 BARREL SUPPORT
440 PISTON ASSY
442 PISTON RING
451 GUIDE PIN
452 RING GEAR

460 TAP ROL BEARING
470 CYL BEARING
476 SPACER WASHER
478 RETAINING RING
488 SHIM
491 HEX SOCKET SCREW
30-29
37
135 ;
r 36
__-7
,452
30-30
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
REMOVAL OF REVOLVING
FRAME ASSEMBLY
A Disconnect the cable from the negative (-) terminal of
the battery.
A Lower the work equipment completely to the ground

and stop the engine. Then loosen the oil filter cap
slowly to relaese the pressure inside the hydraulic
tank.
stop the oil.
side the system.
:
u Hydraulic tank: Approx. 120 B
2. Remove 2 boom cylinder assemblies.

For details, see REMOVAL OF BOOM CYLINDER
ASSEMBLY.
3. Remove work equipment assembly.

For details, see REMOVAL OF WORK EQUIPMENT
ASSEMBLY. __-
KW13OP6097
4. Remove counterweight assembly.

For details, see REMOVAL OF COUNTERWEIGHT
ASSEMBLY.
5. Disconnect top mounting hoses of swivel joint assem-

bly. For details, see REMOVAL OF SWIVEL JOINT
ASSEMBLY. Remove torque arm (1).
6. Remove mounting bolts, then lift of revolving frame

assembly (12). m
* Leave 2 bolts @ each at the front and rear, use a
lever block to adjust the balance of the revolving
frame assembly to the front and rear, and left and
right, then remove the remaining bolts, and lift off.
A When removing the revolving frame assem-

bly be careful not to hit the center swivel joint
assembly.
Revolving frame assembly:

7100 kg (without work equipment)
30-3 1
REVOLVING FRAME
DISASSEMBLY AND ASSEMBLY
30-32
DISASSEMBLY AND ASSEMBLY REVOLVING FRAME
INSTALLATION OF REVOLVING
FRAME ASSEMBLY
a Mating surface of swing circle:

Gasket sealant (LG-1)
a Thread of revolving frame mounting bolt:

ciz’q Revolving frame mounting bolt:
PW170-6 1 20-105 1 26 1549 f 59 (56 f 6)

. Bleeding air
* Bleed the air. For details, see TESTING AND
ADJUSTING, Bleeding air.
30-33
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
REMOVAL OF SWING CIRCLE

ASSEMBLY
1. Remove revolving frame assembly. For details, see
REMOVAL OF REVOLVING FRAME ASSEMBLY.
2. Remove swing circle mounting bolts (l), leaving 1

bolt each in front and rear direction. m
Sr Swing circle assembly mounting bolts: 30
3. Sling swing circle assembly (2) at three points, then

remove remaining mounting bolts.
4. Lift off swing circle assembly (2). m
& kg Swing circle assembly 240 kg

I Swing circle start mark
Socket start mark
2OSFO6557
30-34
DISASSEMBLY AND ASSEMBLY SWING CIRCLE
CIRCLE ASSEMBLY
a Thread of swing circle mounting bolt:

573Fl Swing circle mounting bolt:

549 f 49Nm (56 f 6 kgm)
m
+ Set the soft zone S mark on the inside ring of the
inner race facing the right side as shown in the
diagram, then install to the track frame.
a Swing circle: Grease (G2-LI) 88
30-35
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
1. Drain oil from hydraulic tank.
b
& Hydraulic tank: Approx. 120 G
2. Open engine hood, and remove covers (l), (2), (3),

and (4).
3. Remove engine room partition plate (5), then remove

partition plate (6).
4. Remove frame (7).
5. Disconnect hydraulic filter inlet hoses (8), (9), (IO),

and (11).
6. Remove pressure sensor wiring clamps (12).
7. Remove solenoid valve wiring clamp (13).
9. Remove wiring connector bracket (15).
30-36
10. Disconnect hydraulic tank inlet hose (16).
11. Remove main pump inlet tube (17), then remove

pump suction tube (18).
12. Remove mounting bolts, and lift off hydraulic tank

assembly (19). m
Hydraulic tank assembly: 125 kg
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
m
&&Thread of hydraulic tank mounting bolt:
Thread tightnener (LT-2)
cm Hydraulic tank mounting bolt:

276.9 f 31.9 Nm (28.25 f 3.25 kgm)

Bleeding air
* Bleed the air.
Bleeding air.
30-37
REMOVAL OF MAIN PUMP
ASSEMBLY
a Disconnect he cable from the negative (-) terminal of
the battery.

tank.
- 202FO6609
stop the oil.
and drain the oil from the hydraulic tank and
inside the system.
b
,). Hydraulic tank: Approx. 120 G
2. Open engine hood, and remove main pump top

cover, then remove exhaust muffler covers (1) and
(2).
3. Disconnect connecting pipe portion at turbocharger

end, and remove exhaust muffler (3) together with
bracket.
4. Disconnect hoses (4),a nd remove filter assembly (5)

together with bracket.
6. Disconnect main pump suction tube (7).
9. Disconnect main pump outlet hose (10)
IO. Disconnect main pump drain hose (11).
11. Disconnect TVC l LS valve inlet hoses (12).
L
I I
30-38
12. disconnect engine speed sensor wiring connector

(13), and remove bracket (14).
13. Disconnect TVC solenoid wiring connector (15), and

remove bracket (16).
14. Disconnect ground connection (17).
15. Remove exhaust drain pipe (18).
16. Sling main pump assembly (19), remove mounting

bolts, then use forcing screws 0 to remove.
rq
Main pump assembly: 100 kg
INSTALLATION OF MAIN PUMP

ASSEMBLY
la]
a Mating surface of pump case:

Gasket sealant (LG-6)
. Refilling with oil (hydraulic tank) 25

* Add oil throught the oil filler to the specified
level.
. Bleeding air
Sr Bleed the air from main pump.
Bleeding air.
30-39
DISASSEMBLY AND ASSEMBLY CONTROL VALVE
REMOVAL OF CONTROL
VALVE ASSEMBLY
a Release the remaiing pressure in the hydraulic
circuit.
For details, see TESTING AND ADJUSTING, Re-
leasing pressure in hydraulic circuit.
1. Remove engine room partition plate and chassis

bodywork cover above control valve assembly.
2. Remove clamp (l), then disconnect hoses (2), (3),

(4) and (5).
3. Disconnect hoses (6) and (7).
4. Remove clamp (8), then remove hoses (2), (3), (4),

and (5).
5. Disconnect hoses (9), (lo), (ll), (12), and (13).
6. Disconnect hoses (14), (15), and (16).
7. Disconnect hoses (17), (18), (19), and (20).

+ Disconnect 2 hoses (18).
8. Disconnect hoses (21), (22), and (23).
30-40
9. Remove connector (24) from clip, then disconnect it.

+ Disconnect the wiring harness form the harness
clamps (3 places)
I 25 dA\ n
10. Remove harness bracket (25).
11. Disconnect hose (26).
12. Remove mounting bolts, and lift off control valve

assembly (27).
Control valve assembly : 70 kg
INSTALLATION OF CONTROL
VALVE ASSEMBLY

Bleeding air
* Bleed the air from the circuit between the valve
and the hydraulic cylinder.
Bleeding air.
30-4 1
DISASSEMBLY OF CONTROLVALVE ASSEMBLY

* The set pressure of the safety valve and arm 4. LS shuttle, LS select valve
counterbalance valve, cannot be adjusted Remove LS shuttle valves (25a) and (25b),
when they are installed on the machine, so do and LS select valve (26).
not disassemble. * Mark the mounting positions of LS shuttle
. The following explanation describes the spools valves (25a), and (25b), and be careful
control valve. not to make any mistake when installing.
1. Main relief valve 5. 2nd boom control valve, stabilizer control

Remove main relief valve (1). valve, bucket control valve, arm control
valve, boom control valve, swing control
2. Unload valve, safety-suction valves, suction valve, service control valve
valves 1) Remove case (27), then remove spring
1) Remove unload valve (3) (28) and retainer (29).
2) Remove safety-suction valves (4), (5), (6), 2) Remove spool assembly (30).
(7) and (8). + Do not disassemble spool (30).
3) Remove suction valves (9) and (10). 3) Remove case (31), then remove spring
(32) and retainer (33).
3. Pressure compensation valves + To avoid assembling spring (32) in
+ Before removing any pressure compensa- mistake for spring (39), mark with
tion valve, check and mark its mounting tags.
position.
1) Remove bucket CURL pressure compen- 6. Arm counterbalance valve, check valve,
sation valve (1 l), arm IN pressure com- cover
pensation valve (1 l), boom LOWER 1) Remove arm counterbalance valve (41).
pressure compensation valve (11) + 2nd 2) Remove flange (42), then remove spring
boom IN valve, travel + stabiliser travel (43) and check valve (44).
pressure compensation valve (12), Stabi- 3) Remove covers (45) and (46).
lizer pressure compensation valve (12),
and swing RIGHT pressure compensation 7. Lift check valve
valve (13) and service valve pressure Remove case (47), then remove spring (48),
compensation valve (14). piston (49), and sleeve (50).
* After removing the pressure compen-
sation valves, remove check valve 8. Cooler bypass valve
(17) from each pressure compensa- Remove case (51), then remove spring (52),
tion valve mount. piston (53), and sleeve (54).
2) Remove bucket DUMP pressure compen-
sation valve (18), arm OUT pressure +
2nd boom OUT valve compensation valve
(19), boom RAISE pressure compensa-
tion valve (19), travel pressure compensa-
tion valve (20), Stabilizer pressure com-
pensation valve (20), and swing LEFT
pressure compensation valve (21), and
service valve pressure compensation
valve (22).
* After removing the pressure compen-
sation valves, remove check valve
(24) from each pressure compensa-
tion valve mount.
30-42
ASSEMBLY OF CONTROL VALVE ASSEMBLY

Before assembling coat the sliding surface c$rl LS shuttle valve:
with engine oil. 166.7 f 19.6 Nm (17 f 2.0 kgm)
* Check valve (25a) and (25b) and be
Cooler bypass valve
careful not to mistake them when in-
Assemble sleeve (54), piston (53), and spring
stalling.
(52) to cover (46), then fit O-ring to case (51)
and install. 6. Pressure compensation valve
Check marks made on each pressure compen-
Lift check valve
sation valve when disassembling, and install
Assemble sleeve (50), piston (49), and spring
pressure compensation valves in correct posi-
(48) to cover (46), then fit O-ring to case (47)
tion.
and install.
1) Before installing pressure compensation
Cover, check valve, arm counterbalance valves below, install check valves (17) and
valve (24).
1) Fit O-rings and install cover (46) and (45). 2) Fit O-ring, then install swing LEFT pres-
sure compensation valve (21) Right and
zm Mounting bolt of cover (46):
Left, travel pressure compensation valve
277.1 f 32.3 Nm (28.3 f 3.3 kgm)
and stabilizer valve (20), boom RAISE
m Mounting bolt of cover (45): pressure compensation valve (19), arm
166.3 f 10.3 Nm (17 f 1 kgm) OUT pressure compensation valve (19),
+ Tighten the mounting bolts in the and bucket DUMP pressure compensation
order shown in the diagram. valve (18)
2) Assemble check valve (44) and spring 3) Fit O-ring, then install swing RIGHT pres-
(43), then fit O-ring to flange (42) and sure compensation valve (13), Right and
install. Left travel REVERSE pressure compensa-
3) Fit O-ring to arm counterbalance valve tion valve (12), boom LOWER pressure
(41) and install. compensation valve (1 I), arm IN pressure
compensation valve (ll), and bucket
cm Mounting bolt:
CURL pressure compensation valve (11).
31f3.5 Nm(3.2f0.4 kgm)
* Tighten the mounting bolts in the sm Pressure compensation valve:
order shown in the diagram. 225.5f19.5 Nm (23f2 kgm)
4. 2nd boom control valve stabilizer control 7. Suction valves, safety-suction valves, un-
valve, service control valve, bucket control load valve
valve, arm control valve, boom control 1) Fit O-rings and install suction valves (10)
valve, swing control valve and (9).
1) Assemble spool assembly (30) to valve
QK-I Suction valve:
body.
147.1f9.8 Nm (15fl kgm)
2) Assemble retainer (33) and spring (32) to
2) Fit O-rings and install safety-suction valves
spool, then fit O-ring to case (31) and
install. (8) (7) (6) (5) and (4).
* Check spring (32) when installing. QZYl Safety-suction valve:
147.1 f 9.8 Nm (15fl kgm)
cm Mounting bolt:
3) Fit O-ring and install unload valve (3).
11.3 f 1.5 Nm (1.2 f 0.2 kgm)
3) Assemble retainer (29) and spring (28) to 5x-l Unload valve :
spool, then fit O-ring to case (27) and 166.7f19.7 Nm (17f2 kgm)
install.
cm Mounting bolt:
1) Fit O-ring and install main relief valve (1).
11.3 f 1.5 Nm (1.2 f 0.2 kgm)
sm Main relief valve:
5. LS shuttle valve, LS select valve
98.1f9.8 Nm (1Ofl kgm)
1) Fit O-ring and install LS select valve (26).
gm LS select valve:
127.5 f 19.6 Nm (13f2 kgm)
2) Fit O-rings and install LS shuttle valves
(25a) and (25b).
30-44
30-45
DISASSEMBLY AND ASSEMBLY LS SELECT VALVE
DISASSEMBLY OF LS SELECT
VALVE
202FO6542
1. Remove sleeve (2) and spring (3) from sleeve (1).
2. Remove O-rings (4) and (5), and seal (6) from sleeve
(1).
3. Remove plug (7), then remove pistons (8) and (9),

and spring (10).
4. Remove O-ring (11) from plug (7), then remove seal

(12) and O-ring (13) from piston (9).
* After disassembling, if there is any abnormality
in any part except O-rings (4), (5), (1 l), or seal
(6), replace the whole LS select valve assembly.
ASSEMBLY OF LS SELECT
VALVE
. Before assembling coat the sliding surface with
engine oil.
1. Install O-ring (13) and seal (12) to piston (9), then

assemble piston (8) and spring (lo), and install in
sleeve (1).
2. Assemble O-ring (11) to plug (7) and install to sleeve

(1).
cm Plug: 68.6f9.9 Nm (7fl kgm)
3. Assemble spring (3) to sleeve (2), and install to

sleeve (1).
4. Install O-rings (4) and (5), and seal (6) to sleeve (1).
30-46
DISASSEMBLY AND ASSEMBLY LS SHUTTLE VALVE
DISASSEMBLY OF LS SHUTTLE VALVE

A: LS shuttle valve for work equipment (bucket, arm, boom, 2nd boom, stabiliser).
B: LS shuttle valve for travel.
+: The structure of the parts is the same, but the parts number for the assembly is different, so be careful
when assembling.
(6 Places)
(1 Place)
1. Remove seat (2) from plug (I), then remove O-ring

(3) and ring (4).
TypeA
2. Remove ball (5) from plug (l), then remove O-rings
(6) and (7), and ring (8).
+ After disassembling, if there is any abnormality
in plug (l), seat (2), or ball (5), replace the
whole LS shuttle valve assembly.
ASSEMBLY OF LS SHUTTLE
VALVE
engine oil.
1. Install ring (8) and O-rings (7) and (6) to plug (1)
2. Fit ring (4) and O-ring (3) to seat (2), then assemble
ball (5) to plug (l), and install seat (2).
INDENTIFICATION OF LS
TypeB
SHUTTLE VALVE
Shuttle valves are identified by markings on the valve
assembly.
Type A - 1 mark
Type B - 3 marks
30-47
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
DISASSEMBLY OF PRESSURE COMPENSATION VALVE

ASSEMBLY
Pressure compensation valves

A: For bucket CURL/DUMP, boom Lower arm IN, stabiliser
C: For swing LEFT/RIGHT
D: For arm OUT, boom RAISE
B: For travel
. Disassembly of pressure compensation . Disassembly of pressure compensation

valves A,C,D valve B
. The structure of the parts for pressure com-
pensation valves A, C en D is the same, but 1. Remove piston (13) and spring (14) from
the part number for the assembly marked * is sleeve (12).
different, so be careful when assembling.
2. Remove seals (15) and (16) from piston (13),
1. Remove piston (2) and spring (3) from sleeve then remove O-ring (17), seals (18) and (19),
(1). and O-ring (20) from sleeve (12).

2. Remove plug (4) and ball (5) form piston (2).
in sleeve (12), piston (13), or seals (15) and
3. Remove seals (6) and (7) from piston (2). (16), replace the whole pressure compensa-
tion valve assembly.
4. Remove O-ring (8) from sleeve (l), then
remove seals (9) and (lo), and O-ring (11). IDENTIFICATION OF
* After disassembling, if there is any abnormality PRESSURE COMPENSATION
in sleeve (I), piston (2), plug (4), ball (5), or
seals (6) and (7), replace the whole pressure
VALVE ASSEMBLY
compensation valve assembly.
Valves are identified by markings on the valve
assembly.
Type A - 1 mark.
Type C - 3 marks.
Type D - 4 marks.
Type B - 2 marks.
30-48
DISASSEMBLY AND ASSEMBLY PRESSURE COMPENSATION VALVE
ASSEMBLY OF PRESSURE COMPENSATION VALVE ASSEMBLY
Pressure compensation valves

A: For bucket CURL/DUMP, boom Lower, arm IN.
C: For swing LEFT/RIGHT
D: For arm OUT, boom RAISE
B: For travel

engine oil.
. Assembly of pressure compensation valve

B
1. Install O-rings (17) and (20), and seals (19) and
(18) to sleeve (12).
2. Fit seals (16) and (15) to piston (13), then as-

semble spring (14) and install to sleeve (12).
. Assembly of pressure compensation valves

A,C,D
1. Install O-rings (8) and (1 I), and seals (10) and
(9) to sleeve (1).
2. Fit seals (7) and (6) to piston (2), then assemble

ball (5), plug (4), and spring (3), and insall to
sleeve (1).
30-49
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY
202FO6646
1. Remove ring (l), then remove valve (2) and

spring (3).
2. Loosen nut (4) and remove plug (5), then re-

move O-ring (6) and nut (4) from plug (5).
3. Loosen nut (7) and remove holder (8), then re-

move retainer (9), O-ring (IO), and nut (7) from
holder (8).
4. Remove spring (12) and poppet (13) from

sleeve (1 I), then remove sleeve (14) and seat
(15).
5. Remove ring (16) and O-ring (17) from seat

(15).
6. Remove O-ring (18), seal (19), and O-ring (20)

from sleeve (11).

in valve (2), holder (8), retainer (9), sleeve (14),
seat (15), ring (16), O-ring (17), or sleeve (1 l),
replace the whole main relief valve assembly.
30-50
DISASSEMBLY AND ASSEMBLY MAIN RELIEF VALVE
ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY
202FO6645
. Before assembling coat the sliding surface with sm Nut: 58.8f4.9 Nm (6f0.5 kgm)
engine oil.
8. Tighten nut (4) to specified torque.
1. Install O-ring (17) and ring (16) to seat (15), and
assemble sleeve (11). cm Nut: 44.1f4.9 Nm (4.5f0.5 kgm)
2. Assemble sleeve (14) to sleeve (11). * After installing to the control valve assembly,
adjust the pressure.
3. Install nut (7) and O-ring (10) to holder (8), then For details, see TESTING AND ADJUST-
assemble retainer (9), poppet (13), and spring ING, Testing and adjusting oil pressure of
(12), and install to sleeve (11). work equipment, swing, travel circuits.
* Set contact surface of seat (15) and poppet
(13) in position securely.
4. Assemble nut (4) and O-ring (6) to plug (5), and

install to holder (8).
5. Assemble spring (3) and valve (2) to sleeve

(1 I), and install ring (1).
6. Install O-rings (20) and (18), and seal (19) to

sleeve (11).
7. Tighten nut (7) to specified torque.
30-5 1
DISASSEMBLY AND ASSEMBLY LS CONTROL EPC VALVE
REMOVAL OF LS CONTROL EPC

VALVE ASSEMBLY
1. Remove cover.
2. Disconnect wiring connector (1).
3. Disconnect hose (2).
4. Remove LS control EPC valve assembly (3). m
INSTALLATION OF LS CONTROL
EPC VALVE ASSEMBLY
m
CT7 LS control EPC valve mounting bolt:

11.3f1.5 Nm(l.15f0.15 kgm)
30-52
DISASSEMBLY AND ASSEMBLY SOLENOID VALVE
REMOVAL OF SOLENOID VALVE

ASSEMBLY
a
1.
Disconnect the cable from the negative
the battery.
Open R.H. side cover.

(-) terminal of
1.
1.5 Remove
2. Remove
PPC pumpless
valve bracket
valve
(1).
El Kw13OP6135
3. Remove 5 solenoid wiring connectors (2) from clip,

then disconnect.
+ Mark the male and female ends of each connec-
tor with tags to prevent mistakes when connect-
ing.
4. Disconnect 9 hoses (3).

+ Fit tags on the hoses.
5. Remove mounting bolts, then remove solenoid valve

assembly (4).
. When removing solenoid valve as an individual part

Remove mounting nut (5), then remove solenoid
valve (6). m
INSTALLATION OF SOLENOID
VALVE ASSEMBLY
m
cm Mounting nut (5):

4.9f0.98 Nm (0.5fO.l kgm)
CiGGTj Solenoid valve (6) (individual part):

39.2f9.8 Nm (4fl kgm)
202FO6628
30-53
DISASSEMBLY AND ASSEMBLY PPC SHUTTLE VALVE
REMOVAL OF PPC SHUTTLE

VALVE ASSEMBLY
tank.
1 Disconnect the cable from the negative (-) terminal of
the battery.
+ Make match marks at the male and female ends
of the oil pressure switch connectors.
+ Before disconnecting any hoses, check the
distinguishing tape stuck to the hose, or make
match marks.
I I
1. Disconnect 8 oil pressure switch connectors (1).
2. Disconnect PPC hoses (2). m
2.5 Remove hoses from additional block. BEHIND

CAB
2 3
3. Disconnect control valve hoses (3) (quick joint

connection). m
3.5 Remove epc valve hose connection.
4. Disconnect hoses from EPC valve/clamshell 50.1

valve block.
30-54
5. Disconnect clamp (5).
6. Remove mounting bolts, then remove PPC shuttle

valve assembly (6).
INSTALLATION OF PPC
SHUTTLE VALVE ASSEMBLY
m
. Check that the quick joint does not come out when
the hose is pulled.

30-55
DISASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY
1. Disconnection of valve
Remove mounting bolts (I), and disconnect shuttle
valve assembly (2), EPCklamshell sol. valve and
plate (4).
2. Disassembly of shuttle valve assembly

1) Remove 8 oil pressure switches (5).
2) Remove 2 slow return valves (6).
3) Remove shuttle valve (7).
4) Remove plugs (8), then remove balls (9).
+ There are 6 plugs and 6 balls.
30-56
ASSEMBLY OF PPC SHUTTLE VALVE ASSEMBLY
2. Assembly of shuttle valve assembly 3. Connection of valve

1) Fit O-ring and assemble balls (9), then in- Fit O-ring and assemble shuttle valve as-
stall plugs (8). sembly (2), travel junction valve assembly
* T$?? ayPfju;lugs and 6 balls. (3) and plate (4), then tighten mounting
bolts (1).
34.3 f 4.9 Nm (3.5 f 0.5 kgm) cm Mounting bolt:
2) Fit O-ring and install shuttle valve (7). 66.19f7.35 Nm (6.75f0.75 kgm)
* If the shuttle valve has been disas-
sembled, be careful of the direction of
installation of the poppet when as-
sembling.
3) Fit O-ring and install 2 slow return valves
(6).
+ If the slow return valve has been dis-
assembled, be careful of the direction
of installation of the poppet when as-
sembling.
4) Install 8 oil pressure switches (5).
30-57
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT l SWING PPC VALVE
REMOVAL OF WORK
EQUIPMENT l SWING PPC
VALVE ASSEMBLY
and stop the engine.‘Then loosen the-oil filler-cap
solwly to release the pressure inside the hydraulic
tank.
Remove boot (1) from cover, raise boot, then remove

lever (2).
Remove mounting bolts.
Disconnect wiring connector (3).

3
Disconnect hoses (4) + (5) x 6 + remove valve ass’y. -.

;-.
\
+ Mark the connecting position of the hoses before
disconnecting. L
INSTALLATION OF WORK
EQUIPMENT l SWING PPC
VALVE ASSEMBLY
m
cm Hose mounting joint bolt:
29.4f4.9 Nm (3.0f0.5 kgm)
m
m Hose mounting joint bolt:

39.2f4.9 Nm (4.0f0.5 kgm)
+ If there is excessive play in the control levers,

adjust the PPC valve. for details, see TESTING
AND ADJUSTING, Adjusting PPC valve.
30-58
DISASSEMBLY AND ASSEMBLY TRAVEL PPC PEDAL
REMOVAL OF TRAVEL PPC

PEDAL ASSEMBLY
g Lower the work equipment completely to the ground
and stop the engine. Loosen the oil filter cap slowly to
release the pressure inside the hydraulic tank. Then
set the safety lock lever to the LOCK position.
1. Remove floor mat.
2. Remove under cover (Front).
screws (1) m
3. Remove
4. Disconnect 3 PPC hoses (2), and remove travel PPC

valve assembly (3). m
INSTALLATION OF TRAVEL PPC

PEDAL ASSEMBLY
m
sm Valve mounting bolt:

9.8fl.96 Nm (1 .Of0.2 kgm)
m
cm Hose mounting joint bolt

(width across flats: 22 mm) :
29.4k4.9 Nm (3.0_+0.5 kgm)
30-59
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

ASSEMBLY
a Extend the arm and bucket fully, lower the work
equipment completely to the ground, and put the
safety lock lever in the LOCK position.
1. Disconnect grease hose (1).
2. Sling boom cylinder assembly (2), and remove lock

bolt (3). m 205FO6632
3. Remove plate, then remove head pin (4). m

+ There are shims installed, so check the number
and thickness, and keep in a safe place.
4. Start engine, and retract piston rod, then tie piston

rod with wire to prevent it from coming out.
+ Set stand @ under the cylinder assembly, and
adjust the positon for slinging.
a Release the remaining pressure in the
hydraulic circuit. For details, see TESTING
AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit.
5. Disconnect hoses (5).

5.5 Disconnect safety valve hoses
6. Remove plate, then using forcing screws 0, remove

bottom pin (6), and remove boom cylinder assembly
(2). m
* There are shims installed, so check the number
Boom cylinder assembly 135 kg
202055 I201
30-60
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
m
+ When tightening the locknut, tighten so that the
clearance between the plate and nut is 0.5 - 1.5
mm.
0.5-1,5mm
ZOSFWSS
&& Inside surface of bushing when assembling
pin: Anti-friction compound (LM-P)
a Greasing after assembling pin:

Grease (LM-G) II II Mar. 1 mm
a When aligning the position of the pin hole,

never insert your fingers in the pin hole.
* Adjust the shim thickness so that the clearance
between cylinder rod (7) and plate (8) is below 1
mm.
* Standard shim thickness: 0.5 mm, 1 .O mm
m
F20505401

Grease (LM-G)
between cylinder bottom (9) and bracket (10) is
below 1 mm.
+ Standard shim thickness: 0.8 mm, 1.5 mm

Run the engine to circulate the oil through the F20!%402
Bleeding air
+ Bleed the air from the cylinder. For details, see
TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinder.
30-6 1
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
REMOVAL OF ARM CYLINDER

ASSEMBLY
a Extend the arm cylinder piston rod approx. 200 mm,
lower the work equipment completely to the ground,
then set the remaining safety lock lever to the LOCK
position.
1. Set block @) between arm cylinder and boom.

F20505334

a Release the remaining pressure in the hydraulic
crrcurt. For details, see TESTING AND ADJUST-
ING, Releasing remaining pressure in hydraulic
circuit.
4. Disconnect hoses (2).

4.5 Disconnect safety valve hoses (if applicable)
5. Disconnect grease hose (3).
6. Raise arm cylinder assembly, remove plate, remove

bottom pin (4), then remove arm cylinder assembly
m
(5).
Arm cylinder assembly 200 kg
30-62
DISASSEMBLY AND ASSEMBLY ARM CYLINDER
INSTALLATION OF ARM
CYLINDER ASSEMBLY
m
a Inside surface of bushing when assembling

Grease (LM-G) F20505403
m
ArL3. lnsrde surface of bushing when assembling


Grease (LM-G)
+ Adjust the shim thickness so that the clearance
below 1 mm.
* Standard shim thickness: 0.8 mm, 1.5 mm

Bleeding air
* Bleed the air from the cylinder. For details, see
hydraulic cylinder.
30-63
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
a Extend the bucket cylinder piston rod approx. 200
mm, lower the work equipment completely to the
ground, then set the safety lock lever to the LOCK
position.
1. Set block @) under arm top.

2. Set block @ between link and arm, and block @ UJ
202FO6572
between bucket cylinder and arm.
3. Remove lock bolt (1). m
+ There are shims installed, so check the number
a Release the remaining pressure in the hydraulic
crrcurt. For details, see TESTING AND ADJUST-
ING, Releasing remaining pressure in hydraulic
circuit.
6. Disconnect 2 hoses (3).
7. Raise bucket cylinder assembly, remove plate,
remove bottom pin (4), then remove bucket cylinder
assembly (5). m
202F ‘355 73
& kg Bucket cylinder assembly: 130 kg
30-64
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
m
mm.
m
2OSF6065
& Inside surface of bushing when assembling

a Grease after assembling pin: Grease (LM-G)

g When aligning the position of the pin hole,
m between link (6) and link (7) is below 1 mm.
Inside surface of bushing when assembling

I
205FO6633
i
-Grease after assembling pin: Grease (LM-G)

g
below 1 mm. \
0
Bleeding air
F20505
L
hydraulic cylinder.
30-65
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Piston rod assembly
1) Remove piping from cylinder assembly.
2) Remove mounting bolts, and disconnect head
assembly (1).
3) Pull out piston rod assembly (2).
+ Place a container to catch the oil under the
cylinder.
202FO548 I
4) Disassemble piston rod assembly as follows.

0 Set piston rod assembly (2) in tool 01.
ii) Using tool 02, remove nut (3).
+ Width across flats of nut
Unit: mm
M--r 1BJ:, 1 Arm 1Bucket
PWI 70-6 1 75 1 85 1 75
iii) Remove piston assembly (4).

iv) Remove plunger (5). I 1
202FO5482
. Boom and arm cylinder only
v) Remove collar (6).
. Boom and arm cylinder only
vi) Remove head assembly (7).
vii) Remove cap (8), and pull out 12 balls (g),

then remove plunger (10)
. Arm cylinder only
205FCO5162
202F0550 I -K
30-66
2. Disasssembly of piston assembly

1) Remove rings (11).
2) Remove wear rings (12).
3) Remove piston ring (13).
I 202FO5485
3. Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (14).
19
2) Remove snap ring (15), then remove dust seal 14
(16).
3) Remove rod packing (17).
19
4) Remove buffer ring (18). 16
5) Remove bushing (19).
17
202F05486
30-67
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
* Be careful not to damage the packings, dust seals,
and O-rings.
* Do not try to force the backup ring into position.
Warm it in warm water (50 - 60°C) before fitting it.
1. Assembly of cylinder head assembly

1) Using tool 05, press fit bushing (19).
tOSF06634 205FO6635
2) Assemble buffer ring (18).
3) Assemble rod packing (17).
4) Using tool 06, install dust seal (16), and secure
with snap ring (15).
5) Install backup ring and O-ring (14).
202FO5486
2. Assembly of piston assembly

1) Using tool 03, expand piston ring (13).
* Set the piston ring on the tool 03, and turn
t
the handle 8 - 10 times to compress the
ring.
2) Set tool 04 in position, and retract piston ring
(13).
202F05487D 202FOS467C
3) Assemble wear ring (12).

4) Assemble ring (11).
+ Be careful not to open the end gap of the
ring too wide.
Ring groove: Grease (G2-LI)
202FO5485
L
30-68
3. Piston rod assembly 1

1) Set plunger (10) to piston rod, and assemble 12
balls (9), then secure with cap (8).
* Check that there is a slight play at the tip of
the plunger.
. Arm cylinder only
2) Assemble head assembly (7).

3) Fit O-ring and backup ring, and assemble collar
(6).
Boom and arm cylinder only
4) hssemble plunger (5).
Boom and arm cylinder only
5) hssemble piston assembly (4).
205FCO5162
6) Set piston rod assembly (2) to tool 01.

7) Using tool 02, tighten nut (3).
&&Nut: Thread tightener (LT-2)
c= Nut:
Unit: kNm (kgm)
202FO5462
8) Assemble pison rod assembly (2).
a Seal: Grease (G2-LI)

* Set the end gap of the ring at the horizontal
(side) position, align the center of shaft and
cylinder tube, then insert.
* After inserting, check that the ring is not
broken and has not come out, then push in End gap in ring
fully.
202FO5469
30-69
9) Tighten head assembly (1) with mounting bolts.
m Mounting bolt:
Cylinder Tightening torque
Boom
Arm 330flO Nm (33.7fl .O kgm)
Bucket
IO) Install piping.

w 202FO548
30-70
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
A Extend the arm and the bucket fully and lower the
work equipment completely to the ground, then
operate the control levers 2 to 3 times.
1. Remove lock bolt (1). (See F) m
2. Remove pin (2). (See Fl) m

+ Sling the boom cylinder assembly and remove 202FO54SO
the pin.
Start the engine and retract the boom

cylinder rod, then tie the rod with wire to
prevent it from coming out, and lower it onto
the block.
+ Disconnect the boom cylinder on the opposite

side in the same way.
lALL Release the remaining pressure in the

? circuit. For details, see TESTING AND
ADJUSTING, Releasing pressure in hydrau-
lic circuit for machines with PPC valve.
3. Disconnect hoses (3). (See F2)
4. Disconnect wiring (4). (See F2)
5. Remove pin (5). (See F3)

* Sling work equipment assembly (6), then using
tool H, remove the pin.
6. Remove work equipment assembly (6). (See F4)
600kg
/I 1’
20X05492-1
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
m
mm.
A-
m 0.5-1.5mm
2OSFW65
&I&, Inside surface of bushing when assembling
&& Grease after assembling pin:

Grease (LM-G)
A When aligning the position of the pin hole,
between cylinder rod (10) and plate (11) is
below 1 mm.
m
a Inside surface of bushing when assembling

a Grease after assembling pin:

Grease (LM-G)
A When aligning the position of the pin hole,
between boom (12) and bracket (13) is below 1
mm.
* Standard shim thickness: 0.5 mm. 1 .O mm

Run the engine to circulate the oil through the Max. 1 mm
system. Then check the oil level again. F20505407
. Bleeding air
hydraulic cylinder.
30-72
A Start the engine, and retract the arm
REMOVAL OF BUCKET
cylrnder rod, then tie the rod with wire to
ASSEMBLY prevent it from coming out.
g Set the back of the bucket facing down, \AdRelease the remaining pressure in the
lower the work equipment completeley to t circuit. For details, see TESTING AND
the ground, and operate the control levers ADJUSTING, Releasing pressure in
2 of 3 times. hydraulic circuit for machines with PPC
1. Remove lock bolt (1). (See Fl) m valve.
2. Remove plate (2). (See Fl) m
3. Remove pin (3). (See Fl) m 4. Disconnect hoses (2). (See F4)
4. Remove lock bolt (4). (See Fl) m
5. Remove pin (5). (See Fl) 5. Remove pin (3). (See F4)
6. Remove bucket assembly (6). (See Fl)
+ Raise the work equipment and disconnect 6. Remove arm assembly (4). (See F4)
the arm from the bucket. * Raise the boom and disconnect the boom
from the arm.
& kg 600 kg
See Weight Table.
INSTALLATION OF BUCKET
INSTALLATION OF ARM
ASSEMBLY
ASSEMBLY
. Carry out installation in the reverse order to
removal. . Carry out installation in the reverse order to
removal.
mm m
+ Tighten with the locknut so that the
clearance between the bucket boss and A When aligning the position of the pin hole,
run the engine at low idling, and align
nut is 0.5 - 1.5mm. (See F2)
m slowly.
+ Adjust the shim thickness so that the Never insert your fingers in the pin hole.
clearance between bucket boss (7) and
spacer (8) is 2mm. (See F3)
. Bleeding air
m * Bleed the air from the cylinder.
+ When aligning the position of the pin hole, For details, see TESTING AND ADJUST-
run the engine at low idling, and align ING, Bleeding air from hydraulic cylinder.
slowly. * After bleeding the air from the cylinder,
Never insert your fingers in the pin hole. check the level of the oil in the hydraulic
tank.
REMOVAL OF ARM
ASSEMBLY
1. Bucket assembly
For details, see REMOVAL OF BUCKET
ASSEMBLY.
2. Set work equipment

+ Secure the bucket cylinder assembly to
the arm, then pull in the arm, and lower it
onto block 0.
3. Remove pin (1). (See F4) m

+ Sling the arm cylinder assembly, and
remove the pin.
30-73
F4 Fl
F20106121 F20106 126
F2
0.5-1.5mm ZOSI
%065A
F3
30-74
REMOVAL OF ARM, BUCKET
ASSEMBLY
Extend the arm and bucket fully, lower the work
equipment completely to the ground, and operate the
control levers 2 or 3 times.

+ Set block @) between the arm and the boom,
then sling the arm cylinder, and remove the pin.
a Start the engine, and retract the arm cylin-

der rod, then tie the rod with wire to prevent
it from coming out.
\B” Release the remaining pressure in the

circuit. For details, see TESTING AND
t
ADJUSTING, releasing pressure in hydrau-
2. Disconnect hose (2). (See F2)

+ Sling the arm and bucket assembly, then remove
the pin.
4. Remove arm and bucket assembly (4).

(See F2)
See Weight Table.
INSTALLATION OF ARM,
BUCKET ASSEMBLY
g When aligning the position of the pin hole, run

the engine at low idling, and align slowly.
Never insert your fingers in the pin hole.
. Bleeding air
* Bleed the air from the cylinder.
Bleeding air from hydraulic cylinder.
* After bleeding the air from the cylinder, check
the level of the oil in the hydraulic tank.
30-75
Fl
I
F20505339
F2
I
F20106128
30-76
Fl
REMOVAL OF BOOM ASSEMBLY
1. Arm and bucket assembly
For details, see REMOVAL OF ARM, BUCKET
ASSEMBLY.
2. Remove lock bolt (1). (See Fl) m

+ Sling the boom cylinder assembly, and remove
the pin.
g Start the engine, and retract the boom

cylinder rod, then tie the rod with wire to
prevent it from coming out, and lower it into F2
the block.
+ Disconnect the boom cylinder assembly on the

opposite side in the same way.
LA/ Release the remaining pressure in the

t circuit. For details, see TESTING AND
ADJUSTING, Releasing pressure in hydrau-
4. Disconnect hose (3). (See Fl)
5. Disconnect wiring (4). (See F2)

F3
* Sling the boom assembly, then use tool H to
remove the pin.
7. Remove boom assembly (6). (See F4)
See Weight Table.
205FO5601
F4
I F20109129
DISASSEMBLY AND ASSEMBLY BOOM
INSTALLATION OF BOOM
ASSEMBLY
m
mm.
I 0.5 - 1.5 mm
2OSFSOSS
& Inside surface of bushing when assembling
/$& Grease after assembling pin:

Grease (LM-G)
between cylinder rod (10) and plate (11) is
below 1 mm.

F20505401
6 Grease after assembling pin:

Grease (LM_G)
between boom (12) and bracket (13) is below 1
mm.
* Standard shim thickness: 0.5 mm, 1 .O mm

* Add oil through the oil filler to the specified level. Run
the engine to circulate the oil through the system. Max. 1 mm
Then check the oil level again. F2OSOS407
. Bleeding air
hydraulic cylinder.
30-78
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
REMOVAL OF OPERATOR’S
CAB ASSEMBLY
a Drsconnect the table from the negative (-) terminal of
the battery.
1. Remove floor mat (1).
3. Remove knob (3).
4. Remove 4 caps (4) and clip (5), then remove middle i632
panel (6).
5. Remove bottom panel (7).

+ The panel is held by a clip, so remove the clip
when removing the panel and be careful not to
damage it.
6. Disconnect washer hose (8).
7. Remove radio (11) if fitted (refer to radio operation

manual).
+ Remove plate (9), then remove cover (10).
8. Lift cover (10) away carefully to locate speaker

harness connector. Disconnect and remove panel
completely.
LL-
202FO6634
9. Remove divider board (13).
10. Remove heater duct of air conditioner ducts (14) and

(15) (if fitted).
11. Disconnect wiring connectors CN-HO1 (16), CN-HO2

(17), CN-HO3 (18), CN-HO4 (19), CN-HO5 (20), CN-
HO6 (21), CN-KOl (22), CN-HO7 CN-HO8 CN-HO9
12. Disconnect heater cables or air conditioner cables

(24) (if fitted).
30-80
13. Remove 11 cab mounting bolts (marked ).

Position of mounting bolts
205FO6662
14. Using eyebolts 0, remove opeator’s cab assembly

(25).
Operator’s cab assembly: 300 kg

* When raising the cab assembly, check that all
the wiring has been disconnected, then lift off
slowly and be careful not to hit any part.
06590
INSTALLATION OF OPERATOR’S
CAB ASSEMBLY
. Carry out installation in the reverse order to removal
30-8 1
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
ASSEMBLY
1. Set lifting hook chains of counterweight assembly in
position, and sling.
2. Remove mounting bolts (2) and (3). m
+ Be careful not to lose the shims when removing.
3. Lift off counterweight (1) horizontally with wire or
chain block.
~-kiFv6..,
11
+ Be careful not to hit the engine, radiator and
cooler assembly. ,A --
& kg Counterweight assembly: 2950 kg
INSTALLATION OF
COUNTERWEIGHT ASSEMBLY
.
m
---r
a
E
In
+I
I
” -
/
l
, Counterweight
-1Of4mm
&& Thread of counterweight mounting bolt:

Thread tightener (LT-2) b-Of5mm
cm Counterweight mounting bolt:
1,720 f 190Nm (175f20kgm) 1 Revolving frame
Ig ZVSFO6667
+ Installing and adjusting counterweight

1) Sling counterweight with crane and set in
position on frame.
2) Use counterweight pusher bolt @ and align
mounting bolts holes. Then install shim and
mounting bolts (2) and (3), and adjust to follow-
ing dimensions.
. Clearance from revolving frame:
10 f 5 mm (left and right)
. Clearance from bodywork door:
lOf5 mm (left and right)
. Stepped difference b from revolving frame
in left-to-right direction:
Max. 5 mm
. Stepped difference a from bodywork door
in left-to-right direction:
lOf4mm
. Stepped difference c from bodywork top
cover in up-down direction:
Max. 5 mm
30-82
DISASSEMBLY AND ASSEMBLY PUMP CONTROLLER
REMOVAL OF GOVERNOR PUMP

CONTROLLER ASSEMBLY
g Disconnect the cable from the negative (-) terminal of
the battery.
1. Remove radio (2) if fitted.
2. Remove plate (l), then remove cover (3).
3. Lift cover (3) away carefully to locate speaker har-

ness connector. Disconnect and remove panel
completely.
4. Remove divider board (5).
5. Remove heater / air conditioner duct (5).
6. Disconnect 3 wiring connectors (6), then remove

governor and pump controller assembly (7).
INSTALLATION OF GOVERNOR,
PUMP CONTROLLER ASSEMBLY
m
. Check the performance of the work equipment,
travel, and swing For details, see TESTING AND
ADJUSTING.
30-83
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
REMOVAL OF MONITOR PANEL

ASSEMBLY
a Disconnect the cable from the negative (-) terminal of
the battery.
1. Remove 4 screws (l), and disconnect monitor panel

assembly (2) from bracket.
2. Disconnect connectors (3), then remove monitor

panel assembly (2). m
INSTALLATION OF MONITOR
PANEL ASSEMBLY
m
. Check the mode setting and display function.
For details, see TESTING, AND ADJUSTING, AND
TROUBLESHOOTING.
30-84
DISASSEMBLY OF SWING MACHINERY ASSEMBLY

3. DISASSEMBLING
Initial inspection of the gears and the hydraulic motor, can

be made without dismantling the slew drive from the ma-
chine.
Mark the
assembly position
a Note
Before starting the gearbox disassembly, it is better to

mark the assembly position of: motor adaptor (pos. 50),
brake housing (pos. 32), toothed rings (pos. 25-18), cover
(pos. 21) and gearbox housing (pos. 7) in order to obtain an
exact reference of position at reassembly.
Unscrew and remove the 2 screws M16x40 (pos. 49),
grade 8.8, and remove the hydraulic motor and the O-ring
(pos. 51).
STEP 1
Unscrew the draining plug Ml 8x1,5 (pos. 9) and its washer
(pos. 8) from the gearbox housing (pos. 7) and drain the oil
from the gearbox.
30-86
DISASSEMBLING
STEP 2
Remove the extentions (pos. IO), the elbow (pos. 11) and
the washer (pos. 8) from the gearbox housing (pos. 7).
STEP 3
Unscrew the plug G1/4 (pos. 47) from the motor adaptor
(pos. 50)
STEP 4
Unscrew the elbow (pos. 46) from the motor adaptor (pos.
50).
30-87
DISASSEMBLING
STEP 5
Unscrew the dipstick for oil filling and level kit (pos. 52).
STEP 6
Unscrew the 8 socket head screws MlOx30 (pos. 48)
grade 8.8, fixing the motor adaptor (pos. 50) to the brake
housing (pos. 32).
STEP 7
Remove the 8 socket head screws (pos. 48), the bracket of
oil filling and level kit (pos. 52) and remove the motor adap-
tor (~0s. 50).
30-88
DISASSEMBLING
STEP 8
Remove the O-ring (pos. 44) from its seat in the motor
adaptor (pos. 50).
STEP 9
Unscrew the 11 socket head screws Ml 0x70 (pos. 33)
grade 8.8 and remove the brake assembly.
STEP 10
Overturn the brake assembly and remove the O-ring (pos.
24) from its seat in the break housing (pos. 33).
30-89
DISASSEMBLING
STEP 11
Remove the brake shaft (pos. 35).
STEP 12
Remove the toothed ring (pos. 25).
STEP 13
Remove the 1st stage sun gear (pos. 27).
30-90
DISASSEMBLING
STEP 14
Remove th 1st reduction assembly (pos. 26).
STEP 15
Remove the O-ring (pos. 24) from its seat in the cover (pos.
21).
STEP 16
Using pliers remove the elbow and the extension of the oil
filling and level kit (pos. 52) from the cover (pos. 21) and all
plugs and washers present in the gearbox too.
30-9 1
DISASSEMBLING
STEP 17
Unscrew the 4 socket head screws MlZx80 (pos
grade 12.9, and the 12 socket head screws M12x90
23), grade 12.9, and remove the cover (pos. 21).
STEP 18
Remove the O-ring (pos. 12) from its seat in the end (:over
(pos. 21).
STEP 19
Remove the 2nd stage sun gear (pos. 19).
30-92
DISASSEMBLING
STEP 20
Remove the 2nd reduction assembly (pos. 17).
STEP 21
Remove the toothed ring (pos. 18).
STEP 22
Remove the O-ring (pc3s. 12) from its seaIt in the g earbox
housing (pos. 7).
30-93
a Note
In order to proceed with the slew drive disassembling, it is

now necessary to remove it from the machine and bring it
to a orooerlv eauiooed workshoo. -
STEP 23
By means of a punch, remove the caulking in the edge of
the nut (pos. 15).
STEP 24
Using the tool AT709CO6, unscrew the nut M75x2 (pos.
15).
30-94
DISASSEMBLING
STEP 25
Overturn the output assembly (pos. 16), unscrew and re-
move the 8 socket head screws M8x20 (pos. 4), grade 8.8,
from the front cover (pos. 5)
STEP 26
Place the gearbox housing (pos. 7) on three spacers and
through a press push on the pinion shaft (pos. 1) and re-
move it from the gearbox housing (pos. 7).
STEP 27
Place the pinion shaft (pos. l), front cover (pos. 5) and
bearing (pos. 6) group on a spacer.
Through a press push on the pinion shaft (pos. 1) and ex-
tract the bearing (pos. 6).
30-95
DISASSEMBLING
STEP 28
Remove the front cover (pos. 5).
STEP 29
Use a screwdriver to remove the ringseals (pos. 3) from
their grove in the front cover (pos. 5)
STEP 30
Use a rubber hammer a metal stopper to remove the bear-
ing (pos. 14) from the the gearbox housing (pos. 7).
30-96
DISASSEMBLING
STEP 31
Use a rubber hammer a metal stopper to remove the seal
ring (pos. 13). from the the gearbox housing (pos. 7).
A Important
Disassemble the seal ring only in case it has to be re-

placed.
STEP 32
Through a press and a metal stopper, push on the spring
retainer (pos. 42), thus removing the force of the springs
/;os. 41) on the circlip (pos. 43) and through pliers remove
STEP 33
Remove the springs retainer (pos. 42).
30-97
DISASSEMBLING
STEP 34
Remove the springs (pos. 41) from their groves in the
brake piston (pos. 40).
STEP 35
Remove the brake piston (pos. 40).
To get it easier, pumping compressed air into the brake
port hole (max. 0,2 bar), taking care the piston (pos. 40)
doesn’t jump out the brake housing (pos. 32).
STEP 36
Remove the 1 st O-rings (pos. 34) from its seat in the brake
housing (pos. 32).
30-98
DISASSEMBLING
STEP 37
Remove spacer (pos. 38) and remove the 2nd O-rings
(pos. 34) from its grove in the brake housing (pas. 32).
STEP 38
Remove the O-ring 39) from its seat in the spacer
(pos. 38).
STEP 39
Remove brake discs pack (pos. 36-37).
30-99
DISASSEMBLING
STEP 40
Through pliers remove the circlip (pos. 29) from its grove in
the brake housing (pos. 32).
STEP 41
Remove the discs retainer (pos. 30)
a Note
The gearbox disassembling ends with the above operation:
all items are now available for the necessary inspections.
30-I 00
4. ASSEMBLY
4.1 IMPORTANT NOTES BEFORE THE AS-

SEMBLING
When proceeding with the gearbox reassebly, it is neces-
sary to follow up the rules listed below:
a) In case of damaged gears, for example a planet, do

not replace the single gear, but the whole reduc-
tion stage.
b) Always replace the O-rings of the item to be reas-
sembled after having carefully cleaned the seats and
having butterd some grease on the groves themselves
and on the O-rings to make easier the reassembly.
STEP 42
Place correctly the spacer (pos. 2) on th pinion shaft (pos.
1).
STEP 43
Through a press and a metal stopper push the spacer
(pos. 2) against the shoulder on the pinion shaft (pos. 1)
until1 assembling is complete.
30-I 01
ASSEMBLING
STEP 44
Mount the seal ring (pos. 3) into its grove in the front cover
(pos. 5).
STEP 45
Mount the front cover (pos. 5) on the pinion shaft (pos. 1).
STEP 46
Apply on the bearing (pos. 6) a coat of grease type NGLI 2
with EP characteristics.
30-I 02
ASSEMBLING
STEP 47
Place the bearing (pos. 6) on the pinion shaft (pos. 1).
Through a press and a metal stopper, push the bearing
(pos. 6) against the spacer shoulder (pos. 2).
STEP 48
Pace the seal ring (pos. 13) inside the gearbox housing
(pos. 7).
STEP 49
Through a press and the proper metal stopper AT709C14,
push the seal ring (pos. 13) against the shoulder on the
gearbox housing (pos. 7).
30-I 03
ASSEMBLING
STEP 50
Overturn the gearbox housing (pos. 7) and fill with grease
type NGLI 2 with EP characteristics the upper chamber
placed between the seal ring (pos. 13) and the bearing
(pos. 6).
STEP 51
Place the pinion shaft (pos. 1) -spacer (pos. 2) -front cover
(pos. 5) -bearing (pos. 6) group in the gearbox housing
(pos. 7).
STEP 52
Usa a press and a proper metal stopper to push the pinion
shaft (pos. 1) against the shoulder on the gearbox housing
(pos. 7 until assembling of the unit is complete.
30-I 04
ASSEMBLING
STEP 53
Tighten the 6 socket head screws M8x20 (pos. 4), grade
8.8, by a torque wrench at a torque of 2,5 daNm.
STEP 54
Overturn the gearbox (pos. 7) and place inside it the bear-
ing (~0s. 14).
STEP 55
Use a press and the metal stopper to push the bearing
(pos. 14) against the shoulder in the gearbox housing (pos.
7).
30-I 05
ASSEMBLING
STEP 56
Place a new ring nut (pos. 15) on the pinion shaft (pos. 1).
Never use the nut disassembled because already de-
formed.
STEP 57
Use the tool AT709CO6 to tighten the ring nut M75x2 (pos.
15), by a torque wrech, at a torque of 11 O-l 20 daNm.
STEP 58
Caulk the ring nut (pos. 13) next to 3 spaces placed at 120”
of the pinion shaft spline (pos. 1).
30-106
STEP 60
Assemble the 2nd reduction assembly (pos. 17).
STEP 61
Insert the 2nd stage sun gear (pos. 19).
30-I 07
ASSEMBLING
STEP 62
Assemble the toothed ring (pos. 18).
STEP 63
Apply in the O-ring’s seat in the cover (pos. 21) a coat of
grease.
Mount the 2nd O-ring (pos. 12).
STEP 64
Place the cover (pos. 21) on the toothed ring (pos. 18) and
fix it through 4 socket head screws M12x80 (pos. 22),
grade 8.8, and through 12 socket head screws M12x90
(pos. 23), grade 8.8, tightened by a torque wrench at 12
daNm torque.
30-108
DISASSEMBLING
STEP 65
Apply in the O-ring’s seat in the cove!r (P OS. 17) a coat of
grease.
Mount the 1st O-ring (pos. 2 4).
STEP 66
Assemble the 1st reduction assembly (pos. 26).
STEP 67
Insert the 1st stage sun gear (pos. 27).
30- 109
ASSEMBLING
STEP 68
Assemble the toothed ring (pos. 25).
STEP 69
Apply in the internal seal’s groves of the brake housing
(pos. 32) a coat of grease, and insert the O-rings (pos. 34).
STEP 70
Apply in the inside surface of the spacer (pos. 38) a coat of
grease.
Fit the O-ring (pos. 39) into its seat in the spacer (pos. 38).
30-I IO
ASSEMBLING
STEP 71
Assemble corectly the spacer (pos. 38) to the brake piston
(pos. 40), paying attention not to damage the O-ring (pos.
39) already fitted.
STEP 72
Insert the brake piston-spacer group (pos. 40-38) inside
the brake housing (pos. 32), paying attention not to dam-
age the seals already fitted.
STEP 73
Insert the springs (pos. 41) into the holes in the brake pis-
ton (pos. 40), according the picture arangement.
30-I 11
ASSEMBLING
STEP 74
Insert the springs retainer (pos. 42).
STEP 75
Through a press and a metal stopper, push on the springs
retainer (pos. 42), in lowering it in order to permit the as-
sembly of the circlip (pos. 43) in its grove in the brake hous-
ing (pos. 32).
STEP 76
Overturn the brake housing (pos. 32) and assemble the
brake discs package according to the following order:
firstly insert an external toothed sintered bronze disc (pos.
37).
30-I 12
ASSEMBLING
STEP 77
Then insert, an internal toothed steel disc (pos. 36).
Repete the operation until1 reaching the number of 6
sintered bronze and 5 stell discs.
STEP 78
Assemble the brake shaft (pos. 35) and insert oil at a pres-
sure of 20 bar from the brake pilot port (see installation
drawing ref. 4) in order to permit the assembling of the last
sintered bronze disc (pos. 37) and the discs retainer (pos.
30).
STEP 79
Assemble correctly the discs retainer (pos. 30) in the brake
housing (pos. 32).
30-I 13
ASSEMBLING
STEP 80
Through pliers, assemble the circlip (pos. 29) into its grove.
Then remove the compressed air from the brake assembly
and dismount the brake shaft (pos. 35).
STEP 81
Apply in the O-ring’s seat in the brake housing (pos. 32) a
coat of grease.
Mount the 2nd O-ring (pos. 24).
STEP 82
Assemble the brake shaft (pos. 35).
30-I 14
SWING MACHINERY
ASSEMBLING
STEP 83
Assemble the brake assembly.
STEP 84
Tighten the 11 socket head screws MlOx70 (pos. 33),
grade 8.8, by a torque wrench at 5 daNm torque.
Sl-EP 85
Mclunt the O-ring (pas. 44) ilnto its seaIt in the mo ltor flan
ge
(PI3s. 50).
30-115
ASSEMBLING
STEP 86
Place the motor flange (pos. 50) on the brake housing (pos.
32) and insert the 8 socket head screws Ml 0x30 (pos. 48)
grade 8.8.
Contemporary assemble the flask of the filling and oil level
kit (pos. 52).
STEP 87
Tighten the 8 socket head screws Ml 0x30 (pos. 48), grade
8.8, by a torque wrench at 5 daNm torque.
STEP 88
Using pliers, screw the washer (pos. 8), the elbow and the
extension of the filling and oil level kit (pos. 52) in the cover
(pos. 21).
30416
ASSEMBLING
STEP 89
Mount and tighten the dipstick of the filling and oil level kit
(pos. 52).
STEP 90
Insert and screw all plugs M18x1,5 (pos. 9) and washers
(pos. 8) in the gearbox.
STEP 91
Assemble the angle (pos. 46) in the motor flange (pos. 50).
30-I 17
ASSEMBLING
STEP 92
Assemble the breather plug G l/4 (pos. 47).
STEP 93
Asemble the extensions (pos. lo), the angle (pos. 11) and
the washer (pos. 8) in the gea rbox housing (:pos. 7‘).
STEP 94
Assemble the plug Ml 8x1,5 (pos. 9).
30-118
ASSEMBLING
STEP 95
A Important
After mounting the hydraulic motor, verify, through a depth
slide gauge, the axial dimension of the gearbox measured
by input side of the motor adaptor (pos. 50) to the brake
shaft (pos. 35).
Axial dimension = 93-945 mm.
STEP 96
After having reassebled the gearbox, fit the hydraulic motor
(taking care to include the O-ring pos. 51), throurgh 2 fixing
screws M16x40 (pos. 49), grade 8.8 tightened at a torque
of 21,5 daNm. Fill the gearbox with the lubricant oil as
shown in section 4.2.
30-I 19
5. BRAKE CHECK
In order to verify the correct assembly of the brake group, it

is necessary to carry out a test of the seal rings. Connect
the brake port to a pump and release the brake by pumping
oil. By means of a pressure gauge verify that the pressure
does not decrease (see dwg. 6). In Otherwise case, the
seal rings of the brake leak oil and it is necessary to disas-
sembly the brake and provide for their replacement.
Test data: Test duration = 3 minutes.
Oil Mot tx-essure
\
i
_--
/ 0 100
I:
-\..
~ -1
Dwg. - Correct brake assembly, chec
30-120
SWING MACHINERY
(SPECIALTOOLS FOR SWING MACHINERY)
+ CHANFER 2x45’
I
R 5 iu
I
-
_.
_-------I
D 7
I
I
----_-
I
1
CHANi=ER 1x45’
I- i
12.5
d
30-121
(SPECIAL TOOLS FOR SWING MACHINERY)
Detail ‘*A ” scale 2: I
10 H7+;.0’5 (1”) 025.4 +O.’

02
I
1_
r 1 \\
- L-_J Nos 4 PINS MA T. 40CrMo4 HARDENED AND TEMPERED
30-I 22
DISASSEMBLY AND ASSEMBLY TRANSMISSION
Oil drain
TRANSMISSION Before intervening on transfer box you have to drain
oil (refer to page A)
DISASSEMBLING, SETTING OP-
ERATIONS AND REASSEMBLING Warning: The exhaust oil disposal must be car-
ried out according to the laws in force.
FOREWARD Removal and installation of the box
Oil seals for rotating shafts

Disconnect the controlling brakes pipings, then in-
stall a protection plug.
For correct installation of oil seals adhere to the fol-
lowing recommendations:
Loose all the remaining connections, then separate
the transfer box from the vehicle structure.
Before installation soak the seal for half an hour
in the same oil that will be used in the transfer
Installing the transfer box reverse the order; check
box to be sealed.
for eventual leakages of oil.
Clean the shaft and ensure the seal area of the Check the oil level and, if necessary, re-fill.
same is not damaged, fitted or grooved.
Carry out the braking system bleeding.
Place the sealing lips towards the oil side.
Lubricate the seal lip (oil is better than grease)

and fill with grease the space between oil lip and
dust lip dual lip seals.
lnstal the oil seal using a suitable seal driver.

Avoid hammering directly on the seal.
To avoid damages to the seal lip caused by the

shaft: adequatly protect the same during shaft
assembly procedure.
O-ring
Ensure adequate lubrication of these seals before
inserting them in their seats to avoid twisting during
shaft assembly.
Shims
For each adjustment select the correct shims by indi-
vidual measurements. Do not trust pack measure-
ments or the thickness indicated on the shim.
Bearings
For a correct assembly it is suggested to warm them
in a furnace from 80C to 9OC before installation in
their respective shafts or to cool them before insert-
ing in their respective seats woth outer housing.
Sealing
Use LOCTITE 510 or types following the
sepcifications. Ensure that both sides to be sealed
are clean, dry and totally free from grease and oil.
30- 123
EMERGENCY BRAKE
(Refer to page 30-49)
. Unscrew the screw(l), remove the washer (2) and the

flange (3).
. Unscrew the screws (7) and remove the brake cylidner
(8).
. Keep the brake piston (20) and the seal rings (16-17-
18-l 9); replace if necessary.
. Keep the three trust pins (6) and the O-rings; replace if
necessary
. Do not operate on the screws (5) and the nuts (4), but
only in the event of brake release manual intervention.
In this case carry out theadjustment setting the screws
in touch with the pins (6), then unscrew 1 turn and lock
with the counternut (4).
. Check the disks (10) are not disorted or scorched; if

necessary, replace them.
. Check the friction disks thickness (11) is not lower

than the one specified; if necessary, replace them.
. Check the groove condition on output shaft and on

brake sleeve (12).
. Check the brake drum (13) and the reaction plate (14)
are not worn out.
. Check the O-ring condition (9); replace, if necessary.

Lubricate and use a suitable driver to avoid any dam-
age during assembly.
. Check the Bellaville spring conditions (15).
SPECIAL TOOLS
. Driver for oil seal (9): ref. 119038
. Interchangeable handle: ref. 119033
30-I 24
7
6
6
Kw130P6101
30-125
GEAR AND CONTROL BOX

(Refer to page 30-51)
. Remove the emergency brake group as shown previ-

ously.
. Unscrew the screw (l), remove the washer (2), the

thickness (3) and the flange (4).
. Unscrew the screws (20) and remove the cover (21).
. Check the seal ring condition (16); replace, if neces-

sary. Lubricate and use a suitable coupling tool to
avoid any damage during the assembly.
. Extract output shaft (5) and recover the washers (22).
. Unscrew the lever locking screw (7).
. Set the lever to “DISENGAGED’ in order to reach the

fork locking screw (6).
. Unscrew the screw (6) and extract the fork control le-
ver (8).
. Remove the stop ring (13), then axtract the fork (g),
shaft (15) and sleeve (11) group.
. Separate this group and check pad and sleeve groove

wear; replace, if necessary.
. Replace O-rings (17), (18) and (19).
. In the event of gears (14) and (23) replacement, un-

screw the screws (12) and separate the half-housing.
At re-assembly, clean and degrease the union sur-
faces of the half-housing and use Loctite 510.
. Check for bearing condition and replace, if necessary.
. Check oil drain condition, clean and replace, if neces-

sary.
30-I 26
9-
10-
ll-, 1
15\- (i
Kw13OP6102
30-127
FLANGE POSITIONING
The motion output flange for forward axle (1) must be

mounted by using some adjustment thickness (2) be-
tween washer (3) and shaft (4) in order to assure a
right assembly.
Detect with a gauge the dimension (S) of the thickness

to use.
Insert the previously defined thickness and clamp the

screw (5) with 139 Nm torque.
TIGHTENING TORQUES
(Refer to page 53)
Thread 1 Nm
Screw-fork to shaft 32
Screw-output flanges M 12x25 139
Brake release nut-screw M 10x20 50
Front cover-screw M 10x90 50
Rear cover-screw M 10x30 50
Fork control screw-lever M 10x20 50
Half-housing fastening screw M 10x65 50
Breather Ml0 10
Oil drain, filling and level plug M22 60
Kw13OP6103
30-I 28
_-_ __
KW13OP6104
30-I 29
DISASSEMBLY AND ASSEMBLY FRONT AXLE
Sealing compound
FRONT AXLE Use LOCTITE 510 or types following the specifica-
tions. Ensure that both sides to be sealed are clean,
DISASSEMBLING, SETTING OP- dry and totally free from grease and oil.
ERATIONS AND REASSEMBLING
Disassembling - Reassembling
The overhauling of epicycloidal group and wheel
FOREWARD hubs can be completed without removing the axle
from the vehicle.
Oil seals for rotating shafts
For correct installation of oil seals adhere to the fol- Oil drain
lowing recommendations: Before intervening on axle you have to drain oil from
the final drives and from the axle box (refer to page
Befopre installation soak the seal for half an C.)
hour in the same oil that will be used in the axle
to be sealed. Warning: The exhaust oil disposal must be car-
ried out according to the laws in force.
Clean the shaft and ensure the seal area of the
same is not damaged, fitter or grooved. Removal an dinstallation of the axle
In order to remove the axle, support adequately the
Place the sealing lips towards the oil side. vehicle to get a certain safety.
Lubricate the seal lip (oil is better than grease) Unscrew the fastening nuts and remove the wheels
and fill with grease the space between oil lip and from the hubs.
dust lip of dual lip seals.
Disconnect the controlling brakes pipings, then in-
lnstal the oil seal using a suitable seal driver. stall some protection plugs.
Loose al lthe remaining connections between frame
To avoid damages to the seal lip caused by the and axle, then seperate the axle from the frame
shaft; adequatly protect the same during shaft structure.
assembly procedure.
Installing the axle reverse the order; check for even-
O-ring tual leakes of oil.
Ensure adequate lubricatoin of these seals before
inserting them in their seats to avoid twisting during Check the oil level and, if necessary, re-fill.
shaft assembly.
Carry out the braking system bleeding.
Shims
vidual measurements. Do not trust pack measure-
ments or the thickness indicated on the shim.
Bearings
in a furnace from 80C to 9OC before installing in their
respective shafts or to cool them before inserting in
their respective seats with outer housing.
Elastic plugs
During the plug assembly and with turbo off, ensure
that their notch has oriented towards the stress
which is subjecting the thrust.
On the contrary, the spiral elastic plugs need no as-

sembly orientation.
30-I 30
FINAL DRIVES
. Unscrew the screws (2) of the carrier assy (3).
. Remove the planetary carrier from the wheel hub, us-

ing a puller two screws and operating on the extraction
holes.
. Partially unscrew the screws (4) and knock with a

plastic hammer to separate the planetary carrier (5).
The remove the screws. When reassembling, clean
and degrease the planetary carrier (5) union surface
to the carrier assy (3) and use Loctite 510.
. Check tje condition of the needle bearing (6) and

washers (7). Replace, if necessary.
. Check the planetary pin (8) conditions. As they are

forced on the planetary carrier (3), replace the whole
planetary carrier if damaged. When reassembling, if
necessary, use some grease to hold in position the
needle bearing.
. Turn the wheel hub and position the plug (1) to the
upper point. Fill it with specified oil.
. Turn the wheel hub setting the plug (1) in horizontal

position, then ckeck the oil level.
30-I 31
WHEEL HUBS AND BRAKES
. Remove the ring (I), the reaction plate (2), the brake
disc (3) and the reaction plate (4).
. Unscrew the screws (5) and remove the wheel carrier

(6) and crown gear (7) by using the two extraction
holes M12.
Recover the two O-ring (12) on brake fluid inlet ports.
Separate the wheel carrier from the crown gear and

remove the centering bushes (8).
Extract the wheel hub (9).
Replace the O-ring (11).
Check the brake disc (3) for deformation or burning

traces; replace, if necessary.
. Check that the disc friction material thickness is not

lower than 3.9 to 4.2 mm; replace if necessary.
. Check the reaction plates (2) and (4) do not show any
signs of excessive wear o grooves exceeding 0.20
mm.
30-I 32
WHEEL HUBS AND BRAKES
Kw13OP6107
. The special arrangement “Set right” of bearings needs

no pre-load or backlash specific rules. However, be-
fore reassembling the new spare parts, the following
dimensions must be checked:
A = 51.95 to 52.00
B = 114.175 to 114.225
c = 29.00 to 29.15
D = 3.95 to 4.00
Change the components out of tolerance.
30-I 33
SWIVEL HOUSING
KW13OP6108
. The pivot bearing (1) has to be assembled under the

press for the race placed on the king pin and in cold
conditions (as in azote bath) for the race placed on the
axle.
. The top bush (2) must be cooled (as in azote bath)

before mounting in the axle seat.
. Check the oil seal (4) conditions; if necessary, replace

it. Lubricate it by using a right seal driver to avoid dam-
aging it during the assembly.
. Check the O-ring (5) conditions; if necessary replace

it.
. Check out the swivel pin bearing clearance record.
30-I 34
SWIVEL PIN BEARING CLEARANCE
Kw13OP6109
The swivel pin bearings are set with 0.00 to .I0 mm of

clearance. Make this operation adding or subtracting shims
(6) between king pins (7) and (8) and the swivel housing
(9).
Do the following procedure:

Install the bottom pin (8) with shims (for example 1 .OO
mm) and fix by relative screws.
Without any shims, install the top pin/bearing assem-

bly (7) and fix by relative screws.
Install a dial gauge on the top cover and take note of

the clearance between knucle and cover.
Operate with a lever between knucle and axle beam

(example of measure: 0.50 mm).
Substract from this value the clearance required for

the bearings: 0.50 - (0.00 to 0.10) = 0.50 to 0.40 mm.
Substract from this value from the employed shims

(1 .OO mm). Divide by 2 to obtain the shims to employ
under each cover:
1.00-(o.50 to o.40) = 0.25 to 0.30 mm
2
Remove the covers and install under each of them the

shims established before: 0.25 to 0.30 mm.
Tighten the set screw.
30-I 35
DRIVE SHAFTS
Kw13OP611(
. Inspect the splines on the drive shafts for wear or

damage.
. Replace the spider if worn or damaged.
30-I 36
STEERING CYLINDER -TOE - IN
Kw130P6111
Steering cylinder . Check for the distance (M) is the same both
. Inspect the steering cylinder rod (1) and its pis- side.
ton for wear or damages.
. When the final adjustment is reached, lock the
. Inspect the ball joints assy (2) and (3) for wear nuts (4) and (5) to 300 Nm.
or damages.
. If any leakage is evident, replace the steering

cylinder seal kit.
Toe-in
. The toe-in value has to be of +l to -1 mm.
To adjust follow this procedure:
Tighten the shafts threaded (2) and (3) onto the

cylinder until approaching the final adjustment
value.
Then connect the shafts threaded (2) and (3)

and to the tie rods (6) and (7) by the corre-
sponding pins (8).
Carry out the final adjustment. Turn the cylinder

by the relative end seats, until the adjustment is
correct; you can do it as the shafts (2) and (3)
are threaded left and right hand.
30-I 37
BEVEL GEAR AND PINION SET
KW13OP6112
. Unscrew the screw (1) and the bolts (10) to dis- . Check the oil seal (8) conditions, best replace it.
assemble the complete differential and to be When reassembling, fill with grease the oil seal.
able to work on bench.
The operations to carry out on this group are the fol-
. Check the conditions of the bevel pinion bear- lowing ones:
ings (2) and of the differential bearings (3);
repplace them, if necessary. PINION POSITIONING
PINION BEARINGS PRE-LOAD
. If you change the bevel gear and the pinion set, PINION-CROWN TEETH BACKLASH
you have to replace the ring nut (4), the washers DIFFERENTIAL BEARINGS PRE-LOAD
(5) and (6) and the collapsible spacer (7). ADJUSTMENT FLANGE ON PINION
30-138
PINION POSITIONING
N = Bevel distance (value lo substract from the B value)

x
pinion-crown gear mating number

/
Kw130P6113
Bevel distance
Install the pinion bearings in their seat in the differen-
tial end plate and put them in contact using the tool (1);
it must be possible turn the conical bearings by hand,
never close tight.
Assemble the central gear half-cover and fasten it with

with relative screws.
With the aid of an internal micrometer measure the

diameter (D), bearing seat.
Put a calibrated rod (2) into the central gear bearing

seat and, by using a depth gauge, measure level (Y).
Carry out the following operation:

B=Y - 25 (calibrated rod diameter) + D/2.
In order to determinate the thickness to be inserted

between the pinion and the bearing, simply substract
from the (B) value the one stamped on the pinion
head.
Create this thickness by using the range of the rings

on hand, and inserting them in the pinion shaft.
Insert the bearing in the pinion shaft, and ensure that

it is completely seated.
30- 139
Kw13OP6114
. The bearing pre-load must be 84 to 126 N, measured

on the queue of the pinion outer diameter.
. Tighten progressively the ring nut until the established

pre-load value results.
. To control the pre-load, use a dynamometer with the

rope twist on the pinion queue.
. When the roating torque is a specified, peen the edge

of the ring nut to lock the nut to the shaft (avoid use of
sharp punches or chisels).
30-I 40
BEVEL PINION-GEAR TEETH

BACKLASH
The backlash has to be 0.21 to 0.28 mm.The adjustment is

carried out operating on the side adjustment ring nuts. The
ring nuts, pressing on the bearings, bring the crown to-
wards or away from the pinion.
Operate in the following manner:

Turn the ring nut, crown side, clockwise till getting a
contactr between the crown and the pinion; at the
same time use a plastic hammer in order to settle the
bearing.
Turn the other ring nut clockwise, and at the same time
use a plastice hammer in order to eliminate any bear-
ing backlash. You can get such a condition when the
ring nut rotation becomes difficult.
Position the dial gague so that the probe is in contact

with it, and at 9OC to a tooth of the pinion.
Measure the backlash between pinion and bevel gear.
Repeat the operation on two or more points (teeth)

turning the pinion and remarking the backlash value.
If the amount of backlash is different, put the probe on

the tooth that has the smallest backlash.
Bring the crown towards or away the pinion turning

each ring nut in the same way, until the specified back-
lash is achieved.
DIFFERENTIAL BEARINGS
PRE-LOAD
To carry out the adjustment operate as follows:

. With the crown engaged to the pinion, and having ob-
tained the correct backlash between pinion and bevel
gear, turn the pinion by using a dynanometer with the
string wrapped around the queue of the pinion itself.
Measure the value of the stress necessary to rotate
both the pinion and the differential simultaneously.
. Turn each ring nut to the same extent (tighten or

loosen) in order to maintain the same backlash value.
The total pre-load (T) of the bearings (pinion + differential)

measured on the queue of the pinion must be the following:
T = (P + 29) to (P + 44) N
where P is the actual pre-load measured on the pinion.
30-I 41
ADJUSTMENT OFTHE FLANGE ON THE PINION
KW13OP6115
The motion input flange (4) should be mounted with

some adjusting shims (3) between washer (2) and
bevel pinion in order to ensure a correct assembling.
In order to measure the dimension (S) of the shims to

be used, it is necessary to mount the washer (6) with-
out O-ring (5), and then the flange (4).
Measure dimension (S) by using a gauge.
Remove flange (4), remount O-ring (5) and flange (4).
Interpose the shims (3) whose size has been previ-

ously determined.
Apply Loctite 510 between washer (2) and pinion.
Tighten screw (1) at 139 Nm.
30-I 42
DIFFERENTIAL
3
cd
Kw13OP6116
. Check the condition of thrust washers (1) and (2).
. Also check the condition of all other components,

particulary of pin (3).
. During reassembly, it is suggested to replace the

screws (4) which fasten the bevel gear to the differen-
tial case.
30-I 43
AXLE BEAM
'13OP6117
. Check the condition of the oil breather (l), clean and

replace as necessary.
. Check the condition of the bushes (2) on the center

pivot for wear or damage; replace, if necessary.
. Inspect the drive shaft bushing (3) for wear and dam-
ages; replace, if necessary.
. Replace the oil seal (4).
. It is suggested to replace oil seal (5) on pinion cover

and O-ring (6) between axle housing and differential
support.
. Apply Loctite 510 between axle housing and differen-

tial end plate.
30-I 44
Kw13OP6118
30-I 46
TIGHTENING TORQUES
Thread Nm
Ring nut - bevel pinion M45x1.5 pre-load
Bolt - bevel pinion cover M8x25 27
Bolt - input flange to bevel pinion Ml 2x1.25 139
Bolt - input flange Ml 2x1.25
Bolt - differential support to axle housing M12x33 150
Bolt - crown wheel to differential carrier M14x2 190
(use locite 270)

7 Breather support 15
8 Breather plug MlOxl 5
9 Bolt - ring nut locking plate M6xl xl 0 13
10 Oil drain and filling plug M22x1.5 60
11 Bolts - differential support to axle housing Ml2 80
12 Bolt - differential support half-tie M 16x95 413
13 Brake fluid breather plug 12to16
14 Greaser MlOxl 10
15 Bolt - pivot support M14x35 190
16 Lock nut for steering-stop screw Ml4 100
17 Oil plug 60
18 Screw - pivot shaft lock M16x2 156
19 Screw - steering cylinder M 16x55 240
20 Steering rod lock nuts:

- R.H. thread M36x1.5 300
- L.H. thread M36x1.5 300
21 Bolts - planetary gear carrier M20x80 530
22 Bolts - crown gear carrier to wheel hub M14x1.5 220
23 Bolts - planetary carrier to wheel shaft M8x20 23
24 Oil filing level plug 60
30-I 47
DISASSEMBLY AND ASSEMBLY REAR AXLE
Sealing compound
REAR AXLE Use LOCTITE 510 or types following the specifica-
tions. Ensure that both sides to be sealed are clean,
DISASSEMBLING, SETTING OP- dry and totally free from grease and oil.
ERATIONS AND REASSEMBLING
Disassembling - Reassembling
The overhauling of epicycloidal group and wheel
FOREWARD hubs can be completed without removing the axle
from the vehicle.
Oils seals for rotating shafts
For correct installation of oil seals adhere to the fol- Oil drain
lowing recommendations: Before intervening on axle you have to drain oil from
Before installation soak the seal for half an hour the final drives, from the central gear and from the
in the same oil that will be used in the axle to be reduction gear (refer to page 71)
sealed.
Warning: The exhaust oil disposal must be car-
Clean the shaft and ensure teh seal area of the ried out according to the laws in force.
same is not damaged, fitted or grooved.
Removal and Installation of the axle
Place the sealing lips towards the oil side. In order to remove the axle, support adequately the
vehicle to get a certain safety.
Lubricate the seal lip (oil is better than grease)
and fill with grease the space between oil lip and Unscrew the fastening nuts and remove the wheels
dust lip of dual lip seals. from the hubs.
Install the oil seal using a suitable seal driver. Disconnect the controlling brakes pipings, then in-
stall some protection plugs.
To avoid damages to the seal lip caused by the Loose all the remaining connections between frame
saft: adequately protect the same during shaft and axle, then separate the axle from the frame
assembly procedure. structure.
O-ring Installing the axle reverse the order; check for even-
Ensure adequate lubrication of these seals before tual leakages of oil.
inserting them in their seats to avoid twisting during
shaft assembly. Check the oil level and, if necessary, re-fill.
Shims Carry out the braking system bleeding.

vidual measurements.
Do not trust pack measurement or the tickness indi-
cated on the shim.
Bearings
in a furnace from 80°C to 90°C before installation in
their respective shafts or to cool them before insert-
ing in ther respective seats with outer housing.
Elastic plugs
During the plug assembly and with turbo off ensure
that their notch has oriented towards the stress with
is subjecting the trust.
On the contrary, the spiral elastic plugs need no as-

sembly orientation.
30-I 48
FINAL DRIVES
Kw13OP6119
. Unscrew the screws (2) of the carrier assy (3).
. Remove the planetary carrier from the wheel hub, us-

ing as a puller two screws and operating on the ex-
traction holes.
. Partially unscrew the screws (4) and knock with a

plastic hammer to separate the planetary carrier (5).
Then remove the screws. When reassembling, clean
and degrease the planetary carrier (5) union surface
to the carrier assy (3) and use Loctite 510.
. Check the condition of the needle bearing (6) and

washers (7). Replace, if necessary.
Check the planetary pins (8) conditions. As they are

forced on the planetary carrier (3), replace the whole
planetary cariier if damaged. When reassembling, if
necessary, use some grease to hold in position the
needle bearing.
. Turn the wheel hub and position the plug (1) to the
upper point. Fill it with specified oil.
. Turn the wheel hub setting the plug (1) in horizontal

position, then check the oil level.
30- 149
WHEEL HUBS
KW13OP6120
. Remove the half shaft (5).
. Unscrew the screw (1) and remove the wheel carrier

(2) and crown gear (3) by using the two extraction
holes M12.
. Separate the wheel carrier from the crown gear and

remove the centering bushes (4).
. Extract the wheel hubs (6).
. Check the condition of the cassette seal (7) on the

wheel hub; replace it, if necessary. Lubricate it and
use a correct seal driver to avoid damaging it during
the assembling.
. Check the conditions of the splines on the halft shaft

(5).
. Replace the O-ring (8).
30-I 50
KW13OP6121
. The special arrangement “Set right” of bearing needs

no pre-load or backlash specific rules. However, be-
fore reassembling the new spare parts, the following
dimensions must be checked:
A = 68.95 to 69.00
B = 132.175 to 132.225
c = 29.00 to 29.15
D = 4.95 to 5.00
Change the components out of tolerance.
30-I 51
BRAKES
KW13OP6122
Unscrew the bolts (11) and remove the wheel shaft

(8).
Check the oil seal (10) conditions; replace, if neces-

sary. Lubricate and use a correct seal driver to avoid
damaging during the assembling.
Check the bush (9) conditions; replace, if necessary.
Check the brake disc (1) for deformation or burning

traces; replace if necessary.
Check that the disc friction material thickness is not

lower than 7.9 to 8.3 mm; replace, if necessary.
Check the splines conditions on the side shaft (2) and

on the sleeve (3).
Check the brake piston (4) and the reaction plate (5)
do not show and signs of excessive wear o grooves
exceeding 0.20 mm.
Replace the quadrings (6) and (7).
30-I 52
BEVEL GEAR AND PINION SET
KW13OP6123
. Unscrew the screw (1) and the bolts (10) to dis- . Check the oil seal (8) conditions, best replace it.
assemble the complete differential and to be When reassembling, fill with grease the oil seal.
able to work on bench. The operations to carry out on this group are the
following ones;
. Check the conditions of the bevel pinion bear-
ings (2) and of the differential bearings (3); re- PINION POSITIONING
place them, if necessary. PINION BEARINGS PRE-LOAD
PINION - CROWN TEETH BACKLASH
. If you change the bevel gear and the pinion DIFFERENTIAL BEARINGS PRE-LOAD
bearings (2) and of the differential bearings (3); ADJUSTMENT FLANGE ON PINION
replace them, if necessary.
. If you change the bevel gear and the pinion set,

you have to replace the ring nut (4), the washers
(5) and (6) and the collapsible spacer (7).
30- 153
PINION POSITIONING
from the B value)
pinion-crown gear mating number
Bevel distance
Install the pinion bearings in their seat in the differen-
tial end plate and put them in contact using the tool (1);
it must be possible turn the conical bearings by hand,
never close tight.
Assemble the central gear half-cover and fasten it with

relative screws.
With the aid of an internal micrometer measure the

diameter (D), bearing seat.
Put a calibrated rod (2) into the central gear bearing

seat and, by using a depth gauge, measure level (Y).
Carry out the following operation:

B =Y - 25 (calibrated rod diameter) + D/2.
In order to determinate the tickness to be inserted be-

tween the pinion and the bearing, simply substract
from the (B) valve the one stamped on the pinion
head.
Create this thickness by using the range of the rings

on hand, and inserting the in the pinion shaft.
Insert the bearing in the pinion shaft, and ensure that it

is completely seated.
30-I 54
Kw13OP6125
. The bearing pre-load must be 84 to 126 N, measured

on the queue of the pinion outer diameter.
. Tighten progessively the ring nut until the established

tore-load value results.
. To control the pre-load, use a dynamometer with the

rope twist on the pinion queue.
. When the roating torque is a specified, peen the edge

of the ring nut to lock the nut to the shaft (avoid use of
sharp punches or chisels).
30- 155
BEVEL PINION-GEAR TEETH

BACKLASH
The backlash has to be 0.21 to 0.28 mm.The adjustment is

carried out operating on the side adjustment ring nuts. The
ring nuts, pressing on the bearings, bring the crown to-
wards or away from the pinion.
Operate in the following manner;

Turn the ring nut, crown side, clockwise till getting a
contact between the crown and th pinion; at the same
time use a plastic hammer in order to settle the bear-
ing.
Turn the other ring nut clockwise, and at the same time
use a plastic hammer in order to eliminate any bearing
backlash.You can get such a condition when the ring
nut rotation becomes difficult.
Position the dial gauge so that the probe is in contact

with it, and at 90°C to a tooth of the pinion.
Measure the backlash between pinion and bevel gear.
Repeat the operation on two or more points (teeth)

turning the pinion and remarking the backlash value.
If the amount of backlash is different, put the probe on

the tooth that has the smallest backlash.
Brng the crown towards or away the pinion turning

each ring nut in the same way, until the specified back-
lash is achieved.
DIFFERENTIAL BEARINGS PRE-LOAD
To carry out the adjustment operate as follows:
. With the crown engaged to the pinion, and having ob-

tained the correct backlash between pinion and bevel
gear, turn the pinion by using a dynamometer with the
string wrapped around the queue of the pinion itself.
Measure the value of the stress necessary to rotate
both the pinion and the differential simultaneously.
. Turn each ring nut to the same extent (tighten of

loosen) in order to maintain the same backlash value.
The total pre-load (T) of the bearings (pinion + differential)

measured on the queue of the pinion must be the following:
T = (P+29) to (P+44) N
where P is the actual pre-load measured on the pinion.
30-I 56
ADJUSTMENT OFTHE FLANGE ON THE PINION
KW13OP6126
. The motion input flange (4) should be mounted with

some adjusting shims (3) between washer (2) and
bevel pinion in order to ensure a correct assembling.
. In order to measure the dimension (S) of the shims to

be used, it is necessary to mount the washer (6) with-
out O-ring (5), and then the flange (4).
. Measure dimensions (S) by using a gauge.
. Remove flange (4), remount O-ring (5) and flange (4).
. Interpose the shims (3) whose size has been previ-

ously determined.
. Apply loctite 510 between washer (2) and pinion.
. Tighten screw (1) at 139 Nm.
30- 157
DIFFERENTIAL
KW13OP6127
. Check the condition of thrust washers (1) and (2).
. Also check the condition of all other components, par-

ticularly of pin (3).
. During reassembly, it is suggested to replace the

screws (4) which fasten the bevel gear to the differen-
tial case.
30-I 58
AXLE BEAM
KW13OP6128
. Check the condition of the oil breather (l), clean and

replace as necessary.
. Check the condition of the brake fluid bleeding valves

(2); replace as necessary.
. Replace O-ring (3) between beam and wheel hub.
. It is suggested to replace oil seal (4) on pinion cover

and O-ring (5).
. Between axle beam and differential support apply

Loctite 5 IO.
30-I 59
0
-
1
K-T
W
-
d3
I
KW13OP6129
30-160
TIGHTENING TORQUES
Thread Nm
DIFFERENTIAL CASE
Ring nut - bevel pinion M45x1.5 pre-load
Bolt - bevel pinion cover M8x25 27
Bolt - input flange to bevel pinion Ml 2x1.25 139
Bolt - input flange Ml 2x1.25
Bolt - differential support to axle housing M12x33 150
Bolt - crown wheel to differential carrier M14x2 190
(use loctite 270)

7 Oil breather extension 15
8 Breather plug MlOxl 5
9 Bolt - ring nut locking plate M6xl .x1 0 13
10 Oil drain and filling plug M22x1.5 60
11 Oil drain plug M16x1.5 30
12 Bolts - differential support to axle housing Ml2 80
13 Bolt - differential support half-tie Ml 6x95 413
14 Oil breather extension 90
15 Breather plug 8to12
WHEEL SHAFT AND FINAL DRIVE

16 Bolts - wheel shaft to axle beam Ml4 190
17 Bolts - planetary gear carrier M20x80 530
18 Bolts - crown gear carrier to wheel hub M14x1.5 220
19 Bolts - planetary carrier to wheel shaft M8x20 23
20 Oil filling level plug 60
30-161
DISASSEMBLY AND ASSEMBLY ADAPTER WELDING INSTRUCTION - ELECTRODE WELDING
ADAPTER WELDING
INSTRUCTION - ELECTRODE
WELDING
BE SAFE!
When performing the procedures described in this
catalog, you should WEAR OSHA-approved hard hat,
safety glasses, work gloves and safety shoes.
IMPORTANT!
ESCO weld-on Helilok adapters are hardened typically to
415BHN. In order to eliminate cracking commonly associ-
ated with welding steel at these hardness levels, follow
these procedures carefully and employ good welding tech-
niques and practices.
Summary of Welding Procedures

Mating surfaces to be welded should be shiny base metal,
free of carbon arc surface, hardfacing, grease or dirt.
Use E-7016 or E-701 8 low-hydrogen electrodes (keep
dry!), or E-70T-5 low-hydrogen wire.
Preheat the lip and adapter to 200°F (95°C); 350” to 400°F
(117” to 204°C) if surrounding air temperature is 40°F
(5°C) or less. Measure temperature with a Tempilstik@.
Maintain preheat temperature while welding.
Maximum interpass temperature should not exceed 500°F
(260°C).
After welding, postheat to 350” to 400°F (117” to 204°C) if
surrounding air temperature is 40°F (5°C) or less, then let
air-cool. If air temperature is above 4O”F, postheating is not
necessary.
J-Groove FileI
Welds should fill J-grooves to a 45” angle. If an adapter
does not have a J-groove, apply fillet welds according to
the following:
Bucket Size (volume)
Yards 3 Meter 3 Fillet Size

2 1.8 l/2” (13mm)
2 114-5 2 - 4.6 5/8” (16mm)
5 l/2 - 12 5-11 3/4” (19mm)
above 12 above 11 I” (25mm)
For complete welding information and procedures, refer to

ESCO Products Maintenance Manual, Catalog 100-A,
“How to weld ESCO alloy 12 series.”
Lip Adapter Installation

1. Locate the adapters on a clean bucket, then tackweld
them in place, followed by a root layer all the way
around.
30-I 62
2. To prevent the introduction of weld-weakening impuri- Where conddions allow a non-stop

ties, every weld pass should begin and end across a weld all around the adapter. “se
the two plates on/v
starter/runoff plate. Install these plates, made from
scrap steel, as shown in the diagram.
Do not stop or start a weld at the rear of the
adapter leg!
If rod length, adapter size, and welder position allow a
continuous weld without stopping, use two startemun-
off plates near the lip leading edge.
On large adapters and where stops for welder reposi-
and where the
tioning are required, use two additional starter/runoff welder must slop,
use these hvo
plates at the midpoint on both sides of the adapter. adddmnal plates.
These procedures also apply to the bottom leg of 1 I/Z-
and 2-leg adapters.
Weld around rear

3. If using four starter/runoff plates, weld the rear half of ha// of leg in
the adapter with alternating clockwise and counter alternating directions
clockwise passes. Build up the weld to a full fillet.

If using only two starter/runoff plates, use the same
technique, welding to the ends of the J-groove, then
proceed to step 5. Do not weld to the lip leading
edge!
4. If using four plates, continue welding to the ends of the

J-groove. Do not weld to the lip leading edge! Alter-
nate from side to side until the weld is complete. Main-
tain a full fillet weld and tie weld ends together.
5. Remove the starter/runoff plates, then smooth the for-

ward edge of the welds with a conical grinder.
Blend the welds concave to remove stress concentra-
tions.
6. Turn the bucket over.
7. One-leg Flushmount Adapters fillet weld across the

adapter equal to the lip leading edge thickness. Grind
the ends smooth at weld junctions. If a lighter cavity
extends forward of the lip leading edge, cover the
opening with weld. Maintain a full fillet width over the
entire weld.
Fillet weld
Cone
across adapter
Grinder
---___
, Fill caviry
opening
/
I
_----
B;;;:
radius
30-163
Corner Adapter Modification and Installation
Helilok adapters can be modified by cutting to fit bucket

side plates. A bucket should never be cut to fit an
adapter!
The corner adapter should be positioned so the point
cuts clearance for the bucket. The best bucket wear pro-
tection is achieved when the adapter is positioned so the
nose is flush with an imaginary line extending forward from
the outside edge of the bucket side plate.
If a clean trench is desired, corner adapters can be
mounted so points are positioned flush with the outside of
the bucket.
When modifying an adapter, never remove more
than 50% of the adapter top leg. The edges of the cuts
should be chamfered l/2” X 30” for weld preparation.
Following welding procedures descrebed in “Lip
Adapter Installation.”
Install Helilok points according to the procedures de-
scribed in ESCO Maintenance Catalog 100-l B (Rev. l),
Helilok Tooth System Installation and Removal instruc-
tions.
Bucket Side
P/aleBevel
’ lip of lip
Angle ofcutto march
&-
* x30”
angle of side p/ate \ chamter
leading edge bevel
\ /----;<
<’
-&-__ ‘0‘;_
‘.,_- --
/ \
lmagina( Extension Side’ Plate
ol Side f/ate
Edge of
‘side
cket
I Top of Lip
Adapter Modified far

Bevelled Bucket Side Plate
Side Plate
Typical FEL installation
30-I 64
DISASSEMBLY AND ASSEMBLY OUT RIGGER CYLINDER
OUT RIGGER CYLINDER
REMOVAL OF OUTRIGGER CYLINDER
1) Lower the outriggers until they just touch the ground

but do not take any of the wight of the machine.
2) Turn off the engine.
3) Depressurize the outrigger hydraulic circuit.
4) Disconnect the hydraulic lines from the cylinder.
5) Attach lifting tackle.
6) Remove bolt (2) and pin (1).
7) Remove bolts (4) and pin (3). /
8) Remove cylinder.
9) Important: Depressurize cylinder before opening it.To

depressurize, loosen the two plugs (5) by approx. 2
turns using an Allen key and wait until pressure has
escaped. To be absolutely sure, remove the plugs \
5
completely after pressure has dropped. Fig 2
INSTALLATION OF OUTRIGGER CYLINDER
1) Fit the cylinder by following the above procedure in

reverse sequence.
2) Grease pins (1) and (3) before fitting. Grease bearing

points after assembly.
3) Bleed air from outriggers by raising and lowering the

outriggers several times.
30-165
DISASSEMBLY AND ASSEMBLY BLADE CYLINDER
BLADE CYLINDER
REMOVAL OF BLADE CYLINDER
1) Lower the blade until it just touches the ground. Do not

take any of the weight of the machine on the blade.
2) Turn off the engine.
3) Depressurize the blade hydraulic cicuit.
3) Disconnect the hydraulic lines from the cylinder.
4) Attach lifting tackle.
5) Remove bolts (2) and pin (1).
6) Remove bolts (4) and pin (3).
7) Remove cylinder.
8) Important: Depressurize cylinder before opening it.To

depressurize, loosen the plugs (6) by approx. 2 turns
using an Allen key and wait until all pressure has es-
caped. To be absolutely sure, remove the plugs com-
pletely after pressure has dropped.
INSTALLATION OF BLADE CYLINDER
1) Fit the cylinder by following the reverse of the above

procedure.
2) Grease pins (1) and (3) before fitting. Grease bearing

points after assembly.
3) Bleed air from cylinders by raising and lowering the

blade several times.
30-166
40 MAINTENANCE STANDARD
Engine mount .............................................. .40- 2

Swing machinery.. ....................................... .40- 3
Swing circle ................................................. .40- 5
Control valve ............................................... .40- 6
Suction-safety valve .................................... .40- 14
Swing motor ................................................ .40- 15
Work equipment, swing PPC valve ............. .40- 16
PPC shuttle valve, travel junction valve.. .... ..40 - 17
EPC solenoid valve ..................................... .40- 18
Center swivel joint ....................................... .40- 19
Boom safety valve (Arm safety valve) ......... .40- 20
Hydraulic cylinder.. ...................................... .40- 21
Work equipment .......................................... .40- 22
Dozer blade, outrigger cyl ........................... .40- 30
Outrigger bush pins.. ................................... .40- 31
Transmission ............................................... .40- 32
Front axle .................................................... .40- 33
Rear axle.. ................................................... .40- 34
Arm rotation circle ....................................... .40- 35
40-I
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
A-A
B-B c-c
Unit: mm
No. Check item Criteria Remedy
Standard size Repair limit

1 Free height of front mount rubber A
84 Replace
2 1Free height of rear mount rubber B & C 1
40-2
MAINTENANCE STANDARD SWING MACHINERY
SWING MACHINERY
Standard Clearance limit Check measurement standard
Pos. Check item Component Check measurement limit (mm)
clearance (mm) (mm) (mm) 1
Measurement over pin 04mm
Motor Shaft: 34,144 -0,054 -0,120 Measurement over pin m4mm 33,90
1 Backlash between motor shaft 0,064- 0,155 0,33
and brake shaft Measurement over pin 03,5mm
Brake shaft: Measurement over pin m3,5mm 22,85
22,484 +0,171 +0,063
Measurement over pin 03,5mm

Brake shaft: Measurement over pin 03,5mm 32,89
Backlash between brake shaft 32,611 +O,iOi +O,OOi
2 0,020 0,098 0,27
and 1st stage sun gear Measurement over pin 03,5mm
Sun gear: 43,311 -0,030 -0,076 Measurement over pin 03,5mm 43,lO
Span measurement over 4 teeth

Sun gear: 27,729 -0,037 -0,080 Span measurement over 4 teeth 27,52
Backlash between 1st stage sun
3 gear and 1st stage planet gear 0,093 0,165 0,43
Planet gear: 27,531 -0,050 -0,075 Span measurement over 4 teeth 27,33

Backlash between 1st stage
4 0,133 0,213 0,48
planet gear and toothed ring Measurement over pin m4mm
Toothed ring: Measurement over pin 04mm 192,77
192,072 +0,350 +0,210
Measurement over pin m3,5mm

Planet carrier: Measurement over pin m3,5mm 50,12
Backlash between 1st stage planet 49,879 +0,088 +0,002
5 0,020 0,098 0,27
carrier and 2nd stage sun gear Measurement over pin m3,5mm
Sun gear: 59,847 -0,029 -0,075 Measurement over pin m3,5mm 59,64

Sun gear: 33,511 -0,045 -0,090 Span measurement over 4 teeth 33,27
6 Backlash between 2nd stage sun 0,112 0,192 0,51
gear and 2nd stage planet gear Span measurement over 4 teeth

Planet gear: Span measurement over 4 teeth 32,67
32,911 -0,060 -0,090
7 Backlash between 2nd stage 0,160 0,255 0,58
planet gear and toothed ring Measurement over pin 05mm
Toothed ring: Measurement over pin m5mm 230,57
299,720 +0,426 +0,256
Measurement over pin 04mm

Planet carrier: 60,579 +0,094 -0,002 Measurement over pin m4mm 60,84
8 Backlash between 2nd stage 0,020 0,098 0,27
planet carrier and swing pinion Measurement over pin 04mm
Pinion shaft: 73,232 -0,034 -0,082 Measurement over pin m4mm 73,Oi

Pinion shaft: 78,90 -0,050 -0,200 Span measurement over 3 teeth 78,20
9 Backlash between swing pinion 0,018 - 1,235 2,30
and swing circle Measurement over pin 015mm
Swing circle: Measurement over pin 015mm 927,98
924,3 +2,260 +0,470
Wear of swing pinion oil seal

10 contact surface 084,5
MAINTENANCE STANDARD SWING CIRCLE
IGHTNING
TORQUE
490--608Nm
ARGET 549Nm
490--608Nm
549Nm
Unit: mm
I I I
Check item
I Remedy
Standard clearance Clearance limit

Axial clearance of bearing
1 Replace
(When mounted on machine)
0.5 - 1.6 3.2
40-5
MAINTENANCE STANDARD CONTROL VALVE
CONTROL VALVE
c
q
40-6
Unit: mm
A-A

Pressure
compensation valve Free length X Installed
1 Installed load Free length Installed load
spring (work O.D. length
equipment, swing) 17.6 * 1.0 N 13.2 N Replace
34.4 x 12 20
(1.8kO.l kg) - (1.3 kg) spring if any
damages or
Pressure
25.5 N 19.6 N deformations
2 compensation valve 27.3 x 12 20
(2.6 kg) - (2.0 kg) are found.
spring (travel)
Pressure
compensation valve 74.5 N 55.9 N
3 16.9 15.5
adjuster spring (7.6 kg) - (5.7 kg)
service
40-7
B-B
Unit: mm

I
I I
Free length Installed Replace
1 Spool return spring Installed load Free length Installed load spring if any
X O.D. length
damages or
230.5 * 14.7N 208.7N
45.6 x 28 43 deformations
(23.5 * 1.5kg) - (21.3kg)
are found.
Spool return spring 221 .l * 13.7N 179.3N
2 45.7 x 28 43
(a) (22.6 * 1.4kg) - (18.3kg)
40-8
40-9
CONTROL VALVE
MAINTENANCE STANDARD
D-D
40-I 0
E-E
17.2r2.5Mm
(1.75~0.25 kgm)
F-F
3 17.2&.5Nnl
(?.75+025kgm)
G-G 202FO6295
Unit: mm
Installed Free Installed Replace

Lift check valve Frytr$h Installed load
1 length length load spring if any
spring.
damages or
135.2 f 4.9 N 112.7 N
72.7 x 20.6 42.5 deformations
(13.8 f 0.5 kg) - (11.5 kg)
are found.
2 Cooler bypass 135.2 f 4.9 N 112.7 N
72.7 x 20.6 42.5
valve spring. (13.8 f 0.5 kg) - (11.5 kg)
40-I 1
(A31 183)
H- H TRAVEL -
u J-J -
K-K
40-12
N-N
P-P
40-I 3
MAINTENANCE STANDARD SUCTION-SAFETY VALVE
SUCTION-SAFETY VALVE
lZ.O-+i5kwm
/
TIGHTENING TORQUE RANGE
Unit: mm
Suction valve Free length Installed Free

Installed load Installed load Replace spring
spring. X O.D. length length
if any damages
2.2N 1.6 N or deformations
16.3 x 21.3 9.0
(0.22kg) - (0.16 kg) are found.
Main valve 1.3N 1.6 N
20 x 7 13.7
spring (0.13kg) - (0.16 kg)
40-I 4
MAINTENANCE STANDARD SWING MOTOR
SWING MOTOR
I I I \ \ \
I \
202FO6299
’ A
40-I 5
MAINTENANCE STANDARD WORK EQUIPMENT. SWING PPC VALVE
WORK EQUIPMENT, SWING PPC VALVE
Unit: mm
Centering spring Free length Installed Installed Installed

Free length
(for P3, P4) X O.D. length load load Replace
17.7 N 13.7 N spring if
43.3 x 19.5 33.5
(1.8 kg) - (1.4 kg) there is
damage or
Centering spring 29.0 N 23.2 N
45.5 X 19.6 33.5 deformation
(for Pl, P2) (3.0 kg) - (2.4 kg)
16.7 N 13.7 N
Metering spring 27.6 X 9.5 26
(1.7 kg) - (1.4 kg)
40-16
MAINTENANCE STANDARD PPC SHUTTLE VALVE,TRAVEL JUNCTION VALVE
PPC SHUTTLE VALVE, EPC CLAMSMELL MANIFOLD
40-I 7
MAINTENANCE STANDARD EPC SOLENOID VALVE
EPC SOLENOID VALVE

FOR LS VALVE
11.3+1.5Nm
(1.15+0.15kgm)
\
Unit: mm

I
Standard size I Reoair limit 1Replace

EPC valve
Free length Installed Installed Installed assembly if
Free length
1 Return spring X O.D. length load load there is
3.14 N damage or
9.0x 11.4 7.9 deformation
(0.32 kg) -
40-18
MAINTENANCE STANDARD CENTER SWIVEL JOINT
CENTER SWIVEL JOINT
A’
i
Unit: mm
No.
I Check item
I Criteria Remedy
Clearance between
1
rotor and shaft
Clearance between
2
rotor + shaft
40-I 9
MAINTENANCE STANDARD ARM. BOOM SAFETY VALVE
ARM, BOOM SAFETY VALVE

* For machine equipped with arm safety valve, the Maintenance Standard of arm safety valve is the same as
this valve.
Unit: mm

I
Installed Installed Installed

Free length Free length
length load load
Pilot valve spring.
69.6 N 55.9 N
NO1 (Boom safety 30.9 mm 29.0
(7.1 kg) - (5.7 kg)
valve) Replace
1 spring if any
Pilot valve spring
68.6 N damages or
NO1 (Arm safety
(7.0 kg) deformations
valve)
are found
Pilot valve spring
23.5 N
2 NO2 (Boom and ~ 31.8 mm ~ 25 ~ g”k:j ~ -
arm safety valve) (2.4 kg)
Check valve
3 spring. (Boom and
arm safety valve)
40-20
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
PW170ES6K
w Boom 420 t 42 kgm

Arm - 720 + 72 kgm
m Bucket - 420 f 42 kgm
21.5 e 4.0 kgm 6 - 7.5 kgm 6 - 7.5 kgm
Unit: mm
No. T Check item I- Criteria Remedy
Name of
cylinder
Standard
size
r Tolerance Standard
clearance
Zlearance
limit
Shaft Hole
-0.030 +0.270 0.095 -

Boom 75 0.446
Clearance -0.076 +0.065 0.346
Replace
1 between piston
bushing
rod and bushing -0.036 +0.222 0.083 -
Arm a5 0.412
-0.090 +0.047 0.312
-0.030 +0.270 0.095 -

Bucket 75 0.446
-0.076 +0.065 0.346
-0.030 +0.198 0.154 -

Boom 70 1.0
-0.104 +O. 124 0.302
Clearance
between piston -0.030 +0.211 0.154 -
2 Arm 80 1.0
rod support and -0.104 +O. 124 0.315
bushing
-0.030 +0.198 0.154 -
Bucket 70 1.0
-0.076 +O. 124 0.274 Replace
pin and
-0.030 +O. 198 0.154 -
Boom 70 1.0 bushing
-0.100 +O. 124 0.298
Clearance
3 between cylinder -0.030 +0.211 0.154 -
Arm 80 1.0
bottom support -0.104 +O. 124 0.315
shaft and bushins 1
-0.030 +O. 198 0.154 -
Bucket 70 1.0
-0.104 +O. 124 0.315
40-21
MAINTENANCE STANDARD WORK EQUIPMENT
WORK EQUIPMENT
PWI 70ES6K
Section D-D
Section A-A Section H-H
6-
Section J-J
Section E-E
Section B-B
Section F-F Section K-K
Section C-C
Section G-G Section L-L
202FO5665
40-22
MAINTENANCE STANDARD WORK EQUIPMENT - ONE PIECE BOOM
WORK EQUIPMENT - ONE PIECE BOOM

PW170ES6K
H-H
A-A
J-J
E-E
K-K
F-F
G-G
KW13OP6167
40-23
MAINTENANCE STANDARD WORK EQUIPMENT -TWO PIECE BOOM
WORK EQUIPMENT -TWO PIECE BOOM

PWI 70ES-6K D
D-D
H-H
A-A
2
B-B
J-J
E-E
N-N
K-K
F-F
G-G
Kw13OP6168
40-24
Unit: mm
No. Check item T Criteria T Remedy

Standard T Standard Clearance
Clearance between bushing Hole ,clearance limit
Fnce
1 and connecting pin of
revolving frame and boom +0.240 0.295 -
1 .o
+0.174 0.435
Clearance between bushing

-0.030 +0.337 0.303 -
2 and connecting pin of boom 80 1.0
-0.104 +0.273 0.441
and arm
+0.331 0.300 -
3 and connecting pin of arm 1.0
+0.270 0.407 Replace
and link
+0.331 0.300 -
4 and connecting pin of arm 1.0
+0.270 0.407
and bucket
+0.335 0.305 -
5 and connecting pin of link 1.0
+0.275 0.411
and bucket
-0.030 +0.335 0.305 -
6 and connecting pin of link 70 1.0
-0.076 +0.275 0.411
and link
40-25
MAINTENANCE STANDARD DIMENSIONS OF WORK EQUIPMENT
DIMENSIONS OF WORK EQUIPMENT

PWI 70ES-6K
1. ARM
16 18
SAP00446
40-26
2.25 m ARM 2.6 m ARM
2 98 +A.'96 f 1.2 98 +A.'96 f 1.2

I I
3 284 +cl5
l_o8
-0.3 284 +o 5 lo8-0.3
o o
4 080 +0337
I-0.030 080 +0.337
I-0.030
+o 273 -0.icl4 +a273 -0.icl4
5
I 395.8 f 2
I
399.5 f 2
6 203.8 f 1 173.8f 1
I I
7 745.3f 1 753f 1.0
8 2995.3 3357.6 f 3
9 2377f 1.0 2377f 1.0

I I
10 330 f 0.5 330 f 0.5

I I
11 583 f 0.5 583 f 0.5
12 524 f 0.5 524 f 0.5
13 400.8 400.8
I I
14 (1348) (1348)
I I
15
16 311.5f 1 311.5 f 1
I I
17
18 Arm as individual
part 276 PO., 276 PO.,
When press fitting

bushing 310 310
Min. 1547 1547

19
Max. 2560 2560
40-27
1. BUCKET
A-A SAP00447
40-28
PW170ES-6k
3 103" 23'
5
I 1348
I 311.5 ;O.*
12 96
13 440 A'
I 0130
16 0130
17 440 '00-l
I R95
20 R95
21 311.5 +y
40-29
MAINTENANCE STANDARD DOZER BLADE AND OUTRIGGERS HYDRAULIC CYLINDERS
DOZER BLADE AND OUTRIGGERS HYDRAULIC CYLINDERS
Unit: mm
No. Check item Criteria T Remarks

Clearance Standard
Clearance limit size
1 between piston
60
and bushing
70
Clearance 0.30 60
between piston
2
rod and shaft
0.30 60
support bushing
Clearance 0.30 60
between bottom
3
support shaft and
0.30 60
bushing
Cylinder head 800Nm

4
torque 800Nm
40-30
MAINTENANCE STANDARD OUTRIGGER BUSH PINS
OUTRIGGER BUSH PINS
\
\ 2
1 2
Unit: mm
Max. undersize Max. permissible

Pin dia
1 Pin when new play
2 ) Pin 70 -0.10 0.023

I
I
I
I II I
I
40-3 1
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1. Oil filling m 60 f 6Nm (6.1 f 0.61 kgm)
2. Oil level w 60 f 6Nm (6.1 f 0.61 kgm)
3. Oil drain m 60 f 6Nm (6.1 f 0.61 kgm)
4. Oil brake connection port m 137 +_53Nm (14.0 +_6 kgm)
5. Oil breather m 10 f 1.5Nm (1 .O f 0.15 kgm)
_60f6Nrn
(6.1~0.61 kQm)
\ REAR VIEW
(6.1kO.61 kQm) \ -Z
#d&l 60*6Nm
w 10+1.5Nm (6.1f0.61 kgm) m 137f53 Nm
(l.Of0.15 kgm) (14;0*6kgm)
\
ENGAGED DISENGAGE0
FRONT VIEW
\
m 60*6Nm
(6.1kO.61 kgm) Kw13OP6157
LUBRICATION
Filling: use oil SAE 85W-140 that meets the specification SAE-J306C, API GL5
Oil quantity: 1 litre

Oil checking and changes:
- Initial change at 250 hours
- Subsequent changes every 2000 hours
- Inspection of level every 250 hours
40-32
MAINTENANCE STANDARD FRONT AXLE
FRONT AXLE
1. Wheel hubs drain, filling and level plug m 60 f 6Nm (6.1 f 0.61 kgm)
2. Differential oil filling and level plug w 60 f 6Nm (6.1 f 0.61 kgm)
3. Differential drain plug m 60 f 6Nm (6.1 f 0.61 kgm)
4. Brake control fluid inlet port w 14 f 2Nm (1.4 f 0.15 kgm)
5. Brake circuit bleeding $XKl 14 f 2Nm (1.4 f 0.15 kgm)
6. Axle beam oil breather m 5 f 1 Nm (0.51 f 0.5 kgm)
7. Lubrication point m 10 f 1.5Nm (1 .O f 0.15 kgm)
8. Steering cylinder feeding m 240 f 30Nm (24.5 f 3.06 kgm)
52 kom 60i6Nm
(6.1 f 0.61 bm 1
LUBRICATION GREASING
Filling: use oil SAE 8OW-90 that meets the specifica- Use lithium gun grease with molybdenum bisuphide
tion SAE-J306C API GL5 Applications: every 250 hours.
Oil quantity BRAKES CONTROL

- differential: 15 litres
- epicyclic reduction (each): 2.5 litres Filling: use mineral oil
Oil checking and changes: Oil quantity necessary for activating:

- Initial change at 250 hours - min 4.093 cm3 x 2
- Subsequent changes every 2000 hours - max 10.66 cm3 x 2
40-33
MAINTENANCE STANDARD REAR AXLE
REAR AXLE
1. Wheel hubs drain, filling and level plug m 60 f 6Nm (6.1 f 0.61 kgm)
2. Differential oil filling and level plug w 60 f 6Nm (6.1 f 0.61 kgm)
3. Differential drain plug m 60 f 6Nm (3.1 f 0.4 kgm)
4. Brake control liquid inlet port w 14 f 2Nm (1.4 f 0.15 kgm)
5. Brake circuit bleeding m IO f 2Nm (0.98 f 0.2 kgm)
6. Axle beam oil breather m 5 f 1 Nm (0.51 f 0.1 kgm)
Kw13OP6159
LUBRICATION BRAKES CONTROL

Filling: use oil SAE 8OW-90 that meets the specifica-
tion SAE-J306C, API GL5 Filling: use mineral oil
Oil quantity Oil quantity necessary for activating:

- differential: 20 litres - min 5.23 cm3 x 2
- epicyclic reduction (each): 2.7 litres - max 15.68 cm3 x 2
Oil checking and changes:

- Initial change at 250 hours
- Subsequent changes every 2000 hours
40-34
MAINTENANCE STANDARD ARM ROTATION CIRCLE
ARM ROTATION CIRCLE

PW170ES6K
Unit: mm

I
Standard clearance Clearance limit
Backlash between swing
1 Replace
pinion and swing circle * *
2 Clearance in bearing in
0.08 - 0.25
axial direction
40-35
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

SM Pw170es-6k-962

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UEBM000500

SERIAL NUMBERS PIN1 70ES-6 -K30001 andup

July 1999 Copyright 1999 Komatsu America International Company

Engine related parts ..................................... 1O-2

ENGINE RELATED PARTS

1. Drive plate OUTLINE

RADIATOR l OIL COOLER

1. Reservoir tank SPECIFICATIONS

1. Front axle 11. Swing machinery

1. Swing circle inner race (No. of teeth: 94) SPECIFICATIONS

a. Inner race soft zone S position

1. Swing pinion (No. of teeth: 12)

reduction ratio: 24+78 x 7 = 22.667

SWING HOLDING BRAKE

TRANSMISSION CLUTCH ASS’Y

1. Screw-fork to shaft 7. Gear 1. Casing 7. Plug

CLUTCH CONTROL CIRCUIT

1. Clutch control pump

The clutch is a device which automatically disen-

. A trunnion-type axle shaft with a king pin at the

Axle reduction ratio = 17, 73:i

1. Planetary carrier 16. Roller bearing

1. Planetary gear 16. Seal ring

SUSPENSION LOCK CYLINDER

, Brake pedal (latching)

Actuation force at ‘A’ = 300 - 350 N

When installed in machine

P = Pump Sl = Accumulator service brake

ACCUMULATOR FOR BRAKE SYSTEM

Seal ins Surface Kw130P6014

Volume: 0.75 G * Remove before installation

SHARED WITH BRAKE CIRCUIT

STRUCTURE AND FUNCTION

The hydraulic power from steering pump (2) is

1. HYDRAULIC OIL FILTER

2. HYDRAULIC OIL PUMP (SHARED WITH BRAKING CIRCUIT) l&x/REV

4. STEERING VALVE OSPD 70/l 95 LS DYN.

5. STEERING CILINDER D=090, d=050, STROKE=1 7OP,

6. STEERING WHEEL ... 0352

QUANTITIY OF STEERING TURNS

HYDRAULIC CIRCUIT DIAGRAM

HYDRAULIC CIRCUIT DIAGRAM

a. Pump drain port PD 1. Main pump

2) Center line X of rocker cam (4) maintains

3) If center line X of rocker cam (4) is in line

2. CONTROL OF DISCHARGE AMOUNT

1. Shaft 9. End cap

FUNCTION . Piston (6) carries out relative movement in the

LS VALVE TVC VALVE

Minimum direction 202FO6033

1. LS valve this point, spool (4) is pushed to the left, and

2) Operation in maximum direction for pump

3) Operation in minimum direction for pump

4) When servo piston is balanced

(2) Movement of spring

. The relation of pump pressure Pp and the posi-

Pump discharge pressura Pp

. If command current X sent to solenoid (1) in-

b. When main pump load is heavy

PPC PUMPLESS SYSTEM

From orbitrol I valve I

Port Pp (from main pump)

aa. Port Pls (to pump LS valve)